Safety of Flight CH-47-97-01 |
Summary of Problem: A. Safety-of-Flight Messages (see para 13a and 13b below) issued in April 1990 required the inspection/replacement of NAS577B20A Barrel Nuts to purge the supply system of nuts manufactured by Hartford Aircraft Products (HAP) Inc., Cage 66861. These nuts mount the Forward Transmission to the airframe, and four (4) nuts are required per aircraft. Analysis of several failed Barrel Nuts manufactured by this vendor indicated impurities in steel and alloy segregation. All other manufacturers NAS577B20A Barrel Nuts are acceptable. B. A report was just received that another subject Barrel Nut manufactured by this vendor was found in the field assets. It is logical to assume that additional discrepant nuts manufactured by Hartford Aircraft Products, Inc. maybe installed on H-47 Chinook aircraft. |
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01 16 141510Z NOV 96 OO PP UUUU AA ZYUW FROM :CDRATCOM ST LOUIS MO//AMSAT-R-X// TO :AIG 8881 :AIG 9004 :AIG 8708 :AIG 9042 :AIG 7471 :AIG 12124 :USMILGP BUENOS AIRES AR//ARMY AND AF SEC// :DEFAIR MATERIAL CANBERRA AS//DAAP-AF// :ARMYLMSQN OAKEY AS :AVN REGT HQ SQN OAKEY AS//DAVN-A// :CDRUSARDSG CANBERRA AS//AMXIP-AS// :LOGCON OTTAWA CAN//DTHEM 6-2// :ARGENTINE AIR ATTACHE FMS WASHINGTON DC :EGYPT AF FMS CAIRO EG//ED/MA// :USOMC CAIRO EG//AV// :ODC ATHENS GR//ODCSA// :CHJUSMAG SEOUL KOR//MKAR-AV// :ROK ARMY FMS PUSAN KOR//ALC-LSD-L// :CDR160TH SOAR FT CAMPBELL KY//AOAV-SI// :CDRBGAD RICHMOND KY//SIOBG-GC// :USDAO RABAT MO//AF// :ODC THE HAGUE NL//AVIATION SAFETY// :RNLAF MATERIAL :RNLAF OPERATIONS :CDRUSASAC NEW CUMBERLAND PA//AMSAC-SALO-UK// :CHUSAS RIYADH SA//ASAV// :SAO SINGAPORE SN//AVIATION SAFETY// :ODC MADRID SP//ASM// :SPAIN ARMY FMS MADRID SP :AIT TAIPEI TW :TAIWAN ARMY FMS TAIPEI TW :CJUSMAG THAI BANGKOK TH//MAGTAR-FS// :ROYAL THAI ARMY FMS DUSIT ORDNANCE DEP BANGKOK TH :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK :DHSA YEOVILTON UK//HS-31// INFO :FAA SOUTHWEST RGN HQ FORT WORTH TX//ASW-100// :CDRAMC ALEXANDRIA VA//AMCMR/AMCCS/AMCSM-WAA// XMT :USDAO DHAKA BG :USDAO RANGOON BM :USCINCPAC REP PHNOM PENH CB :USDAO COLOMBO CE :USDAO SUVA FJ :OMADP JAKARTA ID :DSA NEW DELHI IN :AMEMBASSY ANTANANARIVO MA :AMEMBASSY PORT LOUIS :SAO KUALA LUMPUR MY :AMEMBASSY KATHMANDU NP//POL-MIL// :AMEMBASSY VICTORIA ACCT : TEXT :UNCLAS SUBJECT: SAFETY-OF-FLIGHT (SOF) MESSAGE, TECHNICAL, RCS CSGLD-1860(R1), ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, ONE TIME VISUAL INSPECTION OF FORWARD TRANSMISSION MOUNTING (BARREL) NUTS,P/N NAS 577B20A (CH-47-97-01) (TB 1-1520-240-20-91). 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 THIS MESSAGE. ACTION ADDRESSES WILL IMMEDIATELY VERIFY THIS TRANSMISSION TO COMMANDER, ATCOM, ATTN: AMSAT-R-X (SOF COMPLIANCE OFFICER). 1. PRIORITY CLASSIFICATION - A. AIRCRAFT IN USE - UPON RECEIPT OF THIS MESSAGE THE CONDITION STATUS SYMBOL OF THE CITED AIRCRAFT SHALL BE IMMEDIATELY CHANGED TO A CIRCLED RED //X//. THE CIRCLED RED //X// MAY BE CLEARED WHEN THE INSPECTION AND CORRECTION PROCEDURES OF PARA 8 AND 9 BELOW ARE COMPLETED. AIRCRAFT ON A CIRCLED RED //X// STATUS SYMBOL SHALL BE MAINTAINED IN FLYABLE STORAGE CONDITION. B. AIRCRAFT IN DEPOT MAINTENANCE - INSPECT AND CORRECT PRIOR TO ISSUE. AIRCRAFT SHALL NOT BE ISSUED UNTIL COMPLIANCE WITH THIS SOF MESSAGE HAS BEEN COMPLETED. C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A. D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - SAME AS PARA 1A. (2) FERRY STATUS - SAME AS PARA 1A. E. MAINTENANCE TRAINERS (CATEGORY A, B) - SAME AS PARA 1A. F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES - UPON RECEIPT OF THIS SOF MESSAGE THE MATERIEL CONDITION TAGS OF ALL ITEMS LISTED IN PARA 7 BELOW IN ALL CONDITION CODES SHALL BE ANNOTATED TO READ SOF MESSAGE CH-47- 97-01, ONE TIME VISUAL INSPECTION OF FORWARD TRANSMISSION MOUNTING (BARREL) NUTS, P/N NAS 577B20A, MUST BE COMPLIED WITH PRIOR TO ISSUE.. (1) WHOLESALE STOCK - UPON RECEIPT OF THIS SOF MESSAGE, DEPOT COMMANDERS SHALL ENSURE INSPECTION OF ALL ITEMS LISTED IN PARA 7 BELOW LOCATED IN ALL WHOLESALE DEPOTS INCLUDING ALL SATELLITE WHOLESALE DEPOTS AND WAR RESERVE DEPOTS. UPON RECEIPT OF THIS MESSAGE DEPOT COMMANDERS AND OTHERS MAINTAINING WHOLESALE STOCK SHALL ENSURE THAT SERVICEABLE MATERIEL (CONDITION CODES //A//, //B//, AND //C//) IS PLACED IN CONDITION CODE //J// AND TAGGED WITH A SUSPENDED TAG/LABEL - DD FORM 1576/1576-1. THE AUTHORITY BLOCK MUST REFERENCE INSPECTION REQUIRED PER THIS SOF MESSAGE (CH-47-97-01) (TB 1-1520-240-20-91). REPORT COMPLIANCE WITH THIS SOF MESSAGE IN ACCORDANCE WITH PARA 14D(1) BELOW. (2) RETAIL STOCK - UPON RECEIPT OF THIS SOF MESSAGE COMMANDERS AND OTHERS MAINTAINING RETAIL STOCK OF ITEMS LISTED IN PARA 7 BELOW SHALL CONTACT THEIR SUPPORT AVIATION ORGANIZATION TO PERFORM THE INSPECTION REQUIRED BY PARA 8 BELOW AND TO PERFORM THE CORRECTION PROCEDURES OF PARA 9 BELOW ON DISCREPANT MATERIEL. ALL ITEMS LISTED IN PARA 7 BELOW SHALL BE IMMEDIATELY PLACED IN CONDITION CODE //D// AND RETAGGED WITH A TEST/MODIFICATION TAG/LABEL - DD FORM 1576/1576-1 (BLUE COLOR). THE AUTHORITY BLOCK MUST REFERENCE INSPECTION REQUIRED PER THIS SOF MESSAGE (CH- 47-97-01) (TB 1-1520-240-20-91). ITEMS IDENTIFIED AS SERVICEABLE IAW PARA 8 BELOW SHALL BE RETAGGED WITH A SERVICEABLE TAG/LABEL - DD FORM 1574/1574-1 (YELLOW COLOR). INDICATE COMPLIANCE WITH THIS SOF MESSAGE (CH-47-97-01) (TB 1-1520-240- 20-91) IN THE REMARKS BLOCK. ITEMS IDENTIFIED AS DISCREPANT IAW PARA 8 BELOW SHALL BE RETAGGED WITH UNSERVICEABLE (REPARABLE) TAG/LABEL - 1577-2/1577-3 (GREEN COLOR). ANNOTATE REMARKS BLOCK TO INDICATE THAT THE ITEM IS UNSERVICEABLE IAW THIS SOF MESSAGE (CH-47-97-01) (TB 1-1520-240-20-91). ANY ITEMS FOUND DISCREPANT PER THE INSPECTION PROCEDURES CITED IN PARA 8 BELOW SHALL BE DISPOSED OF BY MUTILATION/DEMILITARIZED TO PREVENT RESALE. REPORT COMPLIANCE WITH THIS SOF MESSAGE IN ACCORDANCE WITH PARA 14D(2) BELOW. G. COMPONENTS/PARTS IN WORK - ALL ITEMS LISTED IN PARA 6 BELOW SHALL NOT BE ISSUED UNTIL COMPLIANCE WITH THIS SOF MESSAGE HAS BEEN COMPLETED. 2. TASK/INSPECTION SUSPENSE DATE - WITHIN 10 HOURS/14 DAYS. 3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 6 DEC 1996 PER PARA 14.A OF THIS MESSAGE. 4. SUMMARY OF PROBLEM - A. SAFETY-OF-FLIGHT MESSAGES (SEE PARA 13A AND 13B BELOW) ISSUED IN APRIL 1990 REQUIRED THE INSPECTION/REPLACEMENT OF NAS577B20A BARREL NUTS TO PURGE THE SUPPLY SYSTEM OF NUTS MANUFACTURED BY HARTFORD AIRCRAFT PRODUCTS (HAP) INC., CAGE 66861. THESE NUTS MOUNT THE FORWARD TRANSMISSION TO THE AIRFRAME, AND FOUR(4) NUTS ARE REQUIRED PER AIRCRAFT. ANALYSIS OF SEVERAL FAILED BARREL NUTS MANUFACTURED BY THIS VENDOR INDICATED IMPURITIES IN STEEL AND ALLOY SEGREGATION. ALL OTHER MANUFACTURERS NAS577B20A BARREL NUTS ARE ACCEPTABLE. B. A REPORT WAS JUST RECEIVED THAT ANOTHER SUBJECT BARREL NUT MANUFACTURED BY THIS VENDOR WAS FOUND IN THE FIELD ASSETS. IT IS LOGICAL TO ASSUME THAT ADDITIONAL DISCREPANT NUTS MANUFACTURED BY HARTFORD AIRCRAFT PRODUCTS, INC. MAYBE INSTALLED ON H-47 CHINOOK AIRCRAFT. C. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS, SEE PARA 12 BELOW D. THE PURPOSE OF THIS SOF MESSAGE IS TO REQUIRE ANOTHER ONE TIME VISUAL INSPECTION OF FORWARD TRANSMISSION NAS577B20A MOUNTING (BARREL) NUTS PRIOR TO NEXT FLIGHT AND REMOVAL OF NUTS MANUFACTURED BY HARTFORD AIRCRAFT PRODUCTS INC. WHICH CAN BE IDENTIFIED BY AN IMPRESSION STAMP MARKING OF HAP, OR CAGE CODE 66861, ON THE EXPOSED BARREL NUT CARRIER. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NUMBER NSN FORWARD TRANSMISSION 145D1300-9 1615-01-317-6446 ASSEMBLY 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NUMBER NSN NUT, SELF-LOCKING, NAS577B20A 5310-01-210-3874 BARREL 8. INSPECTION PROCEDURES - A. PREPARE AIRCRAFT FOR SAFE GROUND MAINTENANCE. B. VISUALLY INSPECT THE FOUR(4) NAS577B20A BARREL NUTS (SEE PARA 13 BELOW, REFERENCE C., TASK 6-51, ITEM 13.1, OR REFERENCE D., TASK 6-60, ITEM 15) THAT ATTACH THE FORWARD TRANSMISSION TO THE AIRFRAME. THE NUTS FASTEN TO THE BOTTOM OF THE MOUNTING BOLTS (ITEM 14 OR ITEM 17). C. INSPECT EACH BARREL NUT TO DETERMINE THE MANUFACTURER. USE A FLASHLIGHT AND MIRROR TO IMPROVE READABILITY. D. IF THE EXPOSED BARREL NUT CARRIER IS IMPRESSION STAMPED WITH HAP OR THE CAGE CODE 66861, THE NUT WAS MANUFACTURED BY HARTFORD AIRCRAFT PRODUCTS, INC., IS SUSPECT, AND MUST BE REMOVE FROM SERVICE. PROCEED TO PARA 9 BELOW FOR CORRECTIVE ACTION. E. IF THE EXPOSED BARREL NUT CARRIER IS MARKED IN ANY OTHER WAY ,OR HAS NO MARKINGS, THE NUT IS ACCEPTABLE AND NO FURTHER ACTION IS REQUIRED. RECORD AND REPORT COMPLIANCE WITH THIS SOF MESSAGE IN ACCORDANCE WITH PARA 14 BELOW. 9. CORRECTION PROCEDURES - A. REPLACE NAS577B20A BARREL NUTS EXHIBITING AN IMPRESSION STAMP OF HAP OR CAGE CODE 66861 WITH ANY OTHER MANUFACTURERS NUT PRIOR TO FURTHER FLIGHT. B. WHENEVER A BARREL NUT IS INSTALLED, THE BOLT MUST BE TORQUED IN ACCORDANCE WITH PARA 13 BELOW, REFERENCE C., TASK 6-51, PARA 9, OR REFERENCE D., TASK 6-60, PARA 12. ALSO, A ONE TIME RETORQUE AFTER 25 FLIGHT HOURS IS REQUIRED. C. ANY SUSPECT BARREL NUT REMOVED FROM AN AIRCRAFT OR FOUND IN SUPPLY SHALL BE DISPOSED OF BY MUTILATION/DEMILITARIZED TO PREVENT RESALE, REISSUE, OR USE BY ANY OTHER MDS AIRCRAFT SYSTEMS (I.E., UH-60, AH-64, ETC.). 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - ITEMS CITED IN PARA 7 ABOVE MAY BE REQUIRED TO REPLACE DEFECTIVE ITEMS.. B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT PARTS THROUGH NORMAL SUPPLY CHANNELS USING NORMAL SUPPLY PROCEDURES. ALL REQUSITIONS SHALL USE PROJECT CODE XCS PER THIS MESSAGE. NOTE PROJECT CODE XCS IS REQUIRED TO TRACK AND ESTABLISH A DATA BASE OF STOCK FUND EXPENDITURES INCURRED BY THE FIELD AS A RESULT OF SOF/ASAM ACTIONS. C. BULK AND CONSUMABLE MATERIALS - N/A. D. DISPOSITION - AFTER MUTILATION OR DEMILITARIZATION IAW PUBLISHED PROCEDURES, DISPOSE OF REMOVED COMPONENTS/PARTS IAW NORMAL SUPPLY PROCEDURES. A QDR IS NOT REQUIRED. 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. ESTIMATED TIME REQUIRED - (1) TOTAL OF ONE(1) MAN-HOUR USING ONE(1) PERSON. (2) TOTAL OF ONE(1) HOUR DOWNTIME FOR ONE(1) END ITEM. C. ESTIMATED COST IMPACT OF STOCK FUND ITEMS TO THE FIELD - NOUN PART NO./ QUANTITY UNIT COST TOTAL COST NSN PER ACFT NUT, SELF 145SS131-20/ 4 $123.00 $492.00 LOCKING, 5310-01-334-1248 BARREL 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. MESSAGE, AVSCOM, AMSAV-XSOF, 192100Z APR 90, SUBJECT: SAFETY-OF-FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-1860(R1), ALL CH-47D AIRCRAFT, ONE TIME INSPECTION OF CH-47D FORWARD TRANSMISSION BARREL NUTS, P/N NAS 577B20A, (CH-47-90-07) (TB 55- 1520-240-20-48). B. MESSAGE, AVSCOM, AMSAV-XSOF, 201700Z APR 90, SUBJECT: SAFETY-OF-FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-1860(R1), ALL CH-47D AIRCRAFT, CLARIFICATION TO ONE-TIME INSPECTION OF CH-47D FORWARD TRANSMISSION MOUNTING NUTS, P/N NAS 577B20A, (CH-47- 90-08) (TB 55-1520-240-20-48). C. TM 55-1520-240-23-5. D. TM 1-1520-252-23-6. 14. RECORDING AND REPORTING REQUIREMENTS - A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - UPON ENTERING REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 ON ALL SUBJECT MDS AIRCRAFT, FORWARD A PRIORITY MESSAGE, DATAFAX OR E-MAIL TO COMMANDER, ATCOM, ATTN: AMSAT-R-X (SOF COMPLIANCE OFFICER), PER AR 95-3. DATAFAX NUMBER IS DSN 693-2064 OR COMMERCIAL (314) 263-2064. E-MAIL ADDRESS IS "AMSATRXS (AT SIGN) EMH4.STL.ARMY.MIL". THE REPORT WILL CITE THIS MESSAGE NUMBER, DATE OF ENTRY IN 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) - WITHIN TWO(2) WORKING DAYS OF RECEIPT OF THIS SOF MESSAGE, UNITS WILL FORWARD A PRIORITY MESSAGE TO: COMMANDER, ATCOM, ATTN: AMCPM-CH-L. THE REPORT WILL CITE THIS SOF MESSAGE NUMBER, DATE OF INSPECTION, AIRCRAFT SERIAL NUMBER, AIRCRAFT AND COMPONENT HOURS, AND RESULTS OF THE INSPECTION. INSPECTION AND REPORTS WILL BE COMPLETED NO LATER THAN 7 DAYS AFTER TASK/INSPECTION SUSPENSE DATE. C. REPORTING COMPLIANCE SUSPENSE DATE (SPARES) - (1) MATERIEL IN RETAIL STORAGE - REPORT RECEIPT OF THIS MESSAGE TO THE LOGISTICAL POINT OF CONTACT LISTED IN PARAGRAPH 16B WITHIN TWO(2) WORKING DAYS FROM THE DATE OF THIS MESSAGE. (2) MATERIEL IN WHOLESALE DEPOT STORAGE - REPORT RECEIPT OF THIS MESSAGE TO THE WHOLESALE MATERIEL (SPARES) POINT OF CONTACT LISTED IN PARAGRAPH 16C WITHIN TWO(2) DAYS FROM THE DATE OF THIS MESSAGE. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - (1). MATERIAL IN WHOLESALE DEPOT STORAGE- REPORT COMPLIANCE WITH THIS SOF MESSAGE TO THE WHOLESALE MATERIEL POINT OF CONTACT (SPARES) LISTED IN PARAGRAPH 16C WITHIN TWO(2) WORKING DAYS FROM THE DATE OF THIS MESSAGE. PROVIDE AN ESTIMATE OF THE COST REIMBURSABLE FUNDING REQUIRED TO MOVE THE ITEMS LISTED IN PARA 7 ABOVE TO A WORK AREA, UNPACK THE MATERIEL, REPACK THE MATERIEL AFTER INSPECTION BY ATCOM INSPECTORS, AND TO RETURN THE MATERIEL TO STORAGE. REPORT THE SERIAL NUMBERS, BY ORIGINAL SERVICEABLE CONDITION CODE, OF ALL MATERIAL PLACED IN CONDITION CODE //J//. (2) MATERIAL IN RETAIL STORAGE- REPORT COMPLIANCE WITH THIS MESSAGE TO THE LOGISTICAL POINT OF CONTACT IN PARAGRAPH 16B WITHIN TWO(2) WORKING DAYS FROM THE DATE OF THIS MESSAGE. REPORT THE QUANTITY INSPECTED BY CONDITION CODE, AND THE RESULTING CONDITION CODE. REPORT THE SERIAL NUMBERS OF ALL MATERIEL REQUIRING CORRECTION. PLACE THESE ITEMS IN CONDITION CODE //D// AND PROVIDE COPIES OF SHIPPING DOCUMENTS TO WHOLESALE MATERIEL POINT OF CONTACT LISTED IN PARAGRAPH 16C. 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 2408-15, HISTORICAL RECORD FOR AIRCRAFT. 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINTS OF CONTACT FOR THIS MESSAGE ARE MR. ROBERT A. LAWYER, AMSAT-R-ECC, DSN 693-3820 OR COMMERCIAL 314/263- 3820, RESPECTIVELY. B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. NORM HUSTON, AMCPM-CH-L, DSN 693-1415 OR COMMERCIAL 314/263-1415 AND FAX DSN 693-1485 OR COMMERCIAL 314/263-1485. C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAT-I-MDM, DSN 490-2318 OR COMMERCIAL 314/260- 2318. D. SAFETY POINT OF CONTACT FOR THIS MESSAGE IS MR. JIM WILKINS, AMSAT-R-X, DSN 693-2258 OR COMMERCIAL 314/263-2258. E. FOREIGN MILITARY SALES (FMS) RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT CW5 JAY NANCE OR MR. RON VAN REES, AMSAT-D-S, DSN 693-7844/3216 OR COMMERCIAL 314/263-7844/3216. G. AFTER HOURS CONTACT ATCOM COMMAND OPERATIONS CENTER (COC), DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7. |