SYNOPSIS CH-47-92-ASAM-05 AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, REPLACEMENT OF HI-LOK FASTENERS IN L/H AND R/H BUTT LINE 18 BEAMS AT FUSELAGE STATION 83 TO 120, (TB 1-1520-240-50-02). 162030Z JUN 92, BRAD MEYER, AMSAV-XSOF, X9089.' NOTE: Enter a "Q" + <CR> to exit or <SPACEBAR> to view the entire message. (REPORTING) . 01 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES CDRAVSCOM ST LOUIS MO //AMSAV-XSOF// AIG 6713 AIG 9004 AIG 8708 AIG 9042 CDR4THBN228THAVN SOTO CANO //AVN-AMO// CDRLBAD LEXINGTON KY //SDSLB-GC// INFO DEFARM CANBERRA AS //DOHS-A// DEFNAV CANBERRA AS CDRUSARDSG CANBERRA AS HQLCENG MELBOURNE AS //DAIRENG// LOG CON OTTAWA ONT CAN //DTHEM 6-3// AUSTNAV WASHINGTON DC //DEFNAV// AUSTAIR WASHINGTON DC //SENGSO// USOMC CAIRO EG //AV// ODC ATHENS GR //ODCSA-A// CDR AMCCOM ROCK ISLAND IL //AMSAR-QAS-P// CHMUSLO RABAT MO //AF// CHUSAS RIYADH SA //ASAV// CF: SFAE-AV-CH, AMSAV-ECC, AMSAV-I-RAAF, AMSAV-MEA, AMSAV-L-AOC BRAD MEYER AMSAV-XSOF, X9089 EDWARD J. HOLLMAN CHIEF, SAFETY OFFICE . UNCLAS 02 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES ODC MADRID SP //ARMY AND NAVY SEC// CJUSMAG BANGKOK TH CDRUSARDSG LONDON UK //AMXSN-UK-SE// CDRAMC ALEXANDRIA VA //AMCMR/AMCCS/AMCSM-WAA// XMT USDAO DHAKA BG USDAO RANGOON BM USDAO COLUMBO CE USDAO SUVA FJ OMADP JAKARTA ID DSA NEW DELHI IN USDAO ANTANANARIVO MA SAO KUALA LUMPUR MY USDAO KATMANDU NP //SAO// USDAO SINGAPORE SN //SAO// UNCLAS RELEASABLE TO NATO ADDRESSEES AIG 9004 TAKE FOR INFO ONLY AIG 8708 TAKE FOR INFO ONLY AIG 9042 TAKE FOR INFO ONLY SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS . UNCLAS 03 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES CSGLD-1860(R1), ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, REPLACEMENT OF HI-LOK FASTENERS IN L/H AND R/H BUTT LINE 18 BEAMS AT FUSELAGE STATION 83 TO 120, (CH-47-92-ASAM-05) (TB 1-1520-240-50-02) NOTE - THIS IS AN AVIATION SAFETY ACTION 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 RETRANSMISSIONTO COMMANDER, AVSCOM, ATTN - AMSAV-XSOF (SOF COMPLIANCE OFFICER). 1. PRIORITY CLASSIFICATION - 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 //-// MAY BE CLEARED WHEN THE CORRECTION OF PARA 9 BELOW IS COMPLETED. THE AFFECTED AIRCRAFT SHALL BE INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN THE TASK/INSPECTION SUSPENSE DATE. 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 . UNCLAS 04 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES UNTIL COMPLIANCE WITH THIS ASAM HAS BEEN COMPLETED. C. AIRCRAFT UNDERGOING MAINTENANCE - N/A. D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - N/A. (2) FERRY STATUS - (A) SAME AS PARA 1A. (B) THOSE AIRCRAFT THAT HAVE A DD250 AND ARE AT BOEING HELICOPTER COMPANY HAVE BEEN REWORKED. 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 - WITHIN THE NEXT PHASE INSPECTION OR WHEN AIRCRAFT IS INDUCTED INTO THE SPECIAL TECHNICAL INSPECTION AND REPAIR (STIR) PROGRAM, WHICHEVER OCCURS FIRST. 3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 8 JUL 92 PER PARA 14A OF THIS MESSAGE. 4. SUMMARY OF PROBLEM - A. DURING MANUFACTURE OF THE CH-47D HELICOPTER THE SUBJECT HI-LOK FASTENERS WERE INADVERTENTLY INSTALLED IN OVERSIZED HOLES. . UNCLAS 05 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES THIS MAY REDUCE THE FATIGUE LIFE OF THIS PART OF THE FUSELAGE STRUCTURE. REPLACEMENT OF THE HI-LOK FASTENERS BY OLR TEAM/STIR PROGRAM ASSURES THAT THE PROPER SIZE FASTENER FOR ANY PARTICULAR HOLE IS INSTALLED. B. THE PURPOSE OF THIS MESSAGE IS TO REQUIRE REPLACEMENT OF ALL HI-LOK FASTENERS AT THE NEXT PHASE INSPECTION BY OLR TEAMS OR DURING THE STIR PROGRAM. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D AND MH-47E AIRCRAFT WITH SERIAL NUMBERS 76-18538 THROUGH 90-00222. AIRCRAFT SERIAL NUMBERS 90-00223 AND SUBSEQUENT WILL BE CORRECTED BY PRIME CONTRACTOR DURING PRODUCTION AND THEREFORE RECORDS FOR AIRCRAFT SERIAL NUMBERS 90-00223 AND SUBSEQUENT WILL NOT REQUIRE IDENTIFICATION OF THIS ACTION. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - N/A. 7. PARTS AFFECTED - NOMENCLATURE PART NO. NSN FASTENER (HI-LOK) HL18PB6 5310-00-911-9428 8. INSPECTION PROCEDURES - N/A. 9. CORRECTION PROCEDURES - A. THE HI-LOKS TO BE REPLACED ARE LOCATED IN THE FORWARD . UNCLAS 06 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES TRANSMISSION TORQUE BOX, BLL AND BLR 18, STATION 83 TO 120, WL 52. THE ROWS OF HI-LOKS ARE INBOARD AND ONE TO FOUR INCHES BELOW THE WORK PLATFORMS PER FIGURE 1. (FIGURE 1 IS AVAILABLE FROM YOUR LOCAL OLR OFFICE). B. TO GAIN ACCESS TO THE HI-LOKS TO BE REPLACED, LOWER BOTH MAINTENANCE PLATFORMS ON THE FORWARD PYLON AND REMOVE THE FORWARD TRANSMISSION DRIP PAN PER TM 55-1520-240-23-2. CAUTION TO PREVENT RESIDUE FROM FALLING INTO THE AVIONICS AND OTHER COMPARTMENTS WHEN REMOVING RIVETS FROM SKINS ABOVE THE COMPARTMENTS, COVER THE COMPARTMENT WITH SUITABLE COVERING. IN ACCORDANCE WITH CURRENT FOREIGN OBJECT DAMAGE (FOD) PRACTICES. C. THE FOLLOWING STEPS PROVIDE INSTRUCTIONS FOR REMOVAL OF ALL SKINS AND PANELS TO GAIN ACCESS AND REPLACE ALL OF THE SUBJECT HI-LOK FASTENERS. (1) REMOVE THE FORWARD L/H AND R/H WORK PLATFORMS PER TM 55-1520-240-23-2. (2) REMOVE FAIRING ASSEMBLIES, P/N 145S1905-1 AND -2 PER TM 55-1500-204-25/1. THESE FAIRINGS ARE LOCATED BELOW THE WORK PLATFORMS AND MATE THE FUSELAGE TO THE PYLON. . UNCLAS 07 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES (3) IF REQUIRED TO GAIN ACCESS TO DRILL STRAIGHT HOLES THROUGH THE DRAG ANGLE AND BEAM, REMOVE L/H AND R/H ANGLES P/N 114S1964, THAT ATTACH THE FAIRING ASSEMBLY P/N 145S1905 TO THE CROWN SKIN. (4) TO GAIN ACCESS TO THE FIRST FOUR HI-LOKS STARTING AT STATION 83, REMOVE THE SKIN ATTACHING RIVETS FAR ENOUGH FORWARD TO ALLOW THE CROWN SKIN FAIRING, P/N 114S1602, TO BE RAISED AWAY FROM THE WORK AREA. (5) REMOVE THE DEFECTIVE HI-LOKS PER TM 55-1500-204-25/1. (6) MEASURE THE HOLE AND DETERMINE THE HOLE CONDITION AND SIZE. THE ORIGINAL HOLE WAS A NO. 6 (.1895-.1905) HOLE. THE ORIGINAL HI-LOK USED WAS A HL18P86 WITH A HL79-6 COLLAR. IF THE HOLE IS DAMAGED OR IS THE WRONG SIZE, USE THE FOLLOWING CHART TO DETERMINE THE NEXT OVERSIZE HOLE AND FASTENER TO USE. NOMINAL HOLE SIZES FOR OVERSIZE HI-LOKS 1/64 1/32 1/4 CLOSE .2036 .2192 .2505 REAM .2026 .2182 .2495 . UNCLAS 08 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES REPLACEMENT RIVETS (OVERSIZE) 1/64 1/32 1/4 NO. PER ACFT HL62PB6-3 HL218-6-3 HL18PB8-3 7 HL62PB6-4 HL218-6-4 HL18PB8-4 1 HL62PB6-5 HL218-6-5 HL18PB8-5 17 HL62PB6-6 HL218-6-6 HL18PB8-6 1 HL62PB6-7 HL218-6-7 HL18PB8-7 1 HL62PB6-9 HL218-6-9 HL18PB8-9 1 REPLACEMENT COLLARS (OVERSIZE) 1/64 1/32 1/4 NO. PER ACFT HL79-6 HL84-6 HL79-8 28 NOTE DUE TO TOLERANCE BUILD-UP, FASTENER LENGTHS MAY VARY FROM THOSE NOTED ABOVE. (7) INSTALL REPLACEMENT HI-LOKS PER TM 55-1500-204-25/1. MAKE CERTAIN THAT ALL HOLES ARE REAMED TO THE CORRECT SIZE AND DEBURRED, TREATED AND PRIMED. (8) INSTALL L/H AND R/H ANGLES P/N 114S1964 USING MS20470AD4 AND MS20470DD6 RIVETS PER TM 55-1500-204-25/1. . UNCLAS 09 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES (9) RE-ATTACH THE CROWN SKIN FAIRING P/N 114S1602 USING MS20470AD4 AND MS20470AD5 RIVETS PER TM 55-1500-204-25/1. (10) INSTALL THE L/H AND R/H FAIRING ASSEMBLIES, P/N 145S1905-1 AND -2 USING MS7885/2-4, M7885/2-5, AND MS20470AD4 RIVETS PER TM 55-1500-204-25/1. (11) RE-ATTACH THE FORWARD L/H AND R/H WORK PLATFORMS PER TM 55-1520-240-23-2. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 10C WILL BE FURNISHED BY REPAIR TEAM. B. REQUISITIONING INSTRUCTIONS - N/A. C. BULK AND CONSUMABLE MATERIALS - NOMENCLATURE PART NUMBER NSN RIVET HL62PB-3 5320-01-043-0071 RIVET HL62PB-4 5320-00-457-1331 RIVET HL62PB-5 5320-00-613-0473 RIVET HL62PB-6 5320-00-899-4662 RIVET HL62PB-7 5320-01-099-1008 RIVET HL62PB-9 5320-01-108-7651 RIVET HL218-6-3 5306-00-522-1814 . UNCLAS 10 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES RIVET HL218-6-4 5320-00-494-7983 RIVET HL218-6-5 5306-00-410-1749 RIVET HL218-6-6 5320-01-100-8824 RIVET HL218-6-7 5306-00-494-7985 RIVET HL218-6-9 5320-00-395-6421 RIVET HL18PB8-3 5320-00-813-3920 RIVET HL18PB8-4 5320-00-959-0215 RIVET HL18PB8-5 5320-00-959-0201 RIVET HL18PB8-6 5320-00-959-0200 RIVET HL18PB8-7 5320-00-915-4973 RIVET HL18PB8-9 5320-00-959-0204 COLLAR HL79-6 5320-00-968-9212 COLLAR HL84-6 5320-00-457-1332 COLLAR HL79-8 5320-00-968-9210 PROSEAL 890 N/A 1520-00-080-1549 D. DISPOSITION - DISPOSE OF REMOVED PARTS/COMPONENTS IN ACCORDANCE WITH NORMAL SUPPLY PROCEDURES. E. DISPOSITION OF HAZARDOUS MATERIAL - N/A. 11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A. 12. APPLICATION - . UNCLAS 11 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES A. CATEGORY OF MAINTENANCE - DEPOT OR CONTRACTOR TEAM. AIRCRAFT DOWNTIME WILL BE CHARGED TO DEPOT MAINTENANCE. B. TIME REQUIRED - (1) TOTAL OF 50 MANHOURS USING 2 PERSONS. (2) TOTAL OF 25 HOURS DOWNTIME FOR ONE END ITEM. C. ESTIMATED COST IMPACT OF STOCK FUND ITEMS TO THE FIELD - N/A. 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. TM 55-1500-204-25/1, GENERAL AIRCRAFT MAINTENANCE MANUAL, DATED APRIL 1970, C37 15 SEP 1988. B. TM 55-1520-240-23-2, AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL, CH-47D HELICOPTER, DATED 10 MAY 1983, C11 9 OCT 1990. 14. RECORDING AND REPORTING REQUIREMENTS - A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13 ON ALL . UNCLAS 12 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES SUBJECT MDS AIRCRAFT, FORWARD A PRIORITY MESSAGE, DATAFAX OR E-MAIL TO COMMANDER, AVSCOM, ATTN AMSAV-XSOF (SOF COMPLIANCE OFFICER), PER AR 95-3. DATAFAX NUMBER IS DSN 693-2064 OR COMMERCIAL 314/263-2064. E-MAIL ADDRESS IS "AMSAVXSOF (AT SIGN) ST-LOUIS-EMH4.ARMY.MIL". THE REPORT WILL CITE THIS MESSAGE NUMBER, DATE OF ENTRY IN DA FORM 2408-13, THE AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF AIRCRAFT IN NUMERICAL ORDER. B. TASK/INSPECTION REPORTING SUSPENSE DATE (AIRCRAFT) - N/A. 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 JAN 88 - (1) DA FORM 2408-13, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (2) DA FORM 2408-14, UNCORRECTED FAULT RECORD. (3) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT. (4) SF 368, CATEGORY II QUALITY DEFECIENCY REPORT. 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - . UNCLAS 13 13 162030Z JUN 92 PP PP UUUU ZEXW 1681600Z YES A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. EMANUAL BUELTER, SFAE-AV-CH-T, DSN 693-1639 OR COMMERCIAL 314/263-1639. B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. STEVE KOUCHNERKAVICH, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL 314/263-1415. C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MR. ROGER BARRE/MR. JOHN ZUBER, AMSAV-MPPD, DSN 693-1955 OR COMMERCIAL 314/263-1955. D. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. BRAD MEYER, AMSAV-XSOF, DSN 693-9089 OR COMMERCIAL 314/263-9089. E. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT MW4 JAY NANCE/MR. RON VAN REES, AMSAV-I, DSN 693-3826 OR COMMERCIAL 314/263-3826. F. AFTER HOURS CONTACT AVSCOM COMMAND OPERATIONS CENTER (COC) DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.