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05 1912Z MAY 95
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TEXT
:UNCLAS
SUBJECT - SAFETY-OF-FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-
1860(R1), ALL ARMY CH-47D, MH-47D AND MH-47E AIRCRAFT, ONE
TIME VISUAL INSPECTION AND TORQUE CHECK OF LOWER DRIVE LINK
TO SWASHPLATE RETAINING HARDWARE. (CH-47-95-02) (TB 1-1520-
240-20-76)
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-R-X (SOF COMPLIANCE
OFFICER).
1. PRIORITY CLASSIFICATION -
NOTE - SEE AR 95-3, PARA 5-6A, FOR NONCOMPLIANCE AUTHORITY
OF MAJOR COMMANDERS.
A. AIRCRAFT IN USE - UPON RECEIPT OF THIS MESSAGE THE
CONDITION STATUS SYMBOL OF THE CITED AIRCRAFT WILL BE
CHANGED TO A RED //X//. THE RED //X// MAY BE CLEARED WHEN
THE INSPECTION OF PARA 8 BELOW IS COMPLETED. THE AFFECTED
AIRCRAFT SHALL BE INSPECTED NO LATER THAN THE
TASK/INSPECTION SUSPENSE DATE.
B. AIRCRAFT IN DEPOT MAINTENANCE - AIRCRAFT WILL NOT
BE ISSUED UNTIL COMPLIANCE WITH THIS SOF HAS BEEN COMPLETED.
C. AIRCRAFT UNDERGOING MAINTENANCE - AIRCRAFT WILL NOT BE
RELEASED UNTIL COMPLIANCE WITH THIS SOF MESSAGE HAS BEEN
COMPLETED.
D. AIRCRAFT IN TRANSIT -
(1) SURFACE/AIR SHIPMENT - PRIOR TO NEXT ENGINE
RUN UP.
(2) FERRY STATUS -
(A) AIRCRAFT MUST PERFORM THE VISUAL
INSPECTION PER PARAGRAPH 8B(1) OR 8C(1) PRIOR TO NEXT ENGINE
RUNUP/FURTHER FLIGHT. AIRCRAFT WILL THEN BE CHANGED TO A
CIRCLE RED //X// FOR A ONE TIME FLIGHT TO NEAREST FACILITY
TO PERFORM THE INSPECTION REQUIREMENTS OF PARAGRAPH 8B(2) OR
8C(2). THE CIRCLED RED //X// MAY BE CLEARED WHEN THIS
REMAINING PORTION OF THE INSPECTION OF PARA 8 AND CORRECTIVE
PROCEDURES OF PARA 9 BELOW IS COMPLETED.
(B) 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.
F. COMPONENT/PARTS IN STOCK INCLUDING WAR RESERVES AT
ALL LEVELS (DEPOT AND OTHERS) - N/A
2. TASK/INSPECTION SUSPENSE DATE - PRIOR TO NEXT ENGINE RUN
UP.
3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 1 JUN
95 PER PARA 14A OF THIS MESSAGE.
4. SUMMARY OF PROBLEM -
A. A CH-47D FROM FORT HOOD CRASHED. INITIAL RESULTS
INDICATE THE LOWER DRIVE LINK TO SWASHPLATE RETAINING BOLT
FAILED IN FATIGUE. THE INVESTIGATION IS CONTINUING.
INITIAL SAFETY BOARD FINDINGS INDICATE THAT THE PRIMARY
CAUSE OF THE ACCIDENT MAY HAVE BEEN THE OMISSION OF THE SLIP-
FIT BUSHING IN THE LOWER SWASHPLATE DRIVE ARM. IT IS
POSSIBLE THAT THE ERRORS AND INCONSISTENCIES IN THE -23
MAINTENANCE MANUAL MAY HAVE CONTRIBUTED TO THE OMISSION.
B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA
12.
C. THE PURPOSE OF THIS MESSAGE IS TO DIRECT A ONE TIME
VISUAL INSPECTION OF THE LOWER DRIVE LINK TO SWASHPLATE
RETAINING HARDWARE FOR PROPER INSTALLATION AND PERFORM A
TORQUE CHECK OF BOLTS PART NUMBER 114RS352-2 PRIOR TO NEXT
ENGINE RUN UP. THIS INSPECTION IS REQUIRED FOR BOTH FORWARD
AND AFT SWASHPLATES.
5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D AND MH-
47E AIRCRAFT. CH-47D SERIAL NUMBERS 93-0928 AND SUBSEQUENT
WILL BE INSPECTED/CORRECTED BY CONTRACTOR DURING PRODUCTION
AND THEREFORE RECORDS FOR CH-47D AIRCRAFT SERIAL NUMBERS 93-
0928 AND SUBSEQUENT WILL NOT REQUIRE IDENTIFICATION OF THIS
ACTION. MH-47E SERIAL NUMBERS 92-0475 AND 92-0477 WILL BE
INSPECTED/CORRECTED BY CONTRACTOR DURING PRODUCTION AND
THEREFORE RECORDS FOR MH-47E SERIAL NUMBERS 92-0475 AND 92-
0477 WILL NOT REQUIRE IDENTIFICATION OF THIS ACTION.
6. ASSEMBLY COMPONENTS TO BE INSPECTED - N/A
7. PARTS TO BE INSPECTED -
NOMENCLATURE PART NO. NSN
BOLT 114RS352-2 5306-00-007-2555
BUSHING 114R3116-38 3120-00-849-4375
WASHER, FLAT AN960-616L 5310-00-167-0837
WASHER, FLAT BACW10DH-6 5310-01-144-1004
NUT MS21244-6 5310-00-181-6122
PIN, COTTER MS24665-374 5315-00-241-7332
PIN, COTTER MS24665-304 5315-00-241-7330
8. INSPECTION PROCEDURES - TO BE DONE ON BOTH FORWARD AND
AFT SWASHPLATES.
A. PREPARE AIRCRAFT FOR SAFE GROUND MAINTENANCE.
B. CH/MH-47D AIRCRAFT- REFER TO TASK 5-112, PARAGRAPHS
7 THROUGH 12, OF REFERENCE 13A.
CAUTION
REFERENCE 13A, TASK5-112, PARAGRAPH 10 CALLS FOR THE
0.005 INCH CLEARANCE TO BE BETWEEN THE HEAD OF
BOLT (10) AND INSIDE OF LUG. THIS IS INCORRECT.
0.005 INCH CLEARANCE SHOULD BE BETWEEN THREADED END
OF BOLT AND INSIDE OF LUG/SWASHPLATE RING.
(1) VISUALLY INSPECT SWASHPLATE TO LOWER DRIVE
LINK RETAINING HARDWARE TO ENSURE ALL HARDWARE (BOLT, NUT,
BUSHING, 2 WASHERS (THERE COULD BE AN ADDITIONAL WASHER
UNDER HEAD), COTTER PIN, AND LOCKWIRE) IS INSTALLED. ALSO
VERIFY A MINIMUM 0.005 INCH CLEARANCE EXISTS BETWEEN THE
THREADED END OF BOLT AND INSIDE OF LUG/SWASHPLATE RING AND A
MINIMUM 0.001 INCH GAP BETWEEN BOLT HEAD WASHER AND
SWASHPLATE LUG FACE. IF RETAINING HARDWARE INSTALLATION IS
INCORRECT OR IF 0.005 CLEARANCE OR 0.001 GAP DOES NOT EXIST,
GO TO PARAGRAPH 9 OF THIS MESSAGE.
(2) PERFORM BOLT TORQUE CHECK TO ENSURE BOLT
TORQUE IS AT LEAST 190 (ONE NINE ZERO) INCH POUNDS WHILE
HOLDING NUT STATIONARY. COTTER PIN AND LOCK WIRE MUST BE
REMOVED WHILE PERFORMING THIS CHECK. MARK BOLT HEAD IN
ORDER TO VERIFY ROTATION.
C. MH-47E - REFER TO TASK 5-163, PARAGRAPHS 6 THROUGH
10, OF REFERENCE 13B.
(1) VISUALLY INSPECT SWASHPLATE TO LOWER DRIVE LINK
RETAINING HARDWARE TO ENSURE ALL HARDWARE (BOLT, NUT, SLIP
BUSHING, 2 WASHERS (THERE COULD BE AN ADDITIONAL WASHER
UNDER HEAD), COTTER PIN, AND LOCKWIRE) IS INSTALLED. ALSO
VERIFY A MINIMUM 0.005 INCH CLEARANCE EXISTS BETWEEN THE
THREADED END OF BOLT AND INSIDE OF LUG/SWASHPLATE RING AND A
MINIMUM 0.001 INCH GAP EXISTS BETWEEN BOLT HEAD WASHER AND
SWASHPLATE LUG FACE. IF RETAINING HARDWARE INSTALLATION IS
INCORRECT OR IF 0.005 CLEARANCE OR 0.001 GAP DOES NOT EXIST,
GO TO PARAGRAPH 9 OF THIS MESSAGE.
(2) PERFORM BOLT TORQUE CHECK TO ENSURE BOLT TORQUE
IS AT LEAST 190 (ONE NINE ZERO) INCH POUNDS WHILE HOLDING
NUT STATIONARY.
MARK BOLT HEAD IN ORDER TO VERIFY ROTATION. LOCKWIRE AND
COTTER PIN MUST BE REMOVED WHILE PERFORMING THIS CHECK.
9. CORRECTION PROCEDURES - CH-47D, MH-47D, MH-47E AIRCRAFT
A. IF RETAINING HARDWARE STACK-UP IS CORRECT AND
TORQUE CHECK IS SUCCESSFUL, INSTALL NEW COTTER PIN AND LOCK
WIRE IN ACCORDANCE WITH REFERENCE 13A, TASK 5-112 FOR CH/MH-
47D AIRCRAFT AND REFERENCE 13B, TASK 5-163 FOR MH-47E
AIRCRAFT. INSPECTION IS COMPLETE.
B. IF EITHER SLIP BUSHING OR PRESSED BUSHING ARE
MISSING, THE SWASHPLATE AND BOLT ARE CONSIDERED
UNSERVICABLE. FOLLOW DISPOSITION INSTRUCTIONS IN PARA 10D.
C. IF RETAINING HARDWARE STACKUP IS INCORRECT; BOLT
THREADED END TO LUG/SWASHPLATE RING CLEARANCE IS LESS THAN
0.005; OR THE GAP BETWEEN BOLT HEAD WASHER AND LUG FACE IS
LESS THAN 0.001; OR BOLT TORQUE IS LESS THAN 190 (ONE NINE
ZERO) INCH POUNDS, REMOVE ALL LOWER DRIVE ARM TO SWASHPLATE
RETAINING HARDWARE PER REFERENCE 13A, TASK 5-101 FOR CH/MH-
47D OR REFERENCE 13B, TASK 5-152 FOR MH-47E AIRCRAFT.
D. INSPECT BOLT AND BUSHING FOR SERVICABILITY. NO
CRACKS, GOUGES/SCRATCHES/FRETTING, OR CORROSION WHICH CANNOT
BE REMOVED USING CROCUS CLOTH.
E. INSPECT SWASHPLATE LUG FOR DAMAGE IN ACCORDANCE
WITH REFERENCE 13A, TASK 5-120 FOR CH/MH-47D AIRCRAFT AND IN
ACCORDANCE WITH REFERENCE 13B, TASK 5-173 FOR MH-47E
AIRCRAFT.
F. REINSTALL LOWER DRIVE ARM TO SWASHPLATE UTILIZING
OLD BOLT AND BUSHING IF SERVICEABLE PER PARAGRAPH 12E(1) OF
THIS MESSAGE FOR CH/MH-47D AIRCRAFT.
G. REINSTALL LOWER DRIVE LINK TO SWASHPLATE UTILIZING
OLD BOLT AND BUSHING IF SERVICEABLE WITH TASK 5-163 OF
REFERENCE 13B FOR MH-47E AIRCRAFT.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 7 MAY BE
REQUIRED TO REPLACE DEFECTIVE ITEMS.
B. REQUISITION REPLACEMENT PARTS THROUGH NORMAL SUPPLY
CHANNELS USING NORMAL SUPPLY PROCEDURES. A SAFETY OF FLIGHT
PROJECT CODE WILL BE PROVIDED FOR SWASHPLATE DISPOSITION.
NOTE
THE PROJECT CODE IS REQUIRED TO TRACK AND ESTABLISH A DATA
BASE OF STOCK FUND EXPENDITURES INCURRED BY THE FIELD AS A
RESULT OF ASAM/SOF ACTIONS.
C. BULK AND CONSUMABLE MATERIALS -
NOMENCLATURE PART NO. NSN
WASHER, FLAT BACW10DH-6 5310-01-144-1004
WASHER, FLAT AN960-616L 5310-00-167-0837
NUT MS21244-6 5310-00-181-6122
PIN, COTTER MS24665-304 5315-00-241-7330
D. DISPOSITION - IF EITHER SLIP BUSHING OR PRESSED IN
BUSHING IS MISSING, SAVE BOLTS AND SWASHPLATE, AND CALL
TECHNICAL POINT OF CONTACT FOR DISPOSITION INSTRUCTIONS. DO
NOT TURN IN PARTS WITHOUT INSTRUCTIONS FROM THE 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. ESTIMATED TIME REQUIRED -
(1) TOTAL OF 3 MANHOURS USING 2 PERSONS.
(2) TOTAL OF 1.5 HOURS DOWNTIME FOR ONE END ITEM.
C. ESTIMATED COST IMPACT OF STOCK FUND ITEMS TO THE
FIELD -
NOMENCLATURE NSN COST PER A/C
BOLT 5306-00-007-2555 $10.27 2
BUSHING 3120-00-849-4375 $ 3.00 2
WASHER, FLAT 5310-00-167-0837 $ 0.95/HD 2
WASHER, FLAT 5310-01-144-1004 $ 0.15 2
NUT 5310-00-181-6122 $ 3.07 2
PIN, COTTER 5315-00-241-7330 $ 2.34/HD 2
TOTAL COST PER AIRCRAFT = $ 37.42
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 - REFERENCE 13A AND 13B SHALL BE CHANGED TO
REFLECT THIS MESSAGE. A COPY OF THIS MESSAGE SHALL BE
INSERTED IN THE APPROPRIATE TM AS AUTHORITY TO IMPLEMENT THE
CHANGE UNTIL THE PRINTED CHANGE IS RECEIVED.
(1) REFERENCE 13A, TASK 5-112, PARAGRAPHS 8 THROUGH
12 SHALL BE CHANGED TO READ AS FOLLOWS, BEGIN QUOTE:
CAUTION
SLIP BUSHING (9) DOES NOT COME WITH SWASHPLATE ASSEMBLY.
ENSURE BUSHING (9) IS INSTALLED.
8. CHECK THAT BUSHING (9) IS INSTALLED.
NOTE
AN IMPEDANCE BOLT IS INSTALLED IN LOWER DRIVE ARM LUG.
THIS BOLT HAS SPECIAL REMOVAL AND INSTALLATION
REQUIREMENTS (TASK 1-14).
9. INSTALL BOLT (10), THIN WASHER (11), WASHER (12), AND
NUT (13). TORQUE BOLT TO 190 (ONE NINE ZERO) TO 270 (TWO
SEVEN ZERO) INCH POUNDS AS NEEDED FOR COTTER PIN HOLE
ALIGNMENT. BOLT SHOULD NOT TURN WHEN 65 INCH POUNDS TORQUE
IS APPLIED TO HEAD.
10. CHECK CLEARANCE BETWEEN THREADED END OF BOLT (10) AND
INSIDE OF LUG/SWASHPLATE RING (8). CLEARANCE SHALL BE AT
LEAST 0.005 INCH. ADD WASHER UNDER BOLT HEAD IF NEEDED (ONE
THICK; OR ONE THIN; OR ONE THICK AND ONE THIN). CHECK FOR AT
LEAST 0.001 GAP BETWEEN BOLT HEAD WASHER AND FACE OF LUG.
11. INSTALL COTTER PIN (14). LOCKWIRE BOLT (10) TO HOLE
(15) IN LUG (8). USE LOCKWIRE (E231). END QUOTE.
(2) REFERENCE 13A, TASK 5-115, PARAGRAPH 6 WILL BE
EXPANDED TO REFLECT THE REQUIREMENTS OF PARAGRAPH 12E(1) AND
CORRESPONDING FIGURE WILL BE UPDATED TO ADD BUSHING,
LOCKWIRE, BOLT END TO SWASHPLATE LUG CLEARANCE, 0.001 INCH
GAP BETWEEN BOLT HEAD WASHER AND FACE OF LUG AND IDENTIFY
LOCKWIRE HOLE IN SWASHPLATE.
(3) REFERENCE 13B, TASK 5-167, NOTE WILL BE CHANGED
AND THE FOLLOWING NEW PARAGRAPHS WILL BE ADDED, BEGIN QUOTE:
9. CHECK CLEARANCE BETWEEN THREADED END OF BOLT (5)
AND INSIDE OF LUG/SWASHPLATE RING (7). CLEARANCE SHALL BE
AT LEAST 0.005 INCH. ADD WASHER UNDER BOLT HEAD IF NEEDED
(ONE THICK; OR ONE THIN; OR ONE THICK AND ONE THIN). CHECK
FOR 0.001 GAP BETWEEN BOLT HEAD WASHER AND FACE OF LUG.
10. INSTALL COTTER PIN (1). LOCKWIRE BOLT (5) TO HOLE IN
LUG (7). USE LOCKWIRE (E278). END QUOTE.
-NOTE- FIGURE FROM TASK 5-167, PAGE 4 WILL BE CHANGED TO
REFLECT LUG HOLE.
13. REFERENCES -
A. TECHNICAL MANUAL, TM 55-1520-240-23-4, AVIATION
UNIT AND INTERMEDIATE MAINTENANCE MANUAL CH-47D HELICOPTER,
10 MAY 1983, AS REVISED.
B. TECHNICAL MANUAL, TM 1-1520-252-23-5, AVIATION UNIT
AND INTERMEDIATE MAINTENANCE MANUAL MH-47E HELICOPTER,
MAY 1994, AS REVISED.
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 COMMANDER, ATCOM, ATTN: AMSAT-
R-X (SOF COMPLIANCE OFFICER), PER AR 95-3. DATAFAX NUMBER
IS DSN 693-2064 OR COMMERCIAL 314/263-2064. E-MAIL ADDRESS
IS: AMSATRXS (AT SIGN) ST-LOUIS-EMH4.ARMY.MIL. THE REPORT
WILL CITE THIS MESSAGE NUMBER, 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)
UPON COMPLETION OF INSPECTION, UNITS WILL FORWARD A PRIORITY
MESSAGE TO: COMMANDER, ATCOM, ATTN: AMCPM-CH-L. THE REPORT
WILL CITE THIS MESSAGE NUMBER, DATE OF INSPECTION, AIRCRAFT
SERIAL NUMBER, AIRCRAFT AND COMPONENT HOURS, AND RESULTS OF
THE INSPECTION. INSPECTION AND REPORTS WILL BE COMPLETED NO
LATER THAN 15 DAYS AFTER TASK/INSPECTION SUSPENSE DATE.
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 JUN 92 -
(1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION
RECORD.
(2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND
MAINTENANCE RECORD.
16. POINTS OF CONTACT -
A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR.
LARRY WIESCHHAUS, AMSAT-R-ECC, DSN 693-6678 OR COMMERCIAL
314/263-6678, OR MR ROBERT LAWYER, AMSAT-R-ECC, DSN 693-3820
OR COMMERCIAL 314/263-3820.
B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR.
MIKE MELLIERRE, AMCPM-CH-L, DSN 693-1901 OR COMMERCIAL
314/263-1901.
C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE
IS MS. ANN WALDECK, AMSAT-I-MDM, DSN 693-1821/1758 OR
COMMERCIAL 314/263-1821/1758.
D. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR.
DAVE SCOTT , AMSAT-R-XS, DSN 693-2045 OR COMMERCIAL 314/263-
2045.
E. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING
CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD
CONTACT CW5 JAY NANCE/MR. RON VAN REES, AMSAT-I-IAF, 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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