SYNOPSIS CH-47-93-ASAM-02 AVIATION SAFETY ACTION MESSAGE, ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, INSPECTION HI-LOK FASTENERS AT FUSELAGE STATION 83 TO 120, (TB 1-1520-240-20-64). 021600Z MAR 93, BRAD MEYER, AMSAT-C-XS, X2085. NOTE: Enter a "Q" + <CR> to exit or <SPACEBAR> to view the entire message. (NON-REPORTING) . 01 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES CDRATCOM ST LOUIS MO //AMSAT-C-XS// AIG 6713 AIG 9004 AIG 8708 AIG 9042 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// CDR4THBN228THAVN SOTO CANO HO //AVN-AMO// CDR160TH SOAR FT CAMPBELL KY //AOAV-SI// CDRBGAD RICHMOND KY //SDSBG-GC// CHMUSLO RABAT MO //AF// CHUSAS RIYADH SA //ASAV// CF: SFAE-AV-CH, AMSAT-R-ECC, AMSAV-I-RAAF, AMSAV-MEA, AMSAV-L-AOC BRAD MEYER AMSAT-C-XS, X2085 MINIMIZE CONSIDERED EDWARD J. HOLLMAN CHIEF, SAFETY OFFICE . UNCLAS 02 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES ODC MADRID SP //ARMY AND NAVY SEC// CJUSMAG BANGKOK TH CDRUSARDSG LONDON UK //AMXSN-UK-SE// INFO CDR AMCCOM ROCK ISLAND IL //AMSAR-QAS-P// 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 . UNCLAS 03 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, INSPECTION OF HI-LOK FASTENERS AT FUSELAGE STATION 83 TO 120, (CH-47-93-ASAM-02) (TB 1-1520-240-20-64) 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 RETRANSMISSION TO COMMANDER, ATCOM, ATTN - AMSAT-C-XS (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 INSPECTION OF PARA 8 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 . UNCLAS 04 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES 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 UNTIL COMPLIANCE WITH THIS ASAM HAS BEEN COMPLETED. C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A. D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - SAME AS PARA 1A. (2) FERRY STATUS - SAME AS PARA 1A. E. MAINTENANCE TRAINERS (CATEGORY A, B AND C) - N/A. 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. 3. REPORTING COMPLIANCE SUSPENSE DATE - N/A. 4. SUMMARY OF PROBLEM - A. CH-47-92-ASAM-05 REQUIRED REPLACEMENT OF HI-LOK FASTENERS DUE TO OVERSIZE HOLES AND IMPROPER DEBURRING DURING PRODUCTION. THIS REPLACEMENT WAS NOT COMPLETED BECAUSE OF A SHORTAGE IN REPLACEMENT HI-LOK FASTENERS. SEVERAL WAIVERS WERE GRANTED . UNCLAS 05 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES PROVIDING INTERIM INSTRUCTIONS. THIS MESSAGE PROVIDES CRITERIA FOR CORRECTING LOOSE FASTENERS AND REQUIRES A RECURRING INSPECTION AT EACH PHASE INSPECTION. B. THE PURPOSE OF THIS MESSAGE IS TO: (1) RESCIND CH-47-92-ASAM-05 AND RELATED WAIVERS. (2) INSPECT THE SUBJECT HI-LOKS FOR LOOSENESS AND MAKE NECESSARY CORRECTIONS. (3) REMIND UNITS OF THE INSPECTION REQUIREMENT FOR LOOSE FASTENERS AT EACH PHASE INSPECTION. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D AND MH-47E AIRCRAFT. 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 - NOTE UNITS ARE REMINDED TO INSPECT FOR LOOSE FASTENERS/RIVETS AT EACH PHASE INSPECTION PER TM 55-1520-240-PM, PAGE 2-43, CHANGE 3, . UNCLAS 06 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES INSPECTION REQUIREMENT 7.22.1. A. INSPECT HI-LOK FASTENERS LOCATED IN THE FORWARD TRANSMISSION TORQUE BOX, BLL 18 AND BLR 18, STATION 83 TO 120, WL 52 FOR LOOSENESS. THE ROWS OF HI-LOKS ARE INBOARD AND ONE TO FOUR INCHES BELOW THE WORK PLATFORMS. IF YOU HAVE DIFFICULTY LOCATING THESE FASTENERS, CONTACT YOUR LOCAL LOGISTICS ASSISTANCE REPRESENTATIVE (LAR). B. IF NO LOOSE FASTENERS ARE FOUND, NO FURTHER ACTION IS REQUIRED. C. LOOSE FASTENERS AT LOCATIONS WHERE WASHERS WERE PREVIOUSLY INSTALLED MUST BE REPLACED PER PARA 9. D. LOOSE FASTENERS THAT CAN BE TURNED BY HAND, HAVE CLEARANCE BETWEEN THE HI-LOK AND THE STRUCTURE OR SHOW EVIDENCE OF TURNING, PROCEED AS FOLLOWS: (1) REMOVE COLLAR FROM LOOSE HI-LOK BEING CAREFUL THAT HI-LOK PIN REMAINS IN THE STRUCTURE. (2) CHECK HOLE FOR ELONGATION/OVERSIZE AND CRACKS AROUND THE EDGE OF THE HOLE. IF THE HOLE IS ELONGATED/OVERSIZE, OR THERE ARE CRACKS AROUND THE EDGE OF THE HOLE, REPLACE THE FASTENER PER . UNCLAS 07 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES PARA 9. (3) IF THERE ARE NO CRACKS AND THE FASTENER HOLE IS NOT ELONGATED/OVERSIZE, CHECK PROTRUSION OF THE HI-LOK PIN GRIP THROUGH THE STRUCTURE. IF THE PROTRUDING GRIP IS GREATER THAN 0.050 INCHES, INSTALL A AN960JD10 WASHER AND A HL70-6 COLLAR ON THE EXISTING HI-LOK PIN. IF THE PROTRUDING GRIP IS LESS THAN 0.050 INCHES, INSTALL A AN960JD10LL WASHER AND A HL70-6 COLLAR. 9. CORRECTION PROCEDURES - IF THERE ARE LOOSE FASTENERS AT LOCATIONS WHERE WASHERS WERE PREVIOUSLY INSTALLED, OR IF THERE IS EVIDENCE OF ELONGATED/OVERSIZE HOLES OR CRACKS AROUND THE EDGE OF THE HOLE, REPLACE THE FASTENER AS FOLLOWS: (1) 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 FASTNERS FROM SKINS ABOVE THE COMPARTMENTS, COVER THE COMPARTMENT WITH SUITABLE COVERING IN ACCORDANCE WITH CURRENT FOREIGN OBJECT DAMAGE (FOD) PRACTICES. . UNCLAS 08 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES (2) THE FOLLOWING STEPS PROVIDE INSTRUCTIONS FOR REMOVAL OF ALL SKINS AND PANELS TO GAIN ACCESS TO THE SUBJECT HI-LOK FASTENERS. (A) REMOVE THE FORWARD L/H AND R/H WORK PLATFORMS PER TM 55-1520-240-23-2. (B) REMOVE FAIRING ASSEMBLIES, P/N 145S1905-1 AND -2 PER TM 1-1500-204-23-(SERIES). THESE FAIRINGS ARE LOCATED BELOW THE WORK PLATFORMS AND MATE THE FUSELAGE TO THE PYLON. (C) 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. (D) TO GAIN ACCESS TO THE FIRST FOUR HI-LOKS STARTING AT STATION 83, REMOVE THE SKIN ATTACHING FASTENERS FAR ENOUGH FORWARD TO ALLOW THE CROWN SKIN FAIRING, P/N 114S1602, TO BE RAISED AWAY FROM THE WORK AREA. (E) REMOVE THE DEFECTIVE HI-LOKS PER TM 1-1500-204-23-(SERIES). . UNCLAS 09 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES (F) 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. HOLE SIZES FOR OVERSIZE HI-LOKS 1/64 1/32 1/4 MAX .2036 .2192 .2505 MIN .2026 .2182 .2495 REPLACEMENT HI-LOKS (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 . UNCLAS 10 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES 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. (G) INSTALL REPLACEMENT HI-LOKS PER TM 1-1500-204-23-(SERIES). MAKE CERTAIN THAT ALL HOLES ARE REAMED TO THE CORRECT SIZE AND DEBURRED, TREATED AND PRIMED. (H) INSTALL L/H AND R/H ANGLES P/N 114S1964 USING MS20470AD4 AND MS20470E6 OR MS20470DD6 RIVETS PER TM 1-1500-204-23-(SERIES). (I) RE-ATTACH THE CROWN SKIN FAIRING P/N 114S1602 USING MS20470AD4 AND MS20470AD5 RIVETS PER TM 1-1500-204-23-(SERIES). (J) 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 1-1500-204-23-(SERIES). (K) RE-ATTACH THE FORWARD L/H AND R/H WORK PLATFORMS PER TM 55-1520-240-23-2. . UNCLAS 11 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES (L) REINSTALL FORWARD TRANSMISSION DRIP PAN PER TM 55-1520-240-23-2. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 10C WILL BE FURNISHED BY BOEING HELICOPTERS. B. REQUISITIONING INSTRUCTIONS - ORDER FASTENERS FROM MR. JERRY MAYBERRY, TELEPHONE (215) 591-7719. C. BULK AND CONSUMABLE MATERIALS NOMENCLATURE PART NUMBER NSN HI-LOK HL62PB-3 5320-01-043-0071 HI-LOK HL62PB-4 5320-00-457-1331 HI-LOK HL62PB-5 5320-00-613-0473 HI-LOK HL62PB-6 5320-00-899-4662 HI-LOK HL62PB-7 5320-01-099-1008 HI-LOK HL62PB-9 5320-01-108-7651 HI-LOK HL218-6-3 5306-00-522-1814 HI-LOK HL218-6-4 5320-00-494-7983 HI-LOK HL218-6-5 5306-00-410-1749 HI-LOK HL218-6-6 5320-01-100-8824 HI-LOK HL218-6-7 5306-00-494-7985 . UNCLAS 12 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES HI-LOK HL218-6-9 5320-00-395-6421 HI-LOK HL18PB8-3 5320-00-813-3920 HI-LOK HL18PB8-4 5320-00-959-0215 HI-LOK HL18PB8-5 5320-00-959-0201 HI-LOK HL18PB8-6 5320-00-959-0200 HI-LOK HL18PB8-7 5320-00-915-4973 HI-LOK 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 SEALANT PROSEAL 890 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 - A. CATEGORY OF MAINTENANCE - AVIM. AIRCRAFT DOWNTIME WILL BE CHARGED TO AVIM. B. TIME REQUIRED - . UNCLAS 13 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES (1) INSPECTION - A. TOTAL OF 1 MANHOUR USING 1 PERSON. B. TOTAL OF 1 HOUR DOWNTIME FOR ONE END ITEM. (2) REPLACEMENT - A. TOTAL OF 50 MANHOURS USING 2 PERSONS. B. 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 - TM 55-1520-240-23-2 SHALL BE CHANGED TO REFLECT THE INFORMATION IN THIS MESSAGE. A COPY OF THIS MESSAGE SHALL BE INSERTED IN THE APPROPRIATE TM AS AUTHORITY TO IMPLEMENT THE CHANGE UNTIL THE PRINTED CHANGE IS RECEIVED. 13. REFERENCES - A. TM 1-1500-204-23-(SERIES), GENERAL AIRCRAFT MAINTENANCE MANUAL, DTD 31 JUL 92. (THIS MANUAL SUPERCEDED TM 55-1500-204-25/1. TM 55-1500-204-25/1 MAY BE USED FOR THIS MESSAGE . UNCLAS 14 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES IF TM 1-100-204-23-(SERIES) IS NOT AVAILABLE.) B. TM 55-1520-240-23-2, AVIATION UNIT AND AVIATION INTERMEDIATE MAINTENANCE MANUAL, CH-47D HELICOPTER, DTD 10 MAY 83, C12 4 JUN 92. C. TM 55-1520-240-PM, CH-47D HELICOPTER PHASED MAINTENANCE CHECKLIST, DTD 18 OCT 90, C3 11 DEC 92. 14. RECORDING AND REPORTING REQUIREMENTS - A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - N/A 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 92 - (1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD, IF NEEDED. (3) DA FORM 2408-13-2, RELATED MAINTENANCE ACTIONS RECORD, IF NEEDED. (4) DA FORM 2408-13-3, AIRCRAFT TECHNICAL INSPECTION WORKSHEET, IF NEEDED. . UNCLAS 15 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z YES (5) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT. 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. EMANUEL BUELTER, SFAE-AV-CH-T, DSN 693-3820 OR COMMERCIAL 314/263-3820. 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. BILL WALDROP, AMSAT-I-MDM, DSN 693-1821/1955 OR COMMERCIAL 314/263-1821/1955. D. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. BRAD MEYER, AMSAT-C-XS, DSN 693-2085 OR COMMERCIAL 314/263-2085. 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.