Military

A. NOMENCLATURE-TITLE-PROGRAM

B. SECURITY CLASSIFICATION

1. System Characteristics Unclassified

2. Capabilities Unclassified

3. Functions Unclassified

D. SYSTEM DESCRIPTION

1. Operational Uses. The primary mission of the CH-46D Helicopter is rapid ship-to-ship transfer of supplies and equipment under all-weather conditions, day or night. The primary mission of the CH-46E Helicopter is to rapidly disperse combat troops, support equipment, and supplies from amphibious assault ships and established airfields to advanced bases in undeveloped areas with limited maintenance and logistic support under all-weather conditions, day or night.

2. Foreign Military Sales. Foreign Military Sales (FMS) information is considered sensitive. For FMS information contact Program Manager, Air (PMA) 226.

E. DEVELOPMENTAL TEST AND OPERATIONAL TEST. The DCU program (AFC 433) was validated and verified from January to December 1995. Flight-testing was conducted at the Boeing Helicopter Flight Test Facility. Operational Evaluation was waived for the DCU program in lieu of a Surveillance Plan to track and analyze reworked and redesigned dynamic components. Type Commanders (TYCOM) selected candidate surveillance aircraft to have DCU components removed for special Engineering Investigations (EI) at specified intervals to verify the adequacy of the reworks and redesigns. These special EIs were performed at Naval Aviation Depot (NADEP) Cherry Point, North Carolina.

F. AIRCRAFT AND/OR EQUIPMENT/SYSTEM/SUBSYSTEM REPLACED. The H-46 Helicopter is being replaced throughout the Navy and the Marine Corps. The Navy's transition to the CH-60S Helicopter is to be completed in Fiscal Year (FY) 06. The Marine Corps conversion to the V-22 Osprey is to be completed by FY12.

The Navy will continue to use Helicopter Combat Support Squadron (HC) 3, Naval Air Station (NAS), North Island, California, for Pilot and Aircrew training. Maintenance Training Unit (MTU) 1028 Naval Air Maintenance Training Unit (NAMTRAU) North Island, California, is the H-46 maintenance training site. Both of these activities will provide training for the H-46 and the CH-60S Helicopters during the transition period.

The Marine Corps has relocated its Pilot and Aircrew H-46 training to Medium Marine Helicopter Training Squadron (HMMT)-164, Marine Corps Air Station (MCAS) Camp Pendleton, California. H-46 maintenance training is being conducted at MTU 1027 Naval Air Maintenance Training Group Detachment (NAMTRAGRU DET) CH-46 Fleet Replacement Enlisted Skills Training (FREST), New River, North Carolina. The former H-46 training squadron, Marine Helicopter Training Squadron (HMT)-204 (renamed VMMT-204), is now the V-22 training squadron.

The DCU modification program, which began in 1996, will provide all H-46 Helicopters with improved rotor, drive, and flight control systems without changing the form, fit, or function of these assemblies. Although many components within the rotor, drive, and flight control systems are being upgraded and improved, including new part numbers to identify these items, no equipment, system, or subsystem is being replaced.

G. DESCRIPTION OF NEW DEVELOPMENT

1. Functional Description. The DCU modification program, AFC 433, will provide improved rotor, drive, and flight control systems in all H-46 Helicopters, eliminating the majority of recurring inspections, while extending the aircraft's longevity and improving the capability for future mission performance. AFC 433 is being installed in six parts.

• Part 1 involves the forward and aft rotor heads and lag dampers. Installations began in March 1996.
• Part 2 governs the forward and aft transmissions. Installations began in January 1998.
• Part 3 is the aft drive shaft and aft blade fold distributor modification. Installations began in March 1996 on an attrition basis, or concurrent with Standard Depot Level Maintenance (SDLM).
• Part 4 involves the remaining rotor controls. Installations began in April 1996.
• Part 5 involves forward transmission installations in Safety, Reliability, and Maintainability (SR&M) aircraft. Installations began in January 1998.
• Part 6 involves aft transmission installations in SR&M aircraft. Installations began in February 1998.
• Part 7 governs the Yoke Through-Bolt installation to improve safety due to failure of the original bolts. Installations began in February 1999.

Currently, parts 2 and 4 are being combined and accomplished at the same time for ease of scheduling. Concurrently with SDLM, NADEP Cherry Point performs installations by Field Modification Teams (FMT), or in parts by organizational level maintenance activities as directed by TYCOMs.

a. Rotor System. Two fully articulated rotor systems (forward and aft) are incorporated on the H-46 Helicopter, consisting of three rotor blades and the rotor head. Each blade is capable of movement in three directions and can be folded within the landing gear width for parking. The DCU program modification to the rotor system will include upgraded materials, erosion strips, and more lasting paint. A new rotor hub will be machined from a stainless steel forging, shotpeened to increase fatigue strength, and painted with more corrosion resistant paint. Various other rotor head mechanisms such as hinge seals, dampers, and attachment fittings will be replaced with more durable materials.

b. Drive System. The H-46 drive system includes two transmissions (forward and aft), a mix box, five synchronization shafts, and an aft vertical shaft. Power is transmitted from each of the two engines to the mix box by separate drive shafts. The mix box combines torque of both engines and transmits power directly to the aft transmission, and, by synchronization shafting, to the forward transmission. The forward rotor shaft is an integral part of the forward transmission; the aft vertical drive shaft is attached to the aft transmission. The DCU upgrade to the drive system will provide new forward and aft transmissions modified to include improved lubrication systems, new chrome-plated pinion gears, stronger rotor shafts, new hose and tube configurations, and redesigned debris monitoring capabilities. A new mix box will be created to provide improved lubrication, new support bearings, increased oil capacity, and upgraded chip detector capability. Aircraft electrical systems will be modified to accommodate the forward and aft transmission debris monitoring systems. Other miscellaneous changes include installing modified synchronizing shafts, strengthened aft rotor shaft, and a modified oil cooler blower.

c. Flight Control System. Varying the pitch of the rotor blades both cyclically and collectively controls the H-46 Helicopter. The flight controls are divided into five sections: the cockpit controls, lower controls, forward upper controls, control cable installation, and aft upper controls. The cockpit controls transmit Pilot induced control motion to the lower controls. The lower controls transmit cockpit control inputs to the forward upper controls and the aft upper controls via the control cable assembly. The forward and aft upper controls receive inputs from the lower controls and hydraulically tilt the rotor blades to achieve the desired lateral vector or alter blade pitch equally on all blades to provide the desired lift vector. The control cable assembly transmits collective and lateral control motion from the lower controls to the aft upper controls. DCU modifications to the rotor and flight control systems include new corrosion resistant steel bushings and bearings, improved self-retaining bolts, new drive and stationary links, new collective links, and installation of various improved gaskets and seals.

2. Physical Description. The physical characteristics of the H-46 Helicopter are as follows:

3. New Development Introduction. NADEP Cherry Point, concurrently with SDLM, performs the AFC 433 installation by FMTs, or in parts by organizational level maintenance activities, as directed by TYCOMs.

4. Significant Interfaces. Not Applicable (NA)

5. New Features, Configurations, or Material. The DCU modification program does not change the form, fit, or function of the H-46 Helicopter rotor, drive, or flight control systems. The modification incorporates such features as more durable materials, erosion strips, remanufactured parts to increase fatigue life, corrosion inhibiting materials, improved seals and lubrication, and transmission monitoring systems.

H. CONCEPTS

1. Operational Concept. A minimum crew of three, comprised of one Pilot, one Co-Pilot, and one Crew Chief, operates the H-46 Helicopter. For Marine Corps NVG and combat missions, additional Crewmen are necessary. The H-46 Helicopter is capable of handling a variety of missions, as outlined in the Required Operational Capability and Projected Operating Environment (ROC/POE).

2. Maintenance Concept. The maintenance concept for the CH-46D and CH-46E Helicopters is based on three levels of maintenance as stated in the Naval Aviation Maintenance Program (NAMP), Office of the Chief of Naval Operations Instruction (OPNAVINST) 4790.2G. Current organizational and intermediate level maintenance procedures will not be impacted by the DCU modification.

a. Organizational. Organizational level maintenance consists of maintenance actions normally performed by an operating unit in support of its own operations. These actions include inspecting, servicing, handling, fault-isolation, removal and replacement of Weapon Replaceable Assemblies (WRA), and performing on-aircraft repairs.

(1) Preventive Maintenance. Preventive maintenance is conducted at specified intervals per established procedures as designated by a set of Maintenance Requirement Cards (MRC). Preventive maintenance actions include aircraft corrosion inspections, periodic aircraft washing, phased and special inspections, lubrication and servicing of aircraft, and daily, preflight, postflight, and turnaround inspections.

(2) Corrective Maintenance. Corrective maintenance is work performed on aircraft, aircraft equipment, and support equipment to improve, change, or restore the capability to perform specific missions or functions. Corrective maintenance includes, but is not limited to, modification, repair, and unscheduled inspection, replacement, or test. CH-46 Helicopter corrective maintenance procedures encompass aircraft repair and replacement of faulty WRAs. Faulty WRAs and components are forwarded to the Aircraft Intermediate Maintenance Department (AIMD) or Marine Aircraft Logistics Squadron (MALS).

b. Intermediate. Maintenance at the intermediate level is conducted per specific instructions contained in Maintenance Instruction Manuals for each aircraft system. Intermediate maintenance actions are those normally performed in support of a user activity. These actions include repair, test, and modification of aeronautical equipment, calibration of support equipment, and disposition of assets from stricken aircraft. Intermediate maintenance is performed at AIMDs and MALS, afloat and ashore, to verify faulty WRAs and fault-isolate to a Shop Replaceable Assembly (SRA) or component using the appropriate test equipment. The following table illustrates the intermediate level repair requirements by system.

(1) Preventive Maintenance. Preventive maintenance is performed by AIMD per the appropriate MRCs. Preventive maintenance at the intermediate level includes non-destructive inspection procedures, functional testing, inspection of life support systems, and inspection and treatment for corrosion of removed WRAs and other components.

(2) Corrective Maintenance. Corrective maintenance actions performed in support of organizational activities by AIMD and MALS host activities include repair, test, and modification of aeronautical equipment, calibration of support equipment, and disposition of assets from stricken aircraft. The AIMD or MALS verifies faulty WRAs, isolates the fault to a SRA or component using the appropriate test equipment, replaces defective SRAs or components, and repairs and overhauls engines and other major aircraft components. Corrective maintenance is performed to verify faulty WRAs, fault-isolate to an SRA or component using automatic test equipment or other appropriate test equipment, and replace defective SRAs or components.

c. Depot. Depot level maintenance consists of major overhaul or complete rebuilding, manufacture, or modification of parts, assemblies, subassemblies, and end items beyond the capability of intermediate level maintenance. NADEP Cherry Point provides depot level maintenance for the H-46 Helicopter.

d. Interim Maintenance. NA

e. Life Cycle Maintenance Plan. The H-46 Helicopter is on a five-year SDLM cycle. At the end of a 60-month service period, an Aircraft Service Period Adjustment (ASPA) inspection is performed. Aircraft found to be in satisfactory material condition will be granted a 12-month period extension, whereupon another ASPA inspection is performed. This process continues until an aircraft fails the ASPA inspection and is inducted into standard rework.

3. Manning Concept. The manning concept for the CH-46D and CH-46E Helicopters will not change due to the DCU modification program. Manpower requirements for the CH-46D and CH-46E Helicopters are driven by total preventive and corrective maintenance requirements, required operational capabilities, and the projected operational environment. Manpower requirements for the CH-46D and CH-46E Helicopters are dictated by the deployment workload of 24-hour daily organizational level servicing during cyclic flight operations. The basic watch conditions consist of two sections, each responsible for a 12-hour period.

Current manpower requirements for Navy squadrons are identified in each applicable Activity Manpower Document (AMD). Navy H-46 Activity Manpower requirements were obtained from the Total Force Manpower Management System (TFMMS). The following activities AMDs were used in this report.

Marine Corps squadron manpower requirements are identified in each applicable Table of Organization (T/O). Marine Corps H-46 Activity Manpower requirements were obtained from the following T/Os:

The number of positions requiring manning are dictated by the deployment workload demanding 24 hours of organizational level servicing during cyclic flight operations. The basic watch conditions consist of two sections, each responsible for a twelve-hour period. The manning for such positions is based on Maintenance Man-Hours Per Flight Hour. Squadron missions vary, using either all squadron aircraft assets or separate aircraft detachment deployments, as stated in the ROC/POE. Enlisted personnel from aviation maintenance ratings with Navy Enlisted Classification (NEC) codes 8215 and 8216, and Military Occupational Specialty (MOS) 6172 perform H-46 Helicopter Aircrew duties. Organizational level maintenance is performed by enlisted personnel from aviation maintenance ratings with NECs 7225, 8379, and 8879; and MOSs 6112, 6152, 6322, and 6531. Enlisted personnel from various intermediate maintenance facilities perform intermediate level maintenance.

4. Training Concept. Training for the CH-46D Helicopter Pilot and Aircrew is controlled by the Navy and is conducted by HC-3, NAS North Island. Organizational maintenance training on the CH-46D Helicopter is provided by MTU 1028 NAMTRAU North Island.

Pilot and Aircrew training for the CH-46E Helicopter is controlled by the Marine Corps and is taught at HMMT-164, MCAS Camp Pendleton. Maintenance training for the CH-46E Helicopter is taught at MTU 1027 NAMTRAGRU DET CH-46 FREST, New River.

Intermediate level maintenance training for both H-46 Helicopter models is provided by MTUs located at various NAMTRAUs and NAMTRAGRU DETs around the country.

The established training concept for most aviation maintenance training divides "A" School courses into two or more segments called Core and Strand. Many organizational level "C" School courses are also divided into separate Initial and Career training courses. "A" School Core courses include general knowledge and skills training for the particular rating, while "A" School Strand courses focus on the more specialized training requirements for that rating and a specific aircraft or equipment, based on the student's fleet activity destination. Strand training immediately follows Core training and is part of the "A" School. Upon completion of Core and Strand "A" Schools, graduates going to organizational level activities attend the appropriate Initial "C" School for additional specific training. Initial "C" School training is intended for students in paygrades E-4 and below. Career "C" School training is provided to organizational level personnel, E-5 and above, to enhance skills and knowledge within their field. "A" School graduates going to intermediate level activities attend the appropriate intermediate level "C" School. Intermediate level "C" Schools are not separated into Initial and Career courses.

Training track titles and lengths depicted throughout this document were obtained from the latest available OPNAV Aviation Training Management System (OATMS) data. In cases where the training track title or track length differ by training location, the track model manager data was used. Information from OATMS regarding H-46 Career Organizational courses is not included in this NTSP.

Student throughputs for Navy and Marine Pilot training in Parts II.B.1 and III.A.2 are based on training 50 percent Category 1 students, 30 percent Category 2 students, and 20 percent Category 3 students. For Navy enlisted Aircrew, student throughput is based on training 60 percent Category 1 students and 40 percent Category 2 students.

a. Initial Training. All initial training for the DCU, NVG-HUD, AN/ARC-210 Radio Protection, and CNCS has been completed. All organizational and intermediate level maintenance courses affected by these changes have been revised.

The following table depicts two additional H-46 courses conducted by HC-3 and MTU 1028 that are not regularly scheduled.

Note 1: The H-46 Community was exempted from teaching the Initial and Career course format by OPNAV N789. The following H-46 Career Training Tracks appear in CANTRAC and OATMS are not included in this NTSP.

Note 2: The following course has been deleted from Track M-602-2486, Helicopter Airframe Mechanic CH-46, per Naval Air Maintenance Training Group Letter, 1550 Ser. N5216/0582 dated 6 April 1999.

d. Training Pipelines. With the Navy transition from H-46 to CH-60S Helicopters, the current H-46 training requirements will no longer exist. The phase-out of Navy H-46 training will occur after the (five-year) time frame of this NTSP. The Marine Corps transition to the V-22 will not affect the training requirements identified in this NTSP. Aircraft material changes incorporated by the DCU program will not affect the form, fit, or function of any existing equipment and will be transparent to the aircraft maintenance technician. The DCU program will not affect any existing training pipelines.

I. ONBOARD (IN-SERVICE) TRAINING. Onboard proficiency training will be conducted to improve and enhance the capabilities of individuals.

1. Proficiency or Other Training Organic to the New Development

a. Maintenance Training Improvement Program. The Maintenance Training Improvement Program (MTIP) is a training management tool that, through diagnostic testing, identifies individual training deficiencies at the organizational and intermediate levels of maintenance. MTIP will be replaced by the Aviation Maintenance Training Continuum System (AMTCS). Current planning is for AMTCS to begin full implementation for fleet deployment in FY01.

b. Aviation Maintenance Training Continuum System. AMTCS will provide career path training to the Sailor or Marine from their initial service entry to the end of their military career. AMTCS is planned to be an integrated system that will satisfy the training and administrative requirements of both the individual and the organization. The benefits will be manifested in the increased effectiveness of the technicians and the increased efficiencies of the management of the training business process. By capitalizing on technological advances and integrating systems and processes where appropriate, the right amount of training can be provided at the right time, thus meeting the CNO's mandated "just-in-time" training approach.

Technology investments enable the development of several state-of-the-art training and administrative tools: Computer-Based Training (CBT) for the technicians in the Fleet in the form of Interactive Courseware (ICW) with Computer Managed Instruction (CMI) and Computer Aided Instruction (CAI) for the schoolhouse.

Included in the AMTCS development effort is the Aviation Maintenance Training Continuum System - Software Module (ASM) which provides testing [Test and Evaluation (TEV)], recording [Electronic Training Jacket (ETJ)], and a Feedback system. The core functionality of these AMTCS tools are based and designed around the actual maintenance-related tasks the technicians perform, and the tasks are stored and maintained in a Master Task List (MTL) data bank. These tools are procured and fielded with appropriate COTS hardware and software, i.e., Fleet Training Devices (FTD) - Laptops, PCs, Electronic Classrooms (ECR), Learning Resource Centers (LRC), operating software, and network software and hardware.

Upon receipt of direction from OPNAV (N789H), AMTCS is to be implemented and the new tools integrated into the daily training environment of all participating aviation activities and supporting elements. AMTCS will serve as the standard training system for aviation maintenance training within the Navy and Marine Corps, and is planned to supersede the existing MTIP and Maintenance Training Management and Evaluation Program (MATMEP) programs. AMTCS implementation will begin with the F-14, E-2C, and all models F/A-18 aircraft. For more information on AMTCS contact PMA205-3D3.

c. Operator Proficiency Training. USMC fleet Pilots and Aircrews maintain their proficiency in the CH-46E Helicopter through the use of simulators and in-aircraft flights. Weapon System Trainers provide a cost-effective method that allows Aircrews to simulate flight conditions to develop team coordination and simulate emergency procedures in a safe environment. An H-46 Helicopter Training Device, the 2F173-2, is located at MCAS Camp Pendleton to allow Pilots and Aircrews from West Coast activities to maintain their proficiency in flight procedures. East Coast squadrons utilize a similar Training Device (2F173-1) located at MCAS New River.

2. Personnel Qualification Standards. The Naval Education and Training Support Center, Pensacola, provides Personnel Qualification Standards (PQS).

3. Other Onboard or In-Service Training Packages. Marine Corps onboard training is based on the current series of MCO P4790.12, Individual Training Standards System and MATMEP. This program is designed to meet Marine Corps, as well as Navy OPNAVINST 4790.2G, maintenance training requirements. It is a performance-based, standardized, level-progressive, documented, training management and evaluation program. It identifies and prioritizes task inventories by MOS through a front-end analysis process that identifies task, skill, and knowledge requirements of each MOS. MTIP questions coupled to MATMEP tasks help identify training deficiencies that can be addressed with refresher training. (MATMEP is planned to be replaced by AMTCS.)

1. Manufacturer and Contract Numbers. This is an out of production aircraft that is supported by NADEP Cherry Point.

2. Program Documentation. The DCU Integrated Logistic Support Plan (ILSP), Revision C, was issued by Naval Air Systems Command PMA266, MCAS Cherry Point, in March 1998.

3. Technical Data Plan. In support of the DCU program, Boeing Helicopters will provide changes to the technical work package manuals currently in use. Technical publications impacted by this change include NATOPS manuals, organizational and intermediate maintenance manuals, MRCs, and overhaul manuals. Commands receiving modified H-46 Helicopters with DCU improvements will receive automatic distribution of new and changed publications per Naval Air Technical Data and Engineering Service Command procedures. New maintenance plans are being developed to support DCU modifications.

4. Test Sets, Tools, and Test Equipment. The DCU upgrade will not require any new special test sets, special tools, special test equipment, or software support for operational or training activities.

5. Repair Parts. MCAS Beaufort and NAS North Island have been designated as Initial Supply Support (ISS) activities for the DCU during the period prior to Material Support Date (MSD). ISS warehouses will provide all spares and repair parts support during the interim support period. Following MSD, the Navy Inventory Control Point will provide initial procurement of government spares and repair parts, based upon the Supply Support Management Plan milestones. The MSD for DCU Parts I and III was reached in October 1996. Parts I, III, and IV have been incorporated. Parts II, V, and VI are on track to be completed in FY03.

6. Human Systems Integration. NA

K. SCHEDULES

a. Navy H-46 Phase-Out. The Navy's replacement of H-46 Helicopters with the CH-60S is scheduled to be completed by 2006. HC-5 is scheduled to be the first operational CH-60S squadron in 2002, followed by HC-6 in 2002 and HC-3 in 2003. HC-8 and HC-11 should be fully converted prior to 2006.

b. Marine Corps Transition to the V-22. The Marine Corps transition to the V-22 Osprey is scheduled for completion in 2012. The Marine Corps received its first V-22 in June 1999 and is projected to receive V-22 aircraft at an increasing rate each year, seven aircraft in FY99, 10 in FY00, 16 in FY01, 20 in FY02, and in FY03 level off at 30 units per year until FY12. The first fully operational squadrons are scheduled for FY03 (VMM-264 and VMM-162). No time frame has been identified for ending the training requirements for the CH-46E. The Marine Corps acquisition schedule for V-22 Aircraft can be viewed on the V-22 web site (www.mr22.sra.com).

c. On-Going Changes. The current AFCs are being incorporated into the H-46 Helicopters and will continue as previously scheduled with completion planned for FY03.

d. Installation and Delivery Schedules

e. Ready For Operational Use Schedule

Note: The above schedule is based on the V-22 fielding schedule from the V-22 web site and is subject to change. The quarterly quantity of aircraft is strictly a division of the delivery schedule into quarters. H-46 Helicopters will be replaced on a one-for-one basis with the V-22.

2. Ready For Operational Use Schedule. The H-46 Helicopter is currently Ready For Operational Use (RFOU). AFC-433 Parts V and VI are being incorporated by the FMT during SDLM.

3. Time Required to Install at Operational Sites. Incorporation of one complete DCU modification kit consisting of six parts will require 1,173 man-hours. Organizational level personnel, per TYCOM direction, can install Parts I, II, and III, but Parts V and VI must be installed during SDLM. Installation of Parts III and IV has been completed.

4. Foreign Military Sales and Other Source Delivery Schedule. FMS is considered sensitive information. For FMS information contact PMA226.

5. Training Device and Technical Training Equipment Delivery Schedule. NA

L. GOVERNMENT FURNISHED EQUIPMENT AND CONTRACTOR FURNISHED EQUIPMENT TRAINING REQUIREMENTS. NA

M. RELATED NTSPs AND OTHER APPLICABLE DOCUMENTS