00-20-1.pdf

TO 00-20-1

TECHNICAL MANUAL

AEROSPACE EQUIPMENT MAINTENANCE INSPECTION,

DOCUMENTATION, POLICIES, AND PROCEDURES

(ATOS)

NO CHANGES WILL BE MADE TO THIS TECHNICAL ORDER WITHOUT SPECIFIC APPROVAL OF HQ USAF/ILMM. FOR QUESTIONS CONCERNING TECHNICAL CONTENT OF THIS TECHNICAL MANUAL, CONTACT HQ AFMC/ENBP, WPAFB, OH.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited. HQ AFMC/PA Certificate Number AFMC PAX-04-329.

Submit recommended changes to 558 CBSS/GBHA IAW TO 00-5-1.

Published under authority of the Secretary of the Air Force

30 APRIL 2003 CHANGE 4 - 1 SEPTEMBER 2006

T.O. 00-20-1

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . 30 April 2003 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 31 May 2005 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . 30 June 2003 Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . 1 September 2006 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . . 15 May 2004

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 156, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - v vi Blank 1-1 - 1-2 2-1 - 2-7 2-8 2-9 - 2-10 3-1 - 3-4 3-5 3-6 4-1 - 4-5 4-6 5-1 - 5-6 5-7 - 5-8 5-8.1 Added 5-8.2 Blank 5-9 - 5-46 6-1 - 6-4 6-5 - 6-7 6-8 Blank 7-1 7-2 - 7-6 7-7 - 7-9 7-10 Blank 8-1 - 8-4 9-1 - 9-9 9-10 Blank 10-1 - 10-5 10-6 - 10-7 10-8 Blank 11-1 - 11-22 12-1 - 12-2 A-1 - A-7 A-8 Blank B-1 - B-2 C-1 - C-2

*Zero in this column indicates an original page

A Change 4 USAF

TABLE OF CONTENTS

Chapter Page

1 GENERAL .......................................................................................................................................................................1-1

1.1 Purpose...............................................................................................................................................................1-1

1.2 Recommendations for Technical Order Changes.............................................................................................1-1

1.3 Contract Maintenance Operations.....................................................................................................................1-1

2 AEROSPACE VEHICLE INSPECTIONS.....................................................................................................................2-1

2.1 General...............................................................................................................................................................2-1

2.2 Inspection Requirements ...................................................................................................................................2-1

2.3 Specified Flying Period.....................................................................................................................................2-3

2.4 Pre-Flight Inspections (PR)...............................................................................................................................2-3

2.5 End-of-Runway Inspection (EOR)....................................................................................................................2-3

2.6 Thru-Flight Inspection (TH)..............................................................................................................................2-4

2.7 Basic Post-Flight (BPO) Inspection..................................................................................................................2-4

2.8 Combined Pre-Flight/Basic Post-Flight (PR/BPO) or Pre-Flight/Thru-Flight (PR/TH) Inspection ...............2-4

2.9 Hour Post-Flight Inspection (HPO) ..................................................................................................................2-5

2.10 Periodic Inspection (PE)....................................................................................................................................2-5

2.11 Phase Inspections (PH)......................................................................................................................................2-5

2.12 Periodic and Phase Inspection Adjustments .....................................................................................................2-5

2.13 Isochronal Inspection (ISO) ..............................................................................................................................2-5

2.14 Home Station Check (HSC) Inspection............................................................................................................2-6

2.15 Minor (MIN) ISO..............................................................................................................................................2-7

2.16 Major (MAJ) ISO..............................................................................................................................................2-7

2.17 Programmed Depot Maintenance (PDM) .........................................................................................................2-7

2.18 Aerospace Vehicle Manufacturer Inspections ..................................................................................................2-7

2.19 No-Fly Calendar Inspections.............................................................................................................................2-7

2.20 Transfer Inspections ..........................................................................................................................................2-8

2.21 Acceptance Inspections .....................................................................................................................................2-8

2.22 Unsafe Conditions or Materiel Failure Inspections..........................................................................................2-8

2.23 Aerospace Vehicles in Storage .........................................................................................................................2-9

2.24 Inspection Work Cards......................................................................................................................................2-9

2.25 Inspection Responsibility for Work Accomplished by Depot or Contractor Field Teams (DFT/

CFT) ..............................................................................................................................................................2-9

3 AEROSPACE EQUIPMENT FORMS DOCUMENTATION ......................................................................................3-1

3.1 General...............................................................................................................................................................3-1

3.2 Maintenance Information Systems (MIS).........................................................................................................3-2

3.3 Automated Forms ..............................................................................................................................................3-2

3.4 Standard Date Format........................................................................................................................................3-2

3.5 Minimum Signature...........................................................................................................................................3-2

3.6 Electronic Signature ..........................................................................................................................................3-2

3.7 Use of Printed Characters .................................................................................................................................3-2

3.8 Informational Notes...........................................................................................................................................3-3

3.9 Transfer of Documents......................................................................................................................................3-3

3.10 Missing Documents ...........................................................................................................................................3-3

3.11 Filing ..................................................................................................................................................................3-3

3.12 Disposition of Documents.................................................................................................................................3-4

3.13 Maintenance of Documents During Extended Storage ....................................................................................3-4

3.14 Safeguarding/Documenting Classified Equipment ...........................................................................................3-4

3.15 Fuel Identiplate ..................................................................................................................................................3-5

3.16 Use of USAF Aerospace Vehicle by Bailment Contractors and Air Carrier Contract Operators .................3-5

3.17 Processing of Documents During Depot Maintenance ....................................................................................3-5 i

4 SYMBOLS AND THEIR USE.......................................................................................................................................4-1

4.1 General...............................................................................................................................................................4-1

4.2 Red X.................................................................................................................................................................4-1

4.3 Red Dash (Not Applicable to Ground-Launched Missiles) .............................................................................4-2

4.4 Red Diagonal .....................................................................................................................................................4-3

4.5 Clearing Red Symbol Entries............................................................................................................................4-3

4.6 Changing Symbols After an Original Entry.....................................................................................................4-3

4.7 Downgrading a Red X for One-Time Flight....................................................................................................4-4

4.8 Conventional Munitions and/or Air-Launched Tactical Missiles ....................................................................4-5

4.9 Red W (Ground-Launched Missile Use Only) ................................................................................................4-5

4.10 Additional Red X Requirements.......................................................................................................................4-5

5 AFTO FORM 781 SERIES ............................................................................................................................................5-1

5.1 General Purpose of AFTO Form 781...............................................................................................................5-1

5.2 Aircrew Training Device (ATD) Forms...........................................................................................................5-1

5.3 Arrangement of Forms Within The Binder ......................................................................................................5-1

5.4 Documenting Operational Checks and Functional Check Flights...................................................................5-2

5.5 Recording Engine Storage.................................................................................................................................5-3

5.6 Procedures for Transfer of Data by Depot/Contractor Facility .......................................................................5-3

5.7 Core Automated Maintenance System (CAMS) for Airlift (G081)/CAMS Planning Requirements for Transfer ...................................................................................................................................................5-3

5.8 AFTO Form 781, AFORMS (Air Force Operations Resource Management System) Aircrew/

Mission Flight Data Document (Figures 5-1 and 5-2)................................................................................5-4

5.9 AFTO Form 781A, Maintenance Discrepancy and Work Document (Figures 5-3 and 5-4) ........................5-4

5.10 AFTO Form 781B, Communications Security (COMSEC) Equipment Record (Figure 5-5) .......................5-8

5.11 AFTO Form 781C, Avionics Configuration and Load Status Document (Figures 5-6 and 5-7) ..................5-9

5.12 AFTO Form 781D, Calendar and Hourly Item Inspection Document (Figures 5-8 and 5-9) .......................5-9

5.13 AFTO Form 781E, Accessory Replacement (Figures 5-10 and 5-11)..........................................................5-10

5.14 AFTO Form 781F, Aerospace Vehicle Flight Report and Maintenance Document (Figures 5-12 and 5-13) .....................................................................................................................................................5-12

5.15 AFTO Form 781G, General Mission Classification (Figures 5-14 and 5-15)..............................................5-13

5.16 AFTO Form 781H, Aerospace Vehicle Flight Status and Maintenance Document (Figures 5-16 and 5-17) .....................................................................................................................................................5-13

5.17 AFTO Form 781J, Aerospace Vehicle Engine Flight Document (Figures 5-18 and 5-19) .........................5-17

5.18 AFTO Form 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection, and

Delayed Discrepancy Document (Figures 5-20 and 5-21)........................................................................5-18

5.19 AFTO Form 781L, Record of Removal/Installation of Controlled Cryptographic Items (CCI)

(Figure 5-22) ...............................................................................................................................................5-20

5.20 AFTO Form 781M, Status Symbols and Functional System Codes (Figures 5-23 and 5-24) ....................5-20

5.21 AFTO Form 781N, J-79 Engine Runup Record (Figures 5-25 and 5-26)....................................................5-20

6 ACCESSORY REPLACEMENT AND REUSE PROCEDURES ................................................................................6-1

6.1 Accessory Replacement and Reuse ..................................................................................................................6-1

6.2 Time-Change Item (TCI) Replacement Policies ..............................................................................................6-1

6.3 Time-Change Item Reuse Policies....................................................................................................................6-3

7 SUPPORT EQUIPMENT (SE) .......................................................................................................................................7-1

7.1 Purpose...............................................................................................................................................................7-1

7.2 Forms Location..................................................................................................................................................7-1

7.3 Inspection Requirements ...................................................................................................................................7-1

7.4 War Reserve Material (SRM) or Mobility Equipment ....................................................................................7-2

7.5 Support Equipment Document Administration ................................................................................................7-2

7.6 Unsafe Conditions or Materiel Failures............................................................................................................7-3

7.7 AFTO Form 244, Part I ....................................................................................................................................7-3

7.8 AFTO Form 244, Part II...................................................................................................................................7-4

7.9 AFTO Form 244, Part III .................................................................................................................................7-4 ii

7.10 AFTO Form 244, Part IV .................................................................................................................................7-4

7.11 AFTO Form 244/245, Part V ...........................................................................................................................7-4

7.12 AFTO Form 245................................................................................................................................................7-5

7.13 Disposition Instructions.....................................................................................................................................7-5

7.14 Closing Out AFTO Form 244/245 ...................................................................................................................7-6

8 TRANSIENT MAINTENANCE PROCEDURES..........................................................................................................8-1

8.1 General Requirements .......................................................................................................................................8-1

8.2 Procedures for Maintenance of Transient Aerospace Vehicles .......................................................................8-1

8.3 Expenditures for Transient Aerospace Vehicles ..............................................................................................8-1

9 TRANSFER, STORAGE, AND DEPOT MAINTENANCE ........................................................................................9-1

9.1 Transferring Aerospace Vehicles ......................................................................................................................9-1

9.2 AFTO Form 290 Aerospace Vehicle Delivery Receipt...................................................................................9-3

9.3 Preparation of Aerospace Vehicles for Delivery to a Depot/Contractor Facility ...........................................9-5

9.4 Preparation of Aerospace Vehicle for Transfer by One-Time Flight .............................................................9-5

9.5 Preparation of Aerospace Vehicle to be Transferred or Sold Under the Foreign Assistance Act of

1961 as Amended and the Military Sales Arms Export Control Act.........................................................9-5

9.6 Preparing Aerospace Vehicles For Disposal ....................................................................................................9-6

10 MAINTENANCE HISTORICAL DOCUMENTATION ............................................................................................10-1

10.1 General Maintenance Historical Documentation Requirements ....................................................................10-1

10.2 Non-Automated Procedures ............................................................................................................................10-3

10.3 Flight Safety Critical Aerospace Vehicle Parts (FSCAP) Program ..............................................................10-3

10.4 AFTO Form 95, Significant Historical Data Record (Figure 10-1)..............................................................10-3

10.5 AFTO Form 95, Entries ..................................................................................................................................10-4

10.6 AFTO Form 95, Special Applications............................................................................................................10-5

10.7 Maintenance and Disposition of Historical Records......................................................................................10-5

11 COMMUNICATIONS-ELECTRONICS EQUIPMENT .............................................................................................11-1

11.1 General.............................................................................................................................................................11-1

11.2 Scope................................................................................................................................................................11-1

11.3 Prescribed Forms .............................................................................................................................................11-1

11.4 General Administrative Documentation Procedures ......................................................................................11-1

11.5 Maintenance Inspection Policy .......................................................................................................................11-2

11.6 Maintenance Historical Documentation..........................................................................................................11-6

11.7 Telephone and Wire Maintenance Documents...............................................................................................11-8

12 DECONTAMINATION PROCEDURES.....................................................................................................................12-1

12.1 Decontamination Procedures and Documentation..........................................................................................12-1

A MAINTENANCE TERMS.............................................................................................................................................A-1

A.1 Description of Frequently Used Maintenance Terms .....................................................................................A-1

B APPLICABLE TECHNICAL ORDERS AND SUPPORTING DIRECTIVES........................................................... B-1

B.1 Applicable Technical Orders ........................................................................................................................... B-1 B.2 Supporting Directives ....................................................................................................................................... B-1

C LIST OF ACRONYMS.................................................................................................................................................. C-1 iii

LIST OF ILLUSTRATIONS

Number Title Page

5-1 AFTO FORM 781, AFORMS Aircrew/Mission Flight Data Document (Front) ................................................5-21 5-2 AFTO FORM 781, AFORMS Aircrew/Mission Flight Data Document (Reverse)............................................5-22 5-3 AFTO FORM 781A, Maintenance Discrepancy and Work Document ...............................................................5-23 5-4 AFTO FORM 781A, Maintenance Discrepancy and Work Document (Reverse) ..............................................5-24 5-5 AFTO FORM 781B, Communication Security (COMSEC) Equipment Record ................................................5-25 5-6 AFTO FORM 781C, Avionics Configuration and Loads Status Document .......................................................5-26 5-7 AFTO FORM 781C, Avionics Configuration and Load Status Document (Reverse) ........................................5-27 5-8 AFTO FORM 781D, Calendar and Hourly Item Inspection Document..............................................................5-28 5-9 AFTO FORM 781D, Calendar and Hourly Item Inspection Document (Reverse) .............................................5-29 5-10 AFTO FORM 781E, Accessory Replacement Document ....................................................................................5-30 5-11 AFTO FORM 781E, Accessory Replacement Document (Reverse) ...................................................................5-31 5-12 AFTO FORM 781F, Aerospace Vehicle Flight Status Report Maintenance Document.....................................5-32 5-13 AFTO FORM 781F, Aerospace Vehicle Flight Status Report Maintenance Document (Reverse)....................5-33 5-14 AFTO FORM 781G, General Mission Classifications-Mission...........................................................................5-34 5-15 AFTO FORM 781G, General Mission Classifications-Mission (Reverse)..........................................................5-35 5-16 AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document .........................................5-36 5-17 AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document (Reverse) ........................5-37 5-18 AFTO FORM 781J, Aerospace Vehicle Engine Flight Document......................................................................5-38 5-19 AFTO FORM 781J, Aerospace Vehicle Engine Flight Document (Reverse) .....................................................5-39 5-20 AFTO FORM 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection and Delayed

Discrepancy Document......................................................................................................................................5-40 5-21 AFTO FORM 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection and Delayed

Discrepancy Document (Reverse) .....................................................................................................................5-41 5-22 AFTO FORM 781L, Record of Removal/Installation of Controlled Cryptographic Items (CCI)......................5-42 5-23 AFTO FORM 781M, Status Symbols and Functional System Codes .................................................................5-43 5-24 AFTO FORM 781M, Status Symbols and Functional System Codes (Reverse) ................................................5-44 5-25 AFTO FORM 781N, J-79 Engine Run-Up Record ..............................................................................................5-45 5-26 AFTO FORM 781N, J-79 Engine Run-Up Record (Reverse) .............................................................................5-46 6-1 AFTO FORM 26D...................................................................................................................................................6-5 7-1 AFTO FORM 244, Industrial/Support Equipment Record.....................................................................................7-7 7-2 AFTO FORM 244, Industrial/Support Equipment Record (Reverse)....................................................................7-8 7-3 AFTO FORM 245, Industrial/Support Equipment Record.....................................................................................7-9 9-1 AFTO FORM 345, Aerospace Vehicle Transfer Inspection Checklist and Certification (Front) ........................9-7 9-2 AFTO FORM 345, Aerospace Vehicle Transfer Inspection Checklist and Certification (Reverse) ....................9-8 9-3 AFTO FORM 290....................................................................................................................................................9-9 10-1 AFTO FORM 95, Significant Historical Data ......................................................................................................10-6 10-2 AFTO FORM 95, Significant Historical Data (Reverse) .....................................................................................10-7 11-1 AFTO FORM 224, Cable Record .......................................................................................................................11-14 11-2 AFTO FORM 224A, Cable Record ....................................................................................................................11-15 11-3 AFTO FORM 224A, Cable Record (Reverse)....................................................................................................11-16 11-4 AFTO FORM 224B, Cable Record.....................................................................................................................11-17 11-5 AFTO FORM 224B, Cable Record (Reverse)....................................................................................................11-18 11-6 AFTO FORM 376, Circuit Layout Record/Trouble Report ...............................................................................11-19 11-7 AFTO FORM 233, Cable Transfer Worksheet...................................................................................................11-20 11-8 AFTO FORM 121, Telephone Equipment Line Record Card ...........................................................................11-21 11-9 AFTO FORM 121, Telephone Equipment Line Record Card (Reverse) ..........................................................11-22 iv

LIST OF TABLES

Number Title Page

4-1 Additional Red X Requirements ................................................................................................................................4-5 6-1 Red Symbol Entries for Installed AEROSPACE EQUIPMENT Time Change Items ............................................6-6 6-2 Processing Time Change Items Where Previous Operating Time is Unknown or Known to be Invalid...............6-7 8-1 Documentation Requirements for Transient Aerospace Vehicles .............................................................................8-3 12-1 Decontamination Procedures and Documentation ...................................................................................................12-1 v/(vi blank)

CHAPTER 1

GENERAL

1.1 PURPOSE.

1.1.1 This Technical Order (TO) establishes the policies and procedures for use of the 00-20- series TOs and provides weapon system and equipment maintenance inspection and documentation guidance. It also implements the policies of AFI 21-101, Aerospace Equipment Maintenance Management; AFI 21-116, Maintenance Management of Communications- Electronics; and AFI 11-301, Aircrew Life Support (ALS) Program; and AFI 21-102, Depot Maintenance Management.

1.1.2 Unless otherwise specified, the term “AEROSPACE EQUIPMENT” in this technical order refers to weapon systems and equipment such as aerospace vehicles, equipment, missiles, nuclear weapons, Test Measurement and Diagnostic Equipment (TMDE), ground Communications-Electronics (C-E) equipment, trainers, training equipment, engines, life support equipment (LSE), industrial plant equipment, all related support equipment (SE). This technical order is applicable to all organizations maintaining this equipment.

1.1.3 Major commands (MAJCOM) may supplement 00-20-series technical orders as required. For the purpose of the 00- 20-series Technical Orders, the term AFMC Single Manager (SM) includes System Program Directors (SPD), Product Group Managers (PGM), Supply Chain Managers (SCM), and Materiel Group Managers (MGM).

1.1.4 Air Force activities will not furnish maintenance data in any form to contractors unless the applicable MAJCOM or Field Operating Agency or Weapon System Manager as appropriate has granted approval. Contractors, Air Logistics Center (ALC), or other government agencies are not authorized to levy additional documentation requirements on operating activities without prior approval of your MAJCOM and HQ USAF/ILMM.

1.1.5 In the 00-20-series TOs, the designation, MXG/CC is used to represent the Maintenance Group Commander, Director of Maintenance, Product Director, Chief of Maintenance (CoM) or Communications Group Commander, as applicable to the organizational structure of the unit. At test sites or activities which do not have a MXG/CC, it will be the responsibility of the Chief of Maintenance, Chief of Test Force Teams, Air Mobility Support Squadron Commander, or Installation Team Chief to ensure that the criteria of this TO is complied with.

1.1.6 Forward requests for permanent or temporary waivers from any provisions of this technical order through command channels to USAF/ILMM for approval. Justify the need for the waiver in each request. Refer to TO 00-20-2 for Maintenance Data Documentation system (MDD) waivers.

1.2 RECOMMENDATIONS FOR TECHNICAL ORDER CHANGES.

All changes to this technical order must be forwarded through your MAJCOM. Submit change requests using AFTO FORM 22, TECHNICAL IMPROVEMENT REPORT, IAW TO 00-5-1, Air Force Technical Order System.

1.3 CONTRACT MAINTENANCE OPERATIONS.

1.3.1 When AEROSPACE EQUIPMENT, including bailed AEROSPACE EQUIPMENT and Government Furnished Property (GFP), are undergoing contract maintenance, the contractor is responsible for conforming to the maintenance requirements and procedures prescribed in the technical orders incorporated in the provisions of the contract.

1.3.2 The contractor will provide the Air Force contract administration office with a list of personnel who are authorized to certify that AEROSPACE EQUIPMENT is safe for flight or use. The listing will specifically identify the personnel who are authorized to:

1.3.2.1 Sign exceptional releases.

1.3.2.2 Downgrade Red X or Red W conditions.

1.3.2.3 Sign off Red X or Red W symbol.

1.3.2.4 Certify operational capability.

1.3.2.5 Perform functional check flights (if applicable).

1-1

1.3.2.6 Update weight and balance records IAW 1-1-B-50, Aircraft Weight and Balance.

1.3.3 To ensure continuity of daily operations, contractors will keep the certification lists of authorized personnel to a minimum consistent with requirements and will immediately notify the contract administration office of any changes.

1.3.4 The contractor will develop and maintain a program to ensure that personnel are trained in the areas specified in the contract. The program will have provisions for contractor certification and at least an annual recertification of personnel authorized to perform the specific functions or to operate various SE.

1.3.5 The contract administration office will ensure that the contractor performs the maintenance management and documentation requirements prescribed in applicable Technical Orders. In addition, the contract administration office will ensure that the applicable TOs are referenced as provisions in the contract.

1-2

CHAPTER 2

AEROSPACE VEHICLE INSPECTIONS

2.1 GENERAL.

2.1.1 Inspection intervals required for Air Force aerospace vehicles are prescribed in applicable MDS specific -6 TO maintenance manuals, (derived from commercial, depot engineering data, and user inputs) inspection work cards, or checklists. All requirements pertaining to inspections will normally be accomplished concurrently to avoid complications in scheduling and controlling the required maintenance. The inspection concepts for aerospace vehicles are periodic, phase, isochronal, programmed depot maintenance (PDM), and aerospace vehicle manufacturer maintenance. The MXG/CC establishes the necessary controls to ensure that the periodic, phase, or isochronal inspections are accomplished at or near the scheduled due time as authorized in applicable TOs or approved waivers. The primary responsibility for safe operation of the aerospace vehicles, systems, and components rests with the using activity. MXG/CCs may increase the frequency or scope of scheduled inspections or individual inspection requirements, when required for temporary situations. Scheduling deviations beyond what is authorized in aerospace vehicle specific technical manuals must be approved through the waiver process as defined in para 2.2.5.

2.1.2 All activities are responsible for properly time phasing the accomplishment of new inspection and replacement requirements reflected in changes to the scheduled inspection and maintenance manuals. In general, determine the interval for initial accomplishment of the new requirements by comparing the aerospace vehicles, systems, and components time with the interval prescribed for the new requirement. When age or accrued time of the aerospace vehicles, systems, and components is less than the specified inspection interval, begin accomplishment of the new requirements at the prescribed interval. If the age or time is beyond the specified interval, accomplish initial inspections as soon as practical and regulate subsequent inspections accordingly. When requirements are added or changed for accessory items, determine operating time in accordance with Chapter 6.

2.2 INSPECTION REQUIREMENTS.

2.2.1 Each SM determines minimum scheduled inspection requirements for assigned aerospace vehicles and for ensuring these requirements are maintained current. These requirements are published in the initial MDS specific -6 TO inspection and also in inspection work card decks, (e.g. pre-flight, basic post-flight, thruflight, etc). After the initial publication, the SM may, in coordination with applicable MAJCOMs, delete Section I from the MDS specific -6 TO. Section I contains the same inspection requirements as published in the inspection work card decks.

2.2.2 The basic sub-elements for the periodic, phase, isochronal, programmed depot maintenance (PDM), and aerospace vehicle manufacturer inspection concepts are as follows.

2.2.2.1 PERIODIC CONCEPT:

2.2.2.1.1 Pre-flight (PR).

2.2.2.1.1.1 Pre-Launch Inspection (PLI) or Walk-Around Inspection (WAI)

2.2.2.1.2 End-of-Runway (EOR).

2.2.2.1.3 Thru-flight (TH).

2.2.2.1.3.1 Quick Turn (QT)

2.2.2.1.4 Basic Post-flight (BPO).

2.2.2.1.5 Combined Pre-Flight/Basic Post-Flight (PR/BPO) or Pre-Flight/Thru-flight (PR/TH).

2.2.2.1.6 Hourly Post-flight (HPO).

2.2.2.1.7 Periodic (PE).

2.2.2.2 PHASE CONCEPT:

2.2.2.2.1 Pre-flight (PR).

2-1

2.2.2.2.1.1 Pre-Launch Inspection (PLI) or Walk-Around Inspection (WAI)

2.2.2.2.2 End-of-Runway (EOR).

2.2.2.2.3 Thru-flight (TH).

2.2.2.2.3.1 Quick Turn (QT)

2.2.2.2.4 Basic Post-flight (BPO).

2.2.2.2.5 Combined Pre-flight/Basic Post-flight (PR/BPO) or Pre-flight/Thru-flight (PR/TH).

2.2.2.2.6 Hourly Post-flight (HPO).

2.2.2.2.7 Phase (PH).

2.2.2.3 ISOCHRONAL CONCEPT:

2.2.2.3.1 Pre-flight (PR).

2.2.2.3.2 End-of-Runway (EOR).

2.2.2.3.3 Thru-flight (TH).

2.2.2.3.3.1 Quick Turn (QT)

2.2.2.3.4 Basic Post-flight (BPO).

2.2.2.3.5 Combined Pre-flight/Basic Post-flight (PR/BPO)or Pre-flight/Thru-flight (PR/TH).

2.2.2.3.6 Home Station Check (HSC).

2.2.2.3.7 Minor (MIN).

2.2.2.3.8 Major (MAJ).

2.2.2.4 PROGRAMMED DEPOT MAINTENANCE (PDM).

2.2.2.5 AEROSPACE VEHICLE MANUFACTURER INSPECTION CONCEPT

2.2.2.5.1 A Check.

2.2.2.5.2 B Check.

2.2.2.5.3 C Check.

2.2.2.5.4 D Check.

2.2.3 MAJCOMs may authorize certain aerospace vehicles to use a modified inspection work card deck during contingencies, sortie surge exercises, and increased readiness conditions. The SM designates and publishes work cards in conjunction with the Lead Command for use during these periods. Construct contingency decks to ensure all items impacting aerospace vehicle safety and reducing aerospace vehicle reliability are inspected. Accomplish the normal inspection work card deck upon termination of the contingency, increased readiness or at the expiration of the authorized usage period as directed by the MAJCOM.

2.2.4 Periodic, isochronal, phase HSCs, HPOs, and commercial equivalent inspections are scheduled at equal intervals throughout the total inspection cycle, regardless of when inspections were actually completed. Do not exceed inspection intervals unless authorized by the MDS specific -6 TO, or approved by the MAJCOM and SM to meet mission essential requirements. If the interval is exceeded, use the appropriate Red symbol (specific exceptions will be in the appropriate TOs).

Inspection interval extensions without the use of a Red Dash are authorized only for service tests and special projects that are approved by the SM and the MAJCOM. Changes to prescribed inspection intervals, concepts or requirements will normally be made by the SM only after thorough analysis of data obtained from the Maintenance Information System (MIS) and from using appropriate Reliability Centered Maintenance Analysis (RCMA).

2-2

2.2.5 Scheduled inspection requirements specified in publications other than the MDS specific -6 TO are not applicable to components in an installed status. Inspection requirements for components not installed are contained in the commodity and equipment manuals. If inspection requirements for installed items are listed in publications other than the -6 (or -2 for missiles) TO, bring them to the attention of the SM, who will take action to integrate them into the applicable -6 (or -2) scheduled inspection and maintenance manuals. Aircrew Life Support Equipment (ALSE) not in an installed status and therefore not listed in the MDS specific -6 TO, as defined in appendix A, is exempt from these requirements.

2.3 SPECIFIED FLYING PERIOD.

2.3.1 The specified flying period begins with the first flight and continues for a period of hours as specified by the owning MAJCOM not to exceed 72 hours.

2.4 PRE-FLIGHT INSPECTIONS (PR).

2.4.1 The pre-flight inspection is a flight preparedness inspection done in accordance with the MDS specific -6 TO or maintenance requirements manual (as applicable). The pre-flight inspection includes visually examining the aerospace vehicle and operationally checking certain systems and components to ensure there are no serious defects or malfunctions.

2.4.2 A preflight will be required prior to the first flight of the flying period, or when the preflight validity period has expired.

2.4.3 MAJCOMs, in conjunction with the aerospace vehicle SM, may select a 24-, 48- or 72- hour pre-flight validity period.

2.4.4 When an aerospace vehicle is mobilizing for deployment, units are authorized to place the aerospace vehicle on alert status. It must be prepared in accordance with established technical orders, accepted by an aircrew, remain under the control of operations, and be monitored by maintenance. When sealing an aerospace vehicle, accomplish a complete pre-flight inspection prior to sealing the aircraft and again before flight after completion of the alert status if the pre- flight validity period has been exceeded. Consequently, further preflight inspection or certification of a pre-flight inspection is not required during the alert period.

2.4.5 When placing an aerospace vehicle on alert status, accomplish a complete pre-flight inspection prior to going on alert and again before flight after completion of the alert period if the pre-flight validity period has been exceeded. Consequently, further preflight inspection or certification of a pre-flight inspection is not required during the alert period. (Placing a unit on alert does not in itself place the unit’s aerospace vehicle on alert status).

2.4.6 Pre-Launch Inspection (PLI) or Walk-Around Inspection (WAI). The PLI and WAI are abbreviated pre-flights and will be accomplished as required by Mission Design Series-specific - 6 TO and/or MAJCOM supplement to this TO.

2.5 END-OF-RUNWAY INSPECTION (EOR).

2.5.1 The EOR inspection is a final visual and/or operational check of the aerospace vehicle. The SM in coordination with the MAJCOM will list minimum inspection requirements in the applicable -6 TO and publish in an existing work card deck.

2.5.2 EOR is performed immediately prior to take-off at a designated location usually near the end of the runway.

2.5.3 The purpose of the inspection is to detect critical defects that may have developed or have become apparent during ground operation of the aerospace vehicle.

2.5.4 Perform this inspection, if applicable, when an aerospace vehicle is launched from either home station or a transient base.

2.5.5 Alert aerospace vehicles launched from alert status do not require this inspection. Alert Force Evaluations will not require an EOR inspection and will be treated as Active Air Defense scrambles. Alert aircraft that launch for training missions from Alert status will require an EOR inspection.

2.5.6 If local requirements dictate, publish additional guidance to technical orders for the inspection in accordance with this TO. Wings must ensure standardization, with the same MDS.

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2.6 THRU-FLIGHT INSPECTION (TH).

2.6.1 The thru-flight inspection is a “between flights” inspection and will be accomplished after each flight when a turnaround sortie or a continuation flight is scheduled and a basic post-flight inspection is not required. This inspection is applicable when prescribed by the applicable MDS specific -6 TO or maintenance manual. The thru-flight inspection consists of checking the aerospace vehicle for flight continuance by performing visual examination and/or operational checks of certain components, areas, or systems, according to established TOs to ensure that no defects exist which would be detrimental to further flight.

2.6.2 Certain aerospace vehicles have thru-flight inspection requirements identified by asterisks in applicable workcard decks. Other aerospace vehicles have separately published thru- flight inspection work card decks.

2.6.3 Accomplish the thru-flight inspection both between flights and after the flying period or mission. MAJCOMs will determine additional thru-flight requirements if necessary. MAJCOMs may also authorize the use of abbreviated thru-flight (quick turn) checklists for those aerospace vehicles resuming alert after flight or placing aerospace vehicles on alert at site locations.

2.6.3.1 For tanker and airlift aerospace vehicles, a thru-flight inspection is required when scheduled ground time exceeds 12 hours for KC-135 (6 hours for AFRC KC-135, AFSOC C-130 units), and 6 hours for all other tanker/airlift aerospace vehicles.

2.6.3.1.1 If a thru-flight is not required, but the applicable aerospace vehicle’s specific technical data (KC-135 for example) requires a quick-turn (QT) inspection, it will be signed off as “QT” on AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document, block 5.

2.6.3.1.2 For tactical aerospace vehicles, if a thru-flight inspection is not accomplished, the minimum inspection required will be the QT as authorized by the -6 TO, and signed off as “QT” on AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document, block 5.

2.6.3.1.3 Tactical aerospace vehicles that are hot refueled and do not shut down engines may resume sortie operations without performing a QT or thru-flight inspection.

2.7 BASIC POST-FLIGHT (BPO) INSPECTION.

2.7.1 The BPO inspection is a more thorough check than the pre-flight or the thru-flight inspections and is accomplished in accordance with the MDS specific -6 TO or maintenance manual for the aerospace vehicle.

2.7.2 This inspection will consist of checking the aerospace vehicle condition by performing visual examination or operational checks of certain components, areas, or systems to assure that no defects exist that would be detrimental to flight.

2.7.3 Maintenance personnel will perform a BPO after the last flight of a specified flying period or a combined pre-flight/BPO prior to the next flying period if the aerospace vehicle has flown.

2.8 COMBINED PRE-FLIGHT/BASIC POST-FLIGHT (PR/BPO) OR PRE-FLIGHT/THRU-FLIGHT (PR/TH)

INSPECTION.

2.8.1 This inspection consolidates the requirements of the pre-flight and basic post-flight inspections into a single inspection accomplished at the end of the specified flying period or prior to the first flight of the next specified flying period.

2.8.2 It has the same validity period as the PR.

2.8.3 When published by the SM, work cards for combined PR/BPO inspections may be used.

2.8.4 Aerospace vehicles operating under the isochronal inspection concept that do not have a BPO inspection will have a thru-flight inspection performed. The thru-flight will be accomplished at the end of the specified flying period and may be combined with a PR inspection.

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2.9 HOUR POST-FLIGHT INSPECTION (HPO).

2.9.1 The HPO inspection is accomplished at equally spaced intervals as specified in the applicable MDS specific -6 TO.

2.9.2 Determine the due time for all HPO inspections at the completion of each periodic/PHASE inspection. Early or late accomplishment of any HPO does not normally change the scheduled time for the next HPO.

2.10 PERIODIC INSPECTION (PE).

2.10.1 The periodic inspection is due upon accrual of the number of flying hours, operating hours, or at the expiration of a calendar period specified in the applicable MDS specific -6 TO. The periodic inspection is more extensive in scope than the HPO or BPO inspections. This inspection is a thorough inspection of the entire aerospace vehicle.

2.11 PHASE INSPECTIONS (PH).

2.11.1 Accomplish phase inspections upon accrual of the number of flying hours specified in the applicable MDS specific - 6 TO and maintenance manual. The phase inspection concept involves consolidation of the BPO and/or HPO and periodic inspection requirements into work deck(s) having approximately the same work content and approximately the same number of clock hours for accomplishment. The primary objective of the phase inspection concept is to minimize the length of time that an aerospace vehicle is out-of-commission for any given scheduled inspection. The phase inspection concept does not apply to those aerospace vehicle types for which the inspection requirements cannot be divided into reasonably equal work decks.

2.11.2 Schedule phase inspections at equal intervals throughout the total inspection cycle regardless of when the inspections are actually accomplished.

2.11.3 When aerospace vehicles under the phase concept are required for extended missions, phases may be accomplished in advance to cover the period of the extended mission, when authorized by the MAJCOM and SM.