J-6_USCBP_TRD_for_Post_MLU-LEK_Depot_DLM_TRD_dated_10-31-17_Revision_2.1_....pdf1.pdf

Customs and Border Protection

P-3 DEPOT LEVEL MAINTENANCE

DLM TECHNICAL REQUIREMENTS DOCUMENT

POST MLU/LEK PDM

October, 31,2017

Document Change History

The following table identifies each version or issue of this document and provides a description of the purpose or reason for the change. Detailed change differences can be identified by performing a document comparison between any two versions of this document.

Version Date Comment

1.1 11/10/2015 Modified To Reflect Post MLU/PDM Aircraft Status 2 3/19/2016 Updated Technical Publications listed in paragraph 9.14, 2.11, 9.1 and 9.3

2.1 3/31/2016 Updated Disassembly Access Open/Close Sections 4.8, 5.36, 5.37, 5.38, and 5.40. Eliminated 8.1 Engineering Reports and 8.3 Structural Sampling Report.

DLM TECHNICAL REQUIREMENTS DOCUMENT

POST MLU/LEK PDM

1 GENERAL

..................................................................................................................................................... 8 1.1

SCOPE

1.2 DEFINITIONS

1.3 ACRONYMS

1.4 DLM INTERVAL

1.5 MAINTENANCE REFERENCES

1.6 CDRL REQUIREMENTS

1.7 PRODUCT ORIENTED SURVEYS

1.8 SPECIFIC EQUIPMENT

1.9 DLM OPERATIONAL DOCUMENT APPROVAL

1.10 UNSCHEDULED ACCESSORY AND COMPONENT REPAIR

1.11 CONCURRENT REPAIR OF REPAIRABLE COMPONENTS

1.12 ECONOMICAL REPAIR

1.13 MAJOR STRUCTURAL REPAIRS

1.14 INVALID NDI REQUIREMENT

1.15 INTERIOR AND EXTERIOR FINISHES

1.16 DISTURBED SYSTEMS

1.17 ENGINEERING SUPPORT

1.18 LIAISON ENGINEERING

1.19 STANDARD REPAIRS

1.20 NONSTANDARD REPAIRS

1.21 TECHNICAL PROCESS CHANGES

1.22 TECHNICAL DATA

1.23 WELDING

1.24 NON-DESTRUCTIVE INSPECTION (NDI)

1.25 COMPONENT PLATING FACILITIES

1.26 AIRCRAFT EXPLOSIVES

1.27 ELECTROSTATIC DISCHARGE CONTROL PROGRAM

1.28 SYSTEM SAFETY PROGRAM PLAN

1.29 AVIATION MISHAP REPORTING AND INVESTIGATION

1.30 QUALITY ASSURANCE PROGRAM

1.31 OZONE DEPLETING SUBSTANCES

1.32 SUPPLIER QUALITY ASSURANCE SYSTEM PROGRAM

1.33 REMOVED AIRCRAFT PARTS PROGRAMS

1.34 AIRCRAFT STATUS REPORT

1.35 ENGINEERING INVESTIGATIONS

1.36 AIRCRAFT INSPECTIONS (SCHEDULED AND CONDITIONAL)

21 1.37 OPERATIONS SECURITY

..................................................................................................................... 21 1.38 CONTRACT LINE ITEMS

NUMBER (CLIN)

1.39 PRODUCTION PLAN

22 1.40 OVER AND ABOVE

1.41 UNSCHEDULED ACCESSORY AND COMPONENT REPAIR

NOTE

1.42 CONCURRENT REPAIR OF REPAIRABLE COMPONENTS

1.43 CANNIBALIZATION

1.44 PROGRAM REVIEWS

1.45 MAJOR STRUCTURAL REPAIRS OF THE ROTODOME PYLON/FUSELAGE PYLON SUPPORT STRUCTURE

1.46 AEW MAINTENANCE REFERENCES

1.47 P-3B AIRBORNE EARLY WARNING (AEW) AIRCRAFT GENERAL DESCRIPTION

IN-COMING REQUIREMENTS

40 IN-COMING

REQUIREMENTS

2.1 INCOMING POST FLIGHT BRIEFING

2.2. AIRCRAFT LOGBOOKS AND RECORDS

2.3 AIRCRAFT EQUIPMENT INVENTORY

2.4 SURVIVAL AND LOOSE EQUIPMENT

2.5 HYDRAULIC SYSTEM CONTAMINATION

2.6 FUEL SYSTEM CONTAMINATION

41 2.7 TURBO SHAFT ENGINES

NOTE

IF ENGINE EFFICIENCY CHANGES BY MORE THAN THREE (3) PERCENTAGE POINTS FROM PREVIOUSLY RECORDED

PERFORMANCE RUN, IMMEDIATELY CONTACT THE DAR

41 2.8 AIRCRAFT FUEL LEAK PROCESSING

2.9 APU

2.10 TOWING, JACKING, HOISTING AND MOORING

2.11 AIRCRAFT PRESERVATION

2.12 MAKE AIRCRAFT HANGAR SAFE

DEPAINT/APPLICATION AND CORROSION INHIBITING APPLICATION PROCESSES

3.0 REPAINT/SEALANT CLEAN AND REMOVAL/CORROSION INSPECTION/CORROSION

INHIBITING APPLICATION/RESEAL/ PAINT

3.1 EXTERIOR AIRCRAFT PAINT REMOVAL

3.2 PAINT REMOVAL, EXTERIOR DETAIL

3.3 CLEAN AIRCRAFT

3.4 CHEMICAL CONVERSION COATING

3.5 EXTERIOR CORROSION INSPECTION

3.6 EXTERIOR AIRCRAFT PRIMING

3.7 EXTERIOR AIRCRAFT SEALING/PAINTING

3.8 EXTERIOR PAINT SCHEME MARKING

DISASSEMBLY ACCESS OPEN/CLOSE

4.0 ACCESS OPEN/ DISASSEMBLY/REASSEMBLE/CLOSE

4.1 ENTRANCE LADDER

4.2 ALL INTERIOR SEATS

4.3 DF-301E UHF/DF ANTENNA

4.4 NOSE RADOM AND FORWARD BULKHEAD

4.5 AFT RADOME

4.6 ECCOSORB BLANKETS (NOSE AND AFT RADOMES)

4.7 INSULATION BLANKETS

4.8 APU, APU EXHAUST DUCT/DOOR AND APU INLET DOOR

4.9 FLUSH TOILETS

4.12 WING TIPS

51 4.13 ELEVATORS

4.14 ELEVATOR TORQUE TUBE AND BEARINGS

4.15 AILERONS

4.17 RUDDER

4.18 RUDDER BELLCRANK TORQUE TUBE

4.19 RUDDER BOOST PACKAGE

52 4.20 AIRCRAFT BATTERY

........................................................................................................................... 53 4.21 LTN 92 BATTERY

4.22 VERTICAL STABILIZER CAP

53 4.24 EMPENNAGE ACCESS PANELS

4.25 EMPENNAGE INTERNAL COTHEN CHASSIS

4.26 #1 & #4 FIRE SHIELD PANELS

4.27 NACELLE ACCESS PANELS

4.28 ENGINE #2 & #3 HRD ACCESS PANELS AND UPPER AND LOWER FIRE SHIELDS

4.29 WING ACCESS PANELS

4.32 WING CENTER SECTION GROUND PLANE ASSEMBLY

4.33 FUSELAGE PANELS

4.34 BOMB BAY INTERNAL STRESS PANELS

4.35 FLIGHT STATION UPPER AND LOWER ACCESS PANELS

4.36 EMPENNAGE FILLET PANELS

4.37 NACELLE TO WING FILLET PANELS

4.38 ENGINE #1 AND #4 TAILPIPES

4.39 ENGINE #2 AND #3 TAILPIPES

4.40 ENGINE #1 AND #4 EXHAUST STRAIGHTENED

4.41 ENGINE #2 AND #3 EXHAUST STRAIGHTENED

4.42 ENGINE #1 AND #4 TAILPIPE SHROUDS

4.43 ENGINE #2 AND #3 TAILPIPE SHROUDS

4.44 FUSELAGE TO WING AND CENTER SECTION FILLET PANELS

4.45 AIRCRAFT FLOOR PANELS

4.46 ROTODOME AND PYLON ACCESS PANELS/FAIRINGS (P-3B AEW)

4.47 RTA-852L WEATHER RADAR RECEIVER/TRANSMITTER/ANTENNA (P-3B LRT ONLY)

ZONAL INSPECTION REQUIREMENTS

64 5.0 ZONAL INSPECTION PROCEDURES/REQUIREMENTS

5.1 NACELLES 1, 2, 3, AND 4 EXTERNAL

5.2 NACELLE 1 AND 4 INTERNAL

5.3 NACELLES 2 AND 3 INTERNAL

5.4 RADOME EXTERNAL

5.5 RADOME INTERNAL (LRT AIRCRAFT ONLY)

5.6 RADOME INTERNAL (AEW AIRCRAFT ONLY)

5.7 NOSE LANDING GEAR WHEEL WELL AND DOORS INTERNAL

5.8 APU/AIR-CONDITIONING SERVICE BAY INTERNAL

5.9 FUEL COMPARTMENT INTERNAL

5.10 WATER ALCOHOL / SERVICE BAY

5.11 LEFT WING INTERNAL

5.12 RIGHT WING INTERNAL

5.13 LEFT WING EXTERNAL

5.14 RIGHT WING EXTERNAL

5.15 LEFT WING LEADING EDGE INTERNAL

5.16 RIGHT WING LEADING EDGE INTERNAL

5.17 LEFT WING TIP INTERNAL

5.18 RIGHT WING TIP INTERNAL

69 5.19 LEFT WING TRAILING EDGE INTERNAL

................................................................................................. 69 5.20 RIGHT WING TRAILING EDGE INTERNAL ............................................................................................... 69 5.21 EMPENNAGE EXTERNAL

5.23 HF ANTENNA BOOM

70 5.24 RADOME - INTERNAL

5.25 LEFT HORIZONTAL STABILIZER – INTERNAL

5.26 RIGHT HORIZONTAL STABILIZER – INTERNAL

5.27 LEFT HORIZONTAL STABILIZER, TRAILING EDGE AND ELEVATOR INTERNAL

5.28 RIGHT HORIZONTAL STABILIZER, TRAILING EDGE AND ELEVATOR, INTERNAL

5.29 VERTICAL STABILIZER, INTERNAL

5.30 VERTICAL STABILIZER, TRAILING EDGE AND RUDDER

72 5.31 WING CENTER SECTION-INTERNAL

5.32 WING FAIRING LEFT - INTERNAL

72 5.33 WING FAIRING RIGHT - INTERNAL

........................................................................................................ 72 5.34 FLIGHT STATION FUSELAGE -

EXTERNAL

5.35 FLIGHT STATION FUSELAGE - INTERNAL

5.36 FLIGHT STATION FUSELAGE UNDERFLOOR - INTERNAL

OBS FUSELAGE EXTERNAL

REQUIREMENT - INSPECT ZONE 18.1. PERFORM VISUAL INSPECTION OF THE EXTERNAL SURFACES OF THE

EXTERNAL FUSELAGE AREA BETWEEN FS 288.0 AND FS 405.0

5.37 OBS FUSELAGE INTERNAL

TACTICAL/SENSOR DETECTION SYSTEM STATION EXTERNAL

REQUIREMENT - INSPECT ZONE 19.1. PERFORM VISUAL INSPECTION OF THE EXTERNAL SURFACES OF THE

EXTERNAL FUSELAGE AREA BETWEEN FS 405.0 AND FS 695.0

5.38 TACTICAL/SENSOR DETECTION SYSTEM STATION - INTERNAL

5.39 CLUB SEATING, AFT OBS. FUSELAGE - INTERNAL

5.40 CLUB SEATING, AFT OBS. FUSELAGE - EXTERNAL

5.41 STAFF AREA

REQUIREMENT - INSPECT ZONE 21.1. PERFORM VISUAL INSPECTION OF THE EXTERNAL SURFACES OF THE

EXTERNAL FUSELAGE AREA BETWEEN FS 920.0 AND FS 1117.0

5.42 STAFF AREA INTERNAL

5.43 UNDER FLOOR AREA - INTERNAL

STRUCTURAL INSPECTION REQUIREMENTS

6.0 STRUCTURAL INSPECTION REQUIREMENTS

6.1 HORIZONTAL STABILIZER, UPPER SURFACE PLANKS

6.2 HORIZONTAL STABILIZER UPPER SURFACE PLANKS

6.3 HORIZONTAL STABILIZER LOWER SURFACE PLANKS

6.4 HORIZONTAL STABILIZER LOWER SURFACE PLANKS

6.5 CANTED BULKHEAD AT HORIZONTAL STABILIZER

6.6 VERTICAL STABILIZER ATTACH ANGLE

STRUCTURAL INSPECTION REQUIREMENTS FOR AEW AIRCRAFT ONLY

6.7 PYLON FWD LH STRUT TO FUSELAGE MOUNTING, FS 754.6, WL 214.8, BL 27.6L - SSI-AEW1

6.8 PYLON FWD RH STRUT TO FUSELAGE MOUNTING, FS 754.6, WL 214.8, BL 27.6R - SSI-AEW2

6.9 PYLON AFT LH STRUT TO FUSELAGE MOUNTING, FS 865.3, WL 214.8, BL 27.6L - SSI-AEW3

6.10 PYLON AFT RH STRUT TO FUSELAGE MOUNTING, FS 865.3, WL 214.8, BL 27.6R - SSI-AEW4

6.11 FUSELAGE ROTODOME SUPPORT FWD STRAP EXTERNAL, FS 754.6 TO 763.9 ABOVE WL 123.5 - SSI-

AEW5

6.12 FUSELAGE ROTODOME SUPPORT AFT STRAP EXTERNAL, FS 865.3 TO 874.6 ABOVE WL 123.5 - SSI-

AEW6

6.13 FUSELAGE ROTODOME SUPPORT LH AFT FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 865.3 AND FS 874.6 - SSI-AEW7

6.14 FUSELAGE ROTODOME SUPPORT RH AFT FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 865.3 AND FS 874.6 - SSI-AEW8

6.15 FUSELAGE ROTODOME SUPPORT LH FWD FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 754.6 AND FS 763.9 - SSI-AEW9

6.16 FUSELAGE ROTODOME SUPPORT RH FWD FORMER WEB SPLICES, BATHTUB FITTINGS AND LOWER

FORMER SPLICE JOINT AT WL 123.5 - INTERNAL, FS 754.6 AND FS 763.9 - SSI-AEW10

6.17 PYLON FWD LH UPPER STRUT TO HOUSING ATTACHMENT, FS 797.5, WL 286.3 - SSI-AEW11

6.18 PYLON FWD RH UPPER STRUT TO HOUSING ATTACHMENT, FS 797.5, WL 286.3 - SSI-AEW12

6.19 PYLON AFT LH UPPER STRUT TO HOUSING ATTACHMENT, FS 826.5, WL 286.3 - SSI-AEW13

6.20 PYLON AFT RH UPPER STRUT TO HOUSING ATTACHMENT, FS 826.5, WL 286.3 - SSI-AEW14

6.21 PYLON INTERIOR BOX WEBS AND ACCESS PANEL OPENINGS - SSI-AEW15

SYSTEM AND COMPONENTS REQUIREMENTS

7.0 SYSTEM AND COMPONENT REQUIREMENTS

7.1 AILERON INSPECTION ACCESS PANELS

7.3 AILERON ASSEMBLY

7.4 AILERON HINGE BEARINGS

85 7.5 ELEVATOR INSPECTION ACCESS

PANELS

7.7 ELEVATOR ASSEMBLY

7.8 RUDDER INSPECTION ACCESS PANELS

7.10 RUDDER ASSY

7.11 CONTROL COLUMN FRICTION PLATES

7.12 ELEVATOR DOWN-SPRING CARTRIDGE

7.13 FORCE LINK TAB MECHANICAL SPRING CARTRIDGE

87 7.14 FORCE LINK TAB MECHANICAL ROLL OFF CARTRIDGE

87 REQUIREMENT

........................................................................................................................................... 87 7.15 CABIN

HEAT EXCHANGERS

7.16 OUTGOING BLEED AIR MANIFOLD

DLM REPORTS

88 8.0 DLM REPORTS

.................................................................................................................................... 88 8.1 NBNC REPORT ................................................................................................................................... 88 FINAL PROCESSING ................................................................................................................................. 89 9.0

FINAL PROCESSING

9.1 DEPRESERVATION

9.2 DISTURBED SYSTEMS

9.4 LTN-92 HEADING REFERENCE SYSTEM ALIGNMENT

9.5 TURBO SHAFT ENGINES

9.6 APU

9.7 AIRCRAFT FUEL LEAK CHECKS

9.8 WEIGHT AND BALANCE

9.9 LOGS AND RECORDS

9.10 HYDRAULIC SYSTEM CONTAMINATION

9.11 MAKE AIRCRAFT READY FOR FLIGHT

9.12 FUNCTIONAL/ACCEPTANCE FLIGHTS

9.13 GOVERNMENT AIRCRAFT ACCEPTANCE

9.14 AEW PECULIAR SYSTEM GOVERNMENT FURNISHED MAINTENANCE REFERENCES

10.0 GOVERNMENT FURNISHED EQUIPMENT

General

1.1 Scope

This document provides instructions and responsibilities for P-3B Airborne Early Warning (AEW) and Long Range Tracker (LRT) aircraft Depot Level Maintenance (DLM) Depot Level Drop-In Maintenance and its associated support to the Customs and border protection (CBP). The goal of this maintenance program is to ensure safe, reliable, and available operation of the aircraft throughout its service period in order to meet US Customs and border protection (CBP) mission requirements. This Technical Requirements Document (TRD) establishes the Depot Level Maintenance (DLM) requirements for the P3B Airborne Early Warning AEW and Long Range Tracker (LRT) systems/equipment and modifications peculiar to the P-3B AEW and LRT aircraft. The depot activity shall perform DLM on the systems/equipment and modifications as required in this Technical Requirements Document. Upon completion of all such repair and DLM, the aircraft and its accessories/components shall be completely reassembled, applicable systems rigged, aligned and/or tested (in accordance with the specified requirements) and the aircraft prepared for the Functional Check Flight process. The aircraft will be flight checked by the Government. The scheduled DLM requirements prescribed in this TRD are the minimum requirements necessary to ensure the timely discovery and correction for actual and/or anticipated defects based on the aircraft intended use. Compliance with these requirements is mandatory. The depot activity shall provide all services, support equipment, tools, tooling, facilities necessary, and any other items necessary in order to perform the requirements of this document.

Preceding requirement excludes the identified Government Furnished Equipment (GFE) identified in this

TRD.

Unscheduled maintenance requirements are those requirements which cannot be directly related to any scheduled requirement. These are only discovered as an incidental result of the following functions which are accomplished as a part of and during the scheduled inspections:

• Review and upkeep aircraft logbooks and all associated records.

• Inspection of the aircraft and its components during DLM

• The DLM requirements described herein provide for airframe, systems, and component inspection;

and for defect correction, preventive maintenance, modification and Technical Directive (TD) compliance, these requirements correspond with safety and reasonable economic considerations.

Additionally, technical support for evaluation of aircraft condition is provided throughout the aircraft service life. These requirements include, but are not limited to:

• A thorough and comprehensive inspection of selected aircraft structure, flight essential systems, and flight critical components by appropriate inspection methods with repair, as required, to ensure the serviceability until the next DLM induction.

• Replacement of time change components, assigned to Depot level, exceeding specified replacement intervals.

• Adjustments, checks, tests, repairs, inspections, preventive maintenance, and the DLM procedures coincidental thereto, shall be accomplished in accordance with applicable directives and publications as directed by this TRD.

• Defect classification shall be subject to review of the Designated Agency Representative (DAR) who will advise and provide recommendations. The correction criteria for each classified defect is as follows:

• Critical Defects All critical defects discovered as a direct result of or incidental to, compliance with DLM requirements shall be corrected in accordance with applicable documents.

• Major Defects All major defects discovered as a direct result of, or incidental to, compliance with DLM requirements may be corrected in accordance with applicable documents and when directed by the Government’s DAR.

• Minor Defects Minor defects discovered as a direct result of, or incidental to, compliance with PDM requirements shall not be corrected except for the following:

Notes Discrepancies discovered in areas not normally opened or inspected by organizational maintenance, or which also may affect the integrity of the exterior paint system, if accessed for correction. DAR approval required for correction of these defects.

Minor corrosion on common hardware, such as screws, bolts, washers, nuts, retaining clips, nut plates, etc., does not require corrosion treatment, removal or documentation provided this corrosion does not affect the function of the hardware and is located in an interior area of the aircraft which if accessed later would not affect the integrity of the exterior paint system.

• ”Noted But Not Corrected Defects” not required to be corrected by the above criteria shall be identified by type, location, and description on the Noted But Not Corrected (NBNC) report for appropriate action.

Component nomenclatures used in this TRD are in general agreement with nomenclature used in the aircraft technical maintenance instruction manuals. Inspection requirements for items identified by nomenclature are applicable to the entire class of part numbers for that item as listed in the P-3 Illustrated Parts Breakdown(s), P-3 Structural Repair Manuals, The inspection, replacement, or other maintenance actions required by this TRD on specific equipment not installed on a particular T/M/S aircraft shall be disregarded. Recommendations for additions, deletions, or changes to the requirements of this TRD shall be submitted to US Customs and Border Protection and documented on the Maintenance History Summary and Corrosion inspection Report

1.2 Definitions

The following definitions are provided to establish the terminology, as applied to the maintenance and DLM requirements of this TRD. Terminology not defined in these paragraphs and used by this TRD shall be understood under the definitions of COMNAVAIRINST 4790.2, and interpreted within the context of the requirements of this TRD. Generally accepted interpretations or colloquial usage of terminology shall be unacceptable rationale for any deviation from the definitions of this TRD.

• Abrasion The wearing away of the applicable material by rubbing or scraping. (Synonymous with

CHAFING.)

• Accessible Areas exposed by the removal of access doors, panels, fairing, etc., and such other disassembly required by the maintenance requirements and not involving destructive disassembly unless specified.

• Accessory A part, subassembly, or assembly designed for use in conjunction with or to supplement another assembly, or a unit or set contributing to the effectiveness thereof without extending or varying the basic function of the assembly or set.

• Aircraft Wiring All electrical wiring considered part of the standard configuration of the aircraft that is permanently installed, and not an integral part of any accessory, component, or “black box”.

• Airframe The structural component, including the framework and skin, of such parts as the fuselage, empennage, wings, control surfaces, landing gear (minus tires) and engine mounts.

• Airframe Accessories The items of equipment that are required for operation of the aircraft and that cannot be considered an integral part of the airframe or engine, such as wheels, brakes, hydraulic equipment, fuel system, deicing equipment, anti-icing equipment and other items not an integral part of the airframe, regardless of whether attached to the engine or airframe.

• Assembly A number of parts or subassemblies, or any combination thereof, joined together to perform a specific function.

Attachment A part, subassembly, or assembly designed for use in conjunction with another assembly, unit, or set contributing to the effectiveness thereof by extending or varying the basic function of the assembly, unit, or set.

• Avionics System Aircraft electrical, electronic, instrument flight control, fire control, missile and bombing equipment and their subsystems, either independent equipment, groups of equipment, or integrated systems necessary to accomplish assigned military missions.

• Calibrate To repair, check, or correct the graduations or indices of measuring devices or to repair, adjust, and align equipment so that it functions within assigned tolerances.

• Caution. Indicates danger to the weapon system. The caution precedes the item to which it refers.

• Chafing The wearing away of the applicable material by rubbing or scraping. (Synonymous with

Abrasion)

• Check To perform a thorough examination to ascertain the existence of unacceptable deviations from the intended state or condition as established by applicable document.

• Check Flight Airborne operational tests performed to determine whether the airframe, power plant, accessories, and other items of equipment are functioning in accordance with predetermined standards while subjected to the intended operating environment.

• Checkout A sequence of functional, operational, and calibration tests to determine the condition and status of a system or element thereof.

• Cleanliness The state of being free from impurities, impediments, and foreign matter not specified to be applied to the surface in question.

• Component A number of parts of subassemblies, or any combination thereof, joined to perform a specific function.

• Component Scheduled Removal Components whose overhaul or replacement schedule is established as a function of service use (flight hours, unit operating time or calendar time, cycles, event, Standard Depot Level Maintenance).

• Component Wiring The components required for the installation, connection, and/or continuation of electrical circuit segments, including relays, switches, fuses, connectors (plugs and receptacles), splices, terminals, terminal panels, grounding studs, harnesses, clamps, conduits, anti-chafing material, etc.

• Condition Inspection A visual examination to determine the existence of external damage and defects that could render the article unacceptable for continued use.

• Configuration Identification The current approved or conditionally approved technical document for a configuration item as set forth in specifications, drawings, and associated lists and documents.

• Continental United States (CONUS) The states on the North American mainland bound by borders with Canada on the north, and Mexico on the south. The United States with the exception of the states of Alaska and Hawaii.

• Corrosion An action or process which destroys metal by chemical or electrochemical action and converts it into an oxide, hydroxide, or sulfate compound.

• Damage The impairment of a part by physical force.

• Defective The state of possessing a deviation from specified requirements.

• Deformation Any disfigurement or change in form or shape from the intended design configuration.

• Delamination A physical break of the bond between the binder material and any two or more plies of laminated panels fabricated of plastic, metal, or other materials or combinations thereof.

• Depot Activity The industrial establishment, either Government or Commercial, designated by the

US Customs and Border Protection as having maintenance responsibility for DLM for a particular model aircraft.

Designated Agency Representative The representative of the Government cognizant for accepting products or services, for approving work or changes to work, or similar duties from contractors or vendors This distinction is necessary to distinguish Government as a contractor from Government as a customer. The DAR represents the customer Government.

• Deterioration The breakup, eating away, or decomposition of a substance by the action of weather, corrosive material, or other environmental condition.

• Discrepancy Any deviation, disagreement, difference, or inconsistency, physical or otherwise, of an aircraft part or assembly from the design specification, usage or operation (synonymous with Defect).

• Distortion Any disfigurement or change in form or shape from the intended design configuration resulting from a twisting or torsion action.

• Disturbed System A system whose installed integrity has been interrupted, broken, or interfered with to the extent that system installation and operation cannot be assured without certification by a functional/operational test.

• Economical Repair Repair that can be accomplished using the economical repair criteria of

NAVAIRINST 4700.20

• Emergency Maintenance The requirement for service, inspection, repair, replacement, modification, and TD compliance to be accomplished on individual aircraft on an unscheduled basis.

• Erosion The act of wearing away by corrosion, friction, scraping, or rubbing.

• Essential Repair Restricted to those repairs, bench checks, functional checks, adjustments, tests, and work necessary to assure that an end item is restored to a serviceable condition and will efficiently accomplish its intended purpose. Essential Repair prohibits expending man-hours accomplishing unnecessary disassembly and complete overhaul.

• Evidence Factual data which establishes the possibility of an existing or impending unsatisfactory condition.

• Evaluation An investigation to determine condition, i.e., the existence of defects and damage.

• Exterior Surface That part of the airframe exposed to the elements when in a “clean” flight configuration including wing and stabilizer control(s). Does not include landing gear structure, wheel wells, etc., or areas exposed by extension of landing gear.

• Failure The inability of a part, unit set, or system to perform its required function within established limits.

• Fraying The wearing away by rubbing, usually of woven, braided, or stranded material, which results in a worn or ragged appearance.

• Functionally Significant Item (FSI) Components, subassemblies, systems, or subsystems that are considered the most important for their effect on the safety of the aircraft and personnel, on the operational reliability of the system or aircraft, or on the economic aspects of repairs and replacements.

• Functional Test The quantitative evaluation of a system or component to assure its ability to perform over the full operating range as designed and within specified limits. Test equipment is normally used to provide precise inputs and to make measurements.

• Electric/Electronic Wiring Circuits Verification (General) A test of system wiring and wiring components to verify ability of aircraft wiring to perform its intended function when mated to a set of operational black boxes. May be accomplished by either of the following procedures:

• Functional or operational test of the system using existing aircraft black boxes, if operable, or “Slave” units if available. Tests shall be limited to the depth required to demonstrate adequacy of system wiring

• Any suitable method of continuity checks.

• Groove Any narrow furrow, depression, or slit on the surface of a part.

Group A collection of units, assemblies, or subassemblies which is a subdivision of a set or system, but which is not capable of performing a complete operational function (See SYSTEM).

• Inclusion A void or discontinuity in the molecular structure of metal.

• Inspect To perform a critical investigation of an item, unit, component, or airframe through the visual, authority, olfactory, and tactile senses, utilizing simple manipulation, gauging, and measurements, as required, for the specific intent of determining its conformance to the assigned specification within the tolerances permitted. The process may require partial disassembly of such items.

• Conditional Inspection An unscheduled inspection required as a result of an over limit situation which occurs during operation of the aircraft (e.g., hard/overweight landings, engine over speed/over temp., etc.). A logbook entry is required for a conditional inspection of an aircraft and any component/equipment having an Aeronautical Equipment Service Record (AESR) logbook

• Special Inspection A scheduled inspection with a prescribed interval other than daily, calendar/phased, major engine or DLM. The intervals are specified in the applicable Periodic Maintenance Inspection Card manual and are based on elapsed calendar time, flight hours, operating hours, or number of cycles/event (e.g., 28,112 days/300, 600 hours, etc.). Logbook entries are required.

• Inspect and Repair as Necessary (IRAN) The process of inspecting and repair of an item only to the extent to make the item serviceable.

• Interior Surfaces Interior surfaces are all aircraft surfaces excluding areas defined as exterior. (SEE EXTERIOR). Interior aircraft surfaces are considered any area on the aircraft within a specific aircraft zone covered by an exterior skin, plank, access panel, door, antennas, radomes, or leading edge. They also include but not are limited to under-floor, inside access panels, access panel surfaces, flap wells, wheel wells, hydraulic service center, rudder/elevator booster “hell hole” and APU compartments, inside bomb bay, inside fuel cell cavities etc.

• Magnetic Control Used to indicate where the applications of special procedures are necessary to minimize excess levels of magnetism.

• Major Structural Damage Damage which requires removal and repair or replacement of airframe structural members.

• Mission Capable That capability built into the aircraft by the manufacturer, and by the incorporation of subsequent necessary modifications and changes, to enable the aircraft to perform its intended mission. Mission capability does not infer a degree of operational readiness, but indicates that the aircraft can be made operationally ready by the operating activity.

• Mission Essential Equipment All equipment, parts, and/or accessories necessary to perform a specified mission.

• Modify To alter in appearance, performance, function, position, or effect.

• NAVAIR The Naval Air Systems Command.

• Nick Any notch, slit, cut, indention, or chip on the surface of a part.

• Note An information item. The note may precede or follow the item to which it refers.

• Noted But Not Corrected A defect determined by the DLM activity to be within Organizational level maintenance capabilities requiring specific documentation by the depot activity.

• Operationally Ready (OR) the material condition statuses of a safe fly able aircraft.

• Operational Service Period (OSP) The period, expressed in months and/or hours between Depot

Level Maintenance actions.

• Operational Test The exercise of a system or component, within its operating modes, to assure operation without interference and in proper direction and sequence of an intended performance.

Normal operation is verified through observation of overall performance without resort to measurement.

Part One piece, or two or more pieces joined together, which is not normally subject to disassembly without destruction of designed use.

• Depot Level Maintenance (DLM) Depot Level Maintenance is described as requirements to be accomplished upon attainment of a specified number of calendar months.

• Pitting Any small, approximately circular indentation, depression, hollow, or scar in the surface of a part, generally the result of corrosion or erosive action.

• Quality Assurance A planned program of actions necessary to provide confidence that material conforms to established standards.

• Quick Engine Change Assembly (QECA) A Quick Engine Change Kit completely assembled on a quick engine change stand with the engine and all accessories, excluding the propeller.

• Ready For Issue (RFI) A condition of an item in which all requirements of repair, check/test, PDM, or modification, as applicable, have been accomplished, making it capable of performing the function or requirements for which originally designed or later modified as directed by approved TDs.

• Ready for Use A serviceable item which can be installed on an aircraft without requiring inspection or repair.

• Refinish Restoration of an existing surface finish without complete removal of all of the existing finish. The process of refinishing includes cleaning affected area to remove all loose and scaling paint or other finish material, defective sealant, soil, and contaminants; feather edging the original finish to smooth surface; application of new finish coatings ( including sealant, chemical conversion coating, primer and top coats) to provide protection from corrosion and to provide uniform appearance.

• Refurbishing The repair and renovation of aircraft interior furnishings.

• Reinstall The return of a part or component to its former position to accomplish its former function after its removal to facilitate inspection, repair, or for security purposes.

• Remove The physical separation of an item from its designed position. Removal is normally required to facilitate a maintenance action on the item removed or on the area or items exposed by the removal.

• Repair Whatever is required to restore an item to serviceable status.

• Replace To install a like serviceable item in place of the removed item.

• Service The performance of any act required to keep an item of equipment in operating condition such as lubricating, fueling, oiling, cleaning, etc. “Service” does not include periodic replacement of parts for any corrective maintenance tasks.

• Serviceable A condition of an item in which all requirements of repair, check/test, repair, or modification, as applicable, have been accomplished, making it capable of performing the function or requirements for which it was originally designed or later modified as required by approved TDs.

• Service Life The projected total operational time of an airframe or component. This total is the sum of the service period criteria (time, cycles, and months) over the total number of planned service periods. Extensions beyond the service life require engineering approval on an individual basis.

• Service Period The projected operational interval of an item in terms of operating time, cycles, or calendar age as determined through engineering estimates or actual operational experience. The time or age figure (i.e. 1500 hours, 24 months, etc.) used in relation to service period represents the point at which continued use of the item would create a high probability of failure within a short period of time.

• Specified Used to define a definite amount, operation or limitation which has been established and is contained in applicable directives.

• Structural Sampling Program (SSP) A program designed to monitor changes in the material condition of SSIs due to fatigue and/or corrosion using representative sampling techniques.

Structurally Significant Item (SSI) Those local areas of primary structure which are identified, by analysis, to be the most important due to vulnerability to fatigue and/or corrosion and failure effect.

• Subassembly Two or more parts, which form a portion of an assembly or a unit, replaceable as a whole, but having a part or parts which are individually replaceable.

• Substitute Items Two or more items possessing such functional and physical characteristics as to be capable of interchangeability for particular application and without alterations of the items themselves.

• Substitute Material Two or more items possessing such functional and physical characteristics as to be capable of interchangeability for particular applications without alteration of the items themselves.

• System A combination of parts, assemblies, and sets joined together to perform a specific operational function or functions.

• Warning Indicates danger to personnel. The warning precedes the item to which it refers.

• Weapons System The complete integrated aircraft including all airframe and system or components thereof.

• Work Unit Code (WUC) A numeric and or alphabetic character code used to identify an aircraft system, subsystem, assembly, component, etc., on which maintenance is performed.

• Zonal Inspection A general visual inspection of all structure and installations contained within the designated boundaries of a zone.

• Zone A specific area of the aircraft defined by physical boundaries, title, and major installations.

Zone descriptions are described in the NAVAIR 01-75PAA-6-3.

1.3 Acronyms

AEW Airborne Early Warning ATDR: Aircraft Technical Directives Requirements BER: Beyond Economical Repair CBP Customs and Border Protection CDRL: Contract Data Requirements List CFM:

Contractor Furnished Material DAR Designated Agency Representative DLM Depot Level Maintenance DID: Data Item Description ECN:

Engineering Change Notice EHR: Equipment Historical Record EOC: Equipment Operational Capability EPW: Engineering Progress Work FCF: Functional Check Flight FLE: Fatigue Life Expended, expressed as percent FLI: Fatigue Life Index GFM: Government Furnished Material IAW: In Accordance With ICN: Interim Change Notification IFR/IMC: Instrument Flight Rules/Instrument Meteorological Conditions IRAN: Inspect and Repair as Necessary ISIS: Isochronal Scheduled Inspection System

LED: Local Engineering Directive LEK Life Extension Kits LPS: Local Process Specification MLU Mid-Life Upgrade MCR: Manual Change Request

MDD Multi Discrepancies Document MHS: Maintenance History Summary MRC: Maintenance Requirement Card NAVICP: Navy Inventory Control Point NBNC: Noted But Not Corrected NDI: Non-Destructive Inspection O&A: Over and Above OSP: Operating Service Period PCO: Procuring Contracting Officer PMIC: Periodic Maintenance Information Card PMRM: Periodic Maintenance Requirements Manual PMS: Planned Maintenance System QECA: Quick Engine Change Assembly RAC: Rapid Action Change RAMEC: Rapid Action Minor Engineering Change RCM: Reliability Centered Maintenance RFI: Ready for Issue RFU: Ready for Use SRC: Scheduled Removal Component SSI: Structurally Significant Item T/M/S: Type/Model/Series TD: Technical Directive TDSA: Technical Directive Status Accounting TPDR: Technical Publications Deficiency Report TRD: Technical Requirements Document TS: Technical Specification VA: Vibration Analysis VFR/VMC: Visual Flight Rules/Visual Meteorological Conditions WRA: Weapons Replaceable Assembly WUC:

Work Unit Code

1.4 DLM Interval

This TRD establishes Depot Level Maintenance (DLM) requirements for systems/equipment and modification peculiar to the US Customs and Border Protection P-3B AEW and LRT aircraft. Each DLM will be performed at 72 months intervals, or extended up to 80 months with approval from COR, and Program Manager.

1.5 Maintenance References

The basic Technical Manuals (NAVAIR Manuals), instructions, drawings, standards and notices referenced in this TRD may be used as job guides, check lists and fault isolation guides. The Technical Manuals specified herein shall be interpreted to include the latest changes, supplements, and revisions. The use of Government approved best business practices are encouraged when they are economically feasible and to the advantage of the Government. Compliance with maintenance references is mandatory when:

• They are aircraft or equipment specific.

• They prescribe repair policies, use of materials and repair procedures. • When directed by the Government.

Note

Maintenance references are listed in this TRD. The most current version or edition of the maintenance references used through this TRD shall be used. The depot activity is responsible for obtaining any updated maintenance references with the task(s) intended in this TRD. Any work scope changes will be reviewed by CBP Program Manager, KO, and COR to determine costs and schedule impacts. Any increased costs will be funded through the O&A process.

1.6 CDRL Requirements

CDRL requirements will be addressed separately in the contract.

1.7 Product Oriented Surveys

The Government may conduct Product Oriented Surveys and Evaluations to verify that the technical requirements are consistent with the DLM effort in quality and performance. These Surveys will assist the contract administrative office of the depot activity and the Government on-site representative(s) in resolving problems pertaining to policies, procedures, and specifications.

1.8 Specific Equipment

Inspection, replacement or other maintenance actions required by this TRD on specific equipment not installed on a particular aircraft shall be disregarded.

1.9 DLM Operational Document Approval

DLM Operational documents for accomplishing all work/inspection requirements of this TRD shall be reviewed and approved by the DAR.

1.10 Unscheduled Accessory and Component Repair

Repairable accessories and components not scheduled for inspection, removal, or replacement as required by this TRD shall be subject to an Inspect and Repair As Necessary (IRAN) and only if determined defective and approved by the DAR Note

A complete overhaul of a repairable accessory or component is not necessary or authorized. Defective items removed will normally receive limited IRAN repair using the following criteria:

• Check, test, or examination as necessary to isolate and identify the discrepancy.

• Disassembly and repair only to the extent necessary in order to correct the discrepancy.

• Correction of critical and major discrepancies discovered coincidental to PDM.

• Check or tests only as necessary to validate the repair performed.

• Installed operational and functional checks or tests to validate proper operation.

1.11 Concurrent Repair of Repairable Components

Concurrent repair may be authorized when directed by the DAR. Authorization will only be granted when supply system’s Ready For Issue (RFI) assets are not available or when response of supply system will cause a work stoppage.

1.12 Economical Repair

An item is considered Beyond Economical Repair (BER) if the repair cost is greater than the repair cost established by NAVICP. BER or non-repairable items shall be replaced with serviceable items. The item shall be repaired when directed by the DAR and:

• Economically feasible.

• Work will stop because a replacement item is not available.

1.13 Major Structural Repairs

For repairs of a critical or major nature exceeding the depth of coverage of the NA 01-75PAA-3-1, NA 0175PAA-3- 1.1, or NA 01-75PAA-3-2 the depot activity shall submit a detailed description of damage and repair plan (see Engineering Support,) to the DAR for disposition. When authorized a logbook entry shall be made in the miscellaneous history section describing the location and type of repair performed.

1.14 Invalid NDI Requirement

An NDI requirement for an area may be considered invalid by a previous structural repair contained within that same area. When a required NDI requirement cannot be accomplished due to a previous repair, the depot activity shall notify the Government for authority to invalidate such NDI requirement. Invalidation of NDI requirements by the Government shall be documented in the Maintenance History Summary and Corrosion Inspection Report.

1.15 Interior and Exterior Finishes

All interior and exterior surface areas affected (discrepancies noted during the inspection process) by compliance with this TRD shall be refinished to meet the finishing requirements of MIL-F-7179, provided customer paint scheme specification and MIL-F-18264.

1.16 Disturbed Systems

When aircraft system integrity has been disturbed as part of or incidental to the compliance with this TRD, the depot activity shall comply with all checks required by the appropriate P-3 technical manual.

1.17 Engineering Support

The depot activity shall provide a dedicated engineering support capability, in order to perform continuous surveillance of the DLM work process; to solve problems and to develop repair procedures or processes not provided by applicable technical manuals. The depot activity shall develop repair procedures or processes that will ensure that the airworthiness and material condition of the aircraft are not jeopardized.

The depot activity shall submit Product Drawings and Associated Lists and Local Engineering Directives (with supporting documentation) for all repairs or processes not specifically covered by General Aircraft P3 technical manuals. The depot activity shall develop a written process for all engineering services and shall ensure that delays related to engineering support are avoided. The engineering staff must be knowledgeable of the format and content of the applicable General Aircraft and P-3 aircraft technical manuals. The staff shall be knowledgeable of the military maintenance practices. The staff shall be familiar with industry technical standards, specifications, and industry accepted aircraft engineering and maintenance practices. During the accomplishment of the tasks of this document, the staff shall identify technical data shortfalls, questionable technical data, and the requirement for non-standard repairs. The staff shall provide accurate engineering interpretation of all applicable General aircraft and P-3 technical data to the depot activity production personnel in a timely manner so as to minimize impact to production operations. Appropriate technical and management reviews must be completed by the depot activity for all data, all alternate processes and all nonstandard repairs prior to submittal of such items to the DAR for review and approval. All requests for engineering services will be documented on a Request for Engineering Services Form. Engineering services shall be routed through the DAR for disposition and tracking.

Note Drawings, repair procedures and other documents generated as a result of accomplishing the requirements of this TRD, including all P-3 aircraft technical and repair data are Government property and shall be surrendered to the Government (or designated official) upon completion/termination of the contract or as requested. All tooling and equipment manufactured at

Government expense will be considered Government property and shall be surrendered at the completion of the contract or as directed.

1.18 Liaison Engineering

A liaison engineering organization must be provided by the depot activity to function as technical advisors to the depot activity production organization and has Engineering Repair Authority for CBP. Configuration control is maintained by CBP by CDRL reporting repairs accomplished. The engineering liaison organization must be adequately staffed in all appropriate technical disciplines with skilled engineers who are knowledgeable of industry technical standards and specifications, format and content of military technical manuals, and industry accepted aircraft engineering and maintenance practices. The depot activity shall:

• Develop engineering disposition of production deviation/nonconformance reports, including recommending suitable material and parts substitutions and development of nonstandard repairs.

• Review and provide technical oversight of the implementation of approved nonstandard repair methods and technical process change.

1.19 Standard Repairs

The depot activity shall implement standard repairs as necessary to correct defects. A standard repair method is one which is found in the P-3 technical manuals. Depot activities engineering interpretation of existing technical data and approved methods are provided to the depot activity production organization to ensure proper implementation of standard repairs. All repairs shall be per the best business practices, appropriate approved technical manuals.

1.20 Nonstandard Repairs

The depot activity shall develop and submit for approval, and implement approved nonstandard repairs as necessary to correct defects for which no guidance is available from the approved technical data. Request for approval of any nonstandard repair/method must be made to the DAR, and must include all pertinent technical substantiation (including appropriate stress, fatigue analyses, or test results). The depot activity shall implement only those repairs on an aircraft or component which have been approved for that aircraft or specific component. The approved non-standard repair is valid only for that applicable occurrence. The depot activity shall submit associated documentation to the DAR. The depot activity shall maintain all associated documentation and make all appropriate aircraft logbook entries for all nonstandard repairs.

1.21 Technical Process Changes

During the performance period of the contract, alternate technical process methods may be identified that facilitate flexibility in the P-3 DLM process without degrading the technical quality. In such instances, the depot activity may request approval of the proposed alternate process by submitting all pertinent data to the DAR. All appropriate technical data substantiating technical equivalency to the baseline process must also be included. Implementation of any changes to the technical basis of the P-3 DLM program may begin upon DAR approval. Requests for approval of any process changes shall be made in writing to the DAR and include all relevant technical data (including appropriate analysis or test results) substantiating technical equivalency. The depot activity shall implement only those technical process changes that have been approved by the DAR.

1.22 Technical Data

During the accomplishment of the tasks of this document, technical manual deficiencies, drawing inaccuracies, and recurring non-standard repairs may be encountered. Recurring non-standard repairs which are identical and can be incorporated into the approved technical database without degradation to quality and safety shall be incorporated. Technical manual deficiencies shall be identified by the depot activity by submitting Technical Publication Deficiency Report (TPDR) through CBP Program Manager and

COR.

1.23 Welding

The depot activity shall provide welding facilities, and aircraft welders who are qualified per American Welding Society certification procedures.

The depot activity shall:

• Establishes written procedures for welding operations, qualifications, and safety precautions are established.

• Furnish a list of qualified welders to the DAR; the list must be current and the DAR must be informed of all updates.

• Perform weld repairs as required.

1.24 Non-Destructive Inspection (NDI)

The depot activity shall provide NDI facilities, NDI personnel who are qualified per American Society for Non-Destructive Testing certification procedures and perform NDI as required in support of the DLM requirements.

The depot activity shall establish NDI operations and the qualifications for the minimum NDI techniques as follows:

• Eddy Current

• Fluorescent Penetrant

• Magnetic Particle

• Radiographic

• Ultrasonic

1.25 Component Plating Facilities

The depot activity shall have facilities available to provide plating capabilities. The depot activity shall develop written procedures for establishing plating facilities, necessary subcontractor capabilities and accomplish required plating operations as required to support the DLM requirements.

1.26 Aircraft Explosives

The depot activity shall establish procedures for handling, storing aircraft pyrotechnic and explosive actuated device ordnance, and accomplish the required aircraft explosive aircraft maintenance as required to support the DLM requirements.

1.27 Electrostatic Discharge Control Program

The depot activity shall develop and maintain an effective electrostatic discharge control program to protect…