Atch_8_-_T.O._1H-60(H)G-23.PDF

15 FEBRUARY 2012 CHANGE 5 - 15 AUGUST 2015

TO 1H-60(H)G-23

TECHNICAL MANUAL

ORGANIZATIONAL

AND

INTERMEDIATE MAINTENANCE

ORGANIZATIONAL, INTERMEDIATE AND

DEPOT CORROSION CONTROL

HH-60 SERIES HELICOPTER

DISTRIBUTION STATEMENT D - Distribution authorized to the Department of Defense and U.S. DoD Contractors only (Administrative or Operational Use) (15 February 2012). Refer Other requests for this document to AFLCMC/WIUBD, Robins AFB GA 31098.

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.

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Published Under the Authority of The Secretary of the Air Force

BASIC AND ALL UPDATES HAVE BEEN MERGED TO MAKE A COMPLETE PUBLICATION

LIST OF EFFECTIVE PAGES INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the margins of the page. Changes to illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

A Change 5 USAF

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TO 1H-60(H)G-23

Title A i ii - iii iv v vi Blank vii - viii ix x Blank xi - xii 1-1 1-2 1-3 1-4 1-4.1 1-4.2 Blank Added 1-5 - 1-7 1-8 1-9 1-10 Blank 2-1 2-2 - 2-4 2-5 2-6 2-7 - 2-8 2-9 2-10 - 2-14 2-15 - 2-19 2-20 2-21 - 2-23 2-24 Blank 3-1 - 3-7 3-8 3-9 3-10 3-11 - 3-12 3-13 - 3-14 3-15 3-16 Blank 4-1 4-2 - 4-5 4-6 Blank 5-1

5-2 - 5-4 5-5 - 5-6 5-7 - 5-13 5-14 - 5-18 5-19 - 5-20 6-1 - 6-3 6-4 6-5 6-6 6-7 6-8 6-9 - 6-12 6-13 - 6-14 6-15 - 6-16 6-17 6-18 - 6-20 6-21 6-22 6-23 - 6-25 6-26 Blank 7-1 - 7-6 7-7 - 7-8 7-9 - 7-10 7-11 - 7-13 7-14 Blank 8-1 8-2 - 8-6 8-7 - 8-8 9-1 - 9-15 9-16 Blank 10-1 - 10-11 10-12 10-13 - 10-16

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*Zero in this column indicates an original page.

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 186 CONSISTING OF THE FOLLOWING:

Dates of issue for original and changed pages are:

Original . . . . . . . 0 . . . . . 15 February 2012 Change . . . . . . . 1 . . . . . . .1 October 2012 Change . . . . . . . 2 . . . . . . 1 February 2014

Change. . . . . . . . 3 . . . . .15 February 2015 Change. . . . . . . . 4 . . . . . . . . 15 June 2015 Change. . . . . . . . 5 . . . . . . 15 August 2015

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS......................................iv 1.6 EMERGENCY CLEANING

PROCEDURE........................................1-9

LIST OF TABLES.......................................................v 2 PAINT AND GENERAL CORROSION

REPAIR................................................................2-1

FOREWORD .............................................................vii 2.1 GENERAL..................................................2-1

2.2 PAINT REMOVAL....................................2-1

2.2.1 Paint Removal.............................................2-1

SAFETY SUMMARY................................................xi 2.2.2 Removing Large Areas of Paint on Aluminum or Magnesium Surfaces ..................................................2-11 CLEANING AND TEMPORARY PRO-

2.2.3 Paint Removal by Plastic MediaTECTION.............................................................1-1 Blasting on Composite Struc-tures ........................................................2-21.1 GENERAL..................................................1-1

2.3 CORROSION REPAIR AND1.2 CLEANING ................................................1-1 PROTECTIVE FINISHES ....................2-31.2.1 Cleaning ......................................................1-1

2.4 CORROSION .............................................2-31.2.2 Waterless Wipedown..................................1-1

2.4.1 Direct Surface Attack .................................2-31.3 FOGGING PROCEDURES OF

2.4.2 Galvanic or Dissimilar MetalLOWER FUSELAGE, TAIL, Corrosion................................................2-3AND STABILIZER...............................1-1

2.4.3 Intergranular Corrosion ..............................2-31.3.1 General........................................................1-1

2.4.4 Pitting..........................................................2-31.3.2 Frequency....................................................1-1

2.4.5 Exfoliation...................................................2-41.3.3 Procedures...................................................1-2

2.4.6 Crevice Attack or Concentration1.4 TEMPORARY PROTECTION..................1-2

Cell Corrosion........................................2-41.4.1 Temporary Corrosion Arrestment

2.4.7 Fretting Corrosion.......................................2-4Procedure ...............................................1-2

2.4.8 Stress Corrosion Cracking..........................2-41.4.2 Temporary Repair of Damaged

2.4.9 Corrosion Fatigue .......................................2-4Sealing Compound.................................1-3

2.4.10 Filiform Corrosion......................................2-41.5 CLEANING PROCEDURES

2.4.11 Microbiological Induced Corro-AND PRINCIPLES ...............................1-3 sion .........................................................2-41.5.1 Types of Surface Soils ...............................1-3

2.5 CORROSION MAINTENANCE...............2-41.5.2 Types of Cleaners.......................................1-3

2.5.1 Inspection for Evidence of Corro-1.5.3 Methods of Cleaning ...............................1-4.1 sion .........................................................2-41.5.4 Terpene-Based, Solvent Emul-

2.5.2 Surface Corrosion Check ...........................2-4sion, Water Dilutable Cleaning

2.5.3 Corrosion Maintenance for Tita-Compound (MIL-PRF-87937

nium, Nickel, and Silver Sur-and MIL-PRF-85570, Type I) ...............1-5 faces .......................................................2-41.5.5 Equipment for MIL-PRF-87937,

2.6 APPLICATION OF CORRO-Type I, and MIL-C-43616.....................1-5 SION PREVENTIVE COM-1.5.6 Preparation for Terpene-Based POUND..................................................2-5Solvent Cleaning, MIL-PRF-

2.6.1 Corrosion Prevention..................................2-587937, Type I.........................................1-5

2.6.2 Applying Corrosion Preventive1.5.7 Aircraft Cleaning Compounds

Compound..............................................2-5(MIL-PRF-85570) ..................................1-6

2.6.3 Using Corrosion Preventive1.5.8 Dry-Cleaning Solvent Cleaning

Compound on UnprotectedProcedure ...............................................1-6 Cables.....................................................2-51.5.9 Application of Dry-Cleaning Sol-

2.6.4 Temporary Repair of Non-Mov-vent, MIL-PRF-680, Type III................1-7 ing Metal Parts.......................................2-51.5.10 Low Temperature Cleaning........................1-7

2.6.5 Fluid Film ...................................................2-51.5.11 Low Temperature Cleaning Com-

2.6.6 Permanent Repair .......................................2-5pound Rinsing Material .........................1-8

Change 1 i

2.7 PAINTING SAFETY PRECAU- 3.12 FAYING SURFACES, JOINTS,

TIONS....................................................2-5 AND SEAMS ......................................3-10

2.8 PAINTED SURFACES (CAM- 3.12.1 Applying Sealing Compound ...................3-10 OUFLAGED AIRCRAFT)....................2-6 3.12.2 Bonding Faying Surfaces .........................3-10

2.9 INTERIOR SURFACES ............................2-6 3.12.3 Using Low Adhesion Compound.............3-10

2.10 EXTERIOR SURFACES ...........................2-6 3.12.4 Sealing Compound on Plastic

2.11 AIRCRAFT MARKINGS ..........................2-7 Surfaces ................................................3-10

3.13 SEALING OF AIRCRAFT

3 SEALANTS ..............................................................3-1 STRUCTURE ......................................3-10

3.13.1 Lap Sealing Where Skins Have

3.1 GENERAL..................................................3-1 Been Lifted ..........................................3-10

3.2 CLASSIFICATION OF SEAL- 3.13.2 Lap Sealing Where Joints Have

ING LEVELS ........................................3-1 Not Been Lifted ...................................3-11

3.2.1 Absolute Sealing.........................................3-1 3.13.3 Sealing Procedures for Typical

3.2.2 Extensive Sealing .......................................3-1 Aircraft Fitting .....................................3-11

3.2.3 Immediate Sealing ......................................3-1 3.13.4 Spar Cap Sealing ......................................3-11

3.2.4 Limited Sealing...........................................3-1 3.13.5 Sealing of Access Doors ..........................3-11

3.3 ENVIRONMENTAL SEALING ...............3-1 3.13.6 Floor Panel Installation ............................3-11

3.3.1 Faying Surface Sealing...............................3-1

3.3.2 Fillet Sealing...............................................3-1 4 CORROSION REMOVAL AND PRE-

3.3.3 Injection Sealing .........................................3-1 VENTION ............................................................4-1

3.3.4 Fastener Sealing..........................................3-1

3.4 TYPES OF ENVIRONMENTAL 4.1 GENERAL..................................................4-1

SEALING...............................................3-2 4.1.1 Inspections ..................................................4-1

3.4.1 Fuel Sealing ................................................3-2 4.1.2 Corrosion Resistant Metals ........................4-1

3.4.2 Weather Sealing..........................................3-2 4.1.3 Surface Corrosion Check ...........................4-1

3.4.3 Firewall Sealing..........................................3-2 4.1.4 Salt Water Deposit Removal......................4-1

3.4.4 Electrical Sealing........................................3-2 4.2 INSPECTION OF ALUMINUM

3.4.5 Acid-Resistant Sealing ...............................3-2 AND MAGNESIUM SUR-

3.4.6 Window Sealing .........................................3-2 FACES ...................................................4-1

3.4.7 High-Temperature Sealing .........................3-2 4.2.1 Inspection....................................................4-1

3.4.8 Aerodynamic Sealing .................................3-5 4.2.2 Chemical Paint Removal............................4-1

3.4.9 Water Integrity Sealing ..............................3-5 4.3 CORROSION REMOVAL AND

3.5 TYPES OF SEALANTS ............................3-5 PREVENTION ON ALUMI-

3.6 CORROSION IN JOINTS .........................3-5 NUM ......................................................4-1

3.7 DISSIMILAR METALS ............................3-5 4.3.1 Corrosion Removal - Aluminum

3.7.1 Grouping of Metals and Alloys .................3-5 Surfaces ..................................................4-2

3.7.2 Type of Corrosion Protection and 4.4 CORROSION REMOVAL AND

Methods of Application.........................3-5 PREVENTION ON MAGNE-

3.8 BOLTS THROUGH DISSIMI- SIUM......................................................4-3

LAR METALS ......................................3-8 4.4.1 Corrosion Removal - Magnesium

3.9 FASTENERS, INSERTS, AND Surfaces ..................................................4-3

LINERS PASSING 4.5 CORROSION REMOVAL AND

THROUGH DISSIMILAR PREVENTION ON STEEL

METALS................................................3-8 AND TITANIUM..................................4-4

3.10 APPLICATION OF PRIMER....................3-8 4.5.1 High Strength Steel ....................................4-4

3.10.1 Coat Bolts and Assorted Hard- 4.5.2 Corrosion Resistant Steel (CRES) .............4-4 ware ........................................................3-8 4.5.3 Titanium Alloys..........................................4-4

3.10.2 Steel Washers .............................................3-8 4.6 BERYLLIUM COPPER.............................4-4

3.11 DISSIMILAR METAL INSULA- 4.6.1 Beryllium Copper Corrosion Re-

TION DURING ASSEMBLY...............3-8 moval Procedure ....................................4-4

3.11.1 Clean Surface with Cheesecloth ................3-8

5 AIRFRAME, LANDING GEAR, FUEL3.11.2 Use Sealing Compound..............................3-8 PROBE, CARGO HOOK, AND3.11.3 Insulate Joining Surfaces............................3-8 HOIST ..................................................................5-13.11.4 Seal Monel Safetywire ...............................3-8

3.11.5 Fill Areas That Could Hold

5.1 GENERAL..................................................5-1Water ......................................................3-8

5.2 CLASSIFICATION ....................................5-13.11.6 Insulate With Sealing Compound .............3-8

5.3 DAMAGE LIMITS ....................................5-13.11.7 Sealing Compound (SAE AMS

5.3.1 Airframe......................................................5-13267/3) ...................................................3-8 ii

5.3.2 Landing Gear ..............................................5-1 6.16 CORROSION REMOV-

5.3.3 Fuel Probe...................................................5-1 AL/TREATMENT ...............................6-20

5.3.4 Cargo Hook.................................................5-2 6.17 SEALANT AND SEALING

5.3.5 Hoist Support Base.....................................5-2 COMPOUND.......................................6-21

5.3.6 Hoist Support Arm .....................................5-2 6.18 FINISHES.................................................6-21

5.3.7 Hoist Airframe Fitting Cup........................5-2

7 ROTOR SYSTEMS ..................................................7-15.4 INSPECTION METHODS.........................5-2

5.5 CORROSION REMOV-

7.1 GENERAL..................................................7-1AL/TREATMENT .................................5-2

7.1.1 Corrosion on Main Rotor Hub...................7-15.5.1 Airframe......................................................5-2

7.1.2 Material Changes........................................7-15.5.2 Landing Gear ..............................................5-5

7.1.3 Corrosion on Rotor System........................7-15.5.3 Fuel Probe...................................................5-5

7.1.4 Corrosion on Tail Rotor Hub.....................7-15.5.4 Cargo Hook.................................................5-6

7.2 ROTOR SYSTEMS CORRO-5.5.5 Hoist Support Base.....................................5-6

SION DAMAGE EVALUA-5.5.6 Hoist Support Arm .....................................5-6 TION AND DAMAGE5.5.7 Hoist Airframe Fitting Cup........................5-6 LIMITS ..................................................7-15.6 SEALANTS ................................................5-6

7.2.1 Inspection....................................................7-15.7 FINISHES...................................................5-6

7.3 ROTOR SYSTEMS CORRO-

6 POWERTRAIN SYSTEMS .....................................6-1 SION DAMAGE REPAIR....................7-7

7.3.1 Repair..........................................................7-7

6.1 GENERAL..................................................6-1 7.4 CORROSION REMOV-

6.1.1 Corrosion Prone Areas ...............................6-1 AL/TREATMENT .................................7-8

6.1.2 Magnesium Alloys......................................6-1 7.5 SEALANTS ................................................7-8

6.2 CLASSIFICATION ....................................6-1 7.6 FINISHES...................................................7-8

6.2.1 Classification...............................................6-1 7.7 TEMPORARY CORROSION

6.2.2 Classification...............................................6-1 ARRESTMENT .....................................7-8

6.3 MAIN TRANSMISSION COR-

8 POWERPLANT SYSTEMS.....................................8-1ROSION DAMAGE AND

LIMITS ..................................................6-1

8.1 GENERAL..................................................8-16.3.1 Minor Damage and Limits .........................6-1

8.2 POWERPLANT SYSTEMS6.3.2 Repairable Damage and Limits..................6-1

CORROSION DAMAGE6.3.3 Touch Up Paint...........................................6-1

EVALUATION AND LIMITS .............8-16.4 MAIN TRANSMISSION COR-

8.3 POWERPLANT SYSTEMSROSION DAMAGE REPAIR .............6-4

CORROSION DAMAGE RE-6.5 INPUT MODULE CORROSION

PAIR.......................................................8-1DAMAGE AND LIMITS......................6-4

8.4 INSPECTION METHODS.........................8-16.6 INPUT MODULE CORROSION

8.5 CORROSION REMOV-DAMAGE REPAIR...............................6-6

AL/TREATMENT .................................8-16.7 ACCESSORY MODULE COR-

8.6 SEALING COMPOUNDS.........................8-1ROSION DAMAGE AND

8.7 FINISHES...................................................8-2LIMITS ..................................................6-6

8.8 TEMPORARY CORROSION6.8 ACCESSORY MODULE COR-

ARRESTMENT .....................................8-2ROSION DAMAGE REPAIR .............6-6

6.9 TAIL DRIVE SHAFTS CORRO-

9 FLIGHT CONTROL SYSTEMS .............................9-1SION DAMAGE AND LIM-

ITS..........................................................6-8

9.1 GENERAL..................................................9-16.10 TAIL DRIVE SHAFTS CORRO-

9.1.1 Flight Control System Corrosion ...............9-1SION DAMAGE REPAIR....................6-8

9.2 FLIGHT CONTROL SYSTEM6.11 INTERMEDIATE GEARBOX

CORROSION DAMAGECORROSION DAMAGE

EVALUATION AND LIM-AND LIMITS ......................................6-13

ITS..........................................................9-16.12 INTERMEDIATE GEARBOX

9.3 FLIGHT CONTROL SYSTEMCORROSION DAMAGE RE-

CORROSION DAMAGE RE-PAIR.....................................................6-14 PAIR.......................................................9-26.13 TAIL GEARBOX CORROSION

9.4 INSPECTION METHODS.........................9-2DAMAGE AND LIMITS....................6-17

9.5 CORROSION REMOV-6.14 TAIL GEARBOX CORROSION

AL/TREATMENT .................................9-2DAMAGE REPAIR.............................6-17

9.6 SEALING COMPOUNDS.........................9-36.15 INSPECTION METHODS.......................6-20 iii iv Change 2

LIST OF ILLUSTRATIONS

Number Title Page

2-1 Typical Nonmetallic Scraper ....................2-3 2-2 Cabin Floor ...............................................2-9 2-3 H-60 Aircraft Camouflage Color

Scheme ................................................2-10

Number Title Page

2-4 H-60 Aircraft Stations, Waterlines, and Buttlines ...................................... 2-15

2-5 H-60 Aircraft Interior Design Markings ............................................ 2-16

2-6 Engine Air Inlet, Anodized Area............ 2-21

TO 1H-60(H)G-23

9.7 FINISHES ...................................... 9-3

9.8 TEMPORARY CORROSION

ARRESTMENT ......................... 9-3

10 ELECTRICAL AND INSTRUMENT

SYSTEMS .....................................................10-1

10.1 GENERAL .................................... 10-1

10.2 ANTENNAS ................................. 10-1

10.3 COCKPIT AND CONTROL

BOXES...................................... 10-1

10.4 ELECTRICAL CONNECTORS.... 10-2

10.4.1 External Corrosion ...................... 10-2

10.4.2 Internal Corrosion ....................... 10-2

10.4.3 Water Displacement and Corr-

osion Prevention ...................... 10-3

10.5 COXIAL AND TRIAXIAL

CONNECTORS ....................... 10-3

10.6 WIRE HARNESSES AND

CABLES ................................... 10-3

10.7 COVERS AND HOUSINGS ......... 10-4

10.7.1 Covers and Housings .................... 10-4

10.7.2 Hinges and Latches ...................... 10-4

10.8 ELECTRICAL BONDING AND

GROUND STRAPS .................. 10-4

10.9 BONDING/GROUNDING SUR-

FACE PREPARATION ............ 10-5

10.10 BONDING/GROUNDING

STRAP CORROSION

PREVENTION ......................... 10-5

10.11 EXTERNAL STORES SUP-

PORT SYSTEM ........................ 10-5

10.12 FRAMES, MOUNTING

RACKS, AND SHOCK

MOUNTS .................................. 10-5

10.13 SWITCHES ................................... 10-5

10.14 TERMINAL BOARDS, RELAY

BOXES, CIRCUIT BREAKER

PANELS, AND JUNCTION

BOXES...................................... 10-6

10.14.1 External Surfaces ......................... 10-6

10.14.2 Internal Components.................... 10-6

10.15 RELAYS AND CIRCUIT

BREAKERS .............................. 10-6

10.16 WAVEGUIDES ............................. 10-7

10.17 EMERGENCY CLEANING

PROCEDURES......................... 10-7

10.17.1 Primary Method ........................... 10-7

10.17.2 Alternate Cleaning Method

(Solvent) .................................... 10-7

10.17.3 Alternate Cleaning Method

(Cleaning).................................. 10-8

10.17.4 Alternate Cleaning Method

(Water Displacing).................... 10-8

10.18 REMOVABLE AND NON-

REMOVABLE AVIONICS

EQUIPMENT............................ 10-8

10.18.1 Non-Removable Avionics

Equipment................................. 10-8

10.18.2 Hermetically Sealed Avionics

Equipment................................. 10-8

10.18.3 Switches and Circuit Breakers..... 10-8

10.18.4 Antenna ......................................... 10-9

10.18.5 Mounting Racks and Shock

Mounts ...................................... 10-9

10.18.6 Miscellaneous Avionics

Equipment................................. 10-9

10.18.7 Electrical Plugs and Recep-

tacles ......................................... 10-9

10.18.8 Electrical Wire Harnesses and

Cables........................................ 10-9

10.18.9 ALE-47(V) Dispenser Ground

Springs and Firing Pins Cleaning Procedures .............. 10-10

10.19 EMERGENCY DRYING

AND CORROSION

PREVENTION........................ 10-11

10.19.1 Heated Compartment Drying

Procedures............................... 10-11

10.19.2 Non-Removable Avionic

Equipment............................... 10-11

10.20 SEALING COMPOUNDS........... 10-11

10.21 FINISHES ................................... 10-11

10.22 ANTENNA MOUNT ASSEM-

BLY, LIGHTWEIGHT AIR-

BORNE RECOVERY

SYSTEM (LARS) .................... 10-11

10.23 ANTENNA MOUNT, UHF

SATCOM/DAMA (AN/ARC-

210(V) SYSTEM (ON AIR-

CRAFT MODIFIED BY

TO 1H-60-836 OR TO

1H-60-986) .............................. 10-12

2-7 Antenna Arrangement................................... 2-22 5-7 External Rescue Hoist Support Base ........... 5-19 2-8 Typical NATO Symbol Dimensions ............ 2-23 5-8 External Rescue Hoist Support Arm............ 5-19 3-1 Faying Surface Sealing................................... 3-2 5-9 External Rescue Hoist Airframe Fitting 3-2 Application of Fillet Seal ............................... 3-3 Cup ........................................................... 5-20 3-3 Typical Injection Seal ..................................... 3-3 6-1 Powertrain System .......................................... 6-2 3-4 Application of Sealant to Joggles, Slots, 6-2 Main Transmission Module............................ 6-3 and Confined Holes ................................... 3-4 6-3 Input Modules ................................................. 6-5 3-5 Typical Methods of Sealing Fasteners ........... 3-4 6-4 Accessory Modules......................................... 6-7 3-6 Water Integrity Sealing................................... 3-6 6-5 Drive Shafts .................................................... 6-9 3-7 Application of Primer ..................................... 3-9 6-6 Flexible Coupling.......................................... 6-13 3-8 Insulating Dissimilar Metals During As- 6-7 Intermediate Gearbox.................................... 6-15 sembly......................................................... 3-9 6-8 Tail Gearbox ................................................. 6-18 3-9 Typical Skin Lap Sealing ............................. 3-12 7-1 Main Rotor Systems ....................................... 7-2 3-10 Sealing Typical Aircraft Fitting ................... 3-12 7-2 Tail Rotor Systems ......................................... 7-9 3-11 Typical Spar Cap Repairs and Sealing ........ 3-13 8-1 Powerplant Systems ........................................ 8-3 3-12 Sealing of Access Doors .............................. 3-13 8-2 Auxiliary Power Unit (APU).......................... 8-5 3-13 Sealability Layout ......................................... 3-15 9-1 Flight Control Systems ................................... 9-4 5-1 Cabin Floor ..................................................... 5-8 9-2 Tail Rotor Control System ............................. 9-9 5-2 Drag Beam ...................................................... 5-9 10-1 LARS Antenna Mount................................ 10-13 5-3 Tail Landing Gear/Stabilator ........................ 5-10 FO-1 H-60 Aircraft Skin Material Identifica- 5-4 Fuel Probe Assembly.................................... 5-11 tion Diagram.............................................FP-1 5-5 Cargo Hook................................................... 5-12 FO-2 H-60 Aircraft Exterior Insignia Mark- 5-6 Main Landing Gear Shock Strut .................. 5-13 ings ...........................................................FP-3

LIST OF TABLES

Number Title Page Number Title Page

1-1 Cleaning of Painted Exterior Surfaces ............. 1-4 7-3 Sealant System ................................................ 7-12 1-2 Recommended Dilution of Low Temper- 7-4 Finish System.................................................. 7-12 ature Cleaner................................................. 1-7 7-5 Support Equipment Required.......................... 7-13 1-3 Materials Required ............................................ 1-8 7-6 Materials Required .......................................... 7-13 2-1 Materials Required ............................................ 2-8 8-1 Corrosion Inspection ......................................... 8-6 3-1 Materials Required .......................................... 3-14 8-2 Corrosion Removal and Repair ........................ 8-7 4-1 Support Equipment Required............................ 4-5 8-3 Sealant System .................................................. 8-7 4-2 Materials Required ............................................ 4-5 8-4 Finish System.................................................... 8-8 5-1 Corrosion Inspection ......................................... 5-6 8-5 Support Equipment Required............................ 8-8 5-2 Corrosion Removal and Repair ...................... 5-14 8-6 Materials Required ............................................ 8-8 5-3 Sealant System ................................................ 5-16 9-1 Corrosion Inspection ....................................... 9-10 5-4 Finish System.................................................. 5-17 9-2 Steel Components............................................ 9-11 5-5 Materials Required .......................................... 5-18 9-3 Corrosion Removal and Repair ...................... 9-11 6-1 Corrosion Inspection ....................................... 6-22 9-4 Finish System.................................................. 9-14 6-2 Corrosion Removal and Repair ...................... 6-22 9-5 Suppport Equipment Required........................ 9-15 6-3 Sealant System ................................................ 6-24 9-6 Materials Required .......................................... 9-15 6-4 Finish System.................................................. 6-24 10-1 Corrosion Inspection ..................................... 10-15 6-5 Support Equipment Required.......................... 6-25 10-2 Corrosion Removal and Repair .................... 10-15 6-6 Materials Required .......................................... 6-25 10-3 Support Equipment Required........................ 10-15 7-1 Corrosion Inspection ......................................... 7-6 10-4 Materials Required ........................................ 10-15 7-2 Corrosion Removal and Repair ...................... 7-11

Change 1 v/(vi blank)

FOREWORD

1. GENERAL. 5. LIST OF RELATED PUBLICATIONS.

This Manual contains Organizational, Intermediate, and Depot level corrosion control instructions for model H-60 List of Related Publications aircraft.

Publication Number Publication Title

2. PURPOSE.

AFI21-105 Air and Space Equipment Structural Maintenance.The purpose of this Corrosion Control manual is to provide maintenance personnel with necessary information to guide MIL-HDBK-1568 Materials and Processes for them in inspecting, evaluating, repairing and preventing Corrosion Prevention and corrosion on the H-60 aircraft. It establishes a uniform Control in Aerospace practice for corrosion control, acceptable to the contractors Weapons Systems.

design purpose for this aircraft, and conforming to the

MIL-HDBK-1587 Materials and Process Re-required safety specifications. Specific repair limitations or quirements for Air Forceacceptable minimum requirements may not always apply to a specific damage condition. Varying degrees of stress Weapon Systems.

throughout the aircraft and the relationship of other damage 00-25-234 General Shop Practice Re-that has occurred to the structure have a definite bearing on quirements for the Repair, the type and extent of repair necessary. If a structural

Maintenance, and Test ofcomponent is damaged beyond limitations specified in this Electrical Equipment.manual, it is recommended that further engineering evalua-tion be made to determine the components final disposition. 00-35D-54 USAF Deficiency Report- Secondary structure and minor damage, as defined in this ing, Investigation, and manual, does not affect the structural integrity of the Resolution.

aircraft, but must be temporarily arrested. It shall, however, 1-1-3 Preparation, Inspection, andbe repaired at the next regularly scheduled maintenance Repair of Aircraftperiod. Repairs to the secondary structure may become Fuel, Oil, and Water Alco-necessary to maintain appearance, and should follow good hol Cells and Integralmaintenance practices.

Tanks.

3. SCOPE. 1-1-8 Application of Organic Coatings, Aerospace Sys-

Corrosion damage to the aircraft structure is categorized as tems.

minor damage, reparable damage and major damage. If

1-1-24 Maintenance Repair andcorrosion damage exceeds the allowable repair limits, the Electrical Requirementsitem or component must be replaced.

for Fiberglass Airborne Radomes.4. ABBREVIATIONS/ACRONYMS.

1-1-689 Prevention and Control of The following nonstandard abbreviations are used in this Corrosion and Fungus in manual. For definitions of standard abbreviations and acro- Communications, Elec-nyms, refer to ASME-Y14.38M.

tronic, Meteorological, and Avionic Equipment.CPC Corrosion Preventive Compounds

CRES Corrosion Resistant Steel 1-1-691 Aircraft Weapon System MEK Methyl Ethyl Ketone Cleaning and Corrosion LARS Light-weight Airborne Recovery Control.

LDS Load-Demand Spindle 1-1A-14 Installation Practices Air- PMB Plastic Media Blasting craft Electric and Elec- RTU Ready-to-Use tronic Wiring.

SPM System Program Manager vii

6. CORROSION PREVENTION/CONTROL. 8. TRAINING AND QUALIFICATION

REQUIREMENTS.

Corrosion prevention and repair are of major importance to the USAF, because corrosion has a great effect on the 8.1 TRAINING REQUIREMENTS. The nature of cor-operational capability and structural integrity of aerospace rosion requires that everyone involved in the construction,equipment and/or any given weapon system. Economy is operation, repair, or maintenance of aerospace equipment,another important consideration, because severe corrosion whether they are engineers, technicians, airframe/corrosioncan ultimately weaken primary structural members suffi-control specialists, engine mechanics, electrical specialists,ciently to require complete replacement or extensive rein-or avionics specialists, general aircraft mechanics, etc., beforcement in order to sustain original design loads. The concerned with corrosion prevention and control. A localdegree of the corrosion problem will vary from minor to training program and instruction in practical application ofsevere, depending on the location of the base or equipment corrosion theory shall be established. Everyone shall beoperational areas and mission requirements. Therefore, it is concerned with safety (use and handling of materials ormandatory that each activity, in conjunction with the appli-components, especially acids and solvent), cleanliness,cable parent command, develop a corrosion preven-work habits, and methods. Personnel assigned to worktion/control program to satisfy specific requirements. The corrosion-related tasks must be trained for this work, andresponsibility for an integrated program (including agree-they must demonstrate that they understand the results ofments between services, host and tenant activities) must be their actions. If this is not done, further damage orfixed, and controls must be stringent enough to ensure problems may be created rather than eliminating the prob-accomplishment of the required corrosion prevention and lem. Personnel working in the corrosion area must be ablecontrol program. Local or specific procedures must be to identify all types of corrosion, know proper protectivedevised and definite schedules established.

coating systems for all alloys and how to apply them.

Personnel using the procedures specified in this and other7. WHO IS RESPONSIBLE FOR CORROSION system peculiar corrosion control technical manuals shall

PREVENTION/CONTROL. be fully qualified.

7.1 CORROSION PREVENTION/CONTROL. 8.2 QUALIFICATION REQUIREMENTS. Qualified Corrosion prevention/control is the responsibility of the corrosion control specialists shall have experience in corro-custodian of the equipment. To have an effective corrosion sion treatment, including handling, use, mixing, and storage program, team effort is required between the operating of solvents, coatings, sealants, and chemicals; corrosion command, user, AFSC/AFLC system and corrosion pro- detection, identification, and maintenance of corrosion con-gram managers, and the supporting item, engine, and/or trol equipment; and applicable safety codes and practices.

component managers. Experience has shown that all activi- Qualified personnel reassigned to the aircraft and missile ties have a corrosion problem regardless of whether the corrosion control from other corrosion control work areas equipment is an aircraft, missile, aerospace ground equip- for the first time shall be placed in a familiarization ment, vehicle, real property, installed equipment, etc. category prior to qualification on the assigned equipment.

7.2 COVERAGE OF CORROSION. Complete spe- 9. CONTRACTOR RESPONSIBILITY.

cific coverage of the corrosion encountered in the H-60 aircraft is provided in this publication. Additional informa- Maintenance contractors at depot field maintenance facili-tion may be obtained by referring to the specific weapon ties performing aircraft or equipment maintenance and/or system or other equipment technical orders dealing with repair functions on USAF equipment will ensure that corrosion. Assistance or additional information on resolv- assigned personnel have received Corrosion Prevention and ing corrosion problems may be obtained from the System Control Training relative to their individual job skill Program Manager (SPM). Field Activities shall report specialty.

uncontrollable problems encountered in weapons system maintenance, when required, to the system, engine, or 10. RECORD OF APPLICABLE TIME component manager in accordance with TO 00-35D-54.

COMPLIANCE TECHNICAL ORDERS (TCTOS).The above shall also be accomplished when corrosion damage exceeds authorized or specified limits in the appli-

The record of applicable TCTOs is a listing of all TCTOscable weapon system repair manuals. All local expertise that affect the technical content of this manual. Currentshall be utilized to assist in making decisions on extent of TCTOs only are listed. A TCTO is deleted from the listcorrosion damage and repair or replacement of compo-when any of the following occur.nents. The controlling factor will be the structural integrity of the airframe. a. The equipment configuration to which the TCTO is applicable is no longer covered in the manual.

viii

b. The TCTO is superseded or replaced. c. The TCTO is rescinded.

Change 3 ix/(x blank)

11. IMPROVEMENT REPORTS.

Recommendations for improvements to this technical orders shall be submitted on AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply. Complete AFTO Form 22 in accordance with TO 00-5-1.

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

1H-60-986 Replacement Of The ARC-222(VHF-FM), ARC-222(VHFAM), ARC-164(UHF-AM) and Existing ARC-210(SATCOM) Radios With ARC-210, (RT-1990(C)) Radios on all HH-60G Helicopters. (HH-60G Fully Digital Multispectrum Transceiver (Radio))

4 April 2014

SAFETY SUMMARY

1. GENERAL SAFETY INSTRUCTIONS. 3. KEEP AWAY FROM LIVE CIRCUITS.

The following are general safety precautions and instruc- Operating personnel must at all times observe all safety tions that must be understood and applied during many regulations. Do not replace components inside the equip-phases of operation and maintenance to ensure personal ment with the voltage supply turned on. Under certain safety and health and the protection of Air Force property. conditions, dangerous potentials may exist when the power Portions of this information may be repeated elsewhere in control is in the off position, due to charges retained by this publication for emphasis. capacitors. To avoid injuries always remove power from, discharge, and ground a circuit before touching it. Adhere to all lock out/tag out requirements.2. WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to 4. DO NOT WEAR JEWELRY.

highlight operating or maintenance procedures, practices, conditions or statements which are considered essential to Remove rings, watches, and other metallic objects which protection of personnel (WARNING) or equipment (CAU- may become grounded and cause electrical shock or burn TION). WARNINGs and CAUTIONs immediately precede hazards.

the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, 5. FINGER RINGS.

CAUTION or icon [see HAZARDOUS MATERIALS WARNINGS]), a statement of the hazard minimum precau- Snagged finger rings have caused many serious injuries.

tions, and possible result if disregarded. NOTEs are used in Unless specifically allowed by shop safety procedures, this manual to highlight operating or maintenance proce- removal of finger rings, during all periods of maintenance, dures, practices, conditions or statements which are not is required.

essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending 6. DO NOT SERVICE OR ADJUST ALONE.

upon the information to be highlighted. The headings used and their definitions are as follows. Do not attempt internal service or adjustment with power applied, unless another person capable of rendering aid and resuscitation is present.

WARNING

7. RESUSCITATION.

Highlights an essential operating or mainte-

Personnel working with or near high voltage shall benance procedure, practice, condition, statement, trained in modern methods of resuscitation. Informationetc., which if not strictly observed, could result and training sources may be obtained from Director of Basein injury to, or death of, personnel or long term Medical Services or the American Red Cross.health hazards.

8. ELECTROSTATIC DISCHARGE (ESD).

CAUTION

Certain circuit card assemblies and their components are susceptible to electrostatic discharge/damage. Care must be

Highlights an essential operating or mainte- exercised during handling/repair of these items. Use elec-nance procedure, practice, condition, statement, trostatic discharge (ESD) precautionary procedures out-etc., which if not strictly observed, could result lined in TO 00-25-234.

in damage to, or destruction of, equipment or loss of mission effectiveness.

9. GIVE CLEANERS/CHEMICALS SPECIAL CARE.

NOTE Keep in approved safety containers and in minimum quan-tities. Some cleaners/chemicals many have an effect on

Highlights an essential operating or mainte- skin, eyes, and respiratory tract. Observe manufacturer’s nance procedure, condition, or statement. WARNING labels and current safety directives. Use only xi in authorized areas. Discard soiled cleaning cloths into all test connections are properly and tightly made prior to safety cans. Unless otherwise indicated in the text, use as applying pressure to the test setup. Personnel must be described in this TO should not result in any immediate protected by a safety shield or located at a distance suffi-health concerns. Consult the local Bioenvironmental Engi- cient to prevent injury. Do not probe for pressure leaks with neer for specific protective equipment and ventilation fingers.

requirements.

15. PROTECTIVE MEASURES.

10. ELECTROSTATIC DISCHARGE (ESD)

a. Containers of chemical paint removers are underSENSITIVE DEVICES.

pressure, even when cold. If pressure is not bled off slowly, remover may splatter violently.Certain assemblies and their components are susceptible to electrostatic discharge/damage. Care must be exercised b. Chemical strippers are toxic and contain ingredi-during handling/repair of these items. Use ESD precaution- ents harmful to skin and eye tissue.

ary procedures outlined in TO 00-25-234.

c. No eating, drinking, or smoking is allowed in areas

11. CHEMICAL FILM MATERIALS. where paint removers or solvents are used or stored.

Chemical film materials are strong oxidizers and are a fire

d. Prolonged breathing of vapors from organic sol-hazard in contact with organic materials such as paint vents or materials containing organic solvents isthinners. Do not store or mix surface treatment materials in dangerous. Use cartridge respirator in confinedcontainers previously containing flammable products. Rags areas and ensure good ventilation. Prolonged skincontaminated with chemical film material shall be thor-contact with organic solvents or materials contain-oughly rinsed and disposed of in accordance with local ing solvents can have a toxic effect on affected skinenvironmental requirements.

areas.

12. USE SAFETY APPROVED EQUIPMENT.

e. When opening a can of chemical remover, or when applying chemical remover, the following itemsWhen cleaners and primers are applied, approved shall be worn:explosion-proof lights, blowers, and other equipment shall be used. Ensure that fire fighting equipment is readily (1) Face shield and splash resistant goggles available and in working order.

(2) Rubber gloves

13. COMPRESSED AIR.

(3) Protective clothing (i.e. rubber apron and rubber Use of compressed air can create an environment for boots) propelled foreign particles. Air pressure shall be reduced to

(4) Cartridge-type respirator with approved organicless than 30 Pound-force per square inch (PSI) and used vapor cartridgewith effective chip guarding and personal protective equip-ment. Do not use compressed air to blow dirt or dust from

f. When opening chemical remover, cover the cap orwork clothes.

bung of the container with a rag to reduce splatter and turn the cap only far enough to break the seal.14. DANGEROUS PRESSURES.

Allow internal pressure to release slowly and com-pletely before removing the cap.Pressure systems safety precautions apply to all ranges of pressure. Care must be taken during testing to ensure that xii

CHAPTER 1

CLEANING AND TEMPORARY PROTECTION

1.1 GENERAL.

Corrosion can occur when damage exposes raw edges of metal and the protective finish is either destroyed or worn away. Too much heat from fire damage, or contamination of the finish oil, grease, acids, salt water, or accumulations of dirt will create corrosive conditions on the exposed surface.

Unapproved cleaning methods/compounds will cause dam-age to the protective finish, erode sealing compounds, and leave deposits of corrosion producing materials in joints and seams.

1.2 CLEANING.

Water washing and fresh water rinsing the aircraft is an effective means of preventing corrosion. Wash aircraft using procedures in TO 1-1-691 and TO 1H-60(H)G-2-1. Fre-quency of water washes will depend on severity of the envi-ronment and the length of time the aircraft is exposed. To prevent buildup of static electricity, ground aircraft during cleaning operation.

1.2.1 Cleaning. The aircraft must be kept as clean as

operating conditions permit. Any accumulation of dirt of oils should be wiped off as soon as possible.

1.2.2 Waterless Wipedown. The following is an

approved method of waterless wipe-down when fresh water is not available.

Avoid breathing vapor or spray mist from Corrosion Preventive Compounds (CPC) and lubricants. Wear goggles, avoid prolonged skin contact, and wear respirators approved by lo-cal Bioenvironmental Engineer.

NOTE

If aircraft has been treated with Cor-Ban 35, do not fog with MIL-PRF-81309. Do not apply any additional CPCs on surfaces that Cor-Ban35 has been applied.

a. Spray area with corrosion prevention compound, MIL-PRF-81309, Type II, Class 2, Cor-Ban 35, or equivalent.

b. Wipe surface with clean cheesecloth, CCC-C-440, to remove loosened dirt.

c. Repeat a. and b. as necessary.

1.2.2.1 Corrosion Prevention Compounds (CPC).

NOTE

Cor-Ban 35 is a long lasting, high volatile, high penetration, water displacing compound for use on high profile aircraft substrates.

Corrosion can be controlled by the use of approved CPCs such as MIL-PRF-81309 Type II Class 2, Cor-Ban 35, or others in accordance with TO 1-1-691.

1.3 FOGGING PROCEDURES OF LOWER FUSE-

LAGE, TAIL, AND STABILIZER.

The purpose of these procedures is to reduce Periodic Depot Maintenance line costs and extend the life of the HH-60 airframe. Each command must place continued emphasis on the importance of a thorough corrosion control program. It is impossible to identify every location where corrosion will occur but whenever found, steps should be taken to arrest corrosion and corrosion preventive compounds applied.

Guidelines for a corrosion control program may be found in AFI 21-105. Prompt detection and removal of corrosion will limit the extent of damage suffered by airframes and aircraft components.

1.3.1 General. Corrosion information including illus-

trations, descriptions of types, theory, and prevention meth-ods are contained in TO 1-1-691 and this TO.

1.3.2 Frequency. Fogging procedures shall be per-

formed twice a year (for aircraft operating in a salt water environment); once a year (minimum) for those aircraft operating in a non-salt water environment and each time that the floorboards are removed. This procedure should be annotated in appropriate 781 series forms.

Change 3 1-1

1.3.3 Procedures. • Tail fold hinge forgings

• IGB mount forging

• Interior structure between IGB and TGB

WARNING • TGB mount forging

• Stabilizer interior, through the drain holes

• Trailing edge airfoil through all openings

Avoid eye and skin contact with MIL-PRF- 81309, Type II, Class 2. Avoid inhalation or ingestion. Use in a well-ventilated area. Wash WARNING thoroughly with soap and water after handling or exposure. Remove contaminated clothing

Avoid eye and skin contact with MIL-PRF-immediately.

81309, Type II, Class 2. Avoid inhalation or ingestion. Use in a well-ventilated area. WashNOTE hands thoroughly with soap and water after handling or exposure. Remove contaminatedIf aircraft has been treated with Cor-Ban 35, do clothing immediately.not fog with MIL-PRF-81309. Do not apply any additional CPCs on surfaces that Cor-Ban

f. Reinstall and close all access panels and lubricate35 has been applied.

hinges with MIL-PRF-81309, Type II, Class 2;

wipe up excess. Wipe spray from all exteriorWearing protective clothing/equipment: face shield, respi-surfaces.rator, surgical gloves, and coveralls, and with appropriate safety equipment, using Corrosion Preventive Compound

1.4 TEMPORARY PROTECTION.MIL-PRF-81309, Type II, Class 2 spray fog interior of lower fuselage drain holes, as follows:

Temporary protection is necessary when the aircraft has parts removed for maintenance that will expose otherwise

CAUTION protected parts. Immediate temporary protection is also necessary to prevent additional damage to the accident-damaged aircraft. Each case must be evaluated separately, Transition Section shall not be fogged to avoid as no two situations are exactly alike.

damage to equipment.

1.4.1 Temporary Corrosion Arrestment Proce-

NOTE dure. If operational commitments prevent immediate cor-rection of corrosion, the following temporary arrestment Do not fog inside of the Transition Section. procedure shall be used:

a. Utilizing Formit-18-90-FOG (part number 008353) 90 degree tip or Handi-Spray System (NSN 8030- WARNING 01-438-4073), fog inside of all hull drain holes.

Additionally, fog both RADALT and ADF antenna

Avoid breathing vapor or spray mist from cor-drain holes.

rosion preventive compounds and lubricants.

b. Remove the following aircraft panels for 6 month Wear goggles, avoid prolonged skin contact, aircraft fogging, in accordance with TO 1H- and wear respirators approved by local 60(H)G-2-2: Bioenviromental Engineer.

• RH tail cone access panel NOTE

• Intermediate gearbox cowling

• Section IV tail driveshaft cover If aircraft has been treated with Cor-Ban 35, do• Forward tail gearbox cowling not fog with MIL-PRF-81309. Do not apply• RH cambered fairing access panel any additional CPCs on surfaces that Cor-Ban

35 has been applied.c. Fog the interior of the tail boom, paying close attention to the tail fold area and all anchor nuts. a. Spray affected area with water displacing corrosion preventive compound, MIL-PRF-81309, Type II,d. Close panel.

Class 2.

e. Fog the remainder of the tail, including:

1-2

NOTE

If aircraft has been treated with Cor-Ban 35, do not fog with MIL-PRF-81309.