01 15 131508Z MAR 97 PP PP UUUU AA ZYUW ZW 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// :CDRUSARDSG CANBERRA AS//AMXIP-AS// :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 BANGKOK TH//BANGSUE DEPOT// :ROYAL THAI AF FMS BANGKOK TH//DUSIT ORDANCE DEPOT// :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK 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// ACCT : TEXT :UNCLAS SUBJECT: AVIATION SAFETY ACTION MESSAGE (ASAM), MAINTENANCE MANDATORY, RCS CSGLD-1860(R1), ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT, ONE TIME INSPECTION FOR AND REPLACEMENT OF AN320-12 CASTELLATED NUTS MADE BY GREER STOP NUT INC. (CH-47-97-ASAM-05) (TB 1-1520-240-20-93). 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 ADDRESSEES 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 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 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 ASAM, THE MATERIEL CONDITION TAGS OF ALL ITEMS LISTED IN PARA 7 BELOW IN ALL CONDITION CODES SHALL BE ANNOTATED TO READ MESSAGE CH-47-97- ASAM-05, ONE TIME INSPECTION AND REPLACEMENT OF AN320-12 CASTELLATED NUTS MADE BY GREER STOP NUT INC. MUST BE COMPLIED WITH PRIOR TO ISSUE.. (1) WHOLESALE STOCK - UPON RECEIPT OF THIS ASAM, DEPOT COMMANDERS SHALL ENSURE INSPECTION OF ALL ITEMS LISTED IN PARA 7 BELOW LOCATED IN ALL WHOLESALE DEPOTS INCLUDING ALL SATELLITE WHOLESALE DEPOTS AND WAR RESERVE DEPOTS. UPON RECEIPT OF THIS ASAM COMMANDERS AND OTHERS MAINTAINING WHOLESALE STOCK SHALL ENSURE THAT SERVICEABLE MATERIEL (CONDITION CODES //A//, //B//, AND //C//) IS PLACED IN CONDITION CODE //J// AND TAGGED WITH A SUSPENDED TAG/LABEL - DD FORM 1576/1576-1. THE AUTHORITY BLOCK MUST REFERENCE INSPECTION REQUIRED PER THIS ASAM (TB 1-1520-240- 20-93). ANY NUTS FOUND DISCREPANT PER THE INSPECTION PROCEDURES CITED IN PARA 8 BELOW SHALL BE DISPOSED OF BY MUTILATION TO PREVENT RESALE, OR REUSE. (2) RETAIL STOCK - UPON RECEIPT OF THIS ASAM, COMMANDERS AND OTHERS MAINTAINING RETAIL STOCK OF ITEMS LISTED IN PARA 7 BELOW SHALL CONTACT THEIR SUPPORT AVIATION ORGANIZATION TO PERFORM THE INSPECTION REQUIRED BY PARA 8 BELOW AND TO PERFORM THE CORRECTION PROCEDURES OF PARA 9 BELOW ON DISCREPANT MATERIEL. ALL ITEMS LISTED IN PARA 7 BELOW SHALL BE IMMEDIATELY PLACED IN CONDITION CODE //D// AND RETAGGED WITH A TEST/MODIFICATION TAG/LABEL - DD FORM 1576/1576-1 (BLUE COLOR). THE AUTHORITY BLOCK MUST REFERENCE INSPECTION REQUIRED PER THIS ASAM (TB 1-1520-240- 20-93). ITEMS IDENTIFIED AS SERVICEABLE IAW PARA 8 BELOW SHALL BE RETAGGED WITH A SERVICEABLE TAG/LABEL - DD FORM 1574/1574-1 (YELLOW COLOR). INDICATE COMPLIANCE WITH THIS ASAM (TB 1-1520- 240-20-93) IN THE REMARKS BLOCK. ANY ITEMS FOUND DISCREPANT PER THE INSPECTION PROCEDURES CITED IN PARA 8 BELOW SHALL BE DISPOSED OF BY MUTILATION TO PREVENT RESALE, OR REUSE. REPORT COMPLIANCE WITH THIS ASAM IN ACCORDANCE WITH PARA 14D(2) BELOW. G. COMPONENTS/PARTS IN WORK - N/A. 2. TASK/INSPECTION SUSPENSE DATE - WITHIN 10 HOURS/14 DAYS. 3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 3 APR 1997 PER PARA 14A OF THIS MESSAGE. 4. SUMMARY OF PROBLEM - A. THERE HAVE BEEN THREE REPORTED INSTANCES OF AN320-12 CASTELLATED NUTS FOUND CRACKED. ONE DURING PRE-FLIGHT INSPECTION OF A CH-47D HELICOPTER WHERE A LAG DAMPER ATTACHMENT NUT AT THE ROTOR HEAD CONNECTION WAS FOUND CRACKED. THE SECOND DURING POST FLIGHT INSPECTION OF A MH-47E HELICOPTER. BOTH NUTS WERE FORWARDED TO CORPUS CHRISTI ARMY DEPOT (CCAD) FOR FAILURE ANALYSIS WHICH REVEALED THE NUTS WERE CRACKED AT THE MANUFACTURERS DESIGNATION (LOGO) IMPRESSION STAMP. THE DEFECTIVE NUTS WERE BOTH DOUBLE IMPRESSION STAMPED WITH THE LETTER CAPITAL G, WHICH IS THE REGISTERED LOGO OF GREER STOP NUT INC. (CAGE 27687). A THIRD INSTANCE INVOLVING A MH-47E HELICOPTER WAS VERY RECENTLY REPORTED AND IS BEING INVESTIGATED. B. THE CCAD FAILURE ANALYSES CONCLUDED THAT THERE WERE THREE CONTRIBUTING CAUSES OF FAILURE. THE DOUBLE STAMP IMPRESSION ON THE CRACKED NUTS AND THE EXCESSIVE DEPTH OF THE IMPRESSIONS PROVIDED AN AREA OF STRESS CONCENTRATION THAT ASSISTED IN THE CRACKING. THE TORQUE VALUE FOR THE NUT IN THE TMS WERE TOO HIGH IN THE DRIVE ARM ATTACHMENT INSTALLATION AND NEEDED TO BE LOWERED TO NOT TO EXCEED 3000 INCH-POUNDS. ALSO, THE GRAIN STRUCTURE CONTAINED ISLANDS OF PEARLITE AND FERRITE, BOTH OF WHICH ARE CHARACTERISTIC OF SOFT PHASES OF STEEL. THE NUTS SHOULD HAVE BEEN QUENCHED AND TEMPERED STEEL. C. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS, SEE PARA 12 BELOW. D. THE PURPOSE OF THIS ASAM MESSAGE IS TO INSPECT THE FORWARD AND AFT ROTOR SYSTEM AND CONTROLS INSTALLATIONS, AS DELINEATED IN PARA 8 BELOW, AND TO REPLACE AN320-12 CASTELLATED NUTS THAT EXHIBIT A LETTER CAPITAL G VENDOR IDENTIFICATION IMPRESSION STAMP. 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 ROTOR SYSTEM INSTL, 145R0002-SERIES N/A (XC) FORWARD AND AFT CONTROLS INSTL, 145R3550-SERIES N/A (XC) FORWARD AND AFT 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN NUT, THIN, PLAIN, AN320-12 5310-00-176-8115 CASTELLATED, SHEAR 8. INSPECTION PROCEDURES - A. PREPARE THE AIRCRAFT FOR SAFE GROUND MAINTENANCE. B. VISUALLY INSPECT THE FORWARD AND AFT ROTOR SYSTEM INSTALLATION AT THE LAG DAMPER (SHOCK ABSORBER) ATTACHMENTS (REFER TO TM 55-1520-240-23P-1, FIGURE 173, ITEM NO. 5 OR TM 1- 1520-252-23P-2, FIGURE 05-1, ITEM NO. 5) AND THE FORWARD AND AFT CONTROLS INSTALLATION AT DRIVE ARM ATTACHMENT TO THE DRIVE COLLAR (REFER TO TM55-1520-240-23P-1, FIGURE 177, ITEM NO. 41 OR TM1- 1520-252-23P-2, FIGURE 05-6, ITEM NO. 41), FOR AN320-12 CASTELLATED NUTS EXHIBITING THE LETTER CAPITAL G VENDOR IDENTIFICATION IMPRESSION STAMP. C. IF THE IMPRESSION STAMP IS ANYTHING OTHER THAN A CAPITAL G, OR THERE IS NONE, NO FURTHER ACTION IS REQUIRED. RECORD AND REPORT COMPLIANCE WITH THIS ASAM IN ACCORDANCE WITH PARA 14 BELOW. D. IF THE IMPRESSION STAMP IS THE LETTER CAPITAL G, PROCEED TO PARA 9 BELOW FOR CORRECTIVE ACTION. 9. CORRECTION PROCEDURES - A. REPLACE AN320-12 CASTELLATED NUTS EXHIBITING THE IMPRESSION STAMPED LETTER CAPITAL G, WHICH IS THE REGISTERED LOGO OF GREER STOP NUT INC. (CAGE 27687), WITH ANY OTHER MANUFACTURERS AN320-12 CASTELLATED NUT. B. ANY AN320-12 CASTELLATED NUTS IN SUPPLY WITH AN IMPRESSION STAMPED LETTER CAPITAL G WAS MANUFACTURED BY GREER STOP NUT INC. AND SHALL BE DISPOSED OF BY MUTILATION TO PREVENT RESALE, OR REUSE. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - ITEMS CITED IN PARA 7 ABOVE MAY BE REQUIRED TO REPLACE DEFECTIVE ITEMS. B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS THROUGH NORMAL SUPPLY CHANNELS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE PROJECT CODE XC6 PER THIS MESSAGE. (2) PROJECT CODE XC6 IS REQUIRED TO TRACK AND ESTABLISH A DATA BASE OF STOCK FUND EXPENDITURES INCURRED BY THE FIELD AS A RESULT OF SOF/ASAM ACTIONS. C. BULK AND CONSUMABLE MATERIALS - N/A. D. DISPOSITION - AFTER MUTILATION, DISPOSE OF REMOVED COMPONENTS/PARTS IAW NORMAL SUPPLY PROCEDURES. A QDR IS NOT REQUIRED. E. DISPOSITION OF HAZARDOUS MATERIAL - N/A. 11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A. 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AVUM. B. ESTIMATED TIME REQUIRED - (1) TOTAL OF 1 MAN-HOURS USING 1 PERSONS. C. ESTIMATED COST IMPACT OF STOCK FUND ITEMS TO THE FIELD - A TOTAL OF (8) P/N AN320-12 NSN 5310-00-176-8115 CASTELLATED NUTS ARE REQUIRED PER AIRCRAFT AT A COST OF $39.29 PER BAG OF (20). 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 - THE FOLLOWING PUBLICATIONS WERE PREVIOUSLY CHANGED TO INCORPORATE THE CORRECT TORQUE VALUES REFLECTED IN THIS ASAM - (1) TM 55-1520-240-23-5, CHAPTER 5, TASK 5-112. (2) TM 1-1520-252-23-5, CHAPTER 5, TASK 5-163. 13. REFERENCES - A. TM 55-1520-240-23-5. B. TM 1-1520-252-23-5. C. TM 55-1520-240-23P-1. D. TM1-1520-252-23P-2. 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 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) - N/A. C. REPORTING COMPLIANCE SUSPENSE DATE (SPARES) - N/A. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - (1). MATERIAL IN WHOLESALE DEPOT STORAGE- REPORT COMPLIANCE WITH THIS ASAM TO THE WHOLESALE MATERIEL POINT OF CONTACT (SPARES) LISTED IN PARA 16C WITHIN 5 WORKING DAYS FROM THE DATE OF THIS MESSAGE. PROVIDE AN ESTIMATE OF THE COST REIMBURSABLE FUNDING REQUIRED TO MOVE THE ITEMS LISTED IN PARA 7 ABOVE TO A WORK AREA, UNPACK THE MATERIEL, REPACK THE MATERIEL AFTER INSPECTION BY ATCOM INSPECTORS, AND TO RETURN THE MATERIEL TO STORAGE. REPORT BY E-MAIL OR DATA FAX AND PROVIDE LOCAL POINT OF CONTACT. (2) MATERIAL IN RETAIL STORAGE- REPORT COMPLIANCE WITH THIS MESSAGE BY E-MAIL OR DATA FAX AND PROVIDE LOCAL POINT OF CONTACT TO THE LOGISTICAL POINT OF CONTACT IN PARAGRAPH 16B WITHIN 5 WORKING DAYS FROM THE DATE OF THIS MESSAGE. REPORT THE QUANTITY INSPECTED BY CONDITION CODE, AND THE RESULTING CONDITION CODE. E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED IN ACCORDANCE WITH DA PAM 738-751, 15 JUN 92 - (1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (3) 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. ROBERT A. LAWYER, AMSAT-R-ECC, DSN 693-3820 OR COMMERCIAL 314/263-3820, HIS DATA FAX NUMBER IS DSN 693-1485 OR COMMERCIAL 314/263-1485. B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. NORM HUSTON, AMCPM-CH-L, DSN 693-1415 OR COMMERCIAL 314/263- 1415, HIS DATA FAX NUMBER IS DSN 693-1485 OR COMMERCIAL 314/263- 1485. C. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) FOR THIS MESSAGE IS MR. HAL BARNES, AMSAT-I-SACA, COMMERCIAL TELEPHONE 314/263-6031, FAX 314/263-6022, AND DSN 693-6031, FAX 693-6022. D. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAT-I-MDM, DSN 490-2318 OR COMMERCIAL 314/260- 2318. E. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. JIM WILKINS, AMSAT-R-X, DSN 693-2258 OR COMMERCIAL 314/263-2258. F. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT CW5 JAY NANCE/MR. RON VAN REES, AMSAT-D-S, DSN 693-7844/3216 OR COMMERCIAL 314/263-7844/3216. G. AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER (COC), DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7. ......................................................................................................................................................................................................................................................................................................................................................................................................................................