03_C-5M Programmed Depot Maintenance (PDM) Work Specification-Appendix A.pdf

Work Spec: FY22 Final

MDS: C005A, C005B, C005C, C005MA, C005MB, C005MC, C005/C005C

07/04/2022

DEPARTMENT OF THE AIR FORCE

1.0 - General

1.1 - Information

1.1.1 - Purpose

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.1.1.1 - This work specification establishes C-5 Programmed Depot Maintenance (PDM) requirements in accordance with (IAW) Technical Order (T.O.) 00-25-4, Depot Maintenance of Aerospace Vehicles and

Training Equipment

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.1.2 - Scope:

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C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

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1.1.2.1 - 1) PDM tasks cover those areas that must be accomplished at a depot level maintenance facility due to equipment, skills, tools, facilities, complexity or economy.

2) The overall work effort encompasses Programmed Depot Maintenance (PDM), and Time Compliance

Technical Orders (TCTOs).

3) This work specification is structured to establish and maintain technical and logistics capability and capacity to perform all on and off aircraft tasks directly related to the C 5 workload within the current flow day schedule, and to perform assigned modification programs or other required component repair.

4) This work specification utilizes maintenance and technical processes consistent with Air Force or commercial aircraft industry-accepted methods, and which will increase efficiencies and reduce costs.

These processes assure equivalent safety relative to the current baseline maintenance program and promote continued airworthiness.

5) The aircraft will be received and reassigned to AFMC in accordance with AFI21-103.

6) Each aircraft will be delivered from the depot with the equipment installed or accounted for that was on the aircraft when received, unless otherwise directed.

7) Accessories or components will not be overhauled, but will be repaired or replaced as directed by the work specification.

8) Work requirements on incoming 781 forms or 103’s will be accomplished if work falls within the purview of the work specification.

9) Maintenance will obtain PAO approval before accomplishing any non-work specification requirements discovered as stumble-on during maintenance effort or as identified on the aircraft’s AFTO form 95, AFTO form 781 or AFTO form 103.

10) Maintenance will advise the PAO immediately of all accidents and incidents as defined by AFI 91-204

AND AFI51-503.

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.1.3 - (Changed) This paragraph is not active.

Assigned MDS(s)

1.2 - Terms Explained

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1.2.1 - Terms Explained Definition of maintenance terms contained in Technical Orders (T.O.s) 00-5-15, 00-20-1, and 00-25-4 apply. Other terms peculiar to this work are defined as follows: NOTE: Terms listed below will NOT be interpreted to delete or minimize any work requirements of T .O.s listed herein. Application of terms listed in this paragraph will be made only to work authorized in this work specification. Terms explained below will NOT be interpreted as establishing work requirements .

• Acceleration. Maximum production required for certain designated mission-essential materiel undergoing depot level maintenance or modification. Maximize production and preparedness by:

a) Suspending routine peacetime aircraft inputs to depot maintenance facilities.

b) Extending the workday and workweek to a 24-hour-a-day; 7-day-a-week operation.

c) Realigning the workstations and redistributing the labor force as required.

d) Cannibalizing as necessary to complete the essential maintenance or modification requirements on the maximum amount of material.

• Accessible. Applies to areas of equipment that may be inspected or worked without disassembly other than that required by this work specification.

• Basic Maintenance Handbook (Instruction Manual). The applicable 1C-5M-2, 1C-5M-3, and 1C-5M-6 series

T.O., Checklist or Work Cards, applicability to systems as designated on the cover page thereof, and pertinent to the aircraft in work. Also, the applicable service or maintenance instructions for components as designated in the List of Applicable Publications (LOAP), T.O. 1C-5M-01.

• Bench Check. Visual inspection, physical test, and functional check using shop facilities, equipment, procedures, and test parameters as set forth in applicable technical publications to determine the exact condition. It also includes repair action when the repair is accomplished concurrently with the bench check

(T.O. 00-20-1).

• Calibration. A comparison between two instruments, one of which is a standard of known accuracy, to detect and correlate or adjust any variation in the accuracy of the instrument being compared.

• Category I Report. A report of emergency conditions of a safety nature on all types of equipment

(T.O.00-35D-54).

• Category II Report. A report of quality or material deficiencies in material which are attributed to :

non-conformance to applicable specifications, drawings, standards, and T.O.s, errors in workmanship; failure to provide or account for all specific parts; or other conditions that can be traced to non-conformance during manufacture, repair, modification, or maintenance (T.O. 00-35D-54).

• Compression. When the maximum production is required for specified mission essential aircraft that are undergoing depot maintenance/modification, production is compressed by:

a. Suspending routine peacetime work requirements and discontinuing aircraft inputs to depot maintenance facilities.

b. Reassembling the aircraft after doing the absolute minimum maintenance essential to the safety of the flight, and only those modifications essential to the weapon’s war mission configuration .

c. Extending the workday and the workweek to 24-hour-a-day, 7-day-a-week operation; realigning the workstations; and redistributing the labor force, as needed to meet maximum production efforts.

d. Resorting to whatever cannibalization is needed to complete the essential maintenance/modification on the maximum number of aircraft.

• Critical Defect. A defect that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or depending on the aircraft or will prevent performance of the tactical function of the aircraft. Examples are:

a. Cracks in primary structural components

b. Hidden corrosion that requires replacement of skin or structural components

c. Defects in flight control system that could cause loss of control

d. Fuel leaks that are explosive safety hazards

e. Landing gear components that could cause gear failure

f. Defects that could cause other major component failures (as applied to components required for safe flight)

· Data. All management, scientific engineering, logistics information, reports, and documentation, which are required. · Depot Level or Maintenance Facility. An industrial type facility established to perform accessory overhaul functions or modifications and maintenance in support of field and using organizations. This includes

Air Force Materiel Command (AFMC) assigned installations and commercial contractors who are engaged in performing depot level work on weapon systems or equipment under a contract issued and managed by

AFMC. · Direct Product Standard Hours (DPSH). The standard labor hours required to process an operation or an end item. · Disassembly. Teardown of the item or parts sufficient to permit the type and amount of

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• Disturbed System. Any system of which the whole or a component part has been removed, disassembled, repaired, adjusted, modified, disconnected, or altered. Disconnect of tubing, hose, or electrical wiring at normal quick-disconnect will NOT constitute “disturbed systems,” BUT will be inspected for proper aircraft installation. Total system WILL NOT require flight check.

• Economy Tasks. (T.O.00-25-4) Predictable maintenance, accomplished concurrent with PDM for economy reasons. Work of this type, located in or adjacent to a depot maintenance requirement, will be strictly limited to those areas worked or opened up in support of Depot Tasks in paragraph 3.2 herein.

• Examination and Inventory (E&I). A thorough inspection of the aircraft based on work specification requirements.

• Flight Safety Tasks (T.O. 00-25-4). This category of work will be limited to those failures or malfunctions that would present a hazardous condition to an end item or personnel during pre-flight, in-flight, or post-flight aircraft operations. Work accomplished under this category must meet one or more of the following criteria :

a. Correction of flight safety TCTOs that become known while the aircraft is in the depot facility .

b. A safety of flight write-up entered on AFTO Form 781A during aircraft delivery to the Source of Repair

(SOR).

c. Those safety- of-flight write-ups discovered during flight preparation or test that will prevent safe return of the aircraft to the user.

• Functional Check Flight (FCF) (T.O. 1C-5M-6CF-1). Includes flight test to determine whether the airframe or equipment is operating in accordance with (IAW) predetermined parameters while operating in the intended environment. Areas to be checked are to be restricted to those involving equipment or systems requiring flight verification. Accomplishment of only those procedures applicable to the systems disturbed in the process of maintenance or modification and the systems interfacing with the disturbed systems are required for airplanes out of PDM or “modification contract” status.

• In-Process Inspection. An inspection performed during the assembly of an end item or its components at those stages when further assembly would prevent inspection for compliance with applicable technical orders

(T.O. 00-20-1). • Inspect or Check. An examination of an item to determine identity, condition, and proper installation.

• Interface. Area or surface immediately adjacent to and forming the limits or border of the principal item being inspected.

• Incidental Maintenance is actually unpredictable work in Organic, this description has been added below.

• Maintenance Facility. The organic or contract facility responsible for accomplishing the work requirements established in this work specification.

• Maintenance Operational Checks (T.O. 1-1-300). A check accomplished on the ground to assure that aircraft systems or components, which have been disturbed during inspection or maintenance operations, have been repaired, reassembled, or adjusted satisfactorily.

• Major Defect. A defect other than critical that is likely to result in failure or reduce materially the usability of the aircraft for its intended purpose. EXAMPLES are:

a. Evidence of a potential or impending primary structural failure defect (all cracks, except those requiring only minor repair such as routing and blending).

b. Evidence of deteriorating conditions in a system having safety or mission performance implications such as fuel system, landing gear, and flight control e.g. (loose fastener in a primary flight control).

c. Corrosion that requires treatment except for surface corrosion in open (normally accessible) areas.

d. Evidence of fatigue failures in the primary structures or systems (all buckled, distorted, and damaged items which require replacement, reinforcements, patch, etc.). Chafing situations that may progress to a hazardous stage, such as fuel or oil leaks, and short circuits.

e. Worn or frozen bearings, bushings, linkages, etc., that may cause failure or malfunction of mechanical subsystems, or devices required for safe flight or mission accomplishment (included are quadrants, bell cranks, arms, torque tubes, rods, hinges, and supporting or attaching brackets).

• Minor Defect. A defect that is NOT likely to reduce materially the usability of the unit or product for its intended purpose or is a departure from established standards having little bearing on the effective use or operation of the unit.

• Modification. A change in the physical configuration or the functional characteristics of a system or equipment.

• Negotiated Maintenance. Predictable or next due major inspections, which have been determined by negotiations between the using command and the System Program Director (SPD) best done during PDM

(T.O. 00-25-4, paragraph 1.1).

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• Negotiated TCTOs. Predictable TCTOs which have been determined by negotiations between the using command and the SPD, best accomplished during PDM.

• Nondestructive Inspection (NDI). Methods for investigating the quality, integrity, properties, and dimensions of materiel and components without damaging or impairing their serviceability.

• Operational Check. A functional test of an accessory, component, or system accomplished in its installed environment to assure proper installation and operation (T.O. 00-20-1).

• Organic Facility. An AFMC in-house facility utilized for accomplishment of depot level maintenance or modifications.

• Over and Above (O&A). Any unspecified non-work specification work requiring negotiation with the PAO.

Unpredictable items of work found during the normal work process that are not related to work called out in the work specification, project directive, or covered under depot tasks, economy or flight safety tasks. Those items of work that require accomplishment to correct a major deficiency will be accomplished after PAO approval and funds are available. Items not approved for accomplishment by the PAO will be entered in the

AFTO form 781 and returned to the using activity. The PAO makes decisions to ensure a completed work package is produced IAW AFSCMAN 21-102.

.• Product Audit. An inspection and evaluation of a repaired or modified item for the purpose of Government verification that all work fully complies with specified requirements.

• Programmed Depot Maintenance (PDM). Depot level modification or maintenance of aircraft normally scheduled on a calendar time cyclic basis.

• Redundant Inspections. Two identical, but completely separate and independent inspections performed by two different individuals. Each independent inspection will include a separate setup and calibration of equipment. If available, separate equipment and probes or transducers should be used for each independent inspection.

• Reinstall. To install the same parts as removed.

• Repair. The restoration or replacement of parts or components of material as necessitated by wear and tear, damage, failure of parts, or the like, in order to maintain the specific item of material in efficient operating condition.

• Repairable. An unserviceable item that can be repaired and restored to a serviceable condition.

• Replace. To install other serviceable parts in the place of parts removed.

• Safety-of-Flight. When a failure or malfunction would present a hazardous condition to equipment or personnel during pre-flight, in-flight, or post-flight operations. A red “X” condition per T.O.s 00-20-1 and

00-20-5.

• Safety Modification. Those modifications required ensuring safety of personnel, systems, or equipment by eliminating operational or physical hazards. If uncorrected, the hazard would ground the system or equipment, restrict flight or ground operations, or result in unacceptable risk to personnel. These modifications are identified by the word “SAFETY” printed in red letters at the top of the TITLE PAGE of the TCTO (they are not

“red bordered”). They are also referred to as Routine Safety Modifications.

• Satisfactory-As-Is (SAI). A determination, by the Examination and Inspection (E&I) team or maintenance team that a maintenance condition is within T.O. limitations. This determination will be based on technical order criteria, or SPD interpretation, if required.

• Serviceable. Capable of meeting the requirement and performing the function for which designed or modified, and meets all test requirements established by this work specification.

• Support Equipment (SE). Support equipment includes all equipment required to perform the support function, except that which is an integral part of the mission equipment. It does not include any of the equipment required to perform mission operation functions. Support equipment should be interpreted as including tools, test equipment, Automatic Test Equipment (ATE)—when ATE is accomplishing a support function— organizational, intermediate, and depot support equipment, and related computer programs and software.

• System Program Director (SPD). The individual responsible for the complete weapon system.

• Technical Order (T.O.). A publication that gives specific technical directives and information with respect to the inspection, storage, operation, modifications, or inspection of equipment, or installation of new equipment.

Reference to T.O.s herein will be interpreted to include their supplements and latest published changes.

• Time Compliance Technical Order (TCTO). An authorized directive issued to provide instructions to the Air

Force activities for accomplishing “one-time” changes, modifications, inspection of equipment, or installation of new equipment. References to TCTOs herein will be interpreted to include their supplements and latest published changes.

• Touch-Up Refinish/Repaint. The repair of small damaged painted areas in an entire area of the organic finish system without removing, repairing, or refinishing the entire area.

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• Unpredictable Operations. Low Frequency operations that may be planned or unplanned that occur on at least 20% of the job order numbers will be fully planned. They can be Project Related (PR) or Non Project

(NPR) related. NPR must be approved by PAO for Over and Above funding before it is worked. Operations are approved by MRT and PAO before work is accomplished per AFSCMAN 21-102.

• Visual Inspection. Consists of visually inspecting for cracks, distortion, corrosion, fastener security, pulled rivets, and undue wear and damage. When inspecting items for corrosion, particular attention must be given to areas of dissimilar metal-to-metal contact (bushings, fasteners, etc.).

• Workbook. A clear and complete set of work documents (logs, work cards or printed forms) for maintenance required by this work specification, which will assure specific and uniform step-by-step directions for accomplishing work accurately, economically, and safely.

• Work Package. A maintenance translation of the work specification requirements into job operations .

• Work Specification. Standard work instructions prepared IAW AFMC regulations and guidelines.

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.3 - Data

1.3.1 - The following Government documents will be used in the accomplishment of the tasks of this document. Unless otherwise noted, the latest version of the Maintenance Records, Forms and Publications document applies.

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1.3.2 - The maintenance facility will accomplish required forms IAW AFSCMAN 21-102, including the following:

(1) Serially controlled, Configured, Time change, or Warranty components identified by an asterisk or one of the following: (S), (C), (T) or (W) in TO 1C-5M-06 (Work Unit Code Manual) that are replaced while aircraft is in the maintenance facility will be reported on an AFMC Form 173 prior to aircraft delivery. The data on the

AFMC form 173 (to include the serial number) will be transferred or reported to the Air force maintenance data collection system of record IAW AFSCMAN 21-102.

(2) In the event of TCTO compliance, a completed AFMC Form 173 will be submitted prior to aircraft delivery.

(3) Annotation of all TCTOs accomplished during PDM will be delivered with aircraft records .

(4) An AFMC Form 173 will be submitted to report all maintenance actions including the correction of defects or discrepancies involving repair, modification, removal and installation of components, and any quality defects associated with aircraft processing These will be approved prior to work being accomplished by Planner and, if out-of-scope, PAO.

(5) Uncorrected defects will be entered in AFTO Form 781.

(6) Maintenance will record deferred items of maintenance not affecting safety of flight and not approved for

PDM accomplishment (Organizational level defects discovered) in appropriate AFTO Form 781 aircraft records for disposition at organizational level maintenance.

(7) Upon compliance of maintenance on each aircraft, appropriate entries will be entered in the AFTO Form 95 indicating the day, month, year, aircraft time, facility name and location, inspector's name and major tasks accomplished to certify prescribed requirements. (Example: PDM, Special Inspections, etc.)

(8) All documents will be processed IAW TO 00-20-1 as appropriate.

(9) Data: All aircraft historical records, forms and publications specified in T.O. 00-20-5 (as provided for in AF

Form 2692) will accompany each aircraft on input. The aircraft historical records, as received, will be considered to be complete and up to date. In the event records are not received, or are illegible, MABA will initiate new records to reflect work accomplished. Applicable forms listed in Column 1 will be kept current by the maintenance facility IAW T.O.s listed in Column 3 from the date the aircraft is received at the facility to the date accepted by the using activity for fly away. COLUMN 1 COLUMN2 COLUMN 3 FORM NO FORM TITLE

APPLICABLE DIRECTIVE AF form 2692 Aircraft Equipment Accountability List AFI 21-103 & T.O. 1C-5M-21

DD form 365 (SERIES) Weight and Balance Record T.O. 1C-5M-5 & T.O. 1-1B-50 AFTO form 44 Historical

Records, Turbine Wheel T.O. 00-20-5 AFTO form 95 Significant Historical Record T.O. 00-20-5 AFTO form

98 Jet Engine or Afterburner Installation Record T.O. 00-20-5 AFTO form 349 Maintenance Data Collections

Record AFTO form 781 Series) Aircraft Flight Data Records T.O. 00-20-5 AFTO form 22 T.O. System

Improvement Record T.O. 00-20-5 REMIS Data Collection System AFI 21-101 & T.O. 00-20-2 DD form 173

CAT I and CAT II MDRs T.O. 00-35D-54.

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.3.3 - Reporting Requirements: Maintenance will prepare all required reports, including but not limited to those below, as specified within the identified directives:

a) All Deficiency Reports IAW T.O. 00-35D-54.

b) T.O. Deficiencies IAW T.O. 00-5-1.

c) A copy of all Engineering Assistance Request (EAR) and 202’s will be forwarded to SPO Engineering upon completion of each aircraft.

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C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

1.4 - Security

1.5 - Quality Control Requirements

1.6 - Condemnation & Repair

1.7 - Accessory and Component Reuse, Repair and Replacement

1.8 - Fuel Tank Storage/Preservation

1.9 - Other

1.9.1 - Incoming Post-Flight Briefing – (IP)

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C005C

C005MA

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Assigned MDS(s)

1.9.1.1 - Maintenance personnel will participate in a post-flight debriefing with the incoming flight crews to discuss and review the AFTO Form 781 Flight Report write-ups. The intent of this debriefing is to isolate and identify any Safety of Flight (SOF) defects at input to minimize schedule delay. The report should include all outstanding discrepancies or malfunctions of aircraft systems and should be in sufficient detail to furnish work requirement information on malfunctioning equipment systems.

C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

Assigned MDS(s)

1.9.2 - ACCELERATION AND COMPRESSION

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C005/C005C

C005A

C005B

C005C

C005MA

C005MB

C005MC

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1.9.2.1 - 1. The C5 aircraft is classified as “mission essential” aircraft designated by HQ USAF as “vital” to a primary mission. Pertinent emergency provisions of AFMCI21-118 and AFI 21-102, apply for aircraft undergoing maintenance. The maintenance facility will develop and maintain a current detailed plan for immediate implementation of a compression or acceleration work specification. This plan will include but not be limited to realigning work stations, redistributing the labor force, multi-shift operation and seven day work week, to expedite return of aircraft to the using command. USAF or a major using command may consider it necessary to accelerate/compress maintenance production to expedite the release of designated aircraft to Air Force units. Under these conditions, compression/acceleration actions require HQ

USAF approval. Requests for compression/acceleration made by the owning major command to HQ USAF during periods of increased tension must identify aircraft requirements by mission/design/series (MDS) and serial number. During the attack phase of general war, maintenance production will be automatically compressed by the various repair activities to make the maximum number of designated war mission aircraft available to the using commands.

2. Routine peacetime aircraft inputs to depot maintenance facilities will be suspended or discontinued in the event of general war; during a period of increased tension inputs will continue as scheduled unless this is specifically waived by HQ USAF. However, if HQ USAF directs total compression during a period of increased tension, all inputs to these facilities will be discontinued. HQ USAF will authorize compression/acceleration under all circumstances short of general war.

3. When compliance with compression requirements is directed, follow the specified requirements instead of the usual basic work specification for C5 aircraft and establish maintenance compression work requirements.

4. All C-5 mission, design, and series (MDS) aircraft at the maintenance facility, when directed for maintenance compression accomplishment, will be prepared for delivery to the Air Force IAW the requirements outlined herein. Outlined requirements will be complied with as long as maintenance compression is in effect. A. All aircraft returned will be “operational ready” or have “war mission systems operable” unless otherwise specified by the using command.

5. When directed, the maintenance facility will prepare “operationally ready” and “war mission systems operable” aircraft for return to using command at the earliest possible date and prepare all flyable aircraft having inoperable war mission systems for evacuation to predetermined dispersal locations for protection during critical phases of enemy attacks. “Operationally ready” aircraft will be accorded first priority to expedite their return to operating units.

6. After critical phase of enemy attack has passed, dispersed aircraft may be returned to the maintenance facility, and when directed, on a “crash” basis, prepare these and any other aircraft which survive an enemy attack to “war mission systems operable” status utilizing available spares or cannibalized parts from other aircraft which require more extensive work.

7. To expedite planning and scheduling, all C-5 aircraft undergoing modification or other repairs at the maintenance facility will be inspected and placed in one of the following condition categories: Condition “A” –

Aircraft in flight test status – outgoing. Condition “B” – aircraft incoming for shop work, that are determined

(by examination of the aircraft forms) to be in flyable status, will be returned to service (turnaround) after compliance with work as required in Section III herein. Condition “C” – Aircraft that can be removed and buttoned up from initial shop line stations and be basically satisfactory with minor expenditures of man-hours. Condition “D” – Aircraft in final shop stations (after fuel system check and with engines installed, etc.). Condition “E” – Aircraft requiring major modification (including those in shop lines already undergoing modification and those in permanent storage).

8. Every effort will be expended to accomplish the required work and deliver the aircraft in the order of condition list above. Aircraft requiring the least amount of work in each condition, “A” through “E”, will be processed first.

9. Terms used for compression and acceleration are defined as follows: “Maintenance Production

Compression” is a maximum all out production of selected war mission aircraft undergoing modification, or area support work within AFMC and contractor maintenance facilities. It entails actions which include suspension of routine modification work and reassembly of aircraft by accomplishment of only essential safety of flight maintenance and minimum acceptable combat war configuration modifications, realignment of work stations, extension of workweek and workday, redistribution of existing labor force, and cannibalization of aircraft on hand if necessary. It may include immediate preparation of non-combat ready by flyable aircraft for evacuation during imminent enemy attack and subsequently completing these to a readiness status by utilizing parts resources including cannibalization of aircraft on hand. “Maintenance

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Production Acceleration” is essentially the same as maintenance production compression except that peacetime work specifications will not normally be altered and input to maintenance facilities will normally continue. “Operationally ready” means that all components and systems will be capable of performing their designed mission or function on the aircraft. “Combat ready” means that the aircraft has a minimum acceptable war configuration and requires only routine inspection and servicing including loading of armament to make the aircraft ready for combat. Aircraft may be rendered “combat Ready” at one configuration or another IAW paragraph (6), below. “War mission systems operable” means that all components and systems on the aircraft are “functional”, that the aircraft is air worthy, and communication, navigation, and landing capability have been verified. Minimum acceptable war configuration for aircraft in

Compression Categories A, B, C, D or E (including stored aircraft) will be that minimum configuration at which the aircraft was delivered to the maintenance facility, unless directed otherwise by the SPD.

“Evacuation” means that flyable aircraft and aircraft which can be readied in a few hours or days will be ferried to pre-arranged “refuge sites” for protection during imminent or actual phases of enemy attack.

“Crash basis” means the maintenance facility will use maximum effort to complete in -work aircraft which survive enemy attacks using only the parts, manpower, and other resources within the facility or immediate vicinity. Aircraft severely damaged and which will require the most work may be cannibalized for necessary parts or components.

10. Maintenance Records, Forms and Publications for compression and acceleration: AFTO Form 781 series and AFTO Form 95 for the work accomplished will be maintained and completed IAW T.O. 00-20-2.

An entry will be made under remarks on AFTO Form 95 to indicate that the aircraft was processed IAW maintenance compression work requirements. All systems that are authorized to be inoperative will be listed on applicable aircraft AFTO 781 series forms as inoperative. All other aircraft records, forms and publications will be brought up to date for work accomplished, unless otherwise directed, and will be returned with the aircraft. Inventory of equipment of AF Form 2692 items IAW AFI 21-103 will be held to minimum readiness essentials on condition “A”, “C”, “D”, and “E” aircraft. Inventory inspection should be accomplished simultaneously with the post-flight inspection. Condition “B” aircraft will be returned as received.

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1.9.2.2 - Compression Work Requirements

1. All aircraft at the maintenance facility will be inspected to determine condition status of each aircraft and the compression category into which it is to be placed. NOTE: This includes aircraft in work, those awaiting input and any that may be in storage at the maintenance facility.

2. All aircraft in Categories “A,“ “B,” “C,”, “D,”, and “E” will receive preflight and post- flight inspections IAW

T.O. 1C-5M-6.

3. Work requirements for the Maintenance Compression described categories will include the following :

Aircraft in Category “B” and “E” will have the maintenance and historical records reviewed to determine condition of the aircraft. Aircraft in Categories “A”, “B”, “C”, “D”, and “E” will have safety of flight discrepancies corrected. Aircraft in Categories “A”, “C”, “D”, and “E” will have aircraft insignia and call letters (Ref T.O. 1-1-8) applied (if removed) or touched up if illegible. No other markings will be required unless otherwise directed. Aircraft in Category “B” will be returned as received. Aircraft is Categories “A”, “C”, “D”, and “E” will have interior of each aircraft inspected and loose debris such as filings, chips, loose hardware, etc., removed particularly those that could be hazardous to flight operations. Aircraft is

Categories “A”, “C”, “D”, and “E” will have accessories and components replaced as required, unless minor repair is necessary. Aircraft is Categories “C”, “D”, and “E” will have modifications that are partly accomplished, completed, and the aircraft reassembled. Aircraft is Categories “A”, “C”, “D”, and “E” will have repairs accomplished when time permits and as authorized by the SPD.

4. The ALC will not begin acceleration/compression of aircraft unless tasked by AFMC Battle Staff. This tasking will be received by the ROC, and will state the number of aircraft and the specific MDS required, and any special equipment needed for the mission at hand. Negotiation and approval by MRT team and by the

Project Administrative Officer (PAO) will be required prior to performing “stumble –on” maintenance and maintenance NOT included in this work specification. Any work requirements accomplished WITHOUT

MTR/ PAO approval WILL NOT be funded. All C-5 aircraft when directed for maintenance compression accomplishment will be prepared for delivery IAW the requirements outlined herein . The requirements outlined herein will be complied with as long as maintenance compression is in effect .

5. Flight Test and Government Acceptance. A. Aircraft is Categories “A”, “C”, “D”, and “E” will have the following work accomplished:

a) If, applicable, de-preserve engines IAW T.O. 2-1-18.

b) If applicable, de-preserve aircraft systems and service the aircraft IAW the pertinent 1C-5M-2 series T.O.

c) Accomplish a preflight inspection IAW T.O. 1C-5M-1 and T.O. 1C-5M-6WC-1. Correct all discrepancies determined to affect safety of flight.

d) Functional check flight of each aircraft will be as determined by the minimum requirements of T .O.

1-1-300 and T.O. 1C-5M-6CL-1.

e) Accomplish post-flight, correct flight safety discrepancies, as necessary, and maintain completed aircraft in flight readiness pending delivery.

f) Aircraft in Category “B” will not be test flown unless work performed falls under provisions of T .O.

1C-5M-6CF-1.

g) Technical Orders and Other Air Force Directive Requirements:

1) “Immediate Action” technical orders will be accomplished, as applicable, on Categories “A”, “B”, “C”, “D”, and “E” aircraft.

2) “Urgent Action” technical orders will be accomplished, as applicable, on Categories “A”, “B” “C”, and “D” aircraft, except when aircraft have progressed to completion and would require disassembly or constitutes a delay that is contrary to the Maintenance Compression Policy.

3) “Routine Type” technical order will only be accomplished when time will permit and when accomplishment does not delay delivery of the aircraft

C005/C005C

C005A

C005B

C005C

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Page 12 of 199April 07, 2022

2.0 - Receipt of Aircraft at Facility

2.1 - Handling and Safety

2.1.1 - Defuel Aircraft – (AP) Defuel will be accomplished IAW T.O. 1C-5M-2-1 and T.O. 00-25-172.

1A2 - Aircraft Incoming Processing (Ap) - Defuel/Refuel

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2.1.2 - Purge Aircraft Fuel Systems – (AP)

a) Aircraft fuel system will be purged and aerated IAW T.O. 1C-5M-2-1, T.O. 1C-5M-2-5, T.O. 1-1-3, and T.O.

42B-1-1.

b) If tank entry is required, fuel system will be purged to a health safe condition of 5% or less Lower Explosion

Limit (LEL) IAW T.O. 1-1-3. A fire safe condition of 20% or lower LEL will be maintained on hangared aircraft.

c) Engine fuel system purging will be accomplished IAW T.O. 1C-5M-2-4,

d) The engines will be preserved to levels specified IAW T.O. 1C-5M-2-4.

e) The auxiliary power unit fuel purging and preservation will be accomplished IAW T .O. 1C-5M-2-4,

f) Appropriate credit will be recorded and credited to the aircraft for all drained fuel.

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2.1.3 - 1A3 AIRCRAFT INCOMING PROCESSING (AP) - JACK/DEJACK

1A3 - Aircraft Incoming Processing (Ap) - Jack/Dejack

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Assigned Tasks

2.1.4 - 1A4 AIRCRAFT INCOMING PROCESSING (AP) - SAFETY

1A4 - Aircraft Incoming Processing (Ap) - Safety

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Assigned Tasks

2.1.5 - Make Aircraft Hangar Safe (AP).

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Assigned Tasks

Page 13 of 199April 07, 2022

2.1.5.1 - A. Ensure fuel system has been drained and purged IAW T.O. 1C-5M-2-1.

B. The liquid oxygen system will be drained and protected IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2298, 2420-9001, 2420-9002, 2420-9003, 2420-9009, 0591-2211, 0591-1001 & 0591-2293)

D. Engine and auxiliary power unit APU fire extinguisher squibs and FE 1301 fire suppression system (FSS) fire bottle squibs will be deactivated IAW T.O. 1C-5M-2-13. Electrical or mechanical safety device will be installed on the squibs after power source is disconnected.

E. Aircraft systems will be electrically isolated for maintenance by pulling and properly tagging circuit breakers IAW T.O. 1C-5M-2-4 and T.O. 1C-5M-2-3.

F. Safety locks and protective covers will be installed IAW T.O. 1C-5M-2-1, T.O. 1C-5M-2-4, T.O.

1C-5M-2-2, T.O. 1C-5M-2-9, and T.O. 1C-5M-2-6.

G. Latrines will be drained and serviced IAW T.O. 1C-5M-2-1.

H. Any AFTO Form 781 entry which requires work prior to hangar input, which is not specifically covered by a core task, will be accomplished under the non-work spec over and above provisions as approved by the

PAO.

I. Facilitate Removal and Installation of 6 each AMP computer display screens to prevent damage while maintenance is performed.

C005MA : 1A5 - Aircraft Incoming Processing (AP) - PDM Prep

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Assigned MDS(s)

Assigned Tasks

2.1.5.2 - A. Ensure fuel system has been drained and purged IAW T.O. 1C-5M-2-1.

B. The liquid oxygen system will be drained and protected IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2298, 2420-9001, 2420-9002, 2420-9003, 2420-9009, 0591-2211, 0591-1001 & 0591-2293)

D. Engine and auxiliary power unit APU fire extinguisher squibs and FE 1301 fire suppression system (FSS) fire bottle squibs will be deactivated IAW T.O. 1C-5M-2-13. Electrical or mechanical safety device will be installed on the squibs after power source is disconnected.

E. Aircraft systems will be electrically isolated for maintenance by pulling and properly tagging circuit breakers IAW T.O. 1C-5M-2-4 and T.O. 1C-5M-2-3.

F. Safety locks and protective covers will be installed IAW T.O. 1C-5M-2-1, T.O. 1C-5M 2-4, T.O.

1C-5M-2-2, T.O. 1C-5M-2-9, and T.O. 1C-5M-2-6.

G. Latrines will be drained and serviced IAW T.O. 1C-5M-2-1.

H. Any AFTO Form 781 entry which requires work prior to hangar input, which is not specifically covered by a core task, will be accomplished under the non-work spec over and above provisions as approved by the

PAO.

I. Facilitate Removal and Installation of 6 each AMP computer display screens to prevent damage while maintenance is performed.

C005MB : 1A5 - Aircraft Incoming Processing (AP) - PDM Prep

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Assigned MDS(s)

Page 14 of 199April 07, 2022

2.1.5.3 - A. Ensure fuel system has been drained and purged IAW T.O. 1C-5M-2-1.

B. The liquid oxygen system will be drained and protected IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2298, 2420-9001, 2420-9002, 2420-9003, 2420-9009, 0591-2211, 0591-1001 & 0591-2293)

D. Engine and auxiliary power unit APU fire extinguisher squibs and FE 1301 fire suppression system (FSS) fire bottle squibs will be deactivated IAW T.O. 1C-5M-2-13. Electrical or mechanical safety device will be installed on the squibs after power source is disconnected.

E. Aircraft systems will be electrically isolated for maintenance by pulling and properly tagging circuit breakers IAW T.O. 1C-5M-2-4 and T.O. 1C-5M-2-3.

F. Safety locks and protective covers will be installed IAW T.O. 1C-5M-2-1, T.O. 1C-5M-2-4, T.O.

1C-5M-2-2, T.O. 1C-5M-2-9, and T.O. 1C-5M-2-6.

G. Latrines will be drained and serviced IAW T.O. 1C-5M-2-1.

H. Any AFTO Form 781 entry which requires work prior to hangar input, which is not specifically covered by a core task, will be accomplished under the non-work spec over and above provisions as approved by the

PAO.

I. Facilitate Removal and Installation of 6 each AMP computer display screens to prevent damage while maintenance is performed.

C005MC : 1A5 - Aircraft Incoming Processing (AP) - PDM Prep

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Assigned MDS(s)

Assigned Tasks

2.1.5.4 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.5.5 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.5.6 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.6 - Tow - (AP)

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Assigned Tasks

2.1.6.1 - A. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-1025).

B. All aircraft towing will be accomplished IAW 1C-5M-2-1.

C005MA : 1A1 - Aircraft Incoming Processing (Ap) - Towing

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Assigned MDS(s)

Assigned Tasks

2.1.6.2 - A. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-1025).

B. All aircraft towing will be accomplished IAW 1C-5M-2-1.

C005MB : 1A1 - Aircraft Incoming Processing (Ap) - Towing

Page 15 of 199April 07, 2022

C005MB

2.1.6.3 - A. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-1025).

B. All aircraft towing will be accomplished IAW 1C-5M-2-1.

C005MC : 1A1 - Aircraft Incoming Processing (Ap) - Towing

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Assigned MDS(s)

Assigned Tasks

2.1.6.4 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.6.5 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.6.6 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.1.7 - Drain LN2 - (AP)

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Assigned Tasks

2.1.7.1 - The liquid nitrogen system will be drained IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C005MA : 1A6 - Aircraft Incoming Processing (Ap) - Aircraft Servicing

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Assigned MDS(s)

Assigned Tasks

2.1.7.2 - The liquid nitrogen system will be drained IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C005MB : 1A6 - Aircraft Incoming Processing (Ap) - Aircraft Servicing

C005MB

Assigned MDS(s)

Assigned Tasks

2.1.7.3 - The liquid nitrogen system will be drained IAW T.O. 1C-5M-2-1 and T.O. 1C-5M-2-13.

C005MC : 1A6 - Aircraft Incoming Processing (Ap) - Aircraft Servicing

C005MC

Assigned MDS(s)

Assigned Tasks

2.1.7.4 - (Changed) This paragraph is not active.

Page 16 of 199April 07, 2022

2.1.7.5 - (Changed) This paragraph is not active.

2.1.7.6 - (Changed) This paragraph is not active.

Assigned MDS(s)

2.2 - Inventory

Page 17 of 199April 07, 2022

2.2.1 - Inventory, Removal and Storage of Loose Equipment (IP).

A. All loose equipment will be removed from the aircraft prior to maintenance work commencing.

B. Spare engine oil and hydraulic fluid will be removed, the quantities recorded, and properly stored.

C. An itemized list/receipt will be made of all loose equipment removed from the aircraft and placed in storage.

D. Special mission equipment kits listed below will be removed from the aircraft prior to delivery to the PDM facility:

1) 4N14000-101A, Palletized Kit, Cargo Compartment

2) 4N21000-101A, Aerial Delivery System Kit

3) 4N11000-101A, Paratroops Kit, Aerial Delivery System4) 4N10000-101A, Seat Kit, Student/Instructor

E. Aircraft will be input with minimum loose equipment, including the items listed below:

(1) Flight Station:

- Crash ax 1

- Flight safety harness/strap 1

- First aid kits 2

- Emergency exit lights 2

- Oxygen bottles 3 (Serviceable)

- Fire extinguishers 1

- Smoke masks (As Required – (one per Crew Member)

- Fire fighter gloves 1 Pair

- Oxygen masks for crew 3

(2) Relief Crew Compartment:

- Fire extinguishers 2

- Oxygen bottles 3 (Serviceable)

- Oxygen masks 2 (spare)

- Emergency exit lights 2

- Service door restraint gate 1

- Escape slide No. 5 Service Door 1 (With updated inspection good for 1 year)

- 2-man seats 2

- 3-man seat 1

- Latrine (serviced)

- Latrine (serviced)

- **Water jug with cups 1

- **Refrigerator

- **Oven

- **Coffee pot,

- **Hot plate

- **First aid kit

- **Smoke masks

(3) Courier Compartment:

- Fire extinguishers 1

- Life raft bottles (With updated inspections good for 1 year)

- **Oxygen masks

- **Life Rafts 2

- **First aid kit

- Seats

(4) Troop Compartment:

- Fire extinguishers 5

- Oxygen bottles 4 (Serviceable)

- Crash ax 1

- Service door restraint gate 1

- Life raft bottles (with updated inspections good for 1 year)

- **Oxygen masks

- **Emergency exit lights 5

- **Seats

- **Refrigerators

- **Ovens

Page 18 of 199April 07, 2022

- **Life Rafts

(5) Cargo Compartment:

- Emergency exit lights 3

- Oxygen bottles 6 (Serviceable)

- Fire extinguishers 6

- 1-gal extinguishers (C 5MB only) 2

- Landing gear pins 5

- NLG strut limiter 1

- Kneeling pad extend pin 1

- Forward ramp lock pins 8

- 2-inch kneeling collars 2

- Aft ramp lock pins 14

- 4-inch kneeling collars 2

- Smoke masks

- Latrine (serviced)

- First aid kits 2

- **10,000 lb. chains 10

- **25,000 lb. chains 10

- **Small tie-down devices 10

- **Large tie-down devices 10

- **Tie-down straps 10

Items with (**) need to be remove and stored at home station prior to delivery to the PDM facility.

F. Other items required for input flight and functional check flight but not included in T .O. 1C-5M-21:

1) Fire-Fighting Mask, Smoke, P/N 651-280 or 358 series Quick-Don Mask with Goggles (6)

2) Aircraft Equipment Accountability List, AF 2692 (1)

3) Aircraft Flight Report and Maintenance Records, (1 set) AFTO 781 Series.

4) For aircraft that have been modified by TCTO 1C-5-714 under the Avionics Modernization Program (AMP), remove and store for later reinstallation, 6 ea. Multifunctional Display Units (MFDU’s) from the flight deck pilot and co-pilot instrument panel.

5) Aircraft modified by TCTO 1C-5-811 (Armor) need to have all armor removed except for the plate under the

LOX converters.

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Assigned MDS(s)

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2.3 - Preservation

2.3.1 - A. If aircraft are input with equipment configurations other than listed above, the differences will be recorded and reported.

B. All batteries will be maintained and stored as required IAW T.O. 8D2-1-31 or T.O. 8D2-3-1, as applicable.

C. All open fuel, oil, pneumatic, and hydraulic system lines, electrical connectors, and openings will be capped, covered, and secured to prevent system contamination and Foreign Object Damage (FOD) while aircraft is in work IAW T.O. 44H3-1-3 and MIL-STD-980. Protective covers, shields, and plugs will be installed while aircraft is in work IAW T.O. 1C-5M-2-1.

D. Turbo jet oil, lubrication oil, and hydraulic fluid drained for any reason will not be reused and will be disposed of IAW T.O. 42B2-1-3.

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Page 19 of 199April 07, 2022

3.0 - Work Requirements

3.1 - General Aircraft

3.1.1 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.1.2 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.1.3 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.1.4 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.1.5 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.1.6 - (Changed) This paragraph is not active.

Assigned MDS(s)

3.2 - Specific Work Requirements

3.2.1 - 1B4L - AIRCRAFT SUPPORT TASKS

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Assigned Tasks

3.2.1.1 - A. Maintenance review Team.

B. Aircraft Logistics Specialist Support

C. Forward Logistics Specialist

1B4L1 - Aircraft Support Tasks - Maintenance Review Team

1B4L2 - Aircraft Support Tasks - Aircraft Logistics Specialist (Als)

1B4L3 - Aircraft Support Tasks - Forward Logistics Specialist

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Assigned Tasks

3.2.2 - 1B5B - NOSE LANDING GEAR WHEEL WELL - INTERNAL (Work Spec 5B)

Page 20 of 199April 07, 2022

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3.2.2.1 - THIS ZONE, LOCATED ABOUT THE CENTERLINE OF THE AIRPLANE BETWEEN FS 524 AND

FS 664, CONTAINS THE PRESSURE SHELL STRUCTURE, GEAR SUPPORT STRUCTURE INSTALLED

WITHIN THE ZONE.

A. Gain access to Area.

B. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2069).

C. Submit correct defects in MWR under Work Spec (B5)

D. After defects are complied with build-up area and perform operational checks as required.

C005MA : 1B5B1 - Nlg Wheel Well - Internal - Gain Access And Build Up

C005MA : 1B5B2 - Nlg Wheel Well - Internal - Clean

C005MA : 1B5B3A - Nlg Wheel Well - Internal - Visual Inspections

C005MA : 1B5B3B - Nlg Wheel Well - Internal - NDI Inspections

C005MA : 1B5B4 - Nlg Wheel Well - Internal Correct Defects

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Assigned MDS(s)

Assigned Tasks

3.2.2.2 - THIS ZONE, LOCATED ABOUT THE CENTERLINE OF THE AIRPLANE BETWEEN FS 524 AND

FS 664, CONTAINS THE PRESSURE SHELL STRUCTURE, GEAR SUPPORT STRUCTURE INSTALLED

WITHIN THE ZONE.

A. Gain access to Area.

B. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2069).

C. Submit correct defects in MWR under Work Spec (B5)

D. After defects are complied with build-up area and perform operational checks as required.

C005MB : 1B5B1 - Nlg Wheel Well - Internal - Gain Access And Build Up

C005MB : 1B5B2 - Nlg Wheel Well - Internal - Clean

C005MB : 1B5B3A - Nlg Wheel Well - Internal - Visual Inspections

C005MB : 1B5B3B - Nlg Wheel Well - Internal - NDI Inspections

C005MB : 1B5B4 - Nlg Wheel Well - Internal Correct Defects

C005MB

Assigned MDS(s)

Assigned Tasks

3.2.2.3 - THIS ZONE, LOCATED ABOUT THE CENTERLINE OF THE AIRPLANE BETWEEN FS 524 AND

FS 664, CONTAINS THE PRESSURE SHELL STRUCTURE, GEAR SUPPORT STRUCTURE INSTALLED

WITHIN THE ZONE.

A. Gain access to Area.

B. Perform Tasks IAW 1C-5M-6WC-8 (Work Card 0591-2069).

C. Submit correct defects in MWR under Work Spec (B5)

D. After defects are complied with build-up area and perform operational checks as required.

C005MC : 1B5B1 - Nlg…