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:UNCLAS
SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY,
RCS CSGLD-1860(R1), CH-47D/MH-47D AIRCRAFT, INITIAL AND RECURRING
INSPECTION OF FUEL PODS FOR CORROSION AND ELECTRICAL BONDING, (CH-
47-00-ASAM-01) (TB 1-1520-240-20-119).
NOTE
THIS IS AN AVIATION SAFETY ACTION MESSAGE ISSUED IAW AR 95-1,
CHAPTER 6, 1 SEP 97. THIS MESSAGE HAS NOT BEEN TRANSMITTED TO UNITS
SUBORDINATE TO ADDRESSEES. ADDRESSEES SHALL IMMEDIATELY RETRANSMIT
THIS MESSAGE TO ALL SUBORDINATE UNITS, ACTIVITIES OR ELEMENTS
AFFECTED OR CONCERNED. THE RETRANSMITTAL SHALL REFERENCE THE
MESSAGE. ACTION ADDRESSES WILL IMMEDIATELY VERIFY THIS TRANSMISSION
TO CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER).
1. PRIORITY CLASSIFICATION -
NOTE
IAW AR 95-1, PARA 6-6A, MACOM COMMANDERS MAY AUTHORIZE TEMPORARY
EXCEPTION FROM ASAM MESSAGE REQUIREMENTS. EXCEPTION MAY ONLY OCCUR
WHEN COMBAT OPERATIONS OR MATTER OF LIFE OR DEATH IN CIVIL DISASTERS
OR OTHER EMERGENCIES ARE SO URGENT THAT THEY OVERRIDE THE
CONSEQUENCES OF CONTINUED AIRCRAFT OPERATION.
A. UPON RECEIPT OF THIS MESSAGE THE CONDITION STATUS SYMBOL
OF THE CITED AIRCRAFT WILL BE CHANGED TO A RED HORIZONTAL DASH //-//.
THE RED HORIZONTAL DASH //-//ENTRY SHALL STATE "INSPECT FUEL PODS IAW
CH-47-00-ASAM-01 (TB 1-1520-240-20-119) WITHIN THE NEXT 10 FLIGHT
HOURS, BUT NLT 14 MAY 2000. THE RED HORIZONTAL DASH //-// MAY BE
CLEARED WHEN THE INSPECTION OF PARA 8 IS COMPLETED. THE AFFECTED
AIRCRAFT SHALL BE INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN 14
MAY 2000. FAILURE TO COMPLY WITH THE REQUIREMENTS OF THIS MESSAGE
WITHIN THE TIME FRAME WILL CAUSE THE STATUS SYMBOL TO BE UPGRADED TO
A RED //X//.
B. AIRCRAFT IN DEPOT MAINTENANCE - AIRCRAFT WILL NOT BE
ISSUED UNTIL COMPLIANCE WITH PARAGRAPHS 8 AND 9 OF THIS ASAM HAVE
BEEN COMPLETED. THIS INCLUDES AIRCRAFT UNDERGOING REFURBISHMENT
AT CORPUS CHRISTI ARMY DEPOT (CCAD).
C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A.
D. AIRCRAFT IN TRANSIT -
(1) SURFACE/AIR SHIPMENT - SAME AS PARA 1A.
(2) FERRY STATUS -
(A) SAME AS PARA 1A.
(B) THOSE AIRCRAFT THAT HAVE A DD 250 AND ARE AT BOEING
HELICOPTERS WILL BE INSPECTED PRIOR TO FERRY TO FINAL DESTINATION.
E. MAINTENANCE TRAINERS (CATEGORY A AND B) - COMPLY WITH
PARAGRAPH 9 WITHIN 90 DAYS OF RECEIPT OF THIS MESSAGE.
F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS)
INCLUDING WAR RESERVES - ON RECEIPT OF THIS MESSAGE THE MATERIAL
CONDITION TAGS OF ALL ITEMS IN ALL CONDITION CODES LISTED IN
PARAGRAPHS 6 AND 7 SHALL BE ANNOTATED TO READ "CH-47-00-ASAM-01
(TB 1-1520-240-20-119), INSPECTION OF FUEL PODS, NOT COMPLIED WITH".
(1) WHOLESALE STOCK - N/A.
(2) RETAIL STOCK - UPON RECEIPT OF THIS MESSAGE COMMANDERS
AND OTHERS MAINTAINING RETAIL STOCK AT INSTALLATION LEVEL AND BELOW
SHALL CONTACT THE SUPPORTED AVIATION UNIT TO PERFORM THE INSPECTION
REQUIRED BY PARAGRAPH 8 AND THE CORRECTION PROCEDURES OF PARAGRAPH 9
ON DISCREPANT MATERIEL. DISPOSITION OF DISCREPANT MATERIEL WILL BE
IAW PARAGRAPH 10.
G. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - ITEMS
LISTED IN PARAGRAPHS 6 AND 7 IN WORK WILL NOT BE ISSUED UNTIL
COMPLIANCE WITH THIS MESSAGE.
2. TASK/INSPECTION SUSPENSE DATE - WITHIN THE NEXT 10 FLIGHT HOURS
BUT NLT 14 MAY 2000, AND REPORT IAW PARA 14B.
3. REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE IAW
PARA 14A NLT 19 MAY 2000.
4. SUMMARY OF PROBLEM -
A. A UNIT REPORTED FINDING CORROSION WHERE THE FUEL POD SKIN
ATTACHES TO THE T-CAP. FURTHER INVESTIGATION REVEALED THIS TO BE
GALVANIC CORROSION. THE MANUFACTURER OF THE PODS MISINTERPRETED
THE DRAWINGS AND PAINTED BARE ALUMINUM WITH A CARBON FILLED PAINT.
THE DISSIMILAR MATERIALS SET UP THE ENVIRONMENT FOR THE GALVANIC
CORROSION. CORROSION PRODUCTS CAN REDUCE CONDUCTIVITY AND MAKE
ELECTRICAL BONDING INEFFECTIVE.
B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA 12.
C. THE PURPOSE OF THIS MESSAGE IS TO -
(1) DIRECT AN INITIAL AND RECURRING INSPECTION FOR
CORROSION AND PROPER ELECTRICAL BONDING.
(2) REQUIRE REPLACEMENT, REWORK, OR USE OF AN ADDITIONAL
BONDING STRAP, AS AN INTERIM MEASURE WHERE ELECTRICAL BONDING IS
INSUFFICIENT.
(3) AT THE NEXT PHASE INSPECTION, REWORK OR REPLACE THE
FUEL POD T-CAPS WHICH HAVE CORROSION.
5. END ITEMS TO BE INSPECTED ALL CH-47D AND MH-47D AIRCRAFT.
6. ASSEMBLY COMPONENTS TO BE INSPECTED -
NOMENCLATURE P/N. NSN
MAIN FUEL POD ASSY 145S5021-1 1560-01-192-2458
AUXILIARY FUEL POD ASSY 145S5022-1 1560-01-192-2459
145S5022-2 1560-01-189-2062
145S5022-3 1560-01-192-2457
145S5022-4 1560-01-192-2456
7. PARTS TO BE INSPECTED -
NOMENCLATURE P/N NSN
ANGLE ASSEMBLY 114S5520-31 1560-00-909-2557
ANGLE ASSEMBLY 114S5521-44 N/A
ANGLE ASSEMBLY 114S5521-45 N/A
ANGLE ASSEMBLY 114S5521-46 N/A
ANGLE ASSEMBLY 114S5521-47 N/A
8. INSPECTION PROCEDURES -
A. PREPARE THE AIRCRAFT FOR SAFE GROUND MAINTENANCE.
B. ON PODS THAT ARE CONSTRUCTED WITH A FIBERGLASS UPPER SKIN
PERFORM THE FOLLOWING -
(1) MEASURE THE ELECTRICAL RESISTANCE IN THE RIVETED
JOINT BETWEEN THE BONDING STRAP AND THE POD ATTACHMENT T-CAP.
THE RESISTANCE SHOULD NOT EXCEED 0.0025 (TWENTY FIVE TEN THOUSANDTHS)
OHMS. IF THE RESISTANCE EXCEEDS 0.0025 OHM, PERFORM THE CORRECTION
PROCEDURES IAW PARA 9A.
(2) VISUALLY INSPECT FOR CORROSION ON THE FUEL POD T-CAPS.
IF CORROSION IS PRESENT ON THE T-CAPS, REPAIR OR REPLACE IAW
PARAGRAPH 9B NLT THE NEXT PHASE INSPECTION.
C. IF ALL AREAS INSPECTED IAW PARA 8B ARE ACCEPTABLE, THE RED
HORIZONTAL DASH //-// WILL BE CLEARED AND COMPLIANCE WITH THIS
MESSAGE AND TB 1-1520-240-20-119 WILL BE NOTED.
9. CORRECTION PROCEDURES
A. IF THE ELECTRICAL RESISTANCE DOES NOT MEET THE INSPECTION
CRITERIA IAW PARAGRAPH 8B(1) -
(1) REPAIR THE BONDING STRAP AS FOLLOWS -
(A) REMOVE CORROSION FROM THE ATTACHING BOLTS AND THE
STRAP INSIDE DIAMETER.
(B) ADD ANOTHER GROUNDING STRAP FROM SUPPLY, OR
FABRICATE ONE SIMILAR TO THE EXISTING STRAP FROM ALUMINUM SHEET.
(C) ATTACH THE NEW STRAP TO A BOLT ON THE FILLER CAP IN
THE SAME MANNER AS THE EXISTING STRAP. ATTACH THE OTHER END TO THE
NEAREST POD T-CAP FUSELAGE MOUNTING BOLT. RE-TEST ELECTRICAL
RESISTANCE IAW 8B(1) ABOVE.
(2) IF UNABLE TO PERFORM THE CORRECTION PROCEDURES IAW
PARA 9A(1) -
(A) CHANGE THE STATUS SYMBOL OF THE AIRCRAFT TO A
CIRCLE RED //X//. THE CIRCLED RED //X// ENTRY SHALL STATE "THE
AIRCRAFT IS RESTRICTED FROM GRAVITY REFUELING IAW CH-47-00-ASAM-01
(TB 1-1520-240-20-119)."
(B) REPAIR TO THE BONDING STRAP WILL BE COMPLETED
IAW PARA 9A(1) NLT THE NEXT PHASE INSPECTION.
(3) A RECURRING INSPECTION OF THE BONDING STRAP WILL BE
COMPLETED DURING EACH SCHEDULED PHASE INSPECTION. THE REQUIREMENT
FOR THIS INSPECTION WILL BE ADDED TO THE APPROPRIATE TECHNICAL
MANUALS IAW PARAGRAPH 12E OF THIS MESSAGE.
B. IF CORROSION IS FOUND FOLLOWING THE INSPECTION IAW
PARA 8B(2), REPAIR OR REPLACE THE T-CAPS AT THE NEXT PHASE INSPECTION
AS FOLLOWS -
(1) REMOVE THE POD IAW TM 55-1520-240-23, TASK 10-7 (MAIN),
TASK 10-23 (FORWARD), OR TASK 10-28 (AFT).
(2) REMOVE THE UPPER T-CAP, P/N 114S5521-44/-45/-46/-47
(AUXILIARY PODS), OR P/N 114S5520-31 (MAIN PODS).
(3) WHERE CORROSION IS FOUND - USING 60 GRIT OR FINER
ALUMINUM OXIDE PAPER OR CLOTH, OR WITH A-A-58054, TYPE 1, GRADE A
OR FINER ABRASIVE MATERIAL, REMOVE CORROSION FROM THE T-CAP. THE
MAXIMUM ALLOWABLE AMOUNT OF MATERIAL THAT CAN BE REMOVED FROM THE
T-CAP IS 0.003 (MINIMUM ALLOWABLE THICKNESS OF THE T-CAP IS 0.054).
(4) IF THE T-CAP CANNOT BE SALVAGED IAW THE GUIDELINES IN
PARA 9B(3), REPLACE WITH A NEW SECTION OF T-CAP IAW TM 55-1520-
240-23, TASK 2-186.
(5) RE-INSTALL THE POD IAW TM 55-1520-240-23, TASK 10-21
(MAIN), TASK 10-26 (FORWARD), OR TASK 10-31 (AFT).
C. AFTER COMPLETION OF THE CORRECTION PROCEDURES IAW PARA 9A
AND 9B (AS APPLICABLE), THE RED HORIZONTAL DASH //-// WILL BE CLEARED
AND COMPLIANCE WITH THIS MESSAGE AND TB 1-1520-240-20-119 WILL BE
NOTED.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPHS 6 AND 7 MAY BE
USED TO REPLACE DEFECTIVE ITEMS.
B. SOME REPLACEMENT PARTS CAN BE LOCALLY FABRICATED AS
FOLLOWS -
(1) T-CAP MATERIAL CAN BE FABRICATED FROM - STRINGER,
AIRCRAFT, P/N 114S5520-31, NSN 1560-00-909-2557.
(2) THE BONDING (GROUNDING) STRAP CAN BE FABRICATED
FROM - 6061-O, ALUMINUM ALLOY PER QQ-A-250/13, 0.016 INCH THICK
BY 1.2 INCH WIDE. CUT TO LENGTH AS REQUIRED.
C. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT
PARTS USING NORMAL SUPPLY PROCEDURES.
D. BULK AND CONSUMABLE MATERIALS - N/A.
E. DISPOSITION - DEMILITARIZE/MUTILATE IAW TM 1-1500-328-23
ANY PART/COMPONENT WHICH DOES NOT MEET INSPECTION CRITERIA.
F. DISPOSITION OF HAZARDOUS MATERIAL - IAW ENVIRONMENTAL
PROTECTION AGENCY DIRECTIVES AS IMPLEMENTED BY YOUR SERVICING
ENVIRONMENTAL COORDINATOR (AR 200-1).
11. SPECIAL TOOLS AND FIXTURES REQUIRED N/A.
12. APPLICATION -
A. CATEGORY OF MAINTENANCE AVUM. AIRCRAFT DOWNTIME WILL
BE CHARGED TO AVUM.
B. ESTIMATED TIME REQUIRED -
(1) TO CONDUCT THE ONE TIME INSPECTION OF THE FUEL POD -
TOTAL OF 2 MAN-HOURS USING 1 PERSON.
(2) TO REMOVE, REPAIR, AND REINSTALL THE FUEL PODS -
(A) TOTAL OF 30 MAN-HOURS USING 3 PERSONS.
(B) TOTAL OF 10 HOURS DOWNTIME FOR ONE END ITEM.
C. ESTIMATED COST IMPACT TO THE FIELD -
NOMENCLATURE PN/NSN QTY COST EA TOTAL
STRINGER, ACFT (T-CAP) 114S5520-31 1 $715.99 $715.99
1560-01-909-2557
TOTAL COST PER AIRCRAFT = $715.99
D. TB/MWOS TO BE APPLIED PRIOR TO OR CONCURRENTLY WITH THIS
INSPECTION - N/A.
E. PUBLICATIONS WHICH REQUIRE CHANGE AS A RESULT OF THIS
INSPECTION TM 55-1520-240-23 AND TM 55-1520-240-PM SHALL BE
CHANGED TO REFLECT THIS MESSAGE. A COPY OF THIS MESSAGE SHALL BE
INSERTED IN THE APPROPRIATE TM AS AUTHORITY TO IMPLEMENT THE
CHANGES UNTIL THE PRINTED CHANGE IS RECEIVED.
13. REFERENCES -
A. TM 55-1520-240-23P.
B. TM 55-1520-240-23.
C. TM 55-1520-240-PM.
D. TM 1-1500-328-23.
E. DA PAM 738-751.
14. RECORDING AND REPORTING REQUIREMENTS -
A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON
ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 ON ALL
SUBJECT MDS AIRCRAFT, FORWARD A PRIORITY MESSAGE, DATAFAX OR E-
MAIL TO CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER),
REDSTONE ARSENAL, AL 35898-5000, IAW AR 95-1. DATAFAX NUMBER IS
DSN 897-2111 OR (256) 313-2111. E-MAIL ADDRESS IS
"SAFEADM@REDSTONE.ARMY.MIL". THE REPORT WILL CITE CH-47-00-ASAM-01
(TB 1-1520-240-20-119), DATE OF ENTRY IN DA FORM 2408-13-1, THE
AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF AIRCRAFT
IN NUMERICAL ORDER.
B. TASK/INSPECTION REPORTING SUSPENSE DATE (AIRCRAFT) - N/A.
C. REPORTING MESSAGE RECEIPT (SPARES) - N/A.
D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - N/A.
E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED
IAW DA PAM 738-751, 15 MAR 99 -
NOTE
ULLS-A USERS WILL USE APPLICABLE "E" FORMS.
(1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD.
(2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND
MAINTENANCE RECORD.
(3) DA FORM 2408-14-1, UNCORRECTED FAULT RECORD.
(4) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
(5) DD FORM 1574/DD FORM 1574-1, SERVICEABLE TAG/LABEL -
MATERIEL (COLOR YELLOW). ANNOTATE REMARKS BLOCK WITH "CH-47-00-
ASAM-01 (TB 1-1520-240-20-119) NOT COMPLIED WITH."
(6) DD FORM 1577-2/DD FORM 1577-3, UNSERVICEABLE
(REPARABLE) TAG/LABEL - MATERIEL TM 55-1520-240-PM (COLOR GREEN).
ANNOTATE REMARKS BLOCK WITH UNSERVICEABLE IAW CH-47-00-ASAM-01
(TB 1-1520-240-20-119)."
15. WEIGHT AND BALANCE - N/A.
16. POINTS OF CONTACT -
A. TECHNICAL POINT OF CONTACT IS MR. DENNIS GANEY, AMSAM-RD-
AE-I-P-C, DSN 897-3361 OR (256) 313-3361, DATAFAX IS DSN 897-4348
OR (256) 313-4348. E-MAIL IS DENNIS.GANEY@REDSTONE.ARMY.MIL".
B. LOGISTICAL POINT OF CONTACT IS MR. BILL OLSON , SFAE-AV-
CH-L, DSN 897-3379 OR (256) 313-3379, DATAFAX IS DSN 897-4348 OR
(256) 313-4348. E-MAIL IS "OLSONW@PEOAVN.REDSTONE.ARMY.MIL".
C. FORMS AND RECORDS POINT OF CONTACT IS MS. ANN WALDECK,
AMSAM-MMC-RE-FF DSN 746-5564 OR (256) 876-5564, DATAFAX IS DSN
746-4904 OR (256) 876-4904. E-MAIL IS
"ANN.WALDECK@REDSTONE.ARMY.MIL"
D. SAFETY POINTS OF CONTACT ARE -
(1) PRIMARY - MR. HARRY TRUMBULL (SAIC), AMSAM-SF-A,
DSN 897-2095 OR (256) 313-2095, DATAFAX IS DSN 895-2111 OR (256)
313-2111. E-MAIL IS "HARRY.TRUMBULL@REDSTONE.ARMY.MIL".
(2) ALTERNATE - MR. HOWARD CHILTON, AMSAM-SF-A, DSN 897-
2068 OR (256) 313-2068, DATAFAX IS DSN 897-2111 OR (256) 313-
2111. E-MAIL IS "HOWARD.CHILTON@REDSTONE.ARMY.MIL".
E. FOREIGN MILITARY SALES RECIPIENTS REQUIRING CLARIFICATION OF
ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT: CW5 JOSEPH L.
WITTSTROM, SECURITY ASSISTANCE MANAGEMENT, AMSAM-SA, DSN 897-0681 OR
(256) 313-0681. EMAIL IS "WITTSTROMJL@REDSTONE.ARMY.MIL" OR MR.
RONNIE W. SAMMONS, AMSAM-SA-CS-NF, DSN 897-0869 OR (256) 313-0869.
DATAFAX IS DSN 897-0411 OR (256) 313-0411. EMAIL IS
"SAMMONSRW@REDSTONE.ARMY.MIL". HUNTSVILLE, AL IS GMT MINUS 5 HRS.
F. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER
(COC) DSN 897-2066/7 OR (256) 313-2066/7.