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SYNOPSIS
CH-47-93-03 SAFETY OF FLIGHT MESSAGE, TECHNICAL, ALL CH-47D, MH-47D AND
MH-47E AIRCRAFT, ONE TIME RECORDS CHECK OF ENGINE TRASMISSIONS,
P/N 145D6300-(SERIES), TO IDENTIFY UNSERVICEABLE
TRANSMISSIONS, (TB 1-1520-240-20-66).
161400Z JUL, BRAD MEYER, AMSAT-C-XS, X2085.
01 14 161400Z JUL 93 OO PP UUUU
FROM
:CDRATCOM ST LOUIS MO //AMSAT-C-XS//
TO
:AIG 8881
:AIG 9004
:AIG 8708
:AIG 9042
: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//
:EGYPT AF FMS CAIRO EG //ED-MA//
:ODC ATHENS GR //ODCSA-A//
:CDR4THBN228THAVN SOTO CANO HO //AVN-AMO//
:CHJUSMAG SEOUL KOR //MKAR-AV//
:HQ ROKA TAEJON KOR //DCSLOG-AVIATION/ROKA AVIATION//
:CDR160TH SOAR FT CAMPBELL KY //AOAV-SI//
:CDRBGAD RICHMOND KY //SDSBG-GC//
:CHMUSLO RABAT MO //AF//
:CHUSAS RIYADH SA //ASAV//
:ODC MADRID SP //ARMY AND NAVY SEC//
:CJUSMAG BANGKOK TH
:CDRUSARDSG LONDON UK //AMXSN-UK-SE//
INFO
:CDRAMCCOM ROCK ISLAND IL //AMSAR-QAS-P//
: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//
ACCT
:
TEXT
:UNCLAS
SUBJECT - SAFETY-OF-FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-1860(R1),
ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, ONE TIME RECORDS CHECK OF
ENGINE TRANSMISSIONS, P/N 145D6300-(SERIES), TO IDENTIFY
UNSERVICEABLE TRANSMISSIONS (CH-47-93-03) (TB 1-1520-240-20-66).
NOTE - THIS IS A SAFETY-OF-FLIGHT 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 TRANSMISSION TO COMMANDER, ATCOM, ATTN: AMSAT-C-XS (SOF
COMPLIANCE OFFICER).
1. PRIORITY CLASSIFICATION -
NOTE - PER AR 95-3, PARA 5-6A, MAJOR COMMANDERS MAY AUTHORIZE
TEMPORARY EXCEPTION FROM SOF MESSAGE REQUIREMENTS. EXCEPTIONS 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. AIRCRAFT IN USE - UPON RECEIPT OF THIS MESSAGE THE
CONDITION STATUS SYMBOL OF THE CITED AIRCRAFT WILL BE CHANGED TO A
CIRCLED RED //X//. THE CIRCLED RED //X// MAY BE CLEARED WHEN THE
INSPECTION OF PARA 8 BELOW IS PASSED. AIRCRAFT THAT DO NOT PASS THE
INSPECTION OF PARA 8 WILL BE UPGRADED TO A RED //X//. IF NEEDED,
AIRCRAFT AWAY FROM HOME BASE MAY BE DOWNGRADED TO A CIRCLED RED
//X// FOR A ONE TIME DIRECT FLIGHT TO THE NEAREST MILITARY BASE WITH
ADEQUATE SECURITY AND MAINTENANCE CAPABILITIES. FLIGHT WILL CONSIST
OF MINIMUM CREW, LOW GROSS WEIGHT AND LOW LEVEL FLIGHT NOT TO EXCEED
500 FT AGL. AIRCRAFT ON RED //X// STATUS SYMBOL WILL BE MAINTAINED
IN FLYABLE STORAGE. GROUND RUN-UPS AT NORMAL OPERATING ROTOR RPM
ARE AUTHORIZED.
B. AIRCRAFT IN DEPOT MAINTENANCE - AIRCRAFT WILL NOT BE ISSUED
UNTIL COMPLIANCE WITH THIS MESSAGE HAS BEEN COMPLETED.
C. AIRCRAFT UNDERGOING MAINTENANCE - AIRCRAFT WILL NOT BE
RELEASED UNTIL COMPLIANCE WITH THIS MESSAGE HAS BEEN COMPLETED.
D. AIRCRAFT IN TRANSIT -
(1) SURFACE/AIR SHIPMENT - PRIOR TO FIRST FLIGHT AT FINAL
DESTINATION.
(2) FERRY STATUS - THOSE AIRCRAFT THAT HAVE A DD250 AND
ARE AT BOEING HELICOPTER COMPANY WILL BE INSPECTED PRIOR TO FERRY TO
FINAL DESTINATION.
E. MAINTENANCE TRAINERS (CATEGORY A, B AND C) - SAME AS PARA
1A FOR CATEGORY A TRAINERS. CATEGORY B AND C TRAINERS SHALL PERFORM
THE REQUIREMENTS OF THIS MESSAGE WITHIN 10 DAYS FROM THE DATE OF
THIS MESSAGE.
F. COMPONENT/PARTS IN STOCK INCLUDING WAR RESERVES AT ALL
LEVELS (DEPOT AND OTHERS) - PERFORM INSPECTION ON DEPOT STOCK IAW
PARA 8 AND REPORT IAW PARA 14D. ITEM MANAGERS HAVE PLACED A CONTROL
ON ENGINE TRANSMISSIONS. ENGINE TRANSMISSIONS, P/N 145D6300-
(SERIES), AND SPIRAL BEVEL GEARS, P/N 145D6302-2 DETERMINED TO BE
UNSERVICEABLE IAW THIS MESSAGE SHALL BE PLACED IN CONDITION CODE
//J//.
NOTE - DEPOTS THAT DO NOT HAVE THE CAPABILITY TO INSPECT THE SUBJECT
ASSEMBLIES IN ACCORDANCE WITH THIS MESSAGE, CONTACT THE LOGISTICAL
POC. DO NOT ISSUE UNTIL THIS MESSAGE HAS BEEN COMPLIED WITH AND/OR
YOU HAVE BEEN NOTIFIED WHICH ARE SERVICEABLE.
2. TASK/INSPECTION SUSPENSE DATE - PRIOR TO NEXT MISSION DAY.
3. REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE TO
COMMANDER, ATCOM, ATTN: AMSAT-C-XS NO LATER THAN 5 AUG 93 PER PARA
14A.
4. SUMMARY OF PROBLEM -
A. A CH-47D HELICOPTER EXPERIENCED AN ENGINE TRANSMISSION
FAILURE RESULTING IN A CLASS C ACCIDENT WHILE AT A STEADY STATE
HOVER. TEARDOWN ANALYSIS OF THE COMPONENTS REVEALED THAT AN ENGINE
TRANSMISSION SPIRAL BEVEL GEAR FAILED FROM FATIGUE ORIGINATING FROM
A DEFECT.
B. THE SECOND SOURCE MANUFACTURER'S GRINDING AND INSPECTION
PROCESSES ARE SUSPECT. THEREFORE, IT IS NECESSARY TO REMOVE FROM
SERVICE ALL SPIRAL BEVEL GEARS, P/N 145D6302-2, MADE BY THIS
MANUFACTURER FOR INSPECTION. ENGINE TRANSMISSIONS CONSIDERED
UNSERVICEABLE ARE IDENTIFIED BY 73 ENGINE TRANSMISSION SERIAL
NUMBERS. IN ADDITION, ANY ENGINE TRANSMISSION HISTORICAL RECORD
HAVING A SPIRAL BEVEL GEAR, P/N 145D6302-2, SERIAL NUMBER WITH A
PREFIX "P" (PAPA), MAKES THAT ENGINE TRANSMISSION UNSERVICEABLE. IF
THE SPIRAL BEVEL GEAR, P/N 145D6302-2, SERIAL NUMBER IS NOT LISTED
ON THE ENGINE TRANSMISSION HISTORICAL RECORD, THE ENGINE
TRANSMISSION IS ALSO CONSIDERED UNSERVICEABLE; UNLESS DETERMINED
SERVICEABLE BY THE LOGISTICAL POC.
C. CONTROLLED SUBSTITUTION IS AUTHORIZED TO MINIMIZE AFFECTED
AIRCRAFT. OTHERWISE, DO NOT REMOVE SUSPECT ENGINE TRANSMISSION FROM
AIRCRAFT BEFORE CONTACTING THE LOGISTICAL POC SO THAT 14 DAY GROUND
RUNUPS CAN BE PERFORMED.
D. THE PURPOSE OF THIS MESSAGE IS TO DIRECT A RECORDS CHECK OF
ALL ENGINE TRANSMISSIONS TO IDENTIFY UNSERVICEABLE TRANSMISSIONS
PRIOR TO NEXT MISSION DAY.
5. END ITEMS TO BE INSPECTED - ALL MH-47D, CH-47D AND MH-47E
AIRCRAFT. AIRCRAFT SERIAL NUMBERS 92-0291 AND SUBSEQUENT WILL BE
INSPECTED/CORRECTED BY CONTRACTOR DURING PRODUCTION AND THEREFORE
RECORDS FOR AIRCRAFT SERIAL NUMBERS 92-0291 AND SUBSEQUENT WILL NOT
REQUIRE IDENTIFICATION OF THIS ACTION.
6. ASSEMBLY COMPONENTS TO BE INSPECTED -
NOMENCLATURE PART NO. NSN
ENGINE TRANSMISSION 145D6300-3 1615-01-146-5273
ENGINE TRANSMISSION 145D6300-2 1615-01-119-3373
ENGINE TRANSMISSION 145D6300-9 1615-01-315-4070
ENGINE TRANSMISSION 145D6300-8 1615-01-320-6787
ENGINE TRANSMISSION 145D6300-6 1615-01-271-0663
ENGINE TRANSMISSION 145D6300-7 1615-01-271-7601
ENGINE TRANSMISSION 145D6300-11 1615-01-315-9364
ENGINE TRANSMISSION 145D6300-10 1615-01-319-3959
7. PARTS TO BE AFFECTED -
NOMENCLATURE PART NO. NSN
SPIRAL BEVEL GEAR 145D6302-2 3040-01-114-9453
NOTE
UNSERVICEABLE GEARS ARE IDENTIFIED BY HAVING THE LETTER "P" (PAPA)
AT THE FRONT OF THE SERIAL NUMBER.
8. INSPECTION PROCEDURES -
A. CHECK AIRCRAFT RECORDS TO DETERMINE SERIAL NUMBER OF ENGINE
TRANSMISSION, P/N 145D6300-(SERIES). THE FOLLOWING ENGINE
TRANSMISSIONS BY SERIAL NUMBER ARE CONSIDERED UNSERVICEABLE:
ENGINE TRANSMISSION SERIAL NUMBERS
A11-430 A11-811 A11-1082
A11-683 A11-812 A11-1096
A11-685 A11-850 A11-1097
A11-686 A11-851 A11-1104
A11-687 A11-852 A11-1134
A11-688 A11-874 A11-1156
A11-707 A11-882 A11-1157
A11-708 A11-885 A11-1158
A11-710 A11-924 A11-1209
A11-732 A11-925 A11-1210
A11-747 A11-938 A11-1213
A11-760 A11-939 A11-1214
A11-773 A11-973 A11-1223
A11-775 A11-976 A11-1224
A11-776 A11-1040 A11-1225
A11-783 A11-1041 A11-1226
A11-784 A11-1042 A11-1245
A11-786 A11-1050 A11-1246
A11-789 A11-1051 A11-1257
A11-790 A11-1052 A11-1258
A11-791 A11-1053 A11-1263
A11-795 A11-1054 A11-1264
A11-798 A11-1056 A11-1270
A11-809 A11-1062
A11-810 A11-1081
B. CHECK DA FORM 2408-16 (COMPONENT) FOR ALL ENGINE
TRANSMISSIONS, P/N 145D6300-(SERIES).
(1) SPIRAL BEVEL GEARS, P/N 145D6302-2 LISTED ON THIS
FORM HAVING A SERIAL NUMBER WITH THE PREFIX "P" (PAPA) MAKES THE
SPIRAL BEVEL GEAR, P/N 145D6302-2 AND THE ENGINE TRANSMISSION
UNSERVICEABLE.
(2) ENGINE TRANSMISSIONS WITH A DA FORM 2408-16
(COMPONENT) THAT DOES NOT LIST SPIRAL BEVEL GEARS, P/N 145D6302-2
ARE CONSIDERED UNSERVICEABLE UNLESS DETERMINED SERVICEABLE BY
LOGISTICAL POC. CONTACT LOGISTICAL POC.
C. AIRCRAFT WITH AN UNSERVICEABLE TRANSMISSION IAW THIS
MESSAGE WILL BE UPGRADED TO A RED //X//.
D. AIRCRAFT THAT DO NOT HAVE AN UNSERVICEABLE ENGINE
TRANSMISSION IAW THIS MESSAGE MAY CLEAR THE CIRCLE RED //X// AND THE
INSPECTION IS COMPLETE.
NOTE
UNITS WILL BE PROVIDED DISPOSITION INSTRUCTIONS FROM LOGISTICAL POC
BY FOLLOW UP COMMUNICATION. CONTROLLED SUBSTITUTION IS AUTHORIZED
TO MINIMIZE AFFECTED AIRCRAFT, OTHERWISE, DO NOT REMOVE SUSPECT
ENGINE TRANSMISSION FROM AIRCRAFT BEFORE CONTACTING LOGISTICAL POC
SO THAT 14 DAYS GROUND RUNUPS CAN BE PERFORMED.
9. CORRECTION PROCEDURES - ENGINE TRANSMISSIONS AND SPIRAL BEVEL
GEARS IDENTIFIED IN PARA 8 WILL BE RECEIVED/RETURNED FROM
SUPPLY/BOEING HELICOPTERS AND INSPECTED/REPAIRED AT A LATER DATE.
INSPECTED/REPAIRED ENGINE TRANSMISSIONS AND SPIRAL BEVEL GEARS
IDENTIFIED IN PARA 8 THAT ARE CONSIDERED SERVICEABLE WILL HAVE
"EB" (ECHO-BRAVO) BEHIND THE ENGINE TRANSMISSION SERIAL NUMBER AND
THE SPIRAL BEVEL GEAR SERIAL NUMBER.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 6 MAY BE REQUIRED
TO REPLACE DEFECTIVE ITEMS.
B. REQUISITIONING INSTRUCTIONS - CONTACT LOGISTICAL POINT OF
CONTACT FOR REQUISITIONING INSTRUCTIONS.
C. BULK AND CONSUMABLE MATERIALS - N/A.
D. DISPOSITION - UNITS WILL BE PROVIDED DISPOSITION
INSTRUCTIONS BY LOGISTICAL POC.
E. DISPOSITION OF HAZARDOUS MATERIAL - N/A.
11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A.
12. APPLICATION -
A. CATEGORY OF MAINTENANCE - AVUM. AIRCRAFT DOWNTIME WILL BE
CHARGED TO AVUM.
B. TIME REQUIRED - TOTAL OF .5 MANHOURS USING 1 PERSON TO
PERFORM RECORDS CHECK.
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 - N/A.
14. RECORDING AND REPORTING REQUIREMENTS -
A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON
ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1, FORWARD
A PRIORITY MESSAGE, DATAFAX OR E-MAIL TO COMMANDER, ATCOM, ATTN
AMSAT-C-XS (SOF COMPLIANCE OFFICER), PER AR 95-3. DATAFAX NUMBER IS
DSN 693-2064 OR COMMERCIAL 314/263-2064. E-MAIL ADDRESS IS
"AMSATCXS (AT SIGN) ST-LOUIS-EMH4.ARMY.MIL". THE REPORT WILL CITE
THIS MESSAGE NUMBER, DATE OF ENTRY ON 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) - UPON
COMPLETION OF INSPECTION UNITS HAVING UNSERVICEABLE ENGINE
TRANSMISSIONS PER THIS MESSAGE SHALL FORWARD A PRIORITY MESSAGE TO
CH-47D PMO, ATTN: SFAE-AV-CH-L. DATAFAX IS DSN 693-1485 OR
COMMERCIAL 314/263-1485. THE REPORT WILL CITE THIS MESSAGE, DATE OF
INSPECTION, AIRCRAFT S/N, ENGINE TRANSMISSION S/N, SPIRAL BEVEL GEAR
S/N, POC AND PHONE NUMBER.
C. REPORTING SUSPENSE DATE (SPARES) - N/A.
D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - UPON
COMPLETION OF THE INSPECTION DEPOT COMMANDERS AND OTHERS HOLDING
STOCK SHALL FORWARD A PRIORITY MESSAGE REPORT OF RESULTS OF THIS
INSPECTION TO LOGISTICAL POC BELOW NLT 10 DAYS FROM THE DATE OF THIS
MESSAGE. THE REPORT SHALL INCLUDE QUANTITY ON HAND, QUANTITY WHICH
PASSED INSPECTION, QUANTITY WHICH FAILED INSPECTION, ENGINE
TRANSMISSION S/N AND SPIRAL BEVEL GEAR S/N.
E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED
IN ACCORDANCE WITH DA PAM 738-751, 15 JUN 92 -
(1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD.
(2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND
MAINTENANCE RECORD.
(3) DA FORM 2408-13-2, RELATED MAINTENANCE ACTIONS
RECORD.
(4) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
(5) DA FORM 2408-5-1, EQUIPMENT MODIFICATION RECORD
(COMPONENT)
(6) DA FORM 2408-16, AIRCRAFT COMPONENT HISTORICAL
RECORD (IF ENGINE TRANSMISSION IS REMOVED OR INSTALLED).
(7) DA FORM 2410, COMPONENT REMOVAL AND
REPAIR/OVERHAUL RECORD. (NORMAL, EVACUATION, REPAIR AND
INSTALLATION CYCLE) (IF ENGINE TRANSMISSION IS REMOVED OR
INSTALLED).
15. WEIGHT AND BALANCE - N/A.
16. POINTS OF CONTACT -
A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. MIKE
WRIGHT, AMSAT-R-ECC, DSN 693-3820 OR COMMERCIAL 314/263-3820.
B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. NORM
HUSTON, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL 314/263-1415.
C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS.
ANN WALDECK, AMSAT-I-MDM, DSN 693-1821 OR COMMERCIAL 314/263-1821.
D. POINT OF CONTACT FOR THIS MESSAGE IS MR. BRAD MEYER, AMSAT-
C-XS, DSN 693-2085 OR COMMERCIAL 314/263-2085.
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-IA, DSN 693-3826/3659 OR
COMMERCIAL 314/263-3826/3659.
F. AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER (COC)
DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.
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