SYNOPSIS
CH-47-93-ASAM-02 AVIATION SAFETY ACTION MESSAGE, ALL CH-47D, MH-47D AND
MH-47E AIRCRAFT, INSPECTION HI-LOK FASTENERS AT FUSELAGE
STATION 83 TO 120, (TB 1-1520-240-20-64).
021600Z MAR 93, BRAD MEYER, AMSAT-C-XS, X2085.
NOTE: Enter a "Q" + <CR> to exit or <SPACEBAR> to view
the entire message. (NON-REPORTING)
.
01 15 021600Z MAR 93 PP PP UUUU ZEXW 0611300Z
YES
CDRATCOM ST LOUIS MO //AMSAT-C-XS//
AIG 6713
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//
ODC ATHENS GR //ODCSA-A//
CDR4THBN228THAVN SOTO CANO HO //AVN-AMO//
CDR160TH SOAR FT CAMPBELL KY //AOAV-SI//
CDRBGAD RICHMOND KY //SDSBG-GC//
CHMUSLO RABAT MO //AF//
CHUSAS RIYADH SA //ASAV//
CF: SFAE-AV-CH, AMSAT-R-ECC, AMSAV-I-RAAF, AMSAV-MEA, AMSAV-L-AOC
BRAD MEYER
AMSAT-C-XS, X2085 MINIMIZE CONSIDERED
EDWARD J. HOLLMAN
CHIEF, SAFETY OFFICE
.
UNCLAS
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YES
ODC MADRID SP //ARMY AND NAVY SEC//
CJUSMAG BANGKOK TH
CDRUSARDSG LONDON UK //AMXSN-UK-SE//
INFO CDR AMCCOM 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//
UNCLAS RELEASABLE TO NATO ADDRESSEES
AIG 9004 TAKE FOR INFO ONLY
AIG 8708 TAKE FOR INFO ONLY
AIG 9042 TAKE FOR INFO ONLY
.
UNCLAS
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YES
SUBJECT - AVIATION SAFETY ACTION MESSAGE, MAINTENANCE MANDATORY, RCS
CSGLD-1860(R1), ALL CH-47D, MH-47D AND MH-47E AIRCRAFT, INSPECTION
OF HI-LOK FASTENERS AT FUSELAGE STATION 83 TO 120,
(CH-47-93-ASAM-02) (TB 1-1520-240-20-64)
NOTE
THIS IS AN AVIATION SAFETY ACTION 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 RETRANSMISSION TO COMMANDER, ATCOM, ATTN - AMSAT-C-XS
(SOF COMPLIANCE OFFICER)
1. PRIORITY CLASSIFICATION -
A. AIRCRAFT IN USE - UPON RECEIPT OF THIS MESSAGE THE CONDITION
STATUS SYMBOL OF THE CITED AIRCRAFT WILL BE CHANGED TO A RED
HORIZONTAL DASH //-//. THE RED HORIZONTAL DASH //-// MAY BE CLEARED
WHEN THE INSPECTION OF PARA 8 BELOW IS COMPLETED. THE AFFECTED
AIRCRAFT SHALL BE INSPECTED AS SOON AS PRACTICAL BUT NO LATER THAN
THE TASK/INSPECTION SUSPENSE DATE. FAILURE TO COMPLY WITH THE
.
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REQUIREMENTS OF THIS MESSAGE WITHIN THE TIME FRAME WILL CAUSE THE
STATUS SYMBOL TO BE UPGRADED TO A RED //X//.
B. AIRCRAFT IN DEPOT MAINTENANCE - AIRCRAFT WILL NOT BE ISSUED
UNTIL COMPLIANCE WITH THIS ASAM 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 AND C) - N/A.
F. COMPONENT/PARTS IN STOCK INCLUDING WAR RESERVES AT ALL
LEVELS (DEPOT AND OTHERS) - N/A.
2. TASK/INSPECTION SUSPENSE DATE - WITHIN THE NEXT PHASE
INSPECTION.
3. REPORTING COMPLIANCE SUSPENSE DATE - N/A.
4. SUMMARY OF PROBLEM -
A. CH-47-92-ASAM-05 REQUIRED REPLACEMENT OF HI-LOK FASTENERS
DUE TO OVERSIZE HOLES AND IMPROPER DEBURRING DURING PRODUCTION.
THIS REPLACEMENT WAS NOT COMPLETED BECAUSE OF A SHORTAGE IN
REPLACEMENT HI-LOK FASTENERS. SEVERAL WAIVERS WERE GRANTED
.
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YES
PROVIDING INTERIM INSTRUCTIONS. THIS MESSAGE PROVIDES CRITERIA FOR
CORRECTING LOOSE FASTENERS AND REQUIRES A RECURRING INSPECTION AT
EACH PHASE INSPECTION.
B. THE PURPOSE OF THIS MESSAGE IS TO:
(1) RESCIND CH-47-92-ASAM-05 AND RELATED WAIVERS.
(2) INSPECT THE SUBJECT HI-LOKS FOR LOOSENESS AND MAKE
NECESSARY CORRECTIONS.
(3) REMIND UNITS OF THE INSPECTION REQUIREMENT FOR LOOSE
FASTENERS AT EACH PHASE INSPECTION.
5. END ITEMS TO BE INSPECTED - ALL CH-47D, MH-47D AND MH-47E
AIRCRAFT.
6. ASSEMBLY COMPONENTS TO BE INSPECTED - N/A.
7. PARTS AFFECTED -
NOMENCLATURE PART NO. NSN
FASTENER (HI-LOK) HL18PB6 5310-00-911-9428
8. INSPECTION PROCEDURES -
NOTE
UNITS ARE REMINDED TO INSPECT FOR LOOSE FASTENERS/RIVETS AT EACH
PHASE INSPECTION PER TM 55-1520-240-PM, PAGE 2-43, CHANGE 3,
.
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YES
INSPECTION REQUIREMENT 7.22.1.
A. INSPECT HI-LOK FASTENERS LOCATED IN THE FORWARD TRANSMISSION
TORQUE BOX, BLL 18 AND BLR 18, STATION 83 TO 120, WL 52 FOR
LOOSENESS. THE ROWS OF HI-LOKS ARE INBOARD AND ONE TO FOUR INCHES
BELOW THE WORK PLATFORMS. IF YOU HAVE DIFFICULTY LOCATING THESE
FASTENERS, CONTACT YOUR LOCAL LOGISTICS ASSISTANCE REPRESENTATIVE
(LAR).
B. IF NO LOOSE FASTENERS ARE FOUND, NO FURTHER ACTION IS
REQUIRED.
C. LOOSE FASTENERS AT LOCATIONS WHERE WASHERS WERE PREVIOUSLY
INSTALLED MUST BE REPLACED PER PARA 9.
D. LOOSE FASTENERS THAT CAN BE TURNED BY HAND, HAVE CLEARANCE
BETWEEN THE HI-LOK AND THE STRUCTURE OR SHOW EVIDENCE OF TURNING,
PROCEED AS FOLLOWS:
(1) REMOVE COLLAR FROM LOOSE HI-LOK BEING CAREFUL THAT
HI-LOK PIN REMAINS IN THE STRUCTURE.
(2) CHECK HOLE FOR ELONGATION/OVERSIZE AND CRACKS AROUND
THE EDGE OF THE HOLE. IF THE HOLE IS ELONGATED/OVERSIZE, OR THERE
ARE CRACKS AROUND THE EDGE OF THE HOLE, REPLACE THE FASTENER PER
.
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YES
PARA 9.
(3) IF THERE ARE NO CRACKS AND THE FASTENER HOLE IS NOT
ELONGATED/OVERSIZE, CHECK PROTRUSION OF THE HI-LOK PIN GRIP THROUGH
THE STRUCTURE. IF THE PROTRUDING GRIP IS GREATER THAN 0.050 INCHES,
INSTALL A AN960JD10 WASHER AND A HL70-6 COLLAR ON THE EXISTING
HI-LOK PIN. IF THE PROTRUDING GRIP IS LESS THAN 0.050 INCHES,
INSTALL A AN960JD10LL WASHER AND A HL70-6 COLLAR.
9. CORRECTION PROCEDURES - IF THERE ARE LOOSE FASTENERS AT
LOCATIONS WHERE WASHERS WERE PREVIOUSLY INSTALLED, OR IF THERE IS
EVIDENCE OF ELONGATED/OVERSIZE HOLES OR CRACKS AROUND THE EDGE OF
THE HOLE, REPLACE THE FASTENER AS FOLLOWS:
(1) TO GAIN ACCESS TO THE HI-LOKS TO BE REPLACED, LOWER
BOTH MAINTENANCE PLATFORMS ON THE FORWARD PYLON AND REMOVE THE
FORWARD TRANSMISSION DRIP PAN PER TM 55-1520-240-23-2.
CAUTION
TO PREVENT RESIDUE FROM FALLING INTO THE AVIONICS AND OTHER
COMPARTMENTS WHEN REMOVING FASTNERS FROM SKINS ABOVE THE
COMPARTMENTS, COVER THE COMPARTMENT WITH SUITABLE COVERING IN
ACCORDANCE WITH CURRENT FOREIGN OBJECT DAMAGE (FOD) PRACTICES.
.
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YES
(2) THE FOLLOWING STEPS PROVIDE INSTRUCTIONS FOR REMOVAL
OF ALL SKINS AND PANELS TO GAIN ACCESS TO THE SUBJECT HI-LOK
FASTENERS.
(A) REMOVE THE FORWARD L/H AND R/H WORK PLATFORMS
PER TM 55-1520-240-23-2.
(B) REMOVE FAIRING ASSEMBLIES, P/N 145S1905-1 AND -2
PER TM 1-1500-204-23-(SERIES). THESE FAIRINGS ARE LOCATED BELOW THE
WORK
PLATFORMS AND MATE THE FUSELAGE TO THE PYLON.
(C) IF REQUIRED TO GAIN ACCESS TO DRILL STRAIGHT
HOLES THROUGH THE DRAG ANGLE AND BEAM, REMOVE L/H AND R/H ANGLES P/N
114S1964, THAT ATTACH THE FAIRING ASSEMBLY P/N 145S1905 TO THE CROWN
SKIN.
(D) TO GAIN ACCESS TO THE FIRST FOUR HI-LOKS STARTING
AT STATION 83, REMOVE THE SKIN ATTACHING FASTENERS FAR ENOUGH
FORWARD TO ALLOW THE CROWN SKIN FAIRING, P/N 114S1602, TO BE RAISED
AWAY FROM THE WORK AREA.
(E) REMOVE THE DEFECTIVE HI-LOKS PER TM
1-1500-204-23-(SERIES).
.
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YES
(F) MEASURE THE HOLE AND DETERMINE THE HOLE
CONDITION AND SIZE. THE ORIGINAL HOLE WAS A NO. 6 (.1895-.1905)
HOLE. THE ORIGINAL HI-LOK USED WAS A HL18P86 WITH A HL79-6 COLLAR.
IF THE HOLE IS DAMAGED OR IS THE WRONG SIZE, USE THE FOLLOWING CHART
TO DETERMINE THE NEXT OVERSIZE HOLE AND FASTENER TO USE.
HOLE SIZES FOR OVERSIZE HI-LOKS
1/64 1/32 1/4
MAX .2036 .2192 .2505
MIN .2026 .2182 .2495
REPLACEMENT HI-LOKS (OVERSIZE)
1/64 1/32 1/4 NO. PER ACFT
HL62PB6-3 HL218-6-3 HL18PB8-3 7
HL62PB6-4 HL218-6-4 HL18PB8-4 1
HL62PB6-5 HL218-6-5 HL18PB8-5 17
HL62PB6-6 HL218-6-6 HL18PB8-6 1
HL62PB6-7 HL218-6-7 HL18PB8-7 1
HL62PB6-9 HL218-6-9 HL18PB8-9 1
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YES
REPLACEMENT COLLARS (OVERSIZE)
1/64 1/32 1/4 NO. PER ACFT
HL79-6 HL84-6 HL79-8 28
NOTE
DUE TO TOLERANCE BUILD-UP, FASTENER LENGTHS MAY VARY FROM
THOSE NOTED ABOVE.
(G) INSTALL REPLACEMENT HI-LOKS PER TM
1-1500-204-23-(SERIES). MAKE CERTAIN THAT ALL HOLES ARE REAMED TO
THE CORRECT SIZE AND DEBURRED, TREATED AND PRIMED.
(H) INSTALL L/H AND R/H ANGLES P/N 114S1964 USING
MS20470AD4 AND MS20470E6 OR MS20470DD6 RIVETS PER TM
1-1500-204-23-(SERIES).
(I) RE-ATTACH THE CROWN SKIN FAIRING P/N 114S1602
USING MS20470AD4 AND MS20470AD5 RIVETS PER TM
1-1500-204-23-(SERIES).
(J) INSTALL THE L/H AND R/H FAIRING ASSEMBLIES, P/N
145S1905-1 AND -2 USING MS7885/2-4, M7885/2-5, AND MS20470AD4 RIVETS
PER TM 1-1500-204-23-(SERIES).
(K) RE-ATTACH THE FORWARD L/H AND R/H WORK PLATFORMS
PER TM 55-1520-240-23-2.
.
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YES
(L) REINSTALL FORWARD TRANSMISSION DRIP PAN PER TM
55-1520-240-23-2.
10. SUPPLY/PARTS AND DISPOSITION -
A. PARTS REQUIRED - ITEMS CITED IN PARAGRAPH 10C WILL BE
FURNISHED BY BOEING HELICOPTERS.
B. REQUISITIONING INSTRUCTIONS - ORDER FASTENERS FROM MR. JERRY
MAYBERRY, TELEPHONE (215) 591-7719.
C. BULK AND CONSUMABLE MATERIALS
NOMENCLATURE PART NUMBER NSN
HI-LOK HL62PB-3 5320-01-043-0071
HI-LOK HL62PB-4 5320-00-457-1331
HI-LOK HL62PB-5 5320-00-613-0473
HI-LOK HL62PB-6 5320-00-899-4662
HI-LOK HL62PB-7 5320-01-099-1008
HI-LOK HL62PB-9 5320-01-108-7651
HI-LOK HL218-6-3 5306-00-522-1814
HI-LOK HL218-6-4 5320-00-494-7983
HI-LOK HL218-6-5 5306-00-410-1749
HI-LOK HL218-6-6 5320-01-100-8824
HI-LOK HL218-6-7 5306-00-494-7985
.
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YES
HI-LOK HL218-6-9 5320-00-395-6421
HI-LOK HL18PB8-3 5320-00-813-3920
HI-LOK HL18PB8-4 5320-00-959-0215
HI-LOK HL18PB8-5 5320-00-959-0201
HI-LOK HL18PB8-6 5320-00-959-0200
HI-LOK HL18PB8-7 5320-00-915-4973
HI-LOK HL18PB8-9 5320-00-959-0204
COLLAR HL79-6 5320-00-968-9212
COLLAR HL84-6 5320-00-457-1332
COLLAR HL79-8 5320-00-968-9210
SEALANT PROSEAL 890 1520-00-080-1549
D. DISPOSITION - DISPOSE OF REMOVED PARTS/COMPONENTS IN
ACCORDANCE WITH NORMAL SUPPLY PROCEDURES.
E. DISPOSITION OF HAZARDOUS MATERIAL - N/A.
11. SPECIAL TOOLS, JIGS AND FIXTURES REQUIRED - N/A.
12. APPLICATION -
A. CATEGORY OF MAINTENANCE - AVIM. AIRCRAFT DOWNTIME WILL BE
CHARGED TO AVIM.
B. TIME REQUIRED -
.
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YES
(1) INSPECTION -
A. TOTAL OF 1 MANHOUR USING 1 PERSON.
B. TOTAL OF 1 HOUR DOWNTIME FOR ONE END ITEM.
(2) REPLACEMENT -
A. TOTAL OF 50 MANHOURS USING 2 PERSONS.
B. TOTAL OF 25 HOURS DOWNTIME FOR ONE END ITEM.
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 - TM 55-1520-240-23-2 SHALL BE CHANGED TO REFLECT THE
INFORMATION IN THIS MESSAGE. A COPY OF THIS MESSAGE SHALL BE
INSERTED IN THE APPROPRIATE TM AS AUTHORITY TO IMPLEMENT THE CHANGE
UNTIL THE PRINTED CHANGE IS RECEIVED.
13. REFERENCES -
A. TM 1-1500-204-23-(SERIES), GENERAL AIRCRAFT MAINTENANCE
MANUAL, DTD 31 JUL 92. (THIS MANUAL SUPERCEDED TM 55-1500-204-25/1.
TM 55-1500-204-25/1 MAY BE USED FOR THIS MESSAGE
.
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YES
IF TM 1-100-204-23-(SERIES) IS NOT AVAILABLE.)
B. TM 55-1520-240-23-2, AVIATION UNIT AND AVIATION INTERMEDIATE
MAINTENANCE MANUAL, CH-47D HELICOPTER, DTD 10 MAY 83, C12 4 JUN 92.
C. TM 55-1520-240-PM, CH-47D HELICOPTER PHASED MAINTENANCE
CHECKLIST, DTD 18 OCT 90, C3 11 DEC 92.
14. RECORDING AND REPORTING REQUIREMENTS -
A. REPORTING COMPLIANCE SUSPENSE DATE (AIRCRAFT) - N/A
B. TASK/INSPECTION REPORTING SUSPENSE DATE (AIRCRAFT) - N/A.
C. REPORTING COMPLIANCE SUSPENSE DATE (SPARES) - N/A.
D. TASK/INSPECTION REPORTING SUSPENSE DATE (SPARES) - N/A.
E. THE FOLLOWING FORMS ARE APPLICABLE AND ARE TO BE COMPLETED
IN ACCORDANCE WITH DA PAM 738-751, 15 JAN 92 -
(1) DA FORM 2408-13, AIRCRAFT STATUS INFORMATION RECORD.
(2) DA FORM 2408-13-1, AIRCRAFT INSPECTION AND MAINTENANCE
RECORD, IF NEEDED.
(3) DA FORM 2408-13-2, RELATED MAINTENANCE ACTIONS RECORD,
IF NEEDED.
(4) DA FORM 2408-13-3, AIRCRAFT TECHNICAL INSPECTION
WORKSHEET, IF NEEDED.
.
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YES
(5) DA FORM 2408-15, HISTORICAL RECORD FOR AIRCRAFT.
15. WEIGHT AND BALANCE - N/A.
16. POINTS OF CONTACT -
A. TECHNICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. EMANUEL
BUELTER, SFAE-AV-CH-T, DSN 693-3820 OR COMMERCIAL 314/263-3820.
B. LOGISTICAL POINT OF CONTACT FOR THIS MESSAGE IS MR. STEVE
KOUCHNERKAVICH, SFAE-AV-CH-L, DSN 693-1415 OR COMMERCIAL
314/263-1415.
C. FORMS AND RECORDS POINT OF CONTACT FOR THIS MESSAGE IS MR.
BILL WALDROP, AMSAT-I-MDM, DSN 693-1821/1955 OR COMMERCIAL
314/263-1821/1955.
D. SAFETY 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, DSN 693-3826 OR COMMERCIAL
314/263-3826.
F. AFTER HOURS CONTACT AVSCOM COMMAND OPERATIONS CENTER (COC)
DSN 693-2066/7 OR COMMERCIAL 314/263-2066/7.