Safety of Flight CH-47-05-01

 

Swashplate Rotating Ring

 

Summary of Problem: Recent inspection of over one hundred H-47 swashplate rotating rings in overhaul revealed the following anomalies: (1) fatigue cracks emanating from the bearing retention flange; (2) a serial number (SN) from an unapproved source; and (3) maintenance induced mechanical damage. The swashplate rotating ring life is based on a specific usage spectrum. Loads derived from this spectrum were then utilized during fatigue testing to substantiate the current rotating ring life. Consequently, the fatigue cracked rotating rings, with relatively low flight hours, were most likely cracked under loads and airspeeds in excess of currently authorized limits. In addition, mechanical damage appearing to have been induced from drifts, punches, and/or screwdrivers on the rotating ring, inner diameter, may develop into further crack initiation sites.

 

UNCLASSIFIED . MSG DTG 041830Z JAN 05 . FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A// . SUBJECT - SAFETY OF FLIGHT (SOF), TECHNICAL, RCS CSGLD-1860(R1), H-47 SERIES AIRCRAFT, SWASHPLATE ROTATING RING, CH-47-05-SOF-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 ....This message is effective until rescinded or superseded.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 - Recent inspection of over one hundred H-47 swashplate rotating rings in overhaul revealed the following anomalies: (1) fatigue cracks emanating from the bearing retention flange; (2) a serial number (SN) from an unapproved source; and (3) maintenance induced mechanical damage. The swashplate rotating ring life is based on a specific usage spectrum. Loads derived from this spectrum were then utilized during fatigue testing to substantiate the current rotating ring life. Consequently, the fatigue cracked rotating rings, with relatively low flight hours, were most likely cracked under loads and airspeeds in excess of currently authorized limits. In addition, mechanical damage appearing to have been induced from drifts, punches, and/or screwdrivers on the rotating ring, inner diameter, may develop into further crack initiation sites. 1.2. Message Purpose - 1.2.1. Rescind all CH-47 fleet Airworthiness Releases (AWRs) permitting operations up to 54,000 pounds. (The MH-47 54,000 lb capability is not affected by this message.) 1.2.2. Emphasize to the fleet to utilize only authorized tools and to exercise caution when conducting maintenance on the swashplate assembly. 1.2.3. Require an initial and recurring (100 flight hours for CH-47D/F and 150 flight hours for MH-47D/E), Eddy Current inspection for all forward and aft swashplate rotating rings. 1.2.4. Require replacement of swashplates incorporating rotating rings from unapproved sources. 2. END ITEMS AFFECTED - All H-47 series aircraft. 3. ASSEMBLIES/COMPONENTS/PARTS AFFECTED - 3.1. Suspect/discrepant assemblies/components/parts - ..Nomenclature PN NSN ..Fwd/Aft Rotating Ring Assembly ........................114R3464-9 1615-01-114-6125 ........................114R3464-11 1615-01-313-2241 3.2. Assemblies/components/parts to be inspected - ..Nomenclature PN NSN ..Swashplate Assy Fwd 145R3551-17 1615-01-395-0006 ........................145R3551-19 1615-01-473-4376 ........................145R3551-1 1615-01-115-3623 ........................145R3551-11 1615-01-352-8575 ........................145R3551-5 1615-01-315-5133 ..Swashplate Assy Aft 145R3551-18 1615-01-395-0007 ........................145R3551-20 1615-01-475-9838 ........................145R3551-2 1615-01-115-3610 ........................145R3551-12 1615-01-352-8576 ........................145R3551-6 1615-01-317-2432 .... ...................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-47-05-SOF-01 before [####.#] aircraft hours but NLT 19 Jan 2005." (Calculate [####.#] as current aircraft flight hours plus 10 hours). 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................... ....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 11 Jan 2005 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 REPORTING 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, and results ....of the inspection. .... 5.1. Aircraft - Submit Task/Inspection Compliance Report for this message to Log POC NLT 21 Jan 2005. 5.2. Retail Stock (Installation level and below) - Report receipt of this message to Log POC NLT 11 Jan 2005. Provide unit POC, address and phone number. Submit Task/Inspection Compliance Report for this message to Log POC NLT 21 Jan 2005. 5.3. Wholesale Stock (Including Depot stock, Depot Maintenance and Single Stock Fund) - Report receipt of this message to Wholesale POC NLT 11 Jan 2005. Provide local POC, address and phone number. Report compliance with this message IAW para 8 to Wholesale POC NLT 21 Jan 2005. 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. 6.3. Aircraft in Transit - 6.3.1. Surface/air shipment - Comply with message requirements within 10 aircraft hours/14 days of arrival. 6.3.2. Ferry status/Aircraft away from home station - Comply with message requirements within 10 aircraft hours/14 days of arrival. 6.4. Maintenance Trainers (Cat A and B) - Comply with message requirements NLT 4 Mar 2005. 6.5. Aircraft on Red //X// status symbol will be maintained in flyable storage. Ground run-ups at normal operating rotor RPM are authorized. 7. TECHNICAL PROCEDURES/INSTRUCTIONS - .... ...................NOTE................... ....Supplemental information (Addendum) for this message ....can be viewed at (use lower case letters only) ...."https://ams14.redstone.army.mil/safety/sof/pic/c47s0501.pdf" .... 7.1. Aircrews will insert the following CAUTIONs into the appropriate Operator's Manual (-10) in chapter 5 (before para 5-5-2.) and chapter 7 (before para 7-1-2.) respectively. .... ...................CAUTION................... ....Strict compliance with the airspeed limitations provided ....in TM 1-1520-240-10, Figures 5-5-1/2, TM 1-1520-252-10, ....Figures 5-5-1/-4, and TM 1-1520-271-10 (Figures 5-5-1/2) is ....required regardless of cruise guide indicator operational ....status. In addition, adherence to in flight cruise guide ....limitations shall also be maintained. .... ...................CAUTION................... ....Continuous power available is the only basis for all ....performance planning calculations except for emergency ....conditions (i.e. single engine capability). .... 7.2. 54,000 Pound CH-47 AWR Rescission - All CH-47 AWRs authorizing 54,000 pounds maximum gross weight are hereby rescinded. The CH-47 fleet is no longer authorized to operate aircraft at 54,000 pounds and are required to operate aircraft in accordance with the limits posted in the aircraft Operator's Manual. Crewmembers and maintenance personnel are to immediately remove and dispose of all CH-47, 54,000 pound AWRs from aircraft log books, reading files, and maintenance files. 7.3 PREVENTION OF MAINTENANCE INDUCED MECHANICAL DAMAGE TO SWASHPLATE ROTATING RINGS - Commanders/Facility Managers will ensure all maintenance personnel are briefed to emphasize that all maintenance, specifically in and around the swashplate area (for the purpose of this message), is performed using only approved tools and procedures listed in the applicable TM. Special attention should be given to avoid the possibility of tools slipping or dropping on the swashplate rotating ring (PN 114R3464-9/-11), bearing retention flange. 7.4. Conduct visual inspection of the forward and aft swashplate assemblies/rotating ring to determine the component SN. 7.4.1. The rotating ring (PN 114R3464-9/-11) SN must have one of the following prefixes: "TM", "GA", "BCW", "ILS", "TZ", or "W". These prefixes indicate the component is from an approved source of supply. 7.4.2. If any rotating ring SN begins with anything other than "TM", "GA", "BCW", "ILS", "TZ", or "W", the swashplate is unserviceable and must be disposed of IAW para 10.4. .... ...................NOTE................... ....Newly manufactured swashplates that have not been through ....overhaul and have less than 100 flight hours (CH-47) or 150 ....flight hours (MH-47) Time Since New (TSN) are exempt from ....the initial Eddy Current inspection but must comply with ....the new recurring inspection which begins at 100 hours TSN ....(CH-47) and 150 hours TSN (MH-47). .... 7.5. The following swashplate rotating rings were recently inspected (Eddy Current) at overhaul and are exempt from the initial inspection but must comply with the new recurring inspection which begins at 100 flight hours Time Since Overhaul (TSO) for CH-47 aircraft and at 150 flight hours TSO for MH-47 aircraft. Additionally, swashplates overhauled on or after 14 Dec 04 are also exempt from the initial Eddy Current inspection as required above. ....BCW-0024, BCW-181, BCW-187, BCW-188, BCW-194, BCW-195, ....BCW-206, BCW-237, BCW-243, BCW-277, BCW-290, BCW-559, ....BCW-585, BCW-600, BCW-603, BCW-742, BCW-749, BCW-787, ....BCW-788, BCW-798, BCW-807, BCW-843, BCW-854, BCW-872, ....BCW-879, BCW-902, BCW-916, BCW-959, BCW-1013, BCW-1038, ....BCW-1065, BCW-1080, BCW-1122, BCW-1123, BCW-1170, ....BCW-1180, BCW-1192, BCW-1217, BCW-1252, BCW-1283, ....BCW-1284, BCW-1300 BCW-1368, BCW-1387, BCW-1407, ....BCW-1435, BCW-1455, BCW-1507, BCW-1584, BCW-1588, ....BCW-1620, BCW-1702, BCW-1709, BCW-1720, BCW-1724, ....BCW-1732, BCW-1733, BCW-1741, BCW-1748, BCW-1767, ....BCW-1811, BCW-1822, BCW-1829, BCW-1843, BCW-1858, ....BCW-1866, BCW-1888, BCW-1908, BCW-1923, BCW-1925, ....BCW-2001, BCW-2010, BCW-2039, BCW-2074, BCW-2385, ....ILS-156, TZ-0217, TZ-0220, TZ-0334, TZ-0345, W1108461-2, ....W1142562-1, W1142367-4, W1202008-1, W1202014-4, ....W1202017-5, W1202017-6, W1295179-2, W1295182-6, ....W1295198-1, W1295199-6, W1381775-4, W1469321-3, ....W1469328-2, W1536939-9, W1540611-3, W1593747-3, ....W1630347-2, W1699540-1, W1701963-5, W1701963-6, ....W1701964-4, W1878359-5, W1893010-6, W1924351-2, ....W1924531-2, W1962014-5, and W4701965-5. .... ...................NOTE................... ....In addition to the SNs specified above, several aircraft were ....inspected IAW the procedures contained in the addendum of ....this message. This inspection was completed as part of the ....inspection procedures validation process. Aircraft that ....successfully passed this inspection with proper documentation ....in the aircraft records are not required to perform another ....initial inspection. Update the aircraft records to reflect ....the recurring requirements noted in this message. .... 7.6. INITIAL AND RECURRING EDDY CURRENT INSPECTION. Complete Eddy Current inspection IAW this message (and Addendum). This inspection is required for initial compliance, except as noted above, and at recurring 100 hour (CH-47) or 150 hour (MH-47) hour intervals. The recurring Swashplate Rotating Ring Eddy Current inspection may be aligned with the 100 hour (CH-47) or 150 hour (MH-47) swashplate bearing inspection, provided the bearing inspection is performed before the rotating ring inspection. 7.7. Annotate the DA Form 2408-18 with a 100 hour (CH-47) or 150 hour (MH-47) recurring Eddy Current inspection of the Forward and Aft Swashplate Rotating Ring, IAW Addendum to CH-47-05-SOF-01. ULLS-A units will use inspection number A-190 (Insp FWD & AFT Swashplate Rotating Ring), reference is CH-47-05-SOF-01, and use this message as authority for changes. 7.8. Clear the initial entry from para 4.1. upon completion of initial inspection 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) - Annotate the serviceability tag with: "CH-47-05-SOF-01, FWD & AFT Swashplate Rotating Ring, not complied with". Do not remove original condition tags. 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. Report message receipt to Log POC IAW para 5. 8.1.2. Suspend issue of affected items until in compliance with message requirements. 8.1.3. Contact the supported aviation unit, as required, to perform the procedures required on affected items. 8.1.4. Comply with inspection and correction procedures as required to return items to serviceable stock. 8.1.5. Submit a Task/Inspection report to Log POC IAW para 5. 8.2. Items in Single Stock Fund and in Work (Overhaul/Repair Facility) - Comply with inspection and correction procedures as required to return items to serviceable stock. 8.2.1. Depot, unit and other maintenance activity commanders will ensure items listed in para 3 are not issued until they are in compliance with this message. The procedures of Depot Maintenance Engineering Order (MEO) number T5054 may be utilized in lieu of the procedures in the Addendum to this message. 8.2.2. Submit Task/Inspection Compliance Report to Wholesale POC IAW para 5.3. 8.3. Items in Wholesale Stock - Depot storage facilities will complete the following procedures - 8.3.1. Report message receipt to Wholesale POC IAW para 5.3. 8.3.2. Suspend issue of affected items until in compliance with message requirements. Commanders and facility managers will ensure all items in condition codes //A//, //B//, //C//, //D//, and //E// that are affected by this message 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. 8.3.3. Submit DD Form 1225 (Storage Quality Control Report) to the Wholesale POC. Include an estimate of the cost reimbursable funding required to move serviceable items on hand affected by message to a work area, unpack the materiel, repack the materiel after inspection, and to return the materiel to storage, as appropriate. Report, by original serviceable condition code, the quantity of materiel placed in condition code //J//. 8.3.4. Comply with additional instructions provided by the Wholesale POC to return items to their original condition code. 9. SPECIAL TOOLS AND FIXTURES REQUIRED - ..Nomenclature PN NSN ..Eddy Current Instrument 9020210 6625-01-515-6713 .....or equivalent ..Reference Standard, Aluminum 7075-T6 (0.008 in, 0.020 in and 0.040 in EDM notches) ..Eddy Current Probe Kit SPCK-217/CH-47 N/A 10. SUPPLY/PARTS (REQUISITION/DISPOSITION) - .... ...................NOTE................... ....The Program Manager, Cargo Helicopters, in coordination ....with 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: ..Noun PN/NSN Qty Cost ea. Total $ ..Swashplate, Aft 145R3551-18 1 $112,935.00 $112,935.00 ......................1615-01-395-0007 ..Swashplate, Fwd 145R3551-17 1 $103,151.00 $103,151.00 ......................1615-01-395-0006 ...........Total maximum cost per aircraft = ....................2 Swashplate Assemblies $216,086.00 .... ...................NOTE................... ....The swashplate assemblies listed above contain all ....of the following individual parts. Units will either ....replace the assembly or will be required to obtain ....the individual parts, as required. .... ..Rotating Ring & Bearing Assembly ...................CH-47-SOF-SWSP 2 $15,546.00 $31,092.00 ......................1615-01-525-4058 ..Seal 114RS306-6 2 $355.47 $710.94 ......................5330-00-999-4077 ..Retainer 114R3417-3 4 $296.95 $1,187.80 ......................5330-01-474-4303 ..Ring Assy 114R3490-1 1 $3,850.62 $3,850.62 ......................1615-01-476-0755 ..Bolt BACB30LC6-38 36 $2.59 $93.24 ......................5306-01-474-3835 ..Bolt BACB30FD5H14 36 $2.91 $104.76 ......................5306-01-476-1906 ..Nut, Self Locking FN22M-524 12 $3.07 $36.84 ......................5310-01-070-9314 ..Bolt, Shear MS21134H05004 12 $2.91 $34.92 ......................5306-01-108-7462 ..Gasket 114R3428-1 2 $31.14 $62.28 ......................5330-00-849-4366 ..Nut, Self FN22M-428 10 $1.13 $11.30 .........Locking 5310-01-184-0356 ..Nut, Self FN22M-624 36 $1.52 $54.72 .........Locking 5310-01-184-0354 ..Retainer, 114R3126-4 2 $1805.25 $3,610.50 .........Swashplate..1615-00-181-4127 ...........Total maximum cost per aircraft = ....................Individual parts (2 sets) $40,849.92 10.2. Bulk and consumable materials - ..Nomenclature PN NSN ..Grease, WTR MIL-G-81322 9150-00-145-0268 ..Cloth, Lint Free MIL-C-24671 4470-01-498-8080 10.3. Requisitioning instructions - Contact the Log POC in para 13.2. for requisitioning instructions. All requisitions shall use Project Code (CC 57-59) "X2Z" (X-Ray-Two-Zulu). .... ...................NOTE................... ....Project Code "X2Z" 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 - Unit will submit a CAT 1 QDR on any Swashplate Rotating Ring that failed the inspections IAW this message. Hold discrepant parts pending disposition instructions from Technical POC. If instructed to dispose of using normal supply procedures, all turn-in documents must include Project Code (CC 57-59) "X2Z" (X-Ray-Two-Zulu). 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 - AVIM. 11.2. Estimated time required - 11.2.1. Time to complete inspection - Total of 12 man-hours using 4 persons with 3 hours "Not Mission Capable Maintenance" (NMCM) time per end item. .... ...................NOTE................... ....The time stated below does not include time for ....Maintenance Operational Checks or Maintenance Test ....Flights, if required. .... 11.2.2. Time for repair/replacement - Total of 128 man-hours using 8 persons with 16 hours "Not Mission Capable Maintenance" (NMCM) time per end item. 12. PUBLICATION REQUIREMENTS - 12.1. References - 12.1.1. AR 95-1. 12.1.2. AR 200-1. 12.1.3. DA Pam 738-751. 12.1.4. TM 55-1520-240-23., Aviation Unit and Aviation Intermediate Maintenance Manual, CH-47D Helicopter. 12.1.5. TM 1-1520-252-23, Aviation Unit and Aviation Intermediate Maintenance Manual, MH-47E Helicopter. 12.1.6. TM 1-1520-240-10, Operator's Manual for CH-47D Helicopters. 12.1.7. TM 1-1520-271-10, Draft Operator's Manual for CH-47F Helicopters. 12.1.8. TM 1-1520-252-10, Operator's Manual for MH-47E Helicopters. 12.1.9. Staveley Eddy Current Operator's Manual, PN 7720064, Dual Eddy Scope Operation Manual, Revision 5, October 2003. 12.2. Publication changes - The following publications shall be changed to reflect this message: TM 55-1520-240-23, TM 1-1520- 252-23, TM 1-1520-240-10, TM 1-1520-252-10, TM 1-1520-271-10. A copy of this message will be used as authority to implement the change until the official change is received. 13. POINTS OF CONTACT - 13.1. Technical POCs are - 13.1.1. Primary - Mr. Neil Sutherland, AMSRD-AMR-AE-C, DSN 897- 3382 or (256) 313-3382. Fax is 897-4726 or (256) 313-4726. Email is "neil.sutherland@peoavn.redstone.army.mil". 13.1.2. Alternate - Mr. Tim Rickmeyer, AMSRD-AMR-AE-C, DSN 645- 6485 or (256) 955-6485. Fax is 897-4726 or (256) 313-4726. Email is "timothy.rickmeyer@us.army.mil". 13.1.3. Non Destructive Test Center of Excellence - Mr. David Nelson, SFAE-AV-AS-AG, DSN 897-0211 or (256) 313-0211. Fax DSN 897-0200 or (256) 313-0200. Email is "ndt-coe@peoavn.redstone.army.mil". 13.2. Logistical POCs are - 13.2.1. Primary - Mr. Bill Olson, SFAE-AV-CH-L, DSN 897-0721 or (256) 313-0721. Fax is 897-4726 or (256) 313-4726. Email is "william.olson@peoavn.redstone.army.mil". 13.2.2. Alternate - Mr. Norm Huston, SFAE-AV-CH-L, DSN 897-0752 or (256) 313-0752. Fax is 897-4348 or (256) 313-4348. Email is "norm.huston@peoavn.redstone.army.mil". 13.3. Wholesale Materiel POC (spares) is Ms. Sue Endicott, AMSAM-MMC-AV-CA, DSN 897-3364 or (256) 313-3364. Fax is DSN 897- 4726. Email is "sue.endicott@us.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. 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". 13.5.2. 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". 13.5. Foreign Military Sales POC is Mr. Ronnie W. Sammons, AMSAM-SA-AS-UT, DSN 897-0875 or (256) 313-0875. Fax is DSN 897- 0411 or (256) 313-0411. Email is "ronnie.sammons@redstone.army.mil". 13.6. After hours, contact the AMCOM Operations Center (AOC) DSN 897-2066/7 or (256) 313-2066/7.