Safety of Flight CH-47-93-03

 

         

                                SYNOPSIS


CH-47-93-03   SAFETY OF FLIGHT MESSAGE, TECHNICAL, ALL CH-47D, MH-47D AND

              MH-47E AIRCRAFT, ONE TIME RECORDS CHECK OF ENGINE TRASMISSIONS,

              P/N 145D6300-(SERIES), TO IDENTIFY UNSERVICEABLE   

              TRANSMISSIONS, (TB 1-1520-240-20-66). 

              161400Z JUL, BRAD MEYER, AMSAT-C-XS, X2085.


01   14   161400Z  JUL  93  OO  PP  UUUU


FROM
:CDRATCOM ST LOUIS MO //AMSAT-C-XS//
TO
:AIG 8881
:AIG 9004
:AIG 8708
:AIG 9042
:DEFARM CANBERRA AS //DOHS-A//
:DEFNAV CANBERRA AS
:CDRUSARDSG CANBERRA AS
:HQLCENG MELBOURNE AS //DAIRENG//
:LOG CON OTTAWA ONT CAN //DTHEM 6-3//
:AUSTNAV WASHINGTON DC //DEFNAV//
:AUSTAIR WASHINGTON DC //SENGSO//
:USOMC CAIRO EG //AV//
:EGYPT AF FMS CAIRO EG //ED-MA//
:ODC ATHENS GR //ODCSA-A//
:CDR4THBN228THAVN SOTO CANO HO //AVN-AMO//
:CHJUSMAG SEOUL KOR //MKAR-AV//
:HQ ROKA TAEJON KOR //DCSLOG-AVIATION/ROKA AVIATION//
:CDR160TH SOAR FT CAMPBELL KY //AOAV-SI//
:CDRBGAD RICHMOND KY //SDSBG-GC//
:CHMUSLO RABAT MO //AF//
:CHUSAS RIYADH SA //ASAV//
:ODC MADRID SP //ARMY AND NAVY SEC//
:CJUSMAG BANGKOK TH
:CDRUSARDSG LONDON UK //AMXSN-UK-SE//
INFO
:CDRAMCCOM ROCK ISLAND IL //AMSAR-QAS-P//
:CDRAMC ALEXANDRIA VA //AMCMR/AMCCS/AMCSM-WAA//
XMT
:USDAO DHAKA BG
:USDAO RANGOON BM
:USDAO COLUMBO CE
:USDAO SUVA FJ
:OMADP JAKARTA ID
:DSA NEW DELHI IN
:USDAO ANTANANARIVO MA
:SAO KUALA LUMPUR MY
:USDAO KATMANDU NP //SAO//
:USDAO SINGAPORE SN //SAO//
ACCT
:
TEXT
:UNCLAS
SUBJECT - SAFETY-OF-FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-1860(R1),
ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, ONE TIME RECORDS CHECK OF
ENGINE TRANSMISSIONS, P/N 145D6300-(SERIES), TO IDENTIFY
UNSERVICEABLE TRANSMISSIONS (CH-47-93-03) (TB 1-1520-240-20-66).
NOTE - THIS IS A SAFETY-OF-FLIGHT MESSAGE AND 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 ADDRESSES WILL IMMEDIATELY
VERIFY THIS TRANSMISSION TO COMMANDER, ATCOM, ATTN:  AMSAT-C-XS (SOF
COMPLIANCE OFFICER).
1.  PRIORITY CLASSIFICATION -
NOTE - PER AR 95-3, PARA 5-6A, MAJOR COMMANDERS MAY AUTHORIZE
TEMPORARY EXCEPTION FROM SOF MESSAGE REQUIREMENTS.  EXCEPTIONS 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 THE
CONDITION STATUS SYMBOL OF THE CITED AIRCRAFT WILL BE CHANGED TO A
CIRCLED RED //X//.  THE CIRCLED RED //X// MAY BE CLEARED WHEN THE
INSPECTION OF PARA 8 BELOW IS PASSED.  AIRCRAFT THAT DO NOT PASS THE
INSPECTION OF PARA 8 WILL BE UPGRADED TO A RED //X//.  IF NEEDED,
AIRCRAFT AWAY FROM HOME BASE MAY BE DOWNGRADED TO A CIRCLED RED
//X// FOR A ONE TIME DIRECT FLIGHT TO THE NEAREST MILITARY BASE WITH
ADEQUATE SECURITY AND MAINTENANCE CAPABILITIES.  FLIGHT WILL CONSIST
OF MINIMUM CREW, LOW GROSS WEIGHT AND LOW LEVEL FLIGHT NOT TO EXCEED
500 FT AGL.  AIRCRAFT ON RED //X// STATUS SYMBOL WILL BE MAINTAINED
IN FLYABLE STORAGE.  GROUND RUN-UPS AT NORMAL OPERATING ROTOR RPM
ARE AUTHORIZED.
     B.  AIRCRAFT IN DEPOT MAINTENANCE - AIRCRAFT WILL NOT BE ISSUED
UNTIL COMPLIANCE WITH THIS MESSAGE HAS BEEN COMPLETED.
     C.  AIRCRAFT UNDERGOING MAINTENANCE - AIRCRAFT WILL NOT BE
RELEASED UNTIL COMPLIANCE WITH THIS MESSAGE HAS BEEN COMPLETED.
     D.  AIRCRAFT IN TRANSIT -
          (1)  SURFACE/AIR SHIPMENT - PRIOR TO FIRST FLIGHT AT FINAL
DESTINATION.
          (2)  FERRY STATUS - THOSE AIRCRAFT THAT HAVE A DD250 AND
ARE AT BOEING HELICOPTER COMPANY WILL BE INSPECTED PRIOR TO FERRY TO
FINAL DESTINATION.
     E.  MAINTENANCE TRAINERS (CATEGORY A, B AND C) - SAME AS PARA
1A FOR CATEGORY A TRAINERS.  CATEGORY B AND C TRAINERS SHALL PERFORM
THE REQUIREMENTS OF THIS MESSAGE WITHIN 10 DAYS FROM THE DATE OF
THIS MESSAGE.
     F.  COMPONENT/PARTS IN STOCK INCLUDING WAR RESERVES AT ALL
LEVELS (DEPOT AND OTHERS) - PERFORM INSPECTION ON DEPOT STOCK IAW
PARA 8 AND REPORT IAW PARA 14D.  ITEM MANAGERS HAVE PLACED A CONTROL
ON ENGINE TRANSMISSIONS.  ENGINE TRANSMISSIONS, P/N 145D6300-
(SERIES), AND SPIRAL BEVEL GEARS, P/N 145D6302-2 DETERMINED TO BE
UNSERVICEABLE IAW THIS MESSAGE SHALL BE PLACED IN CONDITION CODE
//J//.
NOTE - DEPOTS THAT DO NOT HAVE THE CAPABILITY TO INSPECT THE SUBJECT
ASSEMBLIES IN ACCORDANCE WITH THIS MESSAGE, CONTACT THE LOGISTICAL
POC.  DO NOT ISSUE UNTIL THIS MESSAGE HAS BEEN COMPLIED WITH AND/OR
YOU HAVE BEEN NOTIFIED WHICH ARE SERVICEABLE.
2.  TASK/INSPECTION SUSPENSE DATE - PRIOR TO NEXT MISSION DAY.
3.  REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE TO
COMMANDER, ATCOM, ATTN:  AMSAT-C-XS NO LATER THAN 5 AUG 93 PER PARA
14A.
4.  SUMMARY OF PROBLEM -
     A.  A CH-47D HELICOPTER EXPERIENCED AN ENGINE TRANSMISSION
FAILURE RESULTING IN A CLASS C ACCIDENT WHILE AT A STEADY STATE
HOVER.  TEARDOWN ANALYSIS OF THE COMPONENTS REVEALED THAT AN ENGINE
TRANSMISSION SPIRAL BEVEL GEAR FAILED FROM FATIGUE ORIGINATING FROM
A DEFECT.
     B.  THE SECOND SOURCE MANUFACTURER'S GRINDING AND INSPECTION
PROCESSES ARE SUSPECT.  THEREFORE, IT IS NECESSARY TO REMOVE FROM
SERVICE ALL SPIRAL BEVEL GEARS, P/N 145D6302-2, MADE BY THIS
MANUFACTURER FOR INSPECTION.  ENGINE TRANSMISSIONS CONSIDERED
UNSERVICEABLE ARE IDENTIFIED BY 73 ENGINE TRANSMISSION SERIAL
NUMBERS.  IN ADDITION, ANY ENGINE TRANSMISSION HISTORICAL RECORD
HAVING A SPIRAL BEVEL GEAR, P/N 145D6302-2, SERIAL NUMBER WITH A
PREFIX "P" (PAPA), MAKES THAT ENGINE TRANSMISSION UNSERVICEABLE.  IF
THE SPIRAL BEVEL GEAR, P/N 145D6302-2, SERIAL NUMBER IS NOT LISTED
ON THE ENGINE TRANSMISSION HISTORICAL RECORD, THE ENGINE
TRANSMISSION IS ALSO CONSIDERED UNSERVICEABLE; UNLESS DETERMINED
SERVICEABLE BY THE LOGISTICAL POC.
     C.  CONTROLLED SUBSTITUTION IS AUTHORIZED TO MINIMIZE AFFECTED
AIRCRAFT.  OTHERWISE, DO NOT REMOVE SUSPECT ENGINE TRANSMISSION FROM
AIRCRAFT BEFORE CONTACTING THE LOGISTICAL POC SO THAT 14 DAY GROUND
RUNUPS CAN BE PERFORMED.
     D.  THE PURPOSE OF THIS MESSAGE IS TO DIRECT A RECORDS CHECK OF
ALL ENGINE TRANSMISSIONS TO IDENTIFY UNSERVICEABLE TRANSMISSIONS
PRIOR TO NEXT MISSION DAY.
5.  END ITEMS TO BE INSPECTED - ALL MH-47D, CH-47D AND MH-47E
AIRCRAFT.  AIRCRAFT SERIAL NUMBERS 92-0291 AND SUBSEQUENT WILL BE
INSPECTED/CORRECTED BY CONTRACTOR DURING PRODUCTION AND THEREFORE
RECORDS FOR AIRCRAFT SERIAL NUMBERS 92-0291 AND SUBSEQUENT WILL NOT
REQUIRE IDENTIFICATION OF THIS ACTION.
6.  ASSEMBLY COMPONENTS TO BE INSPECTED -
    NOMENCLATURE           PART NO.                    NSN
ENGINE TRANSMISSION       145D6300-3            1615-01-146-5273
ENGINE TRANSMISSION       145D6300-2            1615-01-119-3373
ENGINE TRANSMISSION       145D6300-9            1615-01-315-4070
ENGINE TRANSMISSION       145D6300-8            1615-01-320-6787
ENGINE TRANSMISSION       145D6300-6            1615-01-271-0663
ENGINE TRANSMISSION       145D6300-7            1615-01-271-7601
ENGINE TRANSMISSION       145D6300-11           1615-01-315-9364
ENGINE TRANSMISSION       145D6300-10           1615-01-319-3959
7.  PARTS TO BE AFFECTED -
    NOMENCLATURE            PART NO.                   NSN
SPIRAL BEVEL GEAR         145D6302-2             3040-01-114-9453
                              NOTE
UNSERVICEABLE GEARS ARE IDENTIFIED BY HAVING THE LETTER "P" (PAPA)
AT THE FRONT OF THE SERIAL NUMBER.
8. INSPECTION PROCEDURES -
     A.  CHECK AIRCRAFT RECORDS TO DETERMINE SERIAL NUMBER OF ENGINE
TRANSMISSION, P/N 145D6300-(SERIES).  THE FOLLOWING ENGINE
TRANSMISSIONS BY SERIAL NUMBER ARE CONSIDERED UNSERVICEABLE:
ENGINE TRANSMISSION SERIAL NUMBERS
     A11-430        A11-811        A11-1082
     A11-683        A11-812        A11-1096
     A11-685        A11-850        A11-1097
     A11-686        A11-851        A11-1104
     A11-687        A11-852        A11-1134
     A11-688        A11-874        A11-1156
     A11-707        A11-882        A11-1157
     A11-708        A11-885        A11-1158
     A11-710        A11-924        A11-1209
     A11-732        A11-925        A11-1210
     A11-747        A11-938        A11-1213
     A11-760        A11-939        A11-1214
     A11-773        A11-973        A11-1223
     A11-775        A11-976        A11-1224
     A11-776        A11-1040       A11-1225
     A11-783        A11-1041       A11-1226
     A11-784        A11-1042       A11-1245
     A11-786        A11-1050       A11-1246
     A11-789        A11-1051       A11-1257
     A11-790        A11-1052       A11-1258
     A11-791        A11-1053       A11-1263
     A11-795        A11-1054       A11-1264
     A11-798        A11-1056       A11-1270
     A11-809        A11-1062
     A11-810        A11-1081
     B.  CHECK DA FORM 2408-16 (COMPONENT) FOR ALL ENGINE
TRANSMISSIONS, P/N 145D6300-(SERIES).
          (1)  SPIRAL BEVEL GEARS, P/N 145D6302-2 LISTED ON THIS
FORM HAVING A SERIAL NUMBER WITH THE PREFIX "P" (PAPA) MAKES THE
SPIRAL BEVEL GEAR, P/N 145D6302-2 AND THE ENGINE TRANSMISSION
UNSERVICEABLE.
          (2)  ENGINE TRANSMISSIONS WITH A DA FORM 2408-16
(COMPONENT) THAT DOES NOT LIST SPIRAL BEVEL GEARS, P/N 145D6302-2
ARE CONSIDERED UNSERVICEABLE UNLESS DETERMINED SERVICEABLE BY
LOGISTICAL POC.  CONTACT LOGISTICAL POC.
     C.  AIRCRAFT WITH AN UNSERVICEABLE TRANSMISSION IAW THIS
MESSAGE WILL BE UPGRADED TO A RED //X//.
     D.  AIRCRAFT THAT DO NOT HAVE AN UNSERVICEABLE ENGINE
TRANSMISSION IAW THIS MESSAGE MAY CLEAR THE CIRCLE RED //X// AND THE
INSPECTION IS COMPLETE.
                             NOTE
UNITS WILL BE PROVIDED DISPOSITION INSTRUCTIONS FROM LOGISTICAL POC
BY FOLLOW UP COMMUNICATION.  CONTROLLED SUBSTITUTION IS AUTHORIZED
TO MINIMIZE AFFECTED AIRCRAFT, OTHERWISE, DO NOT REMOVE SUSPECT
ENGINE TRANSMISSION FROM AIRCRAFT BEFORE CONTACTING LOGISTICAL POC
SO THAT 14 DAYS GROUND RUNUPS CAN BE PERFORMED.
9.  CORRECTION PROCEDURES - ENGINE TRANSMISSIONS AND SPIRAL BEVEL
GEARS IDENTIFIED IN PARA 8 WILL BE RECEIVED/RETURNED FROM
SUPPLY/BOEING HELICOPTERS AND INSPECTED/REPAIRED AT A LATER DATE.
INSPECTED/REPAIRED ENGINE TRANSMISSIONS AND SPIRAL BEVEL GEARS
IDENTIFIED IN PARA 8 THAT ARE CONSIDERED SERVICEABLE WILL HAVE
"EB" (ECHO-BRAVO) BEHIND THE ENGINE TRANSMISSION SERIAL NUMBER AND
THE SPIRAL BEVEL GEAR SERIAL NUMBER.
10.  SUPPLY/PARTS AND DISPOSITION -
     A.  PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 6 MAY BE REQUIRED
TO REPLACE DEFECTIVE ITEMS.
     B.  REQUISITIONING INSTRUCTIONS - CONTACT LOGISTICAL POINT OF
CONTACT FOR REQUISITIONING INSTRUCTIONS.
     C.  BULK AND CONSUMABLE MATERIALS - N/A.
     D.  DISPOSITION - UNITS WILL BE PROVIDED DISPOSITION
INSTRUCTIONS BY LOGISTICAL POC.
     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.  TIME REQUIRED - TOTAL OF .5 MANHOURS USING 1 PERSON TO
PERFORM RECORDS CHECK.
     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 - N/A.
14.  RECORDING AND REPORTING REQUIREMENTS -
     A.  REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON
ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1, FORWARD
A PRIORITY MESSAGE, DATAFAX OR E-MAIL TO COMMANDER, ATCOM, ATTN
AMSAT-C-XS (SOF COMPLIANCE OFFICER), PER AR 95-3.  DATAFAX NUMBER IS
DSN 693-2064 OR COMMERCIAL 314/263-2064.  E-MAIL ADDRESS IS
"AMSATCXS (AT SIGN) ST-LOUIS-EMH4.ARMY.MIL".  THE REPORT WILL CITE
THIS MESSAGE NUMBER, DATE OF ENTRY ON 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) - UPON
COMPLETION OF INSPECTION UNITS HAVING UNSERVICEABLE ENGINE
TRANSMISSIONS PER THIS MESSAGE SHALL FORWARD A PRIORITY MESSAGE TO
CH-47D PMO, ATTN:  SFAE-AV-CH-L.  DATAFAX IS DSN 693-1485 OR
COMMERCIAL 314/263-1485.  THE REPORT WILL CITE THIS MESSAGE, DATE OF
INSPECTION, AIRCRAFT S/N, ENGINE TRANSMISSION S/N, SPIRAL BEVEL GEAR
S/N, POC AND PHONE NUMBER.
     C.  REPORTING SUSPENSE DATE (SPARES) - N/A.
     D.  TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) -  UPON
COMPLETION OF THE INSPECTION DEPOT COMMANDERS AND OTHERS HOLDING
STOCK SHALL FORWARD A PRIORITY MESSAGE REPORT OF RESULTS OF THIS
INSPECTION TO LOGISTICAL POC BELOW NLT 10 DAYS FROM THE DATE OF THIS
MESSAGE.  THE REPORT SHALL INCLUDE QUANTITY ON HAND, QUANTITY WHICH
PASSED INSPECTION, QUANTITY WHICH FAILED INSPECTION, ENGINE
TRANSMISSION S/N AND SPIRAL BEVEL GEAR S/N.
     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 2408-13-2, RELATED MAINTENANCE ACTIONS
RECORD.
          (4)  DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
          (5)  DA FORM 2408-5-1, EQUIPMENT MODIFICATION RECORD
(COMPONENT)
          (6)  DA FORM 2408-16, AIRCRAFT COMPONENT HISTORICAL
RECORD (IF ENGINE TRANSMISSION IS REMOVED OR INSTALLED).
          (7)  DA FORM 2410, COMPONENT REMOVAL AND
REPAIR/OVERHAUL RECORD.  (NORMAL, EVACUATION, REPAIR AND
INSTALLATION CYCLE) (IF ENGINE TRANSMISSION IS REMOVED OR
INSTALLED).
15.  WEIGHT AND BALANCE - N/A.
16.  POINTS OF CONTACT -
     A.  TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. MIKE
WRIGHT, AMSAT-R-ECC, DSN 693-3820 OR COMMERCIAL 314/263-3820.
     B.  LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. NORM
HUSTON, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL 314/263-1415.
     C.  FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS.
ANN WALDECK, AMSAT-I-MDM, DSN 693-1821 OR COMMERCIAL 314/263-1821.
     D.  POINT OF CONTACT FOR THIS MESSAGE IS MR. BRAD MEYER, AMSAT-
C-XS, DSN 693-2085 OR COMMERCIAL 314/263-2085.
     E.  FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING
CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT MW4
JAY NANCE/MR. RON VAN REES, AMSAV-I-IA, DSN 693-3826/3659 OR
COMMERCIAL 314/263-3826/3659.
     F.  AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER (COC)
DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.