Safety of Flight CH-47-02-06 |
Summary of Problem - A unit reported that after experiencing a debris screen latch, they found plastic type debris in the combining transmission oil filter. Analysis of the debris revealed that it was plastic media. It has been determined that this material is the result of the use of plastic media blast procedure by CCAD to remove surface coatings from the housing assemblies. This procedure can leave particles inside the transmission that could interfere with necessary oil flow. See also 74-22292. |
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UNCLASSIFIED MSG DTG 190015Z JUN 02 FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A// SUBJECT - SAFETY OF FLIGHT, TECHNICAL, RCS CSGLD-1860(R1), ALL CH/MH-47D/F SERIES AIRCRAFT, INSPECTION OF COMBINING TRANSMISSIONS, CH-47-02-06 (TB 1-1520-240-20-148). NOTE THIS MESSAGE IS ISSUED IAW AR 95-1, 1 SEP 97, CHAPTER 6. THIS MESSAGE 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 ADDRESSEES WILL IMMEDIATELY VERIFY THIS TRANSMISSION TO CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER). 1. PRIORITY CLASSIFICATION - NOTE IAW AR 95-1, PARAGRAPH 6-6A, MACOM COMMANDERS MAY AUTHORIZE TEMPORARY EXCEPTION FROM MESSAGE REQUIREMENTS. EXCEPTION MAY ONLY OCCUR WHEN COMBAT OPERATIONS OR MATTER OF LIFE OR DEATH IN CIVIL DISASTERS OR OTHER EMERGENCIES ARE SO URGENT THAT THEY OVERRIDE THE CONSEQUENCES OF CONTINUED AIRCRAFT OPERATION. A. AIRCRAFT IN USE - UPON RECEIPT OF THIS MESSAGE, MAKE THE FOLLOWING ENTRY ON THE DA FORM 2408-13-1. ENTER A RED HORIZONTAL DASH //-// STATUS SYMBOL WITH THE FOLLOWING STATEMENT: "INSPECT COMBINING TRANSMISSIONS IAW CH-47-02-06 (TB 1-1520-240-20-148) PRIOR TO NEXT ENGINE START BUT NLT 25 JUN 02." CLEAR THE RED HORIZONTAL DASH //-// ENTRY WHEN THE PROCEDURES IAW PARA 8 ARE COMPLETED. COMMANDERS WHO ARE UNABLE TO COMPLY WITH THE REQUIREMENTS OF THIS MESSAGE WITHIN THE TIME FRAME SPECIFIED WILL UPGRADE THE AFFECTED AIRCRAFT STATUS SYMBOL TO A RED //X//. B. AIRCRAFT IN MAINTENANCE - (1) AIRCRAFT IN AVUM, AVIM OR DEPOT LEVEL MAINTENANCE - SAME AS PARA 1A. (2) AIRCRAFT AT CONTRACTOR FACILITY - BOEING WILL INSPECT DD 250 AIRCRAFT PRIOR TO THOSE AIRCRAFT DEPARTING FOR FERRY TO FINAL DESTINATION. C. AIRCRAFT IN TRANSIT - SAME AS PARA 1A. D. MAINTENANCE TRAINERS (CAT A AND B) - SAME AS PARA 1A. E. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES - UPON RECEIPT OF THIS MESSAGE, DEPOT AND MATERIEL ACTIVITY COMMANDERS WILL ENSURE THE MATERIEL CONDITION TAGS OF ALL ITEMS IN ALL CONDITION CODES LISTED IN PARAGRAPH 6 ARE ANNOTATED TO READ: "CH-47-02-06 (TB 1-1520-240-20-148), COMBINING TRANSMISSION, NOT COMPLIED WITH." (1) WHOLESALE STOCK - UPON RECEIPT OF THIS MESSAGE, DEPOT AND MATERIEL ACTIVITY COMMANDERS WILL ENSURE ALL ITEMS IN CONDITION CODES //A//, //B//, //C//, //D//, AND //E//, LISTED IN PARAGRAPH 6, ARE PLACED IN CONDITION CODE //J// AND TAGGED WITH A SUSPENDED TAG/LABEL - MATERIEL, DD FORM 1575/DD FORM 1575-1. DO NOT REMOVE ORIGINAL CONDITION TAGS. (2) RETAIL STOCK - REPORT RECEIPT OF THIS MESSAGE IAW PARAGRAPH 14C(1) NLT 21 JUN 02. UPON RECEIPT OF THIS MESSAGE, COMMANDERS AND FACILITY MANAGERS MAINTAINING RETAIL STOCK AT INSTALLATION LEVEL AND BELOW SHALL CONTACT THE SUPPORTED AVIATION UNIT TO PERFORM THE PROCEDURES REQUIRED IAW PARAGRAPHS 8 AND 9 ON SUSPECT MATERIEL. DISPOSE OF DISCREPANT MATERIEL IAW PARA 10. REPORT COMPLIANCE WITH THIS MESSAGE IAW PARAGRAPH 14C(2) NLT 28 JUN 02. F. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - DEPOT AND OTHER MAINTENANCE ACTIVITY COMMANDERS WILL ENSURE ITEMS LISTED IN PARAGRAPH 6 ARE NOT ISSUED UNTIL THEY ARE IN COMPLIANCE WITH THIS MESSAGE. 2. TASK/INSPECTION SUSPENSE DATE - COMPLETE THE INSPECTION IAW PARAGRAPH 8 PRIOR TO NEXT ENGINE START BUT NLT 25 JUN 02 AND REPORT IAW PARA 14A(2) NLT 28 JUN 02. 3. TAMMS REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE IAW PARA 14A(1) NLT 25 JUN 02. 4. SUMMARY OF PROBLEM - A. A UNIT REPORTED THAT AFTER EXPERIENCING A DEBRIS SCREEN LATCH, THEY FOUND PLASTIC TYPE DEBRIS IN THE COMBINING TRANSMISSION OIL FILTER. ANALYSIS OF THE DEBRIS REVEALED THAT IT WAS PLASTIC MEDIA. IT HAS BEEN DETERMINED THAT THIS MATERIAL IS THE RESULT OF THE USE OF PLASTIC MEDIA BLAST PROCEDURE BY CCAD TO REMOVE SURFACE COATINGS FROM THE HOUSING ASSEMBLIES. THIS PROCEDURE CAN LEAVE PARTICLES INSIDE THE TRANSMISSION THAT COULD INTERFERE WITH NECESSARY OIL FLOW. B. MANPOWER/DOWNTIME AND FUNDING IMPACTS - SEE PARA 12. C. THE PURPOSE OF THIS MESSAGE IS TO - (1) CONDUCT RECORDS CHECK AND VISUAL INSPECTION OF ALL COMBINING TRANSMISSIONS. (2) REMOVE SPECIFIC SERIAL NUMBERED COMBINING TRANSMISSIONS FROM SERVICE. (3) INSPECT COMBINING TRANSMISSIONS OVERHAULED AT CCAD BETWEEN 28 JUN 2000 THROUGH 17 JUN 2002 FOR PRESENCE OF PLASTIC MEDIA BLAST PARTICLES. 5. END ITEMS TO BE INSPECTED - ALL CH/MH-47D/F AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN COMBINING TRANSMISSION ASSY 145D5300-ALL ALL 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN ELEMENT, FILTER, FLUID 145DS023-6 1650-01-117-8026 ELEMENT, FILTER, FLUID 145DS514-4 1650-01-116-2945 ELEMENT, FILTER, FLUID 145DS514-7 1650-01-116-4771 FILTER, ASSEMBLY 145DS523-2 4330-01-114-0918 8. INSPECTION PROCEDURES - NOTE SUPPLEMENTAL INFORMATION FOR THIS MESSAGE CAN BE VIEWED AT (USE LOWER CASE LETTERS ONLY) "www.redstone.army.mil/sof/suppl/c47s0206.pdf". A. CONDUCT RECORDS REVIEW (DA FORM 2408-16 AND DA FORM 2408-5-1) AND VISUAL INSPECTION (SERIAL NUMBER VERIFICATION) OF ALL COMBINING TRANSMISSIONS PRIOR TO NEXT ENGINE START. NOTE ONE-TIME FLIGHTS ARE NOT AUTHORIZED FOR THE FOLLOWING SERIAL NUMBERED COMBINING TRANSMISSIONS WITHOUT WRITTEN AUTHORIZATION FROM THE TECHNICAL POC. ONE-TIME FLIGHTS AUTHORIZATIONS MAY BE APPROVED DEPENDENT UPON SPECIAL INSPECTION RESULTS AS DIRECTED BY THE TECHNICAL POC. B. THE FOLLOWING SERIAL NUMBERED COMBINING TRANSMISSIONS ARE CONSIDERED UNSERVICEABLE: A8-017, A8-066, A8-069, A8-117, A8-125, A8-152, A8-161, A8-173, A8-197, A8-232, A8-267, A8-363, A8-403, A8-463, A8-563, A8-583, A8-654, A8-685. IF THE SERIAL NUMBER IS CONTAINED IN THE PRECEDING LIST, CLEAR THE ENTRY FROM PARA 1A AND MAKE THE FOLLOWING ENTRY ON THE DA FORM 2408-13-1. ENTER A RED //X// STATUS SYMBOL WITH THE FOLLOWING STATEMENT: "COMBINING TRANSMISSION UNSERVICEABLE IAW CH-47-02-06 (TB 1-1520- 240-20-148)". PROCEED TO PARA 9A. NOTE FOR AIRCRAFT AWAY FROM HOME STATION, A ONE-TIME FLIGHT, NOT TO EXCEED FOUR HOURS, WITH INTERMEDIATE STOPS, IS AUTHORIZED TO RETURN TO THE NEAREST SECURED MAINTENANCE FACILITY/HOME STATION THAT WILL FACILITATE INSPECTION/REPAIRS. THIS AUTHORIZATION DOES NOT APPLY TO THE SERIAL NUMBERED COMBINING TRANSMISSIONS LISTED IN PARA 8B. C. FOR COMBINING TRANSMISSIONS NOT LISTED ABOVE, IF LAST OVERHAUL WAS PERFORMED AT CCAD AND WAS OVERHAULED BETWEEN 28 JUNE 2000 AND 17 JUN 2002, CONDUCT VISUAL INSPECTION OF THE MAIN, AUXILIARY, INLET SCREEN, AND ENGINE TRANSMISSION OIL FILTERS ON THE COMBINING TRANSMISSIONS FOR PLASTIC MEDIA BLAST PARTICLES. (1) IF PLASTIC MEDIA BLAST PARTICLES ARE FOUND, THE COMBINING TRANSMISSION IS CONSIDERED UNSERVICEABLE. PROCEED TO PARA 9A. (2) IF NO PLASTIC MEDIA BLAST PARTICLES ARE FOUND, INSPECTION IS COMPLETE. PROCEED TO PARA 9B. D. IF LAST OVERHAUL WAS NOT PERFORMED AT CCAD OR WAS PERFORMED AT CCAD PRIOR TO 28 JUN 2000, COMBINING TRANSMISSION IS CONSIDERED SERVICEABLE. E. COMBINING TRANSMISSIONS OVERHAULED BY CCAD AFTER 17 JUN 2002 ARE CONSIDERED SERVICEABLE AND NOT AFFECTED BY THIS MESSAGE. 9. CORRECTION PROCEDURES - A. IF THE COMBINING TRANSMISSION IS CONSIDERED UNSERVICEABLE IAW PARAGRAPH 8 OF THIS MESSAGE, PROCEED AS FOLLOWS - (1) REPLACE COMBINING TRANSMISSION IAW APPROPRIATE TM PRIOR TO NEXT ENGINE START. (2) REPLACE 2 (TWO) FILTERS (TM 55-1520-240-23P, FIG 194, ITEM 2) PRIOR TO INSTALLATION OF NEW COMBINING TRANSMISSION. NOTE NORMAL PROCEDURES REQUIRE FILTERS AND PACKINGS TO BE REPLACED WHEN REMOVED. THIS MESSAGE AUTHORIZES A ONE-TIME RE-USE AFTER INSPECTION OF THE FILTER AND PACKING. B. IF NO PLASTIC MEDIA BLAST PARTICLES ARE FOUND, THE INSPECTION IS COMPLETE. REINSTALL FILTERS AND CLEAR THE RED HORIZONTAL DASH //-// ENTRY FROM PARA 1A. C. IF LAST OVERHAUL WAS NOT PERFORMED AT CCAD OR WAS PERFORMED AT CCAD PRIOR TO 28 JUN 2000 OR AFTER 17 JUN 2002, CLEAR THE RED HORIZONTAL DASH //-// ENTRY. 10. SUPPLY/PARTS AND DISPOSITION - NOTE HQDA-ADCS-G-3 WILL PRIORITIZE UNITS AND REPAIR PARTS DISTRIBUTION. A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 12C MAY BE REQUIRED TO REPLACE DEFECTIVE ITEMS. B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE PROJECT CODE (CC 57-59) "X1X" (X-RAY-ONE-X-RAY). NOTE PROJECT CODE "X1X" IS REQUIRED TO TRACK AND ESTABLISH A DATA BASE OF STOCK FUND EXPENDITURES INCURRED BY THE FIELD AS A RESULT OF MESSAGE ACTIONS. C. BULK AND CONSUMABLE MATERIALS - NOMENCLATURE PART NO. NSN ELEMENT, FILTER, FLUID 145DS023-6 1650-01-117-8026 O-RING M83248/1-134 5331-00-167-5122 ELEMENT, FILTER, FLUID 145DS514-4 1650-01-116-2945 ELEMENT, FILTER, FLUID 145DS514-7 1650-01-116-4771 O-RING M83248/1-112 5331-00-166-1060 O-RING M83248/1-116 5331-00-166-1068 O-RING M83248/1-122 5331-00-167-5111 GASKET 145DS025-11 5330-01-115-3764 FILTER, ASSEMBLY 145DS523-2 4330-01-114-0918 D. DISPOSITION - DISPOSE OF REMOVED PARTS/COMPONENTS USING NORMAL SUPPLY PROCEDURES. ALL TURN-IN DOCUMENTS MUST INCLUDE PROJECT CODE (CC 57-59) "X1X" (X-RAY-ONE-X-RAY). E. DISPOSITION OF HAZARDOUS MATERIAL - IAW ENVIRONMENTAL PROTECTION AGENCY DIRECTIVES AS IMPLEMENTED BY YOUR SERVICING ENVIRONMENTAL COORDINATOR (AR 200-1). 11. SPECIAL TOOLS AND FIXTURES REQUIRED - AS REQUIRED. 12. APPLICATION - A. CATEGORY OF MAINTENANCE - AVUM. AIRCRAFT DOWNTIME WILL BE CHARGED TO AVUM MAINTENANCE. REPORT AIRCRAFT NON-MISSION CAPABLE MAINTENANCE (NMCM) WHILE UNDERGOING INSPECTION AND CORRECTION IAW THIS MESSAGE. B. ESTIMATED TIME REQUIRED - (1) TIME TO COMPLETE RECORDS CHECK - TOTAL OF 0.5 MAN- HOURS USING 1 PERSON. (2) TIME TO COMPLETE VISUAL INSPECTION - (A) TOTAL OF 6 MAN-HOURS USING 1 PERSON. (B) TOTAL OF 6 HOURS DOWNTIME FOR ONE END ITEM. (3) TIME FOR REPAIR/REPLACEMENT - (A) TOTAL OF 30 MAN-HOURS USING 5 PERSONS. (B) TOTAL OF 6 HOURS DOWNTIME FOR ONE END ITEM. C. ESTIMATED COST IMPACT TO THE FIELD - NOMENCLATURE PART NO./NSN QTY COST EA. TOTAL $ TRANSMISSION, MECH, 145D5300-20 1 $342630.00 $342630.03 HELICOPTER 1615-01-464-3974 TOTAL COST PER AIRCRAFT = $342,630.03 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. DA PAM 738-751 B. TM 55-1520-240-23 C. TM 55-1520-240-23P 14. RECORDING AND REPORTING REQUIREMENTS - A. AIRCRAFT - (1) TAMMS REPORTING COMPLIANCE SUSPENSE - UPON ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 FOR ALL EFFECTED AIRCRAFT, COMMANDERS WILL FORWARD A PRIORITY MESSAGE, FAX OR EMAIL TO CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER), REDSTONE ARSENAL, AL 35898-5000, IAW AR 95-1, NLT DATE SPECIFIED IN PARAGRAPH 3. FAX NUMBER IS DSN 897-2111 OR (256) 313-2111. EMAIL ADDRESS IS "SAFEADM@REDSTONE.ARMY.MIL". THE REPORT WILL CITE THIS MESSAGE AND TB NUMBER, DATE OF ENTRY IN DA FORM 2408-13-1, THE AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF AIRCRAFT IN NUMERICAL ORDER. (2) TASK/INSPECTION REPORTING SUSPENSE - UPON COMPLETION OF INSPECTION, COMMANDERS WILL FORWARD A PRIORITY MESSAGE TO THE LOGISTICAL POINT OF CONTACT LISTED IN PARA 16B THE REPORT WILL CITE THIS MESSAGE AND TB NUMBER, DATE OF INSPECTION, AIRCRAFT AND COMPONENT SERIAL NUMBER, AIRCRAFT AND COMPONENT HOURS, AND RESULTS OF THE INSPECTION. INSPECTION AND REPORTS WILL BE COMPLETED NLT DATE SPECIFIED IN PARAGRAPH 2. B. WHOLESALE SPARE PARTS/ASSEMBLIES - N/A. C. RETAIL SPARE PARTS/ASSEMBLIES - (1) REPORTING MESSAGE RECEIPT - COMMANDERS AND FACILITY MANAGERS WILL REPORT RECEIPT OF THIS MESSAGE BY E-MAIL OR FAX TO THE LOGISTICAL POINT OF CONTACT LISTED IN PARAGRAPH 16B NLT DATE SPECIFIED IN PARAGRAPH 1E(2). PROVIDE LOCAL POINT OF CONTACT. (2) TASK/INSPECTION REPORTING SUSPENSE - COMMANDERS AND FACILITY MANAGERS WILL REPORT INSPECTION RESULTS TO THE LOGISTICAL POINT OF CONTACT IN PARAGRAPH 16B NLT DATE SPECIFIED IN PARAGRAPH 1E(2). REPORT THE QUANTITY INSPECTED BY CONDITION CODE AND THE RESULTING CONDITION CODE. REPORT BY E-MAIL OR FAX AND PROVIDE LOCAL POINT OF CONTACT. D. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED IAW DA PAM 738-751, 15 MAR 99 - NOTE ULLS-A USERS WILL USE APPLICABLE "E" FORMS. (1) DA FORM 2408-5-1, EQUIPMENT MODIFICATION RECORD (COMBINING TRANSMISSION). (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. (ONLY IF COMBINING TRANSMISSION IS REPLACED) (6) DD FORM 1575/DD FORM 1575-1, SUSPENDED TAG/LABEL - MATERIEL (COLOR BROWN). ANNOTATE REMARKS BLOCK WITH "SUSPENDED IAW CH-47-02-06 (TB 1-1520-240-20-148)." (7) DD FORM 1577-2/DD FORM 1577-3, UNSERVICEABLE (REPARABLE) TAG/LABEL - MATERIEL (COLOR GREEN). ANNOTATE REMARKS BLOCK WITH UNSERVICEABLE IAW CH-47-02-06 (TB 1-1520-240-20-148)." 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. STEVE PROSISE, AMSAM-RD-AE-I-P-C, DSN 897-2350 EXTENSION 9851 OR (256) 705-9851. EMAIL IS "STEVE.PROSISE@RDEC.REDSTONE.ARMY.MIL". B. LOGISTICAL POC IS MR. BILL OLSON, SFAE-AV-CH-L, DSN 897- 3379 OR (256) 313-3379, FAX IS EXT 4348. EMAIL IS "WILLIAM.OLSON@PEOAVN.REDSTONE.ARMY.MIL". C. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) IS GAIL MILES, AMSAM-MMC-AV-CA, DSN 897-1455 OR (256) 313-1455, FAX IS DSN 897-1106. EMAIL IS "GAIL.MILES@REDSTONE.ARMY.MIL". D. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAM-MMC-MA-NM, DSN 746-5564 OR (256) 876-5564. FAX IS DSN 746-4904 OR (256) 876-4904. EMAIL IS "ANN.WALDECK@REDSTONE.ARMY.MIL". E. SAFETY POINTS OF CONTACT ARE - (1) PRIMARY - MR. RANDALL RUSHING (SAIC), AMSAM-SF-A, DSN 897-2092 OR (256) 313-2092, FAX IS DSN 897-2111 OR (256) 313-2111. EMAIL IS "RANDALL.RUSHING@REDSTONE.ARMY.MIL". (2) ALTERNATE - MR. RUSSELL PEUSCH, AMSAM-SF-A, DSN 788-8632 OR (256) 842-8632. FAX IS DSN 897-2111 OR (256) 313-2111. EMAIL IS "RUSSELL.PEUSCH@REDSTONE.ARMY.MIL". F. FOREIGN MILITARY SALES RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT MR. RONNIE W. SAMMONS, AMSAM-SA-AS-UT, DSN 897-0407 OR (256) 313-0407. FAX IS DSN 897-0411 OR (256) 313-0411. EMAIL IS "RONNIE.SAMMONS@REDSTONE.ARMY.MIL". G. AFTER HOURS CONTACT THE AMCOM OPERATIONS CENTER (AOC) DSN 897-2066/7 OR (256) 313-2066/7.