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1 * tm 1 -1520-240-MTFMAINTENANCE TESTFLIGHT MANUALARMY MODELCH-47D HELICOPTER*This manual supersedes TM 55-1520-240-MTF, dated 8 September 1982, including all STATEMENT A: Approved for publicrelease; distribution is OF THE ARMY31 JANUARY 2003TM 1-1520-240-MTFa/(b blank) WARNINGA maintenance test flight is an exceptionallydemanding operation and requires a thoroughflight readiness inspection (PREFLIGHT). Theflight readiness inspection is prescribed in TM1-1520-240-10 operators manual and must becompleted prior to each maintenance testflight. Emergency procedures are found in theapplicable -10 or checklist (CL) and are notduplicated in this publication. Prior to eachmaintenance test flight, the pilot will contactmaintenance/quality control personnel todetermine the maintenance that has beenperformed. This manual should be used onlyby qualified maintenance test flight pilots asrequired in AR 95-1 and tm 1 -1520-240-MTFi REPORTING OF ERRORS AND RECOMMENDING IMPROVEMENTSYou can help improve this manual.

2 If you find anymistakes, or if you know of a way to improve theprocedures, please let us know. Mail your letter,DA Form 2028 (Recommended Changes toPublications and Blank Forms) located in the backof the applicable operator s manual, (ensure thepublication number and title reflect this MTF)direct to: Commander, Army Aviation andMissile Command, ATTN: AMSAM-MMC-MA-NP,Redstone Arsenal, AL 35898-5000. A reply will befurnished to you. You may also send in yourcomments electronically to our e-mail or by fax256-842-6546/DSN 788-6546. Instructions forsending an electronic 2028 may be found at theback of the Aircraft Operator s OF CONTENTSSECTIONPAGEI Introduction1-1II Maintenance Test Flight Check-list2-1 Prior to Maintenance TestFlight2-1 Before Interior Check2-1 Interior2-5 Forward Cabin2-5 Aft cabin2-9 Exterior2-11 Aft cabin2-11 Top of Fuselage2-13TM 1-1520-240-MTF iiTABLE OF CONTENTS (Continued)SECTIONPAGER ight Cabin2-21 Forward Cabin2-23 Left Cabin2-24 Before Starting Engines2-27 Starting Engines2-33 Engine Run Up2-55 Before Taxi2-60 Taxiing2-60 Before Hover2-61 Hover2-64 Before Takeoff2-73 Cruise2-74In-Flight2-74 Before Landing2-86 After Landing2-87 Engine Shutdown2-87 Before Leaving Helicopter2-89 III Troubleshooting3-1(Not Applicable)IV Special Procedures4-1A.

3 AFCS Bite Checks4-3B. Self-Tuning Absorber Sys-tems Check4-5C. Control Breakout Forces4-6D. Winch Operational Test4-8E. Looseness Check4-11712714A714A714A712712714A712714 ATM 1-1520-240-MTFiii TABLE OF CONTENTS (Continued) 1 and No. 2 Engine 1 and No. 2 Engine Bellows 1 and No. 2 En-gine Reversionary AssuranceCheck (PAC) AssuranceTest (PAT) Baseline and Trig-ger Air BleedSpeed Adjustment4-31N. AFCS Check4-33O. Heating/Vent Blower Opera-tion4-34P. Cargo hook OperationalCheck4-35Q. Tracking and Balancing Pro-cedures4-37R. Engine Vibration Engine Anal-ysis Check (TEAC)4-39U. Differential Current Protec-tion Circuit Check4-45V. Cargo Ramp and DoorCheck4-46712712712712TM 1-1520-240-MTF ivTABLE OF CONTENTS (Continued)W. Radar Altimeter Check4-50X. Navigation and Communica-tion Check4-51V Charts and Forms5-1 NUMBERTITLEPAGE4-1 Test Course for OverlandAccuracy Doppler4-565-1 Temperature Conversionchart5-35-2 APU Start AccumulatorPrecharge Limits5-55-3 Flight/Utility/Power Steer-ing Accumulator Prechar-ge Limits5-65-4 Brake Accumulator Pre-charge Limits5-75-5 Engine Fire ExtinguisherPressures5-85-6 Interstage Air-BleedClosure Chart5-95-7 Autorotational RRPMC hart for CH-47D5-105-8 Turbine EngineAnalysis Check N1 Chart5-115-9 Turbine EngineAnalysis Check PTITC hart5-125-10 Turbine EngineAnalysis Check TorqueChart5-13712712714A714A714 ATM 1-1520-240-MTFv/(vi blank) TABLE OF CONTENTS (Continued)

4 5-11 Power AssuranceCheck Maximum Continu-ous Power Chart5-145-12 Power AssuranceCheck Maximum PowerChart5-155-13 Power AssuranceCheck Engine Tempera-ture Limits Chart5-165-14 Power AssuranceCheck Engine N1 LimitsChart5-175-15N1 Idle Speed5-185-16 Turbine Engine AnalysisCheck TroubleshootingChart5-19FO-1CH-47D Cockpit ControlsPosition EnvelopeFP-1FO-2 Airspeed Operating Limitswith Inoperative CGIFP-5FO-3 Airspeed Operating Limitswith Retracted LCTFP-7FO-4CH-47D FWD and AFTLCT Indicator ScheduleFP-9FO-5 Maintenance Test FlightCheck SheetFP-13 LIST OF TABLESNUMBERTITLEPAGE2-1 Instrument RangeMarkings2-312-2 Cockpit PRESS TO TESTC aution Lights2-40TM 1-1520-240-MTF1-1 SECTION I purpose of this manual is to providecomplete instructions for performing a maintenance testflight of CH-47D aircraft. For the specific conditions whichrequire a general or limited maintenance test flight, refer toTM 1-1500-328-23 and TM Test functional testflight for which the primary purpose is to determine whetherthe airframe, powerplant, accessories, and otherequipment are functioning in accordance withpredetermined requirements while subjected to theintended , Cautions, and ,Cautions, and Notes are used to emphasize important andcritical instructions and are used for the followingconditions:WARNINGAn operating procedure, practice, ect.

5 , whichif not correctly followed, will result inpersonnel injury or loss of operating procedure, practice, ect., whichif not strictly observed, will result in damageor destruction of operating procedure, condition, ect., which isessential to 1-1520-240-MTF This manual covers only maintenance test flightof CH-47D aircraft and in no way supercedes anyinformation contained in tm 1 -1520-240-10 or applicable-CL, but is to be used in conjunction with the -10 and the purpose of maintenance test flights only, thismanual satisfies all the requirements of the -CL fromInterior Check through Engine Crew requirements will be as specified in TM1-1500-328-23 and TM The duration of the general or limited test flightwill be in accordance with the requirements of and Passengers. Cargo andpassengers are prohibited on maintenance test and Records.

6 Forms and records willbe checked prior to the maintenance test flight todetermine what maintenance has been performed and thetype of maintenance test flight required ( , general orlimited). configuration of theaircraft should be determined prior to each maintenancetest flight in order to determine performance Test Flight thoroughvisual inspection will be performed to the extent necessaryto assure that deficiencies or shortcomings that may havedeveloped as a result of the maintenance test flight a maintenance test flightis required to assure proper operation of a specificsystem(s), refer to the applicable maintenance manual forthe limits of that 1-1520-240-MTF1-3 Test Flight Check Sheet contained in Section V will be used for all testflights. When a test flight is performed to determine ifspecific equipment or systems are operating properly,completion of only that portion of the maintenance testflight Check Sheet applicable to the specific equipment orsystems being tested is required.

7 The aircraft test flightCheck Sheets may be locally reproduced. A check (p) forsatisfactory performance or an (X) for problem detectedwill be recorded and a short statement entered in theremarks block of the Check Sheet. Continuation sheetsmay be used when necessary. Items that prove to beunsatisfactory during the test flight, and require correctiveaction, shall be listed in the remarks block during flight andtransferred to DA Form 2408-13-1 immediately aftertermination of the flight. The MP will sign, enter the time,and date the checksheet. The sheet will be attached to DAForm 2408-13-1 upon completion of the MTF. Afteraccumulation of two or more sheets, the data should bereviewed to determine if trends are proceduresinclude items that may be checked by the flight engineerand that may or may not be installed or are tasks or stepsrequired by the Operators Manual.

8 These items areannotated immediately preceding the check to which theyare pertinent: F for flight engineer, and O to indicate arequirement if the equipment is installed, B for task or steprequired by the Operators Manual and *B through flighttask or step required by the Operators Manual. Thecomplete step as written may not be required only thosesteps as required by the Operators 1-1520-240-MTF 1-4 Symbols Preceding Numbered flight engineer function or If Installed . -Indicates copilot crew stations a task or step required by the OperatorsManual.*B-Indicates a task or step required by the OperatorsManual and for through-flight 1-1520-240-MTF2-1 SECTION II MAINTENANCE TESTFLIGHT section contains the maintenance testflight requirements peculiar to Army Model CH-47 Daircraft. Conditions requiring accomplishment of testflights shall be in accordance with tm 1 -1500-328-23.

9 Therequirements contained herein are established to assurea thorough inspection of the aircraft before flight, duringflight, and upon completion of the maintenance test TO MAINTENANCE TEST FLIGHT Before Interior Check 1. Publications Check DA Forms 2408-12, -13,-14, -18, DD Form 365-4, and DD Form 1896,locally required forms and publications, andavailability of operators manual (-10), andmaintenance test flight Ignition lock switch BATT switch power panel Check tripindicators and stops Check stowed (unlessTEAC is to be performed).6. Cockpit area Check condition of bottom halfinertia Pilot and copilot sliding window Checkcondition open and close maximum of50-lbs force. Slide operation maximum 15lbs, Jettisonable door release handles andlatches (1) Check the handles are stowed andsafetied as 1-1520-240-MTF2-2 PRIOR TO MAINTENANCE TEST FLIGHT (CONT.)

10 Before Interior Check (Cont.) (2) Check the top and bottom latchesengage the door supports and lockingdevises removed.(3) Check through doorplate inspectionholes (upper and lower) that the doorlatches are centered in the latch Fire Extinguisher Check seal, security,date, and properly Seat belts and shoulder harness Fuel sample Check before first flight of AVA equipment installed if tracking is Accelerometers installed if rotor blade vibrationcheck is Tiedowns, locking devises, covers, and groundcables Removed and BATT switch ON. Check MASTERCAUTION/ADVISORY LIGHTS for properindication (no chip detectors). CAUTIONLIGHTS TEST for illumination of allcaution/advisory light APU start (Fire guard posted):a. APU start accumulators Checkprecharged according to chart in Section APU Check condition and EMERGENCY APU FLUID SHUTOFFVALVE Check Electronic Sensing Unit Condition 1-1520-240-MTF2-3 PRIOR TO MAINTENANCE TEST FLIGHT (CONT.)