Digitally signed by QUALITY CONTROL

DN: cn=QUALITY CONTROL,

o=EJERCITO NACIONAL, ou=BAMAV2,
[email protected],
c=CO
Date: 2015.05.29 13:03:04 -05'00'
*TM 1--1520--265--23

TECHNICAL MANUAL

AVIATION UNIT MAINTENANCE (AVUM) AND

AVIATION INTERMEDIATE MAINTENANCE (AVIM)
MANUAL
NONDESTRUCTIVE INSPECTION PROCEDURES
FOR

H--60 HELICOPTER SERIES

H-60-MIM-15-002
REMOVAL OF NON-DESTRUCTIVE TESTING (NDT) REQUIREMENT
FOR THE TAIL ROTOR BLADE SPAR CENTER PLUG
WARNING - This document contains technical data whose export is restricted by the Arms Export Control
Act (Title 22, U.S.C. Sec. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C.,
App 2401 et seq. Violations of these export laws are subject to severe criminal penalities. Disseminate in
accordance with provisions of DOD Directive 5230.25.
DISTRIBUTION STATEMENT D: Distribution authorized to the DOD amd DOD Contractors only due to Critical
Technology effective as of 30 May 2008. Other requests must be referred to Commander, US Army Aviation
and Missile Command, ATTN: SFAE--AV--UH/L, Redstone Arsenal, AL 35898--5230.
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction
of the document.

*This manual supersedes TM 1--1520--265--23, dated 30 November 1996 and all changes.

HEADQUARTERS, DEPARTMENT OF THE ARMY

30 MAY 2008
 TM 1--1520--265--23

WARNING SUMMARY
Personnel performing inspections involving operations, procedures, and practices, which are included or implied in this
technical manual, shall observe the following instructions.

WARNING

Highlights an operation, procedure, practice, condition, statement, etc., if not strictly observed, could result in
injury to, or death of, personnel.

CAUTION

Highlights an operation, procedure, practice, condition, statement, etc., if not strictly observed, could result in
damage to or destruction of equipment or loss of mission effectiveness.

NOTE
Highlights an essential operation, procedure, condition, or statement.

The following are general safety precautions that are not related to any specific procedures and, therefore do not appear
elsewhere in this publication. These are recommended precautions that personnel must understand and apply during
many phases of nondestructive inspections.

GENERAL
Assure compliance with safety requirements in Technical Manual, Nondestructive Inspection General Procedures and
Process Control (ATOS),TM 1--1500--366--23.

Assure compliance with the safety and precautionary measures addressed in the applicable technical manuals listed in
Table 1--1. Refer to these manuals for detailed information relating to safety considerations for the specific area or system
on which the nondestructive inspection procedure is to be preformed.

WARNING

AIRCRAFT GROUNDING
All aircraft shall be grounded in accordance with FM 3-04.500 at all times..

WARNING

ELECTRICAL HAZARD
Assure that all safety precautions for using electrical equipment near aircraft fuel cells, oxygen systems, and
stores have been met.

a
TM 1--1520--265--23

WARNING

SOLVENTS
Most solvents are flammable. Keep away from heat and open flame. Vapors may be harmful. Use with ade--
quate ventilation. Avoid prolonged or repeated breathing of vapor. Avoid contact with skin and eyes. Do not
take internally. Comply with pollution control rules concerning photochemically reactive solvents.

WARNING

LIVE CIRCUITS
Inspection personnel must at all times observe safety regulations. Do not replace components or make adjust--
ments inside equipment with a high voltage supply turned on. Under certain conditions, dangerous potentials
may exist even when the power control is in the off position, due to charges retained by capacitors. To avoid
injuries, always remove power. Discharge and ground a circuit before touching it. Make sure that equipment
is grounded to same earth ground as aircraft.

WARNING

ELECTRONIC OR ELECTRONICAL EQUIPMENT

Do not wear rings, watches, or metal jewelry when working around electrical equipment.

WARNING

CLEANING SOLVENTS
x Those areas where skin and clothing come in contact with cleaning solvents should be washed thoroughly
and immediately after contact.
x Saturated clothing should be removed immediately.
x Areas where cleaning solvents are used should be adequately ventilated to keep vapors to a minimum.
x In case of contact with eyes, nose, or ears, flush them with generous quantities of water and then seek medi--
cal attention immediately.

WARNING

FOREIGN OBJECT DAMAGE (FOD)

x Make sure area is clear of foreign objects before closing access doors, panels, and fairings.
x If area is not clear, damage to components or systems could result in personal injury or death.

b
 TM 1--1520--265--23

WARNING

LIFTING COMPONENTS WITH HOIST

x Lifting or hoisting of components shall be done only by designated personnel.
x Before lifting, alert personnel in immediate areas.
x Before lifting, balance the load.
x Do not stand under load while it is being moved from one area to another on a hoist.
x Do not stand under load to do inspection work.

WARNING

COMPRESSED AIR
x Do not use more than 30 PSIG compressed air for cleaning purposes.
x Use eye protection to prevent injury to personnel.

WARNING

NO STEP AREAS
To prevent injury to personnel and damage to helicopter, stand only on designated surfaces. These areas are
reinforced to withstand frequent use and are treaded to prevent slipping. All other surfaces are NO STEP areas.

WARNING

PLATFORMS AND WORK STANDS

Use only appropriate platforms, work stands, or other approved locally procured stands and restraint equip--
ment when working above 10 feet on helicopters in a nontactical environment. Otherwise, personnel injury
could result from accidental falls.

WARNING

DEGREASING SOLVENT
MIL--PRF--680B, TYPE II
MIL--PRF--680B, Type II is combustible and toxic to eyes, skin, and respiratory tract. Wear protective gloves
and goggles/face shield. Avoid repeated or prolonged contact. Use only in well--ventilated areas (or approved
respirator as determined by local safety/industrial hygiene persenel). Keep away from open flames or other
sources of ignition.

WARNING

COMBUSTIBLE GASES
Electrical equipment shall not be operated in areas where combustible gases or vapors may be present, unless
the equipment is explosion proof.

c
TM 1--1520--265--23

WARNING

BLACK LIGHT USEAGE

x Black lights generate considerable heat during use. Extreme care must be exercised to prevent contacting
the housing with any part of the body.
x To prevent injury to eyes, do not look directly into black light.
x Prolonged direct exposure of hands to the filtered black light’s main beam may be harmful. Suitable gloves
shall be worn when exposing hands to the main beam.

WARNING

INHALATION OF VAPORS
Prolonged or repeated inhalation of vapors or powders may result in irritation of mucous membrane areas of
the nose.

WARNING

LIQUID PENETRANT EXPOSURE

Continual exposure to penetrant inspection material may cause skin irritation.

WARNING

PRESSURIZED CANS
Temperature in excess of 49_C (120_F) may cause bursting of pressurized cans and injury to personnel.

WARNING

VOLATILE FUMES
Volatile fumes may occur, creating both a fire and health hazard.

WARNING

SOLVENT VAPORS
Prolonged breathing of vapor from organic solvents, degreasers, or paint thinners is dangerous. Use respira--
tors in confined areas per Occupational and Environmental Health Respiratory Protection Program (TB MED
502 (DLAM 1000.2)). Have adequate ventilation. Avoid prolonged skin contact. Wear rubber gloves and
goggles.

WARNING

RADIATION HAZARDS
Radiation HazardAssure compliance with all applicable safety precautions set forth in TM 1--1500--366--23 (Non--
destructive Inspection General Procedures and Process Control (ATOS)). A hazard associated with exposure

d
 TM 1--1520--265--23

to ionizing radiation is that serious injury can be inflicted without pain, burning, or other sense of discomfort
during the exposure period. Radiation protection shall be utilized in accordance with AR 385-10.

WARNING

LASER USE
The laser pointer is very dangerous. Looking at the laser beam or its reflection from a shiny surface can cause
permanent blindness. Under no conditions shall the laser beam be pointed at personnel.

WARNING

RESUSCITATION
Personnel working with or near high voltages should be familiar with modern methods of resuscitation. Such information
may be obtained from the Office of Bioenvironment Health or is listed in FM 4-25.11.

CAUTION

MIXING EMULSIFIERS
Penetrant--Emulsifier/Remover Combinations (lipophillic/hydrophilic) from one manufacturer may not be mixed
or used in conjunction with materials from a different manufacturer.

CAUTION

EQUIPMENT OPERATION
Do not operate magnetic particle equipment within 36 inches of aircraft instruments.

CAUTION

MISINTERPRETATION OF INDICATIONS
Misinterpretation of indications can result in rejectable parts being accepted and acceptable parts being re--
jected. Only NDI personnel trained and qualified in accordance with applicable military standards and technical
manuals shall perform and interpret nondestructive inspections.

e/(f blank)
 TM 1--1520--265--23

LIST OF EFFECTIVE PAGES

Insert latest changes; dispose of superseded pages in accordance with applicable policies.

NOTE: On a change page, the portion of the text affected by the latest change is indicated by a vertical
line in the outer margin of the page. Changes to illustrations are indicated by a vertical line in the outer
margin of the page next to the illustration and a hand pointing to the changed area on the illustration.

Dates of issue for original and change pages are:

Original 0 . . . . . . . . . . . . . . . . . . . . . . . . . . 30 May 2008

The total number of pages in this Nondestructive Inspection Procedure Manual is 387.

Page #Change Page #Change

No. No. No. No.

Title . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 2-108 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 3-1 - 3-26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
a-e .................................. 0 4-1 - 4-89 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
f Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 4-90 Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
A ...................................... 0 5-1 - 5-32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
B Blank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 6-1 - 6-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
i - xii . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 A-1 - A-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1-1 - 1-50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 B-1 - B-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
2-1 - 2-107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

# Zero in this column indicates an origianl page.

A/B blank
 *TM 1--1520--265--23

TECHNICAL MANUAL HEADQUARTERS

NO. 1--1520--265--23 DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 30 MAY 2008

Aviation Unit Maintenance (AVUM) and Aviation Intermediate Maintenance (AVIM) Manual
Nondestructive Inspection Procedures
for
H-60 Helicopter Series

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can improve this manual. If you find any mistakes, or if you know of a way to improve these
procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications
and Blank Forms), located in the back of this manual directly to: Commander, U.S. Army Aviation and
Missile Command, ATTN: AMSAM-MMC-MA-NP, Redstone Arsenal, AL 35898-5000. A reply will be
furnished to you. You may also send your comments electronically to our E-mail use:
[email protected] or by fax 256-842-6546/DSN 788-6546. For the World Wide Web use:
https://amcom2028.redstone.army.mil. Instructions for sending an electronic 2028 may be found at the
back of this manual immediately preceding the hard copy 2028.
WARNING - This document contains technical data whose export is restricted by the Arms Export Control
Act (Title 22, U.S.C. Sec 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C.,
App 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in
accordance with provisions of DOD Directive 5230.25.
DISTRIBUTION STATEMENT D. Distribution authorized to the DOD and DOD Contractors only due to
Critical Technology effective as of 15 June 2003. Other requests must be referred to Commander, US Army
Aviation and Missile Command, ATTN: SFAE-AV-UH/L, Redstone Arsenal, AL 35898-5230.
DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction
of the document.
TABLE OF CONTENTS

WARNING SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . a

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.1.1 Special Terms, Abbreviations, and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.1.2 How to Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.1.3 Inspection Item Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.4 Use of NDI Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.5 Use of Reference Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.6 Related Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.7 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.1.8 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
* This manual supersedes TM 1--1520--265--23, dated 30 November 1996 and all changes.

i
TM 1--1520--265--23

TABLE OF CONTENTS - Continued

Section/Paragraph Page
1.1.9 Stations, Waterlines, and Buttlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.2 Type of Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2.1 Rotor System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2.2 Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2.3 Airframe and Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.2.4 Power Plant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.2.5 Flight Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.2.6 Access and Inspection Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.2.7 Steps, Handholds, and Walkways . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
1.3 Marking and/or Recording of Inspection Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4 Nondestructive Inspection (NDI) Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.1 Purpose of NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-17
1.4.2 Selecting the NDI Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.3 Preparation of Helicopter for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.4 Preparation of Part or Area for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-18
1.4.5 Interpretation of Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.6 Acceptance/Rejection Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.7 Equipment Used for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-19
1.4.8 Materials Used for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.9 Post Cleaning and Restoration of Part or Area After NDI . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.10 NDI General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.11 Bond Testing (BT) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.11.1 Bond Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-20
1.4.11.2 Safety Precautions During Bond Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.4.12 Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.4.13 Fluorescent Penetrant (PT) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-23
1.4.13.1 Safety Precautions During Florescent Penetrant Inspection . . . . . . . . . . . . . . . . . . . 1-30
1.4.13.3 Controlling Excess Florescent Penetrant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.4.14 Interpretation of Liquid Penetrant Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.4.15 Indication Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.4.16 Magnetic Particle (MT) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-31
1.4.16.1 Magnetic Particle Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.4.16.2 Magnetic Particle Inspection Interpretations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1.4.16.3 Magnetic Particle Inspection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.4.16.3.1 Magnetic Yokes and Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.4.16.3.2 Hand-held Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-33
1.4.16.4 Safety Precuations During Magnectic Particle Inspections . . . . . . . . . . . . . . . . . . . . 1-33
1.4.17 Demagnetization of Inspection Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4.17.1 Demagnetization Using AC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4.17.2 Demagnetization Using DC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4.18 Radiographic (RT) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4.18.1 Safety Precautions During Radiographic Inspections . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
1.4.18.2 Mixing of Radiographic Film Processing Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.4.18.3 Radiographic Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1.4.18.4 Interpretation of Radiographic Inpsections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36

ii
 TM 1--1520--265--23

TABLE OF CONTENTS - Continued

Section/Paragraph Page
1.4.19 Eddy Current (ET) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.4.19.1 Safety Precautions During Eddy Current Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
1.4.19.2 Eddy Current Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.4.19.3 Eddy Current Scanning Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.4.19.3.1 Scanning Around Fasteners, Inserts and Edges of Parts . . . . . . . . . . . . . . . . . . . . . 1-38
1.4.19.3.2 Bolt-hole Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.4.19.3.3 Scanning Fillets and Radi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1.4.19.4 Eddy Current Instrument Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.4.19.5 Sorting Metal Using Eddy Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.4.19.6 Interpreting Eddy Current Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
1.4.20 Ultrasonic (UT) Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
1.4.20.1 Safety Precuations During Iltrasonic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
1.4.20.2 Ultrasonic Instrument Standardization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1.4.20.3 Ultrasonic Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
1.4.20.4 Ultrasonic Inspection Interpretation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
II ROTOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Split Cones (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 Ferrous Rotor System Bolts and Pins (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.4 Nonferrous Rotor System Bolts and Pins (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.5 Main Rotor Shaft Nut (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.6 Main Rotor Hub (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.7 Main Rotor Hub 11 O’Clock Bolt Hole (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.8 Spindle (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.9 Main Rotor Hub Spindle (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
2.10 Antiflap Bracket (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
2.11 Droop Stop Support Ring Nut (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
2.12 Droop Stop Support (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2.13 Balance Weight Bracket (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-41
2.14 Spindle Horn (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
2.15 Droop Stop Cam (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45
2.16 Damper Assembly (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2.17 Damper Piston (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2.18 Pitch Control Rods (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
2.19 Rotating Swashplate (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-53
2.20 Swashplate Spherical Bearing Holes (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2.21 Lower Link (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-57
2.22 Rotating Scissors (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
2.23 Bifilar Vibration Absorber (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-61
2.24 Bifilar Weight (UT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-64
2.25 Bifilar Weight Bushings (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
2.26 Bifilar Support Arm Bushing (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
2.27 Bifilar Weight Tapered Washers (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2.28 Main Rotor Blade Tip Cap Fairing (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73

iii
TM 1--1520--265--23

TABLE OF CONTENTS - Continued

Section/Paragraph Page
2.29 Main Roto Blade (Voids) (BT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2.30 Main Rotor Blade Cuff Assembly (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-77
2.31 Tail Rotor Blade Spar Center Plug (ET) . . Task . . . . . .deleted
. . . . . . . . .by
. . .H-60-MIM-15-002
................. 2-80
2.32 Tail Rotor Blade (Voids) (BT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82
2.33 Tail Rotor Blade (Fluid) (RT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
2.34 Tail Rotor Blade Tip Cap (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-89
2.35 Tail Rotor Pitch Beam (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
2.36 Tail Rotor Pitch Beam (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2.37 Tail Rotor Blade Pitch Horn (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
2.38 Tail Rotor Pitch Ccontrol Rod Ends (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
2.39 PIitch Beam Washer (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
2.40 PIitch Beam Retaining Nut (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
2.41 Tail Rotor Inboard/Outboard Retention Plates (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
III DRIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Main Transmission (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 Intermediate Gearbox (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3.4 Tail Rotor Drive Shaft (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.5 Tail Rotor Drive Shaft Supports (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3.6 Tail Rotor Drive Shaft Coupling (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3.7 Oil Cooler Drive Shaft (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
3.8 Oil Cooler Axial Fan Shaft (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3.9 Oil Cooler Fan Blades (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
3.10 Tail Gearbox (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3.11 Tail Gearbox Mount Fitting (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.12 Tail Rotor Gearbox Inner/Outer Split Cones (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.13 Ferrous Bolts Contained Within the Flight Control System (MT) . . . . . . . . . . . . . . . . 3-24
3.14 Nonferrous Bolts Contained Within the Flight Control System (PT) . . . . . . . . . . . . . . 3-24
IV AIRFRAME AND LANDING GEAR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Airframe Skin, Panels, Doors, Covers, and Fairings Metal (ET) . . . . . . . . . . . . . . . . 4-4
4.3 Tail Cone Fitting (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 Honeycomb and Composite Structures (BT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 Fluid in Honeycomb Core Panels and Structures (RT) . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6 Ferrous Vibration Absorber Springs (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.7 Nonferrous Vibration Absorber Springs (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.8 Vibration Absorber Structual Fittings (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.9 Roll Vibration Absorber (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.10 Cabin Vibration Upper and Lower Housing (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.11 Aluminum Structual Beams and Frames (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.12 Pilot/Copilot SeatT Midframe Support (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.13 Troop/Cargo Door Upper Track (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.14 Gunner’s Window Lower Track (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

iv
 TM 1--1520--265--23

4.15 Gunner’s Window Upper Track (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30

4.16 Troop/Cargo Door Lower Track (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4.17 Oil Cooler Compartment Access Door (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4.18 Tail Pylon Attach Fitting (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4.19 Tail Rotor Pylon Skin, Station 200 (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4.20 Tail Rotor Pylon Attaching Harware (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
4.21 Tail Pylon Lower Step (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4.22 Stabilator Attach Fitting (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
4.23 Stabilator Actuator Attach Fittings (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4.24 Stabilator Position Sensor Bracket (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
4.25 Stabilator Actuator Housing (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4.26 Drag Beam Support Fitting (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4.27 Drag Beam Jackpad and Tiedown Ring Holes (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-53
4.28 Main Landing Gear Drag Beam (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4.29 Main Landing Gear Fitting Spherical Bearing Bore (PT) . . . . . . . . . . . . . . . . . . . . . . . 4-57
4.30 Main Landing Gear Shock Strut Upper Cylinder (ET) . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4.31 Main Landing Gear Shock Strut Lower Stage Piston (MT) . . . . . . . . . . . . . . . . . . . . 4-60
4.32 Main Landing Gear Wheel Assembly Primary Method (PT) . . . . . . . . . . . . . . . . . . . . 4-62
4.33 Main Landing Gear Wheel Assembly Alternate Method (ET) . . . . . . . . . . . . . . . . . . 4-63
4.34 Main Landing Gear Brake (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
4.35 Main Landing Gear Brake Housing (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69
4.36 Parking Brake Valve Components (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4.37 Slave Mixer Valve Parts (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4.38 Tail Laning Gear Shock Strut (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.39 Tail Landing Gear Yoke (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-73
4.40 Tail Landing Gear Fork (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4.41 Tail Landing Gear Wheel Assembly Primary Method (PT) . . . . . . . . . . . . . . . . . . . . . . 4-79
4.42 Tail Landing Gear Wheel Assembly Alternate Method (ET) . . . . . . . . . . . . . . . . . . . 4-80
4.43 Cargo Hook Trunnions, Trunnion Retaining Bolts and Nuts and Load Beam (MT) 4-84
4.44 Cargo Hook Plate Edge and Bolt Hole Surface (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-86
4.45 Cargo Hook Trunnion Retainers (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4.46 Ferrous Bolts and Pins Contained within the Airframe and Landing Gear
System (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
4.47 Nonferrous Bolts and Pins Contained within the Airframe and Landing Gear
System (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89
V POWER PLANT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 Deswirl Duct Vanes and Loop Clamp (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3 Engine Tubing, Couplings, Air Ducts, Fittings, Supports, Brackets, and Clips (PT) 5-4
5.4 Air Inlet Assembly and Bleed-Air Exhaust Slots (ET) . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5.5 Aft Engine Mount Struts (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5.6 Aft Engine Mount Fittings (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5.7 Aft Engine Mount Links (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.8 Aft Engine Mount Support (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.9 Crotch Assembly and Segment Ring (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
5-10 Forward Support Tube (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.11 Exhaust Ejector and Attaching Angles (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18

v
TM 1--1520--265--23

5.12 Exhaust Fairings (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19

5.13 HIRRS and Nacelle Fairing Support Mounts (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.14 Suppressor Core and Baffle (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
5.15 HIRSS Exhaust Extender (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.16 Rotary Input Assembly (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5.17 Engine Load Demand Control Cable Support (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5.18 Engine Air Inlet “V” Band Clamp (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.19 Starter Flange (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
5.20 Engine Shroud (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.21 Engine Load-Demand Spindle Bellcrank Support (ET) . . . . . . . . . . . . . . . . . . . . . . . 5-30
5.22 Engine Components (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
VI FLIGHT CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Toe-Pedal Actuator (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 Toe-Pedal Assembly (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.4 YAW-Pedal Sopport Shaft (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.5 YAW-Pedal Brake Cylinder Supports (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.6 Pedal Adjuster Arms and Link (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.7 Pilot/Copilot Cyclic and Collective Stick Socket (ET) . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.8 Collective Boost and YAW Boost Servo Input/Output Piston Shafts
and Cylinders (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.9 YAW/Pitch Coupling Link (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.10 Ferrous Flight Control System Push-Pull Rods (MT) . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.11 Nonferrous Flight Control System Push-Pull Rods (ET) . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.12 Pilot Collective Stick Bellcrank Support (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
6.13 Pilot/Copilot Collective Stick Support (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.14 Pilot Collective Stick Bellcrank (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.15 Ferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching
Parts (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.16 Nonferrous Connecting LInks, Rod Ends, Clevises, Levers and
Attaching Parts (ET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.17 Swashplate Links (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.18 Walking Beam (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6.19 Forward Bellcrank (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6.20 Lateral Bellcrank (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
6.21 Aft Bellcrank (MT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.22 Hydraulic/Pneumatic System Components (PT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.23 Ferrous Bolts Contained Within the Flight Control System (MT) . . . . . . . . . . . . . . . 6-44
6.24 NonFerrous Bolts Contained Within the Flight Control System (PT) . . . . . . . . . . . . 6-44
APPENDIX A MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
APPENDIX B EQUIPMENT LISTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
APPENDIX C ILLUSTRATED FIELD MANUFACTURE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . C-1
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

vi
 TM 1--1520--265--23

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Nondestructive Inspection Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

1-2 General Configuration of UH-60 Helicopter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
1-3 Stations, Waterlines, and Buttlines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1-4 Access and Inspection Provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
1-5 Bond Testing Reference Block Displays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-22
1-6 Portable Magnetic Particle Inspection Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
1-7 Signatures of EDM Notches in Test Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
1-8 Typical Metal Sorting Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
2-1 Rotor system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2-2 Split Cones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-3 Ferrous Rotor System Bolts and Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-4 Nonferrous Rotor System Bolts and Pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-5 Main Rotor Shaft Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-6 Main Rotor Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-7 Main Rotor Hub 11 O’Clock Bolt Hole . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-8 Probe Position on Hoizontal and Vertical Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2-9 Spindle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
2-10 Spindle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2-11 End View of Lug RH Scan Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
2-12 End View of Lug, LH Scan Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-13 Calibration Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
2-14 Transducer Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-15 Transducer Positions A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
2-16 Signal Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-23
2-17 RH Inspection, Scan #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-18 RH Inspection, Scan #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
2-19 RH Inspection, Scan #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-20 RH Inspection, Scan #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25
2-21 RH Inspection, Scan #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-22 RH Inspection, Scan #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-26
2-23 RH Inspection, Scan #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-24 RH Inspection, Scan #8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27
2-25 Transducer Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-26 Transducer Positions A and B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-28
2-27 Signal Amplitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2-28 LH Inspection, Scan #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
2-29 LH Inspection, Scan #2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-30 LH Inspection, Scan #3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-30
2-31 LH Inspection, Scan #4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-32 LH Inspection, Scan #5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
2-33 LH Inspection, Scan #6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-34 LH Inspection, Scan #7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32
2-35 LH Inspection, Scan #8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

vii
TM 1--1520--265--23

LIST OF ILLUSTRATIONS - Continued

2-36 Noisy Baseline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-33

2-37 Nonrelevant Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2-38 Crack Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
2-39 Antiflap Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
2-40 Droop Stop Support Ring Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39
2-41 Balance Weight Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42
2-42 Spindle Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
2-43 Droop Stop Cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
2-44 Damper Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
2-45 Longitudinal Crack Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-49
2-46 Circumferential Crack Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
2-47 AC Coil Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-51
2-48 Pitch Control Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-54
2-49 Rotating Swashplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
2-50 Lower Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-59
2-51 Rotating Scissors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-60
2-52 Bifilar Vibration Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
2-53 Bifilar Free Edge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2-54 Baseline Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-66
2-55 Signal Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
2-56 Inspection of Sintered Bondline . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-67
2-57 Sintered Bondline Inspection Zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-68
2-58 6dB Down Length Determination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-69
2-59 Bifilar Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
2-60 Bifilar Support Weight Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
2-61 Bifilar Weight Tapered Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-72
2-62 Main Rotor Blade Tip Cap Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-74
2-63 Main Rotor Blade (Voids) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
2-64 Main Rotor Blade Cuff Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-79
2-65 Tail Rotor Blade Center Spar Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-81
2-66 Tail Rotor Blade (Voids) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-84
2-67 Tail Rotor Blade (Fluid) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
2-68 Tail Rotor Blade Tip Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
2-69 Tail Rotor Pitch Beam Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
2-70 Tail Rotor Pitch Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-94
2-71 Tail Rotor Pitch Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
2-72 Tail Rotor Pitch Control Rod Ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
2-73 Pitch Beam Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-100
2-74 Pitch Beam Retaining Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102
2-75 Tail Rotor Inboard/Outboard Retention Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-104

viii
 TM 1--1520--265--23

LIST OF ILLUSTRATIONS - Continued

3-1 Transmission/Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2 Main Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-3 Intermediate Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-4 Tail Rotor Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
3-5 Tail Rotor Drive Shaft Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-6 Tail Rotor Drive Shaft Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-7 Oil Cooler Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
3-8 Oil Cooler Axial Fan Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-9 Oil Cooler Fan Blades . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
3-10 Tail Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
3-11 Tail Gearbox Mount Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-12 Tail Rotor Gearbox Inner/Outer Split Cones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23.
4-1 Airframe and Landing Gear System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2 Airframe Skin, Panels, Doors, Covers, and Fairings - Metal . . . . . . . . . . . . . . . . . . . 4-6
4-3 Tail Cone Fold Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-3 Honeycomb and Composite Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-4 Fluid in Honeycomb Core Panels and Structures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4-5 Vibration Absorber Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-6 Ferrous Vibration Absorber Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-7 Nonferrous Vibration Absorber Springs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-8 Vibration Absorber Structual Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-9 Roll Vibration Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-11 Aluminum Structural Beams and Frames . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4-12 Pilot/Copilot Seat Midframe Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-13 Troop/Cargo Door Upper Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4-14 Gunner’s Window Lower Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-15 Gunner’s Window Upper Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-16 Troop/Cargo Door Lower Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-17 Oil Cooler Compartment Access Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
4-18 Tail Pylon Attach Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
4-19 Tail Rotor Pylon Skin, Station 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
4-20 Tail Rotor Pylon Attaching Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-41
4-21 Tail Pylon Lower Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
4-22 Stabilator Attach Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-45
4-23 Stabilator Actuator Attach Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
4-24 Stabilator Position Sensor Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
4-25 Stabilator Actuator Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
4-26 Drag Beam Support Fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
4-27 Jackpad and Tiedown Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
4-28 Main Landing Gear Drag Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
4-29 Main Landing Gear Fuselage Fitting Sperical Bearing . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
4-30 Main Landing Gear Shock Strut Upper Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
4-31 Main Landing Gear Shock Strut Lower Stage Piston . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
4-32 Main Landing Gear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-63
4-33 Notched Reference Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

ix
TM 1--1520--265--23

4-34 Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65

4-35 Main Landing Gear Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
4-36 Main Landing Gear Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-68
4-37 Main Landing Gear Brake Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-70
4-38 Parking Brake Valve Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-71
4-39 Slave Mixer Valve Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-72
4-49 Eddy Current Scan Paths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74
4-41 Tail Landing Gear Yoke and Radius Scan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-76
4-42 Typical Dispaly for Radius Cracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-77
4-43 Tail Landing Gear Fork . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-79
4-44 Tail Landing Gear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-80
4-45 Notched Reference Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
4-46 Screen Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82
4-47 Tail Landing Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-83
4-48 Cargo Hook Positions 1-3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4-49 Cargo Hook Position 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85
4-50 Cargo Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-87
4-51 Cargo Hook Trunnion Retainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-88
5-1 Power Plant System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2 Deswirl Duct Vanes and Loop Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-3 Engine Tubing, Couplings, Air Ducts, Fittings, Supports, Brackets and Clips . . . . . . 5-5
5-4 Air Inlet Assembly and Bleed-Air Exhaust Slots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-5 Aft Engine Mount Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-6 Aft Engine Mount Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-7 Aft Engine Mount Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-8 Aft Engine Mount Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5-9 Crotch Assembly and Segment Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-10 Forward Support Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-11 Exhaust Ejector and Attaching Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-12 Exhaust Fairings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5-13 HIRSS and Nacelle Fairing Support Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5-14 Suppressor Core and Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-15 HIRSS Exhaust Extender . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-16 Rotary Input Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
5-17 Engine Load Demand Control Cable Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-18 Engine Air Inlet “V” Band Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-19 Starter Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-20 Engine Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30
5-21 Engine Load demand Spindle Bellcrank Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
5-22 Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
6-1 Flight Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-2 Toe Pedal Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-3 Toe Pedal Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4 Yaw Pedal Support Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-5 Yaw Pedal Brake Cylinder Supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-6 Pedal Adjuster Arms and Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-7 Pilot/Copilot cyclic and Collective Stick Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

x
 TM 1--1520--265--23

LIST OF ILLUSTRATIONS - Continued

6-8 Collective Boost and Yaw Boost Servo Input/Output Piston Shafts and
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-9 Yaw/Pitch Coupling Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-10 Ferrous Flight Control System Push-Pull Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6-11 Nonferrous Flight Control System Push-Pull Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-12 Pilot Collective Stick Bellcrank Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
6-13 Pilot/Copilot Collective Stick Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6-14 Pilot Collective Stick Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6-15 Ferrous Connecting Links, Rod Ends, Clevises, Levers, and attaching Parts . . . . 6-30
6-16 Nonferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
6-17 Swashplate Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
6-18 Walking Beam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
6-19 Forward Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
6-20 Lateral Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
6-21 Aft Bellcrank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
6-22 Hydraulic/Pneumatic System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

xi
TM 1--1520--265--23

LIST OF TABLES

Number Title Page

1-1 Supporting Technical Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1-2 Access Panels and Fairing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15
1-3 Frequency for Liquid Penetrant Process Control Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-24
1-4 Penetrant Procedure (Type I, Method A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-25
1-5 Penetrant Procedure (Type I, Method B) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-26
1-6 Penetrant Procedure-Portable or Field Application (Type I, Method C) . . . . . . . . . . . . . . . . 1-27
1-7 Penetrant Procedure (Type I, Method D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
1-8 Developer Dwell Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-29
1-9 Frequency for Magnectic Partical Process Control Checks . . . . . . . . . . . . . . . . . . . . . . . . . . 1-32
1-10 Frequency for Radiography Process Control Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
1-11 Frequency for Eddy Current Process Control Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
1-12 Frequency for Ultrasonic Inspection Process Control Checks . . . . . . . . . . . . . . . . . . . . . . . . 1-43
1-13 Equipment Used for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-44
1-14 Materials Used for NDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-45
2-1 Rotor System Inspection Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
3-1 Drive System Inspection Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
4-1 Airframe and Landing Gear System Inspection Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
5-1 Power Plant System Inspection Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
6-1 Flight control system Inspection Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

xii
 TM 1-1520-265-23

SECTION I
INTRODUCTION
1. INTRODUCTION.
a. This manual contains instructions for accomplishing Nondestructive Inspection (NDI) of the
H-60 helicopter series at the AVUM and AVIM levels. The procedures described in this manual are
intended to provide instructions for the NDI of locations where service defects would prevent items
from preforming their designated functions, and of components for serviceability. These procedures
were developed through review of H-60 series Technical Manual inspection requirements. The goal
is to upgrade these requirements wherever possible using NDI methodology to improve inspection
quality, decrease inspection time, and increase systems operational readiness. Other factors
involved were maintenance engineering analysis, experience, and comparison with similar
installations. Procedures shall be reviewed and changes and additions made during the service life
of the equipment by continually evaluating the following: performance of the equipment, results of
scheduled inspections, and thorough study of failure data. Local conditions, such as special
utilization of climatic environment, may dictate more detailed inspections. Commanders and their
maintenance officers are expected to exercise their prerogative to increase the frequency and scope
of any inspection as required.
b. This manual may pertain to part, or all types and series, of a model, and may, therefore,
contain requirements applicable to specific equipment that is not installed on an individual model.
When this situation is encountered, those requirements that are not applicable should be
disregarded.
c. This manual does not contain inspection level or frequency, acceptance and rejection
limitations, nor instructions for correcting defective conditions. Inspection levels and frequency are
provided in the inspection requirements manuals. Detailed acceptance and rejections criteria and
instructions for correcting defective conditions are provided in applicable maintenance manuals and
are, therefore, not contained in this manual. Decisions regarding the serviceability of components
properly belong with maintenance technicians trained, skilled, and experienced in their particular
specialty, such as airframe, hydraulic, or propulsion. Also, it would duplicate existing information and
make the task of incorporating the numerous changes to inspection frequency and repair
instructions impractical.
d. The inspection requirements are stated in such a manner as to address the following: (1)
What part or area is to be inspected? (2) What conditions are to be sought? (3) What NDI method
is to be used? (4) How is the method to be performed? In scope, the inspection procedures are
designed to direct attention of maintenance personnel to components and areas where service
defects can occur. The procedures also provide detailed instructions on the application of NDI in an
effort to ensure the serviceability of these areas.
e. Nondestructive inspection methods require application by trained, experienced, and
proficient technicians. This manual provides detailed procedures for the application of
nondestructive methods to inspect specific areas or locations. However, it must be emphasized that
the reliability of the inspection depends upon the proper evaluation of the results obtained from the
inspection equipment.
f. While using this manual, such adjectives as left and right, upper and lower, front and rear,
forward and aft, and clockwise and counterclockwise refer to the helicopter as viewed from the rear
(aft), looking forward.
g. Changes and supplements to this manual will be published when necessary to add, delete,
or change the scope of requirements. Such changes will be based on factual data accumulated as

1--1
TM 1-1520-265-23

a result of maintenance experience with the equipment. Suggested new or revised field developed
inspection procedures or changes to this manual are encouraged and should be made by submitting
a DA Form 2028. Mail to: Commander, U.S. Army Aviation and Missile Command, ATTN:
AMSAM-MMC-MA-NP, Redstone Arsenal, AL 35898-5000. Our fax number DSN 788--6546 or
Commercial 256--842--6546. Our e-mail is [email protected]. Instructions for sending and
electronic 2028 may be found at the back of this manual immediately preceding the hard copy 2028.

h. These NDI procedures are directive in nature, and deviation without prior approval is limited
to compensation for differences in equipment output. Equipment settings, when given, are reference
points only, due to the widely varying outputs from different inspection equipment. The condition that
must be satisfied for accurate inspection is that the inspection equipment be adjusted to obtain the
specified response from the set-up or defect standard, or the specified density reading on
radiographic film. Trained NDI technicians are qualified to make these adjustments.

1.1 GENERAL INFORMATION.

CAUTION
Misinterpretation of indications can result in rejected parts being accepted and
acceptable parts being rejected. Only NDI personnel trained and qualified in
accordance with applicable military standards and technical manuals shall perform
and interpret nondestructive inspections.
a. The use of the words Shall, Should, May and Will. Use the word “Shall” whenever a manual
expresses a provision that is binding. Use the word “Should” and “May” whenever it is necessary
to express non--mandatory provisions. “Will” may be used to express a declaration of purpose. It
may be necessary to use “Will” in cases where simple futurity is required (e.g. “Power for the meter
will be supplied by the ship.”)
b. This manual provides necessary information to enable qualified personnel to perform NDI
on H-60 helicopter series. The selection of components in this manual is based on a review of
applicable technical manuals listed in Table 1-1. All existing NDI callouts were updated. New NDI
procedures were developed for those parts that required check, inspect, or any other NDI related
actions. Section I of this manual contains a list of special terms, abbreviations, acronyms,
information on how to use this manual, use of NDI symbols, and a list of publications. Section I also
contains general information on the H-60 helicopter, including descriptive data, access panels,
major assemblies, stops, handholds, walkways, various NDI method descriptions, and rules of
safety to be observed during nondestructive inspections.
c. Additional information on inspection methods can be found in the Technical Manual,
Nondestructive Inspection Methods, Basic Theory, TM 1-1500-366-23. Detailed inspection
instructions for each main aircraft group are given in Sections II through VI of this manual.

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 TM 1-1520-265-23

Table 1-1. Supporting Technical Documentation

Document Description
DA Pam 385-24 The Army Radiation Safety Program
AR 40--13 Medical Support - Nuclear/Chemical Accidents and Incidents
ASTM-E114 Pulse-Echo Straight-Beam Examination, Ultrasonic, by the Contact
Method
ASTM-E1444 Magnetic Particle Testing
ASTM E1417 Standard Practice for Liquid Penetrant Examination
ASTM--E1742 Radiographic Examination
DA PAM 738-751 Functional Users Manual for the Army Maintenance Management
System - Aviation (TAMMS-A)
DOD 6050.5 Hazard Communication Program
FM 4-25.11 First Aid
NAS 410 NAS Certification and Qualification of Nondestructive Test Person-
nel
TB MED 502 Respiratory Protection Program
(DLAM 1000.2)
TM 1-1500-335-23 Nondestructive Inspection Methods, Basic Theory
TM 1-1500-344-23 Cleaning and Corrosion Control, Volumes 1- IV
TM 1-1500-366-23 Nondestructive Inspection General Procedures and Process
Controls (ATOS)
TM 1-1520-237-23 Technical Manual, Aviation Unit and Intermediate Maintenance for
(series) Army Models UH-60A, UH-60L, EH-60A, HH-60A and HH-60L
Helicopters
Chapter 1 General Information, Equipment Description and Data, Theory of
Operation
Chapter 2 through 4 Troubleshooting Procedures
Chapter 5 through 19 Maintenance Instructions
Chapter 20 Supporting Information
IETM EM 0013 TM 1-1520-BLACK HAWK
IETM EM 0271 Aviation Unit and Intermediate Maintenance Instructions, Engine
Aircraft, Turboshaft Model T700-GE-700, T700-GE--701,
T700-GE-701C

1--3
TM 1-1520-265-23

1.1.1 Special Terms, Abbreviations, and Acronyms.

AC Alternating Current
APU Auxiliary Power Unit
AVIM Aviation Intermediate Maintenance
AVUM Aviation Unit Maintenance
BL Buttline
BT Bond Testing Method
C Celsius
CCW Counterclockwise
CL Centerline
CPG Copilot/Gunner
CRT Cathode Ray Tube
CW Clockwise
DEC Digital Electronic Control
DC Direct Current
EDM Electrically Discharged Machined Notches
EEC Electrical Engine Control
ET Eddy Current Method
F Fahrenheit
FPS Flight Path Stabilization
FSH Full Screen Height
FWD Forward
HdB Horizontal Decibels (Gain)
H Pos Horizontal Position
HPF High Pass Filter
HIRSS Hover Infrared Suppression System
ID Inside Diameter
IR Infrared
INBD Inboard
KHz Kilohertz
LCD Liquid Crystal Display
LE Leading Edge
LH Left-hand (left side of aircraft aft looking forward
LPF Low pass Filter
MAC Maintenance Allocation Chart
MAX Maximum
MHz Megahertz
MIN Minimum

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 TM 1-1520-265-23

MLG Main Landing Gear

M/R Main Rotor
MT Magnetic Particle Method
NDI Nondestructive Inspection
OUTBD Outboard
P/N Part Number
PSI Pounds per Square Inch
PSIG Pounds per Square Inch Gauged
PT Fluorescent Penetrant Method
RH Right-hand (right side of aircraft aft looking forward)
ROT Rotation
RT Radiographic Method
SAS Stability Augmentation System
SPAD Shear Pin Activated Decoupler
STA Station
TLG Tail Landing Gear
TM Technical Manual
T/R Tail Rotor
UT Ultrasonic Method
VdB Vertical Decibels (Gain)
V Pos Vertical Position
WL Waterline
1.1.2 How to Use This Manual. This manual is divided into six sections as follows:
I Introduction
II Rotor System
III Drive System
IV Airframe and Landing Gear System
V Power Plant System
VI Flight Control System
Section I contains the introduction and general information pertaining to the H-60 helicopter series
and Nondestructive Inspections. Section II through VI contain detailed inspection procedures for
specific items located within each system. In general, inspection items are grouped with respect to
part location and function. To use this manual, it is necessary to know the system and name of the
inspection item.
When the system and part name are known:
a. Turn to the applicable section of the manual covering that system. Refer to the system
inspection index table at the beginning of the section. If the item is listed, the corresponding
paragraph and figure number will be referenced in the table.
b. Turn to referenced inspection paragraph and figure for detailed inspection information.
1.1.3 Inspection Item Code. When inspection items, due to their proximity, are grouped in one
illustration, the figure will be indexed using the inspection item code. This code consists of digits
separated by dashes.

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TM 1-1520-265-23

In the text, the inspection item is identified as follows:

a. The first digit refers to the section of the manual in which the item appears. Example:
Paragraph 2.5 is found in Section II.
b. The second digit refers to the item number or order that the part procedure occurs in the
manual section. Example: Paragraph 2.5 refers to item number 5.
1.1.4 Use of NDI Symbols. Nondestructive inspection symbols and their application to detail
inspection figures are shown in Figure 1-1. In the main figures of each section, NDI symbols
representing the type of inspection associated with a part will appear next to the item number on the
figure.
1.1.5 Use of Reference Publications. This manual is applicable to the H-60 helicopter series. The
technician shall be responsible for using the applicable referenced TM for the helicopter being
inspected.
1.1.6 Related Publications. Supporting TMs and reference materials are listed in Table 1-1.
1.1.7 Description. The H-60 helicopter series are twin turbo-shaft engine aircraft. The primary
mission of the UH-60A and the UH-60L is the transportation of troops, litter patients, and equipment.
The primary mission of the HH--60A and HH--60L is to provide medical evacuation and transport
medical teams and supplies. The EH-60A primary mission is electronic surveillance of selected
targets using sophisticated intercept and direction-finding equipment. The UH-60A, HH--60A and
EH-60A helicopters are powered by T700-GE-700 engines while the UH-60L and HH--60L is
powered by T700-GE-701C or T700-GE-701D/CC engines. The T700-GE-701C has a digital
electronic control (DEC) while the -700 has an electrical control unit (ECU).
The primary structure is aluminum alloy with titanium, steel, and reinforced plastic in secondary and
nonstructural members. The UH-60A and UH-60L have 12 troop seats in the helicopter midsection.
The EH-60A has a mission operator and an observer seat along with surveillance equipment in the
same area. The HH--60A/HH--60L contain medial attendant and patient stations as well as medical
oxygen generation systems. All H-60 helicopter series have pilot/copilot accommodations.
1.1.8 Configuration. The general configuration of the H-60 helicopter series is shown in Figure
1-2.
1.1.9 Stations, Waterlines, and Buttlines. Stations, waterlines, and buttlines (in inches) are used
as an accurate method of locating or installing equipment in the airframe. See Figure 1-3 for stations,
waterlines, and buttlines for this helicopter.

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 TM 1-1520-265-23

Figure 1-1. Nondestructive Inspection Symbols

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TM 1-1520-265-23

Figure 1-2. General Configuration of UH-60 Helicopter

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 TM 1-1520-265-23

Figure 1-3. Stations, Waterlines, and Buttlines (Sheet 1 of 2)

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TM 1-1520-265-23

Figure 1-3. Stations, Waterlines, and Buttlines (Sheet 2 of 2)

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 TM 1-1520-265-23

a. Stations. Stations (STA) are distances from a point in front of the helicopter nose. The first
station is zero (0.00).
b. Waterline. Waterlines (WL) are distances from a point below the helicopter.
c. Buttlines. Buttlines (BL) are distances from the center of the helicopter. They start at the
center and show the distance to each side of the helicopter. Buttlines will be either to the left
or right side.
These dimensions help you find any point on the helicopter. Each point shown in Figure 1-3 is a part
of the helicopter you can see.

1.2 TYPE OF CONSTRUCTION.

NOTE
The following paragraphs describe the type of construction and materials used in the
manufacture of the major H-60 helicopter series components.
1.2.1 Rotor System. Four main rotor blades are installed on the main rotor head. The main rotor
blade has a pressurized titanium spar, Nomex honeycomb core, fiberglass skin, nickel and titanium
abrasion strips, a removeable swept-back tip fairing, and a resistive heating mat used when the
blade de-ice system is activated. A titanium cuff and expandable pins or solid pins attach the blade
to the rotor head.
The main rotor head transmits movements of the flight controls to the four main rotor blades. The
main rotor head turns in a counter clockwise direction. The head is supported by the main rotor shaft
extension that is splined to the main transmission main shaft, which drives the head.
The canted tail rotor head is driven by the tail gearbox which is driven by a drive shaft from the main
transmission. The tail rotor blades are attached to the tail rotor head. Tail rotor blades are built
around two graphite composite spars running from tip-to-tip and crossing each other at the center
to form the four blades. The blade spars are covered with cross-ply fiberglass to form the airfoil
shape. Polyurethane and nickel abrasion strips are bonded to the leading edge of the blades.
1.2.2 Drive System. The transmission system carries engine torque to the main rotor and the tail
rotor. It consists of a main transmission with oil cooler, intermediate gearbox, and drive shafts. The
main transmission drives the main rotor, tail rotor, main transmission oil cooler fan, No. 1 and No.
2 hydraulic pump modules, and No. 1 and No. 2 generators.
The intermediate gearbox, driven by tail rotor shafts, is mounted at the base of the pylon. The
intermediate gearbox carries main transmission torque to the tail gearbox. The tail gearbox,
mounted at the top of the pylon, holds the tail rotor head to which the tail rotor blades are attached.
1.2.3 Airframe and Landing Gear System. The helicopter airframe is divided into six sections:
cockpit (nose section), cabin, transition section, tail cone, tail rotor pylon, and main rotor pylon. The
primary structure is aluminum alloy. Some titanium and steel are used for firewalls and various
fittings. Nonstructural members are primarily made of reinforced plastic. The fuselage is
semi-monocoque construction with horizontal anti-plough beams extending through the tub from the
cockpit to the transition section.

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TM 1-1520-265-23

The landing gear system consists of two fixed landing gears and a tail landing gear. Each main
landing gear has a self-adjusting brake assembly. The landing gear system enables the helicopter
to maneuver during ground operations, absorb landing loads through the shock strut assemblies,
and insulates the airframe and occupants from shock.
1.2.4 Power Plant System. Two General Electric T700-GE-700 engines power the UH-60A,
HH--60A and the EH-60A helicopter while two General Electric T-700-GE-701C engines power the
UH-60L and HH--60L helicopter. The biggest difference is that the -700 engines have electrical
control units (ECU) and a history recorder, while the -701C and 701D/CC have a digital electronic
control (DEC).
The de-mountable power packages are mounted on each side of the main transmission. A drive
shaft assembly and forward support tube connect the engine to the input gearbox module of the main
transmission. A power turbine shaft extending through the engine drives the input gearbox module.
Each power package allows a quick change of engines with all components installed, for ease of
maintenance and handling.
1.2.5 Flight Control System. The flight controls consist of the collective, cyclic, and tail rotor
(directional) control systems. These systems use a series of push-pull rods, bellcranks, cables,
pulleys, and servos that transmit control movements from the cockpit to the main and tail rotors. The
pilot and copilot have dual controls. Hydraulic power is supplied by the first stage, second stage, and
backup hydraulic systems. Electrical power is provided by the AC and DC electrical system.
Assistance for the pilot or copilot in pitch, roll, and yaw control is provided by the stability
augmentation system (SAS), flight path stabilization (FPS), and electro-mechanical trim.
1.2.6 Access and Inspection Provisions. Access and inspection provisions consist of access
doors, covers, panels, platforms, screens, and openings used for maintenance, servicing, and
inspection of the helicopter and its components. Principal access and inspection openings are
shown in Figure 1-4 and listed in Table 1-2.

WARNING

To prevent injury to personnel and damage to helicopter, stand only on designated

surfaces. These areas are reinforced to withstand frequent use and are treaded to
prevent slipping. All other surfaces are NO STEP areas.

1.2.7 Steps, Handholds, and Walkways. Steps, handholds, and walkways aid in doing
maintenance, inspections, and servicing on the helicopter.

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 TM 1-1520-265-23

Figure 1-4. Access and Inspection Provisions (Sheet 1 of 2)

1--13
TM 1-1520-265-23

Figure 1-4. Access and Inspection Provisions (Sheet 2 of 2)

1--14
 TM 1-1520-265-23

Table 1-2. Access Panels and Fairing

Item Number Item Access To
1B-GS-A-1 Glide Slope Antenna Nose Vibration Damper
Fairing
1B-2B-1 Nose Door (Hinged) Electronics
4B-26 Access Panel External Power
3T-3 Access Panel (Hinged) Shock Strut
4T-4
3B-30 Access Panel (2 parts) Shock Strut
4B-31
3T-4T-2 Sliding Cover (on tracks) Controls/Accessories
3T-7 Engine Cowling (hinged) Engine
4T-8
3T-5 Access Panel Anti-Icing Valve
4T-6
4B-24 Access Cover Cargo Hook
3T-25 Access Panel (hinged) Oil Cooler
3T-27 Access Panel (hinged) APU
4T-28 Access Panel (hinged) Fire Extinguishers
3T-22 Access Panel (hinged) Gravity Fuel
4T-22
3T-3B-23 Access Panel (hinged) Pressure Fuel
3T-3B-21 Access Panel (hinged) Pneumatic Ground Start
3B-3T-20 Access Panel Mag Flux Valve
5T-6T-9 Access Panel (hinged) Drive Shaft
5T-6T-10 Access Panel (hinged) Drive Shaft
5T-6T-17 Intermediate Gearbox Intermediate Gearbox
Cover
5T-6T-11 Pylon Drive Shaft Cov- Drive Shaft
er/#1 FM Antenna
5T-5B-18 Access Panel Pylon Fold Hinge Bolts
6T-6B-32
5T-6T-12 Tail Gearbox Cover Tail Gearbox
5T-6T-15 Fairing Pylon Trailing Edge
5B-6B-16 Fairing Lower Pylon
5B-45 Cover Stabilator Attach Fittings
6B-46
5B-5T-19 VOR/LOC Antenna
6B-6T-19
5T-6T-13 Troop Commander An-
tenna
5T-14 Access Panel (hinged) Upper Actuator Attach
4B-33 Access Panel (hinged) Electronics
(NOTE 2)

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TM 1-1520-265-23

Table 1-2. Access Panels and Fairing - Continued

Item Number Item Access To
4T-4B-34 Access Panel (hinged)
(NOTE 2)
6B-35 Access Panel (hinged) Filter
(NOTE 2)
6T-36 Access panel, Flux Valve Mag Flux Valve
(NOTE 2)
3T-33 Fairing and Platform ESSS Maintenance Crane Attachment
4T-34 (2 part hinged)
(NOTE 1)
3T-35 Cap Fairing ESSS
4T-36 (NOTE 1)
3T-3B-37 Access panel (hinged) Step/Shock Strut
4T-4B-38 (NOTE 1) Shock Strut
3B-39 Lower Fairing STA 295 ESSS
(NOTE 1)
3B-42 Lower Fairing STA 308 ESSS
(NOTE 1)
4B-43 Lower Fairing STA 295 ESSS
(NOTE 1)
4B-44 Lower Fairing STA 308 ESSS
(NOTE 1)

NOTES
1. ESSS
2. EH-60A
NUMBER CODES
1 Left Side Cockpit
2 Right Side Cockpit
3 Left Side Cabin
4 Right Side Cabin
5 Left Side Tail Cone and Pylon
6 Right Side Tail Cone and Pylon
T Top above WL 232
B Bottom below WL 232

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 TM 1-1520-265-23

1.3 MARKING AND/OR RECORDING OF INSPECTION RESULTS.

NOTE
Only approved pencils listed in Table 1-14 are to be used for temporary marking of
indications found during an NDI inspection. The color of the markings shall contrast
with the color of the part.
a. Wipe the area to be marked with cleaning cloth, MIL-C-85043.
b. Mark surface with appropriate color aircraft pencil, MIL-P-83953, using a light touch.
c. Remove markings as soon as there is no further need for them with a cloth, MIL-C-85043,
dampened with tap water. It is allowable for a shadow of the marking to remain on surfaces
after removal.

WARNING

DEGREASING SOLVENT
MIL--PRF--680B, TYPE II
MIL--PRF--680B, Type II is combustible and toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact.
Use only in well--ventilated areas (or use approved resipirator as determined by local
safety/industrial hygiene personnel). Keep away from open flames or other sources
of ignition.

d. Cleaning compound, MIL--PRF-680B, Type II shall be used for removal of markings on acrylic
lacquer surfaces.
e. Record inspection results as required by the applicable technical manuals listed in Table 1-1.

1.4 NONDESTRUCTIVE INSPECTION METHODS.

1.4.1 Purpose of Nondestructive Inspection (NDI). Methods used in NDI are those that may be
applied to inspect a structure or component to determine its ability to perform its intended function
without damaging or causing any change in the characteristics of the structure or component. During
manufacture, aircraft components are given in-process and final inspections. The most commonly
used methods are magnetic particle and liquid penetrant because these two methods are bulk
processes that provide 100 percent inspection coverage, and are highly effective. It is unusual, but
possible, for NDI personnel to locate defects that are inherent (associated with the production of the
material) or related to the manufacturing operations. It follows that nearly all maintenance
nondestructive inspection requirements are to locate defects that have developed during service
(i.e., corrosion and corrosion-induced cracking; fatigue cracks; and defects resulting from
mechanical damage, improper maintenance, or inappropriate use). It is important that NDI
personnel shall be able to distinguish between inherent and in-service defects. A general knowledge
of typical sites for in-service defect occurrence and specific knowledge of the mode and location of
previous cracking problems for a particular part are relevant. This knowledge will assure that the
crack prone areas are identified for inspection and time will not be wasted inspecting areas not
subject to in-service cracking.

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TM 1-1520-265-23

This manual summarizes the steps necessary to perform satisfactory inspections. It includes the
preparation of the helicopter, the inspection area for NDI, safety rules to be observed, highlights of
each inspection method, and specific safety precautions for each of these methods. For a detailed
description of each method and its application, refer to the Technical Manual, Nondestructive
Inspection General Procedures and Process Controls (ATOS), TM 1-1500-366-23. Specific
instructions peculiar to each part being inspected will be included in the discussion of that inspection
item as it is covered in this manual.
1.4.2 Selecting the NDI Method. Factors governing the selection of an inspection method are:
accessibility, portability of equipment, type of suspected damage, material composition of part to be
inspected, surface condition, and degree of sensitivity required for the inspection. In many cases
the primary method selected will depend primarily on accessibility and practicality. For example, a
threaded item that may qualify for eddy current inspection may instead require the substitution of
an ultrasonic inspection due to accessibility constraints. However, the ultrasonic inspection must be
capable of providing equivalent sensitivity. Also, the type of inspection desired may adversely affect
adjacent parts. Inspection methods in this manual were selected in order to provide maximum
detection sensitivity while requiring a minimum of removal or disassembly; and at the same time,
protect adjacent areas from damage.
1.4.2.1 Backup Method Where one method of inspection (primary) reveals an indication of a crack,
another method (backup) should be used to verify if a crack is actually present. Quite often backup
procedures are limited to disassembly and a good visual inspection. Certain cases may arise when
another NDI method could be used to prevent needless or complicated disassembly. For example,
a crack in a spar cap may not appear clearly on radiographic film due to cloudiness caused by
sealant or substructure clutter. A backup eddy current or ultrasonic method could be used for
verification and if no indications were observed, disassembly would not be necessary. Whenever
a backup method is used, it shall be specified in every case where the initial damage indication may
not be positive proof that a reject condition exists.

CAUTION
The absence of a PT indication, while confirming an ET indication is not always
conclusive that the indication is false. For further guidance contact the responsible
engineering authority.
1.4.2.2 Alternate Method Certain cases may arise when another NDI method could be used to
prevent needless or complicated disassembly because of equipment availability, equipment
malfunction, or other situations when primary methods cannot be performed
1.4.3 Preparation of Helicopter for NDI. Prior to NDI, the helicopter shall be prepared for safe
ground maintenance in accordance with applicable technical manuals listed in Table 1-1.
1.4.4 Preparation of Part or Area for NDI.

WARNING

Prolonged breathing of vapor from organic solvents, degreasers, or paint thinners is

dangerous. Use respirators in confined areas per Respiratory Protection Program (TB
MED 502 (DLAM 1000.2)). Have adequate ventilation. Avoid prolonged skin contact.
Wear rubber gloves and goggles.

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 TM 1-1520-265-23

All NDI methods require proper cleanliness of the part or area being inspected. Refer to Table 1-1 for
the applicable cleaning and corrosion control manual. The cleaning technique to be used will be
determined by the type of foreign matter present, NDI method to be performed, and if the part is
plated, painted, or has a protective coating. Scale and corrosion shall be removed completely before
inspection. If removal of protective coatings, such as paint, phosphate coatings, black oxide, etc., is
required, do not use removal methods that mechanically abrade the surface of the part to be
inspected since this may cause damage or mask over potential surface cracks on the part. Some
inspection methods, by their particular nature, will require that small openings and/or oil holes
leading to obscure passages or cavities be plugged, such as the case of engine parts. A suitable
nonabrasive material (i.e., Vaseline, grease, paraffin) should be used that is soluble in oil and can be
readily removed. Effective masking shall be used to protect those components, such as bearings
and certain non-metallics, that may be damaged by contact with the inspection solution or medium.
1.4.5 Interpretation of Indications. Successful detection of flaws by nondestructive inspection
methods depends upon many factors; chiefly among which are the selection of the appropriate test
method, proper application of the chosen process and the knowledge and ability of the inspector
performing the inspection. Interpretation is the process of determining whether an indication is
relevant, non--relevant, or false. Evaluation involves assessing a relevant indication to determine
its cause and type and concludes with proper disposition of the item under examination.
1.4.5.1 Discontinuities are not necessarily defects, they must be evaluated. The following
information is to assist the inspector for interpretation and evaluating discontinuities.
a. False indications - False indications are caused by poor processing conditions, lack of
cleanliness in the inspection booth or other aspects of the inspection process. The most
serious problem with a false indication is determining whether the indication is masking a
relevant indication.
b. Non-relevant indications - Non-relevant indications are caused by surface irregularities or
part configuration. As with false indications, careful examination of these indications is critical
to ensure that they do not mask a relevant indication.
c. Relevant indications - Relevant indications are those that are caused by discontinuities in the
surface of a part. All relevant indications are discontinuities, however, not all discontinuities
are defects.
1.4.6 Acceptance/Rejection Criteria.

CAUTION
Misinterpretation of indications can result in rejected parts being accepted and
acceptable parts being rejected. Only NDI personnel trained and qualified in
accordance with applicable military standards and technical manuals shall perform
and interpret nondestructive inspections.
Nondestructive inspection procedures in this manual have been selected to enhance the safety of
the aircraft and personnel. Inspection procedures (including primary and backup) have been
outlined to enable NDI personnel to perform a reliable inspection of parts with respect to their design,
composition, and accessibility. In the event that a final interpretation of an indication cannot be made,
assistance from the next higher maintenance level shall be requested.
1.4.7 Equipment Used for NDI. Refer to Table 1-13 for a summary of equipment used for NDI
in this manual. Equivalent equipment may be used unless specified otherwise in the inspection
procedures

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TM 1-1520-265-23

1.4.8 Materials Used for NDI. Refer to Table 1-14 for a summary of materials used for NDI in
this manual. Common commercial grade materials (cheesecloth, paper, etc.) are not listed.
Equivalent materials may be used unless specified otherwise in inspection procedures.
1.4.9 Post Cleaning and Restoration of Part or Area After NDI. Upon completion of the NDI test
and prior to restoration of protective finishes, it is necessary to clean off residual inspection materials
from the part. This cleaning will vary based upon test method, contaminant, and subsequent
processing of the part. In many instances, methods used for pre-cleaning are acceptable for post
cleaning. Refer to Preparation of Part or Area for NDI, paragraph 1.1.4.

WARNING

S Prolonged breathing of vapor from organic solvents, degreasers, or paint thinners

is dangerous. Use respirators in confined areas per Respiratory Protection Program
(TB MED 502 (DLAM 1000.2). Have adequate ventilation. Avoid prolonged skin
contact. Wear rubber gloves and goggles.
S Degreasing Solvent, MIL--PRF--680B, Type II, is combustible and toxic to eyes, skin,
and respiratory tract. Wear protective gloves and goggles/face shield. Avoid repeated
or prolonged contact. Use only in well--ventilated areas (or use approved resipirator
as determined by local safety/industrial hygiene personnel). Keep away from open
flames or other sources of ignition.
a. Following all magnetic particle inspections, clean part by dipping or spraying with degreasing
solvent MIL-PRF-680B, Type II. Wipe dry with a clean, cleaning cloth, MIL-C-85043, or
equivalent.
b. After post cleaning has been performed, the original protective finish or approved alternate
must be restored to the part or area by appropriate personnel. Refer to applicable technical
manuals listed in Table 1-1.
1.4.10 NDI General Safety Precautions.

WARNING

Electrical equipment shall not be operated in areas where combustible gases or

vapors may be present, unless the equipment is explosion proof.

Prior to conducting an NDI inspection, survey the general area in advance. Eliminate possible
hazards created by loose structures, protruding work stands, and support equipment. Secure loose
electric cords and remove toxic fluids or fumes. If AC power is supplied to equipment, be sure that
equipment is well grounded to prevent electrical hazards. Specific safety instructions for each NDI
method used in this manual are contained in the paragraph immediately following the discussion
of that method.
1.4.11 Bond Testing (BT) Method.
A number of different methods of NDI can be applied to the many configurations and types of bonded
structures that are in use. Variables such as skin materials and thickness, adhesive type and
thickness, underlying structure, and accessibility are all factors in the development of specific
inspection procedures. Because of the many inspection methods and structural configurations,
each application must be considered and reference standards representative of the structure must
be evaluated to verify proposed techniques.

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 TM 1-1520-265-23

1.4.11.1 Bond Testing Equipment. The bond testing equipment, Bondmaster, used in the
procedures in this manual, operates by generating a mechanical vibration into the material being
tested. This equipment is designed to detect flaws in bonded metallic and composite structures. The
instrument is capable of determining bad bonds, de-laminations, unbonds, and crushed honeycomb
core defects. The Bondmaster has the following features:
a. Resonance. Detects unbonds and by changes in phase and amplitude at probe resonance.
Couplant is required.
b. Pitch Catch Swept. Measures amplitude and phase changes using a swept frequency
method to detect unbonds and deeper defects. Requires no couplant.
c. Pitch Catch Impulse. Measures amplitude and phase changes using a short burst of energy
to detect unbonds, Requires no couplant.
d. Mechanical Impedance Analysis (MIA). Measures the effect of generated sound waves and
the effect of loading as drive frequency is swept in the range of 2.5 KHz to 10 KHz. This
method can be used on unbonds, crushed core, and defects on the inside of composites.
Requires no couplant. See Figure 1-5, Bond Testing Reference Block Displays.

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TM 1-1520-265-23

Figure 1-5. Bond Testing Reference Block Displays

1--22
 TM 1-1520-265-23

Mechanical vibration energy generated by resonance test equipment can be measured, analyzed
by the tester, then displayed on a screen. There are several ways this energy can be applied to
material and then be analyzed. Because bonded metallic and composite material properties differ
substantially, no one test method will detect flaws in all types of material. For this reason, current
bond testing equipment incorporates at least one or more of the aforementioned features.
1.4.11.2 Safety Precautions During Bond Testing. Follow safety precautions and instructions
contained in this manual and the Nondestructive Inspection Methods manual listed in Table 1-1.

WARNING

Electrical equipment shall not be operated in areas where combustible gases or

vapors may be present, unless the equipment is explosion proof.

a. If instrument is operated using AC power, use a grounded power cord.

b. Turn power OFF before connecting or disconnecting probe cable or power cable.

CAUTION

The equipment shall be periodically tested and inspected to be sure it is functioning

properly.

1.4.12 Process Control. The operator is the critical link in this process. Even if all the equipment
is working properly, the inspector must follow the written procedure and use the correct standard.
No deviations shall be made without proper engineering approval.
1.4.13 Fluorescent Penetrant (PT) Method.
The basic purpose of fluorescent penetrant inspection is to increase the visible contrast between
a discontinuity and its background. This method is performed by applying a fluorescent penetrant
solution to the inspection area which enters the surface opening of the discontinuity. The area is then
wiped or rinsed and a developer is added to draw the fluorescent material from the discontinuity. A
flaw or crack in the part will then become visible under the influence of ultraviolet light (black light).
This method is effective for detecting surface flaws in forgings, castings, extrusions, formed
sections, webs, and skins of materials. The penetrant method of inspection requires that the surface
of the inspection area be thoroughly cleaned. Paint on the part must be removed before inspection.

CAUTION

Penetrant-Emulsifier/Remover Combinations (lipophilic/hydrophilic) from one

manufacturer may not be mixed or used in conjunction with materials from a different
manufacturer.
Two penetrant procedures are given in Tables 1-4 and 1-5. AMS 2644, Type I shall be used while
conducting inspection methods A, B, C or D and Sensitivity Level 3 or 4. Refer to the Nondestructive
Inspection Methods manual listed in Table 1-1 for more detailed instructions. Table 1-4 describes
the procedure for using Type I, Method C, Level 3 or 4 on a removed part or parts attached either

1--23
TM 1-1520-265-23

to a component or to the helicopter. This procedure supports the accomplishment of fluorescent

penetrant inspection at the AVUM and AVIM levels regardless of geographic location. Therefore, the
procedure in Table 1-4 will be the one most frequently referred to in this manual. Table 1-11 lists the
equipment and Table 1-12 lists the fluorescent penetrant materials to be used.

Table 1-3. Frequency for Liquid Penetrant Process Control Checks

(Refer to TM 1--1500--366--23 for each specific process control)

Liquid Penetrant Interval

Material Acceptance Test--Stationary Systems As Received
Material Acceptance Test--Stationary Systems (Aerosols) As Received
Material Performance Test (Crack Chrome Panels) (Material Accep- 7 Days
tance Testing and Open Containers Only)
System Performance Test - Depot Only (Starburst--PSM) (Depot Only) Daily
Water Wash Pressure Daily or Prior to Use
Water Wash Temperature Daily or Prior to Use
Black Light Intensity Daily or Prior to Use
Inspection Booth Cleanliness Daily or Prior to Use
Penetrant Contamination Daily or Prior to Use
Developer Contamination and Coverage (Aqueous: Soluble and Sus- Daily or Prior to Use
pendable)
Dry Developer Condition Daily or Prior to Use
Penetrant (Method A) Water Contamination 30 Days
Penetrant (Method A) Removability 30 Days
Lipophilic Emulsifier Performance Test 30 Days
Hydrophilic Remover Concentration 30 Days
Hydrophilic Remover Performance Test 30 Days
Developer Concentration (Aqueous: Soluble and Suspendable) 30 Days
Ambient White Light 60 Days
Drying Oven Survey 180 Days

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 TM 1-1520-265-23

Table 1-4. Penetrant Procedure-Portable or Field Application

(Type I, Method C)

Task Description
a. Preparation of Part: Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
b. Precleaning Procedure: Refer to TM 1-1500-335-23.
c. Penetrant Application: Apply penetrant either by brushing or spraying. In a confined
area, apply brush to prevent overspray.
d. Penetrant Dwell: Allow a minimum of 30 minutes penetrant dwell time. In tem-
perature below 16_C (60_F), refer to Nondestructive In-
spection Methods manual listed in Table 2-2 for dwell time
compensations.
e. Penetrant Removal: 1. Wipe with a clean, dry, lint-free cloth to remove the major
portion of surface penetrant.
2. When surface penetrant has been reduced to a minimum,
any remaining residual penetrant is removed with a fresh
lint-free rag moistened with solvent.
3. Check area to be inspected with black light to be sure all
surface penetrant has been removed before applying de-
veloper. Do not spray cleaner directly onto part.
4. Wipe with a dry, lint-free cloth to remove any residue of the
cleaner/remover.
f. Developer Application: Spray a light film of developer over area to be inspected.
g. Developer Times: Refer to Table 1-6 for developer times.
h. Inspect: Perform inspection under black light. Observe any obvious
bleed-out as developer dries. Complete inspection after
developer dwell time is complete.
i. Materials: Type I, Method C, Level 3 or 4, Solvent - Removable Fluores-
cent Dye Penetrant (Refer to Table 1-12).

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TM 1-1520-265-23

Table 1-5. Penetrant Procedure (Type I, Method D)

Task Description
a. Preparation of Part: Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
b. Precleaning Procedure: Refer to TM 1-1500-335-23.
c. Penetrant Application: The penetrant may be applied by brushing, spraying, or dip-
ping.
d. Penetrant Dwell: Allow a minimum of 30 minutes penetrant dwell time. In tem-
perature below 10_C (50_F), refer to Nondestructive In-
spection Methods manual listed in Table 2-2 for dwell time
compensations.
e. Penetrant Prerinse: Prerinse part with a water spray at a temperature of 10_C to
38_C (50_F to 100_F) and a spray pressure of 40 PSIG
maximum. Do not overrinse.
f. Remover Application: Apply a solution as recommended by manufacturer of the
specific hydrophilic remover in water to surface of the part.
Dwell time shall be kept to an absolute minimum consis-
tent with complete removal of excess penetrant.
g. Post-rinse Operation: Post-rinse part with a water spray at a temperature of 10_C
to 38_C (50_F to 100_F) and a spray pressure of 40 PSIG
maximum. Do not overrinse. Rinse effectiveness should
be checked with a black light to ensure complete removal
of penetrant remover.
h. Drying/Developer Operation: If a dry nonaqueous developer is to be used, first dry the part
in a drying oven at a temperature not to exceed 60_C
(140_F) until dry. Then apply the developer. If an aqueous
developer is to be used, then submerge the part in the de-
veloper solution immediately after washing. Follow by
drying the part in a drying oven as mentioned above. In ei-
ther case, parts shall be removed from the drying oven as
soon as they are dry.
i. Developer Times: Refer to Table 1--6 for developer times.
i. Inspect: Perform inspection under black light.
j. Materials: Type I, Method D, Level 3 or 4 (hydrophilic remover) Pene-
trant (Refer to Table 1-12).

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 TM 1-1520-265-23

Table 1-6. Developer Dwell Times

Temperature 40_- 60_ Minimum Maximum

Nonaqueous Developer
Service Damage/Fatigue Cracks 20 Minutes 60 Minutes
Stress - Corrosion Cracks 60 Minutes 120 Minutes

Aqueous Developer
Service Damage/Fatigue Cracks 30 Minutes 120 Minutes
Stress - Corrosion Cracks 60 Minutes 120 Minutes

Dry Developer
Service Damage/Fatigue Cracks 30 Minutes 240 Minutes
Stress - Corrosion Cracks 60 Minutes 240 Minutes

Temperature 60_ - 125_ Minimum Maximum

Nonaqueous Developer
Service Damage/Fatigue Cracks 10 Minutes 30 minutes
Stress - Corrosion Cracks 30 Minutes 60 Minutes

Aqueous Developer
Service Damage/Fatigue Cracks 15 Minutes 60 Minutes
Stress - Corrosion Cracks 30 Minutes 120 Minutes

Dry Developer
Service Damage/Fatigue Cracks 15 Minutes 120 Minutes
Stress - Corrosion Cracks 30 Minutes 240 Minutes

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TM 1-1520-265-23

1.4.13.1 Safety Precautions During Fluorescent Penetrant Inspection. Follow safety precautions
found in documents listed in Table 1--1 and instructions contained in this manual and the Basic
Theory Nondestructive Inspection Methods manual.

WARNING

x Black lights generate considerable heat during use. Extreme care must be
exercised to prevent contacting the housing with any part of the body.
x To prevent injury to eyes, do not look directly into black light.
x Prolonged direct exposure of hands to the filtered black light’s main beam may be
harmful. Suitable gloves shall be worn when exposing hands to the main beam.

a. Follow manufacturer’s instructions when using black lights and filters.

b. Do not wear sunglasses or glasses with light-sensitive lenses during fluorescent penetrant
inspections. They can contribute to improper interpretation of defects.

WARNING

Prolonged or repeated inhalation of vapors or powders may result in irritation of

mucous membrane areas of the nose.

c. Provide adequate ventilation when handling cleaner, emulsifier, penetrants, or developers.

WARNING

Continual exposure to penetrant inspection material may cause skin irritation.

d. Observe the following when handling cleaners, emulsifiers, penetrants, or developers.

(1) Avoid contact with penetrant inspection materials by wearing neoprene gloves.
(2) Wash inside and outside of gloves.
(3) Wash exposed areas of body with soap and water.
(4) Check for traces of fluorescent penetrant materials on skin, clothing, and gloves using a
black light source.

WARNING

Temperatures in excess of 49_C (120_F) may cause bursting of pressurized cans and
injury to personnel.

e. Store all pressurized spray cans in a cool, dry area protected from direct sunlight. Avoid
exposure of pressurized spray cans to open flame.

1--28
 TM 1-1520-265-23

WARNING

Volatile fumes may occur, creating both a fire and a health hazard.
f. Exercise extreme caution when handling penetrants that have been heated to a point where
some lighter constituents are driven off.

CAUTION
The process materials and equipment shall be periodically tested and inspected to be
sure they are all functioning properly.
1.4.13.2 Fluorescent Penetrant Inspection Process control shall be performed at the intervals
called out in Table 1-3 of this manual IAW the specific requirements of TM 1--1500--366--23.
1.4.13.3 Controlling Excess Fluorescent Penetrant. After fluorescent penetrant inspection, the
part shall be thoroughly cleaned to ensure all excess penetrant is removed from the part. This shall
include removing the penetrant from cracks as much as possible before disposition of the part. This
can be easily accomplished by performing cleaning operations under a black light.
1.4.14 Interpretation of Liquid Penetrant Inspection. Successful detection of flaws by the
penetrant inspection methods depends upon many factors; chiefly among which, are the selection
of the appropriate materials and processes, the proper application of the chosen process, the quality
of the chosen process, the quality of lighting during the examination and the knowledge and ability
of the inspector performing the inspection.
1.4.15 Indication Evaluation. The following method may be utilized to evaluate the type and
relevance of a penetrant indication. Lightly dampen a cotton swab with a fast drying solvent such
as isopropyl alcohol. Carefully wipe the indication only once with the damp swab. After the solvent
has evaporated examine the bare surface with 3X to 5X magnification and watch the indication as
it begins to self--develop. Evaluation of penetrant indications with a magnifying glass shall be done
without developer applied. If the indication cannot be located spray a light layer of nonaqueous
developer over the area and observe the indication without magnification as it begins and continues
to develop. The redevelopment time shall not be less that 3 minutes. If no penetrant bleedout or
surface imperfection can be seen, the original indication was most likely nonrelevant.
1.4.16 Magnetic Particle (MT) Method.

CAUTION
x When performing magnetic particle inspection on landing gear parts, the paint
shall be removed. Some landing gear components are vulnerable to
stress-corrosion cracking and are cadmium plated for their protection. The
cadmium layer shall remain on the part. Damage to the cadmium plating shall be
avoided.
x The process materials and equipment shall be periodically tested and inspected
to be sure they are all functioning properly.
NOTE
During magnetic particle inspections performed with portable equipment, the operator
shall keep the can of magnetic particle media constantly agitated by continuously
shaking the can prior to application.

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TM 1-1520-265-23

Magnetic particle is a method of detecting cracks or other flaws on the surface or near the surface
of materials that are ferromagnetic. This method will produce good indications of discontinuities,
provided the part is free from grease, oil, loose scale, or other surface contaminants. The inspection
is accomplished on either assembled or disassembled parts. As specified in the procedure, the
inspection is accomplished by inducing a magnetic field in the part and applying a liquid suspension
of iron oxide particles to the surface to be inspected. By controlling the direction of the magnetic flux,
the lines of magnetic force shall be positioned perpendicular to the crack or flaw. All magnetic particle
inspections in this manual shall be of the wet continuous method using fluorescent magnetic
particles.
1.4.16.1 Magnetic Particle Process Control. Process control shall be performed at the intervals
called out in Table 1--7 of this manual IAW the specific requirements of TM 1--1500--366--23.
1.4.16.2 Magnetic Particle Inspection Interpretations. An indication is an accumulation of magnetic
particles being held by a magnetic leakage field to the surface of a part. The indication may be
caused by a discontinuity, or by some other condition that produces a leakage field, or by
mechanically held particle accumulation. The amount or “build-up” of magnetic particles from an
indication are related to the strength of the leakage fields. A narrow indication with significant build
up is indicative of a surface discontinuity and can usually be seen if the magnetic particles are wiped
away. A broad and fuzzy indication whose particles are less tightly held is reminiscent of a
subsurface discontinuity due to the weaker leakage fields.
A magnetic particle indication should be wiped away and the part demagnetized per the applicable
inspection procedure. A localized magnetic particle inspection should then be performed to get the
indication to “repeat”. If the indication is again detected and it is determined to not be from geometric
considerations or other nonrelevant sources, the indication should be considered relevant.

Table 1-7. Frequency for Magnetic Particle Process Control Checks

(Refer to TM 1--1500--366--23 for each specific process control)

Magnetic Particle Testing Interval

Concentration/Suspension Settling Test Prior to use and after 8 hours of continuos use
Vehicle Florescence Test In conjunction with concentration/suspension set-
tling test
System Effectiveness Minimum of once every 7 days
Ambient Light Check 60 days
Black Light Intensity Prior to use
Amperage Indicator Check Every 90 days
Quick Break Every 90 days
Water Break Test Daily
Dead Weight Every 90 days

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 TM 1-1520-265-23

1.4.16.3 Magnetic Particle Inspection Equipment. Considerations involved in the selection of

magnetic particle inspection equipment include the type of magnetizing current and the location and
nature of the inspection. The purpose of this manual is to support the accomplishment of NDI at the
AVUM and AVIM levels. This dictates equipment that can be used on or off the helicopter at remote
sites. Therefore, magnetic particle procedures in this manual use the electromagnetic yokes or
probes and hand-held coils as shown in Figure 1-6. This equipment is common and readily available
to AVUM and AVIM levels. Stationary magnetic particle equipment can be used if facilities, required
shop equipment, and qualified NDI technicians are available. Refer to TM 1-1500-366-23
(Nondestructive Inspection General Procedures and Process Controls (ATOS) ) for stationary
magnetic particle inspection techniques.
1.4.16.3.1 Magnetic Yokes and Probes. Portable induced field inspection equipment is generally
referred to as either a probe or a yoke. These terms are synonymous and differ due to
manufacturer’s nomenclature. They are small, portable, easy to use, and can be used on or off the
helicopter. They induce a strong magnetic field into that portion of a part that lies between the poles
or legs. This limits the magnetization to longitudinal; however, by turning the probe 90_ on the part
for the second position, cracks, either perpendicular or parallel to the axis of the part, can be
detected. Some yokes and probes have both AC and DC capabilities while others have AC only. All
procedures in this manual use AC. AC provides a very desirable and useful field. The vibratory action
of AC adds significantly to the magnetic particle mobility enhancing the formation and build-up of
larger and sharper indications at discontinuities. An AC magnetic field is also used when it is
necessary to reveal only surface cracks, common to in-service parts due to fatigue and stress
cracking. Yokes and probes utilizing AC for magnetization also have the additional advantage that
they can be used for demagnetization.
1.4.16.3.2 Hand-held Coil For longitudinal magnetization of bolts, shafts, spindles, axles, and
similar small parts, the hand-held coil offers a simple, convenient method of inspecting for
transverse cracks. It allows for equipment maintenance inspections wherever a coil can be applied
around the part. Parts are magnetized and demagnetized with the same coil.
1.4.16.4 Safety Precautions During Magnetic Particle Inspections. Follow safety precautions and
instructions contained in this manual and the Nondestructive Inspection Methods manual listed in
Table 1-1.

WARNING

x Black lights generate considerable heat during use. Extreme care must be
exercised to prevent contacting the housing with any part of the body.
x To prevent injury to eyes, do not look directly into black light.
x Prolonged direct exposure of hands to the filtered black light’s main beam may be
harmful. Suitable gloves shall be worn when exposing hands to the main beam.
a. Follow manufacturer’s instructions when using black lights and filter.
b. Do not wear sunglasses or glasses with light-sensitive lenses during fluorescent magnetic
particle inspections. They can contribute to improper interpretation of defects.

1--31
TM 1-1520-265-23

Figure 1-6. Portable Magnetic Particle Inspection Equipment

1--32
 TM 1-1520-265-23

CAUTION

Do not operate magnetic particle equipment within 36 inches of aircraft instruments.

1.4.17 Demagnetization of Inspection Parts. Following magnetic particle inspection of a part, the
residual magnetic field in the part shall be reduced to the lowest possible level. This must be done
prior to returning the part to service or rejecting it as a defective part. Unless this is done properly,
the residual magnetism may cause adverse influence on instruments, unnecessary wear on parts,
or attract ferrous metal chips and dust into bearing surfaces. After demagnetization, a magnetic field
strength meter shall be used to measure residual fields. Readings in excess of three units on a gauss
meter or two units on a field indicator are not acceptable.
1.4.17.1 Demagnetization Using AC. If AC demagnetization is selected, hold the part about 12
inches in front of the coil. Move it slowly and steadily through the coil to at least 36 inches beyond
the end of the coil while current is still flowing. Repeat process as necessary. Rotate and tumble parts
of complex configuration while passing through the coil field. All parts can be demagnetized using
a contour probe in the AC mode. Place the probe against the magnetized part with the switch in AC
position. Turn probe on and withdraw it from the part, or the part from the probe/yoke, about 48
inches before turning the probe off.
1.4.17.2 Demagnetization Using DC. If DC demagnetization is selected, the initial demagnetizing
field shall be higher than, and in nearly the same direction as, the field reached during inspection.
The field shall then be reversed and decreased in magnitude, and the process repeated (cycled)
until an acceptable low value of residual field is reached. Whenever possible, parts that have been
circularly magnetized shall be magnetized in the longitudinal direction before being demagnetized.
This procedure is limited to stationary equipment.
1.4.18 Radiographic (RT) Method.

Radiographic inspection is used to detect internal and external structural details of all types of parts
and materials. This method is used for the inspection of airframe structure for damage, detection
of moisture entrapment, structure alignment, and foreign object intrusion. It can sometimes be used
in areas otherwise inaccessible to other nondestructive inspections and to verify indications
observed by other methods.
Radiographic inspections are accomplished by passing the X-ray beam through the part or
assembly to expose a radiographic film emulsion or other sensitized medium. The processed film
shows the structural details of the part by variations in film density. Requirements for film density,
image quality indicator, identification, and other factors are specified in ASTM-E1742.
Film processing is a series of operations such as developing, fixing, and washing, associated with
the conversion of the latent image into a stable visible image and will be provided by manual or
automatic film processing.
1.4.18.1 Safety Precautions During Radiographic Inspections. Follow safety precautions and
instructions contained in this manual and the Nondestructive Inspection Methods manual listed in
Table 1-1.

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TM 1-1520-265-23

WARNING

Assure compliance with all applicable precautions set forth in TM 1-1500-366-23

(Nondestructive Inspection General Procedures and Process Controls (ATOS)) listed
in Table 1-1. A hazard associated with exposure to ionizing radiation is that serious
injury can be inflicted without pain, burning, or other sense of discomfort during the
exposure period. Radiation protection shall be utilized in accordance with DA Pam
385-24.

1.4.18.2 Mixing of Radiographic Film Processing Chemicals. Exercise extreme care when working
with film processing chemicals. Fixer solution is highly acidic and developer is highly caustic. Avoid
contact with the skin. Flush any skin contact with water.

CAUTION
The process materials and equipment shall be periodically tested and inspected to be
sure they are all functioning properly.

1.4.18.3 Radiographic Process Control. Process control shall be performed at the intervals called
out in Table 1--8 of this manual IAW the specific requirements of TM 1-1500-366-23.

Table 1-8. Frequency for Radiography Process Control Checks

(Refer to TM 1-1500-366-23 for specific process control)

Radiography Inspection Interval

Safelight Fog Evaluation Initial install and requirements described in
TM 1-1500-366-23
Interlock Prior to shift
Testing Developer Activity Monthly
Fixer Control Monthly
Development Process Weekly

1.4.18.4 Interpretation of Radiographic Inspections. Radiographic interpretation cannot be

performed without knowledge of the image quality. Knowledge of image quality validates to the
reader that a particular radiograph meets the quality standard.
It is the duty of the film interpreter to recognize various discontinuities, their magnitude, and be
capable of relating them to the specific inspection requirements. An inspector reading radiographs
should be familiar with the exposure technique used, material radiographed, conditions of
processing, and the geometry of the exposure set up. With his knowledge the interpreter can judge
more accurately the radiographs produced and interpret the discontinuities more accurately.

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 TM 1-1520-265-23

1.4.19 Eddy Current (ET) Method.

The eddy current method is used for discontinuities in electrically conductive materials. The method
is effective when inspecting for discontinuities originating: (1) at the radii of mounting lugs, flanges,
or crevices; (2) at pressed-in (interference fit) grease fittings, guide pins, etc. and (3) from fastener
holes and bushing/bearing bores. Eddy current method will locate surface cracking on any
conductive material, but probes and techniques for inspection of magnetic materials may differ
considerably from those used on materials.
Eddy current has great value for inspecting areas where paint stripping is not desirable and/or
impossible. The method also has wide application in confirming surface indications found by other
methods.
The capability and versatility of the eddy current method has been greatly enhanced by the use of
modern phase analysis (impedance plane display) instruments used in conjunction with shielded
probes. These instruments display a representation of the impedance plane which illustrates both
the magnitude and direction of impedance changes. Impedance variables (conductivity, probe
lift-off, permeability variations, etc.) can be separated by their characteristic video response and are
readily recognized by the trained operator. The interaction of the probe coils and the part is
represented by a “flying spot” (or dot) in the video display.
Equipment is standardized on a test block (reference block) which is constructed of a known material
that contains known good areas, and either simulated or actual defects of known size. The response
of the equipment (eddy current machine and probe) to the good material is set as the starting point
by nulling the equipment on the sound area of the block. By this action, all subsequent readings
represent deviations from the null point and have both magnitude and direction. Careful
manipulation of the controls allows the operator to separate the response (deviation from the null
point) for lift-off and flaw (geometric) effects.
Shielded probes have a cylinder of material which encircles the coil of the probe. This serves to
constrict the probes field and, therefore, reduces the spread of eddy currents beyond the probe’s
diameter. This concentrated electrical field is most useful for scanning around fasteners, near
edges, and into specific small areas. Other types of probes are used for wide area scans, alloy
sorting, conductivity comparisons, coating thickness comparisons, skin thickness comparisons, etc.
1.4.19.1 Safety Precautions During Eddy Current Inspection. Follow safety precautions and
instructions contained in this manual and the Nondestructive Inspection Methods manual used in
Table 1-1.

WARNING

Electrical equipment shall not be operated in areas where combustible gases or

vapors may be present, unless the equipment is explosion-proof.

CAUTION

The process materials and equipment shall be periodically tested and inspected to be
sure they are all functioning properly.

1--35
TM 1-1520-265-23

1.4.19.2 Eddy Current Process Control. Process control shall be performed at the intervals called
out in Table 1-9 of this manual IAW the specific requirements of TM 1--1500--366--23.

Table 1-9. Frequency for Eddy Current Process Control Checks

(Refer to TM 1--1500--366--23 for each specific process control)
Eddy Current Testing Interval
Probe Test 180 days
Slot Test 180 days

1.4.19.3 Eddy Current Scanning Techniques. Eddy current inspection is preformed by moving the
probe over and as close as possible to the surface of the area of interest. If the coil(s) pass over a
defect like a crack, the impedance of the coil will change and be represented as a movement of the
“flying spot”. Before beginning the inspection, the operator will have separated the response from
lift-off and from a flaw by using the test block and manipulating the controls. Therefore, the crack
response will be essentially similar to the response from the known defect and different from the
response from lift-off. Microprocessor controlled instruments have the ability to store responses in
memory. Such stored responses are an invaluable teaching aid.
1.4.19.3.1 Scanning Around Fasteners, Inserts, and Edges of Parts. Shielded probes are
recommended any time that the pattern the eddy current field is likely to extend out such that it comes
in contact with a feature which would mask the response from a defect. Such features may include
edges, fasteners, dissimilar materials attached to the test piece, etc. An unshielded probe can be
used around such features, but the effect of those features must be made constant by keeping the
distance between the probe and the feature constant. Non-conductive mechanical guides (straight
edges, plugs, spacers, etc.) can be used to maintain a constant distance. In fact, the use of
non-conductive mechanical guides is useful for shielded and unshielded probes alike. As operators
gain experience, they become quite innovative in making guides that maintain constant lift-off,
angles, and distance from features which may mask flaw indication. Common materials for
mechanical guides are plastic (polyethylene, acrylic, and polycarbonate), wood, phenolic
impregnated material, and resins for casting into shapes (epoxy, polyester, or hot glue). Careful
selection of probes and construction of suitable mechanical guides will make possible inspection of
problem areas such as sharp edges, tight radii, small openings, and areas near potentially masking
features.
1.4.19.3.2 Bolt hole Inspection. Manual bolt hole inspection probes usually consist of a split 90
degree probe with the exposed shaft inserted in an adjustable collar. The shaft is marked in
increments and the collar secured at the desired increment by means of a set screw through the
collar. The probe is then rotated 360 degrees around the hole at each setting until the entire surface
of the bore has been inspected. These probes are available in federal or commercial catalogs.
1.4.19.3.3 Scanning Fillets and Radii. Using appropriate radius probe, scan fillets and radii several
times in each direction.

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 TM 1-1520-265-23

1.4.19.4 Eddy Current Instrument Standardization. Eddy current inspection equipment and
standards required by the procedures in this manual are listed in Table 1-11. Reference blocks,
instrument settings, and standardization instructions for the eddy current instrument, are included
in each eddy current procedure. Instrument settings, as they are given in this manual, should be
considered typical and present a test block display shown in Figure 1-7. Additional nulling will be
required to reestablish the position of the “flying spot” with the probe on the part/area to be
inspected.(Use Teflon tape listed in Table 1-11 on the probe to reduce wear. Instrument settings shall
be made with Teflon tape on the probe, if used.) The calibration set up shall be verified intermittently
throughout the inspection and upon completion of the inspection.
1.4.19.5 Sorting Metal Using Eddy Current. In addition to the more common usage for crack
detection, eddy current equipment may be used for metal sorting. Electrical conductivity and
magnetic permeability are the material characteristics evaluated during this type of inspection. The
sorting technique cannot directly identify alloy or even the type of metal. But when there are limited
possibilities, conductivity and/or permeability information may permit proper classification (see
Figure 1-8). Typically the need for alloy sorting occurs when changes to parts are made to improve
performance.
If the conductivity of a magnesium component more closely matches the sigma of the aluminum
crack standard, it is acceptable to setup the ET instrument on the aluminum standard.
1.4.19.6 Interpreting Eddy Current Signals. In almost all cases the eddy current signal of the
discontinuity must be compared to the eddy current signal produced by the reference standard. The
relationship between the response to the standard and the corresponding response to the
discontinuity size must be established prior to the test and should be considered an essential part
of the setup process. The change in the magnitude of the eddy current response and the rapidity
of the response, are factors which assist in the evaluation of an eddy current indication. Low
magnification visual examination and fluorescent penetrant inspection are valuable tools in
validating the relevance of an eddy current signal response.

CAUTION
The removal of cadmium plating for investigative purposes shall not be done without
proper engineering approval.

1.4.19.7 Eddy current inspections performed on ferrous materials require a higher degree of
interpretation due to the permeability variations exhibited by most ferrous materials. The addition
of cadmium plating as a protective coating can create significant conductivity variations across the
surface of a test part. Frequent rebalancing of the eddy current test circuit along with careful analysis
of the eddy current response will reduce the opportunity for erroneous inspection results. Eddy
current indications should be confirmed with backup inspection methods if at all possible.

1--37
TM 1-1520-265-23

Figure 1-7. Signatures of EDM Notches in Test Block

1--38
 TM 1-1520-265-23

Figure 1-8. Typical Metal Sorting Display

1.4.19.8 Lift-Off Compensation. For inspections performed over painted surfaces, lift-off caused
by the paint thickness affects sensitivity and requires compensation during instrument
standardization. To compensate for the increased lift-off the appropriate thickness of
non-conductive material (plastic shims, paper, etc.) shall be placed between the probe and the
reference standard during the standardization process unless specified by the part specific
inspection procedure.
a. Position the flying dot at V-POS 20 and H-POS 80.
b. Place the probe on a bare section of the test block and press NULL.
c. Utilize the ANGLE function to achieve horizontal lift-off. Minimize horizontal gain to achieve
a curved lift-off trace. Reference Figure 1-9
d. Place a .002” non-conductive shim on the test block and place the probe on the shim.
e. Note the horizontal deflection from the .002” shim. Holding the probe steady, press DISP, then
press V-POS and rotate the SMARTKNOB.
f. Return the vertical position to 20%.
g. Repeat steps d. and e. utilizing a .010” shim.
h. Place the probe on the material to be tested, note the horizontal deflection.
i. Assess the amount of lift-off from the painted test surface (the lift-off trace may be slightly
different from the reference standard due to the conductivity differences between the test
block and the material being tested).
j. Non-conductive coatings equal to or less than .002” do not require lift-off compensation. If
the coating is greater that .002” utilize the appropriate non-conductive shim during the
instrument set up and standardization process. Non-conductive coatings .010” or greater
shall be removed before the inspection is performed.

1--39
TM 1-1520-265-23

Test Piece

Lift-off with non-conductive 20% signal amplitude reduction

shims due to 2 mils of lift-off

Figure 1-9. Curved Lift-Off Trace

1.4.20 Ultrasonic (UT) Method.

Ultrasonic inspection uses high frequency sound waves as a probing medium to provide information
as to the state of various materials. This method is effective for the inspection of most metals for
surface and subsurface damage. The method requires that at least one surface of the part be
accessible for transducer contact in the vicinity of the area to be examined. The inspection is
accomplished by inducing the ultrasound into the part by coupling the transducer to the part and
picking up reflections of this sound from within the part. Any marked changes in acoustic properties,
defect, interface, or back surface will reflect sound back to the transducer. The detected ultrasonic
reflections are electronically displayed on a Liquid Crystal Display (LCD) and interpreted for
indications of defects. Accessory wedges can be used to provide adequate transducer mating to
curved surfaces or to change the angle of the sound beam and wave of mode propagation.
1.4.20.1 Safety Precautions During Ultrasonic Inspection. Follow safety precautions and
instructions contained in this manual and the Nondestructive Inspection Methods, Basic Theory
manual listed in Table 1-1.

WARNING

Electrical equipment shall not be operated in areas where combustible gases or

vapors may be present, unless the equipment is explosion-proof.

a. If instrument is operated using AC power, use a grounded power cord.

b. Turn power OFF before connecting or disconnecting transducer cable or power cable.
1.4.20.2 Ultrasonic Instrument Standardization. The ultrasonic instrument used in ultrasonic
inspection procedures described throughout this manual is listed in Table 1-11. Reference blocks,
instrument settings, and standardization instructions for the ultrasonic instrument are included in the

1--40
 TM 1-1520-265-23

individual ultrasonic inspection procedures. Because of varied circumstances under which the
inspections may be performed, instrument settings, as they are given in this manual, should be
considered typical. Slight adjustment to the settings may be necessary to achieve the desired CRT
presentation. Illustrations representing typical CRT presentation will, in most cases, include
reference signals representing initial pulse, transducer, and/or wedge echoes that have been moved
off the scope to make room for relevant indications. An effective ultrasonic inspection will depend
largely upon the proper handling of the transducer; therefore, the following steps are recommended:
a. Clean ultrasonic transducer with a cleaning cloth, MIL-C-85043 or equivalent. Clean all
contact surfaces when using a wedge or delay block. Apply couplant to these contact
surfaces and carefully tighten the assembly prior to test.

NOTE
Scratches or similar surface blemishes remaining on the transducer or wedge may
give false indications.

b. Use prescribed or equivalent couplant and in sufficient quantity to achieve proper coupling.
The use of lubricants containing graphite, silicones, and glycerines is prohibited.
c. Apply adequate pressure to keep transducer in contact with part.
d. Use moderate speed for transducer search pattern. If transducer movement is too fast, a flaw
could be passed over without a proper indication.
1.4.20.3 Ultrasonic Process Control. The process control shall be performed at the intervals called
out in Table 10 of this manual IAW the specific requirements of TM 1--1500--366--23.
1.4.20.4 Ultrasonic Inspection Interpretation. In almost all cases the ultrasonic signal of the
discontinuity must be compared to the ultrasonic response produced by a reference standard. The
relationship between the response to the standard and the corresponding response to the
discontinuity size must be established prior to the test and should be considered an essential part
of the set up process. The location of a discontinuity along the time base line and the knowledge
of the position and orientation of relevant discontinuities detected on similar components greatly
improves the inspector’s ability to determine an indication relevance.

1--41
TM 1-1520-265-23

Table 1-10. Frequency for Ultrasonic Inspection Process Control Checks

(Refer to TM 1-1500-366-23 for each specific process control)
Ultrasonic Inspection Interval (In Use Transducers Only)
Vertical Linearity Quarterly
Horizontal Linearity Quarterly
Sensitivity Check Quarterly
Resolution Check Quarterly
Dead Zone Check Quarterly
Angle Beam Point of Incident Quarterly
Angle Beam Angle Determination Quarterly
Angle Beam Skew Angle Quarterly

1--42
 TM 1-1520-265-23

Table 1-11. Equipment Used for NDI

Part Number National Stock

Nomenclature Supplier
Description Number

FLUORESCENT PENETRANT

Fluorescent Penetrant
AMS 2644 Type 1, General Services Admin--
Inspection Kit 6850--00--703--7406
Method C, Level 3 istration (GSA)
(Chemicals Included)
Fluorescent Penetrant
Inspection Kit FMI GSA 6635--00--566--5198
(Chemicals Included)
Spectronics Corp
Radiometer DSE--2000A 956 Brush Hollow Rd. 6635--01--434--5112
Westbury, NY 11590--1714
Lamp, Mercury Vapor
A--A--1765 GSA 6240--01--124--5309
(Medium Base)

Filter, UV 3901 GSA 6632--00--736--5177

MAGNETIC PARTICLE METHOD

Yoke and Coil Kit YL--61 GSA 4920--01--145--3924

Spectronics Corp
Black Light B100XR 956 Bush Hollow Rd. 6635--00--611--5617
Westbury, NY 11590--1714

EDDY CURRENT METHOD

Olympus NDT
Eddy Current Inspection
Nortec 2000D 421 N. Quay St, 6625--01--515--6713
Unit
Kennewick, WA 99336
Cable Assembly
CBM--6 GSA 5995--01--278--1271
(BNC to Microdot)
5KHz - 500 KHz 90
Probe GSA 6635--01--186--6133
Degree
Olympus NDT
Cable, Wheel Probe
CBR--TF--6 7056 S. 220th St. 6625--01--467--7255
(Bundy to Triax Fisher)
Kent, WA 98032
Olympus NDT
Cable Assembly
CN16--M--6 7056 S. 220th St.
(Lemo to Microdot)
Kent, WA 98032

1--43
TM 1-1520-265-23

Part Number National Stock

Nomenclature Supplier
Description Number
Olympus NDT
Cable Assembly
CN16--TF--6 7056 S. 220th St.
(Lemo to Triax Fischer)
Kent, WA 98032
Olympus NDT
Reference Block, Three--
1902510.01 421 N. Quay St.
Notched Aluminum
Kennewick, WA 99336
Olympus NDT
Reference Block, Three--
TB--SMG 421 N. Quay St.
Notched Magnesium
Kennewick, WA 99336
Olympus NDT
Reference Block, Three--
TB--STI 421 N. Quay St.
Notched Titanium (6AL--4V)
Kennewick, WA 99336
Olympus NDT
Reference Block, Three--
SRS--0842S/CH--47 421 N. Quay St.
Notched Steel
Kennewick, WA 99336
Olympus NDT
Reference Block, Block of
1902474.01 421 N. Quay St. 6635--01--518--2193
Six Conductivity Samples
Kennewick, WA 99336
Probe, Right Angle, Olympus NDT
Shielded Surface, MP905--60 7056 S. 220th St. 6635--01--186--6133
50--500KHz Kent, WA 98032
Probe, Right Angle, Olympus NDT
Shielded Surface, 9222075 7056 S. 220th St.
100--500KHz Kent, WA 98032
Olympus NDT
Probe, Straight, Shielded
MP--60 7056 S. 220th St. 6635--01--364--7565
Surface, 50--500KHz
Kent, WA 98032
Olympus NDT
Probe, Right Angle,
MP905--60/2M 7056 S. 220th St.
Shielded Surface, 2 MHz
Kent, WA 98032
Olympus NDT
Probe, Right Angle,
923410 421 N. Quay St.
Shielded Surface, 1--2MHz
Kennewick, WA 99336
Olympus NDT
Probe, Shielded Surface,
MP--60/2M 7056 S. 220th St.
2MHz
Kent, WA 98032
Olympus NDT
Probe, UH--60 Wheel WP--UH60 7056 S. 220th St.
Kent, WA 98032
Olympus NDT
Standard, UH--60 Wheel WS--UH60 7056 S. 220th St.
Kent, WA 98032
Olympus NDT
Kit, UH--60 Main Rotor Hub NEC--8038/N 7056 S. 220th St.
Kent, WA 98032
EC NDT Campus Park
1020 S. 344th St.
Kit, UH--60 Main Rotor Hub SPCK--107A
Suite 214
Federal Way, WA 98003

1--44
 Part Number National Stock
Nomenclature Supplier
Description Number
EC NDT Campus Park
1020 S. 344th St.
Kit, CH--47 Lightening Hole
Suite 214
Federal Way, WA 98003
Olympus NDT
Adapter, Probe 2 MHz ABR--BN/2M 7056 S. 220th St.
Kent, WA 98032

ULTRASONIC INSPECTION

Olympus NDT
Ultrasonic Inspection Unit Sonic 1200 421 N. Quay St. 6624--01--499--7177
Kennewick, WA 99336
Olympus NDT
UH--60 Spindle Lug
NEC--8102 7056 S. 220th St.
Inspection Kit
Kent, WA 98032
Olympus NDT
NEK--9030 FB (Fat 6635--01--535--1077 (FB)
AH--64 Strap Pack Bolt Kit 7056 S. 220th St.
Boy)/NEK--9030 6635--01--474--8674
Kent, WA 98032
Olympus NDT
45, 60, 70 and 80 Degrees
Transducer 1/4” X 1/4” 7056 S. 220th St.
5MHz
Kent, WA 98032
Olympus NDT
Transducer 5 MHz,
Bifilar Inspection 7056 S. 220th St. 6635--00--018--5830
45 Degree, Steel
Kent, WA 98032
Olympus NDT
Transducer 1/4” Delay Line 15 MHz 7056 S. 220th St.
Kent, WA 98032
Olympus NDT
1/2” Straight Beam
5 MHz 7056 S. 220th St.
Transducer
Kent, WA 98032
Olympus NDT
1/4” Straight Beam
10 MHz 7056 S. 220th St.
Transducer
Kent, WA 98032
Olympus NDT
3/8” Delay Line
5 MHz 7056 S. 220th St.
Transducer
Kent, WA 98032
Olympus NDT
Aluminum Step Wedge .100” to .500” 7056 S. 220th St.
Kent, WA 98032
AGFA NDT Inc.,
Krautkramer UT Div.,
IIW Block ATS1166 6635--01--148--5477
50 Industrial Park Rd.,
Lewiston, PA 17044

ATSM Block

1--45
TM 1-1520-265-23

Part Number National Stock

Nomenclature Supplier
Description Number

Rompus

BOND TESTING

Olympus NDT
Bond Testing Inspection
Bondmaster 1000 421 N. Quay St. 6635--01--432--9954
Unit
Kennewick, WA 99336

RADIOGRAPHY

Lorad Corp.
X--Ray Unit (LPX--160 36 Apple Ridge Rd.,
3--000--0762 6635--01--417--1830
Water Cooled Digital) PO Box 710,
Danbury, CT 06813--0710

Hanger, X--Ray Film N00329 6525--00--603--1775

Defense Logistics Agency,

Rope, X--Ray 7404506 700 Robbins Ave., 4010--01--416--2086
Philadelphia, PA 19111

Dosimeter PD10i

Survey Meter 451B

Olympus NDT
Stand, Tube Head 9016300 421 N. Quay St. 6635--01--067--6315
Kennewick, WA 99336
X--Rite, Inc. 4300 44th
Densitometer 301 Street, SE, Grand Rapids, 6635--01--0604--5791
MI
X--Ray Products Corp.,
Viewer, Film 65C1 PICO, 6635--00--587--1524
Rivera, CA 90660

Immersion Heater N00434 New Co.

Floating Thermometer N00340 New Co.

Processing Tank N00389 New Co.

ATSM,
Penetrameter ASTM--E1742 100 Barr Harbor Dr., 6635--00--185--1983
Conshohocken, PA 19428

Beacon, Warning 5010061 New Co.

1--46
 Part Number National Stock
Nomenclature Supplier
Description Number

Interlock 5010060 New Co.

Dryer, Film N00326 New Co.

Safelight, Darkroom N00407 6740--00--597--8440

1--47
TM 1-1520-265-23

Table 1-12. Materials Used for NDI

Part Number National Stock
Nomenclature Supplier
Description Number

FLUORESCENT PENETRANT

Type 1 Method C Kit General Services

Level 3 or Higher 6850--00--782--2740
(9 Cans) Administration ( GSA)
Type 1 Method C
Level 3 or Higher GSA 6850--01--267--4345
Penetrant (12 oz. Cans)
Type 1 Method C
AMS2644 GSA 6850--00--160--8480
Developer (12 oz. Cans)
Type 1 Method C
Cleaner/Remover AMS 2644 CL2 GSA 6850--00--160--8481
(12 oz. Cans)

MAGNETIC PARTICLE METHOD

Florescent Magnetic
Particle Prepared Bath AMS 3046 GSA 6850--00--841--1347
(12 oz. Can)
Qualitative Quality Indica--
KSC4--230 GSA 6635--01--367--2187
tor
Indicator Magnetic
105645 GSA 6655--01--076--9630
(Reads Gauss)

Magnetometer 2480 GSA 6635--00--391--0058

Dead weight Locally Manufactured

EDDY CURRENT METHOD

Teflon Tape 1/2”

A--A--59474 GSA 5970--00--812--7387
(108 ft. Roll)
Teflon Tape 1/4”
A--A--59474 GSA 5970--00--832--4298
(54 ft. Roll)

ULTRASONIC TESTING METHOD

Sonotech, Inc.
Couplant, Ultrasonic (Gal-- Suite 2, Bldg H
Ultragel II 6850--01--157--4348
lon) PO Box 2189
Bellingham, WA 98226

1--48
 Part Number National Stock
Nomenclature Supplier
Description Number

BOND TESTING METHOD

Teflon Tape 1/2”

A--A--59474 GSA 5970--00--812--7387
(108 ft. Roll)
Lead ID Tape, Precut
XRITELABEL GSA 6325--00--880--7257
(4”x2”)
Lead Tape
HH--T--29 GSA 7510--00--664--0001
(2” Roll)

D4 35mm Film

D4 14”x17” Film
CVCPIC GSA 6635--01--428--3453
(100 Sheets)
D4 7”x17” Film
CVCPIC GSA 6635--01--428--3454
(100 Sheets)
D7 14”x17” Film
CVCPIC GSA 6635--01--428--3367
(100 Sheets)
D7 &”x17” Film
CVCPIC GSA 6635--01--428--3370
(100 Sheets)
Envelope
CVCPIC GSA 6525--01--428--1334
(14”x17” Film, 50 ea.)
G128 Developer, Manual
ESOF0128 GSA 6750--01--400--2128
(4 ea. Bottle)
G135 Developer,
Automatic LCWVD GSA 6750--01--461--5235
(2 ea. Bottle)
G335 Fixer
GSA
(Manual and Automatic)
Acetic Acid, Glacial Photo
6750--00--141--6558
(Stop Bath)
Wetting Agent
1395110 GSA 6750--01--418--6682
(2.5 Gallon)
Sign
SM--CHRA--200
(HIGH RAD AREA)
Sign
SMRA--200
(CAUT RAD AREA)
Cleaning Compound
Photographic 1013176 GSA 6750--01--026--0410
(16oz. Bottle)

Pump, Drum MR50--XL GSA 4320--01--099--9666

Gloves, Cotton
MIL--G--81349 GSA 8415--00--782--2809
(Pair)

1--49
TM 1-1520-265-23

Part Number National Stock

Nomenclature Supplier
Description Number
GTE Products Corp.
Viewer Bulbs BBA115--120V 275 W. Main St., 6240--00--196--4476
Hollsboro, NH 03244

MISCELLANEOUS MATERIALS

Gloves Protective
ZZ--G--381 GSA 8415--00--823--7459
(Pair)
Gloves, Surgeon
E--008 GSA 1615--01--149--8843
(Rubber, 50 ea.)
Gloves, Disposable
GL1--LXEXR GSA 8415--01--434--1781
(Latex, 100 ea.)
Applicator, Disposable
362 GSA 6515--01--234--6838
(100 ea.)
Apron, Disposable
E2--2845 GSA 8415--00--222--8074
(100 ea.)
Apron, General Purpose
A--A--55063 GSA 8415--00--082--6108
(1 ea.)
Face Shield
A--A--1770 GSA 4240--00--542--2048
(1 ea.)
Cloth, Low--Lint Cleaning
MIL--C--38736 GSA 7920--00--044--9281
(10lb Box)
Degreasing Solvent
MIL--PRF--680, Type II GSA 6850--01--474--2317
(5 Gallon)
Scotch--Brite, Type A
L--P--0050 GSA 7920--00--659--9175
(4 ea.)
Acetone
O--A--51 GSA 6810--00--223--2739
(Pint)
Isopropyl Alcohol
TT--I--735 GSA 6810--00--286--5435
(Gallon)
Cleaning Solvent,
General Purpose DS--108 GSA 7930--01--367--0996
(5Gallon)
Electron Dielectric Solvent
0296--06 GSA 6850--01--375--5553
(6 Gallon)
Positron Dielectric Solvent
060--6 GSA 6850--01--412--0026
(5 Gallon)
Matting, Floor
MIL--DTL--15562 GSA 7220--00--267--4630
(25 Yard Roll)

TEMPORARY MARKING MATERIALS

Aircraft Marking Pencil,

MIL--P--83953 Yellow GSA 7510--00--537--6930
(China Marker, 1 Dozen)

1--50
 TM 1-1520-265-23

SECTION II
ROTOR SYSTEM
2. GENERAL.
2.1 CONTENTS. The rotor system inspection items covered in this section are those critical items
of the H-60 helicopter series rotor blades, rotor head, and components listed in the Rotor System
Inspection Index (Table 2-1). Corresponding inspection figures and applicable text paragraphs are
listed opposite each inspection item. The index number for each item may be used to locate it in
Figure 2-1.
Table 2-1. Rotor System Inspection Index

Index Inspec- Para- Figure

Number tion graph Number
Nomenclature Method Number
2 Split Cones PT 2.2 2-2
*3 Ferrous Rotor System Bolts and Pins MT 2.3 2-3
*4 Nonferrous Rotor System Bolts and Pins PT 2.4 2-4
*5 Main Rotor Shaft Nut MT 2.5 2-5
*6 Main Rotor Hub ET 2.6 2-6
Main Rotor Hub 11 O’Clock Bolt Hole ET 2.7 2-7
*7 Spindle ET 2.8 2-9
Main Rotor Hub Spindle UT 2.9 2-10
8 Antiflap Bracket ET 2.10 2-39
9 Droop Stop Support Ring Nut ET 2.11 2-40
Droop Stop Support ET 2.12
10 Balance Weight Bracket MT 2.13 2-42
*11 Spindle Horn ET 2.14 2-43
12 Droop Stop Cam ET 2.15 2-44
13 Damper Assembly ET 2.16 2-45
Damper Piston MT 2.17 2-47
*** Damper Assembly Bushing PT 2.42 2-79
*14 Pitch Control Rods ET 2.18 2-50
*15 Rotating Swashplate ET 2.19 2-51
Swashplate Spherical Bearing Holes ET 2.20
*16 Lower Link ET 2.21 2-52
Rotating Scissors PT 2.22 2-53
17 Bifilar Vibration Absorber ET 2.23 2-54
18 Bifilar Weight UT 2.24 2-55
18A Bifilar Weight Bushings PT 2.25 2-62

2--1
TM 1-1520-265-23

Index Inspec- Para- Figure

Number tion graph Number
Nomenclature Method Number
Bifilar Support Arm Bushing PT 2.26 2-63
18B Bifilar Weight Tapered Washers PT 2.27 2-64
*19 Main Rotor Blade Tip Cap Fairing ET 2.28 2-65
*20 Main Rotor Blade (Voids) PT 2.29 2-66
*21 Main Rotor Blade Cuff Assembly ET 2.30 2-67
Tail Rotor Blade Spar Center Plug ET 2.31 2-68
*22 Tail Rotor Blade (Voids) PT 2.32 2-69
*23 Tail Rotor Blade (Fluid) RT. 2.33 2-70
*24 Tail Rotor Blade Tip Cap ET 2.34 2-71
29 Tail Rotor Pitch Beam (Bushings) PT 2.35 2-72
29 Tail Rotor Pitch Beam ET 2.36 2-73
25 Tail Rotor Pitch Horn ET 2.37 2-74
*26 Tail Rotor Pitch Control Rod Ends MT 2.38 2-75
27 Pitch Beam Washer MT 2.39 2-76
28 Pitch Beam Retaining Nut MT 2.40 2-77
30 Tail Rotor Inboard/Outboard Retention Plates ET 2.41 2-78

NOTE: * Indicates Flight Safety Part.

*** Out of numerical/page sequence

2--2
 TM 1-1520-265-23

Figure 2-1. Rotor System (Sheet 1 of 2)

2--3
TM 1-1520-265-23

Figure 2-1. Rotor System (Sheet 2 of 2)

2--4
 TM 1-1520-265-23

2.2 SPLIT CONES (PT).

2.2.1 Description (Figure 2-1, Index No. 2). The split cones and lower pressure plate, in
conjunction with the main shaft nut, secure the shaft extension to the main shaft.
2.2.2 Defects. Defects may occur anywhere on the surface of the split cones. No cracks are
allowed.
2.2.3 Primary method. Fluorescent Penetrant (PT).
2.2.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1--11. Penetrant
materials shall be selected from the approved list in Table 1--12.
2.2.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the split cones removed in accordance with the applicable technical manuals listed in Table 1-1.
2.2.3.3 Access. Not applicable.
2.2.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
2.2.3.5 Perform process control checks per Table 1-3 IAW TM 1-1500-366-23.
2.2.3.6 Inspection Procedure. Perform florescent penetrant Method (PT) paragraph 1.4.13 and
either Table 1-4 or 1-5 depending on Unit capability. Inspect part (Figure 2-2) IAW Interpretation of
Liquid Penetrant Inspection, paragraph 1.4.14 and Indication Evaluation, paragraph 1.4.15.
2.2.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.2.4 Backup Method. None required.

Figure 2-2. Split Cones

2--5
TM 1-1520-265-23

2.2.5 System Securing. Clean the split cones to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The split cones require
installation in accordance with the applicable technical manuals listed in Table 1-1.

2.3 FERROUS ROTOR SYSTEM BOLTS AND PINS (MT).

2.3.1 Description (Figure 2-1, Index No. 3). This inspection is peculiar to all ferrous bolts and pins
contained within the rotor system.
2.3.2 Defects Defects may occur anywhere on the surface of the bolt. No cracks are allowed.
2.3.3 Primary Method. Magnetic Particle.
2.3.3.1 NDI Equipment and Materials. (Refer to Tables 1--11 and 1--12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
2.3.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the bolts or pins removed in accordance with the applicable technical manuals listed in Table
1-1.
2.3.3.3 Access. Not applicable.
2.3.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.3.3.5 NDI Equipment and Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
3.3.3.6 Perform process control checks per Table 1-7 and TM 1-1500-366-23.
2.3.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is illustrated in Figure 2-3.

Figure 2-3. Ferrous Rotor System Bolts and Pins

2--6
 TM 1-1520-265-23

a. Select AC on the AC/DC switch.

b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Inspect opposite side, repeat steps a. through d.
2.3.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.3.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
2.3.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4 and paragraphs 1.4.2.1 and
1.4.7.
2.3.5 System Securing. Clean the bolts or pins thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and restoration of Part or Area After NDI, paragraph 1.4.16.
The bolts or pins require installation in accordance with the applicable technical manuals listed in
Table 1-1.
2.4 NONFERROUS ROTOR SYSTEM BOLTS AND PINS (PT).
2.4.1 Description (Figure 2-1, Index No. 4). This inspection is peculiar to all nonferrous bolts and
pins contained within the rotor system.
2.4.2 Defects. Defects may occur anywhere on the surface of the bolt or pins. No cracks are
allowed.
2.4.3. Primary Method. Fluorescent Penetrant.
2.4.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
2.4.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the bolts or pins removed in accordance with the applicable technical manuals listed in Table
1-1.
2.4.3.3 Access. Not applicable.
2.4.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
2.4.3.5 Perform process control checks per Table 1-3 IAW TM 1-1500-366-23.
2.4.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Florescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part. (Figure 2-4) Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation paragraph 1.4.15.
2.4.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.4.4 Backup Method. None required.
2.4.5 System Securing. Clean the bolt or pins to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The bolts and pins require
installation in accordance with the applicable technical manual listed in Table 1-1.

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TM 1-1520-265-23

Figure 2-4. Nonferrous Rotor System Bolts and Pins

2.5 MAIN ROTOR SHAFT NUT (MT).
2.5.1 Description (Figure 2-1, Index No. 5). The main rotor shaft nut threads onto the top of the
main rotor shaft and holds the shaft extension in place on the main rotor shaft.
2.5.2 Defects. Defects may occur anywhere on the surface of the main rotor shaft nut, especially
the inside diameter thread roots. No cracks are allowed.
2.5.3 Primary Method. Magnetic Particle (MT).
2.5.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking pencil
2.5.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the main rotor shaft nut removed in accordance with the applicable technical manuals listed in
Table 1-1.
2.5.3.3 Access. Not applicable.
2.5.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.5.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.5.3.6 Perform process checks per TM 1-1500-366-23.
2.5.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 2-5.

2--8
 TM 1-1520-265-23

Figure 2-5. Main Rotor Shaft Nut

a. Select AC on the AC/DC switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 2.5.3.8.
f. Repeat steps a. through e. for positions 2 and 3.
g. Inspect opposite side. repeat steps a. through e.
2.5.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.5.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
2.5.4 Backup Method. None required.
2.5.5 System Securing. Clean the main rotor shaft nut thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16.
The main rotor shaft nut requires installation in accordance with the applicable technical manuals
listed in Table 1-1.

2.6 MAIN ROTOR HUB (ET).

2.6.1 Description (Figure 2-1, Index No. 6). The main rotor hub is part of the main rotor head
which transmits movements of the main transmission to the four main rotor blades.
2.6.2 Defects. Defects may occur anywhere on the surface of the main rotor hub. No cracks are
allowed.
2.6.3 Primary Method. Eddy Current. (ET)
2.6.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop

2--9
TM 1-1520-265-23

d. Cable Assembly
e. Adapter Probe
f. Reference Block, three-notched Titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape
h. Aircraft Marking Pencil
2.6.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main
rotor hub shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.6.3.3 Access. Access to the main rotor hub is from the L/R engine cowl (Figure 1-4, Items 3T-7
and 4T-8).
2.6.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of part or
Area for NDI, paragraph 1.4.4.
2.6.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1000 KHz LP Filter 50 H Pos 80%
ANG 60_ HP Filter Off V Pos 20%
H Gain 60db
V Gain 70 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.6.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-6.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.6.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.6.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

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 TM 1-1520-265-23

Figure 2-6. Main Rotor Hub

2.6.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.6.4 Backup Method. Fluorescent Penetrant, refer to paragraph 1.4.13 and Table 1--4.
2.6.5 System Securing. The main rotor hub, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

2.7 MAIN ROTOR HUB 11 O’CLOCK BOLT HOLE (ET).

2.7.1 Description . The 11 o’clock bolt hole is located on the damper bracket attachment flange
on the main rotor hub. (Figure 2-1, Index No. 6)
2.7.2 Defects. This inspection is to detect cracks on the inside surface of the hub where the
eleven o’clock damper bracket attaching bolt extrudes through the interior surface. No cracks are
allowed.
2.7.3 Primary Method. Eddy Current (ET)
2.7.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12)
a. Eddy Current inspection unit, Nortec 2000 or equivalent
b. Probe Kit, SPCK-107A or NEC-8030N
c. Cable Assembly, CBR-TF-6
d. Reference Block, three-notched titanium (0.008”, 0.020” and 0.040” EDM notches)
e. Teflon Tape
f. Aircraft Marking Pencil
g. Borescope

2--11
TM 1-1520-265-23

Figure 2-7. Main Rotor Hub 11O’Clock Bolt Hole

2.7.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1. The inspection of the 11
o’clock bolt hole can be accomplished without component disassembly. The right hand engine work
platform should be closed and secured.
2.7.3.3 Access. The eddy current probes are designed to access the inside surface of the damper
flange through the lightening hole located on the bottom of the main rotor hub.
2.7.3.4 Preparation of Part. The inside surface of the hub around the bolt hole shall be free of
dirt and debris which may be a detriment to the inspection. Smooth all rough surfaces to provide
positive probe contact in accordance with paragraph 1.4.4. If necessary remove the paint in the
inspection area in accordance with applicable technical manuals.
2.7.3.5 NDI Equipment Settings.
a. Make the following initial setting on the Eddy Current Inspection Unit.
MAIN MENU DISPLAY MENU ALARM MENU FILTER MENU
Freq 1000KHZ Sweep Off Type Box (Optional) LP Filter 50
Angle 53 _ V pos 20% +/--/off Off HP Filter Off
H Gain 50 db H pos 80% Horn Off Cont Off
P Drive High Screen Persist Zero Sec Size/Pos (n/a)
Display Erase Off
Dot/Box On
Graticule On

2--12
 TM 1-1520-265-23

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up the test block as follows:
(1) Null the selected probe on the test block.
(2) Adjust the phase angle as required to obtain horizontal lift-off.
(3) Slide the probe over all three notches in the test block. Adjust the gain to obtain a five block
vertical deflection when the probe is passed over the 0.040 inch notch in the test block.
Reference the standard instrument display in Figure 1-7.

NOTE
S Both probes shall be used to maintain contract with the various surfaces around the
bolt hole. The 10 degree probe is intended for inspecting the horizontal surface while
the 45 degree probe is for inspecting the vertical surfaces around the bolt hole. When
the probes are changed, steps b. 1, 2, and 3 shall be repeated. Attempting to inspect
the horizontal surface with the 45 degree probe or the vertical surface with the 10
degree probe significantly reduces the likelihood of identifying cracks in the
component. (Refer to Figure 2--7)
S Due to the High sensitivity required to accomplish this inspection, very small coils
have been utilized in the probe tips. Rough handling, excessive pressure and tapping
the tips will damage the coils. Use extreme care when handling and storing the probes.
S If any part of the probe kit is unserviceable use the backup method.

Figure 2-8. Probe Position on Horizontal and Vertical Surfaces

2.7.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19.

a. Place the probe on a good area in the inspection location and null. Adjust the phase angle
as required to obtain horizontal lift-off.
b. Scan around the perimeter of the bolt hole as close as possible without achieving edge effect.
Scan away from the bolt hole perimeter one-half inch in all directions.
c. The 2-4 and 8-10 o’clock positions are high stress zones. Inspect these area with extreme
care.

2--13
TM 1-1520-265-23

d. Any relevant signal similar to the notches in the test block should be further evaluated.
e. Verify any relevant indication with backup method (PT).
2.7.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required.
2.7.4 Backup Method. Fluorescent Penetrant (PT) refer to paragraph 1.4.13.
2.7.4.1 Preparation of Part.
a. Remove damper brackets (4 places) IAW appropriate TM.
b. Clean the internal surface of the hub with an approved solvent.
c. Mask area surrounding the hole approximately one-half inch from the bolt hole radius.
d. Pace a protective cloth under the hub arm to prevent damage to the swashplate or other
related airframe surfaces.

WARNING

It is essential that the following cleaning procedure be performed prior to the

inspection. Failure to follow these procedures may result in a crack not being detected
by fluorescent penetrant inspection.

CAUTION
Do not allow paint remover to come in contact with elastomeric bearings. Use care
when applying paint remover so that only a small amount is applied to the inspection
area at one time. Do not allow paint remover to enter the threads of the insert hole.

e. Using an acid brush, apply paint remover to the masked area around the bolt hole. Repeat
if necessary to thoroughly remove the paint.
f. Remove all traces of paint remover and clean area and threaded insert with an approved
solvent. Wait fifteen minutes to ensure adequate drying of the inspection area before applying
penetrant.

NOTE
It is not necessary to repaint the surface after completion of the NDI procedure.
2.7.4.2 Inspection Procedure. Perform fluorescent penetrant inspection using Method-C. Refer to
Fluorescent Penetrant Method, paragraph 1.4.13 and Table 1-4, except that the penetrant dwell time
shall be 60 minutes and developer dwell time shall be 30 minutes.

CAUTION
The use of an inspection mirror shall be used only to view the inspection area. Do not
use the mirror to reflect the ultraviolet light onto the inspection area because the
reflected light intensity is reduced below the minimum acceptable limit.
2.7.5 System Securing. Clean the entire area to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. Reinstall the damper bracket
IAW appropriate TM.

2--14
 TM 1-1520-265-23

2.8 SPINDLE (ET).

2.8.1 Description (Figure 2-1, Index No. 7). The spindle couples the blade to the main rotor head.
The main rotor head contains four spindle assemblies.
2.8.2 Defects. The inspection is used to verify suspected crack indications found visually on the
spindle. No cracks are allowed.
2.8.3 Primary Method. Eddy Current (ET).
2.8.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop,
d. Cable Assembly
e. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
spindle shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.8.3.3 Access. Access to the spindle is from the L/R engine cowl (Figure 1-4, Items 3T-7 and 4T-8).
2.8.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.8.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit:.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 30_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.8.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-9.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.

2--15
TM 1-1520-265-23

b. Inspect the part.

c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 2-9. Spindle

NOTE
Either probe identified in paragraph 2.8.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.8.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.8.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

2.8.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4 and paragraphs 1.4.2.1 and
1.4.13.
2.8.5 System Securing. The spindle, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

2.9 MAIN ROTOR HUB SPINDLE (UT).

2.9.1 Description (Figure 2-1, Index No. 7) The main rotor hub spindle couples the rotor blade
to the main rotor head. The main rotor head contains four spindle assemblies.
2.9.2 Defects. This inspection is used to detect cracks initiating from the bore of the blade
attachment lugs. No cracks are allowed.
2.9.3 Primary Method Ultrasonic.
2.9.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12)
a. Ultrasonic Inspection Unit, Conic 1200 or equivalent.
b. Inspection Kit
c. Ultrasonic Couplant
d. Aircraft Marking Pencil
2.9.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
Partial inspection for cause (visual indications, sites or mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the part prior to performance of this procedure.
2.9.3.3 Access. Access to the spindle blade attachment lugs shall be accomplished by removing
one of the blade retention pins and rotating the blade either forward of aft. The remaining two lugs
will be inspected by reinstalling the original pin, removing the pin and rotating the blade in the
opposite direction to gain access to the remaining lugs. An alternate method of access is to remove
the blade from the aircraft in accordance with applicable technical manuals.
2.9.3.4 Preparation of Part. The part shall be thoroughly cleaned prior to the inspection. Flaking
paint and rough surface textures will require careful smoothing with a crocus cloth to provide a
smooth surface. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4

2--17
TM 1-1520-265-23

TYPICAL CRACK ORIENTATION

Figure 2-10. Spindle Assembly

2.9.3.5 NDI Equipment Settings

a. Make the following initial settings on the Ultrasonic inspection Unit (Sonic 1200):
PULSER GATES
GAIN 57 dB GATE 1 +
PULSE 30 ns POSN 1.00 INCH
DAMPING 25 ohms WIDTH 0.400 INCH
MODE SINGLE LEVEL 40%
VOLTAGE 150V GATE 2 OFF
RCVR THICK
DB DIFF 0 dB T-GAUGE OFF
DISPLAY FULLWAVE
FREQ 10 MHz ANGLE
REJECT 0% TRIG OFF
RANGE SPCL
RANGE 2.00 INCH UNITS INCH
DELAY ZERO DAC
VEL 0.240 INCH DAC OFF
MAX REP 1000 Hz MAIN
FREEZE OFF
ZOOM OFF

2--18
 TM 1-1520-265-23

2.9.3.6 Preface
a. The spindle attach lug inspection uses two ultrasonic transducers with focused sound beams.
Focusing the sound beam allows inspection of the bore beneath the outer radius of the lug.
b. Specific directions follow regarding the required ultrasonic techniques to ensure 100%
inspection coverage of the lug bore. Familiarize yourself with the figures below to acquire a
better understanding of the scan path requirements.
c. The Right-Hand (RH) transducer will focus the sound beam to the right of the scan path
direction Reference Figure 2-11
d. Note the position of the transducer parallel to the chamfered out edge of the lug.
e. Performing a scan in the reverse direction along the opposite edge of the lug will inspect the
diagonally opposing corner.
f. Due to the lug geometry, the RH scan pattern leaves two zones of the lug uninspected. The
uninspected zones are represented by the shaded rectangles.

Figure 2-11. End View of Lug, RH Scan Coverage

g. To provide complete inspection coverage, the Left--Hand (LH) transducer is used in the same
manner as the RH transducer providing coverage of the uninspected zones. Reference
Figure 2--12.
h. The complete inspection sequence will require a total of 16 passes per lug, 8 each transducer.
The ultrasonic scans should be performed with a smooth, slow and continuous motion.
i. Avoid excessive downward pressure on the transducer. Unnecessary pressure will deplete
the critical couplant layer between the transducer and the lug edge.

2--19
TM 1-1520-265-23

Figure 2-12. End View of Lug, LH Scan Coverage

2.9.3.7 Reference Standard. Refer to the Ultrasonic Method, paragraph 1.4.20. There are two
reference standard configurations: Either configuration can be used to perform the instrument
standardization. The reference standard has two 0.030” L x 0.030” D Electrical Discharge Machining
(EDM) Notches. The notches are located opposite the washer side of the lug on the inner bore 180_
part. Refer to Figure 2-13.

Figure 2-13. Calibration Standards

2.9.3.8 Right Hand (RH) Transducer Standardization. The RH transducer is identified with a red
transducer casing (within the clear Lucite wedge) which has an “R” on its top. Attach the transducer
and cable to the ultrasonic instrument.
a. With the sound beam directed toward the RH notch, position the transducer parallel to the
outer edge of the lug. Reference Figure 2-14.
b. Slowly slide the transducer toward the EDM notch until a signal is received on the screen.

2--20
 TM 1-1520-265-23

Washer Notch

Side Side

Figure 2-14. Transducer Positioning

c. Adjust the transducer position to optimize the returned signal from the EDM notch. The
transducer position may slightly differ from transducer to transducer or standard to standard.
The optimal position will be the position that obtains the highest amplitude signal with the
least amount of gain. Note the possible location differences in Position A and Position B.
Reference Figure 2-15.

Figure 2-15. Transducer Positions A and B.

d. Adjust the gain to achieve a signal amplitude of 80% Full Screen Height (FSH). Reference
Figure 2--16.

2--21
TM 1-1520-265-23

Figure 2-16. Signal Amplitude.

e. Standardization shall be checked approximately every ten minutes during continual use and
whenever abnormal values are obtained. Whenever an instrument is found to be out of
standardization, all inspection areas examined since the last standardization verification
shall be re--examined.
f. Adjust the gain to achieve a signal amplitude of 80% Full Screen Height (FSH). Reference
Figure 2--16.
2.9.3.9 Right Hand (RH) Inspection Procedure.
a. Perform the following scanning sequence to inspect each lug of the spindle. Be conscious
of transducer positioning and couplant effects. A sudden loss of low level baseline noise
indicates a lack of adequate couplant.
(1) Apply couplant to the edge of a lug, place the transducer parallel to the edge of the lug at
the “start” position note in Figure 2-17.
(2) Align the top edge of the transducer with the top edge of the spindle lug. Slowly slide the
transducer around the lug from right to left.

2--22
 TM 1-1520-265-23

Figure 2-17. RH Inspection, Scan #1.

(3) Scan #2, position the transducer so that it will overlap the first scan position by 50%. The
top edge of the transducer should line up slightly below the bottom edge of the chamfer.
perform this scan slowly from right to left.

Figure 2-18. RH Inspection, Scan #2.

(4) Scan #3, position the transducer to overlap scan #2 by 50%. The bottom edge of the
transducer should align slightly above the top edge of the lower chamfer edge. Perform this
scan slowly from right to left.

2--23
TM 1-1520-265-23

Figure 2-19. RH Inspection, Scan #3.

(5) Scan #4, position the transducer to overlap scan #3 by 50%. The bottom edge of the
transducer should align with the bottom edge of the spindle lug. Perform this scan slowly
from right to left. Remove the remaining couplant from the lug. Repeat steps 1-5.

Figure 2-20. RH Inspection, Scan #4.

(6) Rotate the transducer 180_. Align the top edge of the transducer with the top edge of the
spindle lug. Slowly slide the transducer around the lug from left to right

2--24
 TM 1-1520-265-23

Figure 2-21. RH Inspection, Scan #5.

(7) Scan #6, position the transducer so that it will overlap scan #5 by 50%. The top edge of the
transducer should line up slightly below the bottom edge of the chamfer. Perform this scan
slowly from left to right.

Figure 2-22. RH Inspection, Scan #6.

(8) Scan #7, position the transducer so that it will overlap scan #6 by 50%. The bottom edge
of the transducer should line up slightly above the top edge of the lower chamfer edge.
Perform this scan slowly from left to right.

2--25
TM 1-1520-265-23

Figure 2-23. RH Inspection, Scan #7

(9) Scan #8, position the transducer so that it will overlap scan #7 by 50%. The bottom edge
of the transducer should align with the bottom edge of the spindle lug. Perform this scan
slowly from left to right. Remove the remaining couplant from the spindle lug. Re--apply
couplant and repeat steps 6-9.

Figure 2-24. RH Inspection, Scan #8.

(10) Re-verify the standardization set up for the RH transducer on the reference standard to
ensure the proper sensitivity level was maintained.
2..9.3.10 Left Hand (LH) Transducer Standardization. The LH transducer is identified with a black
transducer casing (within the clear Lucite wedge) which has an “L” on its top. Attach the transducer
and cable to the ultrasonic instrument.
a. With the sound beam directed toward the LH notch, position the transducer parallel to the
upper edge of the lug. Reference Figure 2-25.

2--26
 TM 1-1520-265-23

b. Slowly slide the transducer toward the EDM notch until a signal is received on the screen.

Figure 2-25. Transducer Positioning.

c. Adjust the transducer position to optimize the returned signal from the EDM notch. The
transducer position may slightly differ from transducer to transducer or standard to standard.
The optimal position will be the position that obtains the highest amplitude signal with the
least amount of gain. Note the possible location differences in Position A and Position B.
Reference Figure 2-26.

Figure 2-26. Transducer Positions A and B.

d. Adjust the gain to achieve a signal amplitude of 80% Full Screen Height (FSH). Reference
Figure 2-27.

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TM 1-1520-265-23

Figure 2-27. Signal Amplitude.

e. Standardization shall be checked approximately every ten minutes during continual use and
whenever abnormal values are obtained. Whenever an instrument is found to be out of
standardization, all inspection areas examined since the last standardization verification
shall be re--examined.
2.9.3.11 Left Hand (LH) Inspection Procedure.
a. Perform the following scanning sequence to inspect each lug of the spindle. Be conscious
of transducer positioning and couplant effects. A sudden loss of low level baseline noise
indicates a lack of adequate couplant.
(1) Apply couplant to the edge of a lug and place the transducer parallel with the edge of the
lug at the “start” position noted in Figure 2-28.
(2) Align the top edge of the transducer with the top edge of the spindle lug. Slowly slide the
transducer around the lug from right to left.

Figure 2-28. LH Inspection, Scan #1.

(3) Scan #2, position the transducer so that it will overlap the first scan position by 50%. The
top edge of the transducer should line up slightly below the bottom edge of the chamfer.
Perform this scan slowly from right to left.

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 TM 1-1520-265-23

Figure 2-29. LH Inspection, Scan #2

(4) Scan #3, position the transducer to overlap scan #2 by 50%. The bottom edge of the
transducer should align slightly above the top edge of the lower chamfer edge. Perform this
scan slowly from right to left.

Figure 2-30. LH Inspection, Scan #3.

(5) Scan #4, position the transducer to overlap scan #3 by 50%. The bottom edge of the
transducer should align with the bottom edge of the spindle lug. Perform this scan slowly
from right to left. Remove the remaining couplant from the lug. Repeat steps 1-5.

2--29
TM 1-1520-265-23

Figure 2-31. LH Inspection, Scan #4.

(6) Rotate the transducer 180_. Align the top edge of the transducer with the top edge of the
spindle lug. Slowly slide the transducer around the lug from the left to the right.

Figure 2-32. LH Inspection, Scan #5.

(7) Scan #6, position the transducer so that it will overlap scan #5 by 50%. The top edge of the
transducer should line up slightly below the bottom edge of the chamfer. Perform this scan
slowly from the left to the right.

2--30
 TM 1-1520-265-23

Figure 2-33. LH Inspection, Scan #6.

(8) Scan #7, position the transducer so that it will overlap scan #6 by 50%. The bottom edge
of the transducer should line up slightly above the top edge of the lower chamfer edge.
Perform this scan slowly from the left to the right.

Figure 2-34. LH Inspection, Scan #7.

(9) Scan #8, position the transducer so that it will overlap scan #7 by 50%. The bottom edge
of the transducer should align with the bottom edge of the spindle lug. Perform this scan
slowly from left to right. Remove the remaining couplant from the spindle lug. Re-apply
couplant and repeat step 6-9.

2--31
TM 1-1520-265-23

Figure 2-35. LH Inspection, Scan #8.

(10) Re--verify the standardization set up for the LH transducer on the reference to ensure the
proper sensitivity level was maintained.
2.9.3.13 CRT Display Interpretation. Excessive baseline noise and/or nonrelevant indications can
be displayed on the CRT screen as a result of several conditions. If either of the conditions below
are detected, proceed with the following to remedy the situation or determine the relevancy of an
indication detected.
a. Condition - Excessive Base Line Noise Level (Greater than 30% FSH): A noisy baseline can
sometimes be remedied by simply adding additional couplant to the inspection surface and
rescanning. If additional couplant does not quiet the baseline, verify the gain setting used to
achieve 80% FSH on the reference standard. Change the microdot to BNC transducer cable
and recalibrate the instrument, A failing transducer cable can require additional gain, thereby,
increasing baseline noise levels.

Figure 2-36. Noisy Baseline.

2--32
 TM 1-1520-265-23

b. Condition - Baseline Noise with Intermittent Signal Breaking Gate: To determine the
relevancy of a recurring ultrasonic signal, completely remove all paint and primer from the
questionable lug per best shop practice. Re--inspect the lug. Nonrelevant signals can often
be identified by their wide base along the CRT baseline. Generally a nonrelevant signal will
increase in amplitude as the transducer is rotated on the lug lessoning the couplet layer and
contact area, where a signal from a crack will decrease in amplitude as the transducer to lug
contact is minimized.

Figure 2-37. Nonrelevant Signal.

2.9.3.14 Marking and Recording of Inspection Results Mark and record inspection results as
required by paragraph 1-3.
2.9.3.15 Acceptance/Rejection Criteria Relevant signals exceeding the 40% gate threshold are
rejectable. Cracks propagating from the inner bore of the lug will appear in the gated area on the
CRT display. The signal received from a crack will usually have a very quick rise and fall time when
scanning. A legitimate crack indication will have a consistent transducer location on the lug edge
and can be readily detected on subsequent scans.

Figure 2-38. Crack Signal.

2--33
TM 1-1520-265-23

2.9.3.16 Backup Method. None

2.9.3.17 Post Clean. The spindle assembly should be thoroughly cleaned after completing the
inspection to remove the inspection media. Refer to Post-Cleaning and Restoration of Part after NDI
paragraph 1.4.9.
2.10 ANTIFLAP BRACKET (ET).
2.10.1 Description (Figure 2-1, Index No. 8). The antiflap brackets are installed on each of the four
main rotor spindle modules next to the hub. The antiflapping assemblies prevent the blades from
flapping when the main rotor head is slowing down or stopped.
2.10.2 Defects. The inspection is used to verify suspected crack indications found visually on the
antiflap bracket. No cracks are allowed.
2.10.3 Primary Method. Eddy Current.
2.10.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Adapter, Probe
f. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape
h. Aircraft Marking Pencil
2.10.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
antiflap bracket shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.10.3.3 Access. Access to the antiflap bracket is from the L/R engine cowling (Figure 1-4, Items
3T-7 and 4T-8).
2.10.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.10.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1500 KHz LP Filter 100 H Pos 80%
ANG 57_ HP Filter Off V Pos 20%
H Gain 56db
V Gain 74 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:

2--34
 TM 1-1520-265-23

(1) Null probe on test block.

(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.10.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-39.
a. Place probe on good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.10.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.10.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.10.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.10.4 Backup Method. Florescent Penetrant, refer to Table 1-4 paragraphs 1.4.13.and 1.4.2.1
2.10.5 System Securing. The antiflap bracket, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

2--35
TM 1-1520-265-23

Figure 2-39. Antiflap Bracket

2--36
 TM 1-1520-265-23

2.11 DROOP STOP SUPPORT RING NUT (ET).

2.11.1 Description (Figure 2-1, Index No. 9). The droop stop support ring nut holds the droop stop
support ring and outer sleeve assembly in place on the spindle.
2.11.2 Defects. The inspection is used to verify suspected crack indications found visually on the
droop stop support ring nut. No cracks are allowed.
2.11.3 Primary Method. Eddy Current.
2.11.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.11.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
antiflap bracket shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.11.3.3 Access. Access to the droop stop support ring nut is from the L/R engine cowling (Figure
1-4, Items 3T-7 and 4T-8).
2.11.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.11.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 30_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

2--37
TM 1-1520-265-23

2.11.3.6 Inspection Procedure.. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-40.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

NOTE
Either probe identified in paragraph 2.11.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.11.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.11.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.11.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.11.5 System Securing. The droop stop support ring nut, if removed, requires installation in
accordance with the applicable technical manual listed in Table 1-1.

Figure 2-40. Droop Stop Support Ring Nut

2.12 DROOP STOP SUPPORT (ET).

2.12.1 Description. The droop stops, on the spindle module next to the hub, limit droop of the
blades when the main rotor head is slowing down or stopped.
2.12.2 Defects Defects may occur anywhere on the droop stop support.
2.12.3 Primary Method. Eddy Current.
2.12.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12)

2--38
 TM 1-1520-265-23

a. Eddy Current Inspection Unit.

b. Probe, 90 degree 1/2 inch drop, shielded surface, 100 KHz-500KHz.
c. Probe, straight, shielded surface, 100KHz-500KHz.
d. Cable Assembly.
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape.
g. Aircraft Marking Pencil.
2.12.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure.
2.12.3.3 Access. Remove blades if necessary.
2.12.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.12.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in the test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in the test block. (See the standard
instrument display shown in Figure 1-7.
2.12.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 1-7.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the areas of concern.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.12.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.12.3.5b
(1), (2) and (3) shall be repeated each time a change is made.
2.12.3.7 Marking and Recording Results Mark and record inspection results as required by
paragraph 1.3.

2--39
TM 1-1520-265-23

DROOP STOP SUPPORT

SPINDLE

Figure 2-41. Droop Stop Support

2.12.4 Backup Method. Fluorescent Penetrant Inspection Table 1-4, paragraph 1.4.2 and
paragraph 1.4.13.
2.12.5 System Securing. The droop stop support requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

2.13 BALANCE WEIGHT BRACKET (MT).

2.13.1 Description (Figure 2-1, Index No. 10). There are two balance weight brackets attached
to each of the four spindles. The brackets provide the means of attaching the balance weights for
balancing the rotor head assembly.
2.13.2 Defects. Defects may occur anywhere on the surface of the balance weight bracket. No
cracks are allowed.
2.13.3 Primary Method. Magnetic Particle.
2.13.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.8.1.2 and Figure 1-6.
2.13.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may

2--40
 TM 1-1520-265-23

be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the balance weight bracket shall be removed in accordance with the
applicable technical manuals listed in Table 1-1.
2.13.3.3 Access. Access to the balance weight bracket is from L/R engine cowling (Figure 1-4,
Items 3T-7 and 4T-8).
2.13.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.13.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.13.3.6 Perform process control checks per TM 1-1500-366-23.
2.13.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 2-42.

Figure 2-42. Balance Weight Bracket

2--41
TM 1-1520-265-23

a. Select AC on the AC/DC power switch.

b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 1.4.17.
f. Repeat steps a. through e. for position 2.
g. Inspect opposite side repeat steps a. through f.
2.13.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.13.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
2.13.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and 1.4.13.
2.13.5 System Securing. Clean the balance weight bracket thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,
paragraph 1.4.16. The balance weight bracket, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

2.14 SPINDLE HORN (ET).

2.14.1 Description (Figure 2-1, Index No. 11). The spindle horn is attached to the main rotor
spindle and transmits pitch movement from the rotary swashplate, through the pitch control rod to
rotate the spindle, and changes the blade angle.
2.14.2 Defects. Defects may occur anywhere on the surface of the spindle horn. All areas where
rework has been performed shall be inspected for cracks. No cracks are allowed.
2.14.3 Primary Method. Eddy Current.
2.14.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.14.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
spindle horn shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.14.3.3 Access. Access to the spindle horn is from the L/R engine cowling (Figure 1-4, Items 3T-7
and 4T-8).

2--42
 TM 1-1520-265-23

2.14.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.14.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.14.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-43.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.14.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.14.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

2--43
TM 1-1520-265-23

Figure 2-43. Spindle Horn

2.14.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.14.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and 1.4.13.
2.14.5 System Securing. The spindle horn, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

2.15 DROOP STOP CAM (ET).

2.15.1 Description (Figure 2-1, Index No. 12). The droop stop cam is the contact point between
the main rotor spindle and main rotor hubs which limit the droop of the blades when the rotor head
is slowing or stopped.
2.15.2 Defects. This inspection is used to verify suspected crack indentions found visually on the
droop stop cam. No cracks are allowed.
2.15.3 Primary Method. Eddy Current.
2.15.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.15.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may

2--44
 TM 1-1520-265-23

be performed on all exposed surfaces of the installed part using this procedure. If required, the droop
stop cam shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.15.3.3 Access. Access to the droop stop cam is from the L/R engine cowling (Figure 1-4, Items
3T-7 and 4T-8).
2.15.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparations of Part
or Area for NDI, paragraph 1.4.4.
2.15.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.15.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-44.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

2--45
TM 1-1520-265-23

Figure 2-44. Droop Stop Cam

NOTE
Either probe identified in paragraph 2.15.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.15.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.15.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.15.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.15.5 System Securing. The droop stop cam, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.
2.16 DAMPER ASSEMBLY (ET).
2.16.1 Description (Figure 2-1, Index No. 13). Dampers are installed between each of the main
four rotor hub and spindle modules to restrain lead and lag motion of the blades during rotation and
to absorb rotor head engagement loads.
2.16.2 Defects. The inspection is used to verify suspected crack indications found visually on the
damper assembly. No cracks are allowed.
2.16.3 Inspection Intent. The following inspection procedure is intended to validate indications
detected during visual inspection but may also be utilized as required during disassembly and repair
of the damper assembly.

2--46
 TM 1-1520-265-23

2.16.4 Primary Method. Eddy Current.

2.16.4.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, 90_ 1/2 inch drop, shielded surface, 100 KHz-500KHz
c. Probe, 90_ 1/2 inch drop, shielded surface, 1-2 MHz
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape.
h. Aircraft Marking Pencil
2.16.4.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
2.16.4.3 Access. The damper assembly shall be removed from the aircraft to facilitate access to
the varius area of inspection as necessary.
2.16.4.4 Preparation of Part. The part shall be thoroughly cleaned followed by verification of the
nonconductive coating thickness on all painted surfaces prior to Eddy Current Inspection.
Nonconductive coatings greater than 10 mils (0.010”) shall be removed. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.16.4.5 NDI Equipment Settings.(Aluminum)
a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 75_ HP Filter Off V Pos 20%
H Gain 50db
V Gain 67 db
Probe Drive Mid

b. Set up on the reference standard as follows:

(1) Verify the nonconductive coating thickness on the part to be inspected. Nonconductive
coatings less than 0.003” do not require lift-off compensation.
(2) Null the probe on the reference standard with the appropriate thickness of nonconductive
shim between the probe and the reference standard.
(3) Adjust phase rotation as required to obtain horizontal lift-off.
(4) .Place the nonconductive shim over the three EDM notches and slide the probe across the
test block. Obtain a five (5) screen division vertical response from the 0.040” EDM notch
(70% FSH).
(5) .Verify standardization every 10 minutes.
2.16.4.6 Inspection Procedure.
a. Place probe in the inspection area and null the instrument. Adjust phase rotation angle as
required to obtain horizontial lift-off.

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TM 1-1520-265-23

b. Inspect the cylinder assembly around the spherical bearing, the cylinder head flange, and
attachment nuts detailed, reference Figure 2-45.
c. Any signal similar to the response received from the reference standard should be further
evaluated in accordance with prargraph 2.16.4.9 Indication Evaluation.

Figure 2-45. Damper Assembly

2.16.4.7 NDI Equipment Settings (Titanium)
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1.5 MHz LP Filter 100 H Pos 80%
ANG 32_ HP Filter Off V Pos 20%
H Gain 49db
V Gain 67 db
Probe Drive High
b. Set up on the reference standard as follows:
(1) Verify the nonconductive coating thickness on the part to be inspected. Nonconductive
coatings less than 0.003” do not require lift-off compensation.
(2) Null the probe on the reference standard with the appropriate thickness of nonconductive
shim between the probe and the reference standard.
(3) Adjust phase rotation as required to obtain horizontal lift-off.
(4) Slide the probe over the theree notches in the test block. Obtain a five (5) screen division
vertical response from the 0.040” EDM notch (70% FSH).
(5) .Verify standardization every 10 minutes.
2.16.4.8 Inspection Procedure
a. Place the probe in the inspection area and null the instrucment. Adjust the phase rotation
angle as required to obtain horizontial lift-off.
b. Inspect the rod end around the shperical bearing and along all edges and transitions.
Reference Figure 2--46.

2--48
 TM 1-1520-265-23

c. Any signal similar to the response received from the reference standard should be further
evaluated in accordance with 2.16.4.9 Indication Evaluation.

Figure 2-46. Titanium Rod End Scan Pattern

2.16.4.9 Indication Evaluation. Any vertical signal that is distinguishable (seperated) from the
background noise and not caused by geometry or conductivity shall warrant further investigation and
rescanning in the area of interest.
2.16.5 Post Inspection Standarization.
a. Place the probe on the reference standard and press null.
b. Slide the probe over the 0.040” EDM notch and verify the vertical response is between
60-80% FSH.
c. If the vertical response from the 0.040” notch is less than 60% FSH all inspections performed
since the last standardization shall be repeated. If the response is greater than 80% FSH all
suspect indication identified shall be reevaluated.
2.16.6 Backup Method. Fluorescent Penetrant may be used to aid with determining the relevance
of Eddy Current indication as required, refer to Table 1-4, paragraph 1.4.2.1 and paragraph 1.4.13.
2.16.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.16.8 System Securing. The damper assembly, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

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TM 1-1520-265-23

2.17 DAMPER ASSEMBLY, PISTON (MT).

2.17.1 Description. Dampers are installed between each of the main four rotor hub and spindle
modules to restrain lead and lag motion of the blades during rotation and absorb rotor head
engagement loads.
2.17.2 Defects. Defects are most likely to occur at transitional areas, around bored openings and
radii. No cracks are allowed.
2.17.3 Primary Method. Magnetic Particle.
2.17.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12)
a. Magnetic Particle Inspection Coil
b. Magnetic Particle Inspection Probe/Yoke
c. Magnetometer
d. Black Light
e. Fluorescent Magnetic Particles
f. Consumable Materials
g. Aircraft Marking Pencil
h. Digital Radiometers or Equivalent
2.17.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
2.17.3.3 Access. The damper assembly shall be dissassembled in accordance with applicable
technical manuals listed in Table 1-1..
2.17.3.4 Preparation of Part. The part shall be thoroughly cleaned, Refer to Preparation of Part
of Area for NDI, paragraph 1.4.4.
2.17.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.17.3.6 Inspection Procedure. (Longitudinal Crack Detection) A magnetic field shall be applied
to the part perpendicular to the orientation of possible cracks. Positions required for tlongitudinal
crack detection are illustrated in Figures 2-47.
a. Place the probe/yoke as shown in Figure 2-47.
b. Select AC on the AC/DC power switch.
c. Press the power switch and apply a light coat of magnetic particle media at the same time.
Discontinue the flow of inspection media momentarily before removing the current.
d. Inspect for cracks using the black light. Cracks will appear in a longitudinal orientation.
e. Repeat steps a through d for position 2 through 6.
f. Rotate the piston 180 degrees and repeat steps a through d for position 1 through 6.
g. Demagnetize the piston and the probe/yoke in the positions 1-6. Apply current and withdraw
the probe/yoke from the part for a distance of two feet. The piston is considered
demagnetized when three units or less on a gauss meter, or two units or less on a field
indicator is achieved.

2--50
 TM 1-1520-265-23

Figure 2-47. Longitudinal Crack Detection.

2.17.3.7 Inspection Procedure. (Circumferential Crack Detection) A manetic field shall be applied
to the part perpendicular to the orientation of possible cracks. Positions required for circumferential
crack detection are illustrated in Figure 2-48
a. Select AC on the AC/DC power switch.
b. Place the probe/yoke in position 7 as shown in Figure 2-48.
c. Press the power switch and apply a light coat of magnetic particle media a the same time.
Discontinue the flow of inspection media momentarily before removing the current.
d. Inspect for cracks using the black light. Cracks will appear in a circumferential direction.
e. Rotate the piston 180 degrees and repeat position 7, steps c and d.
f. Continue the inspection placing the probe in positiion 8. Be mindful to rotate the piston 180
degrees and repeat steps c and d..
g. In position 9 trequires the probe/yoke to be located at three locations around the part diameter
120 degrees apart. Repeat steps c and d at all locations.
h. Demagnetize the piston with the probe/yoke placed in position 7-9. Apply current and
withdraw the probe/yoke from the part for a distance of two feet. The piston is considered
demagnetized when three units or less of a gauss meter, or two units or less on a field
indicator are achieved.

NOTE
Paragraph 2.17.3.8 is an optional inspection with the portable coil in liew of positions
7 through 9 with the yoke.

2--51
TM 1-1520-265-23

Figure 2-48. Circumferential Crack Detection

2.17.3.8 Inspection Procedure. (Circumferential Crack Detection with a Coil) A magnetic field shall
be applied to the part perpendicular to the orientation of possible cracks. Positions required for
longitudinal magnetiztion are illustrated in Figure 2-49.
a. Place the piston in coil at the locations as shown in Figure 2-49.
b. Press the power switch and apply a light coat of magnetic particle media at the same time.
Discontinue the flow of inspection media momentarily before removing the current.
c. Inspect for cracks using the black light. Cracks will appear in a circumferential orientation.
d. Repeaat steps c and d at the remaining coil locations.
e. Demagnetize the piston with the coil by applying the current and removing the piston from
the coil simultaneously. The piston is considered demagnetized when three units or less on
a gauss meter, or two units or less on a field indicator are achieved.

Figure 2-49. AC Coil Locations

2--52
 TM 1-1520-265-23

2.17.3.9 Marking and Recording Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.17.4 Backup Method. Florescent Penetrant, refer to Table 1-4, Paragraphs 1.4.2.1 and 1.4.13.
2.17.5 System Securing Clean the piston thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning of Part or Area After NDI, paragraph 1.4.9.The piston requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

2.18 PITCH CONTROL RODS (ET).

2.18.1 Description (Figure 2-1, Index No. 14). The pitch control rods extend from the rotating
swashplate to the blade pitch horn on the spindle. The pitch control rods transmit all movement of
the flight controls from the swashplate to the main rotor blades.
2.18.2 Defects. Defects may occur anywhere on the pitch control rods. All areas where rework
has been performed shall be inspected for cracks. No cracks are allowed.
2.18.3 Primary Method. Eddy Current.
2.18.3.1 NDI Equipment and Materials. (Refer Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Adapter Probe
f. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape
h. Aircraft Marking Pencil
2.18.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the pitch
control rods shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.18.3.3 Access. Access to the pitch control rods is from the L/R engine cowling (Figure 1-4, Items
3T-7 and 4T-8).
2.18.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.18.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1000 KHz LP Filter 100 H Pos 80%
ANG 30_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

2--53
TM 1-1520-265-23

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.18.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.11 and Figure 2-50.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.18.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.18.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

Figure 2-50. Pitch Control Rods

2.18.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.18.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

2--54
 TM 1-1520-265-23

2.18.5 System Securing. The pitch control rods, if removed, require installation in accordance with
the applicable technical manuals listed in Table 1-1.
2.19 ROTATING SWASHPLATE (ET).
2.19.1 Description (Figure 2-1, Index No. 15). The swashplate has stationary and rotating discs
joined by a bearing. It transmits flight control movement to the main rotor head through the four pitch
control rods. The swashplate is permitted to slide on the main rotor shaft and tilt
2.19.2 Defects. Defects may occur anywhere on the surface of the swashplate. No cracks are
allowed.
2.19.3 Primary Method. Eddy Current.
2.19.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.19.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
swashplate shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.19.3.3 Access. Access to the swashplate is from the L/R engine cowling (Figure 1-4, Items 3T-7
and 4T-8).
2.19.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.19.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

2--55
TM 1-1520-265-23

2.19.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-51.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

2--56
 TM 1-1520-265-23

Figure 2-51. Rotating Swashplate

2--57
TM 1-1520-265-23

NOTE
Either probe identified in paragraph 2.19.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.19.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.19.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.19.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.13 and
paragraph 1.4.2.1.
2.19.5 System Securing. The swashplate, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

2.20 SWASHPLATE SPHERICAL BEARING HOLES (ET).

2.20.1 Description. The swashplate (Figure 2-1, Index No. 15) spherical bearing holes have
inserts which hold the bearing retainer plate.
2.20.2 Defects. This inspection is to check for cracks found visually on the swashplate spherical
bearing retainer insert holes, and when replacing swashplate spherical bearing inserts. No cracks
are allowed.
2.20.3 Primary Method. Eddy Current
2.20.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12)
a. Eddy Current Inspection Unit
b. Probe, shielded surface, 100 KHz - 500KHz, 90 degree 1/2 inch drop
c. Probe, straight, shield surface, 100 KHz - 500 KHz
d. Cable Assembly
e. Reference Block, three notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.20.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure.
2.20.3.3 Access. Inserts removed.
2.20.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.

2--58
 TM 1-1520-265-23

2.20.3.5 NDI Equipment and Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in the test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in the test block. (See the standard
instrument display shown in Figure 1-7.
2.20.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-1.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect areas of concern.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.20.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If probes are changed, steps 2.20.3.5 (1),
(2) and (3) shall be repeated each time a change is made.
2.20.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.20.4 Backup Method. Fluorescent Penetrant Inspection, Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.20.5 System Securing. The swashplate spherical bearing hole insert requires installation in
accordance with the applicable technical manual listed in Table 1-1.

2.21 LOWER LINK (ET).

2.21.1 Description (Figure 2-1, Index No. 16). The lower link provides the attaching point for the
rotating scissors and rotating swashplate.
2.21.2 Defects. Defects may occur anywhere on the surface of the lower link. No cracks are
allowed.
2.21.3 Primary Method. Eddy Current.
2.21.3.1 NDI Equipment and Materials. (Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit

2--59
TM 1-1520-265-23

b. Probe, straight, shielded surface, 2 MHz

c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.21.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the lower
link shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.21.3.3 Access. Access to the lower link is from the L/R engine cowling (Figure 1-4, Items 3T-7
and 4T-8).
2.21.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to preparation of Part or
Area for NDI, paragraph 1.4.4.
2.21.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1000 KHz LP Filter 100 H Pos 80%
ANG 30_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.21.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-52.

2--60
 TM 1-1520-265-23

Figure 2-52. Lower Link

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.21.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.21.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.21.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.21.4 Backup Method. Fluorescent Penetrant, refer Table 1-4, to paragraph 1.4.2.1 and
paragraph 1.4.13.
2.21.5 System Securing. The lower link, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

2.22 ROTATING SCISSORS (PT).

2.22.1 Description. (Figure 2-1). The rotating scissors are titanium. They connect the swashplate
to the shaft extension which turns the main rotor.
2.22.2 Defects. This inspection is to verify suspect indications found visually and to check for
cracks when replacing the lower bushing on the rotating scissors. No cracks are allowed.
2.22.3 Primary Method. Fluorescent Penetrant.

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TM 1-1520-265-23

2.22.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12. QPL-AMS-2644-4 level 3 or higher
penetrant materials shall be selected from the approved list in Table 1-12.
2.22.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause ( visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
rotating scissors shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.
2.22.3.3 Access. Not applicable.
2.22.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.22.3.5 Perform process control check per Table 1-3 in accordance with TM 1-1500-366-23.
2.22.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect per Figure 2-53. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 2-53. Rotating Scissors

2.22.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

2.22.4 Backup Method. None Required.

2.22.5 System Securing. The rotating scissors, if removed, requires installation in accordance
withe applicable technical manuals listed in Table 1-1.

2.23 BIFILAR VIBRATION ABSORBER (ET).

2.23.1 Description (Figure 2-1, Index No. 17). The bifilar vibration absorber absorbs vibrations and
stresses. It not only contributes to longer life of all components, but to a smoother ride for the crew
and passengers.
2.23.2 Defects. This inspection is used to verify suspected crack indications found visually on the
bifilar vibration absorber. No cracks are allowed.
2.23.3 Primary Method. Eddy Current.
2.23.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.23.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the bifilar
vibration absorber shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.
2.23.3.3 Access. Access to the bifilar vibration absorber is from the L/R engine cowl (Figure 1-4,
Items 3T-7 and 4T-8).
2.23.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to preparation of Part or
Area for NDI, paragraph 1.4.4.
2.23.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.

2--63
TM 1-1520-265-23

(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.23.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-54.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

NOTE
Either probe identified in paragraph 2.23.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.23.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

Figure 2-54. Bifilar Vibration Absorber

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 TM 1-1520-265-23

2.23.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.23.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4 and paragraph 1.4.2.1 and
paragraph 1.4.13.
2.23.5 System Securing. The bifilar vibration absorber, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

2.24 BIFILAR WEIGHT (UT).

2.24.1 Description (Figure 2-1, Index No. 18). The bifilar weight is part of an assembly that pivots
on two points at the end of each bifilar absorber support arm.

NOTE
Weights marked with the letter “X” following the part number are fabricated as one
piece and do not require ultrasonic inspection.
2.24.2 Defects. This inspection is to detect unbonds within the sintered bondline between the two
legs and the body of the weight.
2.24.3 Primary Method. Ultrasonic specific.
2.24.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Ultrasonic Inspection Unit
b. Transducer, 5.0 MHz, 45_, shear wave, 1/4 x 1/4 inch element
c. Cable Assembly, BNC to Microdot
d. Consumable Materials
e. Aircraft Marking Pencil
2.24.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
Partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may be
performed on all exposed surfaces of the installed part using applicable positions of this procedure.
If required, the bifilar weight shall be removed from the helicopter in accordance with applicable
technical manuals listed in Table 1-1.
2.24.3.3 Access. Not applicable.
2.24.3.4 Preparation of Part. The part shall be thoroughly cleaned. Flaking paint and rough surface
textures will require careful smoothing with a crocus cloth to provide a smooth surface. Refer to
Preparation of Part or Area for NDI, paragraph 1.4.4.

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TM 1-1520-265-23

Figure 2-55. Bifilar Weight

2.24.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Ultrasonic Inspection Unit, Sonic 1200:
PULSER RCVR
GAIN 45 Db dB DIFF 0 dB
PULSE 100 ns DISPLAY Fullwave
DAMPING 200 ohms FREQ 5 MHz
MODE Single REJECT 0%
VOLTAGE 150 V
GATE 1
RANGE GATE 1 +
RANGE 2.50 inch POSN 0.500 inch
DELAY 0.00 inch WIDTH 1.00 inch
VEL .1130 inch LEVEL 80%

THICK
GATE 2 T--GAUGE OFF
GATE 2 OFF
SPCL
ANGLE LEAVE AT DEFAULT SETTINGS
TRIG OFF
MAIN
DAC FREEZE OFF
DAC OFF ZOOM OFF

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 TM 1-1520-265-23

2.24.3.6 Set up.

a. Calibration set--up should be performed at several locations on the bifilar weight free edge.
The area producing the highest signal amplitude at the lowest gain setting edge on the
UPPER edge shall be utilized for calibration. A burred or rounded edge will cause attenuation
losses requiring higher gain settings.
b. Attach the transducer and cable to the ultrasonic instrument. Couple the transducer to the
upper surface of the bifilar weight with the sound beam directed towards the free edge. See
Figure 2-56.

Direct sound beam towards free edge to calibrate.

Compare locations for highest signal amplitude
with the least amount of gain.

Figure 2-56. Bifilar Free Edge

c. With the transducer’s forward edge extending over the free edge of the bifilar weight
maximize the signal from the lower free edge. Mark this location along the baseline of the
ultrasonic instruments CRT display. See Figure 2-57.

Signal received from the lower

Verify the signal on the lower free edge of
edge of the weight
the bifilar weight by dampening the signal
with your finger

Figure 2-57. Baseline Signal

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TM 1-1520-265-23

d. Slide the transducer away from the free edge, the lower edge signal will decrease in
amplitude and be replaced by the signal from the upper free edge. This signal will be located
further out in time along the time baseline. Again, verify this signal by “damping” and mark
its position along the time baseline. Adjust the amplitude of this signal to 80% of full screen
height (FSH). See Figure 2-58.

Figure 2-58. Signal Adjustment

2.24.3.7 Inspection Procedure.

a. Couple the transducer to the upper surface of the bifilar weight. Direct the sound beam
towards the sintered bondline. Slide the transducer back and forth to interrogate the sintered
bond line with both legs of the sound beam. Any signals appearing on the screen at or
between the markings along the time baseline shall be evaluated in accordance with the
accept/reject criteria of paragraph 2.24.3.8. Repeat the inspection procedure for both the
upper and lower bond lines on all the bifilar weights. See Figure 2--59.

Figure 2-59. Inspection with the First and Second Legs of the Sound Beam

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 TM 1-1520-265-23

b. Ultrasonic inspection of the full thickness is required for Zones A and C. See Figure 2-60.

Figure 2-60. Sintered Bondline Inspection Zones

c. Inspection of the full thickness may not be possible in Zone B. See Figure 2-60.
2.24.3.7 Acceptance/Rejection Criteria.
a. Any signal appearing at or between the two locations marked along the time baseline that
exceeds 80% of FSH and the acceptance criteria listed below is rejectable.
Zone A The ultrasonic signal must exceed 80% FSH. No linear indications
are allowed.
Zone B The ultrasonic signal must exceed 80%FSH and be greater than
1.25 inches in length.
Zone C The ultrasonic signal must exceed 80% FSH and be greater than
0.500 inches in length
2.24.3.8 Defect Length Determination.
a. The length of a linear indication within the sintered bond line must be determined for a
accurate disposition of the bifilar weight. The “6dB down” technique will be utilized to
determine the length of all indications exceeding 80% FSH. All linear indications will be
evaluated with regards to the criteria established for each specific zone of the bifilar weight.
See Figure 2-61.
b. 6dB down technique. Mark the transducer’s centerline on the forward end of the transducer
casing. Maximize the signal from the indication being evaluated. Take an aircraft marking
pencil and draw a line across the signal on the screen at 40% FSH. This line represents the
“6dB down” line (from the 80% rejection level).
NOTE
Any signal regardless of screen height, when reduced by 6dB, will be 50% of its
original screen height.

2--69
TM 1-1520-265-23

c. With the transducer positioned to obtain the maximum signal amplitude, slide the transducer
parallel to the sintered bond line while monitoring the signal height. Mark the bond line in
relation to the centerline of the transducer when the signal is reduced in amplitude to the 6dB
down line. Slide the transducer in the opposite direction parallel to the bond line to determine
the length of the indication in the opposite direction. See Figure 2--61.

B
A
C

Figure 2-61. 6dB Down Length Determination

d. Physically measure the unbond indication length when the ends of the indication have been
transferred onto the bifilar weight. Reference the chart in paragraph 2.24.3.7 for specific zone
versus length acceptance limits.
2.24.3.9 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.24.4 Backup Method. None required.
2.24.5 System Securing. The bifilar weight should be thoroughly cleaned after completing the
inspection to remove the inspection media. Refer to Post Cleaning and Restoration of Part or Area
After NDI, paragraph 1.4.9.

2--70
 TM 1-1520-265-23

2.25 BIFILAR WEIGHT BUSHINGS (PT).

2.25.1 Description (Figure 2-1, Index No. 18A) The bifilar weight bushings are installed within the
body of the bifilar weight. See Figure 2-62.

Figure 2-62. Bifilar Weight Bushings

2.25.2 Defects. Inspect the inside diameter of the bushings for stress cracks along its edges. No
cracks allowed.
2.25.3 Primary Method. Fluorescent Penetrant.
2.25.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
2.25.3.2 Preparation of Helicopter.. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. The bifilar weight
shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.25.3.3 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
2.25.3.4 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
2.25.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Tables 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 2-59. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15.
2.25.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3
2.25.4 Backup Method. None required.
2.25.5 System Securing. Clean the bushings to remove inspection media. Refer to Post Cleaning
and Restoration of Part or Area After NDI, paragraph 1.4.9. The bifilar weight requires installation
in accordance with the applicable technical manuals listed in Table 1-1.

2--71
TM 1-1520-265-23

2.26 BIFILAR SUPPORT ARM BUSHING.(PT)

2.26.1 Description (Figure 2-1 Index No. 17) The bifilar support army bushings are found on the
extended arm portion of the bifilar vibration absorber.
2.26.2 Defects. This inspection is to check for cracks found visually on the bifilar support arm
bushings. No cracks are allowed.
2.26.3 Primary Method. Fluorescent Penetrant.
2.26.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1--11. Penetrant
materials shall be selected from the approved list in Table 1-12.
2.26.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
2.26.3.3 Access. Access to the bifilar support arm bushings shall be accomplished by disassembly
of the bifilar weights in accordance with the applicable technical manuals listed in Table 1-1.
2.26.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.26.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500--366-23.
2.26.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 2-63. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15.

Figure 2-63. Bifilar Support Weight Bushings

2.26.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required in paragraph 1.3.
2.26.4 Backup Method. None Required.
2.26.5 System Securing. Clean the bushings thoroughly to remove all residual inspection media.
Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The bifilar
weights require installation in accordance with the applicable manuals listed in Table 1-1.

2--72
 TM 1-1520-265-23

2.27 BIFILAR WEIGHT TAPERED WASHERS (PT).

2.27.1 Description (Figure 2-1, Index No. 18B) The bifilar weight washers are installed within the
body of the bifilar weight.
2.27.2 Defects. Inspect the washers for stress cracks. No cracks allowed.
2.27.3 Primary Method. Florescent Penetrant.
2.27.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12. .
2.27.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. The washers shall
be removed from the bifilar weight in accordance with the applicable technical manuals listed in
Table 1-1.
2.27.3.3 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
2.27.3.4 Perform process control check per Table 1-4, in accordance with TM 1-1500-366-23.
2.27.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part, Figure 2-64. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15..
2.27.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.27.4 Backup Method. None Required.
2.27.5 System Securing. Clean the washers to remove inspection media. Refer to Post Cleaning
and Restoration of Part or Area After NDI, paragraph 1.4.9. The washers require installation in
accordance with the applicable technical manuals listed in Table 1-1.

Figure 2-64. Bifilar Weight Tapered Washers

2--73
 TM 1-1520-265-23

2.28 MAIN ROTOR BLADE TIP CAP FAIRING (ET).

2.28.1 Description (Figure 2-1, Index No. 19). The main rotor blade tip cap fairing is located at
the tip end of the main rotor blade where it forms the tip end contour of the blade airfoil..
2.28.2 Defects. This inspection is used to verify suspected crack indications found visually on the
main rotor blade tip cap fairing. No cracks are allowed.
2.28.3 Primary Method. Eddy Current.
2.28.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.28.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main
rotor blade tip cap fairing shall be removed in accordance with the applicable technical manuals
listed in Table 1-1.
2.28.3.3 Access. Not applicable.
2.28.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.28.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.28.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-65.

2--74
 TM 1-1520-265-23

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.28.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.28.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

2.28.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.28.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.28.5 System Securing. The main rotor blade tip cap fairing, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

Figure 2-65. Main Rotor Blade Tip Cap Fairing

2--75
TM 1-1520-265-23

2.29 MAIN ROTOR BLADE (VOIDS) (BT).

2.29.1 Description (Figure 2-1, Index No. 20). The four main rotor blades have a pressurized
titanium spar, Nomex honeycomb core, fiberglass skin, nickel and titanium abrasion strips, a
removable swept-back tip fairing, and a resistive heating mat used when the blade de-ice system
is activated.
2.29.2 Defects. Void damage can occur anywhere on both sides of the blade shown in Figure
2-66.

NOTE
A void is defined as an unbonded area that is supposed to be bonded. Many
sub-definitions of voids are given, such as lack of adhesive, gas pocket, misfit, etc.
However, this manual makes no distinction among these, instead grouping them all
under one general term (”void”).

Figure 2-66. Main Rotor Blade (Voids)

2.29.3 Primary Method. Bond Testing.

2.29.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Bond Test Unit
b. Probe, Mechanical Impedance Analysis
c. Probe Holder
d. Cable Assembly
e. Test Block, metal honeycomb with skin thickness closest to that of the panel to be inspected.
f. Test Block, Composite Defect Standard #1
g. Teflon Tape
h. Aircraft Marking Pencil

2--76
 TM 1-1520-265-23

2.29.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main
rotor blade shall be installed in accordance with applicable technical manuals listed in Table 1-1.
2.29.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.
2.29.3.4 Preparation of Part. The main rotor blades shall be thoroughly cleaned. refer to
Preparation of Part or Area for NDI, paragraph 1.4.4.
2.29.3.5 NDI Equipment Settings. Refer to Bond Test Equipment, paragraph 1.4.11.1.
a. Attach cable and probe to Bondmaster. Protect probe with Teflon tape and install in probe
holder.
b. Turn on Bondmaster, press SPCL, and make the following adjustments:
H Pos - 40%
V Pos - 80%
PHASE REF - O
DRIVE - MID
c. Press SET and select DISPLAY - PHASE.
d. Place probe on the good area of test blocks and press GOOD PART. Do this several times
while moving the probe to different spots in the good area of the standard. Note the video
signature for each. Select and enter a representative good area by pressing GOOD PART
one last time.
e. Place probe on void area of test block and press BAD PART. Do this several times while
moving the probe slightly to different positions within the void area. Select and enter a
position that gives a strong difference between good and void areas. Use DIFF soft key to
observe difference between good and bad areas of test block.

NOTE
If, during setup, the flying spot deflects upward or to the side when the probe passes
over the bad part instead of the desired down deflection toward the alarm box, press
SPCL and toggle to a different phase setting (90, 180, or 270), and repeat steps d.
and e. Continue to try phase setting until the flying spot moves in the desired down
direction.
f. Place probe on good area of test block and press RUN. Flying spot should be near the
top-center of the ACTIVE screen. If not, press NULL. Slide probe from good void area and
note response from flying spot. This response should provide both amplitude (vertical) and
phase (horizontal) movement. The default gate/alarm setting may be incorrect for this
set-up. Turn off or reset gate/alarm as desired.

2--77
TM 1-1520-265-23

g. The Bondmaster is programmed to automatically set test parameters to a start-up or initial

bond test. By following the steps outlined above, adjustments to the FREQ, GAIN, and
ALARM can help to refine the selectivity in locating defects among differing bonded metallic
and composite materials.
2.29.3.6 Inspection Procedure. Refer to Bond Testing Method, paragraph 1.4.11 and inspection
areas shown in Figure 2-66.
a. Skin-to-Honeycomb Voids. Place probe on main rotor blade in location where test for
skin-to-honeycomb bond separation is desired and press NULL. Move probe from good
suspect area and note response. A strong amplitude change and phase shift similar to the
standard is indicative of a void. This set-up is very sensitive to thin skin-to-core bonding.
Move probe slowly over the skin and note the slight amplitude change (bounce) as the probe
senses alternately the honeycomb cell nodes and cell walls.

NOTE
The basic set-up provided above also selects a frequency that provide a satisfactory
inspection for voids associated with skin-to-spar, skin-to-trailing edge,
doubler-to-doubler and doubler-to-skin, and trim tab bonding.
b. Use the NULL and GAIN adjustments to reset the ACTIVE screen for the areas to be
inspected (do not go back to SET mode). Also, compare similar areas. For example, to check
for spar to skin voids, check front and back of blade in the same area, or check another blade
in the same area. Observe that, when moving the probe cordwise from the spar to the trailing
edge, the transitions at the spar-to-honeycomb and the honeycomb-to-trailing edge strip are
easily detected. When inspecting these areas, adjust the NULL and GAIN and move the
probe carefully along the transition using a straight edge or other guide. A localized phase
and amplitude shift similar to the test block indicates a void.

2.29.3.7 Marking and Recording of Inspection Results. Mark and record as required by paragraph
1.3.

NOTE
Attention shall be directed to accurately mark the boundaries of all voids. These
markings will be needed to determine acceptance or rejection criteria in accordance
with applicable technical manuals.

2.29.4 Backup Method. None required.

2.29.5 System Securing. None required.

2.30 MAIN ROTOR BLADE CUFF ASSEMBLY (ET).

2.30.1 Description (Figure 2-1, Index No. 21). The main rotor blade cuff assembly is bolted and
bonded to the inboard end of the main rotor blade. It provides a bolted attachment for the main rotor
blade to the main rotor head spindle.
2.30.2 Defects. This inspection is used to verify suspected crack indications found visually on the
main rotor blade cuff assembly. No cracks are allowed.

2--78
 TM 1-1520-265-23

2.30.3 Primary Method. Eddy Current.

2.30.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2MHz
c. Probe, right angle, shielded surface, 2MHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Adapter, Probe
f. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape
h. Aircraft Marking Pencil
2.30.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main
rotor blade shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.30.3.3 Access. Access to the main rotor blade cuff assembly is from the L/R engine cowling
(Figure 1-4, Items 3T-7 and 4T-8).
2.30.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.30.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1500KHz LP Filter 100 H Pos 80%
ANG 57_ HP Filter Off V Pos 20%
H Gain 56 db
V Gain 74 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.30.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-67.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

2--79
H-60-MIM-15-002
TM 1-1520-265-23

NOTE
Either probe identified in paragraph 2.30.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.30.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.30.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.30.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.30.5 System Securing. The main rotor blade, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

Figure 2-67 Main Rotor Blade Cuff Assembly

2.31 TAIL ROTOR BLADE SPAR CENTER PLUG (ET).

2.31.1 Description. The spar center plug is the main attachment point of the tail rotor blade.
2.31.2 Defects. Defects may occur anywhere on the spar plug.
2.31.3 Primary Method. Eddy Current.
2.31.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, 90 degree 1/2 inch drop, shield surface, 100KHz-500KHz
Task deleted by H-60-
2--80 MIM-15-002, procedure not
to be performed anymore!
 H-60-MIM-15-002 TM 1-1520-265-23

c. Probe, straight shielded surface, 100 KHz--500KHz

d. Cable Assembly
e. Reference Block, three notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.31.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure.
2.31.3.3 Access. Tail rotor blades must be removed.
2.31.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.31.3.5 NDI Equipment Settings.
a Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in the test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in the test block. (See the standard
instrument display shown in Figure 1-7.)
2.31.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-68.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect both sides of the spar plug to include the bore of the 2.5 inch diameter hole. Scan
the 2.5 inch bore hole axially and circumferentially.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

Task deleted by H-60-

MIM-15-002, procedure not
to be performed anymore

2--81
H-60-MIM-15-002
TM 1-1520-265-23 Task deleted by H-60-
MIM-15-002, procedure not
to be performed anymore

Figure 2-68. Tail Rotor Blade Center Spar Plug

2.31.3.7 Evaluation. Eddy current indications having a measurable linear dimension are
rejectable. A localized (nonlinear) indication shall be re--evaluated by performing a fluorescent
penetrant inspection.
a. Refer to Fluorescent Penetrant Inspection Method, Table 1-4, paragraphs 1.4.2.1 and
paragraph 1.4.13
b. Fluorescent penetrant indications that are linear are rejectable. Fluorescent penetrant
indications that are nonlinear (pitting) shall be evaluated in accordance with appropriate
TM 1-1520-237-23 series manual.
2.31.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.31.4 Backup Method. Fluorescent Penetrant Inspection, Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.31.5 System Securing The tail rotor blade requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

2--82
 TM 1-1520-265-23

2.32 TAIL ROTOR BLADE (VOIDS) (BT).

2.32.1 Description (Figure 2-1, Index No. 22). The rotor blade is built around two graphite
composite spars running from tip-to-tip and crossing each other at the center to form the four blades.
The blade spars are covered with cross ply fiberglass to form the airfoil shape.
2.32.2 Defects. Void damage may occur anywhere on both sides of the blade.

NOTE
A void is defined as an unbonded area that is supposed to be bonded. Many
sub-definitions of voids are given, such as lack of adhesive, gas pocket, misfit, etc.
However, this manual makes no distinction among these, instead grouping them all
under one general term (”void”).
2.32.3 Primary Method. Bond Testing.
2.32.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12)
a. Bond Test Unit
b. Probe, Mechanical Impedance Analysis
c. Probe Holder
d. Cable Assembly
e. Test Block, metal honeycomb with skin thickness closest to that of the panel to be inspected.
f. Test Block, Composite Defect Standard #1
g. Test Block, Composite Defect Standard #3
h. Teflon Tape
i. Aircraft Marking Pencil
2.32.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, remove
the tail rotor blade in accordance with the applicable technical manuals listed in Table 1-1.
3.32.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.
2.32.3.4 Preparation of Part. The components shall be thoroughly cleaned. Refer to Preparation
of Part or Area for NDI, paragraph 1.4.4.
2.32.3.5 NDI Equipment Settings. Refer to Bond Test Equipment, paragraph 1.4.11.1.
a. Attach cable and probe to Bondmaster. Protect probe with Teflon tape and install in probe
holder.

2--83
TM 1-1520-265-23

b. Turn on Bondmaster, press SPCL, and make the following adjustments:

H Pos - 40%
V Pos - 80%
PHASE REF - O
DRIVE - MID
c. Press SET and select DISPLAY - PHASE.
d. Place probe on the good area of test blocks and press GOOD PART. Do this several times
while moving the probe to different spots in the good area of the standard. Note the video
signature for each. Select and enter a representative good area by pressing GOOD PART
one last time.
e. Place probe on void area of test block and press BAD PART. Do this several times while
moving the probe slightly to different positions within the probe area. Select and enter a
position that gives a strong difference between good and void areas. Use DIFF soft key to
observe difference between good and bad areas of test block.

NOTE
If, during setup, the flying spot deflects upward or to the side when the probe passes
over the bad part instead of the desired down deflection toward the alarm box, press
SPCL and toggle to a different phase setting (90, 180, or 270), and repeat steps d.
and e. Continue to try phase setting until the flying spot moves in the desired down
direction.
f. Place probe on good area of test block and press RUN. Flying spot should be near the
top-center of the ACTIVE screen. If not, press NULL. Slide probe from good to void area and
note response from flying spot. This response should provide both amplitude (vertical) and
phase (horizontal) movement. the default gate/alarm setting may be incorrect for this set-up.
Turn off or reset gate/alarm as desired.
g. The Bondmaster is programmed to automatically set test parameters to a start-up or initial
bond test. By following the steps outlined above, adjustments to the FREQ, GAIN, and
ALARM can help to refine the selectivity in locating defects among differing composite
materials.
2.32.3.6 Inspection Procedure. Refer to Bond Testing Method, paragraph 1.4.11 and inspection
areas are shown in Figure 2-69.

a. Skin-to-Honeycomb Voids. Place probe on tail rotor blade in location where test for
skin-to-honeycomb bond separation is desired and press NULL. Move probe from good to suspect
area and note response. A strong amplitude change and phase shift similar to the standard is
indicative of a void. This setup is very sensitive to thin skin-to-core bonding. Move probe slowly over
the skin and note the slight amplitude change (bounce) as the probe senses alternately the
honeycomb cell nodes and cell walls.

2--84
 TM 1-1520-265-23

Figure 2-69. Tail Rotor Blade (Voids)

NOTE
The basic set-up provided above also selects a frequency that provides a satisfactory
inspection for voids associated with skin-to-spar, skin-to-trailing edge,
doubler-to-doubler and doubler-to-skin, and trim tab bonding.
b. Use the NULL and GAIN adjustments to reset the ACTIVE screen for the areas to be
inspected (do not go back to SET mode). Also, compare similar areas. For example, to check for
spar to skin voids, check front and back of blade in the same area, or check another blade in the
same area. Observe that, when moving the probe cordwise from the spar to the trailing edge, the
transitions at spar-to-honeycomb and the honeycomb-to-trailing edge strip are easily detected.
When inspecting these areas, adjust the NULL and GAIN and move the probe carefully along the
transition using a straight edge or other guide. A localized phase and amplitude shift similar to the
test block indicates a void.
2.32.3.7 Marking and Recording of Inspection Results. Mark and record as required by paragraph
1.3.

NOTE
Attention shall be directed to accurately mark the boundaries of all voids. These
markings will be needed to determine acceptance or rejection criteria in accordance
with applicable technical manuals.

2.32.4 Backup Method. None required.

2.32.5 System Securing. The tail rotor blade, if removed, requires installation in accordance with
the applicable technical manual listed in Table 1-1.

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2.33 TAIL ROTOR BLADE (FLUID) (RT).

2.33.1 Description (Figure 2-1, Index No. 23). The tail rotor blade is built around two graphite
composite spars running from tip-to-tip and crossing each other at the center to form the four blades.
The blade spars are covered with cross ply fiberglass to form the airfoil shape.
2.33.1 Defects. Fluid in the honeycomb core.
2.33.3 Primary Method. Radiography.

WARNING

Assure compliance with all applicable safety precautions set forth in

TM 1-1500-366-23 (Nondestructive Inspection General Procedures and Process
Controls (ATOS)) listed in Table 1.1. A hazard associated with exposure to ionizing
radiation is that serious damage can be inflicted without pain, burning, or other sense
of discomfort during the exposure period. Radiation protection shall be utilized in
accordance with AR 385-10 and AR 40-13.
2.33.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-11)
a. X-ray Unit
b. Tripod, X-ray tubehead stand
c. Film Processor
d. Film, Ready Pack 14 inch x 17 inch
e. Marking Material
2.33.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
Partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor blade shall be removed in accordance with applicable technical manuals listed in Table 1-1.
2.33.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.
2.33.3.4 Preparation of Part. The rotor blade shall be thoroughly cleaned. Refer to Preparation
of Part or Area for NDI, paragraph 1.4.4.

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2.33.3.5 NDI Equipment Settings.

a. Refer to Radiographic (X-ray) method, paragraph 1.4.18.
b. Typical equipment settings, inspection, and exposure data are given in Figure 2-70.
2.33.3.6 Inspection Procedures.. Inspect designated areas, refer to Figure 2-70 for typical fluid
entrapmentand source film/placement.
a. Position film and desired nameplate data for exposure number 1.
b. Position X-ray tubehead for exposure number 1.
c. Set X-ray unit to the values given in the Radiographic Inspection Data chart for exposure
number 1.
d. Make exposure number 1.
e. Remove exposed film.
f. Repeat inspection procedure (steps a. through e. above) for each exposure.
g. Process and interpret film for defects as noted in paragraph 2.33.2 and as shown in Figure
2-67.

2.33.4 Backup Method. None required.

2.33.5 System Securing. The tail rotor blade shall be cleaned as necessary. Refer to Post
Cleaning and Restoration of Part or Area after NDI, paragraph 1.4.9. The tail rotor blade, if removed,
requires reinstallation in accordance with the applicable technical manual listed in Table 1-1.

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TM 1-1520-265-23

Figure 2-70. Tail Rotor Blade (Fluid) (Sheet 1 of 2)

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 TM 1-1520-265-23

Figure 2-70. Tail Rotor Blade (Fluid) (Sheet 2 of 2)

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TM 1-1520-265-23

2.34 TAIL ROTOR BLADE TIP CAP (ET).

2.34.1 Description (Figure 2-1, Index No. 24). The tail rotor blade tip cap is riveted to the end of
the tail rotor blade. The tip cap is the access area to the blade counter weight.
2.34.2 Defects. This inspection is used to verify suspected crack indications found visually on
the tail rotor blade tip cap. No cracks are allowed.
2.34.3 Primary Method. Eddy Current.
2.34.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.34.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
2.34.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.
2.34.3.4 Preparation of Part. The part shall be thoroughly cleaned, refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.34.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.

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 TM 1-1520-265-23

(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.34.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-71.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 2-71. Tail Rotor Blade Tip Cap

NOTE
Either probe identified in paragraph 2.24.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.24.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

2.34.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.34.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.34.5 System Securing. None required.

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2.35 TAIL ROTOR PITCH BEAM (PT)

2.35.1 Description. (Figure 2-1, Index No. 29.) The tail rotor pitch beam is a four--armed pitch
beam bolted to the end of the pitch change shaft. The pitch beam increases or decreases the pitch
of all blades simultaneously through pitch links connected to the blades.
2.35.2 Defects. This inspection is to spot check for suspected cracks on the tail rotor pitch beam,
and is mandatory for replacing bushings. No cracks are allowed.
2.35.3 Primary Method. Fluorescent Penetrant.
2.35.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-AMS-2644-4 level 3 or higher penetrant materials shall be selected from the approved list in
Table 1-12.
2.35.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the pitch
beam shall be removed in accordance with the technical manuals listed in Table 1-1.
2.35.3.3 Access. Not applicable.
2.35.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to preparation of Part
or Area for NDI, paragraph 1.4.4.
2.35.3.6 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
2.35.3.7 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Tables 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 2-72. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15.
2.35.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.35.4 Backup Method. None required.
2.35.5 System Securing. The pitch beam, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

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 TM 1-1520-265-23

Figure 2-72. Tail Rotor Pitch Beam Bushings.

2.36 TAIL ROTOR PITCH BEAM (ET).

2.36.1 Description (Figure 2-1, Index No. 29). The four-armed pitch beam is bolted to the end of
the pitch change shaft. The pitch beam increases or decreases the pitch of all blades
simultaneously through pitch links connected to the blades.
2.36.2 Defects. This inspection is used to verify suspected crack indications found visually on the
pitch beam. No cracks are allowed.
2.36.3 Primary Method. Eddy Current.
2.36.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz--500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil

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TM 1-1520-265-23

2.36.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the pitch
beam shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
2.36.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.

2.36.3.4 Preparation of Part. The part shall be thoroughly cleaned, refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.

2.36.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.36.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-73.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.36.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.36.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

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 TM 1-1520-265-23

2.36.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.36.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.36.5 System Securing. The pitch beam, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 2--73. Tail Rotor Pitch Beam

2.37 TAIL ROTOR PITCH HORN (ET).

2.37.1 Description (Figure 2-1, Index No. 25). The tail rotor pitch horn transmits input from the
pitch control rod to change pitch of the tail rotor blades.
2.37.2 Defects. This inspection is used to verify suspected crack indications found on the tail rotor
pitch horn. No cracks allowed.
2.37.3 Primary Method. Eddy Current.

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TM 1-1520-265-23

2.37.31. NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12).)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
2.37.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be preformed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor pitch horn shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
2.37.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.

2.37.3.4 Preparation of Part. The part shall be thoroughly cleaned, refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.37.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.37.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-74.

2--96
 TM 1-1520-265-23

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 2.36.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.36.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.
2.37.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.37.4 Backup Method. Fluorescent penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.paragraph 1.4.7.
2.37.5 System Securing. The tail rotor pitch horn, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

Figure 2-74. Tail Rotor Pitch Horn

2.38 TAIL ROTOR PITCH CONTROL ROD ENDS (MT).

2.38.1 Description (Figure 2-1, Index No. 26). The pitch control links are installed on the tail rotor
head assembly. Each link connects an arm of the pitch beam to a pitch control horn on the blade.
2.38.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail rotor pitch control rod ends. no cracks are allowed.

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TM 1-1520-265-23

2.38.3 Primary Method. Magnetic Particle.

2.38.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
2.38.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the tail rotor pitch control rods shall be removed in accordance with the
applicable technical manuals listed in Table 1-1.
2.38.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.

2.38.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.38.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.38.3.6 Perform process control checks in accordance with TM 1-1500-366-23.
2.38.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is illustrated in Figure 2-75.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Inspect opposite side. Repeat steps a. through d.
2.38.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

2.38.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
2.38.4 Backup Method. None required.
2.38.5 System Securing. Clean the tail rotor pitch control rod ends thoroughly to remove all
residual magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,
paragraph 1.4.9. The tail rotor pitch control rod ends, if removed, require installation in accordance
with applicable technical manuals listed in Table 1-1.

Figure 2-75. Tail Rotor Pitch Control Rod Ends

2.39 PITCH BEAM WASHER (MT).

2.39.1 Description (Figure 2-1, Index No. 27). The pitch beam washer is installed between the
pitch beam retaining nut and pitch beam.
2.39.2 Defects. This inspection is used to verify suspected crack indications found visually on the
pitch beam washer. No cracks allowed.

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TM 1-1520-265-23

2.39.3 Primary Method. Magnetic Particle.

2.39.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
2.39.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the pitch beam washer removed in accordance with the applicable technical manuals listed in
Table 1-1.
2.39.3.3 Access. Not applicable.
2.39.3.4 Preparation of Part. The part shall be thoroughly cleaned, refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
2.39.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.40.3.6 Perform process control checks in accordance with TM 1-1500-366-23.
2.39.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 2-76.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 1.4.17.
f. Repeat steps a. through e. for position 2.
g. Inspect the opposite side. Repeat steps a. through f.
2.39.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.39.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
2.39.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
2.39.5 System Securing. Clean the pitch beam washer thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,

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 TM 1-1520-265-23

paragraph 1.4.9. The pitch beam washer requires installation in accordance with the applicable
technical manuals listed in Table 1-1.

Figure 2-76. Pitch Beam Washer

2.40 PITCH BEAM RETAINING NUT (MT).

2.40.1 Description (Figure 2-1, Index No. 28). The pitch beam retaining nut retains the pitch beam
to the tail rotor gearbox shaft.
2.40.2 Defects. This inspection is used to verify suspected crack indications found visually on the
pitch beam retaining nut. No cracks are allowed.
2.40.3 Primary Method. Magnetic Particle.

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TM 1-1520-265-23

2.40.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
2.40.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the pitch beam retaining nut shall be removed in accordance with the
applicable technical manuals listed in Table 1-1.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.
2.40.3.3 Access. Not applicable.
2.40.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.40.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
2.40.3.6 Perform process control checks in accordance with TM 1-1500-366-23.
2.40.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 2-77.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 1.4.17.
f. Repeat steps a. through e. for position 2.
g. Inspect opposite side and repeat steps a. through f.
2.40.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.40.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.

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 TM 1-1520-265-23

2.40.4 Backup Method. None required.

2.40.5 System Securing. Clean the pitch beam retaining nut thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,
paragraph 1.4.9. The pitch beam retaining nut, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

Figure 2-77. Pitch Beam Retaining Nut

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TM 1-1520-265-23

2.41 TAIL ROTOR INBOARD/OUTBOARD RETENTION PLATES (ET).

2.41.1 Description (Figure 2-1, Index No. 30). The tail rotor inboard/outboard retention plates are
the attaching points for tail rotor blades.
2.41.2 Defects. Defects may occur anywhere on the surface of the inboard/outboard retention
plates. No cracks are allowed.
2.41.3 Primary Method. Eddy Current.
2.41.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz--500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking pencil
2.41.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor inboard/outboard retention plates shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
2.41.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
non-tactical environment. Otherwise, personnel injury could result from accidental
falls.

2.41.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
2.41.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200KHz LP Filter 100 H Pos 80%
ANG 30_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

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 TM 1-1520-265-23

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
2.41.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 2-78.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 2-78. Tail Rotor Inboard/Outboard Retention Plates

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TM 1-1520-265-23

NOTE
Either probe identified in paragraph 2.41.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 2.41.3.5
b. (1), (2), and (3) shall be repeated each time a change is made.

2.41.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
2.41.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
Paragraph 1.4.13.
2.41.5 System Securing. The tail rotor inboard/outboard retention plates, if removed, require
installation in accordance with the applicable technical manuals listed in Table 1-1.

2.42 DAMPER ASSEMBLY, BUSHINGS (PT).

2.42.1 Descriiption. Dampers are installed between each of the main four rotor hub and spindle
modules to restrain lead and lag motion of the blades during rotation and absorb rotor head
engagement loads.
2.24.2 Defects. No crack allowed.
2.42.3 Primary Method. Fluorescent Penetrant Inspection.
2.42.3.1 Inspection Intent. The following inspection procedure is intended to support maintenance
manaul requirements for fluorescent penetrant inspection of the damper bushing and sleeve
bearing.
2.42.3.2 NDIEquipment and Materials. (Refer to Tables 1-11 and 1-12.) Insepction equipment is
listed in Table 1-11. QPL-AMS-2644 Level 3 penetrant materials shall be selected from the
approved list in Table 1-12.
2.42.3.3 Preparation of Helicopter The helicopter shall be prepared for safe ground maintenance.
2.42.3.4 Access. The damper assembly shall be disassembled in accorandance with technical
manual listed in Table 1-1.
2.42.3.5 Preparation of Part. Refer to Preparation of Part of Area for NDI, paragraph 1.4.4.
2.42.3.6 Fluorescent Penetrant Inspection. Complete the appropriate process control checks
prior to performing this inspection. Perform the fluorescent penetrant inspectin. Refer to
Fluorescent Penetrant Method, Table 1-4, paragraph 1.4.2.1 and paragraph 1.4.13.
2.42.3.7 Marking and Recording of Inspection Results Marking and Recording of Inspection
Results
2.42.4 Backup Method. None required.
2.42.5 System Securing. The damper assembly requires re--assembly per applicable technical
manauls listed in Table 1-1.

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 TM 1-1520-265-23

Figure 2-79. Damper Assembly Bushings

2--107/(2--108 blank)
 TM 1-1520-265-23

SECTION III
DRIVE SYSTEM

3. GENERAL.
3.1 CONTENTS.The drive system inspection items covered in this section are those items of the
H-60 helicopter series transmission, gearboxes, drive shafts, and components listed in the Drive
System Inspection Index (Table 3-1). Corresponding inspection figures and the applicable text
paragraphs are listed opposite each inspection item. The index number for each item may be used
to locate it in Figure 3-1.

Table 3-1. Drive System Inspection Index

Index Inspection Paragraph Figure

Number Nomenclature Method Number Number

*2 Main Transmission ET 3.2 3-2

Rotor Brake Housing ET 3.3 3--3
*3 Intermediate Gearbox ET 3.4 3-4
*4 Tail Rotor Drive Shaft ET 3.5 3-5
*5 Tail Rotor Drive Shaft Supports ET 3.6 3-6
*6 Tail Rotor Drive Shaft Coupling PT 3.7 3-7
*7 Oil Cooler Drive Shaft ET 3.8 3-8
*8 Oil Cooler Axial Fan Shaft MT 3.9 3-9
*9 Oil Cooler Fan Blades ET 3.10 3-10
*10 Tail Gearbox ET 3.11 3-11
11 Tail Gearbox Mount Fitting ET 3.12 3-12
12 Tail Rotor Gearbox Inner/Outer Split PT 3.13 3-13
Cones
13 Ferrous Bolts MT 2.3 2.3
14 Nonferrous Bolts PT 2.4 2.4

NOTE: *Indicates Flight Safety Part.

3--1
TM 1-1520-265-23

Figure 3-1. Transmission/Drive System

3--2
 TM 1-1520-265-23

3.2 MAIN TRANSMISSION (ET).

3.2.1 Description (Figure 3-1, Index No. 2). The main transmission is mounted on the main
fuselage. It mounts and drives the main rotor head, changes the angle of drive from the engines,
reduces engine rpm, and drives the tail rotor drive shaft along with the accessory modules.

NOTE
The transmission casing is made out of magnesium and should be treated as such
during maintenance procedures and repairs.
3.2.2 Defects. Defects may occur anywhere on the surface of the main transmission. All areas
where rework has been performed shall be inspected for cracks. No cracks are allowed.
3.2.3 Primary Method. Eddy Current.
3.2.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.2.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main
transmission shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
3.2.3.3 Access Not applicable.
3.2.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.2.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.

3--3
TM 1-1520-265-23

(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

Figure 3-2. Main Transmission

3.2.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-2.

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

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 TM 1-1520-265-23

NOTE
Either probe identified in paragraph 3.2.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.2.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
3.2.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.2.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4 paragraph 1.4.2.1 and
paragraph 1.4.13.
3.2.5 System Securing. The main transmission, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

3.3 ROTOR BRAKE HOUSING H--60 INSPECTION (ET).

3.3.1 Description This inspection procedure is intended to be used as a means to evaluate areas
of the front and rear housing assembly. Areas having visible damage (nicks, dents, corrosion) or are
suspected of being cracked may be inspected using this inspection procedure.
3.3.2 Defects. Defects may occur at random locations on the components being inspected.
Special attention should be directed towards bores, fasteners, radii and edges. No cracks are
allowed.
3.3.3 Primary Method. Eddy Current.
3.3.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12)
a. Eddy Current Inspection Unit, Nortec 2000D or equivalent.
b. Probe, 90 degree 1/2 inch drop, shielded surface, 100-500 KHz.
c. Probe, straight shaft, shielded surface, 100-500 KHz.
d. Cable Assembly.
e. Reference Block, three--notched aluminum (0.008”, 0.020”, 0.040” EDM notches)
f. Teflon Tape.
g. Aircraft Marking Pencil.
3.3.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure.
3.3.3.3 Access. A required per applicable technical manual.
3.3.3.4 Preparation of Part. The inspection area shall be clean of any surface contamination or
rough paint that may interfere with adequate probe-surface contact. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.3.3.5 Coating Lift-Off Compensation. The lift-off caused by paint thickness affects sensitivity and
requires compensation during instrument standardization. To compensate for the increased lift-off,
the appropriate thickness of non-conductive material (plastic shims, paper, Teflon tape, etc.) shall
be placed between the probe and the test block during the standardization process unless otherwise
specified by the part specific procedure. Utilize the technique in paragraph 1.4.19.8 of this
manual to determine the appropriate non--conductive shim to use during instrument set up
and for lift-off compensation.

3--5
TM 1-1520-265-23

CAUTION

Coating thickness greater than .010 inch (10 mils) shall be removed prior to
conducting Eddy Current inspection. Coating thickness on the inspection surface
greater than .010 inch thick will significantly reduce inspection sensitivity and can
result in the failure to detect cracks.
a. Make the following initial settings on the Eddy Current inspection unit:
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP FILTER 100 H Pos 80%
ANG 77_ HP Filter Off V Pos 20%
H Gain 55 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on the test block as follows:
(1) Determine non--conductive coating thickness on test material. Refer to paragraph 1.4.19.8.
(2) Null the probe on the test block with the appropriate thickness of nonconductive shim
between the probe and the reference standard. The shim should be large enough to cover
all three EDM notches.
(3) Adjust phase angle as required to obtain horizontal lift--off.
(4) Slide the probe over the three notches in the test block with the appropriate thickness shim
(if required) in place. Obtain a five (5) screen division vertical response from the 0.040” EDM
notch (70% FSH).

Figure 3-3. Front and Rear Rotor Brake Housing

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 TM 1-1520-265-23

3.3.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-3..
a. With the instrument standardization for the appropriate lift-off compensation, place the probe
on a good area of the part near the inspection area and null. Adjust phase as required to
obtain a horizontal lift-off..
b. Inspect entire area of interest 100% in two directions, 90 degrees apart. Eddy current scan
passes should overlap slightly for optimum small flaw detection.
c. Verify instrument sensitivity by passing the probe over the reference standard at a maximum
interval of 10 minutes.
d. Any signal similar to the notches in the test block is cause for rejection.
e. Perform post inspection sensitivity verification per the Post Inspection Standardization
instructions in paragraph 3.3.3.8.
3.3.3.7 Indication Evaluation. Any vertical signal that is distinguishable (separated) from the
background noise and not caused by geometry or conductivity shall warrant further investigation and
rescanning in the area of interest.
3.3.3.8 Post Inspection Standardization.
a. Place the probe on the reference standard and press null.
b. Slide the probe over the 0.040” EDM notch and verify the vertical response is between 60%
and 80% FSH.
c. If the vertical response from the 0.040” notch is less than 60% FSH all inspections performed
since the last standardization shall be repeated. If the response is greater than 80% FSH, all
suspect indications identified shall be re--evaluated.
3.3.3.9 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.3.4 Backup Method. Fluorescent penetrant inspection may be used to aid in determining the
relevance of eddy current indications as required.
3.3.5 System Securing. The inspected part requires installation IAW the applicable technical
manuals listed in Table 1-1.
3.4 INTERMEDIATE GEARBOX (ET).
3.4.1 Description (Figure 3-1, Index No. 3). The intermediate gearbox is mounted at the base
of the pylon. The intermediate gearbox carries main transmission torque to the tail gearbox.

NOTE
The gearbox is made out of magnesium and should be treated as such during
maintenance procedures and repairs.
3.4.2 Defects. This inspection is used to verify suspected crack indications found visually on the
intermediate gearbox. All areas where rework has been performed shall be inspected for cracks.
No cracks are allowed.
3.4.3 Primary Method. Eddy Current.
3.4.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz

3--7
TM 1-1520-265-23

c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.4.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
intermediate gearbox shall be removed in accordance with the applicable technical manuals listed
in Table 1-1.
3.4.3.3 Access. Access is obtained through the intermediate gearbox cover (Figure 1-4, Item
5T-6T-17).
3.4.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.4.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all notches in test block. Adjust gain to obtain a five block vertical signal
when probe is passed over 0.040-inch notch in test block. (See the standard instrument
display shown in Figure 1-7.)
3.4.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-4.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 3.3.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.3.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
3.4.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

3.4.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
3.4.5 System Securing. The intermediate gearbox, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

Figure 3-4. Intermediate Gearbox

3.5 TAIL ROTOR DRIVE SHAFT (ET).

3.5.1 Description (Figure 3-1, Index No. 4). The tail rotor is driven by a series of seven shafts.
The shafts run from the tail take off flange on the rear of the main transmission to the intermediate
gearbox. The tail rotor drive shaft then runs from the intermediate gearbox to the tail gearbox.
3.5.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail rotor drive shaft. No cracks are allowed.

3--9
TM 1-1520-265-23

3.5.3 Primary Method. Eddy Current.

3.5.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.5.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor drive shaft shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
3.5.3.3 Access. Accessibility of the tail rotor drive shaft varies considerably. Refer to Figure 1-4 and
Table 1-2 to locate applicable access provisions.
3.5.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.5.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.5.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.11 and Figure 3-5.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 3.4.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.4.3.5.b.
(1), (2), and (3) shall be repeated each time a change is made.

3--10
 TM 1-1520-265-23

3.5.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required in paragraph 1.3.
3.5.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1. and
paragraph 1.4.13.
3.5.5 System Securing. The tail rotor drive shaft, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

Figure 3-5. Tail Rotor Drive Shaft

3.6 TAIL ROTOR DRIVE SHAFT SUPPORTS (ET).

3.6.1 Description (Figure 3-1, Index No. 5). The tail rotor drive shaft support attaches the tail rotor
drive shafts to the airframe throughout the tail cone section of the helicopter.
3.6.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail rotor drive shaft supports. No cracks are allowed.
3.6.3 Primary Method. Eddy Current.
3.6.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit.

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TM 1-1520-265-23

b. Probe, straight, shielded surface, 100 KHz-500 KHz

c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.6.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the drive
shaft shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
3.6.3.3 Access. Access to the tail rotor drive shaft supports varies considerably. Refer to Figure 1-4
and Table 1-2 to locate applicable access provisions.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
3.6.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.6.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.6.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-6.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

3--12
 TM 1-1520-265-23

Figure 3-6. Tail Rotor Drive Shaft Supports

NOTE
Either probe identified in paragraph 3.5.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.5.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
3.6.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.6.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
3.6.5 System Securing. The tail rotor drive shaft supports, if removed, require installation in
accordance wit the applicable technical manuals listed in Table 1-1.

3.7 TAIL ROTOR DRIVE SHAFT COUPLING (PT).

3.7.1 Description (Figure 3-1, Index No. 6). The tail rotor drive shaft couplings are multiple disc,
flexible couplings which are used to carry torque and allow for minor misalignment of the tail drive
shaft components. Also, the couplings allow the drive shaft to remain in alignment as the airframe
flexes in flight.
3.7.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail rotor drive shaft coupling. No cracks are allowed.
3.7.3 Primary Method. Fluorescent Penetrant.

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TM 1-1520-265-23

3.7.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
3.7.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor drive shaft coupling shall be removed in accordance with the applicable technical manuals
listed in Table 1-1.
3.7.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, workstands, or other approved locally procured

stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
3.7.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
3.7.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
3.7.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4, or 1-5 depending on Unit capability.
Inspect part Figure 3-7. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 3-7. Tail Rotor Drive Shaft Coupling

3.7.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.7.4 Backup Method. None required.
3.7.5 System Securing. Clean the tail rotor drive shaft coupling to remove inspection media.
Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The tail rotor
drive shaft coupling, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

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 TM 1-1520-265-23

3.8 OIL COOLER DRIVE SHAFT (ET).

3.8.1 Description (Figure 3-1, Index No. 7). The oil cooler drive shaft is aft of, and driven by, the
shouldered shaft of the fan. The fan forces air through the radiator, which cools the hot oil from the
main module sump. The forward flange of the oil cooler drive shaft is steel, the aft end is titanium,
and the drive shaft tube is aluminum.
3.8.2 Defects. This inspection is used to verify suspected crack indications found visually on the
aluminum and titanium portions of the oil cooler drive shaft. No cracks are allowed.
3.8.3 Primary Method. Eddy Current.
3.8.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 1-2 MHz (Titanium)
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop (Titanium)
d. Probe, right angle, shielded surface, 1-2 MHz (Titanium)
e. Probe, straight, shielded surface, 100 KHz-500KHz. (Aluminum)
f. Adapter, Probe
g. Cable Assembly
h. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
i. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
j. Teflon Tape
k. Aircraft Marking Pencil
3.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the oil
cooler drive shaft shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.
3.8.3.3 Access. Access is obtained through the oil cooler access panels (Figure 1-4, Item 3T-25).

WARNING

Use only appropriate platforms, workstands, or other approved locally procured

stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
3.8.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.

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TM 1-1520-265-23

3.8.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ (Aluminum) 200 KHz LP Filter 100 H Pos 80%
(Titanium) 1500KHz
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.8.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-8.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 3-8. Oil Cooler Drive Shaft

NOTE
Either probe identified in paragraph 3.7.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.7.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
3.8.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.8.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

3--16
 TM 1-1520-265-23

3.8.5 System Securing. The oil cooler drive shaft, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

3.9 OIL COOLER AXIAL FAN SHAFT (MT).

3.9.1 Description (Figure 3-1, Index No. 8). The oil cooler axial fan shaft passes through and dries
the fan rotor. There are two configurations: one with an integral flange and one with a
removeable/companion flange and nut. This inspection is for the removable/companion flange type.
3.9.2 Defects. Defects may occur anywhere on the surface of the oil cooler fan shaft. This
inspection is to find cracks on the oil cooler axial fan shaft identified, at or around the cotter pin holes.
No cracks are allowed.
3.9.3 Primary Method. Magnetic Particle.
3.9.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
3.9.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
If required, the fan shaft/blower assembly shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
3.9.3.3 Access. Not applicable.
3.9.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
3.9.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.8.
3.9.3.6 Perform process control checks per TM 1-1500-366-23.
3.9.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 3-9.

3--17
TM 1-1520-265-23

Figure 3-9. Oil Cooler Axial Fan Shaft

a. Select AC on the AC/DC power switch.

b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 3.8.3.8.
f. Inspect opposite side, repeat steps a. through f.
g. Repeat steps a. through e. for position 2.
3.9.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.9.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
3.9.4 Backup Method. None required.
3.9.5 System Securing. Clean the oil cooler fan shaft thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The oil cooler fan shaft, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

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 TM 1-1520-265-23

3.10 OIL COOLER FAN BLADES (ET).

3.10.1 Description (Figure 3-1, Index No. 9). The oil cooler fan blades are part of the transmission
blower assembly. The blower forces air through the oil cooler.
3.10.2 Defects. Defects may occur anywhere on the surface of the oil cooler fan blades. Particular
attention shall be given to the blade/hub area. No cracks are allowed.
3.10.3 Primary Method. Eddy Current.
3.10.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.10.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the oil cooler fan, if required, shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
3.10.3.3 Access. Access to the oil cooler fan blades is through the oil cooler access panel (Figure
1-4, Item 3T-25).
3.10.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
3.10.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.10.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-10.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.

3--19
TM 1-1520-265-23

b. Inspect the part.

c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 3.9.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.9.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.

Figure 3-10. Oil Cooler Fan Blades

3.10.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.10.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
3.10.5 System Securing. The oil cooler fan, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

3.11 TAIL GEARBOX (ET).

3.11.1 Description (Figure 3-1, Index No. 10). The tail gearbox is mounted at the top of the pylon.
It holds the tail rotor head and changes the direction of the drive.

NOTE
The gearbox is made out of magnesium and should be treated as such during
maintenance procedures and repair.
3.11.2 Defects. Defects may occur anywhere on the surface of the tail gearbox. Particular
attention should be given to the mounting point area. Also, all areas where rework has been
performed shall be inspected for cracks. No cracks are allowed.

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 TM 1-1520-265-23

3.11.3 Primary Method. Eddy Current.

3.11.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.11.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
gearbox shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
3.11.3.3 Access. Access is obtained through the tail gearbox cover (Figure 1-4, Item 5T-6T-12).

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
3.11.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
3.11.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.11.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-11.

3--21
TM 1-1520-265-23

Figure 3-11. Tail Gearbox

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated

NOTE
Either probe identified in paragraph 3.10.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.10.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
3.11.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.11.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

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 TM 1-1520-265-23

3.11.5 System Securing. The tail gearbox, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

3.12 TAIL GEARBOX MOUNT FITTING (ET).

3.12.1 Description (Figure 3-1, Index No. 11). The tail gearbox mount fitting is a structural
component of the pylon. It serves as the attaching point for the tail gearbox assembly.
3.12.2 Defects. Defects may occur anywhere on the surface of the tail gearbox mount fitting.
Particular attention shall be given to the joining area with the fitting to front spar caps in the area of
high strength fasteners. No cracks are allowed.
3.12.3 Primary Method. Eddy Current.
3.12.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
3.12.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail
rotor gearbox shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
3.12.3.3 Access. Access is obtained through the tail rotor gearbox cover (Figure 1-4, Item
5T-6T-12).

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
3.12.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
3.12.3.5 NDI Equipment Settings.

3--23
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57 db
V Gain 69 db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
3.12.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 3-12.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 3.11.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 3.11.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.

Figure 3-12. Tail Gearbox Mount Fitting

3--24
 TM 1-1520-265-23

3.12.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.12.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
3.12.5 System Securing. The tail gearbox mounting fitting, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.
3.13 TAIL ROTOR GEARBOX INNER/OUTER SPLIT CONES (PT).
3.13.1 Description (Figure 3-1, Index No. 12). The tail rotor gearbox split cones provide support
to the inner retention plate attached to the output shaft of the tail rotor gearbox.
3.13.2 Defects. Defects may occur anywhere on the surface of the tail rotor gearbox inner/outer
split cones. All areas where rework has been performed shall be inspected for cracks. No cracks
are allowed.
3.13.3 Primary Method. Fluorescent Penetrant.
3.13.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
3.13.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the tail rotor gearbox inner/outer split cones removed in accordance with the applicable
technical manuals listed in Table 1-1.
3.13.3.3 Access. Not applicable.
3.13.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
3.13.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
3.13.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and either Table 1-4, or 1-5 depending on Unit capability.
Inspect part Figure 3-13. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15.
3.13.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
3.13.4 Backup Method. None required.
3.13.5 System Securing. Clean the tail rotor gearbox inner/outer split cones to remove inspection
media. Refer to Post Cleaning and Restoration of Part of Area After NDI, paragraph 1.4.9. The tail
rotor gearbox inner/outer split cones require installation in accordance with the applicable technical
manuals listed in Table 1-1.

Figure 3-13. Tail Rotor Gearbox Inner/Outer Split Cones

3--25
TM 1-1520-265-23

3.14 FERROUS BOLTS CONTAINED WITHIN THE FLIGHT CONTROL SYSTEM (MT).
3.14.1 Description (Table 3-1, Index No. 13). Refer to paragraph 2.3 for inspection procedures.

3.15 NONFERROUS BOLTS CONTAINED WITHIN THE FLIGHT CONTROL SYSTEM (PT).
3.15.1 Description (Table 3-1, Index No. 14). Refer to paragraph 2.4 for inspection procedures.

3--26
 TM 1-1520-265-23

SECTION IV
AIRFRAME AND LANDING GEAR SYSTEM
4. GENERAL.
4.1 CONTENTS. The airframe and landing gear system inspection items covered in this section
are those critical items of the H-60 helicopter series listed in the Airframe and Landing Gear System
Inspection Index (Table 4-1). Corresponding inspection figures and applicable text paragraphs are
listed opposite each inspection item. The index number for each item may be used to locate it in
Figure 4-1.

Table 4-1. Airframe and Landing Gear System Inspection Index

Index Nomenclature Inspection Paragraph Figure

Number Method Number Number
2 Airframe Skin, Panels, Doors, Covers, and ET 4.2 4-2
Fairings - Metal
Tail Cone Fold Fitting ET 4.3 4-3
3 Honeycomb and Composite Structures BT 4.4 4-4
4 Fluid in Honeycomb Core Panels and RT 4.5 4-5
Structures
5 Ferrous Vibration Absorber Springs MT 4.6 4-6
Nonferrous Vibration Absorber Springs PT 4.7 4-7
6 Vibration Absorber Structural Fittings ET 4.8 4-8
7 Roll Vibration Absorber PT 4.9 4-9
Cabin Vibration Upper and Lower Housing PT 4.10 4.10
8 Aluminum Structural Beams and Frames ET 4.11 4-11
9 Pilot/Copilot Seat Midframe Support MT 4.12 4-12
10 Troop/Cargo Door Upper Track ET 4.13 4-13
11 Gunner’s Window Lower Track ET 4.14 4-14
12 Gunner’s Window Upper Track ET 4.15 4-15
13 Troop/Cargo Door Lower Track ET 4.16 4-16
14 Oil Cooler Compartment Access Door PT 4.17 4-17
15 Tail Pylon Attach Fitting ET 4.18 4-18
16 Tail Rotor Pylon Skin, Station 200 ET 4.19 4-19
17 Tail Rotor Pylon Attaching Hardware PT 4.20 4-20
18 Tail Pylon Lower Step ET 4.21 4-21
*19 Stabilator Attach Fitting ET 4.22 4-22
20 Stabilator Actuator Attach Fittings MT 4.23 4-23
Stabilator Position Sensor Bracket PT 4.24 4-24

4--1
TM 1-1520-265-23

*21 Stabilator Actuator Housing PT 4.25 4-25

*22 Drag Beam Support Fitting ET 4.26 4-26
Drag Beam Jackpad and Tiedown Ring MT 4.27 4-27
Holes
*23 Main Landing Gear Drag Beam MT 4.28 4-28
Main Landing Gear Fitting Spherical PT 4.29 4-29
Bearing Bore
24 Main Landing Gear Shock Strut Upper Cyl- ET 4.30 4-30
inder
25 Main Landing Gear Shock Strut Lower MT 4.31 4-31
Stage Piston
26 Main Landing Gear Wheel Assembly PT 4.32 4-32
Primary Method (PT)
26 Main Landing Gear Wheel Assembly ET 4.33 4-35
Alternate Method
27 Main Landing Gear Brake MT 4.34 4-36
28 Main Landing Gear Brake Housing ET 4.35 4-37
29 Parking Brake Valve Components PT 4.36 4-38
30 Slave Mixer Valve Parts PT 4.37 4-39
Tail Landing Gear Shock Strut ET 4.38 4-40
Tail Landing Gear Yoke ET 4.39 4-41
32 Tail Landing Gear Fork ET 4.40 4-43
34 Tail Landing Gear Wheel Assembly Primary PT 4.41 4-44
Method (PT)
34 Tail Landing Gear Wheel Assembly ET 4.42 4-47
Alternate Method
Cargo Hook Trunnions, Trunnion Retaining MT 4.43 4-48
Bolts and Nuts and Load Beam
Cargo Hook Plate Edge and Bolt Hole Sur- ET 4.44 4-50
face
Cargo Hook Trunnion Retainers PT 4.45 4-51
35 Cargo Hook MT 4.35 4-35
*36 Ferrous Bolts and Pins Contained Within MT 4.36 2-3
the Airframe and Landing Gear System
*37 Nonferrous Bolts and Pins Contained With- PT 4.37 2-4
in the Airframe and Landing Gear System
NOTE: *Indicates Flight Safety Part.

4--2
 TM 1-1520-265-23

Figure 4-1. Airframe and Landing Gear System

4--3
TM 1-1520-265-23

4.2 AIRFRAME SKIN, PANELS, DOORS, COVERS, AND FAIRINGS - METAL (ET).
4.2.1 Description (Figure 4-1, Index No. 2). This inspection is applicable to all skins, panels,
doors, covers, and fairings constructed of nonferrous metallic material throughout all airframe
sections of this helicopter.
4.2.2 Defects. This inspection is used to verify suspected crack indications found visually on the
part being inspected. No cracks are allowed.
4.2.3 Primary Method. Eddy Current.
4.2.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 1-2 MHz (Titanium)
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop (Titanium)
d. Probe, straight, shielded surface, 100 KHz-500KHz (Aluminum)
e. Probe, right angle, shielded surface, 1-2 MHz (Titanium)
f. Adapter, Probe
g. Cable Assembly
h. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
i. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
j. Reference Block, three-notched magnesium (0.008, 0.020, 0.040 EDM notches)
k. Teflon Tape
l. Aircraft Marking Pencil
4..2.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the part using this procedure. If required, the airframe skin,
panels, doors, covers, and fairings - metal shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
4.2.3.3 Access Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
4.2.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.

4--4
 TM 1-1520-265-23

4.2.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ (Aluminum) 200 KHz LP Filter 100 H Pos 80%
(Magnesium) 200 KHz
(Titanium) 1000 KHz
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.2.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-2.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.2.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.2.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.2.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.2.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.2.5 System Securing. The inspected part requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

4--5
TM 1-1520-265-23

Figure 4-2. Airframe Skin, Panels, Doors, Covers, and Fairings - Metal

4.3 TAIL CONE FOLD FITTING (ET).

4.3.1 Description (Figure 4-1, Index No. XX.) The tail cone fold fittings are located on the right
side of the tail cone and tail pylon. When the stabilator is removed the the fold fittings allow the tail
pylon to be folded forward along the right side of the tail cone.
4.3.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail cone fitting, and after a hard landing. No cracks are allowed.
4.3.3 Primary Method. Eddy Current.
4.3.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.0080, 0.0020, 0.0040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.3.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required the tail
cone shall be removed in accordance with the applicable technical manuals listed in Table 1-1.

4--6
 TM 1-1520-265-23

4.3.3.3 Access. Not applicable.

4.3.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
4.3.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test blocks as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.3.3.6 Inspection Procedures. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-3.
a. Place probe on the good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block are cause for rejection.

NOTE
Either probe identified in paragraph 4.3.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 4.3.3.5b
(1), (2), and (3) shall be repeated each time a change is made.
4.3.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.3.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.3.5 System Securing. The tail cone, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

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TM 1-1520-265-23

Figure 4-3. Tail Cone Fold Fittings

4.4 HONEYCOMB AND COMPOSITE STRUCTURES (BT).

4.4.1 Description (Figure 4-1, Index No. 3). This inspection is applicable to parts or components
made of metallic/nonmetallic skins bonded to metallic/nonmetallic cores and lamination of facings
of metal or fiberglass panels. The structural assembly components identified for inspection are:
honeycomb panels, cabin floors, drive shaft covers, access doors and covers, cowlings, and work
platforms.
4.4.2 Defects. Perform the NDI method contained herein on the components listed above for the
purpose of verification of void damage identified by visual inspection. Void damage may occur
anywhere on either side of bonded panels as a result of mechanical damage (dents, punctures,
scratches, etc.) or fluid intrusion/corrosion.

NOTE
A void is defined as an unbonded area that is suppose to be bonded. Many
sub-definitions are given such as bond separation, delamination, lack of adhesive, gas
pocket, misfit, etc. This procedure makes no distinction among these instead grouping
under the general term “void.”
4.4.3 Primary Method. Bond Testing.
4..4.3.1NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Bond Test Unit
b. Probe Mechanical Impedance Analysis
c. Probe Holder
d. Cable Assembly
e. Test Block, metal honeycomb with skin thickness closest to that of the panel to be inspected
(refer to Appendix B)

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 TM 1-1520-265-23

f. Test Block, Composite Defect Standard #1

g. Test Block, Composite Defect Standard #3
h. Teflon Tape, consumable material
i. Aircraft Marking Pencil
4..4.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with applicable technical manuals listed in Table 1-1.
4.4.3.3 Access. Not applicable.
4.4.3.4 Preparation of Part. The components shall be thoroughly cleaned. Refer to Preparation of
Part or Area for NDI, paragraph 1.4.4.
4.4.3.5 NDI Equipment Settings. Refer to Bond Testing Equipment, paragraph 1.4.11.1.
a. Attach cable and probe to Bondmaster. Protect probe with Teflon tape and install in probe
holder.
b. Turn on Bondmaster, press SPCL, and make the following adjustments:
H Pos - 40%
V Pos - 80%
PHASE REF - O
DRIVE - MID
c. Press SET and select DISPLAY - PHASE.
d. Place probe on good area of test block and press GOOD PART. Do this several times while
moving the probe to different spots in the good area of the test block. Note the video signature
for each. Select and enter a representative good area by pressing GOOD PART one last time.
e. Place probe on void area of the test block and press BAD PART. Do this several times while
moving the probe slightly to different positions within the void area. Select and enter a position
that gives a strong difference between good and void areas. Use DIFF soft key to observe
difference between good and bad areas of test block.

NOTE
If during setup the flying spot deflects upward, or to the side, when the probe passes
over the bad part, instead of the desired down deflection toward the alarm box, press
SPCL and toggle to a different phase setting (90, 180, or 270), and repeat steps d. and
e. Continue to try phase setting until the flying spot moves in the desired down
direction.
f. Place probe on good area of test block and press RUN. Flying spot should be near the
top-center of the ACTIVE screen. If not, press NULL. Slide probe from good to void area and
note response from flying spot. This response should provide both amplitude (vertical) and
phase (horizontal) movement. The default gate/alarm setting may be incorrect for this setup.
Turn off or reset gate/alarm as desired.
g. The Bondmaster is programmed to automatically set test parameters to a start-up or initial
bond test. By following the steps outlined above, adjustments to the FREQ, GAIN, and
ALARM can help to refine the selectivity in locating defects among differing composite
materials.
4..4.3.6 Inspection Procedure. Refer to Bond Testing Method, paragraph 1.4.11 and inspection
areas shown in Figure 4-4. Place probe in location where test for void is desired and press NULL.
Move probe from good to suspect area and note response. A strong amplitude change and phase
shift similar to the test block is indicative of a void.

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TM 1-1520-265-23

Figure 4-4. Honeycomb and Composite Structures

NOTE
This setup is very sensitive to thin skin-to-core bonding. If the panel skin is 0.020 inch
thick or less, move the probe slowly over the skin and note the slight amplitude change
(bounce) as the probe senses alternately the honeycomb cell nodes and cell walls. Be
sure of panel configuration. Panel edges and attachment points may not be bonded
structure and do not normally contain honeycomb. These areas will respond similarly
to voids with the Bondmaster. Panels having ruggedized skins are more easily
scanned using wide Teflon tape on the probe holder.
4.4.3.7 Marking and Recording of Inspection Results. Mark and record as required by paragraph
1.3.

NOTE
Attention shall be directed to accurately marking the boundaries of all voids on both
sides of the panel. These markings will be needed to determine acceptance/rejection
criteria in accordance with the applicable technical manuals listed in Table 1-1.
4.4.4 Backup Method. None required.
4.4.5 System Securing. Reinstall acceptable panels that were removed for inspection in
accordance with the applicable technical manual listed in Table 1-1.

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 TM 1-1520-265-23

4.5 FLUID IN HONEYCOMB CORE PANELS AND STRUCTURES (RT).

4.5.1 Description (Figure 4-1, Index No. 4). This inspection is applicable to parts or components
made of metallic/nonmetallic skins bonded to metallic/nonmetallic cores and laminations of facings
of metal or fiberglass panels. The structural assembly components identified for inspection are:
honeycomb panels, cabin floors, drive shaft covers, access doors and covers, cowlings, and work
platforms.
4.5.2 Defects. Fluid in honeycomb core of the components listed above.
4.5.3 Primary Method. Radiography.

WARNING

Assure compliance with all applicable safety precautions set forth in

TM 1--1500--366--23 (Nondestructive Inspection General Procedures and Process
Controls (ATOS)) listed in Table 1.1. A hazard associated with exposure to ionizing
radiation is that serious damage can be inflicted without pain, burning, or other sense
of discomfort during the exposure period. Radiation protection shall be utilized in
accordance with AR 11--9 and AR 40--13.
4.5.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. X-ray Unit
b. Tripod, X-ray tubehead stand
c. Film Processor
d. Film, Ready Pack 14 inch x 17 inch
e. Marking Material
4.5.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with applicable technical manuals listed in Table 1-1.
4.5.3.3 Access. Not applicable.
4.5.3.4 Preparation of Part. The identified area of interest shall be thoroughly cleaned. Refer to
Preparation of Part or Area for NDI, paragraph 1.4.4.
4.5.3.5 NDI Equipment Settings.
a. Refer to Radiographic (X-ray) method, paragraph 1.4.18.
b. Typical equipment settings, inspection and exposure data are given in Figure 4-5.

4--11
TM 1-1520-265-23

Figure 4-5. Fluid in Honeycomb Core Panels and Structures (Sheet 1 of 2)

4--12
 TM 1-1520-265-23

Figure 4-5. Fluid in Honeycomb Core Panels and Structures (Sheet 2 of 2)

4--13
TM 1-1520-265-23

4.5.3.6 Inspection Procedure. Inspect designated areas, refer to Figure 4-5 for typical fluid
entrapment and source/film placement.
a. Position film and desired nameplate data for exposure number 1.
b. Position X-ray tubehead for exposure number 1.
c. Set X-ray unit to the values given in the Radiographic Inspection Data chart for exposure
number 1.
d. Make exposure number 1.
e. Remove exposed film.
f. Repeat inspection procedure (steps a. through e. above) for each exposure.
g. Process and interpret film for defects as noted in paragraph 4.5.2 and as shown in Figure 4-5.
4.5.4 Backup Method. None required.
4.5.5 System Securing. The inspected area shall be cleaned as necessary. Refer to Post
Cleaning and Restoration of Part or Area after NDI, paragraph 1.4.9.

4.6 FERROUS VIBRATION ABSORBER SPRINGS (MT).

4.6.1 Description (Figure 4-1, Index No. 5). Vibration absorbers are installed in the nose section,
cabin overhead, and under each of the drag beam support fairings. The other vibration absorber,
located at the rear of the pylon, is not included in this inspection. This inspection is applicable to the
steel spring elements which are included above.
4.6.2 Defects. This inspection is used to verify suspected crack indications found visually on the
ferrous vibration absorber springs. No cracks are allowed.
4.6.3 Primary Method. Magnetic Particle.
4.6.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
4.6.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required the vibration absorber shall be removed and disassembled in accordance with
the applicable technical manuals listed in Table 1-1.
4.6.3.3 Access. Location of these parts varies considerably. Refer to Figure 1-4 and Table 1-2 to
locate applicable access provisions.
4.6.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
4.6.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.

4--14
 TM 1-1520-265-23

4.6.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Typical springs and positions required for this inspection are
illustrated in Figure 4-6. Perform process control checks per TM 1-1500--366-23..
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.6.3.8.
f. Repeat steps a. through e. for positions 2 and 3.
g. Inspect opposite side, repeat steps a. through f.
4.6.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.6.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.6.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.6.5 System Securing. Clean the spring thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The
vibration absorber, if removed, requires assembly and installation in accordance with the applicable
technical manuals listed in Table 1-1.

Figure 4-6. Ferrous Vibration Absorber Springs

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TM 1-1520-265-23

4.7 NONFERROUS VIBRATION ABSORBER SPRINGS (PT).

4.7.1 Description (Figure 4-1, Index No. 5). Vibration absorbers are installed in the nose section,
cabin overhead, and under each of the drag beam support fairings. The other vibration absorber,
located at the rear of the pylon, is not included in this inspection. This inspection is applicable to all
spring elements which are included above.
4.7.2 Defects. This inspection is used to verify suspected crack indications found visually on the
vibration absorber springs. No crack are allowed.
4.7.3 Primary Method. Fluorescent Penetrant.
4.7.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.7.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable portions of this
procedure. If required, the vibration absorber shall be removed and disassembled in accordance
with the applicable technical manuals listed in Table 1-1.
4.7.3.4 Access. Location of these parts varies considerably. Refer to Figure 1-4 and Table 1-2 to
locate applicable access provisions.
4.7.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Method, paragraph 1.4.13 and either Table 1-4 or 1-5, depending on Unit capability. Inspect part,
Figure 4-7. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14.
4.7.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.7.4 Backup Method. None required.
4.7.5 System Securing. Clean the springs thoroughly to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area after NDI, paragraph 1.4.9. The vibration absorber, if
removed, requires assembly and installation in accordance with the applicable technical manuals
listed in Table 1-1.

4--16
 TM 1-1520-265-23

Figure 4-7. Nonferrous Vibration Absorber Springs

4.8 VIBRATION ABSORBER STRUCTURAL FITTINGS (ET).
4.8.1 Description (Figure 4-1, Index No. 6). The vibration absorber structural fittings attach the
vibration absorbers to the helicopter structure. Due to similarity, this procedure is applicable to cabin
and nose fittings.
4.8.2 Defects. This inspection is used to verify suspected crack indications found visually on the
vibration absorber fittings. No cracks are allowed.
4.8.3 Primary Method. Eddy Current.
4.8.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed fittings using this procedure. If required, the
fittings shall be removed in accordance with the applicable technical manuals listed in Table 1-1.

4--17
TM 1-1520-265-23

4.8.3.3 Access. Remove cabin ceiling soundproofing for access to cabin fitting. Access nose fitting
through fairing (Figure 1-4, Item 1B-GS-A-1).
4.8.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
4.8.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.8.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-8.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.8.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.8.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.8.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.8.4 Backup Method. None required.
4.8.5 System Securing. The vibration absorber fittings, if removed, require installation in
accordance with the applicable technical manuals listed in Table 1-1.

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 TM 1-1520-265-23

Figure 4-8. Vibration Absorber Structural Fittings

4.9 ROLL VIBRATION ABSORBER (PT).

4.9.1 Description (Figure 4-1, Index No. 7). A roll vibration absorber is installed under each drag
beam support fairing. The absorbers are tuned to reduce roll vibrations.
4.9.2 Defects. This inspection is used to verify suspected crack indications found visually on the
roll vibration absorber. No cracks are allowed.
4.9.3 Primary Method. Fluorescent Penetrant.
4.9.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.9.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the roll
vibration absorber shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.

4--19
TM 1-1520-265-23

4.9.3.3 Access. Remove the drag beam support fairing.

4.9.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.9.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Method, paragraph 1.4.13 and either Table 1-4 or 1-5, depending on Unit capability. Inspect part,
Figure 4-9. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14
4.9.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.9.4 Backup Method. None required.
4.9.5 System Securing. Clean the roll vibration absorber to remove inspection media. Refer to
Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The roll vibration
absorber, if removed, requires installation in accordance with the applicable technical manuals listed
in Table 1-1.

Figure 4-9. Roll Vibration Absorber

4.10 CABIN VIBRATION UPPER AND LOWER HOUSING (PT).

4.10.1 Description. The cabin box frame vibration absorber is under the soundproofing just
forward of the main transmission near station 308. The vibration absorber is tuned to reduce cabin
overhead vertical 4/rev vibrations.
4.10.2 Defects. Defects may occur anywhere on the surface. No cracks are allowed.
4.10.3 Primary Method. Fluorescent Penetrant.
4.10.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-SAE-AMS-2644-3 level 3 or higher penetrant materials shall be selected from the approved
list in Table 1-12.

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 TM 1-1520-265-23

4.10.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the cabin vibration housing if removed shall be in accordance with the applicable technical
manuals listed in Table 1-1.
4.10.3.3 Access. Not applicable.
4.10.3.4 Preparation of Part. Refer to Preparation of Area or Part for NDI, paragraph 1.4.4.
4.10.3.5 Inspection Procedure. Perform process control checks per Table 1-3 IAW
TM 1-1500-366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Method, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part,
Figure 4-10. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14
4.10.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.10.4 Backup Method. None required.
4.10.5 System Securing. Clean part to remove inspection media. Refer to Post Cleaning and
Restoration of Part or Area after NDI, paragraph 1.4.9.

BOX FRAME
ABSORBERS

Figure 4-10. Cabin Vibrators Upper and Lower Housings.

4.11 ALUMINUM STRUCTURAL BEAMS AND FRAMES (ET).

4.11.1 Description (Figure 4-1, Index No. 8). The primary airframe structure is aluminum alloy.
This procedure can be used on all-aluminum beams and frames as well as aluminum skin panels
and doors.

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TM 1-1520-265-23

4.11.2 Defects. This inspection is used to verify suspected crack indications found visually on the
aluminum structural beams and frames. No cracks are allowed.
4.11.3 Primary Method. Eddy Current.
4.11.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.11.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
4.11.3.3 Access. Generally easily accessed. If required, see Figure 1-4, and Table 1-2.
4.11.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.11.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.11.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-11.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.11.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.11.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

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 TM 1-1520-265-23

4.11.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.11.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.11.5 System Securing. Secure access and inspection provisions in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 4-11. Aluminum Structural Beams and Frames

4.12 PILOT/COPILOT SEAT MIDFRAME SUPPORT (MT).

4.12.1 Description (Figure 4-1, Index No. 9). The midframe support is an integral portion of the
vertical adjustment of the pilot/copilot seats.
4.12.2 Defects. This inspection is used to verify suspected crack indications found visually on the
midframe supports. No cracks are allowed.
4.12.3 Primary Method. Magnetic Particle.
412.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)

4--23
TM 1-1520-265-23

a. Magnetic Particle Inspection Probe/Yoke

b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
4.12.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the midframe support shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
4.12.3.3 Access. Not applicable.
4.12.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.12.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
4.12.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 4-12.
Perform process control checks per TM 1-1500-366-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.9.3.8.
f. Repeat steps a. through e. for positions 2 and 3.
g. Inspect opposite side and repeat steps a. through f.
4.12.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.12.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.12.4 Backup Method. None required.
4.12.5 System Securing. Clean the midframe support thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
the midframe support, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

4--24
 TM 1-1520-265-23

Figure 4-12. Pilot/Copilot Seat Midframe Support

4.13 TROOP/CARGO DOOR UPPER TRACT (ET).

4.13.1 Description (Figure 4-1, Index No. 10). These rear sliding doors on either side of the
helicopter cabin open to the troop/cargo compartment. This inspection applies to the upper track on
which the doors slide.
4.13.2 Defects. This inspection is used to verify suspected crack indications found visually on the
cargo door upper track. No cracks are allowed.
4.13.3 Primary Method. Eddy Current.
4.13.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2/ inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.13.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the cargo
door shall be removed in accordance with the applicable technical manuals listed in Table 1-1.

4--25
TM 1-1520-265-23

4.13.3.3 Access. Not applicable.

4.13.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.13.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.13.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-13.

Figure 4-13. Troop/Cargo Door Upper Track

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

4--26
 TM 1-1520-265-23

NOTE
Either probe identified in paragraph 4.13.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.13.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.13.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.13.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.13.5 System Security. The cargo door upper track, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

4.14 GUNNER’S WINDOW LOWER TRACK (ET).

4.14.1 Description (Figure 4-1, Index No. 11). The gunner window slider tracks are on both sides
of the helicopter.
4.14.2 Defects. This inspection is used to verify suspected crack indications found visually on the
lower track. No cracks are allowed.
4.14.3 Primary Method. Eddy Current.
4.14.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.14.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
gunner’s window shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.
4.14.3.3 Access. Not applicable.
4.14.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.14.3.5 NDI Equipment Settings.

4--27
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.14.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-14.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain the horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.14.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.14.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.14.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.14.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.14.5 System Securing. The gunner’s window, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

4--28
 TM 1-1520-265-23

Figure 4-14. Gunner’s Window Lower Track

4.15 GUNNER’S WINDOW UPPER TRACK (ET).

4.15.1 Description (Figure 4-1, Index No. 12). The gunner’s window slides forward and aft and is
held in place and guided by an upper track. Tracks are on both sides of the helicopter.
4.15.2 Defects. This inspection is used to verify suspected crack indications found visually on the
upper track. No cracks are allowed.
4.15.3 Primary Method. Eddy Current.

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TM 1-1520-265-23

4.15.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.15.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
gunner’s window and retainer assembly shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
4.15.3.3 Access. Not applicable.
4.15.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.15.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.15.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-15.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

NOTE
Either probe identified in paragraph 4.15.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.15.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

4--30
 TM 1-1520-265-23

Figure 4-15. Gunner’s Window Upper Track

4.15.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.15.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.15.5 System Securing. The gunner’s window and retainer assembly, if removed, require
installation in accordance with the applicable technical manuals listed in Table 1-1.

4--31
TM 1-1520-265-23

4.16 TROOP/CARGO DOOR LOWER TRACK (ET).

4.16.1 Description (Figure 4-1, Index No. 13). These rear sliding doors on either side of the
helicopter cabin open to the troop/cargo compartment. This inspection applies to the lower track on
which the doors slide.
4.16.2 Defects. This inspection is used to verify suspected crack indications found visually on the
troop/cargo door lower track. No cracks are allowed.
4.16.3 Primary Method. Eddy Current.
4.16.3.1 NDI Equipment and Materials. (Refer to Tables 1--11 and 1--12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.16.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the cargo
door shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
4.16.3.3 Access. Not applicable.
4.16.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.16.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.16.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-16.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.

4--32
 TM 1-1520-265-23

b. Inspect the part.

c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.16.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.16.3.5.b(1), (2), and (3) shall be repeated each time a change is made.
4.16.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.16.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.16.5 System Securing. The cargo door, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 4-16. Troop/Cargo Door Lower Track

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TM 1-1520-265-23

4.17 OIL COOLER COMPARTMENT ACCESS DOOR (PT).

4.17.1 Description (Figure 4-1, Index No. 14). The oil cooler compartment access door (provision
3T-25) is provided to facilitate inspection and maintenance of the oil cooler.
4.17.2 Defects. This inspection is used to verify suspected crack indications found visually on the
door assembly. This inspection includes the door hinges, catches, and fittings. No cracks are
allowed.
4.17.3 Primary Method. Fluorescent Penetrant.
4.17.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12..
4.17.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the door
shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
4.17.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.

Figure 4-17. Oil Cooler Compartment Access Door

4.17.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.

4--34
 TM 1-1520-265-23

4.17.3.5 Inspection Procedure. Perform process control checks per Table 1-3 IAW
TM 1-1500-366-23. Perform fluorescent Penetrant Method, paragraph 1.4.13 and either Table 1-4
or 1-5 depending on the Unit capability. Inspect part Figure 4-17. Refer to Interpretation of Liquid
Penetrant Inspection, paragraph 1.4.14 and Indication Evaluation, paragraph 1.4.14.
4.17.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.17.4 Backup Method. None required.
4.17.5 System Securing. Clean the door assembly to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The door assembly, if
removed, requires installation in accordance with the applicable technical manuals listed in Table
1-1.

4.18 TAIL PYLON ATTACH FITTING (ET).

4.15.1 Description (Figure 4-1, Index No. 15) The tail pylon is attached to the tail cone by a hinge
assembly mounted on the cone. This inspection is applicable to the pylon and cone attaching
structures, and in particular for cracks in the surface around the lower barrel nut holes in the tail rotor
intermediate gearbox fitting.
4.18.2 Defects. This inspection is used to verify suspected crack indications found visually on the
pylon/cone attaching structures. No cracks are allowed.
4.18.3 Primary Method. Eddy Current.
4.18.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.18.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
4.18.3.3 Access. Open the tail pylon.
4.18.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.18.3.5 NDI Equipment Settings.

4--35
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.18.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-18.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 4-18. Tail Pylon Attach Fitting

4--36
 TM 1-1520-265-23

NOTE
Either probe identified in paragraph 4.18.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.18.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.18.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.18.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.18.5 System Securing. The tail pylon requires securing in accordance with the applicable
technical manuals listed in Table 1-1.

4.19 TAIL ROTOR PYLON SKIN, STATION 200 (ET).

4.19.1 Description (Figure 4-1, Index No. 16). This procedure is applicable to tail rotor pylon skin
at station 200. If skin cracks are noted, inspect inside surfaces of fitting where attached to front spar
cap angles.
4.19.2 Defects. This inspection is used to verify suspected crack indications found visually on the
tail rotor pylon. No cracks are allowed.
4.19.3 Primary Method. Eddy Current.
4.19.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.19.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
4.19.3.3 Access. Not applicable.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
4.19.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.

4--37
TM 1-1520-265-23

4.19.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

Figure 4-19. Tail Rotor Pylon Skin, Station 200

4.19.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-19.

4--38
 TM 1-1520-265-23

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.19.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.19.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.19.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.19.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.19.5 System Securing. The tail pylon, if opened, requires securing in accordance with the
applicable technical manuals listed in Table 1-1.

4.20 TAIL ROTOR PYLON ATTACHING HARDWARE (PT).

4.20.1 Description (Figure 4-1, Index No. 17). This procedure is primarily for use on tapered pins,
attachment bolts, barrel-nuts, washers, retainers, pylon hinge bolts, washers, and nuts used on the
tail rotor pylon.
4.20.2 Defects. This inspection is used to detect cracks found anywhere on the parts described
above. No cracks are allowed.
4.20.3 Primary Method. Fluorescent Penetrant.
4.20.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12..
4.20.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the tail pylon removed in accordance with the applicable technical manuals listed in Table 1-1.
4.20.3.3 Access. Not applicable.
4.20.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.20.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Method, paragraph 1.4.13 and Table 1-4. Inspect area of concern. See Figure 4-20.
4.20.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.20.4 Backup Method. None required.

4--39
TM 1-1520-265-23

Figure 4-20. Tail Rotor Pylon Attaching Hardware

4.20.5 System Securing. Clean the inspected part to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The tail pylon requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

4.21 TAIL PYLON LOWER STEP (ET).

4.21.1 Description (Figure 4-1, Index No. 18). The step mounted in the tail pylon and is the first
step in accessing the upper pylon/tail rotor area.
4.21.2 Defects. This inspection is used to verify suspected crack indications found visually on the
lower step and tube. No cracks are allowed.
4.21.3 Primary Method. Eddy Current.

4--40
 TM 1-1520-265-23

4.21.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.21.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the lower
step shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
4.21.3.3 Access. Not applicable.
4.21.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.21.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.
4.21.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-21.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.21.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.21.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

4--41
TM 1-1520-265-23

4.21.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.21.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.215 System Securing. The tail pylon lower step, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

Figure 4-21. Tail Pylon Lower Step

4--42
 TM 1-1520-265-23

4.22 STABILATOR ATTACH FITTING (ET).

4.22.1 Description (Figure 4-1, Index No. 19). The stabilator attach fitting is integrated into the aft
end of the tail pylon on both the right and left side. The horizontal stabilator is attached to these
fittings.
4.22.2 Defects. This inspection is used to detect cracks in the lug area of the left and right fittings.
No cracks are allowed.
4.22.3 Primary Method. Eddy Current.
4.22.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.22.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
horizontal stabilator shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.
4.22.3.3 Access. Access is obtained by removing provisions (Figure 1-4, Items 5B-45 and 6B-46).
4.22.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.22.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.22.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-22.

4--43
TM 1-1520-265-23

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.22.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.22.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

Figure 4-22. Stabilator Attach Fitting

4.22.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.22.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.22.5 System Securing. The horizontal stabilator, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

4.23 STABILATOR ACTUATOR ATTACH FITTINGS (MT).

4.23.1 Description (Figure 4-1, Index No. 20). The stabilator actuator upper end is attached to an
aluminum fitting in the pylon and the lower end to an aluminum fitting on the top of the stabilator.
4.23.2 Defects. This inspection is used to verify suspected crack indications found visually on the
stabilator actuator attach fittings. No cracks are allowed.

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 TM 1-1520-265-23

4.23.3 Primary Method. Magnetic Particle.

4.23.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
4.23.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required the stabilator actuator shall be disconnected from either/both fittings or the
fittings shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
4.23.3.3 Access. Not applicable.
4.23.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.23.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.8.
4.23.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 4-20.
Perform process control checks per TM 1-1500--366-23..
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more that five
seconds. Verify that a magnetic field exists using a gauss meter or field indictor.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.20.3.8.
f. Repeat steps a. through e. for position 2.
g. Inspect opposite side, repeat steps a. through f.
4.23.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.23.3.6 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.23.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.23.5 System Securing. Clean the stabilator actuator attach fittings thoroughly to remove all
residual magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,

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TM 1-1520-265-23

paragraph 1.4.9. The stabilator actuator attach fittings, if removed, require installation in accordance
with the applicable technical manuals listed in Table 1-1.

Figure 4-23. Stabilator Actuator Attach Fittings

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 TM 1-1520-265-23

4.24 STABILATOR POSITION SENSOR CLEVIS (PT).

4.24.1 Description (Figure 4-1).
4.24.2 Defects. This inspection is used to verify suspect indications found visually on the stabilator
position sensor clevis. No cracks are allowed.
4.24.3 Primary Method. Fluorescent Penetrant.
4.24.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-SAE-AMS-2633-3 level 3 or higher penetrant materials shall be selected from the approved
list in Table 1-12.
4.24.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
and partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
sensor bracket shall be removed in accordance with the applicable technical manuals listed in Table
1-1..
4.24.3.3 Access. Not applicable.
4.24.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.24.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-3 or 1-4 depending on Unit capability. Inspect part
Figure 4-24.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14
4.24.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.24.4 Backup Method. None required.
4.24.5 System Securing. Clean the inspected part to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The sensor bracket, if removed
requires installation in accordance with the applicable technical manuals listed in Table 1-1.

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TM 1-1520-265-23

CLEVIS

Figure 4-24. Stabilator Position Sensor Clevis

4.25 STABILATOR ACTUATOR HOUSING (PT).

4.25.1 Description (Figure 4-1, Index No. 21). The hydraulically-operated actuator is mounted to
the pylon and the horizontal stabilator. It reacts to commands from the cockpit and moves the
horizontal stabilator in an up or down direction.
4.25.2 Defects. This inspection is used to verify crack indications found visually on the actuator
housing. No cracks are allowed.
4.25.3 Primary Method. Fluorescent Penetrant.
4.25.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.25.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the actuator removed in accordance with the applicable technical manuals listed in Table 1-1.
4.25.3.3 Access. Not applicable.
4.25.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.25.3.6 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-25.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14
4.25.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.25.4 Backup Method. None required.
4.25.5 System Securing. Clean the actuator to remove inspection media. Refer to Post Cleaning
and Restoration of Part or Area After NDI, paragraph 1.4.9. The actuator requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

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 TM 1-1520-265-23

Figure 4-25. Stabilator Actuator Housing

4.26 DRAG BEAM SUPPORT FITTING (ET).

4.26.1 Description (Figure 4-1, Index No. 22). The drag beam support fitting connects the main
landing gear drag beam to each side of the fuselage midsection.
4.26.2 Defects. This inspection is used to verify suspected crack indications found visually on the
support fitting, especially at the lug areas and bearing bores. No cracks are allowed.
4.26.3 Primary Method. Eddy Current.
4.26.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit

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TM 1-1520-265-23

b. Probe, straight, shielded surface, 100 KHz-500 KHz

c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.26.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the drag
beam and the bushings shall be removed in accordance with the applicable technical manuals listed
in Table 1-1.
4.26.3.3 Access. Not applicable.
4.26.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.26.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.
4.26.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-26.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.26.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.26.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.26.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

4.26.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.26.5 System Securing. The drag beam, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 4-26. Drag Beam Support Fitting

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TM 1-1520-265-23

4.27 DRAG BEAM JACKPAD AND TIEDOWN RING HOLES (MT)

4.27.1 Description. The jackpad attaches to the main landing gear drag beam.
4.27.2 Defects. Defects may occur anywhere on the surface. No cracks allowed.
4.27.3 Primary Method. Magnetic Particle.
4.27.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke.
b. Gauss Meter or Field Indicator
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
g. Black Light Meter
h. Ambient Light Meter

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
4.27.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
4.27.3.3 Access. Not applicable.
4.27.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.27.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
4.27.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is illustrated in Figure 4-27.
Perform process control checks per Table 1-9 and in accordance with TM 1-1500-366-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown on each fitting
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
applicator prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 1.4.17.
f. Repeat step b. though e. for position 2, 3 and 4.
g. Inspect opposite side. Repeat steps b. through f.
4.27.3.7 Marking and Recording Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.27.3.8 Demagnetization. With the switch remaining in the AC position., place the probe/yoke legs
in the same position used for magnetizing,. Press the test switch and withdraw the probe/yoke from
the part or the part from the probe/yoke for a distance of two feet before releasing the switch.

4--52
 TM 1-1520-265-23

4.27.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.27.5 System Securing. Clean the jack pad and tiedown ring thoroughly to remove all residual
magnetic media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The jackpad and tiedown rings require installation in accordance with the applicable technical
manuals listed in Table 1-1.

JACKPAD

TIEDOWN RING

Figure 4-27. Jackpad and Tiedown Ring

4.28 MAIN LANDING GEAR DRAG BEAM (MT).

4.28.1 Description (Figure 4-1, Index No. 23). the drag beam is a cylinder attached to the airframe
at one end and to the shock strut at the other, which transmits landing loads to the airframe and shock
strut and to which the wheel is attached.
4.28.2 Defects. This inspection is used to verify crack indications found visually on the drag beam.
Particular attention shall be given to the jackpad hole and adjacent flat surfaces. No cracks are
allowed.
4.28.3 Primary Method. Magnetic Particle.
4.28.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer

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TM 1-1520-265-23

c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
4.28.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the drag beam shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
4.28.3.3 Access. Not applicable.

CAUTION
When performing magnetic particle inspection on landing gear parts, the paint shall
be removed. Some landing gear components are vulnerable to stress--corrosion
cracking and are cadmium plated for their protection. The cadmium layer shall remain
on the part. Damage to the cadmium plating shall be avoided.
4.28.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.28.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.8.
4.28.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 4-23.
Perform process control checks per TM 1-1500-366-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.23.3.8.
f. Repeat steps a. through e. for positions 2, 3, 4, and 5.
g. Inspect opposite side repeat steps a. through f.
4.28.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.28.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.28.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

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 TM 1-1520-265-23

4.28.5 System Securing. Clean the drag beam thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The drag
beam, if removed, requires installation in accordance with the applicable technical manuals listed
in Table 1-1.

Figure 4-28. Main Landing Gear Drag Beam

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TM 1-1520-265-23

4.29 MAIN LANDING GEAR FITTING SPHERICAL BEARING BORE (PT).

4.29.1 Description (Figure 4-1)
4.29.2 Defects. This inspection is to check for cracks in the bearing bore when replacing the
spherical bearing. No crack allowed.
4.29.3 Primary Method. Fluorescent Penetrant.
4.29.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11.
QPL-SAE-AMS-2644-3 level 3 or higher penetrant materials shall be selected from the approved
list in Table 1-12.
4.29.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
4.29.3.3 Access. Not Applicable.
4.29.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.29.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500-366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-29Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14.
4.29.3.6 Marking and Recording Inspection Results. Mark and record inspection results as
required in paragraph 1.3.
4.29.4 Backup Method. None required.
4.29.5 System Securing. Clean the bore thoroughly to remove all residual inspection media. Refer
to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9

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 TM 1-1520-265-23

Figure 4-29. Main Landing Gear Fuselage Fitting Spherical Bearing Bore

4.30 MAIN LANDING GEAR SHOCK STRUT UPPER CYLINDER (ET).

4.30.1 Description (Figure 4-1, Index No. 24). The shock strut supports the helicopter during
ground operations and absorbs impact when landing.
4.30.2 Defects. This inspection is used to verify suspected crack indications found visually on the
main landing gear shock strut upper cylinder. No cracks are allowed.
4.30.3 Primary Method. Eddy Current.
4.30.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.30.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the main

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TM 1-1520-265-23

landing gear shock strut upper cylinder shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
4.30.3.3 Access Access to the MLG shock strut upper cylinder is through the shock strut hinged
panel (Figure 1-4, Items 3T-3 and 4T-4).
4.30.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.30.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.30.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-30.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

NOTE
Either probe identified in paragraph 4.30.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.30.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

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 TM 1-1520-265-23

Figure 4-30. Main Landing Gear Shock Strut Upper Cylinder

4.30.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.30.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.30.5 System Securing. The main landing gear shock strut upper cylinder, if removed, requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

4.31 MAIN LANDING GEAR SHOCK STRUT LOWER STAGE PISTON (MT)
4.31.1 Description (Figure 4-1, Index No. 25). The shock strut consists of two pistons. The lower
one absorbs the normal landing loads.

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TM 1-1520-265-23

4.31.2 Defects. Defects may occur anywhere on the surface of the lower stage piston. Particular
attention shall be directed to the bearing bore lug. No cracks are allowed.
4.31.3 Primary Method. Magnetic Particle.
4.31.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
4.31.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the main landing gear shock strut shall be removed and disassembled in
accordance with the applicable technical manuals listed in Table 1-1.
4.31.3.3 Access. Not applicable.

CAUTION
When performing magnetic particle inspection on landing gear parts, the paint shall
be removed. Some landing gear components are vulnerable to stress--corrosion
cracking and are cadmium plated for protection. The cadmium layer shall remain on
the part. Damage to the cadmium plating shall be avoided.
4.31.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.31.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
4.31.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 4-25.
Perform process control checks per TM 1-1500-366-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds, Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.25.3.8.
f. Repeat steps a. through e. for position 2.
g. Inspect opposite side, repeat steps a. through f.

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 TM 1-1520-265-23

Figure 4-31. Main Landing Gear Shock Strut Lower Stage Piston

4.31.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.31.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.31.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.31.5 System Securing. Clean the shock strut thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The shock
strut, if removed, requires assembly and installation in accordance with the applicable technical
manuals listed in Table 1-1.

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TM 1-1520-265-23

4.32 MAIN LANDING GEAR WHEEL ASSEMBLY PRIMARY METHOD (PT).

4.32.1 Description (Figure 4-1, Index No. 26). The main landing gear wheel assembly provides
a mount for the tires and permits the helicopter to be rolled during ground handling.
4.32.2 Defects. Defects may occur anywhere on the surface of the main landing gear wheel
assembly. Pay particular attention to bead seat, bolt boss mating surfaces, and valve hole areas.
No cracks are allowed.
4.32.3 Primary Method. Fluorescent Penetrant.
4.32.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-SAE-AMS-2644-3 level 3 or higher penetrant materials shall be selected from the approved
list in Table 1-12.
4.32.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the wheel removed and disassembled in accordance with the applicable technical manuals
listed in Table 1-1.
4.32.3.3 Access. Not applicable.
4.32.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.32.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-32.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14

Figure 4-32. Main Landing Gear Wheel Assembly

4.32.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

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 TM 1-1520-265-23

4.32.4 Backup Method. Eddy Current, see paragraph 4.33 for the detail procedure..
4.32.5 System Securing. Clean the main landing gear wheel to remove all inspection media. Refer
to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The wheel requires
assembly and installation in accordance with the applicable technical manuals listed in Table 1-1.

4.33 MAIN LANDING GEAR WHEEL ASSEMBLY ALTERNATE METHOD (ET).

4.33.1 Description. (Figure 4-1, Index No. 26.) The main landing gear wheel assembly provides
a mount for the tires and permits the helicopter to be rolled during ground handling.
4.33.2 Defects. Defects may occur anywhere on the surface of the main landing gear wheel
assembly. Pay particular attention to the bead seat, bolt boss mating surfaces, and valve hole areas.
No cracks allowed.
4.33.3 Primary Method. Fluorescent Penetrant, refer to paragraph 4.32. This Eddy Current
Method is to be used as an alternate to FPI in the event that the paint removal process can not be
performed or to evaluate specific area of concern.
4.33.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1--12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz - 500KHz
c. Probe, right angle, shielded surface, 100 KHz - 500 KHz, 90_ 1/2 inch drop
d. Probe, sliding, differential, WP-UH60, 50-500 KHz
e. Reference Standard, WS-UH60
f. Cable Assembly
g. Reference Block, three-notched aluminum (0.008”, 0.020”, 0.040” EDM notches).
h. Teflon Tape
i. Aircraft Marking Pencil
4.33.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the wheel removed and disassembled in accordance with the applicable technical manuals
listed in Table 1-1.
4.33.3.3 Access. Not Applicable.
4.33.3.4 Preparation of Part. The part shall be thoroughly cleaned, Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.33.3.5 Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
STANDARD PENCIL PROBE
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H pos 80%
ANG 56_ HP Filter Off V pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

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TM 1-1520-265-23

SLIDING PROBE (Bead Seat)

MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H pos 50%
ANG 72_ HP Filter Off V pos 50%
H Gain 73.4 db
V Gain 84.2 db
Probe Drive Hi

4.33.3.5.1 Calibration (Standard Pencil Probe). Refer to Eddy Current Method, paragraph 1.4.19.
Set up on reference block as follows: Place probe in a good area on the reference block.
(1) Null probe on notched reference block.
(2) Raise and lower probe on/off surface and adjust phase as required to obtain horizontal
lift-off.
(3) Move probe over all three notches in test block. Adjust Gain setting to obtain a five block
vertical signal when probe is passed over the 0.040-inch reference block. (See the
standard instrument display shown in Figure 1-7.)
4.33.3.5.2 Calibration (Sliding Probe). Refer to Eddy Current Method, paragraph 1.4.19. Set up
on notched reference standard as follows: Place probe in a good area on the reference block.
(1) Null probe on notched reference standard (See Figure 4--33).

Figure 4-33. Notched Reference Standard.

(2) Rock the probe slightly and adjust phase angle as required to obtain horizontal lift-off.
(3) Slide the probe over all three EDM notches. Adjust Gain to obtain a 2 1/2 to 3 division
vertical signal in either direction ( See Figure 4-34).

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 TM 1-1520-265-23

Figure 4-34. Screen Display

4.33.3.6 Inspection Procedure (Standard Pencil Probe). Refer to Eddy Current Method, paragraph
1.4.19 and Figure 4.35.
a. Place the probe on a good area in the inspection location and null the instrument. Adjust
phase angle as required to re--establish horizontal lift-off.
b. Inspect the part in accordance with the scan paths indicated in Figure 4-35. Scan paths
should overlap slightly to assure 100 percent inspection. A technique to ensure consistent
scan paths are achieved, is to mark out an area with an approved marking pencil, spray a
light coating of Non--aqueous Wet Developer (NAWD) on the inspection surface and monitor
the trace marks of the probe face.
c. Any relevant signal similar to the notches in the calibration block should be further evaluated.
by Fluorescent Penetrant Inspection (FPI) to characterize the indication as linear (crack-like)
or round (porosity). In the event FPI does not exhibit an indication, contact the NDT CoE for
further evaluation instructions.

NOTE
Either probe identified in paragraph 4.33.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 4.33.3.5
(1), (2) and (3) shall be repeated each time a change is made.
4.33.3.7 Inspection Procedure (Sliding Probe)
a. Place the probe on a good area of the bead seat and null the instrument. Adjust phase angle
as required to re--establish horizontal lift--off.
b. Slide the probe around the bead seat. This area is considered a critical zone, make two
revolutions to assure indications were not missed.
c. Any signal with a response to the notches in the calibration block should be further evaluated
by Fluorescent Penetrant Inspection (FPI) to characterize the indication as linear (crack--like)
or round (porosity). In the event FPI does not exhibit an indication, contact the NDT CoE for
further evaluation instructions.

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Figure 4-35. Main Landing Gear Wheel

4.33.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required in paragraph 1.3.
4.33.4 Backup Method. Fluorescent Penetrant, see paragraph 4.32 for detailed procedure.
4.33.5 System Securing The wheel requires assembly and installation in accordance with the
applicable technical manuals listed in Table 1-1.

4.34 MAIN LANDING GEAR BRAKE (MT).

4.34.1 Description (Figure 4-1, Index No. 27) The main landing gear brakes are self-adjusting,
double disc, three-cavity brake assembly, which includes a visual brake lining wear indicator.
4.34.2 Defects. Cracks can occur anywhere on the surface of the stationary disc, rotating discs,
backing plate, and torque tube. Pay particular attention to rotating and stationary disc slots. No
cracks are allowed.
4.34.3 Primary Method. Magnetic Particle.
4.34.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.

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 TM 1-1520-265-23

4.34.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the brake removed and disassembled in accordance with the applicable technical manuals
listed in Table 1-1.
4.34.3.3 Access. Not applicable.

CAUTION
When performing magnetic particle inspection on landing gear parts, the paint shall
be removed. Some landing gear components are vulnerable to stress--corrosion
cracking and are cadmium plated for protection. The cadmium layer shall remain on
the part. Damage to the cadmium plating shall be avoided.
4.34.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.34.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
4.34.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is illustrated in Figure 4-36.
Perform process control checks per TM 1-1500-366-23..
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.34.3.9
f. Repeat steps a. through e. for the other positions.
g. Inspect opposite side, repeat steps a. through f.
4.34.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.34.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
4.34.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.34.5 System Securing. Clean the main landing gear brake thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,
paragraph 1.4.9. The main landing gear brake requires assembly and installation in accordance with
the applicable technical manuals listed in Table 1-1.

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TM 1-1520-265-23

Figure 4-36. Main Landing Gear Brake

4.35 MAIN LANDING GEAR BRAKE HOUSING (ET).

4.35.1 Description (Figure 4-1, Index No. 28). The main landing gear brakes are self-adjusting,
double disc, three-cavity brake assembly, which includes a visual-brake lining wear indicator. The
housing contains the pistons.
4.35.2 Defects. Defects may occur anywhere on the surface of the main landing gear brake
housing. No cracks are allowed.
4.35.3 Primary Method. Eddy Current.
4.35.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)

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 TM 1-1520-265-23

a. Eddy Current Inspection Unit

b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.35.3.2Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the brake assembly removed and disassembled in accordance with the applicable technical
manuals listed in Table 1-1.
4.35.3.3 Access. Not applicable.
4.35.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.35.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.35.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-28.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.
NOTE
Either probe identified in paragraph 4.35.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.35.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.35.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.35.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

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TM 1-1520-265-23

4.35.5 System Securing. The housing requires assembly and installation in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 4-37. Main Landing Gear Brake Housing

4.36 PARKING BRAKE VALVE COMPONENTS (PT).

4.36.1 Description (Figure 4-1, Index No. 29). The parking brake valve traps fluid pressure to the
brakes to prevent helicopter movement. This inspection pertains to the components contained
within the parking valve body.
4.36.2 Defects. This inspection is used to verify crack indications found visually on the parking
brake valve components. No cracks are allowed.
4.36.3 Primary Method. Fluorescent Penetrant.
4.36.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.36.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the parking valve removed and disassembled in accordance with the applicable technical
manuals listed in Table 1-1.
4.36.3.3 Access. Not applicable.
4.36.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.36.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-38.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.15.

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 TM 1-1520-265-23

Figure 4-38. Parking Brake Valve Components

4.36.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.36.4 Backup Method. None required.
4.36.5 System Securing. Clean the parking brake valve components to remove inspection media.
Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The parking valve
requires assembly and installation in accordance with the applicable technical manuals listed in
Table 1-1.

4.37 SLAVE MIXER VALVE PARTS (PT).

4.37.1 Description (Figure 4-1, Index No. 30). The slave mixer valve isolates the pilot and copilot
brake line circuits from each other. This inspection pertains to the components contained within the
slave mixer valve body.
4.37.2 Defects. This inspection is used to verify crack indications found visually on the slave mixer
valve components. No cracks are allowed.
4.37.3 Primary Method. Fluorescent Penetrant.
4.37.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.37.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the slave mixer removed and disassembled in accordance with the applicable technical
manuals listed in Table 1-1.

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TM 1-1520-265-23

4.37.3.3 Access. Not applicable.

4.37.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.37.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-39. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.15.

Figure 4-39. Slave Mixer Valve Parts

4.37.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.37.4 Backup Method. None required.
4.37.5 System Securing. Clean the components to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The slave mixer valve requires
assembly and installation in accordance with the applicable technical manuals listed in Table 1-1.

4.38 TAIL LANDING GEAR SHOCK STRUT (ET).

4.38.1 Description. The shock strut supports the helicopter’s rear structure during ground
operations and cushions impact loads when landing. The shock strut is a two-stage air-oil type strut
with two floating pistons separating air from hydraulic fluid, with a servicing valve for each stage.
4.38.2 Defects. Defects may occur anywhere on the shock strut.
4.38.3 Primary Method. Eddy Current.
4.38.3.1 NDI Equipment and Materials.
a. Eddy Current Inspection Unit
b. Probe, 90 degree 1/2 inch drop, shielded surface, 100 KHz - 500 KHz
c. Probe, straight, shielded surface, 100 KHz -500 KHz

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 TM 1-1520-265-23

d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.38.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure.
4.38.3.3 Access Not Applicable.
4.38.3.4 Coating Lift-Off Compensation. Perform Coating Lift-Off Compensation as required by
paragraph 1.4.19.
Non--conductive coatings less than .003 inch do not require lift-off compensation. If the coating is
greater than .003 inch, utilize the appropriate non-conductive shim during the instrument set-up
process.

WARNING

Coating thickness greater than .010 inch (10 mils) shall be removed prior to
conducting Eddy Current inspections. Coating thickness on the inspection surface
greater than .010 inch thick will significantly reduce inspection sensitivity and can
result in the failure to detect cracks.
4.38.3.5 NDI Equipment and Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ F1 200KHz LP Filter 100 H pos 80%
HdB 57.0 HP Filter 0 V Pos 20%
VdB 69.0
Rot 56_
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null the probe on the reference standard with the appropriate thickness of non-conductive
shim between the probe and the reference standard.
(2) Adjust phase rotation as required to obtain horizontal lift-off.
(3) Slide the probe over the three notches in the test block. Obtain a five (5) screen division
vertical response from the 0.040 inch EDM notch (70% FSH).
(4) Verify standardization every 10 minutes.
4.38.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-40.

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Carefully inspect around the bushing bore and adjacent area.

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TM 1-1520-265-23

c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified n paragraph 4.38.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 4.38.3.6b
(1), (2), and (3) shall be repeated each time a change is made.

Figure 4-40. Landing Gear Shock Strut

4.38.3.7 Indication Evaluation. Any vertical signal that is distinguishable (separated) from the
background noise and not caused by geometry or conductivity shall warrant further investigation and
rescanning in the area of interest.
4.38.3.8 Post Inspection Standardization
a. Place the probe on the reference standard and press null.
b. Slide the probe over the 0.040 inch EDM notch and verify that the vertical response is
between 60-80% FSH.
c. If the vertical response from the 0.040 inch notch is less than 60% FSH all inspections
performed since the last standardization shall be repeated. If the response is greater than
80% FSH all suspect indication identified shall be re-evaluated.
4.38.3.9 Marking and Recording Mark and record inspection results as required by paragraph 1.3.
4.38.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.38.5 System Securing. The shock strut, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

4.39 TAIL LANDING GEAR YOKE (ET).

4.39.1 Description (Figure 4-1, Index No. 31). The yoke assembly, attached to the tail cone
structure and the shock strut, transmits landing loads to the helicopter airframe and shock strut.
4.39.2 Defects. This inspection is used to verify suspected cracks on the tail landing gear yoke.
Pay particular attention to the transition blend radius between the barrel diameter and the forked end
of the yoke. No cracks are allowed.

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 TM 1-1520-265-23

4.39.3 Primary Method. Eddy Current.

4.39.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 50 KHz-500 KHz
c. Probe, right angle, shielded surface, 50 KHz-500 KHz
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.39.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable aircraft technical manual.. A partial inspection for cause (visual
indications, sites of mechanical damage, corrosion, etc.) may be performed on all exposed surfaces
of the installed part using this procedure. If required, the yoke shall be removed in accordance with
the applicable aircraft technical manuals listed in Table 1-1.
4.39.3.3 Access. Access to the upper yoke structure will require the removal of the tail landing gear
fairings.
4.39.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4..39.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 50 H Pos 80%
ANG 60_ HP Filter Off V Pos 20%
H Gain 50db
V Gain 62db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
deflection when the probe is passed over 0.040-inch notch. Reference the standard
instrument display shown in Figure 1-7.
4.39.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-41.
a. Place the probe on a good area in the inspection location and null. Adjust the phase angle
as required to obtain horizontal lift-off.
b. Inspect the transition blend radius and any additional suspect areas.
c. Scan the Eddy Current probe across the radius 100%. Pay particular attention to the sides
of the tail wheel yoke. Reference Figure 4-41.

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TM 1-1520-265-23

Figure 4-41. Tail Landing Gear Yoke and Radius Scan

d. Any localized vertical deflection in the transition blend radius should be considered a suspect
crack.
e. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
S Either probe identified in paragraph 4.39.3.1 may be used depending primarily on
the ease of accessibility and user friendliness. If the probes are changed, steps
4.39.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
S The Eddy Current display from the cracks in the radius have a somewhat unique
signature due to the crack orientation, probe angle and part contour. Refer to Figure
4-42 for an example of this signature.

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Figure 4-42. Typical Display for Radius Cracks

4.39.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.39.4 Backup Method. Fluorescent Penetrant, refer to paragraph 1.4.7.
4.39.5 System Securing. The yoke, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

4.40 TAIL LANDING GEAR FORK (ET).

4.40.1 Description (Figure 4-1, Index No. 32). The fork assembly, secured to the yoke assembly
is the attachment point for the tail wheel and allows the wheel to swivel through 360_ for ground
control.
4.40.2 Defects. Defects may occur anywhere on the surface of the tail landing gear fork. No cracks
are allowed.
4.40.3 Primary Method. Eddy Current.
4.40.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
4.40.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the tail

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landing gear fork shall be removed in accordance with the applicable technical manuals listed in
Table 1-1.

4.40.3.3 Access. Not applicable.

4.40.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.

4.4.0.4.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.

MAIN MENU FILTER MENU DISPLAY MENU

FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
4.40.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-43.

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.40.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.40.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
4.40.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

4.40.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

4.40.5 System Securing. The fork, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

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Figure 4-43. Tail Landing Gear Fork

4.41 TAIL LANDING GEAR WHEEL ASSEMBLY PRIMARY METHOD (PT).

4.41.1 Description (Figure 4-1, Index No. 34). The tail landing gear wheel assembly provides a
mount for the tires and permits the helicopter to be rolled during ground handling.
4.41.2 Defects. Defects may occur anywhere on the surface of the tail landing gear wheel
assembly. Pay particular attention to bead seat, bolt boss mating surfaces, and valve hole areas.
No cracks are allowed.
4.41.3 Primary Method. Fluorescent Penetrant.
4.41.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. AMS 2644
level 3 penetrant materials shall be selected from the approved list in Table 1-12.
4.41.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the wheel removed and disassembled in accordance with the applicable technical manuals
listed in Table 1-1.
4.41.3.3 Access. Not applicable.
4.41.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.41.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-44.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.15.

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4.41.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.41.4 Backup Method. Eddy Current, see paragraph 4.42 for detailed procedure..
4.41.5 System Securing. Clean the tail landing gear wheel assembly to remove all inspection
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9 The tail
landing gear wheel requires assembly and installation in accordance with the applicable technical
manuals listed in Table 1-1.

Figure 4-44. Tail Landing Gear Wheel Assembly

4.42 TAIL LANDING GEAR WHEEL ASSEMBLY ALTERNATE METHOD (ET).

4.42.1 Description. (Figure 4-1, Index No. 34.) The tail landing gear wheel assembly provides a
mount for the tires and permits the helicopter to be rolled during ground handling.
4.42.2 Defects. Defects may occur anywhere on the surface of the tail landing gear wheel
assembly. Pay particular attention to the bead seat, bolt boss mating surfaces, and valve hole areas.
No cracks allowed.
4.42.3 Primary Method. Fluorescent Penetrant, refer to paragraph 4.41. This Eddy Current
Method is to be used as an alternate to FPI in the event that the paint removal process can not be
performed or to evaluate specific area of concern.

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 TM 1-1520-265-23

4.42.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1--12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz - 500KHz
c. Probe, right angle, shielded surface, 100 KHz - 500 KHz, 90_ 1/2 inch drop
d. Probe, sliding, differential, WP-UH60, 50-500 KHz
e. Reference Standard, WS-UH60T
f. Cable Assembly
g. Reference Block, three-notched aluminum (0.008”, 0.020”, 0.040” EDM notches).
h. Teflon Tape
i. Aircraft Marking Pencil
4.42.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the wheel removed and disassembled in accordance with the applicable technical manuals
listed in Table 1-1.
4.42.3.3 Access. Not Applicable.
4.42.3.4 Preparation of Part. The part shall be thoroughly cleaned, Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.42.3.5 Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
STANDARD PENCIL PROBE
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H pos 80%
ANG 56_ HP Filter Off V pos 20%
H Gain 57db
V Gain 69 db
Probe Drive Mid

SLIDING PROBE (Bead Seat)

MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H pos 50%
ANG 234_ HP Filter Off V pos 50%
H Gain 67 db
V Gain 84 db
Probe Drive Hi

4.42.3.5.1 Calibration (Standard Pencil Probe). Refer to Eddy Current Method, paragraph 1.4.19.
Set up on reference block as follows: Place probe in a good area on the reference block.
(1) Null probe on notched reference block.
(2) Raise and lower probe on/off surface and adjust phase as required to obtain horizontal
lift-off.

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(3) Move probe over all three notches in test block. Adjust Gain setting to obtain a five block
vertical signal when probe is passed over the 0.040-inch reference block. (See the
standard instrument display shown in Figure 1-7.)
4.42.3.5.2 Calibration (Sliding Probe). Refer to Eddy Current Method, paragraph 1.4.19. Set up
on notched reference standard as follows: Place probe in a good area on the reference block.
(1) Null probe on notched reference standard (See Figure 4--45).

Figure 4-45. Notched Reference Standard

(2) Rock the probe slightly and adjust phase angle as required to obtain horizontal lift-off.
(3) Slide the probe over all three EDM notches. Adjust Gain to obtain a 1 1/2 to 2 division
vertical signal in either direction on the smallest EDM notch. ( See Figure 4-46).

Figure 4-46. Screen Display

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4.42.3.6 Inspection Procedure (Standard Pencil Probe). Refer to Eddy Current Method, paragraph
1.4.19 and Figure 4-47.
a. Place the probe on a good area in the inspection location and null the instrument. Adjust
phase angle as required to re--establish horizontal lift-off.
b. Inspect the part in accordance with the scan paths indicated in Figure 4-47. Scan paths
should overlap slightly to assure 100 percent inspection. A technique to ensure consistent
scan paths are achieved, is to mark out an area with an approved marking pencil, spray a
light coating of Non--aqueous Wet Developer (NAWD) on the inspection surface and monitor
the trace marks of the probe face.
c. Any relevant signal similar to the notches in the calibration block are cause for rejection.
Questionable signals should be further evaluated by Fluorescent Penetrant Inspection (FPI)
to characterize the indication as linear (crack-like) or round (porosity). In the event FPI does
not exhibit an indication, contact the NDT CoE for further evaluation instructions.
NOTE
Either probe identified in paragraph 4.42.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 4.42.3.5
(1), (2) and (3) shall be repeated each time a change is made.

Figure 4-47. Tail Landing Wheel Assembly

4.42.3.7 Inspection Procedure (Sliding Probe). Refer to Eddy Current Method, paragraph 1.4.19
and Figure 4-47.
a. Place the probe on a good area of the bead seat and null the instrument. Adjust phase angle
as required to re--establish horizontal lift--off.
b. Slide the probe around the bead seat. This area is considered a critical zone, make two
revolutions to assure indications were not missed.
c. Any signal with a response to the notches in the calibration block should be further evaluated
by Fluorescent Penetrant Inspection (FPI) to characterize the indication as linear (crack--like)
or round (porosity). In the event FPI does not exhibit an indication, contact the NDT CoE for
further evaluation instructions.

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TM 1-1520-265-23

4.42.3.8 Marking and Recording of Inspection Results Mark and record inspection results as
required by paragraph 1.3.
4.42.4 Backup Method Fluorescent Penetrant,see paragraph 4--41 for detailed procedure.
4.42.5 System Securing. The wheel requires assembly and installation in accordance with the
applicable technical manuals listed in Table 1-1..

4.43 CARGO HOOK TRUNNIONS, TRUNNION RETAINING BOLTS AND NUTS AND LOAD
BEAM (MT).
4.43.1 Description (Figure 4-1, Index No. XXX). The 9,000 pound capacity cargo hook is in the
cargo hook well beneath the cabin floor.
4.43.2 Defects. This inspection is to check for cracks in the trunnions, trunnion retaining bolts and
nuts, and load beam. No cracks are allowed.
4.43.3 Primary Method. Magnetic Particle.
4.43.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Gauss Meter or Field Indicator
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
g. Black Light Meter
h. Ambient Light Meter
4.43.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the cargo hook removed in accordance with the applicable technical manuals listed in Table 1-1.
4.43.3.3 Access. Not applicable.
4.43.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
4.43.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
4.43.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 4-48 and
Figure 4-49. Perform process control per TM 1-1500-366-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown in Figure 4-48 and Figure 4-49.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a magnetometer.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 4.35.3.8.
f. Repeat steps b. through e. for position 2, 3, and 4.
g. Inspect opposite side. Repeat steps b. through f.

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 TM 1-1520-265-23

Figure 4-48. Cargo Hook Positions 1-3

Figure 4-49. Cargo Hook Position 4

4.43.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.43.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.

4--85
TM 1-1520-265-23

4.43.4 Backup Method. None required.

4.43.5 System Securing. Clean the cargo hook thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The cargo
hook requires installation in accordance with the applicable technical manuals listed in Table 1-1.
4.44 CARGO HOOK PLATE EDGE AND BOLT HOLE SURFACE (ET).
4.44.1 Description. (Figure 4-1, Index No.xx.) The 9,000 pound capacity cargo hook is in the cargo
hook well beneath the cabin floor.
4.44.2 Defects. This inspection is to check for cracks in the plate edge and bolt hole surface areas.
No cracks allowed.
4.44.3 Primary Method. Eddy Current.
4.44.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz - 500KHz
c. Probe, right angle, shielded surface, 100 KHz - 500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008”, 0.020”, 0.040” EDM notches).
f. Teflon Tape
g. Aircraft Marking Pencil
4.44.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the cargo hook removed in accordance with the applicable technical manuals listed in Table 1-1.
4.44.3.3 Access. Not Applicable.
4.44.3.4 Preparation of Part. The part shall be thoroughly cleaned, Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
4.44.3.5 Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 71_ HP Filter Off V Pos 20%
H Gain 49db
V Gain 61db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Place a wide layer of Teflon tape on the face of the crack standard. Place a second layer
of Teflon tape, half the width of the first layer, on the first layer
(4) Null the instrument with the probe placed on this bare surface. Place the probe on both
layers of tape and note the horizontal position of each. Place the probe on the surface of
the cargo hook plate and note the horizontal position. Use the layer(s) of tape nearest the
coating thickness as a null reference.

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 TM 1-1520-265-23

(5) Move probe over all three notches in test block using the determined tape layer.. Adjust gain
to obtain a five block vertical signal when probe is passed over 0.040-inch notch in test
block. (See the standard instrument display shown in Figure 1-7.)
4.44.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 4-50.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 4.44.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
4.44.3.5b.(1), (2), and (3) shall be repeated each time a change is made.
TYPICAL CRACK ORIENTATION

POS 2 POS 2

POS 4

POS 1

POS 4

POS 1 POS 3

HOOK
TYPICAL CRACK ORIENTATION POS 3

POSITION THE PROBE LEG ON THE OPPOSITE

SIDE OF THE SPRING CENTER RELIEF CUT

Figure 4-50. Cargo Hook

4.44.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
4.44.5 System Securing. The cargo hook requires installation in accordance with the applicable
technical manuals listed in Table 1-1.

4.45 CARGO HOOK - TRUNNION RETAINERS (PT).

4.45.1 Description (Figure 4-1). The cargo hook trunnion retainers secure the cargo hook trunnion
to the cargo hook.
4.45.2 Defects. This inspection is used to check for cracks in the trunnion retainers. No cracks are
allowed.

4--87
TM 1-1520-265-23

4.45.3 Primary Method. Fluorescent Penetrant.

4.45.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
4.45.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the cargo hook removed in accordance with the applicable technical manuals listed in Table 1-1.
4.45.3.3 Access. Not applicable.
4.45.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
4.45.3.5 Inspection Procedure. Perform process control checks per Table 1-3 in accordance with
TM 1-1500--366-23. Perform fluorescent penetrant inspection. Refer to Fluorescent Penetrant
Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability. Inspect part
Figure 4-51.Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and Indication
Evaluation, paragraph 1.4.14.
4.45.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
4.45.4 Backup Method. None required.
4.45.5 System Securing. Clean the components to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The cargo hook requires
assembly and installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 4-51. Cargo Hook Trunnion Retainers

4--88
 TM 1-1520-265-23

4.46 FERROUS BOLTS AND PINS CONTAINED WITHIN THE AIRFRAME AND LANDING
GEAR SYSTEM (MT).

CAUTION
When performing magnetic particle inspection on landing gear parts, the paint shall
be removed. Some landing gear components are vulnerable to stress-corrosion
cracking and are cadmium plated for their protection, The cadmium layer shall remain
on the part. Damage to the cadmium plating shall be avoided.
4.46.1 Description (Figure 4-1, Index No. 36). Refer to paragraph 2.3 for inspection procedure.

4.47 NONFERROUS BOLTS AND PINS CONTAINED WITHIN THE AIRFRAME AND LANDING
GEAR SYSTEM (PT).
4.47.1 Description (Figure 4-1, Index No. 37). Refer to paragraph 2.4 for inspection procedure.

4--89/(4--90 blank)
 TM 1-1520-265-23

SECTION V
POWER PLANT SYSTEM

5. GENERAL.

5.1 CONTENTS. The power plant system inspection items covered in this section are those items
of the H-60 helicopter series models T700-GE-700/T700-GE-701C turboshaft engines and
components listed in Table 5-1, Power Plant System Inspection Index. Corresponding inspection
figures and applicable text paragraphs are listed opposite each item. The index number for each item
may be used to locate it in Figure 5-1.

Table 5-1. Power Plant System Inspection Index

Index Nomenclature Inspection Paragraph Figure

Num- Method Number Number
ber
2 Deswirl Duct Vanes and Loop Clamp PT 5.2 5-2
3 Engine Tubing, Couplings, Air Ducts, Fittings, PT 5.3 5-3
Supports, Brackets and Clips
4 Air Inlet Assembly and Bleed-Air Exhaust Slots ET 5.4 5-4
*5 Aft Engine Mount Struts MT 5.5 5-5
*6 Aft Engine Mount Fittings MT 5.6 5-6
*7 Aft Engine Mount Links PT 5.7 5-7
*8 Aft Engine Mount Support ET 5.8 5-8
9 Crotch Assembly and Segment Ring PT 5.9 5-9
10 Forward Support Tube PT 5.10 5-10
11 Exhaust Ejector and Attaching Angles PT 5.11 5-11
12 Exhaust Fairings PT 5.12 5-12
13 HIRSS and Nacelle Fairing Support Mounts PT 5.13 5-13
14 Suppressor Core and Baffle PT 5.14 5-14
15 HIRSS Exhaust Extender PT 5.15 5-15
16 Rotary Input Assembly PT 5.16 5-16
17 Engine Load Demand Control Cable Support PT 5.17 5-17
18 Engine Air Inlet “V” Band Clamp PT 5.18 5-18
19 Starter Flange ET 5.19 5-19
20 Engine Shroud PT 5.20 5-20
21 Engine Load Demand Spindle Bellcrank ET 5.21 5-21
Support
22 Engine Components PT 5.22 5-22

NOTE: *Indicates Flight Safety Part

5--1
TM 1-1520-265-23

Figure 5-1. Power Plant System

5--2
 TM 1-1520-265-23

5.2 DESWIRL DUCT VANES AND LOOP CLAMP (PT).

5.2.1 Description (Figure 5-1, Index No. 2). The deswirl duct, containing the deswirl duct vane
is attached to the engine power turbine flange by a loop clamp.
5.2.2 Defects. This inspection is used to verify crack indications found visually on the deswirl duct
vanes and the loop clamp. No cracks are allowed.
5.2.3 Primary Method. Fluorescent Penetrant.
5.2.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.2.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance and
the deswirl duct and loop clamp removed in accordance with the applicable technical manuals listed
in Table 1-1.
5.2.3.3 Access. Not applicable.
5.2.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.2.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.2.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-2. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 5-2. Deswirl Duct Vanes and Loop Clamp

5--3
TM 1-1520-265-23

5.2.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.2.4 Backup Method. None required.
5.2.5 System Securing. Clean the duct vanes and loop clamp to remove inspection media. Refer
to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The duct vanes and loop
clamp require installation in accordance with the applicable technical manuals listed in Table 1-1.

5.3 ENGINE TUBING, COUPLINGS, AIR DUCTS, FITTINGS, SUPPORTS, BRACKETS, AND
CLIPS (PT).
5.3.1 Description (Figure 5-1, Index No. 3). This task is for all metallic, unpainted engine tubing,
couplings, air ducts, related fittings, supports, brackets, and bracket clips.
5.3.2 Defects. This inspection is used to verify crack indications found visually. No cracks are
allowed.
5.3.3 Primary Method. Fluorescent Penetrant.
5.3.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.3.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the part(s)
shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.3.3.3 Access. Location of these parts varies considerably. Refer to Figure 1-4 and Table 1-2 to
locate applicable access provisions.
5.3.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.3.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.3.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-3. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.3.3.7 Marking and Recording of Inspection Results. Mark and record the inspection results as
required by paragraph 1.3.
5.3.4 Backup Method. None required.
5.3.5 System Securing. Clean the part(s) to remove inspection media. Refer to Post Cleaning and
Restoration of Part or Area After NDI, paragraph 1.4.9. The part(s), if removed, requires installation
in accordance with the applicable technical manuals listed in Table 1-1.

5--4
 TM 1-1520-265-23

Figure 5-3. Engine Tubing, Couplings, Air Ducts, Fittings, Supports, Brackets, and Clips

5.4 AIR INLET ASSEMBLY AND BLEED-AIR EXHAUST SLOTS (ET).

5.4.1 Description (Figure 5-1, Index No. 4). The aluminum air inlet assembly is at the front of the
engine through which air is directed into the engine. The bleed air exhaust slots are in the forward
inboard cone area.
5.4.2 Defects. This inspection is used to verify suspected crack indications found visually on the
air inlet and around the bleed air exhaust slots. No cracks are allowed.
5.4.3 Primary Method. Eddy Current.
5.4.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz

5--5
TM 1-1520-265-23

c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
5.4.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance in
accordance with the applicable technical manuals listed in Table 1-1.
5.4.3.3 Access. Not applicable.
5.4.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.4.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

NOTE
Either probe identified in paragraph 5.4.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 5.4.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
5.4.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 5-4.

5--6
 TM 1-1520-265-23

Figure 5-4. Air Inlet Assembly and Bleed-Air Exhaust Slots

a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.
5.4.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.4.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
5.4.5 System Securing. Not applicable.

5.5 AFT ENGINE MOUNT STRUTS (MT).

5.5.1 Description (Figure 5-1, Index No. 5). The aft engine mount struts attach to fittings on the
air frame and links attach to the engine.
5.5.2 Defects. Cracks may occur anywhere on the surface of the aft engine mount struts. No
cracks are allowed.
5.5.3 Primary Method. Magnetic Particle.
5.5.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light

5--7
TM 1-1520-265-23

d. Fluorescent Magnetic Particles

e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3..2 and Figure 1-6.
5.5.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the struts shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
5.5.3.3 Access. Access to the aft engine mount strut is through hinged engine cowls (Figure 1-4,
Items 3T-5 and 4T-8).

WARNING

Use only appropriate platforms, work stands, or other approved locally procured stands
and restraint equipment when working above 10 feet on helicopters in a nontactical
environment. Otherwise, personnel injury could result from accidental falls.
5.5.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.5.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
5.5.3.6 Perform process control checks per TM 1-1500-366-23.
5.5.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 5-5.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 5.5.3.8.
f. Repeat steps a. through e. for positions 2 and 3.
g. Repeat steps a. through f. for each strut.
h. Inspect opposite side, repeat steps a. through g.
5.5.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.5.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
5.5.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.

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 TM 1-1520-265-23

5.5.5 System Securing. Clean the struts thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The
engine mount struts, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

POS POS TYPICAL CRACK ORIENTATION

1 1

POS POS POS

POS POS
4 4 1
3 3
POS POS
POS 3 3
2 POS
POS
POS 2
2
1 POS
POS
1
1
POS
POS POS
3 POS POS
POS 4 4
4 4
2
POS POS
POS POS 2 2
5 5

POS
3

Figure 5-5. Aft Engine Mount Struts

5.6 AFT ENGINE MOUNT FITTINGS (MT).

5.6.1 Description (Figure 5-1, Index No. 6). The aft engine mount struts are attached to the aft
mount fittings (two inboard and one outboard) which are secured to the airframes.
5.6.2 Defects. Cracks may occur anywhere on the aft engine mount fittings. No cracks are
allowed.
5.6.3 Primary Method. Magnetic Particle.
5.6.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.

5--9
TM 1-1520-265-23

5.6.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance and
the engine removed in accordance with the applicable technical manuals listed in Table 1-1.
5.6.3.3 Access. Not applicable.
5.6.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.6.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.8.
5.6.3.6 Perform process control checks per TM 1-1500-366-23.
5.6.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 5-6.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown for each fitting.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gauss meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 5.6.3.8.
f. Repeat steps a. through e. for position 2 on each fitting.
g. Inspect opposite side, repeat steps a. through f.
5.6.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.6.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
5.6.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
5.6.5 System Securing. Clean the fittings thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The engine
requires installation in accordance with the applicable technical manuals listed in Table 1-1.

5--10
 TM 1-1520-265-23

Figure 5-6. Aft Engine Mount Fittings

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TM 1-1520-265-23

5.7 AFT ENGINE MOUNT LINKS (PT).

5.7.1 Description (Figure 5-1, Index No. 7). The aft engine mount links attach the mount struts
and the aft mount support to the engine. Each engine has six links.
5.7.2 Defects. Cracks may occur anywhere on the mount links. No cracks are allowed.
5.7.3 Primary Method. Fluorescent Penetrant.
5.7.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.7.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance and
the engine removed in accordance with the applicable technical manuals listed in Table 1-1.
5.7.3.3 Access. Not applicable.
5.7.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.7.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.7.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-7. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15
5.7.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.7.4 Backup Method. None required.
5.7.5 System Securing. Clean the links to remove inspection media. Refer to Post Cleaning and
Restoration of Part or Area After NDI, paragraph 1.4.16. The engine requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-7. Aft Engine Mount Links

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 TM 1-1520-265-23

5.8 AFT ENGINE MOUNT SUPPORT (ET).

5.8.1 Description (Figure 5-1, Index No. 8). The aft engine mount is secured to the engine deck
and two links attached to the engine.
5.8.2 Defects. Cracks may occur anywhere on the mount support. No cracks are allowed.
5.8.3 Primary Method. Eddy Current.
5.8.3.1 NDI Equipment and Materials (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop
d. Probe, Adapter
e. Cable Assembly
f. Reference Block, three-notched titanium (0.008, 0.020, 0.040 EDM notches)
g. Teflon Tape
h. Aircraft Marking Pencil
5.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance and
the engine removed in accordance with the applicable technical manuals listed in Table 1-1.
5.8.3.3 Access. Not applicable.
5.8.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.8.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 1000 KHz LP Filter 100 H Pos 80%
ANG 57_ HP Filter Off V Pos 20%
H Gain 56db
V Gain 74db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

NOTE
Either probe identified in paragraph 5.8.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 5.8.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.

5--13
TM 1-1520-265-23

5.8.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 5-8.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.
5.8.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.8.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
5.8.5 System Securing. The engine requires installation in accordance with the applicable
technical manuals listed in Table 1-1.

Figure 5-8. Aft Engine Mount Support

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 TM 1-1520-265-23

5.9 CROTCH ASSEMBLY AND SEGMENT RING (PT).

5.9.1 Description (Figure 5-1, Index No. 9). The crotch assembly is mounted around the forward
support tube and is attached to the engine swirl frame with a sealed firewall plate.
5.9.2 Defects. This Inspection is to be used to confirm suspect crack indications detected visually
through the casting. No cracks are allowed.
5.9.3 Primary Method. Fluorescent Penetrant.
5.9.3.1 NDI Equipment and Materials Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.9.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance and
the crotch assembly removed in accordance with the applicable technical manuals listed in Table 1-1.
5.9.3.3 Access. Not applicable.
5.9.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.9.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.9.3.6Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-9. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.9.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.9.3.8 Backup Method. None required.
5.9.3.9 System Securing. Clean the part area to remove the inspection media. Refer to the post
cleaning and restoration of part or area after NDI paragraph 1.4.16. Protective coatings shall be
applied as required. Parts or components if removed or disassembled, required installation or
re-assembly in accordance with the applicable technical manuals listed in Table 1--1.

Figure 5-9. Crotch Assembly and Segment Ring

5--15
TM 1-1520-265-23

5.10 FORWARD SUPPORT TUBE (PT).

5.10.1 Description (Figure 5-1, Index No. 10). The forward support tube attaches to the engine swirl
frame. The output shaft is installed through restrainer rings fastened inside the tube.
5.10.2 Defects. This inspection is used to confirm suspect crack indications detected visually
through the casting. No cracks are allowed.
5.10.3 Primary Method. Fluorescent Penetrant.
5.10.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.10.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the engine removed in accordance with the applicable technical manuals listed in Table 1-1.
5.10.3.3 Access. Not applicable.
5.10.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.10.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.10.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-10. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.10.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.10.4 Backup Method. None required.
5.10.5 System Securing. Clean the part area to remove the inspection media. Refer to the post
cleaning and restoration of part or area after NDI paragraph 1.4.9. Protective coatings shall be
applied as required. Parts or components if removed or disassembled, required installation or
re-assembly in accordance with the applicable technical manuals listed in Table 1--1.

Figure 5-10. Forward Support Tube

5--16
 TM 1-1520-265-23

5.11 EXHAUST EJECTOR AND ATTACHING ANGLES (PT).

5.11.1 Description (Figure 5-1, Index No. 11). The stainless steel exhaust ejector is mounted by
attaching angles to the exhaust module. It directs the hot exhaust away from the helicopter.
5.11.2 Defects. Defects can occur anywhere on the surface of the ejector. Inspect the attaching
angles also. No cracks are allowed.
5.11.3 Primary Method. Fluorescent Penetrant.
5.11.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.11.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the exhaust ejector removed in accordance with the applicable technical manuals listed in Table
1-1.
5.11.3.3 Access. Not applicable.
5.11.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.11.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.11.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-11. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.11.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.11.4 Backup Method. None required.
5.11.5 System Securing. Clean the exhaust ejector to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The exhaust ejector requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-11. Exhaust Ejector and Attaching Angles

5--17
TM 1-1520-265-23

5.12 EXHAUST FAIRINGS (PT).

5.12.1 Description (Figure 5-1, Index No. 12). The upper and lower fairings are the portions of the
exhaust module that contain the exhaust ejector.
5.12.2 Defects. Defects can occur anywhere on the surface of the exhaust fairings. No cracks are
allowed. Repeat this inspection after repairs.
5.12.3 Primary Method. Fluorescent Penetrant.
5.12.3.1 NDI Equipment and Materials. (Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.12.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the exhaust module removed in accordance with the applicable technical manuals listed in Table
1-1.
5.12.3.3 Access. Not applicable.
5.12.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.12.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.12.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4, or 1-5 depending on Unit capability.
Inspect part Figure 5-12. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.12.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.12.4 Backup Method. None required.
5.12.5 System Securing. Clean the exhaust fairing to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The exhaust module requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-12. Exhaust Fairings

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 TM 1-1520-265-23

5.13 HIRSS AND NACELLE FAIRING SUPPORT MOUNTS (PT).

5.13.1 Description (Figure 5-1, Index No. 13). The hover infrared suppression system is contained
within the HIRSS module. Parts of the support mounts are: fail-safe plate, rear suppressor support
fitting and link, lower nacelle support fitting and link, and upper nacelle support fitting and link.
5.13.2 Defects. Defects can occur anywhere on the surface of the described parts. No cracks are
allowed.
5.13.3 Primary Method. Fluorescent Penetrant.
5.13.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-SAE-AMS-2644-3 level 3 or higher penetrant materials shall be selected from the approved list
in Table 1-12.
5.13.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
5.13.3.3 Access. Not applicable.
5.13.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
Individual parts shall be separated from adjoining parts..
5.13.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.13.3.6 Inspection Procedure Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-12. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 5-13. HIRSS and Nacelle Fairing Support Mounts

5--19
TM 1-1520-265-23

5.13.3.6 Marking and Recording of inspection Results. Mark and record inspection results as
required by paragraph 1.3
5.13.4 Backup Method. None Required.
5.13.5 System Securing. Clean inspected parts to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area after NDI, paragraph 1.4.9.

5.14 SUPPRESSOR CORE AND BAFFLE (PT).

5.14.1 Description (Figure 5-1, Index No. 14). The HIRSS kit contains a three stage core and inner
baffle which reduces exhaust gas radiation and prevents line-of-sight viewing of hot engine surfaces.
Areas included in this procedure are within two inches of mounts or stage-to-stage attachments,
within two inches of bulkhead where it attaches to support flange on the core, finger seal inlet holes,
stage 1 inner duct assembly, stage 1 outer duct assembly, stage 2 duct, second/third stage wiggle
strips, stage 3 duct, baffle guide slot, end plates, splitter plates, support brackets, and baffles.
5.14.2 Defects. Defects can occur anywhere in/on the suppressor core and baffle. Particular
attention shall be given to the areas described above. No cracks are allowed.
5.14.3 Primary Method. Fluorescent Penetrant.
5.14.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.14.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
in accordance with the applicable technical manuals listed in Table 1-1.
5.14.3.3 Access. Not applicable.
5.14.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
Individual parts shall be separated from adjoining parts..
5.14.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.14.3.6 Inspection Procedure Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-14. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.14.3.7 Marking and Recording of inspection Results. Mark and record inspection results as
required by paragraph 1.3
5.14.4 Backup Method. None Required.
5.14.5 System Securing. Clean inspected parts to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area after NDI, paragraph 1.4.9. The suppressor requires
assembly and installation in accordance with the applicable technical manuals listed in Table 1-1.

5--20
 TM 1-1520-265-23

Figure 5-14. Suppressor Core and Baffle

5--21
TM 1-1520-265-23

5.15 HIRSS EXHAUST EXTENDER (PT).

5.15.1 Description (Figure 5-1, Index No. 15). The exhaust extender is attached to the aft end of
the HIRSS and directs the exhaust away from the helicopter. This procedure is applicable to the
attach angles, support beams, and struts.
5.15.2 Defects. Defects can occur anywhere on the described items. No cracks are allowed.
5.15.3 Primary Method. Fluorescent Penetrant.
5.15.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.15.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the exhaust extender removed in accordance with the applicable technical manuals listed in
Table 1-1.
5.15.3.3 Access. Not applicable.
5.15.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.15.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.15.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-15. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15
5.15.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.15.4 Backup Method. None required.
5.15.5 System Securing. Clean the inspected parts to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16. The exhaust extender requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

5--22
 TM 1-1520-265-23

Figure 5-15. HIRSS Exhaust Extender

5.16 ROTARY INPUT ASSEMBLY (PT).

5.16.1 Description (Figure 5-1, Index No. 16). The rotary input assembly is at the end of the
push-pull cable and controls engine power available to the engine hydromechanical unit. This
procedure covers the inspection of the load demand and power available rotary barrels, drive
assemblies, adapters, and housings.
5.16.2 Defects. Defects can occur anywhere on the items described. No cracks are allowed.
5.16.3 Primary Method. Fluorescent Penetrant.
5.16.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.

5--23
TM 1-1520-265-23

5.16.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the load demand unit removed and disassembled in accordance with the applicable technical
manuals listed in Table 1-1.
5.16.3.3 Access. Not applicable.
5.16.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.16.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.16.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-16. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 5-16. Rotary Input Assembly

5.16.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.16.4 Backup Method. None required.
5.16.5 System Securing. Clean the inspected parts to remove inspection media. Refer to Post
Cleaning and Restoration or Part or Area After NDI, paragraph 1.4.9 The rotary input assembly
requires assembly and installation in accordance with the applicable technical manuals listed in
Table 1-1.

5--24
 TM 1-1520-265-23

5.17 ENGINE LOAD DEMAND CONTROL CABLE SUPPORT (PT).

5.17.1 Description (Figure 5-1, Index No. 17). The cable support is mounted on top of the
transmission and secures the engine load-demand push-pull rods.
5.17.2 Defects. Defects can occur anywhere on the surface of the support. No cracks are allowed.
5.17.3 Primary Method. Fluorescent Penetrant.
5.17.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
5.17.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the cable
support shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.17.3.3 Access. Access is obtained through the sliding cover (Figure 1-4, items 3T-4T-2).
5.17.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.17.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.17.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-17. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.17.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.17.4 Backup Method. None required.
5.17.5 System Securing. Clean the cable support to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The cable support, if removed,
requires installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-17. Engine Load Demand Control Cable Support

5--25
TM 1-1520-265-23

5.18 ENGINE AIR INLET “V” BAND CLAMP (PT).

5.18.1 Description (Figure 5-1, Index No. 18). The air inlet flange is integral to air inlet. The engine
(compressor case) flange is integral to the compressor case. The “V” band clamp holds the air inlet
to the compressor case.
5.18.2 Defects. This inspection is used to verify crack indications found visually in the “V” band
clamp. No cracks are allowed.
5.18.3 Primary Method. Fluorescent Penetrant.
5.18.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.18.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
flanges shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.18.3.3 Access. Access is through engine cowl (Figure 1-4, items 3T-7 or 4T-8).
5.18.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.18.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.18.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-18. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 5-18. Engine Air Inlet “V” Band Clamp

5.18.3.6 Marking and Recording of Inspection Results. Mark and record the inspection results as
required by paragraph 1.3.
5.18.4 Backup Method. None required.

5--26
 TM 1-1520-265-23

5.18.5 System Securing. Clean the “V” band clamp to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The “V” band, if removed,
requires installation in accordance with the applicable technical manuals listed in Table 1-1.

5.19 STARTER FLANGE (ET).

5.19.1 Description (Figure 5-1, Index No. 19). The air starter is located on the right upper side of
the engine and is mounted to the engine accessory drive case. It uses compressed air from the APU
to turn the engine.
5.19.2 Defects. This inspection is used to verify suspected crack indications found visually on the
starter flange. No cracks are allowed.
5.19.3 Primary Method. Eddy Current.
5.19.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
5.19.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the starter
shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.19.3.3 Access. Access is through engine access cowl (Figure 1-4, items 3T-7 or 4T-8).
5.19.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.19.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)

5--27
TM 1-1520-265-23

NOTE
Either probe identified in paragraph 5.19.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
5.19.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

5.19.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 5-19.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.
5.19.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.19.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
5.19.5 System Securing. The starter flange, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

Figure 5-19. Starter Flange

5--28
 TM 1-1520-265-23

5.20 ENGINE SHROUD (PT).

5.20.1 Description (Figure 5-1, Index No. 20). The engine shroud is mounted on top of the engine.
5.20.2 Defects. This inspection is used to verify crack indications found visually. No cracks are
allowed.
5.20.3 Primary Method. Fluorescent Penetrant.
5.20.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.20.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
shroud shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.20.3.3 Access. Access is through engine cowl (Figure 1-4, items 3T-7 or 4T-8).
5.20.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.20.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.20.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-20. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.20.3.7 Marking and Recording of Inspection Results. Mark and record the inspection results as
required by paragraph 1.3.
5.20.4 Backup Method. None required.
5.20.5 System Securing. Clean the shroud to remove inspection media. Refer to Post Cleaning
and Restoration of Part or Area After NDI, paragraph 1.4.9. The shroud, if removed, requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-20. Engine Shroud

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TM 1-1520-265-23

5.21 ENGINE LOAD DEMAND SPINDLE BELLCRANK SUPPORT (ET).

5.21.1 Description (Figure 5-1, Index No. 21). This support is located on the transmission bay dock,
just forward of the transmission. It is the point at which three systems join. It ties the engines (torque
sensing) to the flight controls (collective) and is mounted in the main part of the airframe.
5.21.2 Defects. This inspection is used to verify suspected crack indications found visually on the
support. No cracks are allowed.
5.21.3 Primary Method. Eddy Current.
5.21.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
5.21.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
support shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.21.3.3 Access. Access is through engine cowl (Figure 1-4, items 3T-7 and 4T-8).
5.21.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
5.21.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
5.21.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 5-21.
a. Place probe on a good area in the inspection location and null. Adjust phase as required to
obtain horizontal lift-off.

5--30
 TM 1-1520-265-23

b. Inspect the part.

c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 5.21.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 5.21.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
5.21.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
5.21.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
5.21.5 System Securing. The support, if removed, requires installation in accordance with the
applicable technical manuals listed in Table 1-1.

Figure 5-21. Engine Load Demand Spindle Bellcrank Support

5--31
TM 1-1520-265-23

5.22 ENGINE COMPONENTS (PT).

5.22.1 Description (Figure 5-1, Index No. 22). The engine components to be inspected are the
power turbine, combustion chamber and compression housing.
5.22.2 Defects. This inspection is to verify cracks found by visual inspection and to ensure no
cracks are present after repairs.
5.22.3 Primary Method. Fluorescent Penetrant.
5.22.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12
5.22.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the engine
shall be removed in accordance with the applicable technical manuals listed in Table 1-1.
5.22.3.3 Access. Access is through engine cowl (Figure 1-4, items 3T-7 or 4T-8).
5.22.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
5.22.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
5.22.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.13 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 5-22. Refer to Interpretation of Liquid Penetrant Inspection, paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.
5.22.3.7 Marking and Recording of Inspection Results. Mark and record the inspection results as
required by paragraph 1.3.
5.22.4 Backup Method. None required.
5.22.5 System Securing. Clean the inspected area to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The engine, if removed,
requires installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 5-22. Engine Components

5--32
 TM 1-1520-265-23

SECTION VI
FLIGHT CONTROL SYSTEM
6. GENERAL.
6.1 CONTENTS. The flight control system inspection items covered in this section are those items
of the H-60 helicopter series flight control and related hydraulic systems. The parts and components
are listed in the Flight Control System Inspection Index (Table 6-1). Corresponding inspection
figures and applicable text paragraphs are listed opposite each item. The index number for each
item may be used to locate it in Figure 6-1.

Table 6-1. Flight Control System Inspection Index

Index Nomenclature Inspection Paragraph Figure

Number Method Number Number
Main Module Attaching Point for Gust Lock and PT 6.2 6-2
Output Housing
2 Toe Pedal Actuator PT 6.3 6-3
3 Toe Pedal Assembly ET 6.4 6-4
4 Yaw Pedal Support Shaft MT 6.5 6-5
5 Yaw Pedal Brake Cylinder Supports ET 6.6 6-6
Yaw Control Pedal Supports MT 6.7 6.7
*6 Pedal Adjuster Arms and Link ET 6.8 6-8
*7 Pilot/Copilot Cyclic and Collective Stick Socket ET 6.9 6-9
8 Collective Boost and Yaw Boost Servo Input/ MT 6.10 6-10
Output Piston Shafts and Cylinders
*9 Yaw/Pitch Coupling Link ET 6.11 6-11
*10 Ferrous Flight Control System Push-Pull Rods MT 6.12 6-12
*11 Nonferrous Flight Control System Push-Pull ET 6.13 6-13
Rods
*12 Pilot Collective Stick Bellcrank Support ET 6.14 6-14
*13 Pilot/Copilot Collective Stick Support ET 6.15 6-15
*14 Pilot Collective Stick Bellcrank ET 6.16 6-16
*15 Ferrous Connecting Links, Rod Ends, Clevises, MT 6.17 6-17
Levers, and Attaching Parts
*16 Nonferrous Connecting Links, Rod Ends, Cle- ET 6.18 6-18
vises, Levers, and Attaching Parts
*17 Swashplate Links MT 6.19 6-19
*18 Walking Beam MT 6.20 6-20
*19 Forward Bellcrank MT 6.21 6-21
*20 Lateral Bellcrank MT 6.22 6-22

6--1
TM 1-1520-265-23

Table 6-1. Flight Control System Inspection Index - Continued

Index Nomenclature Inspection Paragraph Figure

Number Method Number Number
*21 Aft Bellcrank MT 6.23 6-23
*22 Hydraulic/Pneumatic System Components PT 6.24 6-24
*23 Ferrous Bolts Contained Within the Flight Con- MT 6.25 6-25
trol System
*24 Nonferrous Bolts Contained Within the Flight PT 6.26 6-26
Control System

NOTE: *Indicates Flight Safety Part.

6--2
 TM 1-1520-265-23

Figure 6-1. Flight Control System

6--3
TM 1-1520-265-23

6.2 MAIN MODULE ATTACHING POINT FOR GUST LOCK AND OUTPUT HOUSING (PT)
6.2.1 Description (Figure 6-1)
6.2.2 Defects. This inspection is to check for cracks found visually, and after single-engine
operation above idle with the gust lock engaged, on the main module attaching point for the gust
lock and output housing. No cracks allowed.
6.2.3 Primary Method. Fluorescent Penetrant.
6.2.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11.
QPL-AMS-2633-3 level 3 or higher penetrant materials shall be selected from the approved list in
Table 1-12.
6.2.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required the
attaching point shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
6.2.3.3 Access. Not applicable.
6.2.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to preparation of Part or
Area for NDI, paragraph 1.4.4.
6.2.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
6.2.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.12 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 6-2. Refer to Interpretation of Liquid Penetrant Inspection, Paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15.

Figure 6-2. Main Module Attaching Point.

6--4
 TM 1-1520-265-23

6.2.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.2.4 System Securing. The attaching points, if removed, requires installation in accordance with
the applicable technical manuals listed in Table 1-1.

6.3 TOE PEDAL ACTUATOR (PT).

6.3.1 Description (Figure 6-1, Index No. 2). The toe pedal actuator attaches to the toe pedal
assembly. The toe pedal actuator senses foot contact on the pedal and activates a microswitch.
6.3.2 Defects. Defects may occur anywhere on the surface of the toe pedal actuator. No cracks
are allowed.
6.3.3 Primary Method. Fluorescent Penetrant.
6.3.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12.
6.3.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the toe
pedal actuator shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
6.3.3.3 Access. Access to the toe pedal actuator is from the cockpit area.
6.3.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
6.2.3.5 Perform process control checks per Table 1-3 in accordance with TM 1-1500-366-23.
6.3.3.6 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.12 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 6-3. Refer to Interpretation of Liquid Penetrant Inspection, Paragraph 1.4.14 and
Indication Evaluation, paragraph 1.4.15..
6.3.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.3.4 Backup Method. None required.
6.3.5 System Securing. Clean the toe pedal actuator to remove inspection media. Refer to Post
Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The toe pedal actuator, if
removed, requires installation in accordance with the applicable technical manuals listed in Table
1-1.

6--5
TM 1-1520-265-23

Figure 6-3. Toe Pedal Actuator

6.4 TOE PEDAL ASSEMBLY (ET).

6.4.1 Description (Figure 6-1, Index No. 3). The toe pedal assembly is attached to the pedal
support assembly. The tail rotor control pedals control the helicopter’s directional headings.
6.4.2 Defects. Defects may occur anywhere on the surface of the toe pedal assembly. No cracks
are allowed.
6.4.3 Primary Method. Eddy Current.
6.4.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.4.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the toe
pedal assembly shall be removed in accordance with the applicable technical manuals listed in Table
1-1.
6.4.3.3 Access. Access to the toe pedal assembly is from the cockpit area.
6.4.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.

6--6
 TM 1-1520-265-23

6.4.3.5 NDI Equipment Settings.

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.4.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.11 and Figure 6-4.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

NOTE
Either probe identified in paragraph 6.4.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.4.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.4.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.4.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.4.5 System Securing. The toe pedal assembly, if removed, requires installation in accordance
with the applicable technical manuals listed in Table 1-1.

6--7
TM 1-1520-265-23

Figure 6-4. Toe Pedal Assembly

6.5 YAW PEDAL SUPPORT SHAFT (MT).

6.5.1 Description (Figure 6-1, Index No. 4). The yaw pedal support shaft supports the right and
left pedal support tubes. The support shaft provides the pivot point for the pedal support tubes.
6.5.2 Defects. Defects may occur anywhere on the surface of the yaw pedal support shaft. No
cracks are allowed.
6.5.3 Primary Method. Magnetic Particle.
6.5.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.5.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the yaw pedal support removed in accordance with the applicable technical manuals listed in
Table 1-1.

6--8
 TM 1-1520-265-23

6.5.3.3 Access. Not applicable.

6.5.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
6.5.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.5.3.6 Perform process control checks per TM 1-1500-366-23.
6.5.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-5.

Figure 6-5. Yaw Pedal Support Shaft

a. Select AC on the AC/DC power switch.

b. Place probe/yoke on part in position 1 as shown
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify a that magnetic field exists using a gause meter or field indicator..
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.5.3.8.
f. Repeat steps a. through e. for position 2.
g. Inspect opposite side, repeat steps a. through f.
6.5.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.5.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.5.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.5.5 System Securing. Clean the yaw pedal support shaft thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI,
paragraph 1.4.9. The yaw pedal support shaft requires installation in accordance with the applicable
technical manuals listed in Table 1-1.

6--9
TM 1-1520-265-23

6.6 YAW CONTROL PEDAL SUPPORTS (MT)

6.6.1 Description (Figure 6-1)
6.6.2 Defects. Defects may occur anywhere on the surface of the yaw control pedal supports.
No cracks are allowed.
6.6.3 Primary Method. Magnetic Particle.
6.6.3.1 NDI Equipment and Materials. Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Gause Meter or Field Indicator
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil
g. Black Light Meter
h. Ambient Light Meter

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.6.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance
and the yaw control pedal supports shall be removed in accordance with the applicable technical
manuals listed in TABLE 1-1.
6.6.3.3 Access. Not applicable.
6.6.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.9.
6.6.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.6.3.6 Perform process control checks per TM 1-1500-366-23.
6.6.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is illustrated in Figure 6-6.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown for each fitting.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator..
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.6.3.8.
f. Repeat steps b. through e. for positions 2,3 and 4.
g. Inspect opposite side. Repeat steps b. through f.

6--10
 TM 1-1520-265-23

Figure 6-6. Yaw Control Pedal Support.

.6.6.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.6.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part or the part from the probe/yoke for a distance of two feet before releasing the switch.
6.6.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.6.5 System Securing. Clean the yaw control pedal supports thoroughly to remove all residual
magnetic particle media. Refer to Post Cleaning and Restoration of Part Area After NDI, paragraph
1.4.9. The yaw pedal brake cylinder supports require installation in accordance with the applicable
technical manual listed in Table 1-1.

6.7 YAW PEDAL BRAKE CYLINDER SUPPORTS (ET).

6.7.1 Description (Figure 6-1, Index No. 5). The yaw pedal brake cylinder support connects the
brake cylinder to the independent toe-operated wheel brake controls.
6.7.2 Defects. Defects may occur anywhere on the surface of the yaw pedal brake cylinder
supports. No cracks are allowed.
6.7.3 Primary Method. Eddy Current.
6.7.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit

6--11
TM 1-1520-265-23

b. Probe, straight, shielded surface, 100 KHz-500 KHz

c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.7.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the yaw
pedal brake cylinder supports shall be removed in accordance with the applicable technical manuals
listed in Table 1-1.
6.7.3.3 Access. Access is through floor panel’s surrounding pedals.
6.7.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
6.7.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.7.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-7.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

6--12
 TM 1-1520-265-23

Figure 6-7. Yaw Pedal Brake Cylinder Supports

NOTE
Either probe identified in paragraph 6.7.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.7.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.7.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.7.4 Backup Method. None required.
6.7.5 System Securing. The yaw pedal brake cylinder supports, if removed, require installation
in accordance with the applicable technical manuals listed in Table 1-1.

6.8 PEDAL ADJUSTER ARMS AND LINK (ET).

6.8.1 Description (Figure 6-1, Index No. 6). The pedal adjuster arms and link provide adjustment
of the directional control pedals to suit the pilot’s leg length.
6.8.2 Defects. Defects may occur anywhere on the surface of the pedal adjuster arms and link.
No cracks are allowed.
6.8.3 Primary Method. Eddy Current.
6.8.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the pedal

6--13
TM 1-1520-265-23

adjuster arms and link shall be removed in accordance with the applicable technical manuals listed
in Table 1-1.
6.8.3.3 Access. Access to the pedal adjuster arms and link is from the cockpit area.
6.8.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
6.8.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.8.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-8.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated..

6--14
 TM 1-1520-265-23

Figure 6-8. Pedal Adjuster Arms and Link

NOTE
Either probe identified in paragraph 6.8.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.8.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.8.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.8.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.8.5 System Securing. The pedal adjuster arms and link, if removed, require installation in
accordance with the applicable technical manuals listed in Table 1-1.

6.9 PILOT/COPILOT CYCLIC AND COLLECTIVE STICK SOCKET (ET).

6.9.1 Description (Figure 6-1, Index No. 7). The pilot/copilot cyclic and collective stick socket are
located at the base of the cyclic and collective stick assemblies. The sockets permit the movement
of the cyclic and collective stick assemblies.
6.9.2 Defects. Defects may occur anywhere on the surface of the pilot/copilot cyclic and
collective stick socket. No cracks are allowed.
6.9.3 Primary Method. Eddy Current.

6--15
TM 1-1520-265-23

6.9.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape,
g. Aircraft Marking Pencil
6.9.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
pilot/copilot cyclic and collective stick socket shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.9.3.3 Access. Access is gained through the cockpit area and unzipping the boot at the base of
the cyclic/collective stick assemblies.
6.9.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part or
Area for NDI, paragraph 1.4.4.
6.9.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid
b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.9.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-9.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 6.9.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps
6.9.3.5b.(1), (2), and (3) shall be repeated each time a change is made.

6--16
 TM 1-1520-265-23

6.9.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.9.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.9.5 System Securing. The pilot/copilot cyclic and collective stick socket, if removed, requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

Figure 6-9. Pilot/Copilot Cyclic and Collective Stick Socket

6.10 COLLECTIVE BOOST AND YAW BOOST SERVO INPUT/OUTPUT PISTON SHAFTS AND
CYLINDERS (MT).
6.10.1 Description (Figure 6-1, Index No. 8). The collective and yaw boost servos both reduce
stick and flight control friction. The yaw boost servo also provides rate damping through a SAS
actuator.
6.10.2 Defects. This inspection is used to verify crack indications found visually on the collective
boost servo and yaw boost servo. No cracks are allowed.
6.10.3 Primary Method. Magnetic Particle.
6.10.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles

6--17
TM 1-1520-265-23

e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.10.8.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required the above shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
6.10.3.3 Access. Access is through the controls/accessories sliding cover (Figure 1-4, Item
3T-4T-2).

WARNING

Use only appropriate platforms, work stands, or other approved locally procured stands
and restraint equipment when working above 10 feet on helicopters in a nontactical
environment. Otherwise, personnel injury could result from accidental falls.
6.10.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.10.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.10.3.6 Perform process control checks per TM 1-1500-366-23.
6.10.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. The position required for this inspection is listed in Figure 6-10.

Figure 6-10. Collective Boost and Yaw Boost Servo Input/Output Piston Shafts and Cylinders

6--18
 TM 1-1520-265-23

a. Select AC on the AC/DC power switch.

b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied no more that five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Inspect opposite side repeat steps a. through f.
6.10.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.10.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.10.4 Backup Method. None required.
6.10.5 System Securing. Clean the collective boost and yaw boost servo thoroughly to remove
all residual magnetic particle media. Refer to Post Cleaning and Restoration of Part or Area After
NDI, paragraph 1.4.9 The collective boost and yaw boost servo, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

6.11 YAW/PITCH COUPLING LINK (ET).

6.9.1 Description (Figure 6-1, Index No. 9). The yaw/pitch coupling link is a component of the
mixer assembly which is part of the collective control system.
6.11.2 Defects. This inspection is used to verify crack indications found visually on the yaw/pitch
coupling link. No cracks are allowed.
6.11.3 Primary Method. Eddy Current.
6.11.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.11.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
yaw/pitch coupling link shall be removed in accordance with the applicable technical manuals listed
in Table 1-1.
6.11.3.3 Access. Access is through the controls/accessories sliding cover (Figure 1-4, Item
3T-4T-2).

6--19
TM 1-1520-265-23

WARNING

Use only appropriate platforms, work stands, or other approved locally procured stands
and restraint equipment when working above 10 feet on helicopters in a nontactical
environment. Otherwise, personnel injury could result from accidental falls.
6.11.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.11.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.11.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-9.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 6.11.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.11.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.11.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.11.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.11.5 System Securing. The yaw/pitch coupling link, if removed, requires installation in
accordance with the applicable technical manuals listed in Table 1-1.

6--20
 TM 1-1520-265-23

Figure 6-11. Yaw/Pitch Coupling Link

6.12 FERROUS FLIGHT CONTROL SYSTEM PUSH-PULL RODS (MT).

6.12.1 Description (Figure 6-1, Index No. 10). This is a generic inspection pertaining to ferrous
flight control system push-pull rods throughout the helicopter.
6.12.2 Defects. This inspection is used to verify crack indications found visually on the push-pull
rods. All areas where rework has been performed shall be inspected for cracks. No cracks are
allowed.
6.12.3 Primary Method. Magnetic Particle.
6.12.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil,

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.12.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may

6--21
TM 1-1520-265-23

be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the push-pull rods shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.12.3.3 Access. Not applicable.
6.12.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.12.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.12.3.6 Perform process control checks per TM 1-1500-366-23.
6.12.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-12.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.12.3.8.
f. Repeat steps a. through e. for other positions, as required.
g. Inspect opposite side, repeat steps a. through f..

Figure 6-12. Ferrous Flight Control System Push-Pull Rods

6.12.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.

6--22
 TM 1-1520-265-23

6.12.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.12.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.12.5 System Securing. Clean the push-pull rods thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.16.
The push-pull rods, if removed, require installation in accordance with the applicable technical
manuals listed in Table 1-1.

6.13 NONFERROUS FLIGHT CONTROL SYSTEM PUSH-PULL RODS (ET).

6.13.1 Description (Figure 6-1, Index No. 11). This is a generic inspection pertaining to nonferrous
flight control system push-pull rods throughout the helicopter.
6.13.2 Defects. This inspection is used to verify crack indications found visually on the push-pull
rods. All areas where rework has been performed shall be inspected for cracks. No cracks are
allowed.
6.13.3 Primary Method. Eddy Current.
6.13.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz (Titanium)
c. Probe, right angle, shielded surface, 2MHz, 90_ 1/2 inch drop (Titanium)
d. Probe, straight, shielded surface, 100-500 KHz (A1)
e. Probe, right angle, shielded surface, 100-500 KHz, 90_ 1/2 inch drop (A1)
f. Cable Assembly
g. Adapter, Probe
h. Reference Block, three-notched Aluminum (0.008, 0.020, 0.040 EDM notches)
i. Reference Block, three-notched Titanium (0.008, 0.020, 0.040 EDM notches)
j. Teflon Tape
k. Aircraft Marking Pencil
6.13.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
nonferrous flight control system push-pull rods shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.13.3.3 Access. Not applicable.
6.13.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.13.3.5 NDI Equipment Settings.

6--23
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ (Aluminum) 200 KHz LP Filter 100 H Pos 80%
(Titanium) 1000 KHz
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.13.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-13.

Figure 6-13. Nonferrous Flight Control System Push-Pull Rods

a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

6--24
 TM 1-1520-265-23

NOTE
Either probe identified in paragraph 6.13.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.13.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.13.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.13.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.13.5 System Securing. The push-pull rods, if removed, require installation in accordance with
the applicable technical manuals listed in Table 1-1.

6.14 PILOT COLLECTIVE STICK BELLCRANK SUPPORT (ET).

6.14.1 Description (Figure 6-1, Index No. 12). The pilot structural collective stick bellcrank support
provides not only structural support, but also a pivot point for the collective stick bellcrank.
6.14.2 Defects. This inspection is used to verify crack indications found visually on the pilot
collective stick bellcrank support. No cracks are allowed.
6.14.3 Primary Method. Eddy Current.
6.14.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.14.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the pilot collective stick bellcrank support shall be removed in accordance
with the applicable technical manuals listed in Table 1-1.
6.14.3.3 Access. Access is by removal of the boot, cover and panel which is behind the pilot’s seat
in crew compartment.
6.14.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.14.3.5 NDI Equipment Settings.

6--25
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.14.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-14.

Figure 6-14. Pilot Collective Stick Bellcrank Support

a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

6--26
 TM 1-1520-265-23

NOTE
Either probe identified in paragraph 6.14.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.14.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.14.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.14.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.14.5 System Securing. The pilot collective stick bellcrank support, if removed, requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

6.15 PILOT/COPILOT COLLECTIVE STICK SUPPORT (ET).

6.15.1 Description (Figure 6-1, Index No. 13). The pilot/copilot collective stick bellcrank support
provides the attaching point for the collective control stick.
6.15.2 Defects. This inspection is used to verify crack indications found visually on the pilot/copilot
collective stick support. No cracks are allowed.
6.15.3 Primary Method. Eddy Current.
6.15.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil
6.15.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the pilot/copilot collective stick support shall be removed in accordance with
the applicable technical manuals listed in Table 1-1.
6.15.3.3 Access. Access is by removal of the boot and cover.
6.15.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.15.3.5 NDI Equipment Settings.

6--27
TM 1-1520-265-23

a. Make the following initial settings on the Eddy Current Inspection Unit..
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.15.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-15.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches in the test block should be further evaluated.

NOTE
Either probe identified in paragraph 6.15.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.15.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.15.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.15.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.15.5 System Securing. The pilot/copilot collective stick support, if removed, requires installation
in accordance with the applicable technical manuals listed in Table 1-1.

6--28
 TM 1-1520-265-23

Figure 6-15. Pilot/Copilot Collective Stick Support

6.16 PILOT COLLECTIVE STICK BELLCRANK (ET).
6.16.1 Description (Figure 6-1, Index No. 14). The pilot collective stick bellcrank receives input
from the collective control stick and transmits it to the collective control system.
6.16.2 Defects. This inspection is used to verify crack indications found visually on the pilot
collective stick bellcrank. No cracks are allowed.
6.16.3 Primary Method. Eddy Current.
6.16.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 100 KHz-500 KHz
c. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop
d. Cable Assembly
e. Reference Block, three-notched aluminum (0.008, 0.020, 0.040 EDM notches)
f. Teflon Tape
g. Aircraft Marking Pencil

6--29
TM 1-1520-265-23

6.16.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the collective stick bellcrank shall be removed in accordance with the
applicable technical manuals listed in Table 1-1.
6.16.3.3 Access. Access is by removal of the access cover from inside the cargo/passenger
compartment.
6.16.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.16.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ 200 KHz LP Filter 100 H Pos 80%
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.16.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-16.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.
b. Inspect the part.
c. Any relevant signal similar to the notches on the test block should be further evaluated..

NOTE
Either probe identified in paragraph 6.14.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.14.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.16.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.16.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.16.5 System Securing. The pilot/copilot collective stick bellcrank, if removed, requires
installation in accordance with the applicable technical manuals listed in Table 1-1.

6--30
 TM 1-1520-265-23

Figure 6-16. Pilot Collective Stick Bellcrank

6.17 FERROUS CONNECTING LINKS, ROD ENDS, CLEVISES, LEVERS, AND ATTACHING
PARTS (MT).
6.17.1 Description (Figure 6-1, Index No. 15). Ferrous connecting links, rod ends, clevises, levers
and attaching parts are found in various locations in the helicopter flight controls.
6.17.2 Defects. This inspection is used to verify crack indications found visually on the links, rod
ends, clevises, levers, and attaching parts. No cracks are allowed.
6.17.3 Primary Method. Magnetic Particle.
6.17.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.

6--31
TM 1-1520-265-23

6.17.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc., ) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the connecting links, rod ends, clevises, levers, and attaching parts shall be
removed in accordance with the applicable technical manuals listed in Table 1-1.
6.17.3.3 Access. This is a generic inspection. Access to these parts is gained on a generic basis
in accordance with the applicable technical manuals listed in Table 1-1 and Figure 1-4.
6.17.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.17.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.17.3.6 Perform process control checks per TM 1-1500-366-23
6.17.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-17.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.17.3.8.
f. Repeat steps a. through e. for other positions, as required.
g. Inspect opposite side, repeat steps a. through f.
6.17.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.17.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.17.4 Backup Method. None required.
6.17.5 System Securing. Clean the parts thoroughly to remove all residual magnetic particle
media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9. The
connecting links, rod ends, clevises, levers, and attaching parts, if removed, require installation in
accordance with the applicable technical manuals listed in Table 1-1.

6--32
 TM 1-1520-265-23

Figure 6-17. Ferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching Parts

6.18 NONFERROUS CONNECTING LINKS, ROD ENDS, CLEVISES, LEVERS, AND

ATTACHING PARTS (ET).
6.18.1 Description (Figure 6-1, Index No. 16). Nonferrous connecting links, rod ends, clevises,
levers, and attaching parts are found in various locations in the helicopter flight controls.
6.18.2 Defects. This inspection is used to verify crack indications found visually on the links, rod
ends, clevises, levers, and attaching parts. No cracks are allowed.

6--33
TM 1-1520-265-23

6.18.3 Primary Method. Eddy Current.

6.18.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Eddy Current Inspection Unit
b. Probe, straight, shielded surface, 2 MHz (Titanium)
c. Probe, right angle, shielded surface, 2 MHz, 90_ 1/2 inch drop (Titanium)
d. Probe, straight, shielded surface, 100 KHz-500 KHz (A1)
e. Probe, right angle, shielded surface, 100 KHz-500 KHz, 90_ 1/2 inch drop (A1)
f. Cable Assembly
g. Reference Block, three-notched Aluminum (0.008, 0.020, 0.040 EDM notches)
h. Reference Block, three-notched Titanium (0.008, 0.020, 0.040 EDM notches)
i. Teflon Tape
j. Aircraft Marking Pencil
6.18.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc., ) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the links,
rod ends, clevises, levers, and attaching parts shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.18.3.3 Access. This is a generic inspection. Access to these parts is gained on a generic basis
in accordance with the applicable technical manuals listed in Table 1-1 and Figure 1-4.
6.18.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.18.3.5 NDI Equipment Settings.
a. Make the following initial settings on the Eddy Current Inspection Unit.
MAIN MENU FILTER MENU DISPLAY MENU
FREQ (Aluminum) 200 KHz LP Filter 100 H Pos 80%
(Titanium) 1000 KHz
ANG 56_ HP Filter Off V Pos 20%
H Gain 57db
V Gain 69db
Probe Drive Mid

b. Refer to Eddy Current Method, paragraph 1.4.19. Set up on test block as follows:
(1) Null probe on test block.
(2) Adjust phase as required to obtain horizontal lift-off.
(3) Move probe over all three notches in test block. Adjust gain to obtain a five block vertical
signal when probe is passed over 0.040-inch notch in test block. (See the standard
instrument display shown in Figure 1-7.)
6.18.3.6 Inspection Procedure. Refer to Eddy Current Method, paragraph 1.4.19 and Figure 6-18.
a. Place probe on a good area in the inspection location and null. Adjust phase as required
to obtain horizontal lift-off.

6--34
 TM 1-1520-265-23

b. Inspect the part.

c. Any relevant signal similar to the notches in the test block should be further evaluated.

Figure 6-18. Nonferrous Connecting Links, Rod Ends, Clevises, Levers, and Attaching Parts

NOTE
Either probe identified in paragraph 6.18.3.1 may be used depending primarily on the
ease of accessibility and user friendliness. If the probes are changed, steps 6.18.3.5b.
(1), (2), and (3) shall be repeated each time a change is made.
6.18.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.18.4 Backup Method. None required.
6.18.5 System Securing. The links, rod ends, clevises, levers, and attaching parts, if removed,
require installation in accordance with the applicable technical manuals listed in Table 1-1.

6--35
TM 1-1520-265-23

6.19 SWASHPLATE LINKS (MT).

6.19.1 Description (Figure 6-1, Index No. 17). The swashplate links are part of the swashplate
linkage. They transmit flight control inputs from the servo bellcranks to the main rotor swashplate.
The links are machined from a 4340 steel forging, cadmium plated, and protected by an epoxy
primer and polyurethane paint. The upper ends of the links contain spherical bearings.
6.19.2 Defects. This inspection is used to verify crack indications found visually on the swashplate
links. All areas where rework has been performed, and the spherical bearings, shall be inspected
for cracks. No cracks are allowed.
6.19.3 Primary Method. Magnetic Particle.
6.19.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.19.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the swashplate links shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.19.3.3 Access. Not applicable.
6.19.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.19.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.19.3.6 Perform process control checks per TM 1--1500--366--23.
6.19.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-19.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.19.3.8.
f. Repeat steps a. through e. for positions 2 and 3 for each link
g. Inspect opposite side, repeat steps a. through f..

6--36
 TM 1-1520-265-23

Figure 6-19. Swashplate Links

6.19.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.19.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.19.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.19.5 System Securing. Clean the swashplate links thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The swashplate links, if removed, require installation in accordance with the applicable technical
manuals listed in Table 1-1.

6.20 WALKING BEAM (MT).

6.20.1 Description (Figure 6-1, Index No. 18). The walking beam is a straight bellcrank mounted
on the forward bridge support. It transmits flight control inputs from the aft longitudinal servo to the
main rotor swashplate via a connecting linkage. It is machined from a 4340 steel forging, cadmium
plated, and protected by epoxy primer and polyurethane paint.
6.20.2 Defects. This inspection is used to verify crack indications found visually on the walking
beam. Inspect all reworked areas for cracks. Inspect walking beam lugs and surface areas for
cracks. Visually inspect walking beam flanged pivot bushing for cracks. No cracks are allowed.
6.20.3 Primary Method. Magnetic Particle.

6--37
TM 1-1520-265-23

6.20.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.20.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the walking beam shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.20.3.3 Access. The walking beam is accessible on aircraft. Inspection of the pivot bushing
requires removal and disassembly of the walking beam. Inspection of the walking beam lug areas
requires removal of the walking beam from the aircraft.
6.20.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.20.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.20.3.6 Perform process control checks per TM 1-1500-366-23.
6.20.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-20.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.20.3.8.
f. Repeat steps a. through e. for positions 2, 3, and 4.
g. Inspect opposite side, repeat steps a. through f.
6.20.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.20.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.

6--38
 TM 1-1520-265-23

Figure 6-20. Walking Beam

6.20.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.20.5 System Securing. Clean the walking beam thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The walking beam, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

6.21 FORWARD BELLCRANK (MT).

6.211 Description (Figure 6-1, Index No. 19). The forward bellcrank, supported by the bellcrank
support (bridge) in the swashplate linkage installation, transfers flight control movements through
a connecting servo link to the main rotor swashplate. It is machined from a 4340 steel forging,
cadmium plated, and protected by epoxy primer and polyurethane paint.
6.21.2 Defects. This inspection is used to verify crack indications found visually on the forward
bellcrank. Inspect all reworked areas for cracks. Inspect forward bellcrank lug and rib surfaces.
Visually inspect bellcrank flanged pivot bushings. No cracks are allowed.
6.21.3 Primary Method. Magnetic Particle.
6.21.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles,

6--39
TM 1-1520-265-23

e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.21.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the forward bellcrank shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.21.3.3 Access. Not applicable.
6.21.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.21.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.21.3.6 Perform process control checks per TM 1-1500-366-23.
6.21.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-21.

Figure 6-21. Forward Bellcrank

6--40
 TM 1-1520-265-23

a. Select AC on the AC/DC power switch.

b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.21.3.8.
f. Repeat steps a. through e. for positions 2 through 5.
g. Inspect opposite side repeat steps a. through f.
6.21.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.21.3.8 Demagnetization. with the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.21.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13..
6.21.5 System Securing. Clean the forward bellcrank thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The forward bellcrank, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

6.22 LATERAL BELLCRANK (MT).

6.22.1 Description (Figure 6-1, Index No. 20). The lateral bellcrank, supported by the bellcrank
support (bridge) in the swashplate linkage installation, transfers flight control movements through
a connecting servo link to the main rotor swashplate. It is machined from a 4340 steel forging,
cadmium plated, and protected by epoxy primer and polyurethane paint.
6.22.2 Defects. This inspection is used to verify crack indications found visually on the lateral
bellcrank. Inspect all reworked areas for cracks. Inspect lateral bellcrank lug and rib surfaces.
Visually inspect bellcrank flanged pivot bushings. No cracks are allowed.
6.22.3 Primary Method. Magnetic Particle.
6.22.3.1 NDI Equipment and Materials. (Refer to Tables 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil

NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.

6--41
TM 1-1520-265-23

6.22.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the lateral bellcrank shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.22.3.3 Access. Not applicable.
6.22.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.22.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.22.3.6 Perform process control checks per TM 1-1500-366-23.
6.22.3.7 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-22.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than fives
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.22.3.8.
f. Repeat steps a. through e. for positions 2 through 5.
g. inspect opposite side, repeat steps a. through f.

Figure 6-22. Lateral Bellcrank

6--42
 TM 1-1520-265-23

6.22.3.8 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.22.3.9 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.
6.22.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13..
6.22.5 System Securing. Clean the lateral bellcrank thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The lateral bellcrank, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

6.23 AFT BELLCRANK (MT).

6.23.1 Description (Figure 6-1, Index No. 21). The aft bellcrank, supported by the bellcrank
support (bridge) in the swashplate linkage installation, transfers flight control movements through
a connecting servo link to the main rotor swashplate. It is machined from a 4340 steel forging,
cadmium plated, and protected by epoxy primer and polyurethane paint.
6.23.2 Defects. This inspection is used to verify crack indications found visually on the aft
bellcrank. Inspect all reworked areas for cracks. Inspect aft bellcrank lug and rib surfaces. Visually
inspect bellcrank flanged pivot bushings. No cracks are allowed.
6.23.3 Primary Method. Magnetic Particle.
6.23.3.1 NDI Equipment and Materials. (Refer to Table 1-11 and 1-12.)
a. Magnetic Particle Inspection Probe/Yoke
b. Magnetometer
c. Black Light
d. Fluorescent Magnetic Particles
e. Consumable Materials
f. Aircraft Marking Pencil,
NOTE
Hand-held magnetic coil may be used. Refer to paragraph 1.4.16.3.2 and Figure 1-6.
6.23.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using applicable positions of this
procedure. If required, the aft bellcrank shall be removed in accordance with the applicable technical
manuals listed in Table 1-1.
6.23.3.3 Access. Not applicable.
6.23.3.4 Preparation of Part. The part shall be thoroughly cleaned. Refer to Preparation of Part
or Area for NDI, paragraph 1.4.4.
6.23.3.5 NDI Equipment Settings. Refer to Magnetic Particle Method, paragraph 1.4.16.
6.23.3.6 Perform process control checks per TM 1-1500-366-23.

6--43
TM 1-1520-265-23

6.23.3.6 Inspection Procedure. A magnetic field shall be applied to the part perpendicular to the
orientation of possible cracks. Positions required for this inspection are illustrated in Figure 6-23.
a. Select AC on the AC/DC power switch.
b. Place probe/yoke on part in position 1 as shown.
c. Press the test switch and apply a light coat of magnetic particle media. Discontinue media
application prior to removing the current. Current should be applied for no more than five
seconds. Verify that a magnetic field exists using a gause meter or field indicator.
d. Inspect for cracks using the black light.
e. Demagnetize before moving to the next position. Refer to paragraph 6.21.3.8.
f. Repeat steps a. through e. for positions 2 through 5.
g. Inspect opposite side, repeat steps a. through f.
6.23.3.7 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.23.3.8 Demagnetization. With the switch remaining in the AC position, place the probe/yoke legs
in the same position used for magnetizing. Press the test switch and withdraw the probe/yoke from
the part for a distance of two feet before releasing the switch.

Figure 6-23. Aft Bellcrank

6.23.4 Backup Method. Fluorescent Penetrant, refer to Table 1-4, paragraph 1.4.2.1 and
paragraph 1.4.13.
6.23.5 System Securing. Clean the aft bellcrank thoroughly to remove all residual magnetic
particle media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The aft bellcrank, if removed, requires installation in accordance with the applicable technical
manuals listed in Table 1-1.

6--44
 TM 1-1520-265-23

6.24HYDRAULIC/PNEUMATIC SYSTEM COMPONENTS (PT).

6.24.1 Description (Figure 6-1, Index No. 22). This inspection is applicable to all unpainted valves,
fittings, and tubes contained within the hydraulic/pneumatic system. This inspection can also be
used to verify any indications found on painted surfaces, providing the paint is only removed from
the immediate area of interest.
6.24.2 Defects. This inspection is used to verify crack indications found visually on the
hydraulic/pneumatic system components. No cracks are allowed.
6.24.3 Primary Method. Fluorescent Penetrant.
6.24.3.1 NDI Equipment and Materials. Inspection equipment is listed in Table 1-11. Penetrant
materials shall be selected from the approved list in Table 1-12..
6.24.3.2 Preparation of Helicopter. The helicopter shall be prepared for safe ground maintenance.
A partial inspection for cause (visual indications, sites of mechanical damage, corrosion, etc.) may
be performed on all exposed surfaces of the installed part using this procedure. If required, the
hydraulic/pneumatic system components shall be removed in accordance with the applicable
technical manuals listed in Table 1-1.
6.24.3.3 Access. Accessibility to the hydraulic/pneumatic system components varies considerably.
Refer to Figure 1-4 and Table 1-2 to locate applicable access provisions.

WARNING

Use only appropriate platforms, work stands, or other approved locally procured
stands and restraint equipment when working above 10 feet on helicopters in a
nontactical environment. Otherwise, personnel injury could result from accidental
falls.
6.24.3.4 Preparation of Part. Refer to Preparation of Part or Area for NDI, paragraph 1.4.4.
6.24.3.5 Inspection Procedure. Perform fluorescent penetrant inspection. Refer to Fluorescent
Penetrant Methods, paragraph 1.4.12 and either Table 1-4 or 1-5 depending on Unit capability.
Inspect part Figure 6-24. Refer to Interpretation of Liquid Penetrant Inspection, Paragraph 1.4.14
and Indication Evaluation, paragraph 1.4.15.
6.24.3.6 Marking and Recording of Inspection Results. Mark and record inspection results as
required by paragraph 1.3.
6.24.4 Backup Method. None required.
6.24.5 System Securing. Clean the hydraulic/pneumatic system components to remove
inspection media. Refer to Post Cleaning and Restoration of Part or Area After NDI, paragraph 1.4.9.
The hydraulic/pneumatic system components, if removed, require installation in accordance with
the applicable technical manuals listed in Table 1-1.

6--45
TM 1-1520-265-23

Figure 6-24. Hydraulic/Pneumatic System Components

6.25 FERROUS BOLTS CONTAINED WITHIN THE FLIGHT CONTROL SYSTEM (MT).
6.25.1 Description (Figure 6-1, Index No. 23). Refer to paragraph 2.3 for inspection procedure.

6.26 NONFERROUS BOLTS CONTAINED WITHIN THE FLIGHT CONTROL SYSTEM (PT).
6.26.1 Description (Figure 6-1, Index No. 24). Refer to paragraph 2.4 for inspection procedure.

6--46
 TM 1--1520--265--23

APPENDIX A
MAINTENANCE ALLOCATION CHART NONDESTRUCTIVE INSPECTION

NDI METHODS/EQUIPMENT
001 Fluorescent Penetrant Method
002 Magnetic Particle Method
003 Eddy Current Method
004 Ultrasonic Method
005 Bond Testing Method
006 Radiographic Method
NOMENCLATURE OF END ITEMS
HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
REQUIREMENTS
AVUM AVIM DEPOT
2.2 Split Cones Cracks n 001

2.3 Ferrous Rotor System Cracks n 002

Bolts and Pins
2.4 Nonferrous Rotor System Cracks n 001
Bolts and Pins
2.5 Main Rotor Shaft Nut Cracks n 002

2.6 Main Rotor Hub Cracks n 003 Backup

001
2.7 Main Rotor Hub 11 O’Clock Cracks n 003 Backup
Bolt Hole 001
2.8 Spindle Cracks n 003 Backup
001
2.9 Main Rotor Hub Spindle Cracks 004

2.10 Antiflap Bracket Cracks n 003 Backup

001
2.11 Droop Stop Support Ring Cracks n 003 Backup
Nut 001
2.12 Droop Stop Support Cracks n 003 Backup
001
2.13 Balance Weight Bracket Cracks n 002

2.14 Spindle Horn Cracks n 003 Backup

001
2.15 Droop Stop Cam Cracks n 003 Backup
001

A--1
TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
AVUM AVIM DEPOT REQUIREMENTS
2.16 Damper Assembly Cracks n 003 Backup
001
2.17 Damper Piston Cracks n 002 Backup
001
2.18 Pitch Control Rods Cracks n 003 Backup
001
2.19 Rotating Swashplate Cracks n 003 Backup
001
2.20 Swashplate Spherical Cracks n 003 Backup
Bearing Holes 001
2.21 Lower Link Cracks n 003 Backup
001
2.22 Rotating Scissors Cracks n 001

2.23 Bifilar Vibration Absorber Cracks n 003 Backup

001
2.24 Bifilar Weight Cracks n 004

2.25 Bifilar Weight Bushings Cracks n 001

2.26 Bifilar Support Arm Cracks n 001

Bushing
2.27 Bifilar Weight Tapered Cracks n 001
Washers
2.28 Main Rotor Blade Tip Cap Cracks n 003
Fairing
2.29 Main Rotor Blade Voids n 005
(Voids)
2.30 Main Rotor Blade Cuff Cracks n 003 Backup
Assembly 001
2.31 Tail Rotor Blade Spar Cen-- Cracks n 003 Backup
ter Plug 001
2.32 Tail Rotor Blade (Voids) Voids n 005

2.33 Tail Rotor Blade (Fluid) Fluid n 006

2.34 Tail Rotor Blade Tip Cap Cracks n 003 Backup

001
2.35 Tail Rotor Pitch Beam Cracks n 001

A--2
 TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
AVUM AVIM DEPOT REQUIREMENTS
2.36 Tail Rotor Pitch Beam Cracks n 003 Backup
001
2.37 Tail Rotor Pitch Horn Cracks n 003 Backup
001
2.38 Tail Rotor Pitch Control Cracks n 002
Rod Ends
2.39 Pitch Beam Washer Cracks n 002 Backup
001
2.40 Pitch Beam Retaining Nut Cracks n 002

2.41 Tail Rotor Inboard/Out-- Cracks n 003 Backup

board Retention Plates 001
3.2 Main Transmission Cracks n 003 Backup
001
3.3 Intermediate Gearbox Cracks n 003 Backup
001
3.4 Tail Rotor Drive Shaft Cracks n 003 Backup
001
3.5 Tail Rotor Drive Shaft Sup-- Cracks n 003
ports
3.6 Tail Rotor Drive Shaft Cou-- Cracks n 001
pling
3.7 Oil Cooler Drive Shaft Cracks n 003 Backup
001
3.8 Oil Cooler Axial Fan Shaft Cracks n 002

3.9 Oil Cooler Fan (Blades) Cracks n 003 Backup

001
3.10 Tail Gearbox Cracks n 003 Backup
001
3.11 Tail Gearbox Mount Fitting Cracks n 003 Backup
001
3.12 Tail Rotor Gearbox Inner/ Cracks n 001
Outer Split Cones
3.13 Ferrous Bolts Contained Cracks n 002
within the Flight Control
System
3.14 Non--Ferrous Bolts Con-- Cracks n 001
tained within the Flight
Control System

A--3
TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
AVUM AVIM DEPOT REQUIREMENTS
4.2 Airframe Skin, Panels, Cracks n 003 Backup
Doors, Covers, and Fair-- 001
ings - Metal
4.3 Tail Cone Fitting Cracks n 003 Backup
001
4.4 Honeycomb and Compos-- Voids n 005
ite Structures
4.5 Fluid in Honeycomb Core Fluid n 006
Panels and Structures
4.6 Ferrous Vibration Absorber Cracks n 002 Backup
Springs 001
4.7 Non--Ferrous Vibration Ab-- Cracks n 001
sorber Springs
4.8 Vibration Absorber Structu-- Cracks n 003
al Fittings
4.9 Roll Vibration Absorber Cracks n 001

4.10 Cabin Vibration Upper and Cracks n 001

Lower Housing
4.11 Aluminum Structural Cracks n 003 Backup
Beams and Frames 001
4.12 Pilot/Copilot Seat Mid-- Cracks n 002
frame Support
4.13 Troop/Cargo Door Upper Cracks n 003 Backup
Track 001
4.14 Gunner’s Window Lower Cracks n 003 Backup
Track 001
4.15 Gunner’s Window Upper Cracks n 003 Backup
Track 001
4.13 Troop/Cargo Door Lower Cracks n 003 Backup
Track 001
4.17 Oil Cooler Compartment Cracks n 001
Access Door
4.18 Tail Pylon Attach Fitting Cracks n 003 Backup
001
4.19 Tail Rotor Pylon Skin, Sta-- Cracks n 003 Backup
tion 200 001
4.20 Tail Rotor Pylon Attaching Cracks n 001 Backup
Hardware 001
4.21 Tail Pylon Lower Step Cracks n 003 Backup
001

A--4
 TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
REQUIREMENTS
AVUM AVIM DEPOT
4.22 Stabilator Attach Fitting Cracks n 003 Backup
001
4.23 Stabilator Actuator Attach Cracks n 002 Backup
Fittings 001
4.24 Stabilator Position Sensor Cracks n 001
Bracket
4.25 Stabilator Actuator Hous-- Cracks n 001
ing
4.26 Drag Beam Support Fitting Cracks n 003 Backup
001
4.27 Drag Beam Jackpad and Cracks n 002 Backup
Tiedown Ring Holes 001
4.28 Main Landing Gear Drag Cracks n 002 Backup
Beam 001
4.29 Main Landng Gear Fitting Cracks n 001
Spherical Bearng Bore
4.30 Main Landing Gear Shock Cracks n 003 Backup
Strut Upper Cylinder 001
4.31 Main Landing Gear Shock Cracks n 002 Backup
Strut Lower Stage Piston 001
4.32 Main Landing Gear Wheel Cracks n 001
Assembly Primary Method
4.33 Main Landing Gear Wheel Cracks n 003 Backup
Assembly Alternate 001
Method
4.34 Main Landing Gear Brake Cracks n 002 Backup
001
4.35 Main Landing Gear Brake Cracks n 003 Backup
Housing 001
4.36 Parking Brake Valve Cracks n 001
Components
4.37 Slave Mixer Valve Parts Cracks n 001

4.38 Tail Landing Gear Shock Cracks n 003 Backup

Strut 001
4.39 Tail Landing Gear Yoke Cracks n 003 Backup
001
4.40 Tail Landing Gear Fork Cracks n 003 Backup
001
4.41 Tail Landing Gear Wheel Cracks n 001 Backup
Assembly Primary Method 003

A--5
TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
REQUIREMENTS
AVUM AVIM DEPOT
4.42 Tail Landing Gear Wheel Cracks n 003 Backup
Assembly Alternate Meth-- 001
od
4.43 Cargo Hook Trunnions, Cracks n 002
Trunnion Retaining Bolts
and Nuts and Load Beam
4.44 Cargo Hook Plate Edge Cracks n 003 Backup
and Bolt Hole Surface 001
4.45 Cargo Hook Trunnion Re-- Cracks n 001
tainers
4.46 Ferrous Bolts and Pins Cracks n 002
Contained Within the Air--
frame and Landing Gear
System
4.47 Nonferrous Bolts and Pins Cracks n 001
Contained Within the Air--
frame and Landing Gear
System
5.2 Deswirl Duct Vanes and Cracks n 001
Loop Clamp
5.3 Engine Tubing, Couplings, Cracks n 001
Air Ducts, Fittings, Sup--
ports, Brackets, and Clips
5.4 Air Inlet Assembly and Cracks n 003 Backup
Bleed--Air Exhaust Slots 001
5.5 Aft Engine Mount Struts Cracks n 002 Backup
001
5.6 Aft Engine Mount Fittings Cracks n 002 Backup
001
5.7 Aft Engine Mount Links Cracks n 001

5.8 Aft Engine Mount Support Cracks n 003 Backup

001
5.9 Crotch Assembly and Seg-- Cracks n 003 Backup
ment Ring 001
5.10 Forward Support Tube Cracks n 001

5.11 Exhaust Ejector and At-- Cracks n 001

taching Angles
5.12 Exhaust Fairings Cracks n 001

A--6
 TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
REQUIREMENTS
AVUM AVIM DEPOT
5.13 HIRSS and Nacelle Fairing Cracks n 001
Support Mounts
5.14 Suppressor Core and Cracks n 001
Baffle
5.15 HIRSS Exhaust Extender Cracks n 001

5.16 Rotary Input Assembly Cracks n 001

5.17 Engine Load Demand Cracks n 001

Control Cable Support
5.18 Engine Air Inlet “V” Band Cracks n 001
Clamp
5.19 Starter Flange Cracks n 003 Backup
001
5.20 Engine Shroud Cracks n 001

5.21 Engine Load Demand Cracks n 003 Backup

Spindle Bellcrank Support 001
5.22 Engine Components Cracks n 001

6.2 Main Module Attaching Cracks n 001

Point for Gust Lock and
Output Housing
6.3 Toe Pedal Actuator Cracks n 001

6.4 Toe Pedal Assembly Cracks n 003 Backup

001
6.5 Yaw Pedal Support Shaft Cracks n 002 Backup
001
6.6 Yaw Pedal Supports Cracks n 002 Backup
001
6.7 Yaw Pedal Brake Cylinder Cracks n 003
Supports
6.8 Pedal Adjuster Arms and Cracks n 003 Backup
Link 001
6.9 Pilot/Copilot Cyclic and Cracks n 003 Backup
Collective Stick Socket 001

A--7
TM 1--1520--265--23

NOMENCLATURE OF END ITEMS

HELICOPTER, H--60 Series
(1) (2) (3) (4) (5) (6)
PROCEDURE INSPECT MAINTENANCE INSPECTION REMARKS
NUMBER COMPONENT/ASSEMBLY FOR CATEGORY EQUIPMENT
REQUIREMENTS
AVUM AVIM DEPOT
6.10 Collective Boost an d Cracks n 002
Yaw Boost Servo Input/
Output Piston Shafts and
Cylinders
6.11 Yaw/Pitch Coupling Link Cracks n 003 Backup
001
6.12 Ferrous Flight Control Cracks n 002 Backup
System Push--Pull Rods 001
6.13 Nonferrous Flight Control Cracks n 003 Backup
System Push--Pull Rods 001
6.14 Pilot Collective Stick Cracks n 003 Backup
Bellcrank Support 001
6.15 Pilot/Copilot Collective Cracks n 003 Backup
Stick Support 001
6.16 Pilot Collective Stick Cracks n 003 Backup
Bellcrank 001
6.17 Ferrous Connecting Links, Cracks n 002
Rod Ends, Clevises, Lev--
ers, and Attaching Parts
6.18 Nonferrous Connecting Cracks n 003
Links, Rod Ends, Clevises,
Levers, and Attaching
Parts
6.19 Swashplate Links Cracks n 002 Backup
001
6.20 Walking Beam Cracks n 002 Backup
001
6.21 Forward Bellcrank Cracks n 002 Backup
001
6.22 Lateral/Bellcrank Cracks n 002 Backup
001
6.23 Aft Bellcrank Cracks n 002 Backup
001
6.24 Hydraulic/Pneumatic Cracks n 001
System Components
6.25 Ferrous Bolts Contained Cracks n 002
Within the Flight Control
System
6.26 Nonferrous Bolts Cracks n 001
Contained Within the Flight
Control system

A--8
 TM 1--1520--265--23

APPENDIX B
ILLUSTRATED FIELD MANUFACTURE ITEMS LIST

Introduction

A. This appendix contains complete instructions for manufacturing nondestructive inspection

support accessories in the field.

B. An index order is provided for cross-referencing the number of the item to be manufac-
tured to the figure number which covers fabrication criteria.

C. All bulk materials needed for manufacture of an item are listed by part number or specifi-
cation number.

D. See Figure C-1.

Item Support Accessories
Number
WS-2 Test block with aluminum honeycomb (0.75 or 1.0 inch) between 0.020
fiberglass skin and a 0.063 aluminum skin
WS-4 Test block with aluminum honeycomb (0.75 or 1.0 inch) between a 0.040
aluminum skin and a 0.020 skin

NOTES
1. All dimensions (+/-) 1/16 inch. Break all sharp edges and corners.
2. Scuff sand the adhesive side of the fiberglass panel.
3. Scotchbrite scuff and alcohol/acetone rinse the adhesive side of the aluminum panels.
4. Milling or grinding of core cutouts is preferable ove crushing techniques. A rotary file or
end mill cutter should produce acceptable results.
5. Polyolefin disks (inserts) should be flush with core if not slightly recessed.
6. Mix adhesives per manufacturer’s insructions; exercise caution applying around inserts.
7. Moderate weight should be applied to the panels throughout the cure cycle.

BULK MATERIALS
1. 2024-T3 aluminum panels (0.020, 0.040 and 0.063 inch thick) specification QQ-4-250/5
2. Fiberglass panel 0.020 inch thick, specification MIL-I-24768/27
3. Aluminum honeycomb core 0.75 or 1.0 inch thick, 1/8 cell size specification MIL-C-7438-G
4. Polyolefin disks 0.025-0.030 inch thick (High-Density Polyethylene or Polypropylene)
5. Adhesive EA934 or equivalent

B--1
TM 1--1520--265--23

Figure A--1. Composite Test Blocks

B--2
 TM 1-1520-265-23

By Order of the Secretary of the Army

GEORGE W. CASEY, JR.

General, United States Army
Official: Chief of Staff

JOYCE E. MORROW
Administrative Assistant to the
Secretary of the Army
0811307

DISTRIBUTION:

To be distributed in accordance with the initial distribution number (IDN) 313682, requirements
for TM 1-1520-265-23.
 These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” [email protected]
To: [email protected]
Subject: DA Form 2028
1 From: Joe Smith
2 Unit: home
3 Address: 4300 Park
4 City: Hometown
5 St: MO
6 Zip: 77777
7 Date Sent: 19--OCT--93
8 Pub no: 55--2840--229--23
9 Pub Title: TM
10 Publication Date: 04--JUL--85
11 Change Number: 7
12 Submitter Rank: MSG
13 Submitter FName: Joe
14 Submitter MName: T
15 Submitter LName: Smith
16 Submitter Phone: 123--123--1234
17 Problem: 1
18 Page: 2
19 Paragraph: 3
20 Line: 4
21 NSN: 5
22 Reference: 6
23 Figure: 7
24 Table: 8
25 Item: 9
26 Total: 123

27 Text:
This is the text for the problem below line 27.
 Use Part II (reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND
BLANK FORMS
Catalogs/ Supply Manuals (SC/SM) 8/30/02
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 - ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And
TM 9-1005-433-24 16 Sep 2002 General Support Maintenance Manual for
Machine Gun, .50 Caliber M3P and M3P
Machine Gun Electrical Test Set Used On
Avenger Air Defense Weapon System
ITEM PAGE PARA- LINE FIGURE TABLE
NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

L E
P
A M
E X
* Reference to line numbers within the paragraph or subparagraph.
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTENSION

MSG, Jane Q. Doe, SFC 788-1234

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe 8/30/02
ATTN: AMSAM-MMC-MA-NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565

PART II - REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

L E
P
M
PART III - REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

A
E X
TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE
PLUS EXTENSION
MSG, Jane Q. Doe, SFC 788-1234
USAPA V3.01
 Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMC-MA-NP Redstone Arsenal, AL 35898

PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE

NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP Redstone Arsenal, AL
35898

PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMC-MA-NP Redstone Arsenal, AL 35898

PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE

NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP Redstone Arsenal, AL
35898

PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 Use PartII(reverse) for Repair Parts and DATE
Special Tool Lists (RPSTL) and Supply
RECOMMENDED CHANGES TO PUBLICATIONS AND Catalogs/ Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command ATTN:
AMSAM-MMC-MA-NP Redstone Arsenal, AL 35898

PART 1 --ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA- LINE FIGURE TABLE

NO. NO. GRAPH NO. * NO. NO. RECOMMENDED CHANGES AND REASON

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS
EXTENSION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP Redstone Arsenal, AL
35898

PART II --REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
ITEMS RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO.
SUPPORTED

PART III --REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and blank forms.
Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 The Metric System and Equivalents
Linear Measure Liquid Measure
1 centimeter = 10 millimeters = .39 inch 1 centileter = 1 milliliters = .34 fl. ounce
1 decimeter = 10 centimeters = 3.94 inches 1 deciliter = 10 centiliters = 3.38 ounces
1 meter = 10 decimeters = 39.37 inches 1 liter = 10 deciliters = 33.81 fl. ounces
1 dekameter = 10 meters = 32.8 feet 1 dekaliter = 10 liters = 2.64 gallons
1 hectometer = 10 deka meters = 328.08 feet 1 hectoliter = 10 dekaliters = 26.42 gallons
1 kilometer = 10 hectometers = 3,280.8 feet 1 kiloliter = 10 hectoliters = 264.18 gallons
Weights Square Measure
1 centigram = 10 milligrams = 1.5 grain 1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 decigram = 10 centigrams = 1.54 grains 1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 gram = 10 decigrams = .035 ounce 1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 dekagram = 10 grams = .35 ounce 1 sq. dekameter (are) = 100 sq. meters = 1,076.4 feet
1 hectogram = 10 dekagrams = 3.52 ounces 1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 kilogram = 10 hectograms = 2.2 pounds 1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons

Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 100 cu. decimeters = 35.31 feet

Approximate Conversion Factors

To Change To Multiply By To Change To Multiply By

inches centimeters 2.540 ounce--inches newton--meters .007062
feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces mililiters 29.573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound--feet newton--meters 1.356 metric tons short tons 1.102
pound--inches newton--meters .11296

Temperature (Exact)

˚F Fahrenheit 5/9 (after Celsius ˚C

temperature subtracting 32) temperature
PIN: 075218-000