01 18 141451Z DEC 00 PP PP UUUU AA ZYUW NO FROM :CDRAMCOM REDSTONE ARSENAL AL//AMSAM-SF-A// TO :AIG 8881 :AIG 9004 :AIG 7471 :AIG 12124 :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// :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 :RNLAF TACTICAL AIR FORCE :CDRUSASAC NEW CUMBERLAND PA//AMSAC-SALO-UK// :SINGAPORE AF FMS SINGAPORE SN :ODC SINGAPORE SN :ODC MADRID SP//ASM// :SPAIND ARMY FMS MADRID SP :AIT TAIPEI TW//TECH// :TAIWAN ARMY FMS TAIPEI TW :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//AMCLG-OP-AVN/AMCSF-A/AMCRDA// XMT : ACCT : TEXT :UNCLAS SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), ALL H-47 AIRCRAFT, ONE TIME INSPECTION OF ROTOR HEAD ASSEMBLY DROOP STOP BOLTS FOR PROPER LENGTH, CH-47-01-ASAM-05 (TB 1-1520-240-20-132). 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, MAKE THE FOLLOWING ENTRY ON THE DA FORM 2408-13-1. ENTER A RED HORIZONTAL DASH //-// STATUS SYMBOL WITH THE FOLLOWING STATEMENT: "INSPECT DROOP STOP BOLTS IAW CH-47-01-ASAM-05 (TB 1-1520-240-20-132) WITHIN THE NEXT 10 FLIGHT HOURS, BUT NLT 29 DEC 00." CLEAR THE RED HORIZONTAL DASH //-// ENTRY WHEN THE PROCEDURES IAW PARA 8 AND 9 ARE COMPLETED. THE AFFECTED AIRCRAFT SHALL BE INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN NLT 29 DEC 00. 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//. B. AIRCRAFT IN DEPOT MAINTENANCE - DEPOT COMMANDERS WILL NOT ISSUE AIRCRAFT UNTIL THEY ARE IN COMPLIANCE WITH THIS MESSAGE. C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - WITHIN 10 HOURS/ 14 DAYS OF ARRIVAL. (2) FERRY STATUS - (A) SAME AS PARA 1A. (B) BOEING, PHILADELPHIA WILL INSPECT CH-47F AIRCRAFT PRIOR TO FIRST FLIGHT. E. MAINTENANCE TRAINERS (CATEGORY A AND B) - COMPLY NLT 30 MARCH 2001. F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES - UPON RECEIPT OF THIS MESSAGE, DEPOT AND MATERIEL ACTIVITY COMMANDERS WILL ENSURE THE MATERIEL CONDITION TAGS OF ALL ITEMS IN ALL CONDITION CODES LISTED IN PARAGRAPH 6 IS ANNOTATED TO READ: "CH-47-01-ASAM-05 (TB 1-1520-240-20-132), INSPECTION OF ROTOR HEAD ASSEMBLY DROOP STOP BOLTS FOR PROPER LENGTH NOT COMPLIED WITH". 2. TASK/INSPECTION SUSPENSE DATE - COMPLETE THE INSPECTION IAW PARAGRAPH 8 WITHIN THE NEXT 10 FLIGHT HOURS BUT NLT 29 DEC 00 AND REPORT IAW PARA 14B. 3. REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE IAW PARA 14A NLT 8 JANUARY 2001. 4. SUMMARY OF PROBLEM - A. AN ACCIDENT OCCURRED DURING SHUTDOWN OF A CH-47D. INVESTIGATION WAS CONDUCTED AND FINDINGS INDICATED THAT 2 INCORRECT BOLTS WERE INSTALLED IN THE DROOP STOP ON THE RED BLADE OF THE AFT ROTOR HEAD ASSEMBLY. A SHORTER BOLT P/N NAS624H5 WAS INSTALLED INSTEAD OF THE CORRECT BOLT P/N NAS624H7 (1/8 INCH DIFFERENCE). IT APPEARS THE EXCESSIVE FORCE ON THE THREADS ALONG WITH LOADS SEEN DURING DROOP STOP CONTACT CAUSED THE THREADS ON THE BOLTS TO FAIL. B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA 12. C. THE PURPOSE OF THIS MESSAGE IS TO REQUIRE - (1) A ONE TIME INSPECTION OF DROOP STOP BOLTS ON ALL H- 47 ROTOR HEAD ASSEMBLIES FOR PROPER LENGTH. (2) TO INSPECT RETAIL STOCKAGE AND STORAGE OF BOLTS TO INSURE PROPER IDENTIFICATION. 5. END ITEMS TO BE INSPECTED - ALL H-47 AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. FORWARD ROTOR HEAD ASSY 145R2003-ALL AFT ROTOR HEAD ASSY 145R2004-ALL 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN BOLT ASSEMBLY NAS624H7 5306-00-862-8202 DROOP STOP, FWD 114R2063-7 1615-00-967-9759 DROOP STOP, AFT 114R2087-3 1615-01-199-1785 8. INSPECTION PROCEDURES - A. RETAIL STOCK INSPECTION - (1) INSPECT BOLTS IN RETAIL/BENCH STOCK IAW PARA 8B(3)BELOW. (2) INSPECT RETAIL/BENCH STOCK STORAGE BINS TO ENSURE THAT BOLTS ARE SORTED AND LABELED CORRECTLY. B. AIRCRAFT INSPECTION - NOTE THIS MESSAGE AUTHORIZES THE REUSE OF THE DROOP STOP BOLT AFTER PERFORMING A SERVICEABILITY CHECK. THE REQUIREMENT IN THE MANUAL FOR INSTALLING ONLY NEW BOLTS IS REMOVED FOR THIS ONE TIME INSPECTION ONLY FOLLOWING SERVICEABILITY CHECK OF BOLT. (1) PREPARE AIRCRAFT FOR SAFE GROUND MAINTENANCE. (2) REMOVE DROOP STOP BOLTS (12 TOTAL) IAW TM 55-1520- 240-23, TASK 5-48 (CH-47D) AND TM 1 55-1520-252-23, TASK 5-59 (MH-47E). (3) INSPECT BOLT FOR PROPER LENGTH. THE NAS624H7 BOLT SHALL BE .912 +/- .015 INCHES (MEASURED FROM UNDER HEAD OF BOLT TO END OF THREADS). (4) IF LENGTH IS CORRECT, INSPECT BOLT FOR SERVICEABILITY BY CHECKING FOR CORROSION, DAMAGED THREADS, AND INSPECTING THREAD ROOTS FOR CRACKS WITH A 10X MAGNIFYING GLASS. IF BOLT IS CRACKED, CONTACT TECHNICAL POC IN PARAGRAPH 16A. (5) IF BOLT IS THE PROPER LENGTH AND IS SERVICEABLE, REINSTALL PER TM 55-1520-240-23, TASK 5-48 (CH-47D) AND TM 1 55- 1520-252-23, TASK 5-59 (MH-47E). THE INSPECTION IS COMPLETE. IF THE BOLT IS THE WRONG LENGTH, CONTACT LOGISTICAL POC IN PARAGRAPH 16B. (6) IF BOLT IS IMPROPER LENGTH OR DOES NOT PASS SERVICEABILITY CHECK, INSPECT THREADS OF DROOP STOP FOR SERVICEABILITY BY CHECKING FOR CORROSION OR DAMAGED THREADS. IF NO DAMAGE OR CORROSION IS FOUND, ATTEMPT TO SCREW IN A NEW BOLT BY HAND THROUGH AT LEAST FOUR THREADS OF THE DROOP STOP. IF BOLT DOES NOT SCREW IN PROPERLY USING HAND PRESSURE, THE DROOP STOP IS UNSERVICEABLE. PROCEED TO PARAGRAPH 9. 9. CORRECTION PROCEDURES - IF BOLTS WERE UNSERVICEABLE DUE TO DAMAGE, CORROSION OR IMPROPER LENGTH, PERFORM THE FOLLOWING CORRECTIVE ACTIONS: WARNING MEASURE NEW BOLT TO THE ABOVE DIMENSIONS TO ENSURE CORRECT BOLT LENGTH. (A) IF DROOP STOP IS SERVICEABLE, REINSTALL WITH NEW BOLTS IAW TM 55-1520-240-23, TASK 5-48 (CH-47D) AND TM 1 55-1520-252-23, TASK 5-59 (MH-47E). (B) IF DROOP STOP IS UNSERVICEABLE, REPLACE DROOP STOP AND REINSTALL WITH NEW BOLTS IAW TM 55-1520-240-23, TASK 5-48 (CH- 47D) AND TM 1 55-1520-252-23, TASK 5-59 (MH-47E). 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - NOMENCLATURE PART NUMBER NSN BOLT NAS624H 5306-00-862-8202 DROOP STOP, AFT 114R2087-3 1615-01-199-1785 DROOP STOP, FWD 114R2063-7 1615-00-967-9759 B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE PROJECT CODE (CC 57-59) "XOF", "X-RAY-ZERO-FOXTROT". NOTE PROJECT CODE "XOF", "X-RAY-ZERO-FOXTROT" 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 - NOMENCLATURE, PART NUMBER, NSN. LOCKWIRE MS20995NC20 9525-00-618-0257 D. DISPOSITION - DISPOSE OF REMOVED PARTS/COMPONENTS USING NORMAL SUPPLY PROCEDURES. (IF CRACK IS DETECTED IN BOLT CONTACT TECHNICAL POINT OF CONTACT IN PARAGRAPH 16A FOR DISPOSITION INSTRUCTIONS). E. DISPOSITION OF HAZARDOUS MATERIAL - N/A. 11. SPECIAL TOOLS AND FIXTURES REQUIRED - N/A 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AIRCRAFT DOWNTIME WILL BE CHARGED TO AVUM. REPORT AIRCRAFT NON-MISSION CAPABLE MAINTENANCE (NMCM) WHILE UNDERGOING INSPECTION AND CORRECTION IAW THIS MESSAGE. B. ESTIMATED TIME REQUIRED - (1) TOTAL OF 18 MAN-HOURS USING 3 PERSONS. (2) TOTAL OF 6 HOURS DOWNTIME FOR ONE END ITEM. C. ESTIMATED COST IMPACT TO THE FIELD - NOMENCLATURE PART NO./NSN QTY COST EA. TOTAL $ BOLT NAS624H7 12 $7.50 $90.00 5306-00-862-8202 DROOP STOP, AFT 114R2087-3 3 $134.12 $402.36 1615-01-199-1785 DROOP STOP, FWD 114R2063-7 3 $27.95 $83.85 1615-00-967-9759 TOTAL COST IF ANY ONE AIRCRAFT REQUIRED REPLACEMENT OF ALL BOLTS AND DROOP STOPS $576.21 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 - (1) TM 55-1520-240-23P-1, FIGURE 176, ITEM 94. ADD SECOND ITEM 94, 114R2087-3 DROOP STOP U/O P/N 145R2004-20. (2) TM 1-1520-252-23P-2, A. FIGURE 5-4 ITEM 94 CHANGE U/O P/N TO 114R2003-10 B. FIGURE 5-5 ITEM 94 CURRENT ITEM 94 CHANGE TO U/O P/N 145R2004-20. (3) TM 55-1520-240-23-4, TASK 5-48 PAGE 5-168 ADD NOTE BEFORE STEP 9. TO READ AS FOLLOWS: NOTE - PRIOR TO INSTALLATION MEASURE NEW BOLT TO INSURE BOLT IS PROPER LENGTH 0.912 +/- 0.015 INCHES (MEASURED FROM UNDER HEAD OF BOLT TO END OF THREADS) (4) TM 1-1520-252-23-5, TASK 5-59 PAGE 3 ADD NOTE BEFORE STEP 9. TO READ AS FOLLOWS NOTE PRIOR TO INSTALLATION MEASURE NEW BOLT TO INSURE BOLT IS PROPER LENGTH 0.912 +/- 0.015 INCHES (MEASURED FROM UNDER HEAD OF BOLT TO END OF THREADS) 13. REFERENCES - A. DA PAM 738-751, 15 MAR 99. B. TM 55-1520-240-23. C. TM 1-1520-252-23. 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, COMMANDERS WILL 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 AND TB 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, COMMANDERS WILL FORWARD A PRIORITY MESSAGE TO: LOGISTICS POINT OF CONTACT PARAGRAPH 16B. THE REPORT WILL CITE THIS MESSAGE AND TB NUMBER, DATE OF INSPECTION, AIRCRAFT SERIAL NUMBER, AIRCRAFT AND ROTOR HEAD HOURS, AND RESULTS OF THE INSPECTION. INSPECTION AND REPORTS WILL BE COMPLETED NLT 30 JANUARY 2001. C. REPORTING MESSAGE RECEIPT (SPARES) - N/A. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - 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 (FWD/AFT MAIN ROTOR 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 1574/DD FORM 1574-1, SERVICEABLE TAG/LABEL - MATERIEL (COLOR YELLOW). ANNOTATE REMARKS BLOCK WITH "CH-47- 01-ASAM-05 (TB 1-1520-240-20-132) NOT COMPLIED WITH" (6) DD FORM 1577/DD FORM 1577-1, UNSERVICEABLE (CONDEMNED) TAG/LABEL - MATERIEL (COLOR RED). ANNOTATE REMARKS BLOCK WITH "CONDEMNED IAW CH-47-01-ASAM-05 (TB 1-1520-240-20-132)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. LARRY WIESCHHAUS, AMSAM-RD-AE-I-P-C, DSN 897-3341 OR (256) 313-3341, DATAFAX IS DSN 897-4348. E-MAIL IS "LARRY.WIESCHHAUS@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 EXT 4348. E-MAIL IS "WILLIAM.OLSON@PEOAVN.REDSTONE.ARMY.MIL". C. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) IS - N/A. D. 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". E. SAFETY POINTS OF CONTACT ARE - (1) PRIMARY - MR. FRANK ROSEBERY(SAIC), AMSAM-SF-A, DSN 788-8631 OR (256) 842-8631, DATAFAX IS DSN 897-2111 OR (256) 313- 2111. E-MAIL IS "FRANK.ROSEBERY@REDSTONE.ARMY.MIL". (2) ALTERNATE - MR. RUSSELL PEUSCH, AMSAM-SF-A, DSN 788-8632 OR (256) 842-8632, DATAFAX IS DSN 897-2111 OR (256) 313- 2111. E-MAIL IS "RUSSELL.PEUSCH@REDSTONE.ARMY.MIL". F. FOREIGN MILITARY SALES RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT - (1) CW5 JOSEPH L. WITTSTROM, SECURITY ASSISTANCE MANAGEMENT, AMSAM-SA, DSN 897-0410 OR (256) 313-0410. EMAIL IS "WITTSTROMJL@REDSTONE.ARMY.MIL". (2) 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". G. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER (COC) DSN 897-2066/7 OR (256) 313-2066/7. HUNTSVILLE, AL IS GMT MINUS 6 HRS.