UNCLASSIFIED 041600Z OCT 01 FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A// SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), ALL H-47 SERIES AIRCRAFT, ONE TIME INSPECTION OF THE TUNNEL COVER STRUT ASSEMBLIES CH-47-02-ASAM-01 (TB 1-1520- 240-20-142). 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 STRUT ASSEMBLIES IAW CH-47-02-ASAM-01 (TB 1-1520-240-20-142) WITHIN THE NEXT 10 FLIGHT HOURS, BUT NLT 18 OCTOBER 2001." 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 18 OCTOBER 2001. 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 MAINTENANCE FACILITY - (1) AIRCRAFT IN AVUM, AVIM OR DEPOT - SAME AS PARA 1A. (2) AIRCRAFT AT CONTRACTOR FACILITY - BOEING WILL INSPECT DD 250 AIRCRAFT PRIOR TO THOSE AIRCRAFT DEPARTING FOR FERRY TO FINAL DESTINATION. C. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - SAME AS PARA 1A. (2) FERRY STATUS - SAME AS PARA 1A. D. MAINTENANCE TRAINERS (CATEGORY A AND B) - SAME AS PARA 1A. E. 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 PARAS 6 AND 7 ARE ANNOTATED TO READ: "CH-47-02-ASAM-01 (TB 1-1520-240-20-142), INSPECTION OF THE TUNNEL COVER STRUT ASSEMBLY NOT COMPLIED WITH." (1) WHOLESALE STOCK - UPON RECEIPT OF THIS MESSAGE, DEPOT AND MATERIEL ACTIVITY COMMANDERS WILL ENSURE ALL ITEMS IN CONDITION CODES //A//, //B//, //C//, //D//, AND //E//, LISTED IN PARAGRAPHS 6 AND 7, ARE PLACED IN CONDITION CODE //J// AND TAGGED WITH A SUSPENDED TAG/LABEL - MATERIEL, DD FORM 1575/DD FORM 1575-1. DO NOT REMOVE ORIGINAL CONDITION TAGS. (2) RETAIL STOCK - UPON RECEIPT OF THIS MESSAGE, COMMANDERS AND FACILITY MANAGERS MAINTAINING RETAIL STOCK AT INSTALLATION LEVEL AND BELOW SHALL CONTACT THE SUPPORTED AVIATION UNIT TO PERFORM THE PROCEDURES REQUIRED IAW PARAGRAPHS 8 AND 9 ON SUSPECT MATERIEL. DISPOSE OF DISCREPANT MATERIEL IAW PARA 10. F. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - DEPOT AND OTHER MAINTENANCE ACTIVITY COMMANDERS WILL ENSURE ITEMS LISTED IN PARAGRAPHS 6 AND 7 ARE NOT ISSUED UNTIL THEY ARE IN COMPLIANCE WITH THIS MESSAGE. 2. TASK/INSPECTION SUSPENSE DATE - COMPLETE THE INSPECTION IAW PARAGRAPH 8 WITHIN THE NEXT 10 FLIGHT HOURS BUT NLT 18 OCTOBER 2001. 3. TAMMS REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE IAW PARA 14A(1) NLT 26 OCTOBER 2001. 4. SUMMARY OF PROBLEM - A. A REPORT HAS BEEN RECEIVED FROM THE FIELD DOCUMENTING THAT THE PIN IN A TUNNEL COVER STRUT ASSEMBLY WAS NOT STAKED. IF THE PIN BECOMES DISLODGED FROM THE STRUT ASSEMBLY, THE STRUT HALVES AND/OR THE PIN CAN CAUSE DAMAGE TO THE HYDRAULIC LINES AND SYNC SHAFTS. B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA 12. C. THE PURPOSE OF THIS MESSAGE IS TO - (1) REMOVE FROM SERVICE ALL STRUT ASSEMBLIES MANUFACTURED BY PRECISION STANDARD. (2) PERFORM A ONE TIME INSPECTION OF ALL STRUT ASSEMBLIES MANUFACTURED BY NORCO. 5. END ITEMS TO BE INSPECTED - ALL H-47 SERIES AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN TUNNEL COVER ASSY 114S2915-70 1560-00-150-2708 TUNNEL COVER ASSY 114S2915-72 1560-00-150-2710 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN STRUT ASSEMBLY A297-1 1560-00-168-5725 STRUT ASSEMBLY 114S2915-61 N/A 8. INSPECTION PROCEDURES - NOTE SUPPLEMENTAL INFORMATION FOR THIS MESSAGE CAN BE VIEWED AT (USE LOWER CASE LETTERS ONLY) "www.redstone.army.mil/sof/suppl/c47a0201.pdf". A. PREPARE AIRCRAFT FOR SAFE GROUND MAINTENANCE. NOTE AS THE "STAKED PIN" IS COMMONLY REFERRED TO AS THE "ELBOW PIN" BY THE FIELD, THE TERM "ELBOW PIN" WILL BE USED FOR THE REMAINDER OF THIS MESSAGE. B. INSPECT THE STRUT TO DETERMINE IF THEY ARE MANUFACTURED BY PRECISION STANDARD OR NORCO. REFERENCE FIGURE 58, ITEMS 13 AND 69, TM 55-1520-240-23P (CH/MH-47D), OR FIGURE 2-42, ITEM 67, TM 1- 1520-252-23P (MH-47E). USE THE FOLLOWING CRITERIA TO DETERMINE ORIGIN OF MANUFACTURE. (1) ELBOW PIN - (A) NORCO - BUCKED/STAKED ON BOTH SIDES, ROUND OR PROTRUDING HEAD. (B) PRECISION STANDARD - FLUSH OR NEARLY FLUSH WITH OUTER EDGE OF ELBOW CLEVIS. (2) UPPER STRUT HALF FRONT RIVETS (FACING OBSERVER IN INSTALLED POSITION) - (A) NORCO - STANDARD ROUND HEAD RIVETS, BUCKED/STAKED ON ONE (1) SIDE. (B) PRECISION STANDARD - FLUSH RIVETS (2), COUNTERSUNK ON BOTH SIDES. (3) STRUT SIDE OPPOSITE PULL RING - (A) NORCO - COUNTERSUNK BUCKED/STAKED RIVETS, SLIGHT PROTRUSION FROM SURFACE. (B) PRECISION STANDARD - COUNTERSUNK FLUSH RIVETS. (4) PART MARKING - (A) NORCO - IF THE NONMETALLIC SHIELDS (ITEM 12 OR 68, TM 55-1520-240-23P {CH/MH-47D}, OR ITEM 66, TM 1-1520-252-23P {MH-47E}) ARE NOT INSTALLED ON THE STRUT ASSEMBLY AND THE STRUT HAS NOT BEEN PAINTED, THE STRUT ASSEMBLY PART MARKING WILL BE VISIBLE. THE MARKING INCLUDES THE MANUFACTURER NAME (NORCO, INC), THE MANUFACTURER CODE, THE PART NUMBER (A297-1), AND THE NSN. (B) PRECISION STANDARD - IF THE NONMETALLIC SHIELDS ARE NOT INSTALLED, THE PART MARKING (114S2915-61) WILL BE VISIBLE. NOTE IF THE ELBOW PIN IS NOT INSTALLED, MAKE A THOROUGH SEARCH OF THE ENTIRE TUNNEL AREA FOR THE ELBOW PIN AND ANY OTHER DEBRIS. C. IF A PRECISION STANDARD STRUT ASSEMBLY IS INSTALLED, PROCEED TO PARA 9. D. IF A NORCO STRUT ASSEMBLY IS INSTALLED, INSPECT THE WHOLE STRUT ASSEMBLY FOR OVERALL HARDWARE INTEGRITY - (1) FOR ANY STRUT ASSEMBLY WITHOUT A "BUCKED" OR "STAKED" ELBOW PIN AND/OR RIVETS, OR IF THE ENDS OF THE ELBOW PIN ARE FLUSH OR NEARLY FLUSH WITH OUTER EDGE OF THE ELBOW CLEVIS, PROCEED TO PARA 9. (2) IF ALL STRUT ASSEMBLY ELBOW PINS AND RIVETS ARE PROPERLY INSTALLED, AND THERE IS NO OTHER DAMAGE TO THE ASSEMBLY, THE INSPECTION IS COMPLETE, PROCEED TO PARA 9C. 9. CORRECTION PROCEDURES - CAUTION WIND TURBULENCE, BOTH NATURALLY OCCURRING AND FROM NEARBY AIRCRAFT, CAN CAUSE DAMAGE TO THE ACCESS COVER(S) IF NOT SECURED. A. REMOVE THE STRUT ASSEMBLY FROM THE AIRCRAFT (ITEMS 2,3,4,5 AND 7 AND/OR ITEM 63, TM 55-1520-240-23P {CH/MH-47D}, OR ITEM 61, TM 1-1520-252-23P {MH-47E}) AND REPLACE WITH AN INSPECTED NORCO STRUT ASSEMBLY IF - (1) A PRECISION STANDARD STRUT ASSEMBLY IS INSTALLED. (2) A NORCO STRUT ASSEMBLY IS INSTALLED AND THE ELBOW PIN OR A RIVET IS EITHER NOT PROPERLY INSTALLED OR IS MISSING, OR THE STRUT ASSEMBLY IS DEFECTIVE IN ANY WAY OTHER THAN THE ABSENCE OF THE NONMETALLIC STRUT SHIELDS. NOTE FIGURE 58, TM 55-1520-240-23P (CH/MH-47D), AND FIGURE 2-42, TM 1-1520-252-23P (MH-47E), DO NOT INCLUDE THE FASTENER HARDWARE FOR ATTACHMENT OF THE TUNNEL COVER (ITEM 62 FOR CH/MH-47D, ITEM 60 FOR MH-47E) STRUT ASSY'S (ITEM 63 FOR CH/MH-47D, ITEM 61 FOR MH-47E) TO THE AIRCRAFT. FOR REMOVAL AND REINSTALLATION OF EACH STRUT ASSEMBLY, REMOVE AND REINSTALL THE FOLLOWING HARDWARE AS NEEDED - NOMENCLATURE PART NUMBER PIN, COTTER MS24665-153 BOLT, MACHINE AN3-7 WASHER, FLAT AN960-10 (CH/MH-47D ONLY) WASHER, FLAT NAS1149F0363P (MH-47E ONLY) NUT, PLAIN AN310-3 B. AFTER INSPECTION AND REPLACEMENT AS REQUIRE - (1) THE RED HORIZONTAL DASH //-// WILL BE CLEARED ONLY IF A SERVICEABLE STRUT IS INSTALLED AT EACH LOCATION. (2) IF A REPLACEMENT STRUT IS NOT AVAILABLE, SERVICEABLE STRUTS SHOULD BE RELOCATED, IF POSSIBLE, TO ENSURE THAT AT LEAST ONE (1) SERVICEABLE STRUT IS LOCATED ON EACH TUNNEL COVER. CLEAR THE RED HORIZONTAL DASH //-// ENTRY AND PLACE THE FOLLOWING RED DIAGONAL \\/\\ ENTRY ON THE DA FORM 2408-13-1: "TUNNEL COVER STRUT ASSEMBLY (ENTER STRUT LOCATION HERE) REMOVED AND REQUIRES REPLACEMENT IAW CH-47-02-ASAM-01 (TB 1-1520-240-20-142)." A SEPARATE ENTRY IS REQUIRED FOR EACH STRUT ASSEMBLY REMOVED TO INCLUDE THE APPROPRIATE TUNNEL COVER NUMBER AND EITHER THE AFT OR FORWARD STRUT TO PROPERLY IDENTIFY THE ASSEMBLY REMOVED. C. WHEN ALL STRUT ASSEMBLIES HAVE BEEN REPLACED AS REQUIRED, THE RED DIAGONAL \\/\\ STATUS SYMBOL WILL BE CLEARED. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPHS 6 AND 7 MAY BE REQUIRED TO REPLACE DEFECTIVE ITEMS. B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE PROJECT CODE (CC 57-59) "X14" (X-RAY ONE FOUR). NOTE PROJECT CODE "X14" 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 NO. NSN PIN, COTTER MS24665-153 5315-00-185-0037 BOLT, MACHINE AN3-7 5306-00-144-3648 WASHER, FLAT AN960-10 5310-00-167-0818 WASHER, FLAT NAS1149F0363P 5310-00-167-0818 NUT, PLAIN AN310-3 5310-00-167-1284 D. DISPOSITION - DEMILITARIZE/MUTILATE IAW TM 1-1500-328-23 ANY PART/COMPONENT WHICH DOES NOT MEET INSPECTION CRITERIA. E. DISPOSITION OF HAZARDOUS MATERIAL - N/A. 11. SPECIAL TOOLS AND FIXTURES REQUIRED - N/A. 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AVUM. REPORT AIRCRAFT NON- MISSION CAPABLE MAINTENANCE (NMCM) WHILE UNDERGOING INSPECTION AND CORRECTION IAW THIS MESSAGE. B. ESTIMATED TIME REQUIRED - (1) TOTAL OF 2 MAN-HOURS USING 1 PERSON. (2) TOTAL OF 2 HOURS DOWNTIME FOR ONE END ITEM. C. ESTIMATED COST IMPACT TO THE FIELD - NOMENCLATURE PART NO./NSN QTY COST EA. TOTAL $ STRUT ASSEMBLY A297-1 5 $477.42 $2387.10 1560-00-168-5725 TOTAL COST PER AIRCRAFT = $2387.10 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 - A. DA PAM 738-751, 15 MAR 99. B. TM 55-1520-240-23. C. TM 1-1520-252-23. D. TM 55-1520-240-23P. E. TM 1-1520-252-23P. F. TM 1-1500-328-23. 14. RECORDING AND REPORTING REQUIREMENTS - A. AIRCRAFT - (1) TAMMS REPORTING COMPLIANCE SUSPENSE - UPON ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 FOR ALL EFFECTED 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, NLT DATE SPECIFIED IN PARA 3. DATAFAX 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 NUMERICAL ORDER. (2) TASK/INSPECTION REPORTING SUSPENSE - N/A. B. WHOLESALE SPARE PARTS/ASSEMBLIES - N/A. C. RETAIL SPARE PARTS/ASSEMBLIES - N/A. D. 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 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (3) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT. (4) DD FORM 1574/DD FORM 1574-1, SERVICEABLE TAG/LABEL - MATERIEL (COLOR YELLOW). ANNOTATE REMARKS BLOCK WITH "INSPECTED SERVICEABLE IAW CH-47-02-ASAM-01 (TB 1-1520-240-20-142)." (5) DD FORM 1575/DD FORM 1575-1, SUSPENDED TAG/LABEL - MATERIEL (COLOR BROWN). ANNOTATE REMARKS BLOCK WITH "SUSPENDED IAW CH-47-02-ASAM-01 (TB 1-1520-240-20-142)." (6) DD FORM 1577/DD FORM 1577-1, UNSERVICEABLE (CONDEMNED) TAG/LABEL - MATERIEL (COLOR RED). ANNOTATE REMARKS BLOCK WITH "CONDEMNED IAW CH-47-02-ASAM-01 (TB 1-1520-240-20-142) AND MUTILATED IAW TM 1-1500-328-23." 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT IS MR. MIKE MOORE, AMSAM-RD- AE-I-P-C, DSN 897-3359 OR (256) 313-3359, DATAFAX IS EXT. 4348. E-MAIL IS MICHAEL.B.MOORE@REDSTONE.ARMY.MIL". B. LOGISTICAL POINT OF CONTACT IS 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. FORMS AND RECORDS POINT OF IS MS. ANN WALDECK, AMSAM- MMC-MA-NM, 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 ARE - (1) PRIMARY - MR. HARRY TRUMBULL (SAIC), AMSAM-SF-A, DSN 897-2095 OR (256) 313-2095, DATAFAX IS DSN 895-2111 OR (256) 313-2111. E-MAIL IS "HARRY.TRUMBULL@REDSTONE.ARMY.MIL". (2) ALTERNATE - MR. RUSS 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". E. FOREIGN MILITARY SALES RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT - (1) PRIMARY - MR. RONNIE W. SAMMONS, AMSAM-SA-CS-NF, DSN 897-6856 OR (256) 313-6856. DATAFAX IS DSN 897-6630 OR (256) 313-6630. EMAIL IS "RONNIE.SAMMONS@REDSTONE.ARMY.MIL". (2) ALTERNATE - MR. PAUL W. TARR, AMSAM-SA-CS-NF, DSN 897-6861 OR (256) 313-6861. DATAFAX IS DSN 897-6630 OR (256) 313-6630. EMAIL IS E-MAIL "TARRPW@REDSTONE.ARMY.MIL". G. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER (COC) DSN 897-2066/7 OR (256) 313-2066/7.