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.