01 15 101848Z MAY 00 PP PP UUUU AA ZYUW FROM :CDRAMCOM REDSTONE ARSENAL AL//AMSAM-SF-A// TO :AIG 8881 :AIG 9004 :AIG 7471 :AIG 12124 :USMILGP BUENOS AIRES AR//ARMY AND AF SEC// :DEFAIR MATERIAL CANBERRA ACT AS//DAAP-AF// :CDRUSARDSG CANBERRA ACT AS//AMXIP-AS// :ARGENTINE AIR ATTACHE FMS WASHINGTON DC :EGYPT AF FMS CAIRO EG//ED/MA// :USOMC CAIRO EG//AV// :ODC ATHENS GR//ODCSA// :CDR1STBN228THAVN SOTO CANO HO//AVN-AMO// :CHJUSMAGK SEOUL KOR//MKAR-AV// :ROK ARMY FMS PUSAN KOR//ALC-LSD-L// :CDR160THSOAR FT CAMPBELL KY//AOAV-SI// :CDRBGAD RICHMOND KY//SIOBG-GC// :USDAO RABAT MO//AF// :ODC THE HAGUE NL//AVIATION SAFETY// :RNLAF MATERIAL THE HAGUE NL :RNLAF OPERATIONS THE HAGUE NL :CDRUSASAC NEW CUMBERLAND PA//AMSAC-SALO-UK// :CHUSAS RIYADH SA//ASAV// :SAO SINGAPORE SN//AVIATION SAFETY// :ODC MADRID SP//ASM// :SPAIN ARMY FMS MADRID SP :AIT TAIPEI TW :TAIWAN ARMY FMS TAIPEI TW :CJUSMAGTHAI BANGKOK TH//MAGTAR-FS// :ROYAL THAI AF FMS BANGKOK TH//BANGSUE DEPOT// :ROYAL THAI ARMY FMS BANGKOK TH//DUSIT ORDANCE DEPOT// :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK INFO :FAA SOUTHWEST RGN HQ FORT WORTH TX//ASW-100// :CDRAMC ALEXANDRIA VA//AMCMR/AMCCS/AMCSM-WAA// XMT : ACCT : TEXT :UNCLAS SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), CH-47D, MH-47D, AND MH-47E AIRCRAFT, INITIAL AND RECURRING INSPECTIONS AND REPLACEMENT OF HORIZONTAL HINGE PIN SHOULDERED BOLTS, P/N 114R2201-1, CH-47-00-ASAM-02, (TB 1-1520- 240-20-118). 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 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 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. 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 //-// ENTRY SHALL STATE "INSPECT IAW CH-47-00-ASAM-02 (TB 1-1520-240-20-118) AT THE NEXT DAILY INSPECTION, BUT NLT 25 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 25 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 PARAGRAPH 8 OF THIS ASAM HAS BEEN COMPLETED. THIS INCLUDES AIRCRAFT UNDERGOING REFURBISHMENT AT CCAD. C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A. D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - INSPECT PRIOR TO FIRST FLIGHT. (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) SAME AS PARA 1A. F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES - N/A. (1) WHOLESALE STOCK - N/A. (2) RETAIL STOCK - N/A. G. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - ITEMS LISTED IN PARAGRAPH 6 IN WORK WILL NOT BE ISSUED UNTIL COMPLIANCE WITH PARAGRAPH 9 OF THIS MESSAGE. 2. TASK/INSPECTION SUSPENSE DATE - AT THE NEXT DAILY INSPECTION BUT NLT 25 MAY 2000 AND REPORT IAW PARA 14B. 3. REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE IAW PARA 14A NLT 2 JUNE 2000. 4. SUMMARY OF PROBLEM - A. DURING POST FLIGHT INSPECTION A HORIZONTAL HINGE PIN SHOULDERED BOLT, P/N 114R2201-1, WAS FOUND TO HAVE THE BOLT HEAD SEPARATED. FAILURE ANALYSIS DETERMINED A CRACK HAD INITIATED AT THE GROOVE BETWEEN THE SHANK AND THE HEAD OF THE BOLT. THE CRACK PROPAGATED UNTIL THE BOLT HEAD BROKE OFF. A REDESIGNED BOLT, P/N 114R2201-2, WHICH DOES NOT HAVE A GROOVE IS NOW BEING PROCURED. B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA 12. C. THE PURPOSE OF THIS MESSAGE IS TO DIRECT THE INITIAL INSPECTION OF EACH P/N 114R2201-1 BOLT, AND DIRECT A RECURRING INSPECTION TO BE PERFORMED DURING EACH SCHEDULED DAILY INSPECTION, PREFLIGHT INSPECTION, AND POSTFLIGHT INSPECTION. REPLACEMENT OF THE P/N 114R2201-1 BOLT IS REQUIRED AT EACH 1200 HOUR HORIZONTAL HINGE PIN ROTATION OR AT ANY UNSCHEDULED MAINTENANCE REQUIRING HORIZONTAL HINGE PIN REMOVAL. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. HEAD, ROTARY WING, FWD 145R2003-ALL HEAD, ROTARY WING, AFT 145R2004-ALL 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN BOLT 114R2201-1 5306-00-843-7117 8. INSPECTION PROCEDURES - NOTE IF BOLT, P/N 114R2201-2, IS INSTALLED, IT DOES NOT REQUIRE THIS SPECIAL DAILY INSPECTION AND IS COVERED BY EXISTING DAILY INSPECTION OF ROTOR HEAD. NOTE ON INITIAL INSPECTION BOLT HEADS MAY BE COVERED WITH ADHESIVE (RTV 730) . THE BOLT MAY APPEAR TO BE SECURE WHEN IT IS BEING HELD BY THE ADHESIVE. IF THE BOLT HEAD IS COMPLETELY COVERED REMOVE THE ADHESIVE USING A PLASTIC SCRAPER BEFORE PERFORMING THE INSPECTION IN PARAGRAPH 8A, BELOW. FOLLOWING THE INITIAL INSPECTION RE-APPLY ADHESIVE WITH A THIN BEAD COVERING ONLY THE BASE OF THE BOLT HEAD AND WASHER TO PREVENT MOISTURE FROM ENTERING HORIZONTAL HINGE PIN. NOTE COMMANDERS WILL INSURE THAT ALL CREW MEMBERS ARE MADE AWARE OF THIS SPECIAL INTEREST INSPECTION AND THE IMPORTANCE OF CONDUCTING THE INSPECTION DURING PRE AND POST FLIGHT INSPECTIONS. A. PERFORM THE FOLLOWING INSPECTIONS - (1) INITIAL INSPECTION - INSPECT EACH BOLT, P/N 114R2201-1, APPLY HAND PRESSURE TO THE HEAD TO ASSURE THE ADHESIVE IS NOT HOLDING THE BOLT HEAD IN PLACE. IF THE BOLT HEAD IS BROKEN OFF, THE ROTOR HEAD IS CONSIDERED UNSERVICEABLE UNTIL THE INSPECTION OF PARAGRAPH 8B IS COMPLETED. IF IT IS NECESSARY TO REMOVE EXCESSIVE ADHESIVE RTV, THE UNITS HAVE 10 FLIGHT HOURS BUT NLT 25 MAY 2000 TO COMPLY WITH PROPER APPLICATION OF ADHESIVE RTV IAW THE NOTE ABOVE. (2) RECURRING INSPECTIONS - DURING EACH DAILY INSPECTION, PREFLIGHT AND POSTFLIGHT, INSPECT EACH BOLT, P/N 114R2201-1, APPLY HAND PRESSURE TO THE HEAD TO ASSURE THE ADHESIVE IS NOT HOLDING THE BOLT HEAD IN PLACE. IF THE BOLT HEAD IS BROKEN OFF, THE ROTOR HEAD IS CONSIDERED UNSERVICEABLE. B. IF A BROKEN BOLT HEAD IS FOUND, INSPECT THE FOLLOWING PARTS WHILE THE HORIZONTAL HINGE PIN IS DISASSEMBLED: HORIZONTAL HINGE PIN, TIE BAR, AND NUT (REFERENCE 13A,FIGURE 176, ITEMS 113, 87, AND 121 RESPECTIVELY) OR (REFERENCE 13B, FIGURE 5-4, ITEMS 98, 87, AND 121 RESPECTIVELY). INSPECT FOR SCORING, DEFORMATION, OR ANY EVIDENCE THAT PARTS HAVE ABNORMAL WEAR. 9. CORRECTION PROCEDURES - A. IF A BROKEN BOLT HEAD IS FOUND, REPLACE BOLT WITH P/N 114R2201-1 OR 114R2201-2 IAW TASK 5-44 AND TASK 5-46, REFERENCE 13D OR TASK 5-55 AND TASK 5-57, REFERENCE 13E. USE ADHESIVE (E63.1 OF REFERENCE 13D OR E67 OF REFERENCE 13E) AND APPLY A THIN BEAD COVERING THE BASE OF THE BOLT HEAD AND WASHER. B. BOLT P/N 114R2201-1 SHALL BE REPLACED WITH A NEW BOLT (EITHER A -1 OR -2) AT EACH 1200 HOUR HORIZONTAL HINGE PIN INSPECTION (ROTATION OR REPLACEMENT) OR DURING ANY UNSCHEDULED MAINTENANCE REQUIRING HORIZONTAL HINGE PIN REMOVAL OR DURING DEPOT OVERHAUL. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - BOLT, P/N 114R2201-1 OR 114R2201-2, MAY BE REQUIRED TO REPLACE DEFECTIVE ITEMS OR THOSE REQUIRED TO BE CHANGED IAW PARAGRAPH 9B ABOVE. BOLT, P/N 114R2201 WILL BE ISSUED UNTIL STOCK IS DEPLETED OR P/N 114R2201-2 BOLTS ARE AVAILABLE IN THE SUPPLY SYSTEM. B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE PROJECT CODE (CC 57-59) "XC8", "X-RAY-CHARLIE-EIGHT". NOTE PROJECT CODE "XC8", "X-RAY-CHARLIE-EIGHT" IS REQUIRED TO TRACK AND ESTABLISH A DATA BASE OF STOCK FUND EXPENDITURES INCURRED BY THE FIELD AS A RESULT OF SOF ACTIONS. C. BULK AND CONSUMABLE MATERIALS - 730 RTV MIL-A-46146 8040-00-251-2312 D. DISPOSITION - (1) HEADS - DISPOSE OF REMOVED PARTS/COMPONENTS USING NORMAL SUPPLY PROCEDURES. ALL TURN-IN DOCUMENTS MUST INCLUDE PROJECT CODE (CC 57-59) "X-RAY-CHARLIE-EIGHT". (2) BOLTS - DEMILITARIZE/MUTILATE IAW TM 1-1500-328-23 ANY PART/COMPONENT WHICH DOES NOT MEET INSPECTION CRITERIA. (3) TIE BARS OR HORIZONTAL HINGE PINS - HOLD ANY DISCREPANT PART/COMPONENT PENDING DISPOSITION INSTRUCTIONS FROM TECHNICAL POINT OF CONTACT IN PARAGRAPH 16. E. 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 - PLASTIC SCRAPER 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AVUM. AIRCRAFT DOWNTIME WILL BE CHARGED TO AVUM MAINTENANCE. B. ESTIMATED TIME REQUIRED - (1) FOR INSPECTION - (A) TOTAL OF 1 MAN-HOURS USING 1 PERSONS. (B) TOTAL OF 9 HOURS DOWNTIME FOR ONE END ITEM, ONE HOUR FOR THE INSPECTION PLUS EIGHT HOURS FOR THE ADHESIVE RTV TO DRY, IF REQUIRED. (2) FOR REPLACEMENT - (A) TOTAL OF 200 MAN-HOURS USING 4 PERSONS. (B) TOTAL OF 50 HOURS DOWNTIME FOR ONE END ITEM. C. ESTIMATED COST IMPACT TO THE FIELD - NOMENCLATURE PART NO. NSN QUANTITY COST EA. TOTAL $ BOLT 114R2201-1 5306-00-843-7117 6 $19.41 $116.46 OR BOLT 114R2201-2 5306-01-472-3594 6 $19.41 $116.46 TOTAL COST PER AIRCRAFT = $116.46 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, TM 1-1520-252-23, TM 55-1520-240- PMD AND TM 1-1520-252-PMD SHALL BE CHANGED TO REFLECT THIS MESSAGE. A COPY OF THIS MESSAGE SHALL BE INSERTED IN THE APPROPRIATE TM AND UNIT PILOTS READING FILE AS AUTHORITY TO IMPLEMENT THE CHANGE UNTIL THE PRINTED CHANGE IS RECEIVED. 13. REFERENCES - A. DA PAM 738-751 B. TM 55-1520-240-23P C. TM 1-1520-252-23P D. TM 55-1520-240-23 E. TM 1-1520-252-23 F. TM 55-1520-240-PMD G. TM 1-1520-252-PMD 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 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) - N/A. C. REPORTING MESSAGE RECEIPT (SPARES) - N/A. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES). (1) MATERIEL IN WHOLESALE DEPOT STORAGE - N/A. (2) MATERIEL IN RETAIL STORAGE - 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 2408-5-1, EQUIPMENT MODIFICATION RECORD (ROTARY WING HEAD). (2) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (3) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (4) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT. (5) DD FORM 1577/DD FORM 1577-1, UNSERVICEABLE (CONDEMNED) TAG/LABEL - MATERIEL (COLOR RED). ANNOTATE REMARKS BLOCK WITH "CONDEMNED IAW CH-47-00-ASAM-02 (TB 1-1520-240-20-118) AND MUTILATED IAW TM 1-1500-328-23." 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. MATT WESSELSCHMIDT, AMSAM-RD-AE-I-P-C, DSN 897-3380 OR (256) 313-3380, DATAFAX IS 897-4348. E-MAIL IS "MATTHEW.WESSELSCHMIDT@REDSTONE.ARMY.MIL". B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. BILL OLSON, SFAE-AV-CH-L, DSN 897-3379 OR (256) 313-3379, DATAFAX IS DSN 897-4348. E-MAIL IS "OLSONW@PEOAVN.REDSTONE.ARMY.MIL". C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAM-MMC-RE-FF DSN 746-5564 OR (256) 876-5564, DATAFAX IS DSN 746-4904. E-MAIL IS "ANN.WALDECK@REDSTONE.ARMY.MIL". D. SAFETY POINTS OF CONTACT FOR THIS MESSAGE ARE - (1) MR. FRANK ROSEBERY (SAIC) AMSAM-SF-A, DSN 788-8631 OR (256) 842-8631, DATAFAX IS DSN 897-2111. EMAIL IS "FRANK.ROSEBERY@REDSTONE.ARMY.MIL". (2) MR. HOWARD CHILTON, AMSAM-SF-A, DSN 897-2068 OR (256) 313-2068, DATAFAX IS (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 897-0410 OR (256) 313-0410. EMAIL IS "WITTSTROMJL@REDSTONE.ARMY.MIL" OR MR. RONNIE W. SAMMONS, AMSAM-SA-CS-NF, DSN 897-0408 OR (256) 313-0408. DATAFAX IS DSN 897-0411 OR (256) 313-0411. EMAIL IS "SAMMONSRW@REDSTONE.ARMY.MIL". HUNTSVILLE, AL IS GMT MINUS 5 HRS. G. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER (COC) DSN 897-2066/7 OR (256) 313-2066/7.