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| Safety of Flight CH-47-03-01 |
Swashplate Bearing |
| Summary of Problem: During ground run, a CH-47D Chinook aircraft experienced an aft rotating ring drive arm lug failure that resulted in a rotor blade strike to the fuselage, upper tunnel cover and other significant aircraft damage. Investigation has revealed that this incident was the end result of an Aft Swashplate Bearing failure. See also 91-00233. |
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UNCLASSIFIED
.
MSG DTG 042115Z OCT 02
.
FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A//
.
SUBJECT - SAFETY OF FLIGHT TECHNICAL, RCS CSGLD-1860(R1), ALL H-47
CHINOOK AIRCRAFT, SWASHPLATE BEARING, FWD AND AFT, CH-47-03-01.
...................NOTE...................
....This message is effective until rescinded or superseded.
...................NOTE...................
....This message is issued IAW AR 95-1 and has not been
....transmitted to units subordinate to addressees.
....Addressees will immediately retransmit this message
....to all subordinate units, activities or elements
....affected or concerned. MACOMs will immediately
....verify this transmission to the AMCOM SOF Compliance
....Officer (AMSAM-SF-A, safeadm@redstone.army.mil).
...................NOTE...................
....MACOM commanders may authorize temporary exception from
....message requirements IAW AR 95-1, Ch 6. 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.
1. SUMMARY -
1.1. Background - During ground run, a CH-47D Chinook aircraft
experienced an aft rotating ring drive arm lug failure that
resulted in a Rotor Blade strike to the fuselage, upper tunnel
cover and other significant aircraft damage. Investigation has
revealed that this incident was the end result of an Aft
Swashplate Bearing failure.
1.2. Message Purpose -
1.2.1. Require an immediate and recurring (every 100 flight
hours) visual inspection of all H-47 Forward and Aft Swashplate
Bearings.
1.2.2. Require an immediate grease purge of all H-47D/F Forward
and Aft Swashplate Bearings.
1.2.3. Require an immediate and recurring (every 50 flight
hours) grease sample of all H-47D/F Forward and Aft Swashplate
Bearings.
1.2.4. Increase the frequency of lubrication for the H-47D/F
Forward and Aft Swashplate Bearings from every 100 flight hours
to every 50 flight hours.
1.2.5. Clarify the daily visual inspection of the forward and
aft swashplates to emphasize inspection of the lower seal area.
2. END ITEMS AFFECTED - All H-47 series aircraft.
3. ASSEMBLIES/COMPONENTS/PARTS AFFECTED -
..Nomenclature Part No. NSN
Swashplate Assy FWD 145R3551-19 1615-01-473-4376
145R3551-17 1615-01-395-0006
145R3551-1 1615-01-115-3623
145R3551-11 1615-01-352-8575
145R3551-5 1615-01-315-5133
Swashplate Assy AFT 145R3551-20 1615-01-475-9838
145R3551-18 1615-01-395-0007
145R3551-2 1615-01-115-3610
145R3551-12 1615-01-352-8576
145R3551-6 1615-01-317-2432
Bearing, Swashplate 114RS308-1 3110-00-141-3750
Bearing, Swashplate 114RS308-2 3110-01-356-0489
...................NOTE...................
....When complying with the requirements of this message,
....complete forms and records entries IAW DA PAM 738-751.
....ULLS-A units will use appropriate "E" forms.
4. INITIAL TAMMS (THE ARMY MAINTENANCE MANAGEMENT SYSTEM)
COMPLIANCE REQUIREMENTS -
4.1. 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: "Comply with requirements of
CH-47-03-01 prior to next flight, but NLT 19 Oct 02." 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//.
...................NOTE...................
....The TAMMS compliance reporting form is available at
...."www.redstone.army.mil/sof/tamms.xls" (use lower case
....letters only) or may be obtained from the units
....servicing LAR. Alternate forms may be approved by
....the AMCOM SOF Compliance Officer.
...................NOTE...................
....MH-47E aircraft that have completed a swashplate
....bearing inspection within the previous 100 flight
....hours are exempt from the initial bearing visual
....inspection but must comply with the new 100 hour
....inspection interval which begins 100 flight hours
....from the last swashplate inspection.
...................NOTE...................
....Any H-47 aircraft that have swashplate assemblies
....with less than 100 flight hours Time Since New or
....Time Since Overhaul (TSN/TSO) are exempt from the
....initial swashplate bearing visual inspection but must
....comply with the new 100 hour inspection interval
....which begins 100 flight hours from TSN/TSO.
...................NOTE...................
....The TAMMS Compliance Report only confirms the unit has
....made the initial logbook entry for assigned aircraft.
....TAMMS Compliance Reports will include aircraft serial
....numbers (in numerical order), date of entry on DA Form
....2408-13-1, unit address, local POC name and phone number.
4.2. TAMMS Compliance Report - Submit TAMMS Compliance Report
via priority email to "safeadm@redstone.army.mil" NLT 15 Oct 02
IAW AR 95-1. If email is not available, the report may be faxed
to: SOF Compliance Officer at DSN 897-2111 or (256) 313-2111.
5. TASK/INSPECTION COMPLIANCE REQUIREMENTS -
...................NOTE...................
....The Task/Inspection Reporting Form is available at
...."www.redstone.army.mil/sof/log.xls" (use lower case
....letters only) or may be obtained from the units
....servicing LAR. This report will cite the message
....number, date of inspection, aircraft serial number,
....aircraft hours, component serial number, component
....hours, and results of the inspection.
5.1. Aircraft - Submit Task/Inspection Compliance Report for
this message to Log POC NLT 19 Oct 02.
5.2. Retail Stock (Installation level and below) - Submit
Task/Inspection Compliance Report for this message to Log POC NLT
19 Oct 02.
5.3. Wholesale Stock (Including Depot stock, Depot Maintenance
and Single Stock Fund) - N/A.
6. SPECIAL PROVISIONS TO MESSAGE REQUIREMENTS (AIRCRAFT) -
6.1. Aircraft in AVUM, AVIM, or Depot level maintenance -
Commanders, facility managers and contractors will not issue
aircraft until they are in compliance with this message.
6.2. Aircraft at Contractor Facility - Boeing Helicopters will
inspect DD 250 aircraft prior to those aircraft departing for
ferry to final destination if not relieved by PARA 4.1 notes.
6.3. Aircraft in Transit -
6.3.1. Surface/air shipment - Comply with message requirements
prior to first flight after arrival.
6.3.2. Ferry status/Aircraft away from home station - Aircraft
in Ferry status/Aircraft away from home station are authorized a
one-time flight (with intermediate stops) to the nearest secure
maintenance facility to facilitate message compliance.
6.4. Maintenance Trainers (Cat A and B) - Comply with message
requirements NLT 30 April 2003.
7. TECHNICAL PROCEDURES/INSTRUCTIONS -
...................NOTE...................
....Supplemental information for this message can
....be viewed at (use lower case letters only)
...."www.redstone.army.mil/sof/suppl/c47s0301.pdf".
...................NOTE...................
....Do not lubricate the swashplate prior to performing
....the visual inspection of the swashplate bearing.
7.1. Visual initial and 100 hour recurring inspection of all
H-47 Forward and Aft Swashplate Bearings.
...................NOTE...................
....This inspection can be performed on aircraft or off.
...................CAUTION...................
....It is imperative that the Rotor Head be locked out
....prior to performing the bearing inspection or damage
....to components will occur.
7.1.1 Lock out the Rotor Heads: H-47D/F per TM 55-1520-240-23;
Task 11-28, Install Servocylinder Safety Blocks and Task 5-97,
Remove Pitch Link (Pitch Link Lockpins installed). MH-47E per TM
1-1520-252-23; Task 11-33, Install Servocylinder Safety Blocks and
Task 5-145, Remove Pitch Link (Pitch Link Lockpins installed).
...................NOTE...................
....Prior to removing hardware, thoroughly wipe
....clean all upper seal surfaces (only), by hand
....with a lint free cloth. Remove only the Upper
....Seal, P/N 114R3428-1. Do not remove the Upper
....Bearing Retainer, P/N 114R3126-4. Only 12 Bolts
....and washers (Aft) or Nuts and washers(Fwd)
....need to be removed.
7.1.2. Remove Forward and Aft Swashplate Upper Seal, P/N
114R3428-1, per TM 55-1520-240-23, Task 5-122, Paragraphs 1a and
2a (H-47D/F) or TM 1-1520-252-23, Task 5-175, Paragraphs 1a and
2a (MH-47E).
...................WARNING...................
....If this inspection is performed on aircraft,
....Ensure no FOD enters the bearing. Do not attempt
....to clean or wipe the bearing prior to performing
....the next step.
7.1.3. Use a flashlight or other suitable light source to
visually inspect for raised, overlaping or broken cage segments.
Inspect for orange/red pieces of debris. The lower grease seal
is elastomeric orange/red in color; therefore this type of rubber
debris may be indicative of damage to this lower seal.
...................WARNING....................
....Do not use cloths or rags to clean the bearing area,
....as this may snag or catch on the bearing cage and
....disturb the balls.
7.1.4. Wipe away excess grease in cavity using fingers.
Use a flashlight or other suitable light source to visually
inspect for raised, overlaping or broken cage segments or
multiple adjacent uncaged ball bearings. Inspect for orange/red
pieces of rubber debris
...................NOTE...................
....The design of the bearing allows for up to
....3 individual cage segments with each segment
....separated by one uncaged ball.
7.1.5. If any of these conditions are found, except for those in
the note above, the Swashplate Assembly shall be considered
unserviceable and disposition is IAW paragraph 10.4 of this
message. This inspection will now be required every 100 flight
hours for all H-47 aircraft.
...................NOTE...................
....If replacement self-locking nuts are not available,
....re-use of the original nuts is authorized provided
....they meet the following torque requirement. The
....torque required to start the nut rotating with a
....minimum of one full thread extending from the end
....of the nut shall be at least 7 in-lbs. The standard
....procedure of using new nuts at each removal and
....reinstallation shall be followed as soon as new
....nuts are available.
7.1.6. If the bearing passes the inspections of 7.1.3,and 7.1.4
install the Swashplate Upper Seal, P/N 114R3428-1, per TM 55-
1520-240-23, Task 5-125, Paragraphs 7b and 8e-h (H-47D/F) or TM
1-1520-252-23, Task 5-179, Paragraphs 7b and 8e-h (MH-47E). If
nuts were reused on forward swashplate, apply a torque stripe to
all nuts for visual inspection reference. A Daily inspection
will be required until new nuts are installed.
7.1.7. Unlock Rotor Heads; H-47D/F per TM 55-1520-240-23; Task
5-99, Install Pitch Links (remove Pitch Link Lockpins) and Task
11-29, Remove Servocylinder Safety Blocks. MH-47E per TM 1-1520-
252-23; Task 5-148, Install Pitch Links (remove Pitch Link
Lockpins) and Task 11-34, Remove Servocylinder Safety Blocks
...................CAUTION...................
....For the purpose of this SOF only, a test flight
....to track the rotor blades is not required as long
....as no adjustments were made to the Pitch Links and
....the Pitch Links are installed back in their original
....location.
7.2. Initial and recurring 50 hour lubrication/purge and initial
and 50 hour recurring grease sample of all H-47D/F Forward and
Aft Swashplate Bearings.
7.2.1. Using a soft, clean, lint-free cloth, dampened with
cleaning solvent (MIL-PRF-680), clean the inner ring assembly and
outer ring assembly at the upper seal. Wipe dirt and grease from
lubrication fitting. Ensure all surface grit, sand, and other
foreign material is removed, ensuring an uncontaminated grease
sample.
...................NOTE...................
....Mobil 28 grease is recommended if available.
...................CAUTION...................
....Pumping grease into swashplate without turning
....rotating ring can result in bearing damage.
...................NOTE...................
....If you cannot pump grease and rotate the
....swashplate at the same time, rotate swashplate
....in 12 equal steps, 30 degrees each step.
....Pump in grease between steps.
7.2.2. Army Oil Analysis Program (AOAP) grease sample procedure.
7.2.2.1. Have helper rotate ring by pulling blades around with
tie down line. As ring rotates, pump grease into fitting. Rotate
the ring through at least one full turn (360 degrees) to ensure
thorough purging of the bearing. Use a hand lubricating grease
gun with a flexible hose. Pump until clean grease appears all the
way around the line between the stationary upper seal and rotating
upper seal. Ensure all the old grease is purged from the assembly
and is immediately collected. Use a tongue depressor to fill a
three ounce plastic sampling bottle at least half full and reserve
the remaining purged grease for use in 7.2.3.
7.2.2.2. Once the AOAP sample is taken, the bottle label should
be filled out as completely as possible to avoid confusion with
other grease samples.
7.2.2.3. Submit the AOAP grease sample to the AOAP laboratory
with a complete DD Form 2026.
7.2.2.4. Maintain the DA Form 2408-20 on each swashplate in
accordance with DA PAM 738-751.
7.2.3. Use the additional grease sample and feel for metal chips
in grease. If there are chips, the swashplate shall be
considered unserviceable and disposition IAW paragraph 10.4 of
this message.
7.2.4. The Swashplate Bearing will now be required to be
lubricated and a grease sample taken every 50 flight hours.
7.3. Using a flashlight or other suitable light source, visually
inspect with a mirror or flexible borescope the area between the
underside of the rotating ring and stationary ring for any
slinging or clumping or grease/debris (i.e. seal, bearing cage,
seal spring, wire, or other material) A thin even bead of grease
around the sealing area is considered normal. This inspection
will now be required on the Preventive Maintenance Daily (PMD)
7.4. Annotate the DA Form 2408-18 with the following inspections:
7.4.1. 100 flight hour recurring inspection of the forward and
aft swashplate bearing. ULLS-A units will use inspection number
A182 (Insp FWD & AFT Swashplate bearings IAW CH-47-03-01.
7.4.2. 50 flight hour lubrication/purge and grease sample of the
forward and aft swashplate bearings. ULLS-A units will use
inspection number A121 (Sample & lub FWD & AFT swashplate
bearings IAW CH-47-03-01.
7.5. Clear the initial entry from para 4.1. and note compliance
on DA Form 2408-5-1 (Swashplate Assy.).
8. PROCEDURES/INSTRUCTIONS FOR ASSEMBLIES/COMPONENTS/PARTS IN
WORK OR IN STOCK (AT ALL LEVELS INCLUDING WAR RESERVES) -
8.1. Items in Retail Stock - Commanders and facility managers
that maintain retail stock at installation level and below will
complete the following procedures.
8.1.1. Contact the supported aviation unit, as required, to
perform the procedures required on affected items.
8.1.2. Submit a Task/Inspection report IAW para 5.
8.2. Items in Single Stock Fund and in Work (Overhaul/Repair
Facility) - N/A.
8.3. Items in Wholesale Stock - N/A.
9. SPECIAL TOOLS AND FIXTURES REQUIRED - As required.
10. SUPPLY/PARTS (REQUISITION/DISPOSITION) -
...................NOTE...................
....HQDA-ADCS-G-3 will prioritize units
....and repair parts distribution.
10.1. Parts Required - The following parts/components may be
required to return aircraft to a serviceable condition.
..Nomenclature Part no./NSN Qty Cost ea. Total $
Swashplate, Aft
145R3551-20 / 1615-01-475-9838 1 $133,245.00 $133,245.00
Swashplate, Fwd
145R3551-19 / 1615-01-473-4376 1 $133,245.00 $133,245.00
Bearing
114R3104-4 / 3120-01-342-0061 2 $3599.40 $7198.80
Seal
114RS306-6 / 5330-00-999-4077 2 $533.60 $1067.20
Retainer
114R3417-3 / 5330-01-474-4303 4 $317.98 $1271.92
Ring Assy
114R3490-1 / 1615-01-476-0755 1 $4354.32 $4354.32
Bolt
BACB30LC6-38 / 5306-01-474-3835 36 $2.77 $99.72
Bolt
BACB30FD5H14 / 5306-01-476-1906 36 $3.07 $110.52
Nut, Self Locking
FN22M524 / 5310-01-070-9314 12 $6.11 $73.32
Nut, Self-Locking
FN22M524 / 5310-01-070-9314 12 $6.11 $73.32
Bolt, Shear
MS21134H05004 / 5306-01-108-7462 12 $4.19 $50.28
Gasket
114R3428-1 / 5330-00-849-4366 2 $74.16 $148.32
Nut, Self-Locking
FN22M-428 / 5310-01-184-0356 10 $3.92 $39.20
Nut, Self-Locking
FN22M-624 / 5310-01-184-0354 36 $1.62 $58.32
Retainer, Swashplate
114R3126-4 / 1615-00-181-4127 2 108.49 $6216.98
....................Total max cost per aircraft = $266,563.32
10.2. Bulk and consumable materials -
..Nomenclature Part No. NSN
..Grease, WTR MIL-G-81322 9150-00-145-0268
..Bottle, plastic MIL-B-44054 8125-01-082-9697
..Tongue depressor (wooden) GGD226 6515-00-324-5500
..Cloth, Lint Free MIL-C-24671 4470-01-498-8080
10.3. Requisitioning instructions - Requisition replacement
parts using normal supply procedures. All requisitions shall use
Project Code (CC 57-59) "X22" (X-ray-Two-Two).
...................NOTE...................
....Project Code "X22" is required to track and establish
....a data base of stock fund expenditures incurred by
....the field as a result of message actions.
10.4. Disposition of discrepant parts/components - Submit a
Category I Deficiency Report on any Swashplate Assembly that
failed the inspections detailed in paragraph 7 of this message.
10.5. Disposition of hazardous material - IAW Environmental
Protection Agency directives as implemented by your servicing
environmental coordinator (AR 200-1).
11. MAINTENANCE APPLICATION -
11.1. Category of maintenance - AVUM. Aircraft downtime will be
charged to AVUM.
11.2. Estimated time required -
11.2.1. Time to complete inspection - total of 12 man-hours
using 4 persons with 3 hours downtime per end item.
11.2.2. Time for repair/replacement - total of 125 man-hours
using 8 persons with 16 hours downtime per end item.
12. PUBLICATION REQUIREMENTS -
12.1. References -
12.1.1. AR 95-1.
12.1.2. DA Pam 738-751.
12.1.3.TM 55-1520-240-23, Aviation Unit and Aviation Intermediate
Maintenance Manual, CH-47D Helicopter.
12.1.4. TM 1-1520-252-23, Aviation Unit and Aviation
Intermediate Maintenance Manual, MH-47E Helicopter.
12.1.5. TM 55-1520-240-PMD, Preventive Maintenance Daily, CH-47D
Helicopter.
12.1.6. TM 1-1520-252-PMD, Preventive Maintenance Daily, MH-47E
Helicopter.
12.2. Publication changes - The following publications shall be
changed to reflect this message. A copy of this message will be
used as authority to implement the change until the official
change is received.
12.2.1. TM 55-1520-240-23 and TM 1-1520-252-23 will be changed
to reflect this SOF as follows -
12.2.1.1. Change the frequency of lubrication/purge for the
Forward and Aft Swashplate Bearings from 100 hours to every 50
hours.
12.2.1.2. Add a requirement to inspect the Forward and Aft
Swashplate Bearing by removing the upper seal. Frequency shall
be every 100 flight hours.
12.2.1.3. Add a requirement to take a grease sample of the
Forward and Aft Swashplate Bearings. Frequency shall be every 50
flight hours.
12.2.2. TM 55-1520-240-PMD and TM 1-1520-252-PMD will be
modified to clarify the location to check for accumulated grease
and damaged or displaced seals.
12.2.3. TB 43-0106 Appendix A for the CH-47, Add a requirement
to take a grease sample of the Forward and Aft Swashplate
Bearings. Frequency shall be every 50 flight hours.
13. POINTS OF CONTACT -
13.1. Technical POCs are -
13.1.1. Primary - Mr. Steve Prosise, AMSAM-RD-AE-I-P-C, DSN 897-
2350, extension 9851 or (256) 705-9851. Fax is (256) 705-9900.
Email is "steve.prosise@rdec.redstone.army.mil".
13.1.2. Alternate - Mr. Larry Wieschhaus, AMSAM-RD-AE-I-P-C, DSN
897-2350, extension 9866 or (256) 705-9866. Fax is (256) 705-
9900. Email is "larry.wieschhaus@rdec.redstone.army.mil".
13.2. Logistical POCs are -
13.2.1. Primary - Bill Olson, SFAE-AV-CH-L, DSN 897-3379 or
(256) 313-3379. Fax is DSN 897-4348 or (256) 313-4348. Email is
"william.olson@peoavn.redstone.army.mil".
13.2.2. Alternate - CW5 Jack Martin, SFAE-AV-CH-L, DSN 897-3617
or (256) 313-3617. Fax is DSN 897-4348 or (256) 313-4348. Email
is "john.martin@peoavn.redstone.army.mil".
13.3. Wholesale Materiel POC (spares) is Ms Geri Reddy, AMSAM-
MMC-AV-CA, DSN 897-1454 or (256) 313-1454. Fax is DSN 897-1106.
Email is "geri.reddy@redstone.army.mil".
13.4. Forms and records POC 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".
13.5. Safety POCs are -
13.5.1. Primary - Mr. Frank Rosebery (SAIC), AMSAM-SF-A, DSN
788-8631 or (256) 842-8631. Fax is DSN 897-2111 or (256) 313-
2111. Email is "frank.rosebery@redstone.army.mil".
13.5.2. Alternate - Mr. Russ 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".
13.6. Foreign Military Sales POC is 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".
13.7. After hours, contact the AMCOM Operations Center (AOC) DSN
897-2066/7 or (256) 313-2066/7.