Safety of Flight CH-47-04-01

 

Inspection of the Forward and Aft Swashplate Bearing

 

Summary of Problem: Safety of Flight message, CH-47-03-01, established inspection requirements for the H-47 Forward and Aft Swashplate Assemblies. These inspection requirements included submitting a grease sample for analysis by the Army Oil Analysis Program (AOAP). Inconsistent results from this program do not show correlation between grease sample results and actual swashplate assembly damage/condition. The AOAP grease sampling results can not be considered a reliable method to indicate pending bearing failure or even used to assess the condition of the swashplate bearings. See also 91-00233.

 

 

UNCLASSIFIED . MSG DTG 052030Z FEB 04 . FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A// . SUBJECT - SAFETY OF FLIGHT, TECHNICAL, RCS CSGLD-1860(R1), ALL H-47 AIRCRAFT, FWD AND AFT SWASHPLATE BEARINGS, CH-47-04-01. ...................NOTE................... ....This message is effective until rescinded or superseded. ...................NOTE................... ....This message is issued IAW AR 95-1 and has not been ....transmitted to units subordinate to addressees. ....Addressees will immediately retransmit this message ....to all subordinate units, activities or elements ....affected or concerned. MACOMs will immediately ....verify this transmission to the AMCOM SOF Compliance ....Officer (AMSAM-SF-A, safeadm@redstone.army.mil). ...................NOTE................... ....MACOM commanders may authorize temporary exception from ....message requirements IAW AR 95-1, Ch 6. 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. 1. SUMMARY - 1.1. Background - Safety of Flight message, CH-47-03-01, established inspection requirements for the H-47 Forward and Aft Swashplate Assemblies. These inspection requirements included submitting a grease sample for analysis by the Army Oil Analysis Program (AOAP). Inconsistent results from this program do not show correlation between grease sample results and actual swashplate assembly damage/condition. The AOAP grease sampling results can not be considered a reliable method to indicate pending bearing failure or even used to assess the condition of the swashplate bearings. 1.2. Message Purpose - 1.2.1. Supercede CH-47-03-01. 1.2.2. Revise the procedure IAW para 7.2. of CH-47-03-01. 1.2.3. The visual inspection IAW Para 7.1. of CH-47-03-01 remains the same. 2. END ITEMS AFFECTED - All H-47 series aircraft. 3. ASSEMBLIES/COMPONENTS/PARTS AFFECTED - ..Nomenclature Part No. NSN Swashplate Assy FWD 145R3551-19 1615-01-473-4376 145R3551-17 1615-01-395-0006 145R3551-1 1615-01-115-3623 145R3551-11 1615-01-352-8575 145R3551-5 1615-01-315-5133 Swashplate Assy AFT 145R3551-20 1615-01-475-9838 145R3551-18 1615-01-395-0007 145R3551-2 1615-01-115-3610 145R3551-12 1615-01-352-8576 145R3551-6 1615-01-317-2432 Bearing, Swashplate 114RS308-1 3110-00-141-3750 Bearing, Swashplate 114RS308-2 3110-01-356-0489 . ...................NOTE................... ....When complying with the requirements of this message, ....complete forms and records entries IAW DA PAM 738-751. ....ULLS-A units will use appropriate "E" forms. 4. INITIAL TAMMS (THE ARMY MAINTENANCE MANAGEMENT SYSTEM) COMPLIANCE REQUIREMENTS - 4.1. Upon receipt of this message, make the following entry on the DA Form 2408-13-1. Enter a Red Horizontal Dash //-// status symbol with the following statement: "Comply with requirements of CH-47-04-01 at the next scheduled 50 hour swashplate lubrication/purge." Commanders who are unable to comply with the requirements of this message within the time frame specified will upgrade the affected aircraft status symbol to a Red //X//. ...................NOTE................... ....The TAMMS compliance reporting form is available at ...."www.redstone.army.mil/sof/tamms.xls" (use lower case ....letters only) or may be obtained from the units ....servicing LAR. Alternate forms may be approved by ....the AMCOM SOF Compliance Officer. ...................NOTE................... ....The TAMMS Compliance Report only confirms the unit has ....made the initial logbook entry for assigned aircraft. ....TAMMS Compliance Reports will include aircraft serial ....numbers (in numerical order), date of entry on DA Form ....2408-13-1, unit address, local POC name and phone number. 4.2. TAMMS Compliance Report - Submit TAMMS Compliance Report via priority email to "safeadm@redstone.army.mil" NLT 20 Feb 2004 IAW AR 95-1. If email is not available, the report may be faxed to: SOF Compliance Officer at DSN 897-2111 or (256) 313-2111. 5. TASK/INSPECTION COMPLIANCE REQUIREMENTS - N/A. 6. SPECIAL PROVISIONS TO MESSAGE REQUIREMENTS (AIRCRAFT) - 6.1. Aircraft in AVUM, AVIM, or Depot level maintenance - Commanders, facility managers and contractors will not issue aircraft until they are in compliance with this message. 6.2. Maintenance Trainers (Cat A and B) - Comply with message requirements NLT 6 August 2004. 7. TECHNICAL PROCEDURES/INSTRUCTIONS - ...................NOTE................... ....Do not lubricate the swashplate prior to performing ....the visual inspection of the swashplate bearing. ...................NOTE................... ....Lubrication and visual inspections will remain on ....the same schedule as determined by CH-47-03-01. 7.1. Visual 100 (CH-47D/F) / 150 (all MH-47 aircraft) hour recurring inspection (the following visual inspection remains the same as required IAW CH-47-03-01). ...................NOTE................... ....This inspection can be performed on aircraft or off. ...................CAUTION................... ....It is imperative that the Rotor Head be locked out ....prior to performing the bearing inspection or damage ....to components will occur. 7.1.1 Lock out the Rotor Heads: H-47D/F per TM 55-1520-240-23; Task 11-28, Install Servocylinder Safety Blocks and Task 5-97, Remove Pitch Link (Pitch Link Lockpins installed). MH-47E per TM 1-1520-252-23; Task 11-33, Install Servocylinder Safety Blocks and Task 5-145, Remove Pitch Link (Pitch Link Lockpins installed). ...................NOTE................... ....Prior to removing hardware, thoroughly wipe clean ....all upper seal surfaces (only), by hand with a ....lint free cloth. Remove only the Upper Seal, P/N ....114R3428-1. Do not remove the Upper Bearing Retainer, ....P/N 114R3126-4. Only 12 Bolts and washers (AFT) or .... Nuts and washers(FWS) need to be removed. 7.1.2. Remove Forward and Aft Swashplate Upper Seal, P/N 114R3428-1, per TM 55-1520-240-23, Task 5-122, Para 1a and 2a (H- 47D/F) or TM 1-1520-252-23, Task 5-175, Para 1a and 2a (MH-47E). ...................WARNING................... ....If this inspection is performed on aircraft, ....Ensure no FOD enters the bearing. Do not attempt ....to clean or wipe the bearing prior to performing ....the next step. 7.1.3. Use a flashlight or other suitable light source to visually inspect for raised, overlapping or broken cage segments. Inspect for orange/red pieces of debris. The lower grease seal is elastomeric orange/red in color; therefore this type of rubber debris may be indicative of damage to this lower seal. ...................WARNING.................... ....Do not use cloths or rags to clean the bearing area, ....as this may snag or catch on the bearing cage and ....disturb the balls. 7.1.4. Wipe away excess grease in cavity using fingers. Use a flashlight or other suitable light source to visually inspect for raised, overlapping or broken cage segments or multiple adjacent uncaged ball bearings. Inspect for orange/red pieces of rubber debris ...................NOTE................... ....The design of the bearing allows for up to 3 individual cage ....segments with each segment separated by one uncaged ball. 7.1.5. If any of these conditions are found, except for those in the note above, the Swashplate Assembly shall be considered unserviceable. Dispose of IAW paragraph 10.4 of this message. ...................NOTE................... ....If replacement self-locking nuts are not available, ....re-use of the original nuts is authorized provided ....they meet the following torque requirement. The ....torque required to start the nut rotating with a ....minimum of one full thread extending from the end ....of the nut shall be at least 7 in-lbs. The standard ....procedure of using new nuts at each removal and ....reinstallation shall be followed as soon as new ....nuts are available. 7.1.6. If the bearing passes IAW paragraphs 7.1.3. and 7.1.4., install the Swashplate Upper Seal, P/N 114R3428-1, per TM 55- 1520-240-23, Task 5-125, Paragraphs 7b and 8e-h (H-47D/F), or TM 1-1520-252-23, Task 5-179, Paragraphs 7b and 8e-h (MH-47E). If nuts were reused on forward swashplate, apply a torque stripe to all nuts for visual inspection reference. A recurring entry for a Daily Inspection will be required on DA Form 2408-13-1 until new nuts are installed. 7.1.7. Unlock Rotor Heads; H-47D/F per TM 55-1520-240-23; Task 5-99, Install Pitch Links (remove Pitch Link Lockpins) and Task 11-29, Remove Servocylinder Safety Blocks. MH-47E per TM 1-1520- 252-23; Task 5-148, Install Pitch Links (remove Pitch Link Lockpins) and Task 11-34, Remove Servocylinder Safety Blocks ...................CAUTION................... ....For the purpose of this SOF only, a test flight ....to track the rotor blades is not required as long ....as no adjustments were made to the Pitch Links and ....the Pitch Links are installed back in their original ....location. 7.2. 50 hour recurring lubrication/purge and grease inspection. 7.2.1. Using a soft, clean, lint-free cloth, dampened with cleaning solvent (MIL-PRF-680) - 7.2.1.1. Clean the inner and outer dust cover. Ensure all surface grit, sand, and other foreign material is removed. This will ensure that no FOD is included in the grease sample and that only recently used grease will be included in the sample. 7.2.1.2. Wipe dirt and grease from lubrication fitting to ensure that no foreign material is introduced to the bearings during purging and re-greasing. 7.2.2. Grease inspection procedure. ...................CAUTION................... ....Pumping grease into swashplate without turning/rotating ....ring can result in bearing damage. ...................NOTE................... ....If you cannot pump grease and rotate the swashplate at ....the same time, rotate swashplate in 12 equal steps, 30 ....degrees each step and pump in grease between steps. ...................NOTE................... ....Proper purging of the bearing requires at least 16 ....ounces of new grease. 7.2.2.1. Have helper rotate ring by pulling blades around with tie down line. As ring rotates, use a hand lubricating grease gun with a flexible hose to pump grease into fitting. Rotate the ring through at least one full turn (360 degrees) to ensure thorough purging of the bearing. Pump until clean grease appears all the way around the line between the stationary upper seal and rotating upper seal. ...................NOTE................... ....It is important to collect as much purged used grease as ....possible to improve chances of capturing any grease areas ....that have a higher concentration of metal contaminates. 7.2.2.2. As the old/used grease appears from between the seals, use a clean wooden tongue depressor to collect as much of the grease as possible in a clean container. Label the container with the date, aircraft number, swashplate assembly part number and serial number, swashplate time since overhaul, and hours since last purge. 7.2.2.3. Thoroughly stir the collected grease to ensure a homogeneous mixture. While stirring, visually inspect for orange/red/grey/brown rubber pieces/slivers. If there are any visible pieces/slivers, the swashplate is considered unserviceable and will be disposed of IAW para 10.4. of this message. 7.2.2.4. After stirring the grease, feel for metal particles. If there are particles, the swashplate is considered unserviceable and will be disposed of IAW para 10.4. of this message. 7.2.2.5. If the swashplate is considered serviceable, retain the collected grease pending the results of next 50 hour lubrication/purge and grease inspection. 7.3. Change the DA Form 2408-18, Block 6 (Reference) from "CH- 47-03-01" to "CH-47-04-01" for the 100/150 flight hour recurring FWD & AFT Swashplate bearings and the 50 flight hour recurring FWD & AFT swashplate bearings inspections. ULLS-A units shall use this message as authority to change the Reference for inspections A-182 and A-121. 7.4. Clear the initial entry from para 4.1. and note compliance on DA Form 2408-5-1 (Swashplate Assy). 8. PROCEDURES/INSTRUCTIONS FOR ASSEMBLIES/COMPONENTS/PARTS IN WORK OR IN STOCK (AT ALL LEVELS INCLUDING WAR RESERVES) - 8.1. Items in Retail Stock - Commanders and facility managers that maintain retail stock at installation level and below will complete the following procedures. 8.1.1. Contact the supported aviation unit, as required, to perform the procedures required on affected items. 8.1.2. Submit a Task/Inspection report IAW para 5. 8.2. Items in Single Stock Fund and in Work (Overhaul/Repair Facility) - N/A. 8.3. Items in Wholesale Stock - N/A. 9. SPECIAL TOOLS AND FIXTURES REQUIRED - N/A. 10. SUPPLY/PARTS (REQUISITION/DISPOSITION) - 10.1. Parts Required - The following parts/components may be required to return aircraft to a serviceable condition. ...Nomenclature Part no./NSN Qty Cost ea. Total $ Swashplate, Aft 145R3551-20 1 $133,245.00 $133,245.00 .................1615-01-475-9838 Swashplate, Fwd 145R3551-19 1 $133,245.00 $133,245.00 .................1615-01-473-4376 Bearing 114R3104-4 2 $3599.40 $7198.80 .................3120-01-342-0061 Seal 114RS306-6 2 $533.60 $1067.20 .................5330-00-999-4077 Retainer 114R3417-3 4 $317.98 $1271.92 .................5330-01-474-4303 Ring Assy 114R3490-1 1 $4354.32 $4354.32 .................1615-01-476-0755 Bolt BACB30LC6-38 36 $2.77 $99.72 .................5306-01-474-3835 Bolt BACB30FD5H14 36 $3.07 $110.52 .................5306-01-476-1906 Nut, Self FN22M524 12 $6.11 $73.32 Locking 5310-01-070-9314 Bolt, Shear MS21134H05004 12 $4.19 $50.28 .................5306-01-108-7462 Gasket 114R3428-1 2 $74.16 $148.32 .................5330-00-849-4366 Nut, Self FN22M-428 10 $3.92 $39.20 Locking 5310-01-184-0356 Nut, Self FN22M-624 36 $1.62 $58.32 Locking 5310-01-184-0354 Retainer, 114R3126-4 2 $108.49 $216.98 Swashplate 1615-00-181-4127 .........................Total max cost per aircraft = $281178.90 10.2. Bulk and consumable materials - ..Nomenclature Part No. NSN ..Cleaning Compound, Solvent MIL-PRF-680 6850-01-474-2309 ..Grease, WTR MIL-G-81322 9150-00-145-0268 ..Tongue depressor (wooden) GGD226 6515-00-324-5500 ..Cloth, Lint Free MIL-C-24671 4470-01-498-8080 10.3. Requisitioning instructions - N/A. 10.4. Disposition of discrepant parts/components - Submit a Category I Quality Deficiency Report (QDR) on any Swashplate considered unserviceable IAW para 7 of this message. Retain the current and previous grease collections and await Cat I QDR disposition instructions. 10.5. Disposition of hazardous material - IAW Environmental Protection Agency directives as implemented by your servicing environmental coordinator (AR 200-1). 11. MAINTENANCE APPLICATION - 11.1. Category of maintenance - AVUM. Aircraft downtime will be charged to AVUM. 11.2. Estimated time required - total of 0.5 man-hours using 1 person to update aircraft records. 12. PUBLICATION REQUIREMENTS - 12.1.1. AR 95-1. 12.1.2. DA Pam 738-751. 12.1.3.TM 55-1520-240-23, Aviation Unit and Aviation Intermediate Maintenance Manual, CH-47D Helicopter. 12.1.4. TM 1-1520-252-23, Aviation Unit and Aviation Intermediate Maintenance Manual, MH-47E Helicopter. 12.2. Publication changes - The following publications shall be changed to reflect this message. A copy of this message will be used as authority to implement the change until the official change is received. 12.2.1. TM 55-1520-240-23 - Delete the 50 hour recurring AOAP grease sample of the Forward and Aft Swashplate Bearings. 12.2.2. TM 1-1520-252-23 - Delete the 50 hour recurring AOAP grease sample of the Forward and Aft Swashplate Bearings. 12.2.3. TB 43-0106, Appendix A for the CH-47 - Delete the 50 hour recurring grease sample of the Forward and Aft Swashplate. 12.2.4. TB 1-1520-240-30-02 - Delete the para 9.b. requirement for an AOAP grease sample of the Forward and Aft Swashplates. 13. POINTS OF CONTACT - 13.1. Technical POCs are - 13.1.1. Primary - Mr. Timothy Rickmeyer, AMSRD-AMR-AE-C, DSN 897-2350, extension 9854 or (256) 705-9854. Fax is (256) 705- 9900. Email is "timothy.rickmeyer@rdec.redstone.army.mil". 13.1.2. Alternate - Mr. Michael McCall, AMSRD-AMR-AE-C, DSN 897- 2350, extension 5243 or (256) 319-5243. Fax is (256) 705-9900. Email is "mike.mccall@rdec.redstone.army.mil". 13.2. Logistical POCs are - 13.2.1. Primary - Bill Olson, SFAE-AV-CH-L, DSN 897-3379 or (256) 313-3379. Fax is DSN 897-4348 or (256) 313-4348. Email is "william.olson@peoavn.redstone.army.mil". 13.2.2. Alternate - Mr. Jack Martin (AEPCO), SFAE-AV-CH-L, DSN 897-3617 or (256) 313-3617. Fax is DSN 897-4348 or (256) 313- 4348. Email is "john.martin@peoavn.redstone.army.mil". 13.3. Wholesale Materiel POC (spares) is Ms. Geri Reddy, AMSAM- MMC-AV-CA, DSN 897-1454 or (256) 313-1454. Fax is DSN 897-1106. Email is "geri.reddy@redstone.army.mil". 13.4. Forms and records POC is Ms. Ann Waldeck, AMSAM-MMC-MA-NM, DSN 746-5564 or (256) 876-5564. Fax is DSN 746-4904 or (256) 876-4904. Email is "ann.waldeck@redstone.army.mil". 13.5. Safety POCs are - 13.5.1. Primary - Mr. Harry Trumbull (SAIC), AMSAM-SF-A, DSN 897-2095 or (256) 313-2095. Fax is DSN 897-2111 or (256) 313- 2111. Email is "harry.trumbull@redstone.army.mil". 13.5.2. Alternate - Mr. Russ Peusch, AMSAM-SF-A, DSN 788-8632 or (256) 842-8632. Fax is DSN 897-2111 or (256) 313-2111. Email is "russell.peusch@redstone.army.mil". 13.6. Foreign Military Sales POC is Mr. Ronnie W. Sammons, AMSAM-SA-AS-UT, DSN 897-0875 or (256) 313-0875. Fax is DSN 897- 0411 or (256) 313-0411. Email is "ronnie.sammons@redstone.army.mil". 13.7. After hours, contact the AMCOM Operations Center (AOC) DSN 897-2066/7 or (256) 313-2066/7.