SYNOPSIS
CH-47-92-ASAM-05 AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY,
ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, REPLACEMENT
OF HI-LOK FASTENERS IN L/H AND R/H BUTT LINE 18 BEAMS
AT FUSELAGE STATION 83 TO 120, (TB 1-1520-240-50-02).
162030Z JUN 92, BRAD MEYER, AMSAV-XSOF, X9089.'
NOTE: Enter a "Q" + <CR> to exit or <SPACEBAR> to view
the entire message. (REPORTING)
.
01 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
CDRAVSCOM ST LOUIS MO //AMSAV-XSOF//
AIG 6713
AIG 9004
AIG 8708
AIG 9042
CDR4THBN228THAVN SOTO CANO //AVN-AMO//
CDRLBAD LEXINGTON KY //SDSLB-GC//
INFO DEFARM CANBERRA AS //DOHS-A//
DEFNAV CANBERRA AS
CDRUSARDSG CANBERRA AS
HQLCENG MELBOURNE AS //DAIRENG//
LOG CON OTTAWA ONT CAN //DTHEM 6-3//
AUSTNAV WASHINGTON DC //DEFNAV//
AUSTAIR WASHINGTON DC //SENGSO//
USOMC CAIRO EG //AV//
ODC ATHENS GR //ODCSA-A//
CDR AMCCOM ROCK ISLAND IL //AMSAR-QAS-P//
CHMUSLO RABAT MO //AF//
CHUSAS RIYADH SA //ASAV//
CF: SFAE-AV-CH, AMSAV-ECC, AMSAV-I-RAAF, AMSAV-MEA, AMSAV-L-AOC
BRAD MEYER
AMSAV-XSOF, X9089
EDWARD J. HOLLMAN
CHIEF, SAFETY OFFICE
.
UNCLAS
02 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
ODC MADRID SP //ARMY AND NAVY SEC//
CJUSMAG BANGKOK TH
CDRUSARDSG LONDON UK //AMXSN-UK-SE//
CDRAMC ALEXANDRIA VA //AMCMR/AMCCS/AMCSM-WAA//
XMT USDAO DHAKA BG
USDAO RANGOON BM
USDAO COLUMBO CE
USDAO SUVA FJ
OMADP JAKARTA ID
DSA NEW DELHI IN
USDAO ANTANANARIVO MA
SAO KUALA LUMPUR MY
USDAO KATMANDU NP //SAO//
USDAO SINGAPORE SN //SAO//
UNCLAS RELEASABLE TO NATO ADDRESSEES
AIG 9004 TAKE FOR INFO ONLY
AIG 8708 TAKE FOR INFO ONLY
AIG 9042 TAKE FOR INFO ONLY
SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS
.
UNCLAS
03 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
CSGLD-1860(R1), ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, REPLACEMENT
OF HI-LOK FASTENERS IN L/H AND R/H BUTT LINE 18 BEAMS AT FUSELAGE
STATION 83 TO 120, (CH-47-92-ASAM-05) (TB 1-1520-240-50-02)
NOTE - THIS IS AN AVIATION SAFETY ACTION MESSAGE AND HAS NOT BEEN
TRANSMITTED TO UNITS SUBORDINATE TO ADDRESSEES. ADDRESSEES SHOULD
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 RETRANSMISSIONTO COMMANDER, AVSCOM, ATTN - AMSAV-XSOF
(SOF COMPLIANCE OFFICER).
1. PRIORITY CLASSIFICATION -
A. AIRCRAFT IN USE - 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 //-// MAY BE CLEARED
WHEN THE CORRECTION OF PARA 9 BELOW IS COMPLETED. THE AFFECTED
AIRCRAFT SHALL BE INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN
THE TASK/INSPECTION SUSPENSE DATE. 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
.
UNCLAS
04 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
UNTIL COMPLIANCE WITH THIS ASAM HAS BEEN COMPLETED.
C. AIRCRAFT UNDERGOING MAINTENANCE - N/A.
D. AIRCRAFT IN TRANSIT -
(1) SURFACE/AIR SHIPMENT - N/A.
(2) FERRY STATUS -
(A) SAME AS PARA 1A.
(B) THOSE AIRCRAFT THAT HAVE A DD250 AND ARE AT BOEING
HELICOPTER COMPANY HAVE BEEN REWORKED.
E. MAINTENANCE TRAINERS (CATEGORY A, B AND C) - SAME AS PARA
1A.
F. COMPONENT/PARTS IN STOCK INCLUDING WAR RESERVES AT ALL
LEVELS (DEPOT AND OTHERS) - N/A.
2. TASK/INSPECTION SUSPENSE DATE - WITHIN THE NEXT PHASE INSPECTION
OR WHEN AIRCRAFT IS INDUCTED INTO THE SPECIAL TECHNICAL INSPECTION
AND REPAIR (STIR) PROGRAM, WHICHEVER OCCURS FIRST.
3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 8 JUL 92 PER
PARA 14A OF THIS MESSAGE.
4. SUMMARY OF PROBLEM -
A. DURING MANUFACTURE OF THE CH-47D HELICOPTER THE SUBJECT
HI-LOK FASTENERS WERE INADVERTENTLY INSTALLED IN OVERSIZED HOLES.
.
UNCLAS
05 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
THIS MAY REDUCE THE FATIGUE LIFE OF THIS PART OF THE FUSELAGE
STRUCTURE. REPLACEMENT OF THE HI-LOK FASTENERS BY OLR TEAM/STIR
PROGRAM ASSURES THAT THE PROPER SIZE FASTENER FOR ANY PARTICULAR
HOLE IS INSTALLED.
B. THE PURPOSE OF THIS MESSAGE IS TO REQUIRE REPLACEMENT OF ALL
HI-LOK FASTENERS AT THE NEXT PHASE INSPECTION BY OLR TEAMS OR DURING
THE STIR PROGRAM.
5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D AND MH-47E
AIRCRAFT WITH SERIAL NUMBERS 76-18538 THROUGH 90-00222. AIRCRAFT
SERIAL NUMBERS 90-00223 AND SUBSEQUENT WILL BE CORRECTED BY PRIME
CONTRACTOR DURING PRODUCTION AND THEREFORE RECORDS FOR AIRCRAFT
SERIAL NUMBERS 90-00223 AND SUBSEQUENT WILL NOT REQUIRE
IDENTIFICATION OF THIS ACTION.
6. ASSEMBLY COMPONENTS TO BE INSPECTED - N/A.
7. PARTS AFFECTED -
NOMENCLATURE PART NO. NSN
FASTENER (HI-LOK) HL18PB6 5310-00-911-9428
8. INSPECTION PROCEDURES - N/A.
9. CORRECTION PROCEDURES -
A. THE HI-LOKS TO BE REPLACED ARE LOCATED IN THE FORWARD
.
UNCLAS
06 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
TRANSMISSION TORQUE BOX, BLL AND BLR 18, STATION 83 TO 120, WL 52.
THE ROWS OF HI-LOKS ARE INBOARD AND ONE TO FOUR INCHES BELOW THE
WORK PLATFORMS PER FIGURE 1. (FIGURE 1 IS AVAILABLE FROM YOUR LOCAL
OLR OFFICE).
B. TO GAIN ACCESS TO THE HI-LOKS TO BE REPLACED, LOWER BOTH
MAINTENANCE PLATFORMS ON THE FORWARD PYLON AND REMOVE THE FORWARD
TRANSMISSION DRIP PAN PER TM 55-1520-240-23-2.
CAUTION
TO PREVENT RESIDUE FROM FALLING INTO THE AVIONICS AND OTHER
COMPARTMENTS WHEN REMOVING RIVETS FROM SKINS ABOVE THE
COMPARTMENTS, COVER THE COMPARTMENT WITH SUITABLE COVERING. IN
ACCORDANCE WITH CURRENT FOREIGN OBJECT DAMAGE (FOD) PRACTICES.
C. THE FOLLOWING STEPS PROVIDE INSTRUCTIONS FOR REMOVAL OF ALL
SKINS AND PANELS TO GAIN ACCESS AND REPLACE ALL OF THE SUBJECT
HI-LOK FASTENERS.
(1) REMOVE THE FORWARD L/H AND R/H WORK PLATFORMS PER TM
55-1520-240-23-2.
(2) REMOVE FAIRING ASSEMBLIES, P/N 145S1905-1 AND -2 PER
TM 55-1500-204-25/1. THESE FAIRINGS ARE LOCATED BELOW THE WORK
PLATFORMS AND MATE THE FUSELAGE TO THE PYLON.
.
UNCLAS
07 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
(3) IF REQUIRED TO GAIN ACCESS TO DRILL STRAIGHT HOLES
THROUGH THE DRAG ANGLE AND BEAM, REMOVE L/H AND R/H ANGLES P/N
114S1964, THAT ATTACH THE FAIRING ASSEMBLY P/N 145S1905 TO THE CROWN
SKIN.
(4) TO GAIN ACCESS TO THE FIRST FOUR HI-LOKS STARTING AT
STATION 83, REMOVE THE SKIN ATTACHING RIVETS FAR ENOUGH FORWARD TO
ALLOW THE CROWN SKIN FAIRING, P/N 114S1602, TO BE RAISED AWAY FROM
THE WORK AREA.
(5) REMOVE THE DEFECTIVE HI-LOKS PER TM 55-1500-204-25/1.
(6) MEASURE THE HOLE AND DETERMINE THE HOLE CONDITION AND
SIZE. THE ORIGINAL HOLE WAS A NO. 6 (.1895-.1905) HOLE. THE
ORIGINAL HI-LOK USED WAS A HL18P86 WITH A HL79-6 COLLAR. IF THE
HOLE IS DAMAGED OR IS THE WRONG SIZE, USE THE FOLLOWING CHART TO
DETERMINE THE NEXT OVERSIZE HOLE AND FASTENER TO USE.
NOMINAL HOLE SIZES FOR OVERSIZE HI-LOKS
1/64 1/32 1/4
CLOSE .2036 .2192 .2505
REAM .2026 .2182 .2495
.
UNCLAS
08 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
REPLACEMENT RIVETS (OVERSIZE)
1/64 1/32 1/4 NO. PER ACFT
HL62PB6-3 HL218-6-3 HL18PB8-3 7
HL62PB6-4 HL218-6-4 HL18PB8-4 1
HL62PB6-5 HL218-6-5 HL18PB8-5 17
HL62PB6-6 HL218-6-6 HL18PB8-6 1
HL62PB6-7 HL218-6-7 HL18PB8-7 1
HL62PB6-9 HL218-6-9 HL18PB8-9 1
REPLACEMENT COLLARS (OVERSIZE)
1/64 1/32 1/4 NO. PER ACFT
HL79-6 HL84-6 HL79-8 28
NOTE
DUE TO TOLERANCE BUILD-UP, FASTENER LENGTHS MAY VARY FROM THOSE
NOTED ABOVE.
(7) INSTALL REPLACEMENT HI-LOKS PER TM 55-1500-204-25/1.
MAKE CERTAIN THAT ALL HOLES ARE REAMED TO THE CORRECT SIZE AND
DEBURRED, TREATED AND PRIMED.
(8) INSTALL L/H AND R/H ANGLES P/N 114S1964 USING
MS20470AD4 AND MS20470DD6 RIVETS PER TM 55-1500-204-25/1.
.
UNCLAS
09 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
(9) RE-ATTACH THE CROWN SKIN FAIRING P/N 114S1602 USING
MS20470AD4 AND MS20470AD5 RIVETS PER TM 55-1500-204-25/1.
(10) INSTALL THE L/H AND R/H FAIRING ASSEMBLIES, P/N
145S1905-1 AND -2 USING MS7885/2-4, M7885/2-5, AND MS20470AD4 RIVETS
PER TM 55-1500-204-25/1.
(11) RE-ATTACH THE FORWARD L/H AND R/H WORK PLATFORMS PER
TM 55-1520-240-23-2.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 10C WILL BE
FURNISHED BY REPAIR TEAM.
B. REQUISITIONING INSTRUCTIONS - N/A.
C. BULK AND CONSUMABLE MATERIALS -
NOMENCLATURE PART NUMBER NSN
RIVET HL62PB-3 5320-01-043-0071
RIVET HL62PB-4 5320-00-457-1331
RIVET HL62PB-5 5320-00-613-0473
RIVET HL62PB-6 5320-00-899-4662
RIVET HL62PB-7 5320-01-099-1008
RIVET HL62PB-9 5320-01-108-7651
RIVET HL218-6-3 5306-00-522-1814
.
UNCLAS
10 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
RIVET HL218-6-4 5320-00-494-7983
RIVET HL218-6-5 5306-00-410-1749
RIVET HL218-6-6 5320-01-100-8824
RIVET HL218-6-7 5306-00-494-7985
RIVET HL218-6-9 5320-00-395-6421
RIVET HL18PB8-3 5320-00-813-3920
RIVET HL18PB8-4 5320-00-959-0215
RIVET HL18PB8-5 5320-00-959-0201
RIVET HL18PB8-6 5320-00-959-0200
RIVET HL18PB8-7 5320-00-915-4973
RIVET HL18PB8-9 5320-00-959-0204
COLLAR HL79-6 5320-00-968-9212
COLLAR HL84-6 5320-00-457-1332
COLLAR HL79-8 5320-00-968-9210
PROSEAL 890 N/A 1520-00-080-1549
D. DISPOSITION - DISPOSE OF REMOVED PARTS/COMPONENTS IN
ACCORDANCE WITH NORMAL SUPPLY PROCEDURES.
E. DISPOSITION OF HAZARDOUS MATERIAL - N/A.
11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A.
12. APPLICATION -
.
UNCLAS
11 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
A. CATEGORY OF MAINTENANCE - DEPOT OR CONTRACTOR TEAM.
AIRCRAFT DOWNTIME WILL BE CHARGED TO DEPOT MAINTENANCE.
B. TIME REQUIRED -
(1) TOTAL OF 50 MANHOURS USING 2 PERSONS.
(2) TOTAL OF 25 HOURS DOWNTIME FOR ONE END ITEM.
C. ESTIMATED COST IMPACT OF STOCK FUND ITEMS TO THE FIELD -
N/A.
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 - N/A.
13. REFERENCES -
A. TM 55-1500-204-25/1, GENERAL AIRCRAFT MAINTENANCE MANUAL,
DATED APRIL 1970, C37 15 SEP 1988.
B. TM 55-1520-240-23-2, AVIATION UNIT AND AVIATION INTERMEDIATE
MAINTENANCE MANUAL, CH-47D HELICOPTER, DATED 10 MAY 1983, C11 9 OCT
1990.
14. RECORDING AND REPORTING REQUIREMENTS -
A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON
ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13 ON ALL
.
UNCLAS
12 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
SUBJECT MDS AIRCRAFT, FORWARD A PRIORITY MESSAGE, DATAFAX OR E-MAIL
TO COMMANDER, AVSCOM, ATTN AMSAV-XSOF (SOF COMPLIANCE OFFICER), PER
AR 95-3. DATAFAX NUMBER IS DSN 693-2064 OR COMMERCIAL 314/263-2064.
E-MAIL ADDRESS IS "AMSAVXSOF (AT SIGN) ST-LOUIS-EMH4.ARMY.MIL". THE
REPORT WILL CITE THIS MESSAGE NUMBER, DATE OF ENTRY IN DA FORM
2408-13, THE AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF
AIRCRAFT IN NUMERICAL ORDER.
B. TASK/INSPECTION REPORTING SUSPENSE DATE (AIRCRAFT) - N/A.
C. REPORTING COMPLIANCE SUSPENSE DATE (SPARES) - N/A.
D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - N/A.
E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED
IN ACCORDANCE WITH DA PAM 738-751, 15 JAN 88 -
(1) DA FORM 2408-13, AIRCRAFT INSPECTION AND MAINTENANCE
RECORD.
(2) DA FORM 2408-14, UNCORRECTED FAULT RECORD.
(3) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
(4) SF 368, CATEGORY II QUALITY DEFECIENCY REPORT.
15. WEIGHT AND BALANCE - N/A.
16. POINTS OF CONTACT -
.
UNCLAS
13 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z
YES
A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. EMANUAL
BUELTER, SFAE-AV-CH-T, DSN 693-1639 OR COMMERCIAL 314/263-1639.
B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. STEVE
KOUCHNERKAVICH, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL
314/263-1415.
C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MR.
ROGER BARRE/MR. JOHN ZUBER, AMSAV-MPPD, DSN 693-1955 OR COMMERCIAL
314/263-1955.
D. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. BRAD MEYER,
AMSAV-XSOF, DSN 693-9089 OR COMMERCIAL 314/263-9089.
E. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING
CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT MW4
JAY NANCE/MR. RON VAN REES, AMSAV-I, DSN 693-3826 OR COMMERCIAL
314/263-3826.
F. AFTER HOURS CONTACT AVSCOM COMMAND OPERATIONS CENTER (COC)
DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.