Tool solution reduces '5-Pack' maintenance hours by 75%

The H-60 Bridge Tool Kit contains specially designed tools for the removal and installation of '5-Pack' (gearbox, two engine input and two accessory drive modules) components that include forward and aft bridges, bellcranks, tie rods, eccentric bushings, and longitudinal support assemblies on the H-60 helicopter. The H-60 platform includes all models of the Blackhawk (US), Seahawk/Knighthawk (USN), Pave Hawk (USAF), Jayhawk (USCG) and the White Hawk (USMC, Marine One).

“Every branch of the service has long sought solutions for improving maintenance processes that increase aircraft availability,” said Bob Hill, former US Army Aviation & Missile Command (AMCOM) Field Operations Division Chief and Field Maintenance Deputy Director. “After conducting on-aircraft demonstrations and discussions with numerous H-60 maintenance technicians and other subject matter experts, the toolkit's quality and its performance are undisputable. This tool enhances our Warfighters’ capabilities by reducing time/effort and by preventing damage to the main transmission, which, ultimately, allows more of our H-60’s to maintain mission readiness.”

By avoiding just one transmission case loss, the Services’ H-60 maintenance can realise more than $500,000 savings in time and parts risk during each transmission 5-Pack removal.

“We were able to utilise direct hands-on input from H-60 maintainers to ensure these tools were purpose-built with a goal for zero allowance of collateral component damage,” said Matt Hederstrom, CEO of Varley US. “We were able to achieve that goal while also helping to improve aircraft availability and reduce total maintenance hours from an average of 64 man-hours to remove 5-Pack components to less than nine man-hours per each main transmission disassembly, and achieved a 100% reduction in collateral damage.”