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UNCLASSIFIED
MSG DTG 121715Z JUN 02
FROM CDRAMCOM, REDSTONE ARSENAL, AL //AMSAM-SF-A//
SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY,
RCS CSGLD-1860(R1), CH-47 SERIES AIRCRAFT, INSPECT FOR IMPROPERLY
MANUFACTURED/ASSEMBLED FUEL CONTROL RELAY BOXES, CH-47-02-ASAM-03
(TB 1-1520-240-20-147).
NOTE
THIS MESSAGE IS ISSUED IAW AR 95-1, 1 SEP 97, CHAPTER 6. THIS
MESSAGE 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 ADDRESSEES WILL IMMEDIATELY VERIFY THIS TRANSMISSION TO
CDR, AMCOM, ATTN: AMSAM-SF-A (SOF COMPLIANCE OFFICER).
1. PRIORITY CLASSIFICATION -
NOTE
IAW AR 95-1, PARAGRAPH 6-6A/6-14A, MACOM COMMANDERS MAY AUTHORIZE
TEMPORARY EXCEPTION FROM MESSAGE REQUIREMENTS. 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.
A. AIRCRAFT IN USE - 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: "INSPECT
FUEL CONTROL RELAY BOX IAW CH-47-02-ASAM-03 (TB 1-1520-240-20-
147) WITHIN THE NEXT 10 FLIGHT HOURS, BUT NLT 26 JUNE 2002."
CLEAR THE RED HORIZONTAL DASH //-// ENTRY WHEN THE PROCEDURES IAW
PARA 8 AND 9 ARE COMPLETED. THE AFFECTED AIRCRAFT SHALL BE
INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN 26 JUNE 2002.
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//.
B. AIRCRAFT IN MAINTENANCE -
(1) AIRCRAFT IN AVUM, AVIM OR DEPOT LEVEL MAINTENANCE -
SAME AS PARA 1A.
(2) AIRCRAFT AT CONTRACTOR FACILITY - BOEING WILL
INSPECT DD 250 AIRCRAFT PRIOR TO THOSE AIRCRAFT DEPARTING FOR
FERRY TO FINAL DESTINATION.
C. AIRCRAFT IN TRANSIT -
(1) SURFACE/AIR SHIPMENENT - SAME AS PARA 1A.
(2) FERRY STATUS - SAME AS PARA 1A.
D. MAINTENANCE TRAINERS (CATEGORY A AND B) - SAME AS PARA 1A.
E. COMPONENT/PARTS IN STOCK AT ALL LEVELS (DEPOT AND OTHERS)
INCLUDING WAR RESERVES - UPON RECEIPT OF THIS MESSAGE, DEPOT AND
MATERIEL ACTIVITY COMMANDERS WILL ENSURE THE MATERIEL CONDITION
TAGS OF ALL ITEMS IN ALL CONDITION CODES LISTED IN PARAGRAPH 6
ARE ANNOTATED TO READ: "CH-47-02-ASAM-03 (TB 1-1520-240-20-147)
INSPECT FUEL CONTROL RELAY BOX NOT COMPLIED WITH."
(1) WHOLESALE STOCK - N/A.
(2) RETAIL STOCK - UPON RECEIPT OF THIS MESSAGE,
COMMANDERS AND FACILITY MANAGERS MAINTAINING RETAIL STOCK AT
INSTALLATION LEVEL AND BELOW SHALL CONTACT THE SUPPORTED AVIATION
UNIT TO PERFORM THE PROCEDURES REQUIRED IAW PARAGRAPHS 8 AND 9 ON
SUSPECT MATERIEL. DISPOSE OF DISCREPANT MATERIEL IAW PARAGRAPH 10.
REPORT COMPLIANCE WITH THIS MESSAGE IAW PARAGRAPH 14C(2) NLT 25
JUNE 2002.
F. COMPONENTS/PARTS IN WORK (DEPOT LEVEL AND OTHERS) - DEPOT
AND OTHER MAINTENANCE ACTIVITY COMMANDERS WILL ENSURE ITEMS
LISTED IN PARAGRAPH 7 ARE NOT ISSUED UNTIL THEY ARE IN COMPLIANCE
WITH THIS MESSAGE.
2. TASK/INSPECTION SUSPENSE DATE - COMPLETE THE INSPECTION IAW
PARAGRAPH 8 WITHIN 10 FLIGHT HOURS BUT NLT 26 JUNE 2002 AND
REPORT IAW PARA 14A(2) NLT 2 JULY 2002
3. TAMMS REPORTING COMPLIANCE SUSPENSE DATE - REPORT COMPLIANCE
IAW PARA 14A(1) NLT 2 JULY 2002.
4. SUMMARY OF PROBLEM -
A. THIS ASAM RESULTS FROM A CATEGORY I DEFICIENCY REPORT. A
CH-47D EXPERIENCED AN INOPERATIVE RIGHT HAND SIDE MAIN AFT FUEL
BOOST PUMP DURING FLIGHT CAUSED BY IMPROPER MANUFACTURE/ASSEMBLY
OF THE WIRING HARNESS IN THE FUEL CONTROL RELAY BOX. THE WIRING
DID NOT HAVE TERMINAL LUGS INSTALLED, WIRE IDENTIFICATION WAS
IMPROPERLY MARKED, AND WIRE ENDS WERE DIRECTLY WRAPPED AND
ATTACHED TO THE RELAY SCREWS. IN THIS PARTICULAR RELAY BOX, SIX
(6) WIRES WERE COMPLETELY BROKEN AND ONE (1) WIRE WAS PARTIALLY
BROKEN.
B. MANPOWER/DOWNTIME AND FUNDING IMPACTS - SEE PARA 12.
C. THE PURPOSE OF THIS MESSAGE IS TO:
(1) INSPECT FOR IMPROPERLY MANUFACTURED FUEL CONTROL
RELAY BOX.
(2) REPAIR OR REPLACE AS REQUIRED DEFECTIVE FUEL CONTROL
RELAY BOX.
5. END ITEMS TO BE INSPECTED - CH-47D/CH-47F/MH-47D AIRCRAFT.
(MH-47E AIRCRAFT DO NOT USE THIS BOX)
6. ASSEMBLY COMPONENTS TO BE INSPECTED -
NOMENCLATURE PART NO. NSN
RELAY ASSEMBLY 145E2195-1 5945-01-298-7845
7. PARTS TO BE INSPECTED -
NOMENCLATURE PART NO. NSN
TERMINAL, LUG BACT12AC2 5940-00-204-8966
8. INSPECTION PROCEDURES - OPEN THE FUEL CONTROL RELAY BOX
COVER, TM 55-1520-240-23-8, TASK 10-116.1, AND INSPECT WIRING AND
CONNECTIONS FOR PROPER ASSEMBLY AND INSTALLATION OF THE WIRING
HARNESS AND TERMINAL LUGS.
A. IF THE WIRING HARNESSES ARE PROPERLY MARKED AND TERMINAL
LUGS AND CONNECTIONS ARE PROPERLY MARKED AND CONNECTED, THE
INSPECTION IS COMPLETE AND THE RED HORIZONTAL DASH //-// ENTRY
MAY BE CLEARED.
B. IF THE WIRING HARNESS HAS NOT BEEN PROPERLY ASSEMBLED AND
INSTALLED, CLEAR THE RED DASH //-// ENTRY REQUIRED BY PARA 1A AND
ENTER THE FOLLOWING RED DIAGONAL \\/\\ "FUEL CONTROL RELAY WIRING
HARNESS IMPROPERLY INSTALLED"
C. MAKE THE FOLLOWING CIRCLE RED //X// ENTRY ON THE 2408-13-1
"A/C RESTRICTED TO FLIGHTS BELOW 6000' MSL IAW CH-47-02-ASAM-03 (TB
1-1520-240-20-147)". PERFORM CORRECTION PROCEDURES IAW PARA 9.
9. CORRECTION PROCEDURES -
A. IF A REPLACEMENT BOX IS AVAILABLE, REMOVE AND REPLACE THE
FUEL PUMP RELAY BOX IAW TM 55-1520-240-23-8 TASK 116.1 AND TASK
116.2.
B. IF A REPLACEMENT BOX IS NOT AVAILABLE, CALL THE TECHNICAL
POINT OF CONTACT FOR WIRING HARNESS REPAIR INSTRUCTIONS.
C. ONCE DISCREPANT BOXES HAVE BEEN REPLACED OR WIRING
HARNESS REPAIRED, THE RED DIAGONAL \\/\\ AND CIRCLE RED //X//
ENTRIES WILL BE CLEARED.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 12C MAY BE
REQUIRED TO REPLACE DEFECTIVE ITEMS.
B. REQUISITIONING INSTRUCTIONS - REQUISITION REPLACEMENT
PARTS USING NORMAL SUPPLY PROCEDURES. ALL REQUISITIONS SHALL USE
PROJECT CODE (CC 57-59) "X1U" (X-RAY-ONE-UNIFORM).
NOTE
PROJECT CODE "X1U" IS REQUIRED TO TRACK
AND ESTABLISH A DATA BASE OF STOCK FUND
EXPENDITURES INCURRED BY THE FIELD AS A
RESULT OF MESSAGE ACTIONS.
C. BULK AND CONSUMABLE MATERIALS -
TERMINAL, LUG BACT12AC2 5950-00-204-8966
D. DISPOSITION - DISPOSE OF ANY DISCREPANT PART/COMPONENT
THROUGH THE NORMAL SUPPLY SYSTEM.
E. DISPOSITION OF HAZARDOUS MATERIAL - N/A.
11. SPECIAL TOOLS AND FIXTURES REQUIRED - N/A.
12. APPLICATION -
A. CATEGORY OF MAINTENANCE - AVUM. AIRCRAFT DOWNTIME WILL
BE CHARGED TO AVUM. REPORT AIRCRAFT NON-MISSION CAPABLE
MAINTENANCE (NMCM) WHILE UNDERGOING INSPECTION AND CORRECTION IAW
THIS MESSAGE. REPORT AIRCRAFT NON-MISSION CAPABLE SUPPLY (NMCS)
WHILE WAITING FOR PARTS IAW THIS MESSAGE.
B. ESTIMATED TIME REQUIRED -
(1) TIME TO COMPLETE INSPECTION -
(A) TOTAL OF 0.5 MAN-HOURS USING 1 PERSON.
(B) TOTAL OF 0.5 HOURS DOWNTIME FOR ONE END ITEM.
(2) TIME FOR REPAIR/REPLACEMENT -
(A) TOTAL OF 3 MAN-HOURS USING 3 PERSONS.
(B) TOTAL OF 1 HOUR DOWNTIME FOR ONE END ITEM.
C. ESTIMATED COST IMPACT TO THE FIELD -
NOMENCLATURE PART NO./NSN QTY COST EA. TOTAL $
RELAY, ASSEMBLY 145E2195-1 1 $6428.80 $6428.80
5945-01-298-7845
TERMINAL, LUG BACT12AC2 32 $5.50 HD $1.76
5940-00-204-8966
TOTAL COST PER AIRCRAFT = $ 6430.56
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. DA PAM 738-751, 15 MAR 99.
B. TM 55-1520-240-23.
14. RECORDING AND REPORTING REQUIREMENTS -
A. AIRCRAFT -
(1) TAMMS REPORTING COMPLIANCE SUSPENSE - UPON ENTERING
REQUIREMENTS OF THIS MESSAGE ON DA FORM 2408-13-1 FOR ALL EFFECTED
AIRCRAFT, COMMANDERS WILL 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, NLT DATE SPECIFIED IN
PARAGRAPH 3. DATAFAX NUMBER IS DSN 897-2111 OR (256) 313-2111.
E-MAIL ADDRESS IS "SAFEADM@REDSTONE.ARMY.MIL". THE REPORT WILL
CITE THIS MESSAGE AND TB NUMBER, DATE OF ENTRY IN DA FORM 2408-
13-1, THE AIRCRAFT MISSION DESIGN SERIES AND SERIAL NUMBERS OF
AIRCRAFT IN NUMERICAL ORDER.
(2) TASK/INSPECTION REPORTING SUSPENSE - UPON
COMPLETION OF INSPECTION, COMMANDERS WILL FORWARD A PRIORITY
MESSAGE TO THE LOGISTICAL POINT OF CONTACT LISTED IN PARAGRAPH
16B. THE REPORT WILL CITE THIS MESSAGE AND TB NUMBER, DATE OF
INSPECTION, AIRCRAFT SERIAL NUMBER, AIRCRAFT AND COMPONENT HOURS,
AND RESULTS OF THE INSPECTION. INSPECTION AND REPORTS WILL BE
COMPLETED NLT DATE SPECIFIED IN PARAGRAPH 2.
B. WHOLESALE SPARE PARTS/ASSEMBLIES - N/A.
C. RETAIL SPARE PARTS/ASSEMBLIES -
(1) REPORTING MESSAGE RECEIPT - COMMANDERS AND FACILITY
MANAGERS WILL REPORT RECEIPT OF THIS MESSAGE BY E-MAIL OR DATAFAX
TO THE LOGISTICAL POINT OF CONTACT LISTED IN PARAGRAPH 16B NLT
DATE SPECIFIED IN PARAGRAPH 1E(2). PROVIDE LOCAL POINT OF
CONTACT.
(2) TASK/INSPECTION REPORTING SUSPENSE - COMMANDERS AND
FACILITY MANAGERS WILL REPORT INSPECTION RESULTS TO THE
LOGISTICAL POINT OF CONTACT IN PARAGRAPH 16B NLT DATE SPECIFIED
IN PARAGRAPH 1E(2). REPORT THE QUANTITY INSPECTED BY CONDITION
CODE AND THE RESULTING CONDITION CODE. REPORT BY E-MAIL OR
DATAFAX AND PROVIDE LOCAL POINT OF CONTACT.
D. 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 2408-13, AIRCRAFT STATUS INFORMATION
RECORD.
(2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND
MAINTENANCE RECORD.
(3) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
(4) DD FORM 1577-2/DD FORM 1577-3, UNSERVICEABLE
(REPARABLE) TAG/LABEL - MATERIEL (COLOR GREEN). ANNOTATE REMARKS
BLOCK WITH "UNSERVICEABLE IAW CH-47-02-ASAM-03 (TB 1-1520-240-20-
147)."
15. WEIGHT AND BALANCE - N/A.
16. POINTS OF CONTACT -
A. TECHNICAL POINT OF CONTACTS FOR THIS MESSAGE ARE:
(1) PRIMARY - MR. LARRY WIESCHHAUS, AMSAM-RD-AE-I-P-C,
DSN 897-2350 EXT. 9866 OR (256) 705-9866. DATAFAX IS (256) 705-
9818. E-MAIL IS "LARRY.WIESCHHAUS@RDEC.REDSTONE.ARMY.MIL".
(2) ALTERNATE - MR. LARRY SMITH, AMSAM-RD-AE-I-P-C, DSN
897-2350 EXT. 9859 OR (256) 705-9859. DATAFAX IS (256) 705-9818.
E-MAIL IS "LAWRENCE.SMITH@RDEC.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
897-4348 OR (256) 313-3379. E-MAIL IS
"WILLIAM.OLSON@PEOAVN.REDSTONE.ARMY.MIL".
C. WHOLESALE MATERIEL POINT OF CONTACT (SPARES) IS -
LOGISTICS POC LISTED AT PARA 14B.
D. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS
MS. ANN WALDECK, AMSAM-MMC-MA-NM, DSN 746-5564 OR (256) 876-5564.
DATAFAX IS DSN 746-4904 OR (256) 876-4904. E-MAIL IS
"ANN.WALDECK@REDSTONE.ARMY.MIL".
E. SAFETY POINTS OF CONTACT ARE -
(1) PRIMARY - MR. FRANK ROSEBERY (SAIC), AMSAM-SF-A,
DSN 788-8631 OR (256) 842-8631. DATAFAX IS DSN 897-2111 OR (256)
313-2111. E-MAIL IS "FRANK.ROSEBERY@REDSTONE.ARMY.MIL".
(2) ALTERNATE - MR. RUSSELL PEUSCH, AMSAM-SF-A, DSN
788-8632 OR (256) 842-8632. DATAFAX IS DSN 897-2111 OR (256)
313-2111. E-MAIL IS "RUSSELL.PEUSCH@REDSTONE.ARMY.MIL".
F. FOREIGN MILITARY SALES RECIPIENTS REQUIRING
CLARIFICATION OF ACTION ADVISED BY THIS MESSAGE SHOULD CONTACT
MR. RONNIE W. SAMMONS, AMSAM-SA-AS-UT, DSN 897-0407 OR (256) 313-
0407. DATAFAX IS DSN 897-0411 OR (256) 313-0411. EMAIL IS
"RONNIE.SAMMONS@REDSTONE.ARMY.MIL".
G. AFTER HOURS CONTACT THE AMCOM COMMAND OPERATIONS CENTER
(AOC) DSN 897-2066/7 OR (256) 313-2066/7.
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