UNCLASSIFIED  
.
MSG DTG 031845Z FEB 04  
.
FROM CDRAMCOM, REDSTONE ARSENAL, AL  //AMSAM-SF-A//  
.
SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, 
RCS CSGLD-1860(R1), ALL H47 SERIES AIRCRAFT, AFT FUSELAGE 
BELLCRANK FASTENER, CH-47-04-ASAM-01.  
...................NOTE...................
....This message is effective until rescinded or superseded.  
...................NOTE...................
....This message is issued IAW AR 95-1 and has not been 
....transmitted to units subordinate to addressees.  
....Addressees will immediately retransmit this message 
....to all subordinate units, activities or elements 
....affected or concerned.  MACOMs will immediately 
....verify this transmission to the AMCOM SOF Compliance 
....Officer (AMSAM-SF-A, safeadm@redstone.army.mil).  
...................NOTE...................
....MACOM commanders may authorize temporary exception from 
....message requirements IAW AR 95-1, Ch 6.  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.  
1.  SUMMARY - 
1.1.  Background - The baseline version of the CH-47D and the 
MH-47E Maintenance Manuals contain figures that are either 
incorrect or lack proper resolution, possibly causing incorrect 
Aft Fuselage Bellcrank fastener installation, and consequently 
causing reduced clearance between control system linkages.  
1.2.  Message Purpose -  
1.2.1.  Inspect bolt installations, on certain tunnel control 
linkage joints, for correct bolt orientations.
1.2.2.  Remove incorrectly installed bolts and reinstall with 
correct bolt orientations.
1.2.3.  Change the Technical Manual to reflect this ASAM.
2.  END ITEMS AFFECTED - All H-47 series aircraft.
3.  ASSEMBLIES/COMPONENTS/PARTS AFFECTED - 
3.1.  Suspect/discrepant assemblies/components/parts - 
..Nomenclature                   PN              NSN
..Bolt, Close Tolerance  (4)MS27576-5-19     5306-00-005-0743
3.2.  Additional assemblies/components/parts to be inspected - 
..Nomenclature                   PN              NSN
..Washer, Flat                AN960-516L     5310-00-167-0836
....or                     NAS1149F0563P     5310-00-167-0820
..Nut, Self-locking            MS21224-5     5310-00-151-5430
..Pin, Cotter                MS24665-153     5315-00-234-1854
..Assembly, Bellcrank         145C3516-1     1680-01-397-0417
..Assembly, Link             145CS340-17     3040-01-308-7098
..Assembly, Link              414C2520-3     3040-01-117-7349
..Assembly, Link              414C2520-4     3040-01-117-7350
.
...................NOTE...................
....When complying with the requirements of this message, 
....complete forms and records entries IAW DA PAM 738-751.  
....ULLS-A units will use appropriate "E" forms.
4.  INITIAL TAMMS (THE ARMY MAINTENANCE MANAGEMENT SYSTEM) 
COMPLIANCE REQUIREMENTS - 
4.1.  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: "Comply with requirements of CH-47-
04-ASAM-01, before [####.#] aircraft hours, but NLT 17 FEB 04."  
(Calculate [####.#] as current aircraft flight hours plus 10 
hours).  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//.  
...................NOTE...................
....The TAMMS compliance reporting form is available at 
...."www.redstone.army.mil/sof/tamms.xls" (use lower case 
....letters only) or may be obtained from the units 
....servicing LAR.  Alternate forms may be approved by 
....the AMCOM SOF Compliance Officer.  
...................NOTE...................
....The TAMMS Compliance Report only confirms the unit has 
....made the initial logbook entry for assigned aircraft.  
....TAMMS Compliance Reports will include aircraft serial 
....numbers (in numerical order), date of entry on DA Form 
....2408-13-1, unit address, local POC name and phone number.  
4.2.  TAMMS Compliance Report - Submit TAMMS Compliance Report 
via priority email to "safeadm@redstone.army.mil" NLT 10 FEB 04 
IAW AR 95-1.  If email is not available, the report may be faxed 
to: SOF Compliance Officer at DSN 897-2111 or (256) 313-2111.  
5.  TASK/INSPECTION COMPLIANCE REPORTING REQUIREMENTS - 
...................NOTE...................
....The Task/Inspection Reporting Form is available at 
...."www.redstone.army.mil/sof/log.xls" (use lower case 
....letters only) or may be obtained from the units 
....servicing LAR.  This report will cite the message 
....number, date of inspection, aircraft serial number, 
....aircraft hours, component serial number, component 
....hours, and results of the inspection.  
5.1.  Aircraft - Submit Task/Inspection Compliance Report for 
this message to Log POC NLT 20 FEB 04.  
5.2.  Retail Stock - N/A. 
5.3.  Wholesale Stock - N/A.
6.  SPECIAL PROVISIONS TO MESSAGE REQUIREMENTS (AIRCRAFT) - 
6.1.  Aircraft in AVUM, AVIM, or Depot level maintenance - 
Commanders, facility managers and contractors will not issue 
aircraft until they are in compliance with this message.
6.2.  Aircraft at Contractor Facility - Contractors will inspect 
DD 250 aircraft prior to those aircraft departing for ferry to 
final destination.  
6.3.  Aircraft in Transit - Unit commanders in receipt of 
deployment orders and are unable to comply prior to the date 
specified in Para. 4.1. may defer initial requirements IAW 
Surface/air shipment or Ferry status instructions, as 
appropriate.  
6.3.1.  Surface/air shipment - within 10 aircraft hours/14 days 
of arrival. 
6.3.2.  Ferry status/Aircraft away from home station - Comply 
with message requirements upon arrival at final destination. 
6.4.  Maintenance Trainers (Cat A and B) - Comply with message 
requirements NLT 3 MAR 04. 
7.  TECHNICAL PROCEDURES/INSTRUCTIONS - The baseline version of 
the CH-47D Maintenance Manual, TM 55-1520-240-23-9 Tasks 11-238, 
11-239, 11-244, 11-245, 11-246, and 11-247, contain figures that 
are either incorrect or lack proper resolution, possibly causing 
incorrect fastener installation, and consequently causing reduced 
clearance between control system linkages.  Change 1 of TM 55-
1520-240-23-9 corrects the top figure on page 11-962 in Task 11-
247 for bolt orientation; it does not correct the remaining task 
figures.  The MH-47E Maintenance Manual, TM 1-1520-252-23-13 
Tasks 11-256, 11-257, 11-262 and Task 11-263 also contain figures 
that show incorrect fastener installation.  Additionally, many of 
the figures in these tasks do not include orientation 
designators, i.e., outboard/inboard, forward/aft direction 
arrows, which aid in orienting the technician.
...................NOTE...................
....Figures 389 and 390 of TM 55-1520-240-23P-3, 15 Sep 03 
....(C/MH-47D) and Figures 11-14 and 11-15 of TM 1-1520-252-23P-3
....(MH-47E) should be referenced in performing this inspection. 
...................NOTE...................
....The figure on page 11-952 in Task 11-244 of the CH-47D 
....Maintenance Manual TM 55-1520-240-23-9 does not have 
....adequate resolution to show the bolt orientation.
....The figure in Task 11-264 of MH-47E TM 1-1520-252-23-13 
....does not have adequate resolution to show bolt orientation. 
....All four bolts at Station 444.5 should be shown with the bolt
....heads facing inboard.
7.1  Inspection Procedure - 
7.1.1.  Prepare aircraft for safe ground maintenance.
7.1.2.  Reference Task 11-244 of TM 55-1520-240-23-9, page 11-952 
(CH-47D) and Reference Task 11-262 of TM 1-1520-252-23-13 (MH-47E).  
Inspect Item 15 (4 places) at station 444.5 to determine if the 
bolt heads face inboard.
7.1.3.  If all 4 bolt heads face inboard, the inspection is 
complete.  Proceed to Para. 7.3. 
7.1.4.  If all 4 bolts heads do not face inboard, proceed to 
Para. 7.2.
7.2.  Fastener Removal, Inspection and Replacement - 
...................NOTE...................
....The figure on page 11-952 in Task 11-244 of TM 55-1520-240-
....23-9 (CH-47D) does not have adequate resolution to show the 
....correct bolt orientation.  All four bolts at Station 444.5 
....should be shown with the bolt heads facing inboard. 
....The figure on page 3 of Task 11-262 of TM 1-1520-252-23-13 
....(MH-47E) is incorrect. All four bolts at Station 444.5 should 
....be shown with the bolt heads facing inboard.
...................NOTE...................
....It is not necessary to remove correctly installed fastener 
....hardware unless it prevents removal of incorrectly installed 
....fastener hardware, or visual inspection indicates damage to 
....correctly installed fastener hardware or control linkage 
....hardware.
7.2.1.  Perform Task 11-244 of TM 55-1520-240-23-9 (C/MH-47D), 
Task 11-262 of TM 1-1520-252-23-13 (MH-47E) to remove incorrectly 
installed fastener hardware.
7.2.2.  Inspect the parts at Station 444.5 listed in paragraphs 
3.1 and 3.2 of this message for abnormal wear or abrasion.  If 
cotter pins are removed discard and replace with new ones. 
...................NOTE...................
....Three figures on pages 11-957 and 11-958 in Task 11-244 of 
....TM 55-1520-240-23-9 (CH-47D) either do not have adequate 
....resolution to show the correct bolt orientation, or are 
....incorrect.  All four bolts at Station 444.5 should be shown 
....with the bolt heads facing inboard.  Three figures on pages 1 
....and 2 of Task 11-264 of TM 1-1520-252-23-13 (MH-47E) either 
....do not have adequate resolution to show the correct bolt
....orientation, or are incorrect.  All four bolts at Station 
....444.5 should be shown with the bolt heads facing inboard.
...................NOTE...................
....The figure on page 11-928 in Task 11-238 of TM 55-1520-240-
....23-9 (CH-47D) is incorrect.  All four bolts at Station 444.5 
....should be shown with the bolt heads facing inboard.  The 
....figure on page 2 of Task 11-256 of TM 1-1520-252-23-13 
....(MH-47E) is incorrect. All four bolts at Station 444.5 should 
....be shown with the bolt heads facing inboard.
...................NOTE...................
....The figure on page 11-930 in Task 11-239 of TM 55-1520-240-
....23-9 (CH-47D) does not have adequate resolution and is 
....incorrect.  All four bolts at Station 444.5 should be shown 
....with the bolt heads facing inboard.  The figure on page 2 of 
....Task 11-257 of TM 1-1520-252-23-13 (MH-47E) is incorrect. 
....All four bolts at Station 444.5 should be shown with the bolt 
....heads facing inboard.
7.2.2.1.  If either bellcrank (P/N 145C3516-1) exhibits cracks or 
abnormal wear or abrasion, remove per TM 55-1520-240-23-9 Task 
11-246 and replace per Task 11-247 (C/MH-47D) or remove per TM 1-
1520-252-23-13 Task 11-264 and replace per Task 11-265 (MH-47E).
7.2.2.2.  If any connecting links (P/N's 145CS340-17, 414C2520-3, 
145C2501-2, 414C2520-4) exhibit cracks or abnormal wear or 
abrasion, remove per TM 55-1520-240-23-9 Tasks 11-238 and/or 11-
244, and replace per Tasks 11-239 and/or 11-245 (C/MH-47D); or 
remove per TM 1-1520-252-23-13 Tasks 11-256 and/or 11-262, and 
replace per Tasks 11-257 and/or 11-263 (MH-47E).
...................NOTE...................
....The bottom figure on page 11-955 in Task 11-245 of TM 55-
....1520-240-23-9 is incorrect.  The figure on page 3 in Task 
....11-262 and page 4 (Change 4) in Task 11-263 TM 1-1520-252-
....23-13 is incorrect.  The bolt heads for all four bolts should 
....face inboard.
...................NOTE...................
....The two outboard bolts should be installed first in the step 
....below.
7.2.3.  Perform Steps 10 through 12 of Task 11-245 of TM 55-1520-
240-23-9 (C/MH-47D) to reinstall each of the 4 sets of fastener 
hardware or perform Steps 10 through 12 of Task 11-263 of TM 1-
1520-252-23-13 (MH-47E) to reinstall each of the 4 sets of 
fastener hardware.  Confirm that all four bolt heads face inboard.
7.2.4.  Once fastener hardware is correctly reinstalled per Task 
11-245 of TM 55-1520-240-23-9 (C/MH-47D) or Task 11-263 of TM 1-
1520-252-23-13 (MH-47E), the inspection is complete.  Proceed to 
Para. 7.3.  
7.3.  Clear the initial entry from Para. 4.1. and note compliance 
on the Aircraft DA Form 2408-15.
8.  PROCEDURES/INSTRUCTIONS FOR ASSEMBLIES/COMPONENTS/PARTS IN 
WORK OR IN STOCK (AT ALL LEVELS INCLUDING WAR RESERVES) - N/A.
9.  SPECIAL TOOLS AND FIXTURES REQUIRED - N/A. 
10.  SUPPLY/PARTS (REQUISITION/DISPOSITION) - 
10.1.  Parts Required - 
..Nomenclature...P/N.........NSN........Qty  Cost ea.   Total $
Bolt, Close Tolerance
.........MS27576-5-19  5306-00-005-0743  4  $14.77      $59.08
Washer, Flat
.........AN960-516L  5310-00-167-0836   10  $0.68(HD)    $0.07
..OR..NAS1149F0563P  5310-00-167-0820   10  $1.06(HD)    $0.11
Nut, Self-locking
.........MS21224-5   5310-00-151-5430   8   $1.92       $15.36
Pin, Cotter
........MS24665-153  5315-00-234-1854    8   $1.28(HD)   $0.13
Assembly, Bellcrank
.........145C3516-1  1680-01-397-0417    2  $1170.00  $2340.00
Assembly, Link..
........145CS340-17  3040-01-308-7098    2  $1036.00  $2072.00
Assembly, Link
.........414C2520-3  3040-01-117-7349    1  $997.00    $997.00
Assembly, Link
.........414C2520-4  3040-01-117-7350    1  $975.00    $975.00
.....Total cost per aircraft(if all parts replaced) = $6458.75
10.2.  Bulk and consumable materials - N/A. 
10.3.  Requisitioning instructions - Requisition replacement 
parts using normal supply procedures.  All requisitions shall use 
Project Code (CC 57-59) "X2K" (X-ray-two-kilo).
...................NOTE...................
....Project Code "X2K" is required to track and establish 
....a data base of stock fund expenditures incurred by 
....the field as a result of message actions.  
10.4.  Disposition of discrepant parts/components - 
Demilitarize/mutilate IAW TM 1-1500-328-23. 
10.5.  Disposition of hazardous material - N/A. 
11.  MAINTENANCE APPLICATION - 
11.1.  Category of maintenance - AVUM. 
11.2.  Estimated time required - 
11.2.1.  Time to complete inspection - total of 0.5 man-hours 
using 1 persons with 0 hours downtime per end item.
11.2.2.  Time for repair/replacement - total of 6 man-hours using 
2 persons with 3 hours downtime per end item.
12.  PUBLICATION REQUIREMENTS - 
12.1.  References - 
12.1.1.  AR 95-1.
12.1.2.  DA Pam 738-751  
12.1.3.  TM 55-1520-240-23 
12.1.4.  TM 55-1520-240-23P-3, 15 Sep 03
12.1.5.  TM 1-1520-252-23
12.1.6.  TM 1-1520-252-23P-3
2.2.  Publication changes - TM 55-1520-240-23 and TM 1-1520-252-23 
shall be changed to reflect this message.  A copy of this message 
will be used as authority to implement the change until the 
official change is received.  
13.  POINTS OF CONTACT - 
13.1.  Technical POCs are - 
13.1.1.  Primary - Michael B. Moore, AMSRD-AMR-AE-C, DSN 897-2350, 
ext. 9842 or (256) 705-9842.  Fax is DSN 897-2350, ext. 9900 or 
(256) 705-9900.  Email is "mooremb@rdec.redstone.army.mil".  
13.1.2.  Alternate - Dennis W. Ganey, AMSRD-AMR-AE-C, DSN 897-
2350, ext. 9828 or (256) 705-9828.  Fax is DSN 897-2350, ext. 9900 
or (256) 705-9900.  Email is "ganeydw@rdec.redstone.army.mil". 
13.2.  Logistical POCs are - 
13.2.1.  Primary - Bill Olson, SFAE-AV-CH-CS, DSN 897-3379 or 
(256) 313-3379.  Fax is 897-4348 or (256) 313-4348.  Email is 
"william.olson@peoavn.redstone.army.mil". 
13.2.2.  Alternate - Jack Martin (AEPCO), SFAE-AV-CH-CS, DSN 897-
3617 or (256) 313-3617.  Fax is DSN 897-4348 or (256) 313-4348.  
Email is "jack.martin@peoavn.redstone.army.mil". 
13.3.  Wholesale Materiel POC (spares) is Ms. Geri Reddy, AMSAM-
MMC-AV-CA, DSN 897-1454 or (256) 313-1454.  Fax is DSN 897-1106.  
Email is "geri.reddy@redstone.army.mil".  
13.4.  Forms and Records POC is Ms. Ann Waldeck, AMSAM-MMC-MA-NM, 
DSN 746-5564 or (256) 876-5564.  Fax is DSN 746-4904 or (256) 
876-4904.  Email is "ann.waldeck@redstone.army.mil".  
13.5.  Safety POCs are - 
13.5.1.  Primary - Mr. Frank Rosebery (SAIC), AMSAM-SF-A, DSN 
788-8631 or (256) 842-8631.  Fax is DSN 897-2111 or (256) 313-
2111.  Email is "frank.rosebery@redstone.army.mil".  
13.5.2.  Alternate - Mr. Russ Peusch, AMSAM-SF-A, DSN 788-8632 or 
(256) 842-8632.  Fax is DSN 897-2111 or (256) 313-2111.  Email is 
"russell.peusch@redstone.army.mil".  
13.6.  Foreign Military Sales POC is Mr. Ronnie W. Sammons, AMSAM-
SA-AS-UT, DSN 897-0875 or (256) 313-0875.  Fax is DSN 897-0411 or 
(256) 313-0411.  Email is "ronnie.sammons@redstone.army.mil".
13.7.  After hours, contact the AMCOM Operations Center (AOC) DSN 
897-2066/7 or (256) 313-2066/7.