DMWR 1-1520-237-3

Appendix E. MODIFICATIONS ............................................................................................................. E-1 E-1 UH60A Re-capitalization Program...................................................................... E-1 E-2 Installation of UH-60 9A to A9 Recapitalization Program (50-31).................... E-2 E-3 Door Post Modification Kit (50-22).................................................................... E-20 E-4 Hinge Access Modification Kit (50-35).............................................................. E-39 E-5 Modification Kit (50-5)........................................................................................ E-44 E-6 Station 379 Modification Kit (50-26).................................................................. E-65 E-7 Upper Plating Modification Kit (50-16).............................................................. E-73 E-8 BL 34.5 Modification Kit (50-7)......................................................................... E-88 E-9 ESSS Doubler Modification Kit (50-15)............................................................. E-96 E-10 TRDS Brackets Modification Kit (50-20)........................................................... E-105 *DMWR 1-1520-237 i TABLE OF CONTENTS (Cont) Chapter,Section and/or Group Task Page E-11 Station 485 Modification Kit (50-34).................................................................. E-112 E-12 Lower Aft Transition/Foam Liner Modification Kit (50-6) ............................... E-116 E-13 Enclosure Modification Kit (50-21) .................................................................... E-143 E-14 Support Shaft Modification Kit (50-9)................................................................ E-152 E-15 Shear Deck Modification Kit (50-29) ................................................................. E-162 E-16 Stringer/Frame Modification Kit (50-24) ............................................................ E-167 E-17 Skin Doubler/Plate Installation Modification Kit (50-13) .................................. E-190 E-18 Bulkhead Installation Modification Kit (50-17).................................................. E-202 E-19 Tail Pylon, CRCT Doubler, Front Spar FT Modification Kit (50-8) ................ E-208 E-20 Side Skin Modification Kit (50-10)..................................................................... E-231 E-21 Aft Spar FT Modification Kit (50-25) ................................................................ E-240 E-22 L/H R/H Firewall Modification Kit (50-19) ....................................................... E-253 E-23 Cowl Assembly Modification Kit (50-33) .......................................................... E-261 E-24 HIRSS Repair Kit (50-30) ................................................................................... E-267 *DMWR 1-1520-237 ii TABLE OF CONTENTS (Cont) Chapter,Section and/or Group Task Page E-1 Re-capitalization Modification Kit E-15 E-2 Door Post Modification Kit E-33 E-3 Hinge Access Modification Kit E-42 E-4 Modification Kit E-58 E-5 Station 379 Modification Kit E-70 E-6 Upper Plating Modification Kit E-81 E-7 BL 34.5 Modification Kit E-93 E-8 ESSS Doubler Modification Kit E-102 E-9 Tail Rotor Drive Shaft Brackets Modification Kit E-110 E-10 Station 485 Modification Kit E-114 E-11 Lower Aft Transition Modification Kit E-129 E-12 Foam Liner Modification Kit E-141 E-13 Enclosure Modification Kit E-149 E-14 Support Shaft Modification Kit E-158 E-15 Support Shaft Modification Kit E-160 E-16 Shear Deck Modification Kit E-165 E-17 Stringer/Frame Modification Kit E-178 E-18 Skin Doubler Modification Kit E-197 E-19 Plate Installation Modification Kit E-199 E-20 Bulkhead Installation Modification Kit E-206 E-21 Tail Pylon Modification Kit E-221 E-22 CRCT Doubler Modification Kit E-226 E-23 Front Spar FT Modification Kit E-228 E-24 Side Skin Modification Kit E-237 E-25 Aft Spar Fitting Modification Kit E-250 E-26 L/H Firewall Modification Kit E-257 E-27 R/H Firewall Modification Kit E-259 E-28 Cowl Assembly Modification Kit E-265 E-29 HIRSS Repair Kit E-271 *DMWR 1-1520-237 iii/(iv blank) APPENDIX E MODIFICATIONS E-1. UH60A RE-CAPITALIZATION PROGRAM. The purpose of the UH-60A Re-capitalization Program is to extend the use of the U.S. Army owned UH-60A’s for ap- proximately ten additional years. The program will allow the aircraft to continue to be used until induction into the UH- 60M Modernization Program. Approximately three hundred aircraft will be inducted into the re-capitalization program. The airframe structural kits to be used in this program were developed based on review of the Government furnished Aircraft Corrosion Evaluation/Joint Aircraft Corrosion Evaluation/On Conditional Maintenance (ACE/JACE/OCM) data. The Sikorsky 9Crack Database9 as well as field service reports were also used to determine airframe components that were problematic to the user community. Several of the airfame kits are based on those previously used on other H-60 derivative aircraft such as the MH/HH-60G. Modifications were made as required to account for any structural differences between the parent aircraft and the UH- 60A. In many cases, the structural kits for the re-capitalization program were also incorporated into production via ECP or production change orders. In these cases, the inducted aircraft will then be brought up close to the current UH-60L configuration. The kit description is broken down by aircraft structural component (cockpit, cabin, etc.). This was done because some of the components, namely the cockpit, tailcone and tail rotor pylon, will be reused when the aircraft is inducted into the UH- 60 Modernization program. The strttctural kits for these areas are the same between the re-capitalization and the modernization programs. The item number shown for each kit was established from the first potential kit list shown in July 2001. Some of the kits were subsequently deleted but the original item numbers were retained for historical purposes. The weight and center of gravity data for each of the structural kits is included. This will allow the revised weight and bal- ance to be calculated for the aircraft inducted into the re-capitalization program. DMWR 1-1520-237 E-1 E-2. INSTALLATION OF UH-60 9A TO A9 RECAPITALIZATION PROGRAM (50-31). Subject: Installation of UH-60 9A to A9 Recapitalization Program, dated 31 March 2003 Purpose: The purpose of this Special Service Instructions (SSI) is to describe the modification and repair changes. Mate- rial information paragraph will be top kits and subkits only. Individual parts and parts disposition will not be listed. Step by step modification instructions will only reference SSI instructions and Technical Manuals (TM). Model: UH-60A Description: The Recapitalization Program will modify areas of the UH-60A, Nose/Canopy, Cabin, Transition, Tail Cone, Pylon, Firewall, and Engine Cowls. Drawings required for modification: 70000-03200, 70070-20167, 70070-20266, 70070-20465, 70070-20470, 70070-20488, 70070-20527, 70070-20566, 70070-20568, 70070-20570, 70070-20572, 70070-20575, 70070-20577, 70070-20578, 70070- 20581, 70070-20582, 70070-20583, 70070-20587, 70070-20588, 70070-20615, 70070-20617, 70070-20641, 70070-30307, 70070-30308, 70070-95122, 70072-30000, 70083-20110, 70200-07050, 70201-06164, 70202- 06051, 70203-03003, 70209-03012, 70209-03022, 70209-06056, 70211-01005, 70211-03001, 70211-03002, 70211-03004, 70211-03005, 70211-03006, 70211-03007, 70211-03009, 70212-02307, 70212-03002, 70212- 03003, 70212-05004, 70213-02101, 70213-02301, 70213-02501, 70213-03001, 70213-03002, 70213-03004, 70217-01010, 70217-03001, 70219-03002, 70219-03011, 70304-02114, 70308-03611, 70400-03611, 70500- 01053, 70553-07001, 70551-05140, 70551-03140, 70652-02150, 70551-03101, 70551-03102 References: (a) TM 1-1520-237-MTF, Technical Manual, Operator’s and Crew Member’s Check List (b) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 1, Aircraft General (c) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 2, Airframe (d) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 4, Engine Systems (e) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 5, Rotor System (f) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 6, Drive System (g) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 7, Pneudraulic System (h) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 8, Instrument Systems (i) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 9, Electrical System (j) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 10, Fuel System DMWR 1-1520-237 E-2 (k) TM 1-1520-237-23, Aviation Unit And Intermediate Maintenance For Army Models UH-60A, UH- 60L, EH-60A, and UH-60Q Helicopters, Chapter 11, Flight Control System (l) SSI No. 50-5, Side Fuselage Structural Reinforcement, Installation of, dated 31 March 2003 (m) SSI No. 50-6, Lower Aft Transition Section, Rework of, dated 31 March 2003 (n) SSI No. 50-7, Buttline 34.50, Modification of, dated 31 March 2003 (o) SSI No. 50-8, Tail Rotor Pylon, Modification of, dated 31 March 2003 (p) SSI No. 50-9, Drive Shaft Supports, Modification of, dated 31 March 2003 (q) SSI No. 50-10, Tail Pylon Side Skin, Modification of, dated 31 March 2003 (r) SSI No. 50-13, Tailcone Plating, Installation of, dated 31 March 2003 (s) SSI No. 50-15, ESSS Doublers, Installation of, dated 31 March 2003 (t) SSI No. 50-16, Upper Plating and Doubler Installation, Rework of, dated 31 March 2003 (u) SSI No. 50-17, Station 605.00 Bulkhead, Modification of, dated 31 March 2003 (v) SSI No. 50-19, Left and Right Side Firewall Assemblies, Modification of, dated 31 March 2003 (w) SSI No. 50-20, Tail Rotor Drive Shaft Support Brackets, Modification of, dated 31 March 2003 (x) SSI No. 50-21, Vapor Barrier Support Structure, Replacement of, dated 31 March 2003 (y) SSI No. 50-22, Cockpit Floor and Door Posts, Modification of, dated 31 March 2003 (z) SSI No. 50-24, Tail Cone, Modification of, dated 31 March 2003 (aa) SSI No. 50-25, Tail Rotor Pylon, Aft Spar Stabilator Attachment Fitting, Modification of, dated 31 March 2003 (ab) SSI No. 50-26, Station 379.00 Frame, Modification of, dated 31 March 2003 (ac) SSI No. 50-29, Tail Cone Shear Deck, Modification of, dated 31 March 2003 (ad) SSI No. 50-30, HIRSS Repair Kit, Installation of, dated 31 March 2003 (ae) SSI No. 50-33, Engine Cowl Assembly, Left and Right Side, Modification of, dated 31 March 2003 (af) SSI No. 50-34, Transition Station 485.00, Modification of, dated 31 March 2003 (ag) SSI No. 50-35, Canopy Assembly, Nose Door Hinge Access Holes, Modification of, dated 31 March 2003 DMWR 1-1520-237 E-3 Instructions: NOTE • A complete review of this SSI is recommended before incorporating the installation of UH-60 9A to A9 Recapitalization Program. • Before beginning this modification procedure, use the material information list located in reference SSI’s to inventory the modification kits. Make sure all parts are present and in serviceable condition. • Where drawing numbers are not listed within individual step(s), drawing(s) listed in preceding step(s) are the controlling authority. • The sheet metal, structural, and electrical modifications in this SSI shall be done by personnel experienced in reading modification drawings. Routine steps such as cleaning, layout and drilling, deburring, standard repairs, corrosion control, clean up after rework, chemical coating for aluminum after cutting/trimming parts, peeling shims, paint touch up, routing, clamping, and safety practices may not be called out herein. However, these steps and all other required routine tasks shall be done. • Personnel must be trained and certified in hole quality assurance and proper cold expansion procedures per SS5098. • Slight variations to the instructions contained herein are allowed, as long as the intent of the modification is accomplished. • Trial Installation was performed on helicopter Serial Number (86-24510) at Corpus Christi Army Depot, (CCAD) Corpus Christi, TX. A. Preparation for modification and removal of equipment: (1) Confirm that all warnings, cautions, and notes are complied with. (2) Turn off electrical/hydraulic power and make helicopter safe for ground maintenance. (3) Defuel helicopter per reference (b). (4) Perform arrival inspection. (5) Remove, clean, preserve, and tag main rotor blades per reference (e). (6) Remove, clean, preserve, and tag tailrotor blades per reference (e). (7) Clean and install pitot covers per reference (h). (8) Remove the following airframe components per reference (c). (a) Remove pilots door, pilots seat, copilots door, copilots seat, cockpit floor panels, cockpit floor covers and nose access panel. (b) Remove troop seats, troop seat supports, left cargo door, right cargo door, nose door, gunner seats, gun- ner seat supports, soundproofing, drip pan assembly, control enclosure left side, control enclosure right side, and aft cargo floor at station 397.00 from cabin. (c) Remove fuel cell enclosure panels, drive shaft covers, stabilator fairings, and tail gear box cover from transition, tailcone, and pylon of helicopter. DMWR 1-1520-237 E-4 (d) Remove sliding pylon cover, left engine intake, right engine intake, main rotor gear box fairings, engine exhaust fairings, APU fairings, and oil cooler fairings. (e) Remove stabilator. (f) Remove engine platforms and place on a suitable work area. (g) Remove lower chin windows. (h) Remove (if equipped) ESSS fairings. (9) Remove the following flight controls per reference (k). (a) Disconnect flight control cables at tail cone turnbuckle location. (b) Remove lateral, forward, and aft primary servos. (10) Remove the following Pneudraulic/Hydraulic component per reference (g). (a) Remove No. 1 and No. 2 transfer modules. (b) Remove No. 1 and No. 2 transfer module manifolds. (c) Remove primary servo manifold. (d) Remove boost servo/pilot assist manifold. (e) Disconnect tail rotor servo lines at station 647.00 and station 398.00 and pull forward to gain access to station 605.00 rework. (11) Remove tail rotor drive shafts per reference (e). (12) Remove engines per reference (d). (13) Remove main rotor gear box per reference (f). (14) Remove tail rotor gear box per reference (f). (15) Remove the following electrical and avionics components per reference (i). (a) Disconnect, tag battery with helicopter serial number, and transfer helicopter battery to battery shop. (16) Remove fuel cells and fuel cell liners per reference (j). B. Description of modification. (1) Recapitalization program modifications as follows: (a) Side fuselage structure is reinforced by adding support structure between stations 265.50 and 308.00, left and right side gunners window. (b) Lower aft transition structure is removed, corrosion treated, and new structure is installed. DMWR 1-1520-237 E-5 (c) Buttline 34.50 is modified by installing new reinforcements, coldworking fasteners locations, and installing new fasteners. (d) Tail rotor gear box pylon mount fitting is modified by installing a new left side doubler and two right side straps with coldworked fasteners. Tail gear box mount fitting is removed and a new fitting is installed. Forward spar doubler is removed and replaced with a new doubler. Gear box fairing installation is modified. (e) Tail rotor drive shaft supports are modified at stations 410.00, 471.00, 531.43, and 591.88 by installing new supports, doublers, and brackets. (f) New doublers and stiffeners are added to the existing tail pylon side skin between stations 645.00 and 660.00. (g) Lower skin and doubler between stations 485.00 and 605.00 are removed and new skin and doubler are installed. New doublers are installed at left and right side locations between tailcone stations 625.00 and 635.00. (h) New skins and doublers are installed between stations 295.00 and 308.00 on helicopters equipped with ESSS provisions. (i) New cabin upper plating is installed between stations 320.00 and 380.00 with coldworked fasteners com- mon to buttline 16.5 transmission beams. (j) Tailcone station 605.00 is modified by installing a new doubler, filler, and radius block. (k) New doublers, angles, straps, and spacers are installed to left and right side firewall assemblies. (l) New intercostals which support vapor barriers over fuel cells between stations 413.00 and 443.50 are installed. (m) Station 205.00, left and right side door post locations are modified by installing new fittings, angles and nutplates. (n) Tailcone structure between stations 485.00 and 565.00 is modified by adding stringers and shear ties. (o) Stabilator attachment fittings are modified by removing bushings and liners and installing new Forcemate bushings and spherical bearings. (p) New straps and doublers are installed at station 379.00 frame left and right sides with coldworked fasten- ers. (q) Tail cone shear deck is modified by installing new doublers and angles between stations 605.00 and 645.00. (r) HIRSS structure is modified by installing new doublers, fillers, angles, and radius blocks on helicopters equipped with HIRSS. (s) New hinge fitting assemblies are installed to reinforce the hinge area on the engine cowl assemblies. (t) A new fitting and fasteners are installed at station 485.00. (u) Two access holes, doublers, and new seal are added to the nose door hinge area. DMWR 1-1520-237 E-6 C. Installation (1) Perform recapitalization modifications as follows: (a) Rework nose/canopy per references (y), and (ag). (b) Rework cabin per references (l), (n), (s), (t), and (ab). (c) Rework of transition per references (m), (v), (w), (x), (ad), (ae), and (af). (d) Rework tail cone per references (p), (r), (u), (z), and (ac). (e) Rework tail pylon per reference (o), (q), and (aa). D. Reinstallation of removed equipment: (1) Install fuel cells and fuel cell liners per reference (j). (2) Install main rotor gear box per reference (f). (3) Install tail rotor gear box per reference (f). (4) Install tail rotor drive shafts per reference (e). (5) Install engines per reference (d). (6) Install the following pneudraulic/hydraulic components per reference (g). (a) Install No. 1 and No. 2 transfer modules. (b) Install No. 1 and No. 2 transfer modules manifolds. (c) Install boost servo/pilot assist manifold. (d) Install primary servo manifold. (7) Install the following flight control per reference (k). (a) Install lateral, forward, and aft primary servos. (b) Reconnect flight control cables at tail cone turnbuckle locations. (8) Install the following airframe components per reference (c). (a) Install pilots door, pilots seat, copilots door, copilots seat, cockpit floor panels, and cockpit floor covers. (b) Install aft cargo floor to station 397.00, troop seats, troop seat supports, left cargo door, right cargo door, gunner seats, gunner seat supports, and soundproofing. (c) Install fuel cell enclosure panels, drive shaft covers, stabilator, stabilator fairings, and tail gear box cover. (d) Install sliding pylon cover, left engine intake, right engine intake, main rotor gear box fairings, engine exhaust fairings, engine platform doors, APU fairings, and oil cooler fairings. DMWR 1-1520-237 E-7 (e) Install control enclosure left side and control enclosure right side, nose and cabin vibration absorber, nose access panel, and drip pan assembly. (f) Install lower chin windows. (g) Install ESSS fairings (if equipped). (9) Install tail rotor blades per reference (e). (10) Install main rotor blades per reference (e). (11) Remove covers from pitot tubes per reference (h). E. Perform operational check out as follows: (1) Perform applicable operational checks that are identified in Technical Manual (TM) upon installation of components. F. Record of Compliance: (1) Make an appropriate logbook entry to show compliance with this Special Service Instruction. (2) Upon compliance with these Special Service Instructions, complete SA Form 7614 and return it to Sikorsky Aircraft ILS Manager. Weight and Balance Data: QTY PART NO. NOMENCLATURE POUNDS WEIGHT INCHES AFT OF DATUM MOMENT/ 1000 1 70070-95122-011 Mod. Kit + 61.7 359.1 24.40 Weight and Balance: Change resulting from these instructions are as follows: Change in basic weight: + 61.7 pounds Moment arm: 359.1 in. Change in basic moment/1000 24.40 Manpower (Estimated) No. of Personel No. of Hours Man-hours Sheet Metal Mechanic 8 209.0 *1672.0 Helicopter Electrician 1 8.0 *8.0 Fuel Mechanic 1 2.0 *2.0 *Does not include time required to prepare helicopter or return it to flight status. DMWR 1-1520-237 E-8 Material Information: A. Modification Kit Required: Qty Nomenclature Part Number Source 1 RECAP Top Kit, 70070-95122-011 (1) consisting of: 1 Mod. Kit, Nose/Canopy, 70070-20566-011 consisting of: 1 Mod. Kit, Door Post, 70070-20566-012 consisting of: 1 Mod. Kit, Floor Instl, 70070-20566-015 1 Mod. Kit, Fitting Installation Left Hand, 70070-20566-019 1 Mod. Kit, Fitting Installation Right Hand, 70070-20566-020 1 Mod. Kit, Floor Left Hand, 70070-20566-017 1 Mod. Kit, Floor Right Hand, 70070-20566-018 1 Mod. Kit, Jamb Installation, 70070-20566-034 1 Mod. Kit, Jamb Installation, 70070-20566-035 1 Mod. Kit, Frame Installation, 70070-20566-037 1 Mod. Kit, Frame Installation, 70070-20566-038 1 Mod. Kit, Hinge Access, 70070-20566-013 1 Mod. Kit, Cabin, 70070-20567-011 consisting of: 1 Mod. Kit, Side Fuselage, 70070-20527-011 consisting of: 1 Mod. Kit, 70070-20167-026 1 Mod. Kit, 70070-20470-011 1 Mod. Kit, Beef-Up, 70070-20527-012 1 Mod. Kit, Beef-Up, 70070-20527-013 1 Mod. Kit, Station 379.00, 70070-20568-011 consisting of: 1 Mod. Kit, SPL Instl, 70070-20568-012 1 Mod. Kit, Strap Instl, 70070-20568-013 1 Mod. Kit, Upper Plating, 70070-20570-011 consisting of: 1 Mod. Kit, Plate Instl, 70070-20570-012 1 Mod. Kit, Nutplate Instl, 70070-20570-013 DMWR 1-1520-237 E-9 Qty Nomenclature Part Number Source 1 Mod. Kit, Frame Instl, 70070-20570-014 1 Mod. Kit, Angle Instl, 70070-20570-015 1 Mod. Kit, Buttline 34.50, 70070-20572-011 consisting of: 1 Mod. Kit, R/H Reinforcement, 70070-20572-012 1 Mod. Kit, L/H Reinforcement, 70070-20572-013 1 Mod. Kit, ESSS Doubler, 70070-20641-011 consisting of: 1 Mod. Kit, Support R/H Instl, 70070-20641-012 1 Mod. Kit, Support L/H Instl, 70070-20641-013 1 Mod. Kit, Plating Instl, 70070-20641-014 1 Mod. Kit, Shim Instl, 70070-20641-018 1 Mod. Kit, Transition, 70070-20575-011 consisting of: 1 Mod. Kit, TRDS Brackets, 70070-20488-023 consisting of: 1 Mod. Kit, Support Instl, 70070-20488-012 1 Mod. Kit, Support Instl, 70070-20488-022 1 Mod. Kit, Station 485.00, 70070-20575-012 1 Mod. Kit, Lower Aft Transition, 70070-20577-011 consisting of: 1 Mod. Kit, Plate Assembly, 70070-20577-012 1 Mod. Kit, Frame Instl, 70070-20577-013 1 Mod. Kit, Hardware, 70070-20577-014 1 Mod. Kit, Door Instl, 70070-20577-016 1 Mod. Kit, Fuel Dump, 70070-20577-017 1 Mod. Kit, Fuel Vent, 70070-20577-018 1 Mod. Kit, Foam Liner, 70070-20577-015 1 Mod. Kit, Enclosure, 70070-20578-011 1 Mod. Kit, Tail Cone, 70070-20580-011 consisting of: 1 Mod. Kit, Support, Shaft, 70070-20266-013 1 Mod. Kit, Support, Shaft, 70070-20266-014 DMWR 1-1520-237 E-10 Qty Nomenclature Part Number Source 1 Mod. Kit, Shear Deck, 70070-20581-011 1 Mod. Kit, Stringer/Frame, 70070-20582-011 consisting of: 1 Mod. Kit, Frame, 70070-20582-012 1 Mod. Kit, Frame, 70070-20582-013 1 Mod. Kit, Frame, 70070-20582-014 1 Mod. Kit, Frame, 70070-20582-027 1 Mod. Kit, Frame, 70070-20582-028 1 Mod. Kit, Frame, 70070-20582-015 1 Mod. Kit, Plating, 70070-20582-016 1 Mod. Kit, Skin Assy, 70070-20582-024 1 Mod. Kit, Plating, 70070-20582-017 1 Mod. Kit, Skin Assy, 70070-20582-025 1 Mod. Kit, Skin Assembly, 70070-20582-026 1 Mod. Kit, Skin Doubler, 70070-20583-011 1 Mod. Kit, Plate Instl, 70070-20615-011 1 Mod. Kit, Bulkhead Instl, 70070-20617-011 1 Mod. Kit, Pylon, 70070-20585-011 consisting of: 1 Mod. Kit, Tail Pylon, 70070-20465-017 consisting of: 1 Mod. Kit, Plating, 70070-20465-012 1 Mod. Kit, Fairing, 70070-20465-014 1 Mod. Kit, 70070-20465-015 1 Mod. Kit, 70070-20465-016 1 Mod. Kit, Fitting, 70070-20465-018 1 Mod. Kit, Crescent Doubler, 70070-20465-019 consisting of: 1 Mod. Kit, Plating TRP, 70070-20465-021 1 Mod. Kit, Plating TRP, 70070-20465-022 1 Mod. Kit, Front SPAR Fitting, 70070-20465-020 consisting of: 1 Mod. Kit, Front SPAR, 70070-20465-027 1 Mod. Kit, Support Instl, 70070-20465-028 1 Mod. Kit, Support Instl, 70070-20465-029 DMWR 1-1520-237 E-11 Qty Nomenclature Part Number Source 1 Mod. Kit, Side Skin, 70070-20587-011 consisting of: 1 Mod. Kit, Plating Instl, 70070-20587-015 1 Mod. Kit, Plating Instl, 70070-20587-016 1 Mod. Kit, SPAR Instl, 70070-20587-017 1 Mod. Kit, Aft SPAR Fitting, 70070-20588-011 consisting of: 1 Mod. Kit, Fitting Assembly, 70070-20588-012 1 Mod. Kit, Fitting Assembly 70070-20588-013 1 Mod. Kit, Stab Instl, 70070-20588-014 1 Mod. Kit, LH Firewall Improve- ments, 70070-30307-011 1 Mod. Kit, RH Firewall Improve- ments, 70070-30307-012 1 Mod. Kit, Cowl Engine, 70070-30308-011 1 Mod. Kit, HIRSS Repair, 70072-30000-011 consisting of: 1 Repair Kit, 70072-30000-012 1 Repair Kit LH, 70072-30000-013 B. Consumable Material: WARNING OBSERVE ALL CAUTIONS AND WARNINGS ON CONTAINERS WHEN USING CONSUMABLES. WHEN APPLICABLE, WEAR NECESSARY PROTECTIVE GEAR DURING HANDLING AND USE. IF A CONSUMABLE IS FLAMMABLE OR EXPLOSIVE, MAKE CERTAIN CONSUMABLE AND ITS VAPORS ARE KEPT AWAY FROM HEAT, SPARK, AND FLAME. MAKE CERTAIN EQUIPMENT IS PROPERLY GROUNDED AND FIREFIGHTING EQUIPMENT IS READILY AVAILABLE PRIOR TO USE. FOR AD- DITIONAL INFORMATION ON TOXICITY, FLASHPOINT, AND FLAMMABILITY OF CHEMICALS, CONSULT YOUR MEDICAL PEOPLE, OR MANUFACTURER OF THE CONSUMABLE. Qty Nomenclature Part Number Source 32 oz. Adhesive EC-1357 or equivalent (1) 64 oz. Sealant AMS-S-8802, A2 or equivalent (1) 64 oz. Sealant AMS-S-8802, B2 or equivalent (1) DMWR 1-1520-237 E-12 Qty Nomenclature Part Number Source 64 oz. Sealant MIL-S-8802, Class A2, or equivalent (1) 64 oz. Sealant MIL-S-8802, Class B2, or equivalent (1) 64 oz. Sealant MIL-S-8802, Class C20, or equivalent (1) 8 oz. Chemical Conversion Coating for Aluminum (Alodine 600) MIL-C-5541, Class 3, or equivalent (1) 8 oz. Sealant RTV133 or equivalent (1) 16 oz. Primer MIL-P-85582A or equivalent (1) 16 oz. Paint, Green SS8511-40-34031 or equivalent (1) 16 oz. Paint, Black SS8511-40-37038 or equivalent (1) 8 oz. Chemical Conversion Coating for Aluminum (Alodine 1200) MIL-C-5541, Class 1A, or equivalent (1) 32 oz. Adhesive EA9309.3NA or equivalent (1) 8 oz. Foam Syntactic SS9587-002 or equivalent (1) 8 oz. Foam Syntactic SS9587-001 or equivalent (1) 8 oz. Foam Syntactic SS9587-003 or equivalent (1) 6 oz. Sealant MIL-S-81733, Type 1 or IV or equivalent (1) 2 oz. Primer, Adhesive EC-3917 or equivalent (1) 6 oz. Sealing Compound AMS3267 Class A2 or C2, or equivalent 2 oz. Antiseize Compound MIT-T-83483 or equivalent (1) 2 oz. 1,1,1-Trichloroethane MIL-T-81533 or equivalent (1) 1 pkg Mat, Abrasive MIL-A-9962 or equivalent (1) 1 pkg Cloth, Cheesecloth CCC-C-440 or equivalent (1) 2 oz. Sealing Compound CA1000 or equivalent 4 oz. Compound Dinotrol Av30 or Av15, or equivalent (1) 4 oz. Urethane MIL-C-85285, or equivalent (1) 4 oz. Adhesive 444R, or equivalent (1) 6 oz. Primer MIL-P-23377 or equivalent (1) 8 oz. Clear Epoxy MIL-L-22750, or equivalent (1) 4 oz. Adhesive PLIOBOND No. 20 or equivalent (1) 3 oz. Sealant Tape AMS3255 CL2 or equivalent (1) 8 oz. Adhesive EA9359.3 or equivalent (1) 8 oz. Adhesive DP420 or equivalent (1) 4 oz. Sealing Compound AMS 3265 or equivalent (1) 4 oz. Adhesive EC1751 A/B or equivalent (1) C. Support Equipment: Qty Nomenclature Part Number Source 1 Bearing Removal/Installation Tool (Pylon) 70700-20129-041 or equivalent (1) DMWR 1-1520-237 E-13 Qty Nomenclature Part Number Source 1 Installation Tool (Pylon) 70209-06056-041T046 or equivalent (1) 1 Locally designed and manufactured fuselage support tool N/A (2) 1 Edge Distance Tool (Pylon) 70070-77399-041 (1) 1 Drill Tool (Door post) 70070-20566-017T046 (1) 1 Installation Tool (Hinge) 70070-20566-019T046 (1) 1 Installation Tool (Hinge) 70070-20566-020T046 (1) D. Source: (1) Available through normal supply channels (2) Locally Manufactured DMWR 1-1520-237 E-14 SA AB3088_1 A 1 4 10 16 24 1 2 3 Figure E-1. Re-capitalization Modification Kit (Sheet 1 of 3) DMWR 1-1520-237 E-15 SA AB3088_2 6 7 8 9 5 9 11 12 13 14 15 4 10 17 18 19 20 21 22 23 16 Figure E-1. Re-capitalization Modification Kit (Sheet 2 of 3) DMWR 1-1520-237 E-16 SA AB3088_3 25 26 27 28 29 24 30 31 33 32 A Figure E-1. Re-capitalization Modification Kit (Sheet 3 of 3) DMWR 1-1520-237 E-17 E-1- 70070-95122-011 RE-CAPATIALIZATION MODIFICATION KIT ............. 1 -1 70070-20566-011 . DOOR POST MODIFICATION KIT .......................... 1 -2 70070-20566-012 . . DOOR POST MODIFICATION KIT, (See Fig. E-2 for Breakdown)................................................ 1 -3 70070-20566-013 . . HINGE ACCESS MODIFICATION KIT, (See Fig. E-3 for Breakdown)................................................ 1 -4 70070-20567-011 . CABIN MODIFICATION KIT ..................................... 1 -5 70070-20527-011 . . MODIFICATION KIT, (See Fig. E-4 for Breakdown) ............................................................ 1 -6 70070-20568-011 . . STATION 379 MODIFICATION KIT, (See Fig. E-5 for Breakdown)................................................ 1 -7 70070-20570-011 . . UPPER PLATING MODIFICATION KIT, (See Fig. E-6 for Breakdown)......................................... 1 -8 70070-20572-011 . . BL 34.5 MODIFICATION KIT, (See Fig. E-7 for Breakdown) ............................................................ 1 -9 70070-20641-011 . . ESSS DOUBLER MODIFICATION KIT, (See Fig. E-8 for Breakdown)......................................... 1 -10 70070-20575-011 . TRANSITION MODIFICATION KIT .......................... 1 -11 70070-20488-023 . . TAIL ROTOR DRIVE SHAFT BRACKETS MODIFICATION KIT, (See Fig. E-9 for Breakdown) ............................................................ 1 -12 70070-20575-012 . . STATION 485 MODIFICATION KIT, (See Fig. E-10 for Breakdown).............................................. 1 -13 70070-20577-011 . . LOWER AFT TRANSITION MODIFICATION KIT- , (See Fig. E-11 for Breakdown)........................... 1 -14 70070-20577-015 . . FOAM LINER MODIFICATION KIT, (See Fig. E-12 for Breakdown).............................................. 1 -15 70070-20578-011 . . ENCLOSURE MODIFICATION KIT, (See Fig. E-13 for Breakdown).............................................. 1 -16 70070-20580-011 . TAILCONE MODIFICATION KIT .............................. 1 -17 70070-20266-013 . . SUPPORT SHAFT MODIFICATION KIT, (See Fig. E-14 for Breakdown)....................................... 1 -18 70070-20266-014 . . SUPPORT SHAFT MODIFICATION KIT, (See Fig. E-15 for Breakdown)....................................... 1 -19 70070-20581-011 . . SHEAR DECK MODIFICATION KIT, (See Fig. E-16 for Breakdown).............................................. 1 -20 70070-20582-011 . . STRINGER/FRAME MODIFICATION KIT, (See Fig. E-17 for Breakdown)....................................... 1 -21 70070-20583-011 . . SKIN DOUBLER MODIFICATION KIT, (See Fig. E-18 for Breakdown).............................................. 1 -22 70070-20615-011 . . PLATE INSTALLATION MODIFICATION KIT- , (See Fig. E-19 for Breakdown)........................... 1 -23 70070-20617-011 . . BULKHEAD INSTALLATION MODIFICATION KIT, (See Fig. E-20 for Breakdown) ..................... 1 -24 70070-20585-011 . PYLON MODIFICATION KIT.................................... 1 -25 70070-20465-017 . . TAIL PYLON MODIFICATION KIT, (See Fig. E-21 for Breakdown).............................................. 1 -26 70070-20465-019 . . CRCT DOUBLE MODIFICATION KIT, (See Fig. E-22 for Breakdown).............................................. 1 -27 70070-20465-020 . . FRONT SPAR FT MODIFICATION KIT, (See Fig. E-23 for Breakdown)....................................... 1 -28 70070-20587-011 . . SIDE SKIN MODIFICATION KIT, (See Fig. E-24 for Breakdown)....................................................... 1 -29 70070-20588-011 . . AFT SPAR FITTING MODIFICATION KIT, (See Fig. E-25 for Breakdown)....................................... 1 -30 70070-30307-011 . L/H FIREWALL MODIFICATION KIT, (See Fig. E-26 for Breakdown)................................................. 1 -31 70070-30307-012 . R/H FIREWALL MODIFICATION KIT, (See Fig. E-27 for Breakdown)................................................. 1 -32 70070-30308-011 . COWL ASSEMBLY MODIFICATION KIT, (See Fig. E-28 for Breakdown).......................................... 1 DMWR 1-1520-237 QTY USABLE FIGURE & PER ON INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE E-18 -33 70072-30000-011 . HIRSS REPAIR KIT, (See Fig. E-29 for Breakdown) ............................................................... 1 DMWR 1-1520-237 QTY USABLE FIGURE & PER ON INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE E-19 E-3. DOOR POST MODIFICATION KIT (50-22). Subject: Cockpit Door Posts, Modification of, dated 31 March 2003 Purpose: Provide instructions for the structural strengthening of the left and right side cockpit lower door post hinge area. Model: UH-60A Description: The left and right side lower door post structure at station 205.00 are modified to improve the structural strength at these locations. Drawings required for modification: 70070-20566, 70500-01053, 70211-01005 References: (a) Special Service Instructions (SSI) No. 50-31, Installation of 9A to A9 Recapitalization Program, dated March 31, 2003 Instructions: NOTE • A complete review of this SSI is recommended before incorporating the Door Post Modification Kit. • Before beginning this modification procedure, use the material information list to inventory the modification kit. Make sure all parts are present and in serviceable condition. • The sheet metal and structural modifications in this SSI shall be done by personnel experienced in reading modification drawings. Routine steps such as cleaning, layout and drilling, deburring, standard repairs, corrosion control, clean up after rework, chemical coating for aluminum after cutting/trimming parts, and paint touch up and safety practices may not be called out herein. However, these steps and all other required routine tasks shall be done. • Where drawing numbers are not listed within individual step(s), drawing(s) listed in preceding step(s) are the controlling authority. • Slight variations to the instructions contained herein are allowed, as long as the intent of the modification is accomplished. A. Preparation for modification and removal of equipment: (1) Confirm that all warnings, cautions, and notes are complied with per reference (a). (2) Perform preparation for modification per reference (a). B. Modification, left side door post. (1) Remove fasteners at station 205.00, waterline 226.00, left buttline 41.00 and remove duct assembly (70500-01053-043). Keep for reuse (Dwg 70500-01053, Sheet 1, Zones 14-E and 11-C). (2) Remove two RFI grounding seals (03-0402-A137), straps (70211-01005-103 and 70211-01005-105), and jambs (70211-01005-104 and -107) at station 205.00 (Dwg 70211-01005, Sheet 1, Zones 9-E, 9-F and 6-F). DMWR 1-1520-237 E-20 (3) Remove fasteners, doubler (70214-01003-112), and angle (70211-01011-117) (Dwg 70070-20566, Sheet 6, View H-H, Zones 12-C and 9-B). (4) Remove fasteners shown from floor skin, between station 194.00 and station 209.00, between buttline 30.00 and buttline 40.00 (Sheet 6, Zones 12-B through 9-D). (5) Trim floor skin (70214-01003-101) to agree with support fitting (70209-21206-113) and peel back to sta- tion 210.00 (Sheet 6, View H-H, Zone 11-C). (6) Remove nutplates (MS21075-3N and 52LHA3575-02), station 200.00, waterline 215.00, between buttline 30.00 and buttline 40.00 (Sheet 6, View H-H, Zones 9-D and 12-C). (7) Remove fasteners shown from shim (70219-01000-102), plate (70219-01000-108), washers (70219- 01000-109), radius block (SS1058A10-29-48), and hinge fitting assembly (70219-01008-041 or 70219-01008-043) (Sheet 6, Zones 15-D, 15-E, and 14-E). (8) Remove fasteners and fitting assembly (70217-01024-041 or 70217-01024-045) (Sheet 6, View J-J, Zone 17-F). (9) Remove fasteners at station 205.00, left buttline 40.00 as shown (Sheet 6, View A-A, Zones 15-A through 15-F and, 19-B through 19-G). (10) Remove channel (70211-01011-130) (Sheet 6, Zones 18-G). (11) Remove fasteners and angle (70211-01011-111) (Sheet 6, Zone 11-D). (12) Remove angle (70211-01011-103) (Sheet 6, Zone 19-B). (13) Remove fasteners and angle (70211-01011-105) (Sheet 6, Zone 20-B). (14) Remove fasteners, baffle (70211-01011-127), and radius block (SS1058-7-30-23) (Sheet 6, Zones 18-F, 16-F and 17-C; Sheet 3, Notes 24 and 25). (15) Locate and temporarily install following parts at station 205.00, between waterline 210.00 and waterline 230.00, between left buttline 35.00 and buttline 45.00 as follows: (a) Slot skin and frame existing lower door hinge mount holes to 0.260 X 0.340-inch slots (Dwg 70070- 20566, Sheet 6, Zone 16-D). (b) Plug rivet skin first and third holes below lower door hinge location with fasteners shown (Sheet 6, Zone 14-D). (c) Position angle (70070-20566-107) against forward side of station 205.00 and transfer drill inboard holes from frame through angle. Transfer drill station 205.00 outboard holes and skin below waterline 215.00 only (Sheet 6, View A-A, Zone 19-B). (d) Position angle (70070-20566-111) and transfer drill holes from station 205.00 frame and buttline 30.00 fitting (Sheet 6, Zone 11-D). DMWR 1-1520-237 E-21 NOTE The station 205.00 frame outboard holes above waterline 215.00 are not drilled in the following step. (e) Position angle (70211-01011-105) against aft side of station 205.00 and transfer drill inboard holes from frame through angle. Transfer drill station 205.00 outboard holes below waterline 215.00 (Sheet 6, View A-A, Zone 20- D). (f) Position doubler (70070-20566-105), shim (70204-21003-132), and support fitting (70209-21206-113) on waterline 215.00 against forward face of frame 205.00. Transfer drill holes from angle (70211-01011-105) (Sheet 6, View H-H, Zones 10-B and 10-C). (g) Drill support fitting (70209-21206-113) outboard holes through station 205.00 frame, angles (70070- 20566-107 and 70070-20566-111), and skin clearing support fitting radius (Sheet 6, View A-A, Zones 19-C and 19-D, Note 58). (h) Drill fastener holes from support fitting (70209-21206-113) through shim (70204-21003-132), doubler (70070-20566-105), and structure through support fitting clearing support fitting radius (Sheet 6, View H-H, Zone 10-B). (i) Position channel (70211-01011-130) on station 205.00 frame and transfer drill rivet holes from frame through channel (Sheet 6, View A-A, Zones 15-C through 15-F and 20-B through 19-F). (j) Locate door check channel assembly (70217-01024-045) on inboard and aft sides of channel (70211- 01011-130) (Sheet 6, Views A-A and J-J, Zones 19-D and 17-F). (k) Transfer drill aft side holes from channel assembly (70217-01024-045) through channel (70211-01011- 130) and open inboard hole to agree with frame. (l) Remove door check channel assembly (70217-01024-045) and channel (70211-01011-130). (m) Temporarily attach centerline of baffle (70070-20566-109) to channel (70211-01011-130) aft holes (Sheet 6, View J-J, Zone 16-F). (n) Reposition channel (70211-01011-130) on station 205.00 frame. (o) Transfer drill two fastener holes from inboard side of frame through baffle (70070-20566-109). (p) Transfer drill two 0.250-inch diameter holes from channel (70211-01011-130) through baffle (70070- 20566-109) aft flange. (q) Clamp drill template (70070-20566-019T046) to aft side of frame. (r) Drill two 0.187-inch diameter holes from drill template through frame and support fitting (70209-21206- 113). Remove drill template. (s) Remove support fitting (70209-21206-113) from forward side of frame. (t) Open two 0.250 and 0.187-inch diameter holes to 0.448-inch diameter in channel (70211-01011-103), angles (70070-20566-107 and 70211-01011-105), and baffle (70070-20566-109) (Sheet 6, Zone 16-F). (u) Temporarily position angle (70211-01011-117) on floor aft of station 205.00. Transfer drill fastener holes from floor and frame through angle (Sheet 6, View H-H, Zone 10-B). (v) Temporarily reinstall support fitting (70209-21206-113). DMWR 1-1520-237 E-22 (w) Temporarily attach door check channel assembly (70217-01024-045) to channel (70211-01011-130) with work hardware and bushings (NAS73-4-107). (x) Position installation tool (70070-20566-019T046) onto upper door hinge and door check channel as- sembly (70217-01024-045). (y) Drill two 0.250-inch diameter holes. Remove installation tool. (z) Remove parts from station 205.00, clean, deburr, and touch up as required. (aa) Position radius block (70201-21011-135) onto inboard side of support fitting (70209-21206-113). Drill two No. 30 (0.128-inch diameter) holes with 100° countersink and transfer drill two 0.250-inch diameter holes (Sheet 6, View K-K, Zone 17-B). (ab) Install radius block (70201-21011-135) to support fitting (70209-21206-113) with fasteners shown (Sheet 6, View K-K, Zone 17-B). (ac) Install new frame parts with fasteners shown (Sheet 6, Zones 8 through 20, Note 44). (ad) Install door hinge fitting assembly (70219-01008-045), shim (70219-01000-102), and plate (70219- 01000-108) with fasteners shown (Sheet 6, Zones 7-C, 14-E, and 16-E, Notes 44 and 45). (ae) Install nutplates (MS21075-3N and 52LHA3575-02) with fasteners shown (Sheet 6, Zones 10-D and 12- D). (af) Reinstall floor with fasteners shown (Sheet 6, View H-H, Zone 9-B through 12-D). (ag) Reinstall duct assembly (70500-01053-043) (Dwg 70500-01053, Sheet 1, Zones 14-E and 11-C). (ah) Install two RFI grounding seals (03-0402-A137), straps (70211-01005-103 and -105), and jambs (70211-01005-104 and -107) at station 205.00 with fasteners shown (Dwg 70211-01005, Sheet 1, Zones 9-E, 9-F and 6-F). C. Modification, right side door post. (1) Remove fasteners at station 205.00, waterline 226.00, right buttline 41.00 and remove duct assembly (70500-01053-044). Keep for reuse (Dwg 70500-01053, Sheet 1, Zones 14-E and 11-C). (2) Remove two RFI grounding seals (03-0402-A137), straps (70211-01005-103 and 70211-01005-106), and jambs (70211-01005-104 and -108) at station 205.00 (Dwg 70211-01005, Sheet 1, Zones 9-E, 9-F and 6-F). (3) Remove fasteners and angle (70211-01011-118) (Dwg 70070-20566, Sheet 6, View H-H, Zone 9-G). (4) Remove fasteners shown from floor skin, between station 194.00 and station 209.00, between buttline 30.00 and buttline 40.00 (Sheet 6, Zones 12-B through 9-D). (5) Trim floor skin (70214-01003-102) to agree with support fitting (70209-21206-114) and peel back to sta- tion 210.00 (Sheet 6, View H-H, Zone 11-F). (6) Remove radius block (SS1056-7-24-26) (Sheet 6, View H-H, Zone 11-F). (7) Remove nutplates (MS21075-3N and 52LHA3575-02), station 200.00, waterline 215.00, between buttline 30.00 and buttline 40.00 (Sheet 6, View H-H, Zones 9-E and 12-F). DMWR 1-1520-237 E-23 (8) Remove fasteners shown from shim (70219-01000-102), plate (70219-01000-108), washers (70219- 01000-109), radius block (SS1058A10-29-48), and hinge fitting assembly (70219-01008-042 or 70219-01008-044) (Sheet 6, Zones 15-D, 15-E, and 14-E). (9) Remove fasteners and fitting assembly (70217-01024-042 or 70217-01024-045) (Sheet 6, View J-J, Zone 17-F). (10) Remove fasteners at station 205.00, right buttline 40.00 as shown (Sheet 6, View A-A, Zones 15-A through 15-F and, 19-B through 19-G). (11) Remove channel (70211-01011-131) (Sheet 6, Zones 18-G). (12) Remove fasteners and angle (70211-01011-115) (Sheet 6, Zone 11-E). (13) Remove angle (70211-01011-104) (Sheet 6, Zone 19-B). (14) Remove fasteners and angle (70211-01011-106) (Sheet 6, Zone 20-B). (15) Remove fasteners, baffle (70211-01011-128), and radius block (SS1058-7-30-23) (Sheet 6, Zones 18-F, 16-F and 17-C, Sheet 3, Notes 24 and 25). (16) Locate and temporarily install following parts at station 205.00, between waterlines 210.00 and 230.00, between right buttline 35.00 and buttline 45.00 as follows: (a) Slot skin and frame existing lower door hinge mount holes to 0.260 X 0.340-inch slots (Dwg 70070- 20566, Sheet 6, Zone 16-D). (b) Plug rivet skin first and third holes below lower door hinge location with fasteners shown (Sheet 6, Zone 14-D). (c) Position angle (70070-20566-106) against forward side of station 205.00 and transfer drill inboard holes from frame through angle. Transfer drill from station 205.00 outboard holes and skin below waterline 215.00 only (Sheet 6, View A-A, Zone 19-B). (d) Position angle (70070-20566-110) and transfer drill holes from station 205.00 frame and buttline 30.00 fitting (Sheet 6, Zone 11-D). NOTE The station 205.00 frame outboard holes above waterline 215.00 are not drilled in the following step. (e) Position angle (70211-01011-106) against aft side of station 205.00 and transfer drill inboard holes from frame through angle. Transfer drill station 205.00 outboard holes below waterline 215.00 (Sheet 6, View A-A, Zone 20- D). (f) Position doubler (70070-20566-105), shim (70204-21003-132), and support fitting (70209-21206-114) on waterline 215.00 against forward face of frame 205.00. Transfer drill holes from angle (70211-01011-106) (Sheet 6, View H-H, Zones 10-G and 10-H). (g) Drill support fitting (70209-21206-114) outboard holes through station 205.00 frame, angles (70070- 20566-106 and 70070-20566-110), and skin clearing support fitting radius (Sheet 6, View A-A, Zones 19-C and 19-D, Note 58). DMWR 1-1520-237 E-24 (h) Drill fastener holes from support fitting (70209-21206-114) through shim (70204-21003-132), doubler (70070-20566-105), and structure through support fitting clearing support fitting radius (Sheet 6, View H-H, Zone 10- G). (i) Position channel (70211-01011-131) on station 205.00 frame and transfer drill rivet holes from frame through channel (Sheet 6, View A-A, Zones 15-C through 15-F and 20-B through 19-F). (j) Locate door check channel assembly (70217-01024-044) on inboard and aft sides of channel (70211- 01011-131) (Sheet 6, Views A-A and J-J, Zones 19-D and 17-F). (k) Transfer drill aft side holes from channel assembly (70217-01024-044) through channel (70211-01011- 131) and open inboard hole to agree with frame. (l) Remove door check channel assembly (70217-01024-044) and channel (70211-01011-131). (m) Temporarily attach centerline of baffle (70070-20566-108) to channel (70211-01011-131) aft holes (Sheet 6, View J-J, Zone 16-F). (n) Reposition channel (70211-01011-131) on station 205.00 frame. (o) Transfer drill two fastener holes from inboard side of frame through baffle (70070-20566-108). (p) Transfer drill two 0.250-inch diameter holes from channel (70211-01011-131) through baffle (70070- 20566-108) aft flange. (q) Clamp drill template (70070-20566-019T046) to aft side of frame. (r) Drill two 0.187-inch diameter holes from drill template through frame and support fitting (70209-21206- 114). Remove drill template. (s) Remove support fitting (70209-21206-114) from forward side of frame. (t) Open two 0.250 and 0.187-inch diameter holes to 0.448-inch diameter in channel (70211-01011-103), angles (70070-20566-106 and 70211-01011-106), and baffle (70070-20566-108) (Sheet 6, Zone 16-F). (u) Temporarily position angle (70211-01011-118) on floor aft of station 205.00. Transfer drill fastener holes from floor and frame through angle (Sheet 6, View H-H, Zone 9-H). (v) Temporarily reinstall support fitting (70209-21206-114). (w) Temporarily attach door check channel assembly (70217-01024-044) to channel (70211-01011-131) with work hardware and bushings (NAS73-4-107). (x) Position installation tool (70070-20566-019T046) onto upper door hinge and door check channel as- sembly (70217-01024-045). (y) Drill two 0.250-inch diameter holes. Remove installation tool. (z) Remove parts from station 205.00, clean, deburr, and touch up as required. (aa) Position radius block (70201-21011-135) onto inboard side of support fitting (70209-21206-114). Drill two No. 30 (0.128-inch diameter) holes with 100° countersink and transfer drill two 0.250-inch diameter holes (Sheet 6, View K-K, Zone 17-B). DMWR 1-1520-237 E-25 (ab) Install radius block (70201-21011-135) to support fitting (70209-21206-114) with fasteners shown (Sheet 6, View K-K, Zone 17-B). (ac) Install new frame parts with fasteners shown (Sheet 6, Zones 8 through 20, Note 44). (ad) Install door hinge fitting assembly (70219-01008-044), shim (70219-01000-102), and plate (70219- 01000-108) with fasteners shown (Sheet 6, Zones 7-C, 14-E, and 16-E, Notes 44 and 45). (ae) Install nutplates (MS21075-3N and 52LHA3575-02) and radius block (SS1056-7-24-26) with fasteners shown (Sheet 6, View H-H, Zones 10-E, 11-F, and 12-F). (af) Reinstall floor with fasteners shown (Sheet 6, View H-H, Zone 9-B through 12-D). (ag) Reinstall duct assembly (70500-01053-044) (Dwg 70500-01053, Sheet 1, Zones 14-E and 11-C). (ah) Install two RFI grounding seals (03-0402-A137), straps (70211-01005-103 and 70211-01005-106), and jambs (70211-01005-104 and -108) at station 205.00 with fasteners shown (Dwg 70211-01005, Sheet 1, Zones 9-E, 9-F and 6-F). D. Reidentification: NOTE The following reidentifications are for record purposes only. No physical reidentification is required. FROM TO Nomenclature 70214-01003-011 70070-20566-031 Floor Instl, LH 70214-01003-016 70070-20566-033 Floor Instl, LH 70214-01003-012 70070-20566-030 Floor Instl, RH 70214-01003-017 70070-20566-032 Floor Instl, RH 70214-01003-041 70070-20566-041 Floor Assy, LH 70214-01003-043 70070-20566-043 Floor Assy, LH 70214-01003-042 70070-20566-042 Floor Assy, RH 70214-01003-044 70070-20566-044 Floor Assy, RH 70214-01003-101 70070-20566-103 Skin 70214-01003-102 70070-20566-104 Skin 70219-01000-011 70070-20566-025 Fitting Instl, LH 70219-01000-013 70070-20566-029 Fitting Instl, LH 70219-01000-012 70070-20566-026 Fitting Assy, RH 70219-01000-014 70070-20566-028 Fitting Instl, RH 70211-01011-012 70070-20566-014 Frame Instl 70211-01011-011 70070-20566-039 Frame Instl 70211-01001-041 70070-20566-045 Frame Assy 70211-01001-042 70070-20566-046 Frame Assy 70211-01001-044 70070-20566-047 Frame Assy 70211-01001-045 70070-20566-048 Frame Assy DMWR 1-1520-237 E-26 E. Reinstallation of removed equipment: (1) Perform reinstallation of parts and equipment per reference (a). F. Record of Compliance: (1) Make an appropriate logbook entry to show compliance with this Special Service Instruction. Weight and Balance Data: QTY PART NO. NOMENCLATURE POUNDS WEIGHT INCHES AFT OF DATUM MOMENT/ 1000 1 70070-20566-012 Mod. Kit, Door Post +5.9 210.0 +1.239 Weight and Balance: Change resulting from these instructions are as follows: Change in basic weight: +5.9 pounds Moment arm: 210.0 in. Change in basic moment/1000: 1.239 Manpower (Estimated) No. of Personel No. of Hours Man-hours Sheet Metal Mechanic 2 40.0 *80.0 *Does not include time required to prepare helicopter or return it to flight status. Material Information: A. Modification Kit Required: Qty Nomenclature Part Number Source 1 Mod. Kit, Door Post 70070-20566-011 (1) consisting of: 1 Mod. Kit, Door Post, 70070-20566-012 consisting of: 1 Mod. Kit, Floor Instl, 70070-20566-015 DMWR 1-1520-237 E-27 Qty Nomenclature Part Number Source consisting of: 1 Mod. Kit, Fitting Instl, LH, 70070-20566-019 consisting of: 2 Bolt AN4C14A 2 Nut MS21043-4 2 Fastener, Blind MS90354U0502 3 Fastener, Blind MS90354U0602 3 Rivet NAS1097AD4-9 4 Rivet NAS1097AD5-9 2 Washer, Flat NAS1149D0463K 1 Radius Block 70201-21011-135 4 Washer SS5072-4 1 Shim 70219-01000-102 1 Plate 70219-01000-108 2 Washer 70219-01000-109 1 Fitting Assembly 70219-01008-045 10 Rivet MS20470AD5-9 2 Rivet MS20470AD6-3 3 Rivet RA097AD5-3 4 Rivet, Blind NAS1738B6-5 1 Mod. Kit, Fitting Instl, RH, 70070-20566-020 consisting of: 2 Bolt AN4C14A 2 Nut MS21043-4 2 Fastener, Blind MS90354U0502 3 Fastener, Blind MS90354U0602 3 Rivet NAS1097AD4-9 4 Rivet NAS1097AD5-9 2 Washer, Flat NAS1149D0463K 1 Radius Block 70201-21011-135 4 Washer SS5072-4 1 Shim 70219-01000-102 1 Plate 70219-01000-108 2 Washer 70219-01000-109 1 Fitting Assembly 70219-01008-046 10 Rivet MS20470AD5-9 2 Rivet MS20470AD6-3 3 Rivet RA097AD5-3 4 Rivet, Blind NAS1738B6-5 1 Mod. Kit, Floor LH, 70070-20566-017 DMWR 1-1520-237 E-28 Qty Nomenclature Part Number Source consisting of: 2 Washer AN960PD10L 8 Rivet CCR244SS-3-2 8 Rivet CCR244SS-3-4 16 Collar HL1087A-5 16 Pin, Hi Lok HL20PB-5-4 3 Nutplate MS21075-3N 2 Rivet NAS1097AD5-9 10 Rivet, Blind NAS1738B4-1 10 Rivet, Blind NAS1738B4-2 15 Rivet, Blind NAS1738B5-2 15 Rivet, Blind NAS1739B4-2 2 Rivet, Blind NAS1739B4-3 3 Nutplate 52LHA3575-02 1 Doubler 70070-20566-105 1 Support Fitting 70209-21206-113 1 Angle 70211-01011-117 2 Screw MS27039-1-09 3 Rivet, Blind NAS1739B4-1 1 Shim, Laminated 70204-21003-132 1 Mod. Kit, Floor, RH 70070-20566-018 consisting of: 2 Washer AN960PD10L 8 Rivet CCR244SS-3-2 8 Rivet CCR244SS-3-4 16 Collar HL1087A-5 16 Pin, Hi Lok HL20PB-5-4 3 Nutplate MS21075-3N 2 Rivet NAS1097AD5-9 3 Rivet, Blind NAS1738B4-2 22 Rivet, Blind NAS1738B5-2 16 Rivet, Blind NAS1739B4-2 2 Rivet, Blind NAS1739B4-3 1 Radius Block SS1058-7-24-26 3 Nutplate 52LHA3575-02 1 Doubler 70070-20566-105 1 Shim, Laminated 70204-21003-132 1 Angle 70211-01011-118 1 Support Fitting 70209-21206-114 2 Screw MS27039-1-09 15 Rivet, Blind NAS1738B4-2 1 Mod. Kit, Jamb Instl, 70070-20566-034 consisting of: 2 Pin, Hi Lok HL20PB-5-5 DMWR 1-1520-237 E-29 Qty Nomenclature Part Number Source 2 Collar HL70TW-5 6 Rivet MS20470AD5-3 9 Rivet MS20470AD5-4 3 Fastener, Blind MS90354U0603 1 Washer, Flat NAS1149DN416K 5 Rivet, Blind NAS1738B4-2 2 Rivet, Blind NAS1738B4-3 2 Seal, RFI Grndng 03-0402-A137 1 Strap 70211-01005-103 1 Jamb 70211-01005-104 1 Strap 70211-01005-105 1 Jamb 70211-01005-107 1 Mod. Kit, Jamb Instl, 70070-20566-035 consisting of: 2 Pin, Hi Lok HL20PB-5-5 2 Collar HL70TW-5 6 Rivet MS20470AD5-3 9 Rivet MS20470AD5-4 3 Fastener, Blind MS90354U0603 1 Washer, Flat NAS1149DN416K 5 Rivet, Blind NAS1738B4-2 2 Rivet, Blind NAS1738B4-3 2 Seal, RFI Grndng 03-0402-A137 1 Strap 70211-01005-103 1 Jamb 70211-01005-104 1 Strap 70211-01005-106 1 Jamb 70211-01005-108 1 Mod. Kit, Frame Instl, 70070-20566-037 consisting of: 2 Bolt AN4-21 27 Rivet MS20470AD5-9 2 Nut MS21043-4 7 Fastener, Blind MS90354U0506 2 Washer, Flat NAS1149D0416K 2 Washer, Flat NAS1149D0463K 2 Pin, SWG LKG NAS1525-02 4 Pin, SWG LKG NAS1525-03 5 Pin, SWG LKG NAS1526-03 10 Rivet, Blind NAS1738B5-2 7 Rivet, Blind NAS1738B5-3 2 Bushing NAS73-4-107 1 Baffle 70070-20566-109 1 Channel 70211-01011-130 1 Channel Assembly 70217-01024-045 DMWR 1-1520-237 E-30