TDP 1 Excerpt Pages 1-7 from MWO 1-1520-271-50-22.pdf

ROUTINE

MWO effective date is 1 October 2014 and completion date is 30 September 2019

MWO 1-1520-271-50-22

MODIFICATION WORK ORDER

MODIFICATION INSTRUCTIONS FOR THE INSTALLATION

OF THE ENCRYPTED AIRCRAFT WIRELESS INTERCOM

SYSTEM (EAWIS) ON THE CH-47F HELICOPTER

(NSN 1520-01-457-5179)

(EIC:RCH)

U.S. Army Aviation and Missile Command

30 September 2014

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way to improve these procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms), directly to: Commander, US Army Aviation and Missile Command, ATTN: AMSAM-MSS-LP, Redstone Arsenal, AL 35898-5000. A reply will be furnished to you. You may also send in your comments electronically to our E-mail address: 2028@redstone.army.mil or by fax 256-842-6546/DSN 788-6546. For the World Wide Web use: https://amcom2028.redstone.army.mil. Instructions for sending an electronic 2028 can be found at the back of this manual.

AVAILABILITY NOTICE – This publication is not available through U.S. Army Publication Centers. It must be obtained from U.S. Army Aviation and Missile Command, AMSAM-MSS-LP, Redstone Arsenal, AL 35898-5230.

DISTRIBUTION STATEMENT C – Distribution authorized to U.S. Government agencies and their contractors only to protect technical or operational information from automatic dissemination under the International Exchange Program or by other means. This protection applies to the publications required solely for official use and to those containing valuable technical or operational information. This determination was made in 15 July 2007. Other requests for this document will be referred to Commander, U.S. Army Aviation and Missile Command, PEO Aviation, ATTN: SFAE-AV-CH-L, Bldg. 5678, Hicks Road, Redstone Arsenal, AL 35898-5000.

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

HANDLING AND DESTRUCTION NOTICE – Destroy by any method that will prevent disclosure of contents or reconstruction of this document.

EXCERPTED

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AR 20

MWO 1-1520-271-50-22

1. PURPOSE.

This modification provides the installation instructions for the Encrypted Aircraft Wireless Intercom System (EAWIS) for the CH-47F aircraft.

2. PRIORITY.

This modification is classified ROUTINE.

3. END ITEM(S) OR SYSTEM(S) TO BE MODIFIED.

a. The following CH-47F helicopters will be modified in accordance with the instructions contained in paragraph 10.

NOMENCLATURE NATIONAL STOCK NUMBER LIN CAGEC P/N SERIAL NUMBER

Helicopter 1520-01-457-5179 C15172 77272 CH-47F All

b. The following CH-47F helicopter was modified during validation.

NOMENCLATURE NATIONAL STOCK NUMBER LIN CAGEC P/N SERIAL NUMBER

Helicopter 1520-01-457-5179 C15172 77272 CH-47F 10-08081

c. The following CH-47F helicopter was modified during verification.

NOMENCLATURE NATIONAL STOCK NUMBER LIN CAGEC P/N SERIAL NUMBER

Helicopter 1520-01-457-5179 C15172 77272 CH-47F 05-08017

4. MODULE(S), (COMPONENTS, ASSEMBLIES, SUBASSEMBLIES, BOARDS, AND CARDS) TO BE

MODIFIED.

Not Applicable.

5. PART(S) TO BE MODIFIED.

The following item(s), whether installed or in PLL/ASL or depot stock, shall be modified. Stocked parts shall be modified before issue and shall be marked “altered item part number and cage code near existing part mark (724E4119-17)” so that it can be easily determined that modification has been accomplished.

** NSN not assigned.

6. APPLICATION.

a. Time Compliance Schedule: MWO effective date is 1 October 2014 and completion date is 30 September 2019.

b. Level of Maintenance: Depot or Contractor Field Team (CFT).

c. Requirements: Work force and man-hour requirements for application of this MWO for hardware and wiring are as follows:

WORK FORCE/SKILL MAN-HOURS TOTAL MAN-HOURS

1 General Mechanic (MOS 15U) or equivalent 19 19 2 Electrician (MOS 15F/N) or equivalent 31 62 1 Aircraft Inspector (MOS 15U or 15F) or equivalent 31 31

Total 112

Includes operational checks.

NOMENCLATURE NSN CAGEC PART NUMBER

Ceiling Acoustic Blanket ** 77272 724E4119-17 EXCERPTED

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d. Other MWO(s) Required: MWO(s) that must be applied prior to, or concurrently with, the application of this MWO.

e. Additional Information: Not Applicable.

7. TECHNICAL PUBLICATIONS AFFECTED/CHANGED.

TM 1-1520-271-1022 February 2011

TM 1-1520-271-23&P28 February 2011

8. MWO KIT(S)/PART(S) AND THEIR DISPOSITION.

a. Kit(s)/Part(s) needed to apply the MWO:

NOMENCLATURE NSN CAGEC

PART

NUMBER

WEIGHT

(POUNDS)

DIMENSIONS

(INCHES)

VOLUME

(FEET

CUBED)

EAWIS Kit Collector ** 1K9E4 WTG00092-001 13.54 27 X 15.5 X 11.5 2.78

MWO Kit Security Classification. Unclassified.

**NSN not assigned.

b. Contents of MWO kit(s):

NOMENCLATURE NSN CAGEC PART NUMBER QTY

EAWIS Kit Collector ** 1K9E4 WTG00092-001 1 AWIS A-Kit Collector ** 1K9E4 WTG00093-001 1 Electrical Install ** 1K9E4 WTG00094-001 1 Harness Assembly W1 ** 1K9E4 WTG00028-001 1 Harness Assembly W2 ** 1K9E4 WTG00029-001 1 Harness Assembly W3 ** 1K9E4 WTG00098-001 1 Harness Assembly W4 ** 1K9E4 WTG00031-001 1 Harness Assembly W5 ** 1K9E4 WTG00032-001 1 Harness Assembly W6 ** 1K9E4 WTG00098-003 1

Termination Kit, GND P3 ** 1K9E4 WTG00168-001 1 Terminal Lug 5940-00-143-4771 81343 MS25036-103 2 Washer 5310-01-105-7241 80205 NAS1149D0332J 1 Washer 5310-01-352-2752 80205 NAS1149C0332R 1 Screw, Hex Head 5305-01-076-4895 80205 NAS1801-3-9 1 Washer, Lock 5310-00-045-3296 80205 MS35338-43 1

Termination Kit, GND P7 ** 1K9E4 WTG00168-003 1 Terminal Lug 5940-00-143-4771 81343 MS25036-103 1 Washer 5310-01-105-7241 80205 NAS1149D0332J 1 Washer 5310-01-352-2752 80205 NAS1149C0332R 1 Screw, Hex Head 5305-01-076-4895 80205 NAS1801-3-9 1 Washer, Lock 5310-00-045-3296 80205 MS35338-43 1

Termination Kit, Zeroize Relay ** 1K9E4 WTG00168-005 1 Decal ** 1K9E4 WTG00169-015 1 Wire 60”(AWIS-011A22N) ** 1K9E4 P/O WTG00167-001 1 Relay 5945-01-549-5253 81349 M83536/2-024L 1 Relay Socket 5935-01-309-6113 81349 M12883/45-01 1 Wire 600”(AWIS-023A22) ** 1K9E4 P/O WTG00167-007 1 Wire 600”(AWIS-024A22) ** 1K9E4 P/O WTG00167-009 1

EXCERPTED

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NOMENCLATURE NSN CAGEC PART NUMBER QTY

Termination Kit, MISC ELEC

PALLET

1K9E4 WTG00168-007 1

Contact, Socket 5999-01-063-1868 81349 M39029/22-192 2 Wire 60”(AWIS-023C22) ** 1K9E4 P/O WTG00167-023 1 Contact, Pin 5999-00-473-3551 81349 M39029/58-360 2 Contact, Socket 5999-00-320-7459 81349 M39029/56-348 2 Wire 60”(AWIS-024C22) ** 1K9E4 P/O WTG00167-025 1 Insulation Sleeving 5970-01-087-0377 81343 M23053/5-116-0 3 inches

Termination Kit, ICS ** 1K9E4 WTG00168-009 1 Splice 5940-00-271-7741 81343 M81824/1-2 5 Shield Terminator 5940-01-135-7086 81343 M83519/2-8 12 Terminal Lug 5940-00-143-4771 81343 MS25036-103 1 Wire 5” Unmarked ** 1K9E4 P/O WTG00167-005 3 Contact, Socket ** 81349 M39029/56-348 6 Wire 120”(AWIS-025A22N) ** 1K9E4 P/O WTG00167-011 1 Contact 5999-01-068-9548 81349 M39029/22-191 1 Contact, Socket 5999-00-137-5066 81349 M39029/1-101 2 Shield Terminator 5940-01-192-4850 06090 S03-03-R-100 2 Resistor Module 47Ω ** 58982 TJSE22842 1 Resistor Module 49.9KΩ ** 58982 TJSE20822 1 Twisted Pair Wire 24”

Consisting Of Wire (W701- 105A22BLU) Wire (W701-

104A22WHT)

1K9E4 P/O WTG00167-013 1

Twisted Pair Wire 24”Consisting Of Wire (W701-103A22BLU) Wire (W701-102A22WHT)

1K9E4 P/O WTG00167-015 1

Wire 24”(W701-101A22) ** 1K9E4 P/O WTG00167-017 1 Insulation Sleeving 5970-01-087-0377 81343 M23053/5-116-0 6 inches

Termination Kit, PDP ** 1K9E4 WTG00168-011 1 Terminal Lug 5940-00-557-1629 81343 MS25036-149 1 Circuit Breaker 5925-00-224-7422 81343 MS3320-1 1 Wire 5” unmarked ** 1K9E4 P/O WTG00167-005 1 Shield Terminator 5940-01-135-7077 81343 M83519/1-3 1 Bus Conductor 6150-01-362-9178 81205 BACB29B13S5 1 Screw, Machine 5305-01-522-2652 96906 MS51957-43 1 Decal, EAWIS ** 1K9E4 WTG00169-005 1 Decal ** 1K9E4 WTG00169-015 1 Decal ** 1K9E4 WTG00169-017 1 Wire 600” (AWIS-012A18) ** 1K9E4 P/O WTG00167-021 1 Contact, Socket 5999-01-063-1868 81349 M39029/22-192 1

Termination Kit, EMCON ** 1K9E4 WTG00168-013 1 Splice 5940-00-271-7741 81343 M81824/1-2 3 Plug, End Seal 5935-01-577-3543 96906 MS27488-20-2 20 Wire 5” (Unmarked) ** 1K9E4 P/O WTG00167-005 1 Connector 5935-01-190-7609 81349 D38999/26WB35SN 1 Backshell 5935-01-319-0461 81349 M85049/38S11W 1 Tape, Insulation, Electrical 5970-01-438-5583 81343 AA59163-1II0040 6 inches Plug, End Seal 5935-01-578-1405 96906 MS27488-22-2 8 Wire 240” (AWIS-026A22) ** 1K9E4 P/O WTG00167-033 1 Wire 240” (AWIS-027A22N) ** 1K9E4 P/O WTG00167-035 1 Wire 12” (W564-104B22) ** 1K9E4 P/O WTG00167-037 1

EXCERPTED

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NOMENCLATURE NSN CAGEC PART NUMBER QTY

Cable Marker ** 1K9E4 WTG00167-039 1

Termination Kit, 254P21 ** 1K9E4 WTG00168-015 1 Contact, Socket ** 81349 M39029/56-348 6 Shield Terminator 5940-01-224-9981 06090 S03-03-R-100 1 Shield Terminator 5940-01-224-9981 06090 S03-05-R-100 1 Insulation Sleeving 5970-01-087-0377 81343 M23053/5-116-0 3 inches

Control Panel ASSY, EMCON ** 1K9E4 WTG00143-001 1 Panel, Blank 5340-01-569-8438 81205 BACP10U0150BC 1 Screw, Hex Head 5305-01-076-4895 80205 NAS1801-3-9 2 Washer, Flat 5310-01-352-9570 80205 NAS1149D0332K 2 Clamp, Loop 5340-00-291-5353 81343 AS21919WDG02 1 Clamp, Loop 5340-00-200-8560 81343 AS21919WDG05 3 Clamp, Loop 5340-01-497-9277 81343 AS21919WDG06 2 Clamp, Loop 5340-00-200-8559 81343 AS21919WDG07 7 Clamp, Loop 5340-00-291-5347 81343 AS21919WDG08 1 Clamp, Loop 5340-00-584-6556 81343 AS21919WDG10 6 Clamp, Loop 5340-00-286-9427 81343 AS21919WDG12 5 Clamp, Loop 5340-00-286-9424 81343 AS21919WDG14 15 Clamp, Loop 5340-00-664-8164 81343 AS21919WDG15 1 Clamp, Loop 5340-00-286-9418 81343 AS21919WDG16 2 Clamp, Loop 5340-00-200-7451 81343 AS21919WDG17 7 Clamp, Loop 5340-00-200-7449 81343 AS21919WDG18 2 Clamp, Loop 5340-01-516-6768 81343 AS21919WDG21 3 Clamp, Loop 5340-00-664-8165 81343 AS21919WDG22 4 Clamp, Loop 5340-00-200-3045 81343 AS21919WDG24 1 Clamp, Loop 5340-00-598-0529 81343 AS21919WDG28 1 Clamp, Loop 5340-00-579-9678 81343 AS21919WDG32 1 Spiral Wrap 9330-01-406-9827 06383 T25F-CO 7 inches Connector Body, Plug Elec 5935-01-597-2060 58982 164-895 1 Strap, Tiedown 5975-00-899-4606 81343 MS3367-2-0 17 Mounting Plate 5342-00-728-1389 56501 TC92 2

Mechanical Installation ** 1K9E4 WTG00097-001 1 Mounting Plate ASSY CH-47F ** 1K9E4 WTG00118-003 1 Bracket, Inboard, AWIS CH-47 ** 1K9E4 WTG00060-001 1 Bracket, Outboard, AWIS CH-47 ** 1K9E4 WTG00061-001 1 Rivet, Solid 5320-00-754-0822 80205 MS20470AD4-5 10 Washer 5310-01-352-9564 80205 NAS1149D0463K 10 Screw, Cap, Socket Head 5305-00-001-9750 96906 NAS1351-4-14P 10 Washer 5310-01-352-9570 80205 NAS1149D0332K 3 Washer 5310-01-395-8986 80205 NAS1149D0463J 4 Screw, Hex Head 5305-01-089-1520 80205 NAS1801-3-8 3 Nut, Self-Locking 5310-00-807-1467 80205 MS21042-3 3 Right Angle, SMA Female to Male 5935-01-514-2837 53919 PE9068 1 Washer, Flat Reduced O.D. 5310-00-660-2215 80205 NAS620A10L 3 Acoustic Blanket Mod ** 1K9E4 WTG00140-001 1 Access Panel ASSY CH-47 AWIS ** 1K9E4 WTG00012-001 1 Cable Bag Assy, AWIS Ceiling

Panel Modification

1K9E4 WTG00042-009 1

Tape, Reinforcing, Nylon 72 inches ** 1K9E4 WTG00140-005 1

** NSN not assigned.

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c. Bulk and Expendable Materials: The following materials are not furnished and will be requisitioned. The use of equivalent materials is authorized.

NOMENCLATURE NSN CAGEC PART NUMBER QTY

Tape, Lacing and Tying* 4020-00-753-6557 58536 AA52083-C-3-BLACK 1 Acid Brushes* 7920-00-514-2417 7S147 803-12 2 Towel, Paper* 7920-00-721-8884 80244 7920-00-721-8884 5 Corrosion Resistant Coating* 8030-01-460-0246 71410 MIL-DTL-81706 1 Epoxy Primer Coating Kit* 8010-01-441-6030 81349 MIL-PRF-23377 1 Edge Sealer* 8030-00-936-9940 04963 3950 1 Thread, Nylon 8310-01-090-5821 81348 A-A-59826, Type I or II, Class A Size E, (VT-295 Type 2 CL 1)

Conductive Sealant 8030-01-476-2407 83574 PR2200 B-1 1 Sealing Compound, Low Adhesion

8030-01-497-3276 83574 PR-1428 4

P-29 Tape* 5970-01-239-1154 99742 P-29 1 White Ink (For Stenciling) 7510-00-105-0071 58536 A-A-56032-IIWHTPT 1

Polyurethane Coating* 8010-01-580-7175 81349 MIL-DTL-64159 AR

Corrosion Preventive Compound 8030-00-938-1947 81349 MIL-PRF-81309 AR

Cleaner, Lubricant and Preservative

9150-01-053-6688 81349 MIL-PRF-63460 AR

*Equivalent Items Accepted.

d. Parts Disposition:

(1) All parts removed and not reused shall be set aside and disposed of IAW local SOP.

(2) The following parts are to be retained for reinstallation. Ceiling Acoustic Blanket (724E4119-17).

e. Mandatory Replacement Parts: Not Applicable.

f. Government Furnished Equipment:

NOTE

GFE items shall be fielded directly to the unit.

Items in the table below are shipped separately due to software upgrades.

NOMENCLATURE NSN CAGEC PART NUMBER QTY

Integrated Aircraft Interface Unit (IAIU) with Non- Encrypted Device (NED)

5895-01-602-9889 78111 780-1200-011-CF0065-

M25

Antenna, Trulink 5935-01-539-6253 78711 AN6832-M1 1 Connector, Adapter 5935-01-539-6253 78711 33TNC-SMA-50-1 1 Enhanced Mobile Equipment

(EME)

5821-01-603-0004 78711 ME6880-M1-CF0065-

M23

Jack Box 5821-01-596-0160 9N770 JB6881-M1 3 Antenna, Trulink 5985-01-539-6252 9N770 AN6832-M1 3

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9. SPECIAL TOOLS; TOOL KITS; JIGS; TEST, MEASUREMENT, AND DIAGNOSTIC EQUIPMENT (TMDE);

AND FIXTURES REQUIRED.

NOMENCLATURE NSN CAGEC PART NUMBER QTY

Toolbox, Aircraft Maintenance 5180-01-375-6926 81996 SC 5180-99-B06 1 Toolbox, Mechanic 5180-01-375-6925 81996 SC 5180-99-CLB01 1 4X Rivet Gun ** 00988 Sioux Model 270A-4 1 Corner Rivet Gun ** 07T94 Brown Tool Model BAT-1X 1 Crimp Tool 5120-01-408-3752 81349 M22520/23-01 (AFM-8) 1 Crimping Tool, Terminal, Hand 5120-01-120-8721 06090 AD-1377-1 1 Crimping Tool, Terminal, Hand 5120-00-132-6913 11851 M22520/5-01 (HX-4) 1 Die 5120-00-126-0860 11851 M22520/5-100 1 Heat Gun 4920-01-343-1682 06090 HT-900B 1 Multimeter 6625-01-265-6000 80058 FLUKE-27II/FM 1 Contact Positioner, Terminal Crimp

5120-01-096-8487 11851 620656 1

Contact Positioner, Terminal Crimp

5120-00-165-3913 81349 M22520/2-02 (K1S) 1

Contact Positioner, Terminal Crimp

5120-01-096-6739 81349 M22520/2-07 1

Pulling Head, Riveter 5130-01-045-3507 53551 456MAX-753-54 1 Riveter, Blind, Pneumatic 5130-01-044-7206 81349 G-701A 1 Rivet Gun Kit 5180-01-201-4979 64878 D-100-MIL-2 1 Rivet Squeezer (5-Inch Jaws) 5130-01-230-3158 11976 Chicago Pneumatic Model

CP-0351-ESKEL

Spanner Wrench 5120-00-658-9805 80063 SC-B-61575 1 Torque Screw Driver 0-25 in-lbs 5120-00-568-4742 05047 B25 1 Wrench, Torque (5-150 inch lbs) 5120-00-427-6021 K0662 CH150 1

**NSN Not Assigned.

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