01 16 101555Z OCT 96 PP PP UUUU FROM :CDRATCOM ST LOUIS MO//AMSAT-R-X// TO :AIG 8881 :AIG 9004 :AIG 8708 :AIG 9042 :AIG 7471 :AIG 12124 :USMILGP BUENOS AIRES AR//ARMY AND AF SEC// :DEFAIR MATERIAL CANBERRA AS//DAAP-AF// :ARMYLMSQN OAKEY AS :AVN REGT HQ SQN OAKEY AS//DAVN-A// :CDRUSARDSG CANBERRA AS//AMXIP-AS// :LOGCON OTTAWA CAN//DTHEM 6-2// :ARGENTINE AIR ATTACHE FMS WASHINGTON DC :EGYPT AF FMS CAIRO EG//ED/MA// :USOMC CAIRO EG//AV// :ODC ATHENS GR//ODCSA// :CHJUSMAG SEOUL KOR//MKAR-AV// :ROK ARMY FMS PUSAN KOR//ALC-LSD-L// :CDR160TH SOAR FT CAMPBELL KY//AOAV-SI// :CDRBGAD RICHMOND KY//SIOBG-GC// :USDAO RABAT MO//AF// :ODC THE HAGUE NL//AVIATION SAFETY// :RNLAF MATERIAL :RNLAF OPERATIONS :CDRUSASAC NEW CUMBERLAND PA//AMSAC-SALO-UK// :CHUSAS RIYADH SA//ASAV// :SAO SINGAPORE SN//AVIATION SAFETY// :ODC MADRID SP//ASM// :SPAIN ARMY FMS MADRID SP :AIT TAIPEI TW :TAIWAN ARMY FMS TAIPEI TW :CJUSMAG THAI BANGKOK TH//MAGTAR-FS// :ROYAL THAI ARMY FMS DUSIT ORDNANCE DEP BANGKOK TH :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK :DHSA YEOVILTON UK//HS-31// INFO :FAA SOUTHWEST RGN HQ FORT WORTH TX//ASW-100// :CDRAMC ALEXANDRIA VA//AMCMR/AMCCS/AMCSM-WAA// XMT :USDAO DHAKA BG :USDAO RANGOON BM :USCINCPAC REP PHNOM PENH CB :USDAO COLOMBO CE :USDAO SUVA FJ :OMADP JAKARTA ID :DSA NEW DELHI IN :AMEMBASSY ANTANANARIVO MA :AMEMBASSY PORT LOUIS :SAO KUALA LUMPUR MY :AMEMBASSY KATHMANDU NP//POL-MIL// :AMEMBASSY VICTORIA ACCT : TEXT :UNCLAS SUBJECT: AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT, ONE TIME RECORDS CHECK, VISUAL INSPECTION FOR, AND REMOVAL OF CERTAIN SERIAL NUMBERED 145D3400-23/-25/-32 FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLIES (CH-47-97-ASAM-01) (TB 1-1520-240-20-90) NOTE THIS IS AN AVIATION SAFETY ACTION MESSAGE (ASAM) ISSUED PER AR 95-3, CHAPTER 5 REVISION VIA MESSAGE, HQ AVSCOM, AMSAV-XSOF, 181900Z SEP 90, SUBJECT: CHANGE TO AR 95-3, CHAPTER 5, SAFETY OF FLIGHT MESSAGES. THIS ASAM 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 THIS MESSAGE. ACTION ADDRESSES WILL IMMEDIATELY VERIFY THIS TRANSMISSION TO COMMANDER, ATCOM, ATTN: AMSAT-R-X (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 REQUIREMENTS OF THIS ASAM MESSAGE WITHIN THE TIME FRAME REQUIRED WILL CAUSE THE STATUS SYMBOL TO BE UPGRADED TO A RED //X//. B. AIRCRAFT IN DEPOT MAINTENANCE - INSPECT AND CORRECT PRIOR TO ISSUE. AIRCRAFT SHALL NOT BE ISSUED UNTIL COMPLIANCE WITH THIS ASAM MESSAGE 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) - SAME AS PARA 1A. F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES - UPON RECEIPT OF THIS MESSAGE THE MATERIEL CONDITION TAGS OF ALL ITEMS LISTED IN PARA 6 BELOW IN ALL CONDITION CODES SHALL BE ANNOTATED TO READ CH-47-96-ASAM-XX, ONE TIME RECORDS CHECK, VISUAL INSPECTION OF FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLIES, NOT COMPLIED WITH. (1) WHOLESALE STOCK - REPORT RECEIPT OF THIS MESSAGE, IN ACCORDANCE WITH PARA 14C(1). UPON RECEIPT OF THIS MESSAGE ALL SERVICEABLE ITEMS(CONDITION CODES //A//,//B//,//C//,//D//, AND //E//) LISTED IN PARA 6 LOCATED IN WHOLESALE DEPOT STORAGE SHALL BE PLACED IN CONDITION CODE //J// AND TAGGED WITH A SUSPENDED TAG/LABEL - MATERIEL, DD FORM 1576/ DD FORM 1576-1. DO NOT REMOVE ORIGINAL CONDITION TAGS. REPORT COMPLIANCE WITH THIS MESSAGE IN ACCORDANCE WITH PARA 14D(1). (2) RETAIL STOCK - REPORT RECEIPT OF THIS MESSAGE IN ACCORDANCE WITH PARA 14C(2). UPON RECEIPT OF THIS MESSAGE COMMANDERS AND OTHERS MAINTAINING RETAIL STOCK AT INSTALLATION LEVEL AND BELOW SHALL CONTACT THE SUPPORTED AVIATION UNIT TO PERFORM THE INSPECTION REQUIRED BY PARA 8 BELOW AND THE CORRECTION PROCEDURES OF PARA 9 ON DISCREPANT MATERIEL. DISPOSITION OF DISCREPANT MATERIEL WILL BE IN ACCORDANCE WITH PARA 10. REPORT COMPLIANCE WITH THIS MESSAGE IN ACCORDANCE WITH PARA 14D(2). G. COMPONENTS/PARTS IN WORK - ALL ITEMS LISTED IN PARA 6 BELOW SHALL NOT BE ISSUED UNTIL COMPLIANCE WITH THIS ASAM MESSAGE HAS BEEN COMPLETED. 2. TASK/INSPECTION SUSPENSE DATE - WITHIN 10 FLIGHT HOURS OR 14 DAYS, WHICHEVER OCCURS FIRST. 3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 01 NOV 1996 PER PARA 14A OF THIS MESSAGE. 4. SUMMARY OF PROBLEM - A. CORPUS CHRISTI ARMY DEPOT (CCAD) HAS ANNOUNCED A RECALL DUE TO A PROCESS DEVIATION CONCERNING REWORK PROCEDURES AND THE ASSEMBLY OF THE RETAINER ASSEMBLY TO SOME 145D3400-23/-25/-32 FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLIES. B. FOR A LIMITED PERIOD OF TIME, THE TEFLON INSERTS WERE ERRONEOUSLY BEING REMOVED FROM THE RETAINER ASSEMBLY (PART NUMBER 114D3207-3, NSN 1615-00-066-0285) PRIOR TO INSTALLATION TO THE FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY. C. A TOTAL OF 27 FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLIES ARE SUSPECT. OF THESE, 16 WERE LOCATED LOCALLY AT CCAD AND HAVE BEEN REWORKED TO CONFORM TO THE CORRECT TECHNICAL CRITERIA. THE REMAINING 11 WERE REQUISITIONED AND ISSUED TO CH- 47D FIELD UNITS WORLD WIDE. D. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS, SEE PARA 12 BELOW E. THE PURPOSE OF THIS MESSAGE IS TO PERFORM A ONE TIME RECORDS CHECK, AND CONDUCT A VISUAL VERIFICATION INSPECTION OF ALL 145D3400-23/-25/-32 FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY IDENTIFICATION (DATA) PLATES FOR THE SUSPECT SERIAL NUMBERS LISTED IN PARA 8 BELOW. IF FOUND, THESE FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLIES ARE TO BE REMOVED FROM SERVICE AND RETURNED TO CCAD FOR REWORK AND RETURN SUPPLY. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN DRIVE SHAFT ASSY. 145D3400-23 1615-01-113-0248 DRIVE SHAFT ASSY. 145D3400-25 1615-01-113-0292 DRIVE SHAFT ASSY. 145D3400-32 1615-01-112-5897 7. PARTS TO BE INSPECTED - N/A. 8. INSPECTION PROCEDURES - A. PERFORM A ONE TIME RECORDS CHECK FOR THE FOLLOWING FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY SUSPECT SERIAL NUMBERS: (1) P/N 145D3400-23, NSN 1615-01-113-0248, SERIAL NUMBERS - A-2012 AND A-6334. (2) P/N 145D3400-25, NSN 1615-01-113-0292, SERIAL NUMBER - A-4906. (3) P/N 145D3400-32, NSN 1615-01-112-5897 SERIAL NUMBERS - A-283 A-6292 A-8302 A-2142 A-6922 A-8386 A-3352 A-7044 B. IF THE RECORDS CHECK IS INCONCLUSIVE OR IDENTIFIES A SUSPECT SERIAL NUMBER, PERFORM A VISUAL INSPECTION OF THE COMPONENT IDENTIFICATION (DATA) PLATES AS FOLLOWS - (1) PREPARE THE AIRCRAFT FOR SAFE GROUND MAINTENANCE. (2) OPEN THE DRIVE SHAFT TUNNEL ACCESS COVERS. (REFER TO TM 55-1520-240-23 TASK 2-2 AND TM 1-1520-252-23 TASK 2-2). (3) CHECK THE FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY DATA PLATES FOR ANY OF THE ABOVE SUSPECT SERIAL NUMBERS. C. IF ANY OF THE DRIVE SHAFTS SERIAL NUMBERS ARE IN THE ABOVE LIST OF SUSPECT SERIAL NUMBERS, CALL THE ATCOM LOGISTICAL POINT OF CONTACT (PARA 16C BELOW) FOR DISPOSITION INSTRUCTIONS BEFORE PROCEEDING TO PARA 9 BELOW FOR CORRECTIVE PROCEDURES. D. IF THE DRIVE SHAFTS SERIAL NUMBERS ARE NOT IN THE ABOVE LIST OF SUSPECT SERIAL NUMBERS, NO FURTHER ACTION IS REQUIRED. CLOSE THE DRIVE SHAFT TUNNEL COVERS, AND RECORD AND REPORT COMPLIANCE WITH THIS ASAM IN ACCORDANCE WITH PARA 14 BELOW. 9. CORRECTION PROCEDURES - A. REMOVE THE SUSPECT FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY. (REFER TO TM 55-1520-240-23 TASKS 6-2 THROUGH 6-4, AND TM 1-1520-252-23 TASKS 6-2 THROUGH 6-4 AS APPLICABLE). B. RETURN THE SUSPECT FORWARD DRIVE SHAFT ASSEMBLY TO CCAD IAW THE DISPOSITION INSTRUCTIONS IN PARA 10D BELOW. C. REINSTALL A FORWARD SYNCHRONIZING DRIVE SHAFT ASSEMBLY. (REFER TO TM 55-1520-240-23 TASKS 6-17 THROUGH 6-19 AND TM 1-1520- 252-23 TASKS 6-18 THROUGH 6-20 AS APPLICABLE). D. CLOSE THE DRIVE SHAFT TUNNEL ACCESS COVERS. (REFER TO TM 55-1520-240-23 TASK 2-2 AND TM 1-1520-252-23 TASK 2-2). E PERFORM GROUND RUN. (REFER TO TM 55-1520-240-10/TM 1- 1520-252-10). 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - CCAD WILL REWORK DISCREPANT DRIVE SHAFT ASSEMBLIES. THE ATCOM LOGISTICAL POC FOR THIS RECALL IS DELINEATED IN PARA 16C BELOW. B. REQUISITIONING INSTRUCTIONS - WHEN A SUSPECT SHAFT LISTED IN PARA 8A IS FOUND, CONTACT THE ATCOM POC (PARA 16C) FOR REQUISITION INSTRUCTIONS. THE UNIT CAN CONTINUE TO FLY FOR UP TO FIVE DAYS, UNTIL RECEIPT OF A NEW DRIVE SHAFT WHICHEVER OCCURS FIRST. THE UNIT WILL PROVIDE SHIPPING INFORMATION TO ATCOM AND RECEIVE 100 PERCENT CREDIT FOR THE DRIVE SHAFT. UPON RECEIPT OF THE REPLACEMENT DRIVE SHAFT, THE UNIT WILL CHANGE IT IMMEDIATELY. C. BULK AND CONSUMABLE MATERIALS - N/A. D. DISPOSITION - RETURN DISCREPANT DRIVE SHAFT ASSEMBLIES IAW THE INSTRUCTIONS OF THE ATCOM LOGISTICAL POC (PARA 16C BELOW). UNIT SHALL IDENTIFY A LOCAL POC FOR THIS EFFORT TO THE ABOVE POC. COMMANDER, CORPUS CHRISTI ARMY DEPOT (CCAD) ATTN: SIOSS-QP-RA CORPUS CHRISTI, TEXAS 78419-5260 E. DISPOSITION OF HAZARDOUS MATERIAL - N/A. 11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A. 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AVUM. AIRCRAFT DOWNTIME WILL BE CHARGED TO AVUM. B. ESTIMATED TIME REQUIRED - (1) TOTAL OF 0.5 MAN-HOURS USING 1 PERSON TO PERFORM THE RECORDS CHECK. (2) TOTAL OF 0.5 HOURS DOWNTIME FOR ONE END ITEM. (3) TOTAL OF 3 MAN-HOURS USING 1 PERSON TO REPLACE A SUSPECT DRIVE SHAFT. 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. TM55-1520-240-10. B. TM1-1520-252-10. C. TM 55-1520-240-23. D. TM 1-1520-252-23. 14. RECORDING AND REPORTING REQUIREMENTS - A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 ON ALL SUBJECT MDS AIRCRAFT, FORWARD A PRIORITY MESSAGE, DATAFAX OR E- MAIL TO COMMANDER, ATCOM, ATTN: AMSAT-R-X (SOF COMPLIANCE OFFICER), PER AR 95-3. DATAFAX NUMBER IS DSN 693-2064 OR COMMERCIAL (314) 263-2064. E-MAIL ADDRESS IS "AMSATRXS (AT SIGN) EMH4.STL.ARMY.MIL". THE REPORT WILL CITE THIS ASAM MESSAGE NUMBER, DATE OF ENTRY IN DA FORM 2408-13-1, THE AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF AIRCRAFT IN NUMERICAL ORDER. B. TASK/INSPECTION REPORTING SUSPENSE DATE (AIRCRAFT) - FOR AIRCRAFT WHICH REQUIRED DISCREPANT DRIVE SHAFT REPLACEMENT, UNITS WILL CALL THE LOGISTICAL POC IN PARA 16C WITH THE SERIAL NUMBER OF THE SUSPECT SHAFT. INSPECTION NOTIFICATION WILL BE COMPLETED NO LATER THAN 20 DAYS AFTER TASK/INSPECTION SUSPENSE DATE. C. REPORTING MESSAGE RECEIPT (SPARES) - (1) MATERIEL IN RETAIL STORAGE - REPORT RECEIPT OF THIS MESSAGE BY E-MAIL OR DATA FAX TO THE ATCOM LOGISTICAL POC (PARA 16C BELOW) WITHIN 7 DAYS FROM THE DATE OF THIS MESSAGE. (2) MATERIEL IN WHOLESALE DEPOT STORAGE - REPORT RECEIPT OF THIS MESSAGE BY E-MAIL OR DATAFAX TO THE WHOLESALE MATERIEL (SPARES) POINT OF CONTACT LISTED IN PARA 16D WITHIN 3 WORKING DAYS FROM THE DATE OF THIS MESSAGE. PROVIDE LOCAL POINT OF CONTACT. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - (1) MATERIAL IN WHOLESALE DEPOT STORAGE - REPORT COMPLIANCE WITH THIS MESSAGE TO THE WHOLESALE MATERIEL POINT OF CONTACT (SPARES) LISTED IN PARA 16D WITHIN 7 DAYS OF THE DATE OF THIS MESSAGE. INCLUDE AN ESTIMATE OF THE COST REIMBURSABLE FUNDING REQUIRED TO MOVE SERVICEABLE ITEMS ON HAND LISTED IN PARA 6 TO A WORK AREA, UNPACK THE MATERIEL, REPACK THE MATERIEL AFTER INSPECTION BY ATCOM INSPECTORS, AND TO RETURN THE MATERIEL TO STORAGE. REPORT, BY ORIGINAL SERVICEABLE CONDITION CODE, THE QUANTITY OF MATERIEL PLACED IN CONDITION J. REPORT BY E-MAIL OR DATAFAX AND PROVIDE LOCAL POINT OF CONTACT. (2) MATERIAL IN RETAIL STORAGE - REPORT COMPLIANCE WITH THIS MESSAGE BY E-MAIL OR DATA FAX TO THE ATCOM LOGISTICAL POC (PARA 16C BELOW) WITHIN 5 WORKING DAYS FROM THE DATE OF THIS MESSAGE. REPORT THE SERIAL NUMBERS OF ALL MATERIEL REQUIRING CORRECTION. PLACE THESE ITEMS IN CONDITION CODE //D// AND PROVIDE COPIES OF SHIPPING DOCUMENTS TO WHOLESALE MATERIEL POC (PARA 16D BELOW). . E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED IN ACCORDANCE WITH DA PAM 738-751, 15 JUN 92 - (1) DA FORM 2408-5-1, EQUIPMENT MODIFICATION RECORD (FORWARD SYNCHRONIZING DRIVE SHAFT) (2) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (3) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (4) DA FORM 2408-16, AIRCRAFT COMPONENT HISTORICAL RECORD. (5) DA FORM 2410, COMPONENT REMOVAL AND REPAIR/OVERHAUL RECORD. (6) DD FORM 1574 (YELLOW TAG) FOR IN STOCK ITEMS THAT ARE DETERMINED TO BE SERVICEABLE. (MARK INSPECTED SERVICEABLE IN ACCORDANCE WITH THIS ASAM). (7) DD FORM 1575 (BROWN TAG) FOR IN STOCK ITEMS IN SUSPENDED STATUS AWAITING INSPECTION. (MARK SUSPENDED IN ACCORDANCE WITH THIS ASAM). (8) DD FORM 1577-2 (GREEN TAG) UNSERVICEABLE (REPARABLE) FOR IN STOCK ITEMS THAT ARE DETERMINED TO BE REPARABLE. (MARK UNSERVICEABLE IN ACCORDANCE WITH THIS ASAM). 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR.LARRY WIESCHHAUS, AMSAT-R-ECC, DSN 693-6678 OR COMMERCIAL 314/263-6678. B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE AT CCAD IS MR. WAYNE SYKORA, SIOCC-QP-RA, DSN 861-3478/2587/3872 OR COMMERCIAL 512/939-3478/2587/3872. DATA FAX EXTENSION IS 4578. C. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE AT ATCOM IS MR. MIKE MELLIERE, AMCPM-CH-L, DSN 693-1901 OR COMMERCIAL 314/263- 1901. DATA FAX EXTENSION IS 1485. D. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) FOR THIS MESSAGE IS MR. EDWARD HOLTER, AMSAT-I-SACE, DSN 693-6015 OR COMMERCIAL 314/263-6015. DATA FAX EXTENSION IS 7569. E. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAT-I-MDM, DSN 490-2318 OR COMMERCIAL 314/260- 2318. F. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. JIM WILKENS, AMSAT-R-X, DSN 693-2258 OR COMMERCIAL 314/263-2258. G. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT CW5 J NANCE OR MR. RON VAN REES, AMSAT-D-S, DSN 693-7844/3216 OR COMMERCIAL 314/263-7844/3216. ST. LOUIS IS GREENWICH MEAN TIME MINUS 6 HOURS. H. AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER (COC), DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.