P/N : FI-MRBAT-60-AA
Manufacturer: Frontline Industries
 
 
Our Main Rotor Bushing Alignment Tool is a precision-manufactured device designed for military and commercial H-60/S-70 series helicopters, including all UH-60 Black Hawk and Sikorsky S-70 variants. This tool is engineered in-house to OEM maintenance manual specifications, ensuring it meets the exact requirements outlined by Sikorsky for main rotor hub servicing. It is purpose-built for aligning main rotor blade cuff bushings during installation or replacement – a critical maintenance step for both UH-60 and S-70 rotor heads. Below is a detailed overview of the tool’s features, usage, and compatibility:
Precision Alignment Function: The tool consists of a precisely machined alignment mandrel/pin that fits through the blade cuff lug bores and the new bushings. This guarantees perfect coaxial alignment of the upper and lower bushings within the main rotor blade cuff. By using this alignment mandrel while pressing in the bushings, maintainers can be confident that the bore for the blade attachment bolt is straight and true, exactly as per factory specification. This precision prevents any misalignment that could cause difficulty in inserting the blade pin or uneven loading of the joint.
Compliance with OEM Specs: Manufactured to mirror the Sikorsky OEM tool design, our alignment tool adheres to all relevant dimensions, material standards, and coatings called out in the official work packages. It is made from high-strength steel alloy, heat-treated for hardness and durability, yet with fine tolerances to protect the bushings and cuff. The tool’s exterior is nickel-plated for corrosion resistance (per MIL-SPEC), ensuring longevity in both hangar and field environments​
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. Every unit undergoes strict quality control to guarantee it meets the alignment accuracy and performance demanded by UH-60/S-70 maintenance procedures.
Typical Use Cases: This alignment tool is used whenever main rotor blade cuff bushings are installed or replaced. For example, during a scheduled main rotor hub overhaul or repair (ATA 62), after old bushings are pressed out, new bushings must be pressed into the blade cuff lug holes. The alignment tool is inserted through the cuff as the bushings are pressed from each side, serving as a guide to keep them perfectly aligned. Maintainers at Army Aviation Intermediate Maintenance (AVIM) or commercial MRO facilities will use this tool in the “Replace Main Rotor Blade Cuff Bushings” work package to comply with the manual. It is equally useful whether the rotor hub is on the aircraft or on the bench. By maintaining proper bushing alignment, the tool helps ensure that reattached rotor blades will slide into place smoothly and that critical bolt-hole alignments are preserved, preventing any fit issues when torquing the blade attach pin and associated hardware.
Reliability and Durability: Designed for repeated heavy-duty use, the tool can withstand the substantial pressing forces involved in bushing installation. Its one-piece, robust construction eliminates deflection or bending, meaning it will hold alignment even under load. This reliability is essential for military operators who may perform field repairs in austere conditions, as well as for civilian operators who demand consistency during every maintenance action. Using our alignment tool reduces the risk of bushing damage or improper seating – it effectively “self-centers” the components, removing guesswork from a critical procedure. The result is a safer, faster maintenance process with a higher confidence level in the outcome (no need to reposition and re-press bushings multiple times).
Compatibility: The in-house manufactured tool is fully compatible with all variants of the UH-60 and S-70 helicopter family. This includes the UH-60A/L/M Black Hawks, MH-60 special operations variants, HH-60 Pave Hawk, and international S-70 models such as the S-70i and S-70A. The bushing dimensions and rotor cuff interface are common across these models, so a single tool covers them all. It also fits the naval SH-60/MH-60 Seahawk series, which share the main rotor hub architecture. In essence, any operator of a “Hawk” series helicopter can use this alignment tool for main rotor bushing maintenance, confident that it replicates the OEM-specified fit and function. (Note: While primarily designed for Sikorsky H-60/S-70, this tool can also be used on equivalent main rotor assemblies that utilize the same bushing size and configuration.)
 
 
Aircraft Application: H-60 A/L/M/G, S-70, S70+, S70i
System: Main Rotor Blade Cuff
Maintenance Level (US Army): FIELD
Material: Hardened AISI 4140 Alloy Steel
Country of Origin: USA
Weight: Approximately 1.5–2.0 lbs (0.7–0.9 kg)
Size: 6”L x 1.5”W x 1.5”D
Category: Main Rotor
Part Reference:  Work Package 0612 for UH-60/S-70​