Safety of Flight CH-47-99-04 |
01 16 262005Z AUG 99 OO PP UUUU AA ZYUW FROM :CDRAMCOM REDSTONE ARSENAL AL//AMSAM-SF-A// TO :AIG 8881 :AIG 9004 :AIG 7471 :AIG 12124 :USMILGP BUENOS AIRES AR//ARMY AND AF SEC// :DEFAIR MATERIAL CANBERRA ACT AS//DAAP-AF// :CDRUSARDSG CANBERRA ACT AS//AMXIP-AS// :ARGENTINE AIR ATTACHE FMS WASHINGTON DC :EGYPT AF FMS CAIRO EG//ED/MA// :USOMC CAIRO EG//AV// :ODC ATHENS GR//ODCSA// :CDR1STBN228THAVN SOTO CANO HO//AVN-AMO// :CHJUSMAGK SEOUL KOR//MKAR-AV// :ROK ARMY FMS PUSAN KOR//ALC-LSD-L// :CDR160THSOAR FT CAMPBELL KY//AOAV-SI// :CDRBGAD RICHMOND KY//SIOBG-GC// :USDAO RABAT MO//AF// :ODC THE HAGUE NL//AVIATION SAFETY// :RNLAF MATERIAL THE HAGUE NL :RNLAF OPERATIONS THE HAGUE NL :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 :CJUSMAGTHAI BANGKOK TH//MAGTAR-FS// :ROYAL THAI AF FMS BANGKOK TH//BANGSUE DEPOT// :ROYAL THAI ARMY FMS BANGKOK TH//DUSIT ORDANCE DEPOT// :CDRUSARDSG LONDON UK//AMXSN-UK-SE// :ODC LONDON UK INFO :FAA SOUTHWEST RGN HQ FORT WORTH TX//ASW-100// :CDRAMC ALEXANDRIA VA//AMCMR/AMCCS/AMCSM-WAA// XMT : ACCT : TEXT :UNCLAS SUBJECT - SAFETY OF FLIGHT MESSAGE, TECHNICAL, RCS CSGLD-1860(R1), CH-47D, MH-47D, AND MH-47E AIRCRAFT, INSPECTION OF H-47 AIRCRAFT FOR FORWARD AND AFT TRANSMISSION GEAR/BEARING ASSEMBLIES IDENTIFIED BY SERIAL NUMBER PREFIX "VB", CH-47-99-04 (TB 1-1520-240-20-114). NOTE: THIS IS A SAFETY OF FLIGHT MESSAGE ISSUED IAW AR 95-1, CHAPTER 6, 1 SEP 97. THIS MESSAGE HAS NOT BEEN TRANSMITTED TO UNITS SUBORDINATE TO ADDRESSEES. ADDRESSEES SHALL 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 CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER). 1. PRIORITY CLASSIFICATION - NOTE - SEE AR 95-1, PARA 6-6A, FOR EXCEPTION AUTHORITY OF MAJOR COMMANDERS. A. AIRCRAFT IN USE - SAFETY OF FLIGHT MESSAGE CH-47-99-02 PLACED ALL H-47 SERIES AIRCRAFT ON A RED //X// CONDITION STATUS SYMBOL. THE RED //X// IMPOSED BY CH-47-99-02 MAY BE CLEARED ON SOME AIRCRAFT IF THE INSPECTION PROCEDURES OF PARAGRAPH 8 AND CORRECTION PROCEDURES WITH OPERATING LIMITATION OF PARAGRAPH 9 OF THIS MESSAGE ARE COMPLIED WITH. AIRCRAFT WHICH REMAIN ON RED //X// WILL BE MAINTAINED IN FLYABLE STORAGE WITH THE FOLLOWING RESTRICTIONS: GROUND RUN-UPS ARE RESTRICTED TO OPERATION WITH ECL AT GROUND POSITION, WITH FLAT BLADE PITCH AND NEUTRAL FLIGHT CONTROLS. B. AIRCRAFT IN DEPOT MAINTENANCE - SAME AS PARA 1A. C. AIRCRAFT UNDERGOING MAINTENANCE - SAME AS PARA 1A. D. AIRCRAFT IN TRANSIT - (1) SURFACE/AIR SHIPMENT - SAME AS PARA 1A. PRIOR TO FIRST FLIGHT ON ARRIVAL. (2) FERRY STATUS (A) SAME AS PARA 1A. (B) THOSE AIRCRAFT THAT HAVE A DD 250 AND ARE AT BOEING HELICOPTERS WILL BE INSPECTED PRIOR TO FERRY TO FINAL DESTINATION. E. MAINTENANCE TRAINERS (CATEGORY A AND B) - SAME AS PARA 1A. F. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS) INCLUDING WAR RESERVES: UPON RECEIPT OF THIS MESSAGE THE MATERIAL CONDITION TAGS OF ALL ITEMS IN ALL CONDITION CODES LISTED IN PARAGRAPHS 6 AND 7 SHALL BE ANNOTATED TO READ SOF CH-47- 99-04 (TB 1-1520-240-20-114) NOT COMPLIED WITH. (1) WHOLESALE STOCK - N/A. (2) RETAIL STOCK - UPON RECEIPT OF THIS MESSAGE COMMANDERS AND OTHERS MAINTAINING RETAIL STOCK AT INSTALLATION LEVEL AND BELOW SHALL CONTACT THE SUPPORTED AVIATION UNIT TO PERFORM THE INSPECTION REQUIRED BY PARAGRAPH 8 AND THE CORRECTION PROCEDURES OF PARAGRAPH 9 ON DISCREPANT MATERIEL. REPORT COMPLIANCE WITH THIS MESSAGE IAW PARAGRAPH 14D(2). G. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - ITEMS LISTED IN PARAGRAPHS 6 AND 7 IN WORK WILL NOT BE ISSUED UNTIL COMPLIANCE WITH THIS MESSAGE. 2. TASK/INSPECTION SUSPENSE DATE WITHIN 5 WORKING DAYS FROM THE DTG OF THIS MESSAGE. 3. REPORTING COMPLIANCE SUSPENSE DATE - NO LATER THAN 21 SEP 99 IAW PARA 14A OF THIS MESSAGE. 4. SUMMARY OF PROBLEM - A. ONE DISCREPANT SECOND STAGE PLANETARY TRANSMISSION GEAR/BEARING ASSEMBLY IDENTIFIABLE TO "VB" SERIAL NUMBER PREFIX WAS FOUND. FOUR DISCREPANT SECOND STAGE PLANETARY TRANSMISSION GEAR/BEARING ASSEMBLIES IDENTIFIABLE TO "GG" SERIAL NUMBER PREFIX WERE FOUND. THE DISCREPANCIES WERE NOT DETECTED BY THE REQUIRED INSPECTION PROCEDURES AT TIME OF MANUFACTURE. THESE GEARS ARE LOCATED IN THE FORWARD AND AFT TRANSMISSIONS. AN ANALYTICAL INVESTIGATION AND RESEARCH OF HISTORICAL DATA HAVE LED TO A RISK DETERMINATION THAT GEAR/BEARING ASSEMBLIES IDENTIFIABLE BY A SERIAL NUMBER PREFIX "VB" ARE CONSIDERED SERVICEABLE WITH IMPROBABLE RISK OF FAILURE (I.E. CRACK PROPAGATION) IF THE OPERATING LIMITATION IDENTIFIED BY PARAGRAPH 9 ARE ADHERED TO. NOTE GEAR/BEARING ASSEMBLIES WITH SERIAL NUMBER PREFIX "GG" ARE CONSIDERED UNSERVICEABLE AND MUST BE INSPECTED IAW CH-47-99-03. B. FOR MANPOWER/DOWNTIME AND FUNDING IMPACTS SEE PARA 12. C. THE PURPOSE OF THIS MESSAGE IS TO INSPECT ALL FORWARD AND AFT TRANSMISSION RECORDS FOR SPECIFIC PART NUMBER/SERIAL NUMBER COMBINATIONS. TRANSMISSIONS WITH ALL FIRST AND SECOND STAGE GEAR/BEARING ASSEMBLIES IDENTIFIED BY SERIAL NUMBER PREFIX "VB" ARE CONSIDERED SERVICEABLE WITH OPERATING LIMITATION. 5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D, AND MH-47E AIRCRAFT. 6. ASSEMBLY COMPONENTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN TRANSMISSION, FORWARD 145D1300-ALL 1615-01-317-6446 1615-01-312-5162 1615-01-296-3090 1615-01-306-6971 1615-01-216-3827 TRANSMISSION, AFT 145D2300-ALL 1615-01-315-4071 1615-01-327-1297 1615-01-296-3091 1615-01-307-4842 1615-01-216-3829 7. PARTS TO BE INSPECTED - NOMENCLATURE PART NO. NSN GEAR/BEARING ASSY 145DS010-3 N/A 145DS010-5 3110-01-228-1647 145DS0106 3110-01-353-7369 145DS0108 3110-01-353-7369 GEAR/BEARING ASSY 145DS0116 3020-01-114-9550 145DS011-8 3110-01-232-7708 145DS011-9 3110-01-350-3674 145DS011-11 3110-01-350-3674 8. INSPECTION PROCEDURES A. INSPECT THE FORWARD AND AFT TRANSMISSION DA FORM 2408-16 AIRCRAFT COMPONENT HISTORICAL RECORDS. B. IF THE FORWARD TRANSMISSION DA FORM 2408-16 LISTS FOUR 1ST STAGE GEAR/BEARING ASSEMBLIES WITH PART NUMBER 145DS011-6 OR -8 WITH SERIAL NUMBER PREFIX "VB" AND SIX 2ND STAGE GEAR/BEARING ASSEMBLIES WITH PART NUMBER 145DS010-3 OR -5 WITH SERIAL NUMBER PREFIX "VB", THAT TRANSMISSION IS CONSIDERED SERVICEABLE WITH OPERATING LIMITATION AS DEFINED BY PARAGRAPH 9. C. IF THE AFT TRANSMISSION DA FORM 2408-16 LISTS FOUR 1ST STAGE GEAR/BEARING ASSEMBLIES WITH PART NUMBER 145DS011-6 OR -8 WITH SERIAL NUMBER PREFIX "VB" AND SIX 2ND STAGE GEAR/BEARING ASSEMBLIES WITH PART NUMBER 145DS010-3 OR -5 WITH SERIAL NUMBER PREFIX "VB", THAT TRANSMISSION IS CONSIDERED SERVICEABLE WITH OPERATING LIMITATION AS DEFINED BY PARAGRAPH 9. NOTE ALL TWENTY FORWARD AND AFT TRANSMISSION GEAR/BEARING ASSY SERIAL NUMBERS MUST BEGIN WITH PREFIX "VB" FOR THE AIRCRAFT TO BE CONSIDERED SERVICEABLE WITH THE OPERATING LIMITATION AS DEFINED BY PARAGRAPH 9. D. IF EITHER TRANSMISSION DA FORM 2408-16 LISTS ANY GEAR/BEARING ASSEMBLIES WITH PART NUMBER 145DS010-6 OR -8 OR 145DS011-9 OR -11 OR SERIAL NUMBERS WITH A "GG" PREFIX, THE TRANSMISSION IS UNSERVICEABLE AND THE AIRCRAFT WILL REMAIN ON A RED //X// CONDITION STATUS UNTIL THE TRANSMISSION IS REPLACED WITH ONE WHICH HAS BEEN INSPECTED IAW SOF CH-47-99-03. E. IF A TRANSMISSION DA FORM 2408-16 DOES NOT IDENTIFY ALL INSTALLED FIRST OR SECOND STAGE GEAR/BEARING ASSEMBLIES BY SERIAL NUMBER, THE TRANSMISSION IS CONSIDERED SUSPECT AND UNSERVICEABLE AND THE AIRCRAFT WILL REMAIN ON A RED //X// CONDITION STATUS. TRANSMISSION BUILD RECORDS ARE BEING OBTAINED TO DETERMINE IF THEY ARE SERVICEABLE. CONTACT LOGISTICAL POC IN PARA 16B FOR BUILD RECORD INFORMATION. 9. CORRECTION PROCEDURES A. TRANSMISSIONS WHICH CONTAIN GEAR/BEARING ASSEMBLIES AS IDENTIFIED IN PARAGRAPHS 8B AND 8C ABOVE ARE CONSIDERED SERVICEABLE WITH OPERATING LIMITATION. IF TWO SERVICEABLE TRANSMISSIONS ARE INSTALLED ON SAME AIRCRAFT, THE RED "X" STATUS SYMBOL REQUIRED BY SAFETY OF FLIGHT MESSAGE CH-47-99-02 SHALL BE CHANGED TO A CIRCLED RED //X//. THE CIRCLED RED //X// ENTRY SHALL STATE "AIRCRAFT RESTRICTED TO FLIGHT OPERATIONS AT A MAXIMUM OF 80 PERCENT DUAL ENGINE TORQUE." AIRCRAFT WHICH EXCEED THIS LIMITATION ARE AUTHORIZED AN IMMEDIATE ONE TIME FLIGHT TO THE NEAREST SECURE MAINTENANCE FACILITY AND THE AIRCRAFT SHALL BE PLACED ON A RED //X// CONDITION STATUS. CAUTION IMMEDIATE ACTION MUST BE TAKEN TO REDUCE STRESS WHEN THE CRUISE GUIDE INDICATOR ENTERS THE RED AND YELLOW STRIPED BAND (CH/MH-47D) OR THE RED BAND (MH-47E). THIS CAN BE ACCOMPLISHED BY LOWERING THRUST CONTROL LEVER, REDUCING AIRSPEED, RELEASING BACK PRESSURE ON THE CYCLIC STICK, OR BY REDUCING THE SEVERITY OF THE MANEUVER. HIGH LOAD MANEUVERING CONDITIONS MAY CAUSE THE 80 PERCENT DUAL ENGINE TORQUE LIMIT TO BE EXCEEDED. NOTE TO ENSURE TORQUE REDUCTION OF BOTH FORWARD AND AFT TRANSMISSIONS, WHEN LOADING AIRCRAFT, ATTEMPT TO MAINTAIN NEUTRAL CENTER OF GRAVITY. B. PREFLIGHT PLANNING SHALL ENSURE ABOVE LIMITATION IS NOT EXCEEDED. C. TRANSMISSIONS THAT DO NOT HAVE GEAR/BEARING ASSEMBLIES SERIAL NUMBER DATA ON THE DA FORM 2408-16 ARE UNSERVICEABLE PENDING A SEARCH OF DEPOT RECORDS FOR SERVICEABLE GEAR BEARING ASSEMBLIES IN THE SUSPECT TRANSMISSION. CONTACT THE LOGISTICAL POC IN PARA 16B. D. REPORT THE RESULTS OF THE INSPECTION IAW PARA 14B. E. FOR AIRCRAFT WITH ANALOG GAGES, THE ENGINE TORQUE METER INDICATOR SHALL BE RED TAPED AT 80 PERCENT TO IDENTIFY THIS OPERATING LIMITATION FOR AIRCRAFT WHICH HAVE TRANSMISSIONS IDENTIFIED IN PARA 8B AND 8C. FOR THOSE AIRCRAFT WITH MULTI- FUNCTION DISPLAYS, A PLACARD NOTING THIS OPERATING LIMITATION WILL BE AFFIXED ADJACENT TO THE DISPLAY. THIS MARKING SHALL BE REMOVED WHEN SERVICEABLE TRANSMISSIONS DEFINED BY REFERENCE 13B ARE INSTALLED. 10. SUPPLY/PARTS AND DISPOSITION - A. PARTS REQUIRED - N/A. B. REQUISITIONING INSTRUCTIONS - UNITS SHOULD NOT REQUISITION REPLACEMENT TRANSMISSIONS AT THIS TIME. FUTURE MESSAGES WILL PROVIDE REQUISITIONING INSTRUCTIONS. C. BULK AND CONSUMABLE MATERIALS - N/A. D. DISPOSITION - N/A. E. DISPOSITION OF HAZARDOUS MATERIAL N/A. 11. SPECIAL TOOLS AND FIXTURES REQUIRED - N/A. 12. APPLICATION - A. CATEGORY OF MAINTENANCE - CONTINUE REPORTING AIRCRAFT DOWNTIME IAW CH-47-99-02 (DEPOT MAINTENANCE). B. ESTIMATED TIME REQUIRED FOR INSPECTION- TOTAL OF 1 MAN-HOUR USING 1 PERSON. C. ESTIMATED COST IMPACT TO THE FIELD - N/A. D. TB/MWOS TO BE APPLIED PRIOR TO OR CONCURRENTLY WITH THIS INSPECTION TB 1-1520-240-20-113. E. PUBLICATIONS WHICH REQUIRE CHANGE AS A RESULT OF THIS INSPECTION - N/A. 13. REFERENCES: A. CH-47-99-02. B. CH-47-99-03 (TB 1-1520-240-20-113). 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 CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER), REDSTONE ARSENAL, AL 35898-5000, IAW AR 95-1. DATAFAX NUMBER IS DSN 897-2111 OR (256) 313-2111. E-MAIL ADDRESS IS SAFEADM@REDSTONE.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) - UPON COMPLETION OF INSPECTION, UNITS WILL FORWARD A PRIORITY MESSAGE TO THE LOGISTICAL POINT OF CONTACT IN PARAGRAPH 16B. THE REPORT WILL CITE THIS MESSAGE NUMBER, DATE OF INSPECTION, AIRCRAFT SERIAL NUMBER AND FWD AND AFT TRANSMISSION SERIAL NUMBERS OF AIRCRAFT RELEASED FOR FLIGHT. INSPECTION AND REPORTS WILL BE COMPLETED NO LATER THAN 7 DAYS AFTER TASK/INSPECTION SUSPENSE DATE. C. REPORTING MESSAGE RECEIPT (SPARES) - N/A. D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - N/A. E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED IAW DA PAM 738-751, 15 MAR 99 - NOTE ULLS-A USERS WILL USE APPLICABLE "E" FORMS. (1) DA FORM 2408-5-1, EQUIPMENT MODIFICATION RECORD (TRANSMISSION). (2) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD. (3) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE RECORD. (4) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT. (5) DA FORM 2408-16, AIRCRAFT COMPONENT HISTORICAL RECORD. 15. WEIGHT AND BALANCE - N/A. 16. POINTS OF CONTACT - A. TECHNICAL POINT OF CONTACT IS MR. LARRY T. WIESCHHAUS, AMSAM-AR-E-I-C-H, DSN 897-3341 OR (256) 313-3341, DATAFAX IS (256) 313-4348. E-MAIL IS "LARRY.WIESCHHAUS@REDSTONE.ARMY.MIL". SECONDARY TECHNICAL POINT OF CONTACT IS MR. MATT WESSELSCHMIDT, AMSAM-AR-E-I-C-H, DSN 897-3380 OR (256) 313-3380, DATAFAX IS (256) 313-4348. E-MAIL IS "WESSELSCHMIDT-ML@REDSTONE.ARMY.MIL". B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. BILL OLSON , SFAE-AV-CH-L, DSN 897-3379 OR (256) 313-3379, DATAFAX IS (256) 313-4348 E-MAIL IS "OLSONW@PEOAVN.REDSTONE.ARMY.MIL". C. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) N/A . D. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MS. ANN WALDECK, AMSAM-MMC-RE-FF DSN 746-5564 OR (256) 876-5564, DATAFAX IS DSN 746-4904. E-MAIL IS "WALDECK-AB@REDSTONE.ARMY.MIL". E. SAFETY POC FOR THIS MESSAGE IS MR. ROBERT D. BROCK, AMSAM- SF-A, DSN 788-8632 OR (256) 842-8632. EMAIL IS "BOB.BROCK@REDSTONE.ARMY.MIL". THE ALTERNATE POC IS MR. HOWARD CHILTON, AMSAM-SF-A, DSN 897-2068 OR (256) 313-2068, DATAFAX IS DSN 897-2111 OR (205) 313-2111. E-MAIL IS "HOWARD.CHILTON@REDSTONE.ARMY.MIL". F. FOREIGN MILITARY SALES RECIPIENTS REQUIRING CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT: CW5 JOSEPH L. WITTSTROM, SECURITY ASSISTANCE MANAGEMENT, AMSAM- SA, DSN 897-0681 OR (256) 313-0681. EMAIL IS "WITTSTROMJL@REDSTONE.ARMY.MIL" OR MR. RONNIE W. SAMMONS, AMSAM- SA-CS-NF, DSN 897-0869 OR (256) 313-0869. DATAFAX IS DSN 897- 0411 OR (256) 313-0411. EMAIL IS "SAMMONSRW@REDSTONE.ARMY.MIL". HUNTSVILLE, AL IS GMT MINUS 6 HRS. G. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER (COC) DSN 897-2066/7 OR (256) 313-2066/7. |