TM 55-1520-234-23-2

VOLUME II

TECHNICAL MANUAL

AVUM AND AVIM MAINTENANCE MANUAL

AH-1S (MOD)

This copy is a reprint which includes current

pages from Changes 1 through 24.

HEADQUARTERS, DEPARTMENT OF THE ARMY

30 SEPTEMBER 1976
 TM 55-1520-234-23

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY
No. 55-1520-234-23 WASHINGTON, D C, 30 September 1976

AVIATION UNIT AND INTERMEDIATE

MAINTENANCE MANUAI.

HELICOPTER, ATTACK AH-IS (MOD)

NOTE:

This manual is printed in two volumes, as follows:

TM 55-1520-234-23-1, consisting of Table of Contents, preface, chapters 1 through 9.
TM 55-1520-234-23-2, consisting of Table of Contents, chapters 10 through 17, appendices A through F, and Index.
The Preface, Appendices and Index are applicable to Volumes I and II.

REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistake or if you know of a way to
improve the procedures, please let us know. Mail your letter, DA Form 2028
(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2 located
in the back of this manual direct to: Commander, US Army Troop Support and Aviation
Materiel Readiness Command, ATTN: DRSTS-MTPS, 4300 Goodfellow Blvd., St. Louis,
MO 63120. A reply will be furnished directly to you.

TABLE OF CONTENTS
Paragraph Page

CHAPTER 10 FUEL SYSTEM

Section I Fuel system ..................................................................................... 10-1 10-1
II Fuel cells ......................................................................................... 10-11 10-7

CHAPTER 11 FLIGHT CONTROLS ....................................................................... 11-1

CHAPTER 12 UTILITY SYSTEMS ......................................................................... 12-1

CHAPTER 13 ENVIRONMENTAL CONTROL SYSTEMS ...................................... 13-1

CHAPTER 14 HOISTS AND WINCHES (NOT APPLICABLE)................................. 14-1/14-2

CHAPTER 15 AUXILIARY POWER PLANT (NOT APPLICABLE) .......................... 15-1/15-2

CHAPTER 16 MISSION EQUIPMENT ................................................................... 16-1

CHAPTER 17 EMERGENCY EQUIPMENT............................................................. 17-1

APPENDIX A REFERENCES ................................................................................. A-1

Change 2 i
 TM 55-1520-234-23

Page

APPENDIX B MAINTENANCE ALLOCATION CHART .......................................... B-1

APPENDIX C AIRCRAFT INVENTORY GUIDE ...................................................... C-1

APPENDIX D ILLUSTRATED FIELD MANUFACTURE LIST .................................. D-1

APPENDIX E STORAGE OF AIRCRAFT

Section I General information ......................................................................... E-1
II Flyable storage ................................................................................ E-2
III Short term storage ........................................................................... E-2
IV Intermediate storage ......................................................................... E-10

APPENDIX F WIRING DIAGRAMS ....................................................................... F-1

INDEX ......................................................................................................... Index-1

ii Change 2
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LIST OF ILLUSTRATIONS

Figure Title Page

P-1 AH-1S Helicopter ............................................................................................................ P-3

1-1 Servicing Points Diagram ................................................................................................ 1-2B
1-1A Closed Circuit Refueling System ..................................................................................... 1-2C
1-2 Lubrication Chart ............................................................................................................. 1-29
1-3 Ground Handling Diagram ............................................................................................... 1-33
1-4 Work Aid For Towing Ground Handling Gear .................................................................. 1-34
1-5 Jacking and Mooring Fittings ........................................................................................... 1-36
1-6 Covers Diagram .............................................................................................................. 1-39
1-7 Mooring Diagram ............................................................................................................ 1-40
1-8 Maintenance Hoist T101520 ............................................................................................ 1-42
1-9 Inspection Area Diagram ................................................................................................. 1-44
2-1 Fuselage, Wings, Pylon Mount and Tailboom .................................................................. 2-2
2-2 Structural Panels ............................................................................................................. 2-3
2-3 Non-structural Panels, Doors and Fairings ....................................................................... 2-4
2-4 Primary Structure Caps ................................................................................................... 2-9
2-5 Pilot and Gunner Floor Panels ........................................................................................ 2-11
2-6 Bulkhead at Station 93.0 ................................................................................................. 2-12
2-7 Bulkhead at Stations 148.5 and 171.61 ........................................................................... 2-13
2-8 Bulkheads at Station 184.5 and 213.94 ........................................................................... 2-14
2-9 Bulkheads at Stations 250.0 and 268.5 ............................................................................ 2-15
2-10 Right and Left Main Beam Panels at Station 148.5 to 186.25 .......................................... 2-16
2-11 Right and Left Main Beam Panels at Station 213.94 to 250.0 .......................................... 2-17
2-12 Panel at Forward Fuel Cell at Right Side and Gunners Floor ........................................... 2-18
2-13 Left and Right Beam Panels at Station 250.0 To Boom Station 41.32 ............................. 2-19
2-14 Ammo Floor, Support Panel and Forward Fuel Cell Panel at Station 213.94 .................... 2-20
2-15 Forward Fuel Cell Floor and Lower Panel at Station 186.25 to 213.94 ............................. 2-21
2-16 Lower Aft Fuel Cell Panel and Bottom Panel at Station 250.0
To Boom Station 41.32 ................................................................................................... 2-22
2-17 Engine Deck Installation at Station 213.94 to 298.75 ....................................................... 2-23
2-18 Forward Fuel Cell Panels and Main Beam Panels at Station 186.25 to 214.0 ................... 2-24
2-19 Vertical Fin Honeycomb Panels ...................................................................................... 2-25
2-20 Type A Damage - Body Panel Repairs ............................................................................ 2-26
2-21 Type B Damage - Body Panel Repairs ............................................................................ 2-27
2-22 Type C Damage - Body Panel Repairs ............................................................................ 2-28
2-23 Type D Damage - Body Panel Repairs ............................................................................ 2-30
2-24 Edge Repair For Honeycomb Panel With Fiberglas Skin Opposite Titanium .................... 2-32
2-25 Edge Repair For Honeycomb Panel With Aluminum Alloy Skin
Opposite Aluminum Alloy With Fiberglas Edging ............................................................. 2-33
2-26 Edge Repair For Honeycomb Panel With Aluminum Alloy Skin
Opposite Aluminum Alloy With Fiberglas Finish at Channel ............................................ 2-34
2-27 Typical Rivet Pattern For Channel Section Repair ........................................................... 2-35
2-28 Edge Repair on Vertical Fin ............................................................................................ 2-36
2-29 Injection Type Fastener (Insert) in Vertical Fin Panel ...................................................... 2-38
2-30 Potted Type, Injection Type, and Grommet Type Fastener (Inserts) ................................ 2-40
2-31 Fairing and Cowling For Pylon, Transmission, Engine and Tail Pipe ............................... 2-43
2-32 Fiberglas Honeycomb Fairing Repair .............................................................................. 2-47
2-33 Ammo Floor Scuff Doubler Installation ............................................................................ 2-48
2-34 Station Diagram .............................................................................................................. 2-50

Change 17 iii
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

2-35 Diagonal Brace Tube Installation ..................................................................................... 2-57

2-36 Canopy Frames and Center Window ............................................................................... 2-59
2-37 Aft Bulkhead Rivet Removal (Typical Two Places) .......................................................... 2-60
2-38 Alignment - Upper Right and Left Canopy Frames .......................................................... 2-61
2-39 Upper Center Window ..................................................................................................... 2-63
2-40 Center Window Rivnut Hole Dimensions ......................................................................... 2-64
2-41 Canopy Frame and Cross Member Installation ................................................................ 2-65
2-42 Stress Loads - Canopy Windows ..................................................................................... 2-70
2-43 Insert Repair to Edge of Windows ................................................................................... 2-72
2-43A Deleted ...........................................................................................................................
2-44 Pilots Door ...................................................................................................................... 2-76
2-45 Gunners Door .................................................................................................................. 2-78
2-46 Strut Installation - Pilots and Gunners Doors ................................................................... 2-79
2-47 Door Handles - Pilots and Gunners Doors ....................................................................... 2-82
2-48 Door Strut Assembly P/N 209-030-640-1, -3 and -5 ......................................................... 2-85
2-48A Vent and l)rain Locations ................................................................................................. 2-88A
2-49 Pilots Seat Installation ..................................................................................................... 2-91
2-50 Pilots Seat Assembly ....................................................................................................... 2-92
2-51 Gunners Seat Installation ................................................................................................ 2-94
2-51A Deleted ...........................................................................................................................
2-51B Deleted ...........................................................................................................................
2-52 Armor Panels .................................................................................................................. 2-97
2-53 Engine Mount Installation ................................................................................................ 2-101
2-54 Deleted ........................................................................................................................... 2-102
2-55 Airframe External Components ....................................................................................... 2-106
2-56 Work Aid - Tailboom Support Stand ................................................................................ 2-107
2-57 Tailboom Installation ....................................................................................................... 2-108
2-58 Tailboom and Elevator Skins ........................................................................................... 2-110F
2-59 Tailboom and Synchronized Elevator Structure ............................................................... 2-113
2-60 Bulkhead at Boom Station 59.50 ..................................................................................... 2-114
2-61 Bulkhead at Boom Station 80.44 ..................................................................................... 2-116
2-62 Bulkhead at Boom Station 101.38 ................................................................................... 2-119
2-63 Bulkhead at Boom Station 122.33 .................................................................................... 2-122
2-64 Bulkhead at Boom Station 143.28 ................................................................................... 2-124
2-65 Bulkhead at Boom Station 164.23 ................................................................................... 2-125
2-66 Bulkhead at Boom Station 185.18 (Part No. 209-961-189-7) ........................................... 2-126
2-66A Longeron Damage Limits ................................................................................................ 2-126A
2-66B Typical Tailboom Damage Limits .................................................................................... 2-126D
2-67 Damage Limits - Tail Rotor Drive Support Fittings ........................................................... 2-127
2-68 Elevator Installation ......................................................................................................... 2-132A
2-68A Vertical Fin Honeycomb Panels Damage Limits .............................................................. 2-134A
2-69 Pylon Support Installation ................................................................................................ 2-136
2-70 Hydraulic Fitting Supports P/N 209-030-267-11 and 209-030-267-29
Installation ....................................................................................................................... 2-137
2-71 Pylon Fitting Supporting Structure - Repair of Elongated Holes ....................................... 2-140A
2-72 Damage Limits - Flight Control Power Cylinder Support .................................................. 2-141
2-73 Damage Limits - Fifth Mount Support Fitting Assembly ................................................... 2-142 A
2-74 Wing Installation ............................................................................................................. 2-144
2-75 Limits Chart - Bushings ................................................................................................... 2-145
2-76 Wings, Skins, Doors and Doublers .................................................................................. 2-146

iv Change 17
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

2-77 Wing Structure ....................................................................................................... 2-147

2-78 Wing Skin Repair ................................................................................................... 2-148
2-79 Deleted ............................................................................................................................
3-1 Alighting Gear and Support Installation ...................................................................... 3-2
3-2 Checking Deflection of Cross Tubes .........................................................................3-2D
3-3 Damage Limits-Crosstubes ........................................................................................ 3-3
3-4 Skid Tube Repairs ...................................................................................................... 3-6
3-5 Ground Handling Wheels ........................................................................................... 3-8
3-6 Ground Handling Gear Pump Assembly ................................................................... 3-11
3-6A Ground Handling Gear Pump P/N HP-9902-41-10 .................................................. 3-14A
3-6B Packing Nut Tool .................................................................................................... 3-14B
3-7 Ground Handling Wheels Adjustment Dimensions .................................................... 3-15
4-1 Power Plant Installation .............................................................................................. 4-2
4-2 Deleted ...........................................................................................................................
4-3 Engine Vibration Test Equipment Cabling Tiedown .................................................... 4-4
4-3A Engine Assembly - Removal/Installation .................................................................. 4-4A
4-4 Particle Separator ...................................................................................................... 4-7
4-5 Particle Separator - Exploded View ............................................................................ 4-8
4-6 Airflow Diagram ....................................................................................................... 4-10
4-7 Doubler for Inlet Vane Reinforcement ...................................................................... 4-14
4-8 Removal/Installation Foreign Object Damage Screen .............................................. 4-17
4-9 Procedural Steps Installing Foreign Object Damage Screen (Bottom Half)................ 4-18
4-10 Air Induction Area (Cowling Omitted) ....................................................................... 4-21
4-11 Exhaust System Components .................................................................................. 4-22
4-12 Engine Tailpipe Repair ............................................................................................. 4-24
4-13 Engine Deck and Firewall Sealing ............................................................................ 4-25
4-14 Exhaust Infrared Suppression System ...................................................................... 4-27
4-15 Repair Procedures - Infrared Suppression ................................................................ 4-31
4-16 Engine Oil Supply and Cooling System with Bleed Air Driven Fan ........................... 4-35
4-17 Oil Cooler Cleaning Equipment Setup - Typical ........................................................ 4-36
4-18 Oil Cooling Turbine Fan (Janitrol) ............................................................................. 4-39
4-19 (Deleted)
4-20 Power Lever Control System .................................................................................... 4-46
4-21 Flight Idle Stop Installation ..................................................................................... 4-48A
4-22 Power Turbine Governor RPM Controls ................................................................... 4-50
4-23 Rigging Diagram - Governor RPM Controls .............................................................. 4-52
4-24 Electrical Cable Installation - Engine Left side .......................................................... 4-55
4-25 Electrical Cable Installation - Engine Right Side ....................................................... 4-57
5-1 Main Rotor Installation ............................................................................................... 5-3
5-2 Main Rotor Tracking Chart ......................................................................................... 5-6
5-3 Vertical Vibration Correction Chart ............................................................................. 5-7
5-4 Lateral Vibration Correction Chart .............................................................................. 5-9
5-5 Tracking Main Rotor ................................................................................................. 5-10
5-6 Pitch Link Adjustment ............................................................................................... 5-10
5-6A Vertical and Lateral Vibration Chart for K747 Rotor Blades .................................... 5-10B
5-7 Tool Application Grip Lock Installation on Pitch Horn ............................................... 5-12
5-8 Tool Application - Main Rotor Mast Nut Removal/Installation ................................... 5-13
5-9 Corrosion and Damage Limits - Split Cones ............................................................. 5-14
5-10 Pitch Link Assembly .................................................................................................. 5-15
5-11 Main Rotor Hub and Blade Assembly ..................................................................... 5-16A
5-12 Work Aid For Main Rotor Blade Bolt Removal - Fabrication Instructions ................... 5-17
5-13 Work Aid Application - Removal of Main Rotor Blade Retaining Bolt ........................ 5-18
5-14 Main Rotor Blade ..................................................................................................... 5-19
5-15 Main Rotor Blade Authorized Patch Area ................................................................. 5-22
Change 17 v
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

5-16 Main Rotor Blade Trim Tab Installation ........................................................................... 5-26

5-17 Tool Application - Alignment of Main Rotor Hub and Blades............................................. 5-29
5-17A K747 Main Rotor Blade ................................................................................................... 5-30C
5-17B External Appearance Changes to K747-003-205 Blades Resulting from Improved ...........
Weight Retention Features .............................................................................................. 5-30E
5-17C Internal Modification Incorporated in K747-003-205, -209, and -303 Blades for ................
Improved Weight Retention ............................................................................................. 5-30F
5-17D Damage Limits-Root Fittings (K747 Blade) ...................................................................... 5-30Q
5-17E Damage Limits-Drag Strut (K747 Blade) ......................................................................... 5-30R
5-17F Inspection of K747-003-205, -209, and -303 Blade for Loss of Blade Weight....................
Retention Integrity ........................................................................................................... 5-30S
5-17G Proximity Limits for Patches-K747 Main Rotor Blades ..................................................... 5-30U
5-17H Balance Adjustment for Patches (K747 Blades) ............................................................... 5-30X
5-17J Root Fitting Assembly ..................................................................................................... 5-302
5-17K Application of Skin Patch (K747 Blade) ........................................................................... 5-30AB
5-17L Curing Patch with Blade Repair Fixture (K747 Blade) ...................................................... 5-30AE
5-17M Installation of Plug Patch (K747 Blade) ........................................................................... 5-30AH
5-17N Typical Double Plug Patch Repair (K747 Blade) .............................................................. 5-30AM
5-17P Application of Trailing Edge Doubler Patch (K747 Blade) ................................................ 5-30AR
5-17Q Spline Repair (K747 Blade) ............................................................................................. 5-30AV
5-17R Rebonding Delaminated Leading Edge Erosion Guard (K747 Blade) ............................... 5-30AW
5-17S Typical Repair of Fluorocarbon Erosion Guard Nicks and Cuts using Kit, P/N ..................
K747-207 ........................................................................................................................ 5-30AZ
5-17T Application of Leading Edge Erosion Guard Patch (K747 Blade) ..................................... 5-30BA
5-17U Placement of Erosion Guard Replacement Part (Kit K747-206) And Method for...............
Determining Current Boot Material and Thickness (K747 Blade Series) ........................... 5-30BC
5-17V K747 Blade Uralite Repair ............................................................................................... 5-30BF
5-17W Application of Vacuum Bagging Materials and Placement of Erosion Guard..................... 5-30BH
5-17X Repair Parts and Specimen Orientation (Kit, P/N K747-206) ........................................... 5-30BM
5-17Y Vacuum Bagging for Installation of Erosion Guard Repair Kit, P/N K747-206 .................. 5-30BP
5-17Z Improvised Mold for Casting a Small Section of Leading Edge Filler ............................... 5-30BS
5-17AA Repair Parts Orientation Use for Removal and Installation of Stainless Steel ...................
Erosion Guard - K747-003-303 and -303 Field Modified Blades ....................................... 5-30BU
5-17AB Preparation of K747-003-303 Blade for Application of Sealant ........................................ 5-30BW
5-17AC Application of Sealant to Stainless Steel Guard for K747-003-303 Blade ......................... 5-30BY
5-17-AD Stainless Steel Erosion Guard Holding Fixture ................................................................ 5-30BZ
5-17AE Masking for Paint Touch-up After Installation of Kit K747-206 ......................................... 5-30CD
5-18 Main Rotor Hub Yoke Extension and Grip Assembly ....................................................... 5-32
5-19 Main Rotor Hub Yoke an(d Trunnion for Main Rotor Hub.................................................. 5-35
5-20 Main Rotor Hub Teflon Bearing Wear Pattern .................................................................. 5-36
5-21 Damage Limits - Main Rotor Yoke Extension .................................................................. 5-37
5-22 Damage Limits - Main Rotor Hub Bolt Holes ................................................................... 5-39
5-23 Damage Limits - Main Rotor Hub Yoke ........................................................................... 5-41
5-24 Damage Limits - Main Rotor Hub Grip ............................................................................. 5-42
5-25 Damage Limits - Main Rotor Hub Yoke Extension and Strap Fitting ................................ 5-43
5-26 Damage Limits - Main Rotor Hub Pitch Horn and Inboard Bearing Housing...................... 5-44
5-27 Damage Limits - Main Rotor Drag Brace ......................................................................... 5-45
5-28 Damage Limits - Main Rotor Hub Trunnion ...................................................................... 5-46
5-29 Damage Limits - Main Rotor Hub Elastomeric Bearing .................................................... 5-47
5-30 Main Rotor Hub Yoke Chafing Pad Installation Dimensions ............................................. 5-49
5-31 Tool Application - Bearing Removal From Housing ......................................................... 5-50
5-32 Tool Application - Bearing Removal From Grip ............................................................... 5-51
5-33 Tool Application - Bearing and Seal Installation in Grip ................................................... 5-52
vi Change 17
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

5-34 Main Rotor Hub Trunnion Centering Measurement........................................................... 5-53
5-35 Tool Application - Grip Spacing Adjustment ..................................................................... 5-54
5-36 Main Rotor Hub - Grip Dust Seal To Radius Ring ............................................................. 5-56
5-37 Rotor Balancing Kit P/N 7A050 ........................................................................................ 5-58
5-38 Tool Application - Main Rotor Hub Balancing ................................................................... 5-59
5-39 Interpretation of Balance Indication .................................................................................. 5-60
5-40 Mast Controls Installation ................................................................................................. 5-61
5-41 Tool Application - Drive Plate Spline Wear Measurement ................................................ 5-65
5-42 Collective Lever Thrust Washer Wear Limits ................................................................... 5-66
5-43 Scissors and Sleeve Assembly......................................................................................... 5-68
5-44 Damage Limits - Hub, Sleeve, Scissors and Link ............................................................. 5-70
5-45 Damage Limits - Spline Plate ........................................................................................... 5-75
5-46 Damage Limits - Collective Lever .................................................................................... 5-76
5-47 Damage Limits - Collective Lever Idler Link ..................................................................... 5-77
5-47A Installation of Shims......................................................................................................... 5-78
5-47B Collective Lever Idler Link Assembly................................................................................ 5-78
5-48 Swashplate and Support Assembly .................................................................................. 5-82
5-49 Damage Limits - Swashplate and Support Assembly........................................................ 5-84
5-50 Damage Limits - Swashplate Anti-drive Link, Bellcrank and Support ................................ 5-87
5-51 Deleted ............................................................................................................................
5-52 Damage Limits- Pitch Link Assembly ..............................................................................
5-53 Tracking Tail Rotor........................................................................................................... 5-97
5-54 Tail Rotor Installation ...................................................................................................... 5-98
5-55 Tool Application - Tail Rotor Hub and Blade Assembly Balancing .................................... 5-100
5-56 Tail Rotor Hub and Blade Assembly ................................................................................ 5-104
5-57 Tail Rotor Blade Assembly .............................................................................................. 5-106
5-58 Tail Rotor-Blade Station Diagram and Scratch Type Damage Area Locations .................. 5-106
5-59 Tail Rotor Blade Area Authorized for Patch-Type Repair.................................................. 5-108A
5-60 Tail Rotor Blade Butt Area Repair ................................................................................... 5-109
5-61 Damage Limits - Tail Rotor Blade Pitch Horn .................................................................. 5-110
5-62 Tail Rotor Hub Assembly ................................................................................................. 5-115
5-63 Damage Limits - Tail Rotor Hub Yoke ............................................................................. 5-117
5-64 Damage Limits - Tail Rotor Hub Trunnion Set .................................................................. 5-118
5-65 Bearing Staking Tool P N 101577 ................................................................................... 5-119
5-66 Tool Application - Bearing Installation (Staking) in Tail Rotor Yoke .................................. 5-121
5-67 Tail Rotor Controls - Crosshead, Weights, Links & Control Tube ...................................... 5-123
5-68 Damage Limits - Tail Rotor Control Crosshead ................................................................ 5-126
5-69 Damage Limits - Tail Rotor Control Counterweight Bellcrank .......................................... 5-127
5-70 Damage Limits - Tail Rotor Controls Pitch Link ................................................................ 5-128
5-71 Damage Limits - Tail Rotor Control Counterweight Link ................................................... 5-129
5-72 Damage Limits - Tail Rotor Active Counterweight Support .............................................. 5-130
5-73 Damage Limits - Tail Rotor Control Tube ........................................................................ 5-131
5-74 Damage Limits - Link Assembly ....................................................................................... 5-133
5-75 Damage Limits - Idler ...................................................................................................... 5-134
5-76 Damage Limits - Lever .................................................................................................... 5-135
6-1 Power Train Diagram ....................................................................................................... 6-1
6-2 Metal Particles Contamination of Gearbox Oil.................................................................. 6-7
6-3 Main Driveshaft Installation .............................................................................................. 6-9
6-4 Main Driveshaft Assembly ............................................................................................... 6-10B
6-5 Inspection and Lubrication of Main Driveshaft ................................................................. 6-12
6-6 Coupling Wear Criteria for Driveshaft............................................................................... 6-15
6-6A Limits Chart - Main Driveshaft Assembly.......................................................................... 6-16A
6-7 Positioning Pylon with T101440 Jacks.............................................................................. 6-19
6-8 Checking Driveshaft Alignment ........................................................................................ 6-20
6-8A Main Driveshaft SKCP 2281 ............................................................................................ 6-20C
6-8B Main Driveshaft Installation and Removal Tool ............................................................... 6-20D
6-8C Work Aid Tool Installation on Main Driveshaft ................................................................. 6-20D
6-8D Main Driveshaft Damage Limits ....................................................................................... 6-20E
6-9 Transmission - Left Side................................................................................................... 6-22
6-10 Transmission - Right Side ................................................................................................ 6-23
6-11 Transmission Drive Quill Diagram ................................................................................... 6-24
6-11A Damage Limits - Transmission ........................................................................................ 4B
6-12 Transmission Installation ................................................................................................. 6-25

Change 22 vii
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LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

6-13 Pylon Lift Link and Main Mounts....................................................................................... 6-26
6-14 Transducer Bracket Installation ........................................................................................ 6-27
6-15 Transmission Buildup ....................................................................................................... 6-28
6-16 Transmission Shipping Caps, Covers and Plugs............................................................... 6-32
6-17 Pylon Mounts and Dampers ............................................................................................. 6-38
6-18 Pylon Support Access Hole .............................................................................................. 6-39
6-19 Pylon Fifth Mount Assembly............................................................................................. 6-42
6-20 Pylon Lift Link Attachment ............................................................................................... 6-44A
6-21 Pylon Dampers ................................................................................................................ 6-46
6-22 Pylon Dampers Seal Installation Tool P/N 5120-EG-007 ................................................. 6-47
6-23 Shim Replacement - Damper Barrel Assembly ................................................................ 6-49
6-24 Shim Replacement - Damper Upper Shim........................................................................ 6-50
6-25 Shim Replacement - Damper Lower Shim........................................................................ 6-51
6-26 Main Rotor Mast............................................................................................................... 6-53
6-27 Inspection of Mast Upper Bearing..................................................................................... 6-54
6-28 Main Rotor Mast Damage Limits ...................................................................................... 6-56
6-28A Damage Limits - Main Rotor Mast Assembly .................................................................... 6-56A
6-29 Mast Sleeve Taper and Out of Round .............................................................................. 6-57
6-30 Main Rotor Mast Wear Limits .......................................................................................... 6-58
6-31 Upper Mast Bearing - Shim Adjustment............................................................................ 6-59
6-32 Transmission Top Case - Dimension Check .................................................................... 6-61
6-33 Input Drive Quill Assembly ............................................................................................... 6-64A
6-33.1 Transmission Input Quill Workaid Application................................................................... 6-64B
6-34 Input Drive Quill Installation - Work Aid ........................................................................... 6-65
6-35 Hydraulic Pump and Tachometer Drive Assembly............................................................ 6-68
6-36 Cockpit Air Blower Quill + Seal Replacement................................................................... 6-70A
6-37 Work Aid for Quill Installation........................................................................................... 6-71
6-38 Tail Rotor Drive Quill........................................................................................................ 6-73
6-39 Tail Rotor Driveshaft Installation ...................................................................................... 6-76
6-40 Tail Rotor Driveshaft Inspection Diagram ........................................................................ 6-77
6-40A Tail Rotor Driveshaft Hanger ........................................................................................... 6-80B
6-40B Work Aid for Driveshaft Hanger Support Alignment.......................................................... 6-80C
6-41 Intermediate Gearbox Installation .................................................................................... 6-82
6-42 Damage Limits - Intermediate Gearbox............................................................................ 6-83
6-43 Intermediate Gearbox Quills, Seals, and Couplings (Typical) .......................................... 6-90
6-44 Coupling Teeth Wear Patterns ......................................................................................... 6-90B
6-45 Oil Filter Cap Assembly.................................................................................................... 6-90C
6-46 Deleted ...........................................................................................................................
6-47 Tail Rotor Gearbox Installation-........................................................................................ 6-92
6-47A Damage Limits - Tail Rotor Drive Gearbox ...................................................................... 6-92B
6-48 Tail Rotor Gearbox Assembly........................................................................................... 6-94A
6-49 Roller Bearing Wear Pattern ............................................................................................ 6-95
6-50 Gear Patterns - Ninety Degree Gearbox .......................................................................... 6-96
6-51 Tail Rotor Gearbox Input Quill.......................................................................................... 6-100
6-52 Tool Application - Retainer Bolt Removal & Installation.................................................... 6-101
6-53 Tool Application - Retainer Nut Removal & Installation ................................................... 6-102
6-54 Tail Rotor Gearbox Output Seal Replacement ................................................................. 6-104
6-55 Transmission Oil System Schematic ............................................................................... 6-106
6-56 Transmission Oil System Installation ............................................................................... 6-107
6-57 Oil Filter, Transmission Sump .......................................................................................... 6-108A
6-57A Transmission Oil Pressure Relief Valve ........................................................................... 6-110A
6-58 Oil Cooler Bypass Valve Assembly ................................................................................. 6-11A
6-59 Damage Limits - Inlet Fitting ........................................................................................... 6-117
6-60 Damage Limits - Return Bypass Fitting ........................................................................... 6-118
6-61 Damage Limits - Inlet Bypass Piston ............................................................................... 6-119
6-62 Damage Limits - Piston ................................................................................................... 6-119
6-63 Damage Limits - Nozzles ................................................................................................. 6-120
6-64 Damage Limits - Sleeve................................................................................................... 6-120
6-65 Damage Limits - Universal Fitting Bolt ............................................................................ 6-121
6-66 Damage Limits - Housing Assembly ................................................................................ 6-122
6-67 Damage Limits - Plunger.................................................................................................. 6-124
6-68 Damage Limits - Elbow Fitting ......................................................................................... 6-125
6-69 Repair - Fittings ............................................................................................................... 6-126
6-70 Repair - Nozzles .............................................................................................................. 6-127
viii Change 22
 TM 55-1520-234-23-2

LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

6-71 Repair - Plunger............................................................................................................... 6-128
6-72 Work Aid Application - Plunger and Piston ...................................................................... 6-128
6-73 Bench Test - Oil Cooler Bypass Valve ............................................................................. 6-129
6-74 Transmission Oil Pump ................................................................................................... 6-132
6-75 Test Setup - Transmission Oil Pump ............................................................................... 6-133
7-1 Hydraulic Schematic ....................................................................................................... 7-2
7-1A Hydraulic System No. 1 ................................................................................................... 7-4
7-2 Hydraulic System No. 2 ................................................................................................... 7-4A
7-3 Dual Hydraulic Servo Cylinders Installation ..................................................................... 7-15
7-4 Hydraulic Reservoirs and Modules (Prior to Serial No. 69-16447) .................................... 7-19
7-5 Hydraulic Reservoirs and Modules (Serial No. 70-15936 & Sub.) .................................... 7-20
7-6 Replacing Hydraulic Module Filters ................................................................................. 7-22
7-7 Cleanable and Non-cleanable Filter Elements ................................................................. 7-23
7-8 Deleted ............................................................................................................................
7-8A Hydraulic Reservoir Assembly ......................................................................................... 7-26B
7-9 Emergency Hydraulic Accumulator Charging Diagram .................................................... 7-28
7-10 Hydraulic Accumul or Assembly (Parker-Hannifin) .......................................................... 7-29
7-11 Hydraulic Accumulator Assembly (Sprague) .................................................................... 7-30
7-11A Lockout Valve and Accumulator ...................................................................................... 7-34
7-12 Dual Hydraulic Cylinder Assembly (Typical) .................................................................... 7-35
7-13 Damage Limits for Hydraulic Cylinder Bearing Housing ................................................... 7-36A
7-13A Servo-Cylinder Removal Work Aid .................................................................................. 7-38A
7-14 Hydraulic Servo Cylinder.................................................................................................. 7-39
7-15 Flight Control Hydraulic Servo Cylinder ........................................................................... 7-42
7-16 Dual Hydraulic Cylinder Valve Connections ..................................................................... 7-44
7-17 Connection of Hydraulic Cylinders to Swashplate ............................................................ 7-47
7-18 SCAS Servo Actuator Assembly ..................................................................................... 7-48
7-19 Tail Rotor Control Cylinder and Support Assembly - Removal and Installation ................ 7-50
7-19A Tail Rotor Control Cylinder and Support Assembly - Disassembled ................................. 7-50A
7-20 Armament Pylon Actuator ............................................................................................... 7-56
7-21 Work Aid for Armament Pylon Actuator Disassembly/Assembly ...................................... 7-57
7-22 Work Aid for Seal Installation on Armament Pylon Actuator ............................................ 7-58
7-23 Schematic Diagram of Connections To Armament Pylon Actuator for Bench Test ........... 7-59
7-24 Armament Pylon Actuator Installed in Test Fixture .......................................................... 7-60
8-1 Instrument System Equipment Location .......................................................................... 8-2
8-1A Deleted ...........................................................................................................................
8-2 Pitot Static System .......................................................................................................... 8-21
8-2A Connection for Pitot Leak Check (Typical) ....................................................................... 8-26C
8-2B Connection for Static Leak Check (Typical) ..................................................................... 8-26D
8-3 Test Circuit Setup for Fuel Tank Unit Capacitance and Resistance Checks ..................... 8-31
8-4 Test Circuit Setup for Fuel Quantity Indicator Bench Test ............................................... 8-32
8-5 Circuit Arrangement and Adapter Cable for Fuel Quantity Adjustment Procedures on In-
stalled System ................................................................................................................. 8-33
8-6 Volt-Ammeter Test Setup ................................................................................................ 8-38

9-1 Simplified Electrical Bus Wiring Schematic ..................................................................... 9-2

9-2 Equipment Locations ....................................................................................................... 9-3
9-3 Gunners Section - Equipment Location ........................................................................... 9-5
9-4 Pilots Section - Equipment Location ................................................................................ 9-6
9-5 Standby Inverter Adjustment ........................................................................................... 9-29

Change 17 ix
 TM 55-1520-234-23-2

LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

9-5A Pilots Night Vision Lighting Circuitry................................................................................. 9-36B
9-5B Gunners Night Vision Lighting Circuitry ........................................................................... 9-36C
9-6 Caution Panel Assembly ................................................................................................. 9-39
9-7 RPM Limit Warning Detector Nameplate (Saturn) ........................................................... 9-45
9-8 RPM Limit Warning Detector Nameplate (Bell) ............................................................... 9-46
9-9 Alignment of RPM Limit Detector (Saturn or Symbolic) ................................................... 9-47
9-10 Alignment of RPM Limit Detector (Bell)............................................................................ 9-48
9-11 Bench Test Setup for Saturn and Symblic Display Designed Detectors ........................... 9-52
9-12 Bench Test Setup for BHC Designed Detectors ............................................................... 9-55
9-13 Armament Equipment Location ....................................................................................... 9-74
9-14 Wing Stores Armament Test Panel ................................................................................. 9-82
9-15 Wing Stores Armament Test Panel Wiring Diagram ........................................................ 9-83
9-16 TOW Missile launcher Positions ...................................................................................... 9-98

x Change 17
 TM 55-1520-234-23-2

LIST OF ILLUSTRATIONS (Cont)

Figure Title Page

10-1 Fuel System..................................................................................................................... 10-2A
10-1A Fuel Boost Pump Cartridge ............................................................................................. 10-6B
10-1B Work Aid for Fuel Pump Cartridge Removal ................................................................... 10-6C
10-2 Collapsing Forward Fuel Cell .......................................................................................... 10-10
10-3 Installed Forward Fuel Cell .............................................................................................. 10-11
10-4 Collapsing Aft Fuel Cell ................................................................................................... 10-13
11-4 Collective Controls .......................................................................................................... 11-4
11-1A Anti-torque System Wear and Damage Limits ................................................................. 11-6D
11-1B Elevator Control System Wear and Damage Limits ......................................................... 11-6L
11-1C Collective Control System Wear and Damage Limits ...................................................... 11-6N
11-1D Cyclic Control System Wear and Damage Limits ............................................................ 11-6U
11-1E Flight Control System Bearings ....................................................................................... 11-6Z
11-1F Power Cylinder Support - Lateral Cyclic and Collective Controls ..................................... 11-7
11-1G Power Cylinder Support - Fore and Aft Cyclic Controls .................................................... 11-8
11-2 Pilot Collective Pitch Stick .............................................................................................. 11-8B
11-3 Pilot Collective Stick Mounting Details ............................................................................ 11-10
11-4 Gunner Collective Pitch Stick .......................................................................................... 11-12
11-4A Gunner Collective Pitch Stick - Wear .............................................................................. 11-12A
11-5 Fore and Aft Cyclic Controls ............................................................................................ 11-14
11-6 Lateral Cyclic Controls .................................................................................................... 11-15
11-7 Work Aid for Rigging Swashplate .................................................................................... 11-16B
11-8 Swashplate Rigging Swashplate Dimensions ................................................................... 11-17
11-9 Pilot Cyclic Stick ............................................................................................................. 11-19
11-10 Pilot Cyclic Stick Friction Adjustment ............................................................................... 11-22A
11-11 Gunner Cyclic Stick.......................................................................................................... 11-24
11-11A Fore and Aft Cyclic Jackshaft .......................................................................................... 11-26A
11-11B Fore and Aft Cyclic Jackshaft Wear and Damage Limits ................................................. 11-26B
11-12 Tail Rotor Controls .......................................................................................................... 11-27
11-13 Tail Rotor Pedal Installation ............................................................................................ 11-31
11-14 Elevator Controls ............................................................................................................ 11-36
11-14A Stability and Control Augmentation System (SCAS) ........................................................ 11-38B
11-14B Fore and Aft Cyclic Controls ............................................................................................ 11-38C
11-14C Lateral Cyclic Controls .................................................................................................... 11-38E
11-14D Tail Rotor Controls .......................................................................................................... 11-38G
11-15 SCAS Transducer Calibration .......................................................................................... 11-40
12-1 Fire Detector System ...................................................................................................... 12-2
12-2 Rain Removal Nozzle Assembly ..................................................................................... 12-5
12-3 Rain Removal Nozzle and Cleared Area Pattern . ............................................................ 12-6
13-1 Environmental Control System ........................................................................................ 13-2
13-2 Environmental Control Unit ............................................................................................. 13-4
13-3 Environmental System Schematic ................................................................................... 13-5
13-4 Blower Impeller Assembly P N 209-072-436-1.................................................................. 13-9
13-4A Blower Impeller Installation Typical for Impeller P/N 209-070-585-1 and P/N
197803-1 ......................................................................................................................... 13-10B
13-5 Air Distribution Valve Assembly ...................................................................................... 13-12
13-6 Limits Chart - Air Distribution Valve ................................................................................. 13-13
13-7 Tool Application Seal Installation on Poppet .................................................................... 13-15
13-8 Vent Air Control Valve - Installation ................................................................................. 13-19
13-9 Vent Air Control Valve Assembly ..................................................................................... 13-21
13-10 Vent Air Control Valve Setup ........................................................................................... 13-22
13-11 Temperature Control Valve ............................................................................................. 13-27
13-12 Temperature Control Valve Schematic ............................................................................ 13-28
13-12A ECU Cooling Turbine Lubrication .................................................................................... 13-28A
13-13 Pressure Regulator and Shutoff Valve ............................................................................. 13-30
13-14 Pressure Regulator and Shutoff Valve Schematic ........................................................... 13-31
16-1 M118 Wing Mounted Smoke Dispenser ........................................................................... 16-2
16-2 Cradle Assemblies in Stow Position for Installation on Outboard Rack ............................ 16-5
16-3 Cradle Assemblies in Position for Installation on Rocket Launcher .................................. 16-6
Change 17 xi
 TM 55-1520-234-23-2

LIST OF ILLUSTRATIONS (Cont)

Figure Title
16-4 Wing Stores Pylon ...........................................................................................................
16-5 Special Tools for Ejector Rack ........................................................................................
16-6 Outboard Ejector Rack Installation ..................................................................................
16-7 Ejector Rack Alignment ...................................................................................................
16-8 Inboard Ejector Rack Installation .....................................................................................
16-9 Outboard Ejector Rack - Exploded View ..........................................................................
16-10 Electrical Connections for Ejector Rack............................................................................
16-11 Inboard Rack with Ejector Disassembled .........................................................................

17-1 Canopy Removal System Interconnections ......................................................................

17-2 Installation of Window Cutting Assembly in Gunners Window .........................................
17-3 Installation of Window Cutting Assembly in Pilots Window ..............................................
17-4 Installation of Window Cutting Assembly in Gunners Door ..............................................
17-5 Installation of Window Cutting Assembly in Pilots Door ....................................................
17-6 Installation of Junction Manifolds and Arming/Firing Units in
Canopy Removal System .........................................................................................
17-7 Typical Shell Installation ..................................................................................................
C-1 Inventory Items List .........................................................................................................
F-1 Wiring Identification Code ...............................................................................................
F-2 Symbols Charts ...............................................................................................................
F-3 AC Load Analysis Chart ..................................................................................................
F-4 DC Load Analysis Chart ..................................................................................................
F-5 AC Power System Wiring Diagram ..................................................................................
F-6 Anticallision and Position Lights Systems ........................................................................
F-6A NVG Position Lights System ...........................................................................................
F-7 Armament Systems Wiring Diagram ...............................................................................
F-8 Attitude Indicating System Wiring Diagram .....................................................................
F-9 Battery System Wiring Diagram ......................................................................................
F-10 Caution Panel Internal Schematic Diagram .....................................................................
F-11 Caution Panel Internal Schematic Diagram .....................................................................
F-12 Engine De-Ice System Wiring Diagram ...........................................................................
F-13 Environmental Control System Wiring Diagram ..............................................................
F-14 External Power System Wiring Diagram...........................................................................
F-15 Force Trim System Wiring Diagram ................................................................................
F-16 Fuel Valve and Engine Oil Valve System Wiring Diagram................................................
F-17 Fuel Boost System Wiring Diagram .................................................................................
F-18 Fuel Quantity Indicating System Wiring Diagram ............................................................
F-19 Generator and DC Bus System Wiring Diagram ..............................................................
F-20 Governor Control System Wiring Diagram .......................................................................
F-21 Hydraulic Control System Wiring Diagram ......................................................................
F-22 Idle Stop System Wiring Diagram ...................................................................................
F-23 Igniter System Wiring Diagram .......................................................................................
F-24 Interior Lights System Wiring Diagram ............................................................................
F-25 Pilot Heater System Wiring Diagram ...............................................................................
F-26 Pressure Indicating Systems Wiring Diagram ..................................................................
F-27 RPM Limits Warning System Wiring Diagram .................................................................
F-28 RPM Test Set Schematic Diagram ..................................................................................
F-29 Searchlight and Skid Landing Landing Light Systems ......................................................
F-30 Starter System Wiring Diagram........................................................................................
F-31 Tachometer Indicator Systems Wiring Diagram ..............................................................
F-32 Temperature Indicating Systems Wiring Diagram ............................................................
F-33 Tow Blower Cooling System Wiring Diagram ..................................................................
F-34 Turn and Slip Indicating System Wiring Diagram ............................................................
xii Change 17
 TM 55-1520-234-23-2
LIST OF TABLES

Figure Title Page

1-1 Engine Fuel Specifications .............................................................................................. 1-3
1-2 Approved Fuels ............................................................................................................... 1-4
1-3 Consumable Maintenance Supplies and Materials ........................................................... 1-11
1-4 Special Tools and Equipment .......................................................................................... 1-19
1-5 Adhesive Mix Ratio, Pot Life, and Cure Cycles ............................................................... 1-24
2-1 Tailboom Skin and Structure Classification and Damage ................................................ 2-109
2-1A Treatment of Corroded Surfaces ...................................................................................... 2-173
2-2 Structural Repair Materials............................................................................................... 2-175
4-1 Repair Methods ............................................................................................................... 4-28
4-2 Troubleshooting - Engine Oil System .............................................................................. 4-32
4-3 Dimension Tolerance - Turbine Fan ................................................................................ 4-42
5-1 Troubleshooting - Main Rotor System ............................................................................. 5-1
5-1A Difference Between Models K747-003 Blades ................................................................. 5-30D
5-1B Classification of Damage-K747 Main Rotor Blades .......................................................... 5-30J
5-1C Classification of Damage-K747 Main Rotor Blades .......................................................... 5-30N
5-1D Plug Patch Data ............................................................................................................... 5-30AG
5-2 Troubleshooting - Tail Rotor System ................................................................................ 5-95
6-1 Troubleshooting-Drive Train System ............................................................................... 6-2
7-1 Troubleshooting - Hydraulic System ................................................................................ 7-7
7-2 Maximum Allowable Leakage for Hydraulic System ........................................................ 7-12
7-3 Torque Values for Fluid Connections ............................................................................... 7-16A
8-1 Troubleshooting-Dual and Gas Producer Tachometers .................................................... 8-8A
8-2 Troubleshooting - Engine Oil Pressure Indicating System ................................................ 8-12
8-3 Troubleshooting - Engine Oil Temperature Indicator ........................................................ 8-13
8-4 Deleted ...........................................................................................................................
8-5 Troubleshooting - Fuel Pressure Indicator ....................................................................... 8-17
8-6 Troubleshooting - Torque Pressure Indicators ................................................................. 8-19
8-6A Tolerance ± knots) .......................................................................................................... 8-20A
8-6B Vertical Velocity Tolerance Feet Scale Accuracy ............................................................. 8-20B
8-6C Altimeter Scale Error ....................................................................................................... 8-20B
8-7 Troubleshooting - Airspeed Indicators ............................................................................. 8-23
8-8 Troubleshooting - Altimeters ............................................................................................ 8-24
8-9 Troubleshooting - Attitude Indicators ............................................................................... 8-25
8-10 Troubleshooting - Turn & Slip Indicator ........................................................................... 8-26
8-11 Troubleshooting - Vertical Velocity Indicator .................................................................... 8-26A
8-12 Troubleshooting - Standby Compass ............................................................................... 8-28
8-13 Troubleshooting - Clock .................................................................................................. 8-29
8-14 Troubleshooting - Fuel Quantity Indicator ........................................................................ 8-30
8-15 Fuel Tank Table of Limits ................................................................................................ 8-33
8-16 Troubleshooting - Free Air Temperature Gage ................................................................ 8-35
8-17 Troubleshooting - Voltmeter/Ammeter ............................................................................. 8-37
8-18 Troubleshooting - Pilots Steering Indicator (PSI) ............................................................. 8-39
9-1 Troubleshooting - Battery System ................................................................................... 9-15
9-2 Troubleshooting - External Power System ....................................................................... 9-18
9-3 Troubleshooting - Generator and DC Bus System ........................................................... 9-21
9-4 Troubleshooting - Inverter System ................................................................................... 9-26
9-5 Troubleshooting - Starting System .................................................................................. 9-32

Change 17 xiii
 TM 55-1520-234-23-2
LIST OF TABLES (Cont)

Figure Title Page

9-6 Troubleshooting - Ignition System ................................................................................... 9-34
9-7 Troubleshooting - Cockpit Lights ..................................................................................... 9-34A
9-8 Troubleshooting - Instrument Panel & Console Lights ...................................................... 9-3
9-9 Troubleshooting - Rpm Limit Warning System ................................................................ 9-50
9-10 Troubleshooting - Position Lights System ........................................................................ 9-57
9-11 Troubleshooting - Anticollision Light System ................................................................... 9-58A
9-12 Troubleshooting - Searchlight System ............................................................................. 9-59
9-13 Troubleshooting - Transmission Oil Level Light ............................................................... 9-61
9-14 Troubleshooting - Engine De-ice Circuitry ....................................................................... 9-62
9-15 Troubleshooting - Engine Oil Bypass Circuitry ................................................................. 9-63
9-16 Troubleshooting - Fuel Valve Circuitry ............................................................................. 9-64
9-17 Troubleshooting - Fuel Boost Pump Circuitry .................................................................. 9-65
9-18 Troubleshooting - Governor Control System Circuitry ...................................................... 9-66
9-19 Troubleshooting - Idle Stop Solenoid Circuitry ................................................................. 9-67
9-20 Troubleshooting - Force Trim System Circuitry ................................................................ 9-68
9-21 Troubleshooting - Hydraulic Control System Circuitry ...................................................... 9-70
9-22 Troubleshooting - Environmental Control System Circuitry .............................................. 9-71
9-23 Troubleshooting - Pitot Heating System Circuitry ............................................................. 9-72A
9-24 Troubleshooting - TOW Blower Cooling System .............................................................. 9-72B
9-25 Troubleshooting - Rocket Launcher Circuitry ................................................................... 9-87
9-26 Troubleshooting - XM-18 Minigun Circuitry ...................................................................... 9-90A
9-27 Troubleshooting - Wing Stores Jettison Circuitry ............................................................. 9-92A
9-28 Troubleshooting - Smoke Grenade Dispenser System Circuitry ....................................... 9-95
10-1 Troubleshooting - Fuel System ........................................................................................ 10-1
11-1 Troubleshooting - Flight Controls ..................................................................................... 11-1
12-1 Troubleshooting - Fire Detector System .......................................................................... 12-1
13-1 Troubleshooting - Environmental Control System ............................................................ 13-6
13-2 Troubleshooting - Air Distribution Valve .......................................................................... 13-17
16-1 Troubleshooting - Ejector Racks ...................................................................................... 16-7
17-1 Shell Assemblies ............................................................................................................. 17-14
F-1 Equipment List (Electrical) .............................................................................................. F-3
F-2 Equipment List (Armament) ............................................................................................. F-14
F-3 XM65 Interconnection Wire List ....................................................................................... F-17

xiv Change 17
 TM 55-1520-234-23-2

TECHNICAL MANUAL
No. 55-1520-234-23-2
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 30 September 1976

Aviation Unit and Aviation Intermediate

Maintenance Manual

ARMY MODEL AH-1S (MOD) HELICOPTER

NOTE:

This manual is printed in two volumes, as follows:

TM 55-1520-234-23-1, consisting of Table of Contents, preface, chapters 1 through 9.

TM 55-1520-234-23-2, consisting of Table of Contents, chapters 10 through 17, appendices A through F, and
Index.
The Appendices and Index are applicable to Volumes I and II.

Change 1
 TM 55-1520-234-23

CHAPTER 10
FUEL SYSTEM

Section I. FUEL SYSTEMS

10-1. Fuel System. b. Before removing any line or hose, be sure it
is properly identified and its route understood for
a. The fuel supply is in two interconnected cells replacement in the same manner.
in the fuselage, located forward and aft of the pylon.
(Refer to figure 10-1.) The system is filled at right side c. Cap or cover any open lines, fittings or
of the forward cell. A crossover hose allows free flow to exposed openings to protect fuel system from
the aft cell, and has a check valve that restricts flow contamination. Be sure vent lines are not obstructed.
from aft to forward cell to avoid sudden shifting of
balance in nosedown flight attitude. Each cell has a 10-2A. Perform troubleshooting of the fuel system in
transmitter probe for the fuel quantity gage system, and accordance with Table 10-1.
a float switch for the 10% FUEL caution panels. Sump
drain valves are provided on both cells; the large valve 10-3. Fuel Filter.
on the aft cell is also used for system defueling. Vent
lines from cells are connected together and to a single The filter (26, figure 10-1) is mounted on a bracket
overboard line. The aft cell has a connection, with a located on left side of the engine compartment deck.
check valve, for return of fuel bled from the engine fuel The filter contains a replaceable paper-type element (6)
control overspeed governor. and has an internal bypass, with electrical connection to
the FUEL FILTER caution panels to warn when the filter
b. Electrically operated boost pumps deliver is about to be bypassed due to clogging. Piping
fuel from each cell to a manifold containing two connections on the filter include the inlet line, drain line,
directional flow check valves, with thermal relief bypass pressure transmitter line, and a quick disconnect outlet
provisions. From the manifold outlet, fuel passes coupling.
through an electrically operated shut-off valve to the
filter, which has an outlet coupling for the engine fuel a. Removal.
control inlet hose. Two pressure switches on the
manifold have electrical circuits to FWD FUEL BOOST
and AFT FUEL BOOST caution panels, and the fuel (1) Open left side of engine compartment
pressure gage system transmitter is connected to the cowling.
outlet side of the filter. (2) Disconnect fuel hose from outlet coupling
on top of filter.
10-2. General Maintenance - Fuel Supply System.
(3) Drain fuel from filter by opening drain line
Observe the following general instructions and valve. Use a suitable tool to slightly depress self-closing
precautions in maintenance of the fuel supply system. valve of filter outlet coupling to admit some air and
Operational checks will be in accordance with TM 55- assist drainage.
1520-234-10. Servicing instructions are contained in
Chapter 1; electrical circuit diagrams and information (4) Open coupling clamp (7) and remove
are in Chapter 9 of this manual. Fuel lines and bowl (4) and filter element (6) from filter head. Separate
components on the engine constitute the fuel control element (6) and packings (5) from bowl.
system and will be found in TM 55-2840-229-24.

CAUTION NOTE
After aircraft has been defueled a Filter head will usually be left in
small amount of fuel may be place, but can be removed as in
present in the cells. Care should the following step.
be taken to catch remaining fuel
in a suitable container when (5) Disconnect electrical cable plug, and fuel
removing fuel cell components. inlet, pressure, and drain lines from filter head. Detach
head assembly from bracket by removing four bolts,
a. Conduct any defueling or drainage of fuel in nuts and washers.
accordance with applicable directives, and with extreme
care to avoid fire hazards. (Refer to chapter 1.)

Change 21 10-1
 TM 55-1520-234-23

Table 10-1. Troubleshooting Fuel System

CONDITION
TEST OR INSPECTION
CORRECTIVE ACTION

1. FUEL FILTER lamp illuminated.

STEP 1. Remove filter element and check for clogged filter.

Replace filter element if dirty or clogged. Refer to paragraph 10-3.

2. AFT or FWD FUEL BOOST caution lamps illuminated.

STEP 1. Check for sound of pump running.

If pump is running, but there is no indication of fuel flow to engine, pump has failed or lines are
loose or clogged or leaking. Check manifold and shutoff valves for malfunction if lights are off
without flow to engine. Replace pump. Refer to paragraph 10-8.

STEP 2. If pump is not running, check for electrical continuity.

If electrical continuity is not present, repair wiring. If continuity is normal, replace pump.

3. FUEL LOW lamp illuminated.

STEP 1. Defuel helicopter and refuel. FUEL LOW lamp should go out after approximately 26 gallons of fuel is
in fuel cells.

If lamp remains on, check low level warning switch. Replace if defective.

STEP 2. Check electrical circuit for continuity.

If continuity is not normal, repair as needed.

10-2 Change 8
 TM- 55-1520-234-23

Figure 10-1. Fuel system (Sheet 1 of 2)

Change 8 10-2A/(10-2B blank)

 TM 55-1520-234-23

Figure 10-1. Fuel system (Sheet 2 of 2)

10-3