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Subject: MCB:P 251159Z JUN
07 CG 2ND MAW ALD(uc) RE-ADDRESSAL V-22
MAINTENANCE MEETING DISCUSSION UNCLAS VMMT 204(uc) COMNAVAIRFOR SAN DIEGO CA V-22 MAINTENANCE MEETING
DISCUSSION POC/JOHNSON, HAROLD.D.JOHNSON1 AT
USMC.MIL//RMKS/1. CONCUR WITH THE MAG-26 CO
AND THE URGENCY TO RESOLVE THESE ISSUES UNCLAS UNCLAS
THE CURRENT OR FLEET PERCEIVED STATUS OF THESE ISSUES, COMPARE PRACTICES OR INCREASED
UTILIZATION OF AIRCRAFT 2. THE FOLLOWING ARE
ITEMS OF CONCERN, IN ORDER OF PRIORITY: A. ICE PROTECTION
SYSTEM:
ANOTHER SIGNIFICANT ISSUE
IS BLADE HEATING ELEMENT FAILURES, CURRENT PROBLEMS ARE
DIFFICULT TO TROUBLESHOOT /IDENTIFY, MANY TIMES LEADING TO
SHOT-GUNNING PARTS, ALL WITH LONG LEAD TIMES. THE SYSTEM IMPACTS THE
TRANSFORMATIONAL USE OF THE AIRCRAFT ANYTIME/ANYWHERE. TO DATE THE SYSTEM HAS IMPACTED 46 A/C, ACCOUNTED FOR 17,589 TOTAL SCIR HOURS, 5,949 HOURS OF NMC AND 11,640 PMC HOURS, WITH 26 CANNIBILIZATION ACTIONS. 2. IETMS
CHANGES TO ASSIST IN TROUBLESHOOTING AND THE ABILITY TO
FCC*S, DURING 2006 HAD 33
RETURNS: VERIFIED 2. HAVING
DIFFICULTY IDENTIFYING PROBLEMS/ISOLATING FAULTS (FST A BY PRODUCT OF THIS
SITUATION IS LACK OF CONFIDENCE AND ADDED FRUSTRATION DUE TO THE HISTORY OF
REPEAT GRIPES. C. ECS - AIR CYCLE
MACHINE MULTIPLE ENGINEERING
INVESTIGATIONS HAVE BEEN SUBMITTED. TO PREVENT FUTURE FAILURES
IT IS PROPOSED TO INSTALL A NEW, IMPROVED FILTER.
THE UNDERSTOOD CURRENT
PLAN, FOR THE PROGAM, IS TO PROVIDE ADEQUATE SPARES TO MITIGATE THE POSSIBILTY
OF HAVING LONG TERM DOWN A/C. IF SPARE SUPPORT IS
AVAILABLE IN ADEQUATE QUANTITIES, THIS SHOULD NOT BE A LONG TERM MAJOR IMPACTOR.
+++++++++HOWEVER, IT WILL CONTINUE TO IMPACT A/C READINESS AND AVAILABILITY,
WITH REGARDS TO DOWN TIME FOR REMOVAL AND REPLACEMENT OF THE COMPONENT. IF NOT PROPERLY MANAGED,
THIS COULD VERY WELL BE THE ITEM THAT HAS THE GREATEST POTENTIAL TO ADVERSELY
AFFECT OPERATIONAL CAPABILITIES WHILE DEPLOYED FORWARD. TO DATE THE SYSTEM
HAS IMPACTED 61 A/C, ACCOUNTED FOR 4,161 TOTAL SCIR HOURS, 2,978 HOURS OF NMC
AND 1,183 PMC HOURS, WITH ZERO CANNIBILIZATION ACTIONS. D. INFRARED
(IR)
SUPPRESSOR PANELS AND ASSOCIATED HARDWARE: DAMAGED TUBES LEFT
INSTALLED CREATE A PARTIAL CURRENTLY, FRC EAST IS
ATTEMPTING TO REPAIR SEVERAL OF THE LESS DAMAGED TUBES THEREBY
CREATING A POOL OF RFI TUBES. TO DATE THE SYSTEM HAS
IMPACTED 157 A/C, ACCOUNTED FOR 57,089 SCIR HOURS, 53,688 HOURS OF NMC AND 3,401
PMC HOURS, WITH 24 CANNIBILIZATION ACTIONS. 2. IRS PANEL
MODIFICATIONS ARE FORTHCOMING WITH TWO RETROFIT KITS PER IRS PANELS ARE
EXPERIENCING 14 DIFFERENT DISCREPANCIES, OF WHICH SIX WILL BE ADDRESSED OR
MITIGATED BY THIS MODIFICATION. IN THE MEANTIME, SQUADRONS
HAVE RECENTLY USED DEPOT LEVEL P&E REPAIR PROCESS
TAKES BETWEEN SEVEN AND FOURTEEN DAYS. DESIRED IMMEDIATE REMEDIES
INCLUDE CREATING IRS PANEL REPAIR KITS CONTAINING ALL REQUIRED
FASTENERS AS WELL AS DEPOT PRODUCED STIFFENERS, CREATING AND MAINTAINING A
SUPPLY OF SPARE IRS PANELS AND OBTAINING A SUPPLY OF SPARE COANDA/DEFLECTOR
TUBES. E. PITCH CONTROL
LINK (PCL) BEARINGS: REPAIR PROCEDURES
ARE IN PLACE AT MALS-26, SUPPLY LOCATED A LIMITED QUANTITY OF BEARINGS TO REPAIR
PCL*S UNDERGOING REPAIR, CURRENTLY ZERO ON-HAND IN
THE SYSTEM.
LIMITED SUPPLY OF BEARINGS
AND/OR ROD ENDS NEGATIVELY IMPACT 2. IT WAS RECOMMENDED BY FST
TO START FORCED REMOVAL AT THE ONLY OPTION IS THE
REPAIR OF PCL ON CONDITION, BY REMOVING AND REPLACING THE BEARING OR ROD END
ASSEMBLES. LONG TERM FIX WILL BE
POSSIBLE REDESIGN OF ROD END AND/OR NO WORK AROUND EXIST, DUE
TO THE NATURE OF THE F. ENGINE AIR
PARTICLE SEPARATOR (EAPS) INSPECTION AND ASSOCIATED QUICK
TO DATE THE SYSTEM HAS
IMPACTED 16 A/C AND ACCOUNTED FOR 2,072 TOTAL PMC SCIR HOURS, WITH ZERO
CANNIBILIZATION ACTIONS. CURRENTLY
QUICK DISCONNECT PROBLEM
WILL NOT BE TOTALLY ELIMINATED WITH 3. ADDITIONAL ITEMS
DISCUSSED ARE AS FOLLOWS, ALTHOUGH THESE ITEMS ARE A. NOSE LANDING GEAR FOLLOW-UP INSPECTION OF
ALL AIRCRAFT REVEALED, FIVE OUT OF SEVEN AIRCRAFT WERE OUT OF PROPER RIG.
CONTRIBUTING FACTORS INCLUDE DEFORMED TORQUE TUBES FROM OVER-TORQUED
SELF-LOCKING NUTS ON THE END FITTINGS. BINDING IN MOVEMENT OF THE
TORQUE TUBE AT THE TORQUE TUBE END FITTINGS DUE TO DEBRIS IN THE END FITTINGS
AND/OR DEFORMATION OF THE TORQUE TUBES, AND SPRING STRUT NOT RETURNING THE
CENTER BELLCRANK ASSEMBLY TO AN *OVER CENTER* POSITION. ALL PREVIOUSLY IDENTIFIED
CONTRIBUTORS WERE CAUSAL FACTORS IN MISALIGNMENT OF THE BELLCRANK ROLLER WITH
THE UPPER TORQUE LINK BRACKET (C-CHANNEL). THIS MISALIGNMENT PREVENTS
PROPER RETRACTION OF THE NLG DOORS CAUSING THEM TO BECOME *STUCK* ONCE IN THE
CLOSED POSITION. TO DATE THE SYSTEM HAS IMPACTED 32 A/C, ACCOUNTED FOR
7,591 TOTAL SCIR HOURS, 7,503 HOURS OF NMC AND 88 PMC HOURS, WITH 01
CANNIBILIZATION ACTION. 2. NEAR TERM FIX WAS
AN IMPROVED ALIGNMENT PROCEDURE, AS WELL AS REPLACING THE CLAMP BUSHINGS AND
INSTALLING A NEW THIS PROBLEM REPRESENTS A
SAFETY OF FLIGHT ISSUE WHICH PREVENTS THE EXTENSION OF THE NOSE LANDING GEAR.
EXPEDITIOUS INCORPORATION OF THIS TD IS CRITICAL. HOWEVER, THERE IS STILL
CONCERN THAT THE INTRODUCTION OF THIS CHANGE MAY INTRODUCE DIFFERENT PROBLEMS.
ALTHOUGH CONTINUED TRAINING AND INSPECTION MAY MITIGATE THIS PROBLEM, ECP 702, THE NOSE LANDING GEAR
REDESIGN, NEEDS TO BE A HIGH PRIORITY. B. FUEL SYSTEM THE BIGGEST DEGRADER IS
THE VENT MANIFOLDS,SPECIFICALLY THE BLOWING OF RUPTURE DISKS. THE ORIGINAL
DISCREPANCY, RUPTURING OF THE DISC, IS OFTEN MASKED BY THE FACT THERE'S NONE IN
SUPPLY AND/OR IT'S EASIER TO DATE THE SYSTEM HAS
IMPACTED 19 A/C, ACCOUNTED FOR 2,763 TOTAL NMC SCIR HOURS, WITH 02
CANNIBILIZATION ACTIONS. 2. THIS
PROBLEM REPRESENTS A SAFETY ISSUE FROM INCREASED CHANCE OF FUEL LEAKS/SPILLS.
NEAR TERM FIX IS TO UTILIZE AN ADJUSTED FUEL LOAD , NOT FUELING A/C TO
ADVERTISED CAPACITY. A MOD TO THE FUEL SYSTEM IS CURRENTLY BEING
INCORPORATED BY THE BOEING FIELD TEAM, NEW AND IMPROVED RUPTURE DISC AND SWEENEY
FEED CELL CHECK VALVE. EXPEDITIOUS INCORPORATION
OF THE MOD IS CRITICAL, ESPECIALLY AS WE GET CLOSER TO A POSSIBLE SHIPBOARD
DEPLOYMENT FOR VMM-266, AN ENVIRONMENT WHERE PROBLEMS OF THIS NATURE ARE
PARTICULARLY HAZARDOUS. 4. USMC AIRCRAFT
OPERATE IN HARSH ENVIRONMENTS WHICH CHALLENGE OUR MARINES* ABILITY TO
MAINTAIN/REPAIR CRITICAL SYSTEMS AND PROVIDE FULL OVER THE PAST 9 MONTHS
V-22 BLOCK A AIRCRAFT READINESS HAS BEEN AN AVERAGE OF 47.8% MISSION CAPABLE AND
34.9% FULL MISSION CAPABLE WHILE BLOCK B AIRCRAFT READINESS HAS BEEN ON AVERAGE
79.3% MISSION CAPABLE AND 62.1% FULL MISSION CAPABLE. BASED ON THE HISTORICAL
DATA AVAILABLE, THERE IS A REASON FOR CONCERN WITH REGARD TO AIRCRAFT READINESS
AND AVAILABILITY AS OUR BLOCK B AIRCRAFT BEGIN TO REACH THE FLIGHT HOUR
THRESHOLDS WE HAVE ON OUR BLOCK A AIRCRAFT, THRESHOLDS WE WILL REACH
MORE QUICKLY WITH THE ADDITION OF SUSTAINED HIGH TEMPO OPERATIONS IN OIF.
WITH THIS IN MIND, AND WITH THE ADDED OPERATIONAL CHALLENGES THE OIF ENVIRONMENT
WILL PRESENT, IT IS IMPERATIVE THAT CURRENTLY KNOWN PROBLEMS/ISSUES ARE FULLY
UNDERSTOOD, AND SOLUTIONS ARE AGGRESSIVELY PURSURED. FAILURE TO BRING
THESE ISSUES TO CLOSURE QUICKLY WILL RUN THE RISK OF SIGNIFICANTLY IMPACTING
AIRCRAFT MATERIAL CONDITION, REDUCING READINESS, INCREASING SUPPLY COSTS, AND
DEGRADING THE AIRCRAFT'S ABILITY TO SUPPORT THE FULL SCOPE OF OPERATIONAL
MISSIONS AND TASKINGS ONCE IN THEATER.// ______________________________________________
And remember this is not a
"new" aircraft overcoming growing pains. It first flew in 1989,
they've spent $20 billion "fixing" this flawed design over these past
18 years. |