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. |