1-1-300.pdf

T.O. 1-1-300

TECHNICAL MANUAL

MAINTENANCE OPERATIONAL CHECKS AND CHECK

FLIGHTS

(ATOS)

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Published under authority of the Secretary of the Air Force

14 NOVEMBER 2007

3.3. Maintenance operational checks involving ground or1. PURPOSE.

hover taxi of helicopter or high-speed taxi of fixed wing aircraft will be accomplished and certified by pilots quali-1.1. This technical manual establishes policy and require-fied as specified in paragraph 5.1. Pilots performing high-ments to perform Maintenance Operational Checks and speed taxi checks will compute takeoff data to indicate theCheck Flights on USAF aircraft. It establishes requirements highest speed expected and the stopping distance.to ensure the aircraft is airworthy via Functional Check

Flights (FCF) or capable of mission accomplishment via

3.4. Maintenance operational checks will be recorded onOperational Check Flights (OCF). It establishes require- AFTO Form 781A and/or AFTO Form 349 and/or CAMSments to be used by USAF in accepting new production in accordance with 00-20-1 and 00-20-2 series technicalaircraft and guidelines for conducting Acceptance Check manuals.Flights (ACF). It also establishes requirements to be used for noncritical systems checks via Equipment Check 3.5. Acceptance inspections on newly produced weapon Flights (ECF). systems, major system modifications or upgrades will be accomplished on receipt at either test or operational loca-1.2. Submit proposed changes to this technical manual tions for the purpose of ensuring proper configurationthrough the major command to HQ AFMC/A3V, 508 W control and to provide feedback to the developing com-Choctawhatchee Ave, Suite 4, Eglin AFB, FL 32542-5713.

mand and contractors concerning manufacturing quality assurance.

2. SCOPE.

4. CHECK FLIGHTS.This technical manual applies to all commands, field oper-ating agencies, and direct reporting units of the USAF, Air

4.1. Check flights are performed to determine whether anForce Reserve Command, Air National Guard, and Air aircraft and its various components are functioning accord-Force contractors involved in the manufacture of new ing to predetermined specifications while subjected to theproduction aircraft, having bailed aircraft or processing flight environment. Such flights are conducted when it isaircraft on contract for maintenance, modification or not feasible to determine safe or required operation (aero-removal from storage.

dynamic reaction, air loading, signal propagation, etc.) by means of ground or shop tests. Equipment operating proce-

3. MAINTENANCE OPERATIONAL CHECKS. dures, limit pressure readings, and conditions to be noted and recorded during ACF/FCF are normally specified in the

3.1. Maintenance operational checks are checks accom- -6CF Acceptance/Functional Check Flight Procedures plished on the ground to ensure aircraft systems or compo- Manual. Check flights are normally conducted following nents, which have been disturbed during inspection or maintenance work and prior to release of the aircraft for maintenance operations, have been repaired, reassembled operational use. For the purpose of this instruction, to or adjusted satisfactorily. ensure aircraft is airworthy, primary aircraft systems are those affecting engines; flight controls; landing gear; and3.2. These checks will be accomplished to simulate, inso-those systems affecting the basic Instrument Flight Rulesfar as possible, the conditions under which the system or (IFR) capability of the aircraft (i.e., pitot static; compasses;component will be operated. The affected equipment will attitude references, air data computers, etc.).be operated through a sufficient number of cycles to ensure aircraft is safe for operational use.

4.1.1. Acceptance Check Flight (ACF). Includes check a. Be conducted at power settings within the limits flights for performance and operation of systems/equipment specified in flight operating flight to verify contractual conformance and/or to ensure aircraft manual/publications.

is airworthy in accordance with paragraph 4.1. This is

b. Be conducted within the designated check flightapplicable to all aircraft on new aircraft production, modifi-airspace of the base from which the flight wascation or Programmed Depot Maintenance (PDM) con-launched except when the flight must be conductedtracts. ACF missions are flown to check the operations of under specific environmental conditions not com-selected systems or equipment that requires flight verifica-patible with local conditions and/or restrictions.tion. Full ACF profiles are flown when required.

This does not preclude departing from an auxiliary

4.1.2. Equipment Check Flight (ECF). Airborne func- field or base within the home station.

tional check to establish if a basic aircraft noncritical

c. Be conducted from runways with an operable bar-system, subsystem or equipment when subjected to design rier system for those aircraft equipped with arrest-environment, is operating properly. Generally, areas ing gear (tail hook). See published MAJCOMchecked on the ECF are equipment or systems whose guidance (AFI 11-2MDS, Vol 3) for detailedfailure would not adversely affect flight safety.

requirements and/or exceptions to this requirement.

4.1.3. Functional Check Flight (FCF). Check flight con-

4.7. Combat and combat support aircraft assigned to unitsducted for other than contractual conformance and/or to engaged in armed conflict, which have had temporaryensure aircraft is airworthy in accordance with paragraph repairs made at an auxiliary or recovery base, may have an4.1. FCF missions are flown to check the operations of FCF accomplished enroute to home station or a designatedselected systems or equipment that requires flight verifica-repair facility. The FCF portion of the flight will betion. Full FCF profiles are flown when required.

accomplished in the immediate area of the departure base

4.1.4. Operational Check Flight (OCF). Check flight con- to determine the aircraft is airworthy for the flight. The ducted after maintenance to ensure aircraft mission specific decision to approve combined FCF and ferry flight is the equipment is operational and the aircraft is mission ready, responsibility of the wing commander of the unit to which (i.e., AC-130U 105 mm gun check firing). the aircraft is assigned, in coordination with the wing or equivalent commander of the unit where the repair is

4.2. Conditions requiring an ACF/FCF are specified in the accomplished. Prior to approval, the following should be -6 inspection manual for each type of aircraft. Time Com- considered: pilot proficiency, route of flight, weather con-pliance Technical Orders (TCTO) may also require an FCF ditions, extent of repair, and conditions under which the for work accomplished in accordance with the TCTO. In repairs were accomplished. Authority to approve combined the event the aircraft manufacturer does not provide gui- FCF and ferry flights will not be delegated. The wing or dance as to what maintenance actions require a functional equivalent commander shall have the option to conduct check flight, the MAJCOM/LG will develop an combat aircraft functional check flights with loaded and ACF/FCF/maintenance action guidance matrix for use by charged internal gun systems in a hostile environment.

the field.

4.8. If the mission is an ACF/FCF flown to ensure aircraft

4.3. Under circumstances other than those specified in the is airworthy. Mission or training events may be flown at the aircraft -6 inspection manual, the need for an aircraft Check end of the sortie, provided the primary aircraft systems as Flight following maintenance or repair work is an engineer- defined in paragraph 4.1 are first checked and verified as ing decision to be exercised by the commander. Such functional.

decisions will be based upon the scope of work accom-plished and consideration of the affected components rela- 4.9. The wing or equivalent commander may authorize a tive to safety of operation. combination ACF/FCF with a mission or training flight if the ACF/FCF is being flown to check the operation of

4.4. Any flight performed to accept or check accomplish- auxiliary systems or components.

ment of depot maintenance or modification will be identi-fied as an ACF/FCF. Any modification or TCTO that 4.10. Commanders or their maintenance officers may affects a primary aircraft system as defined in paragraph expand the scope of check flight requirements. During the

4.1 will be identified as an ACF/FCF. crew briefing, the check flight items/scope will be mutually understood.

4.5. Any flight performed to accept or check new aircraft

production will be identified as an ACF. Normally all -6 4.11. Major commands may waive ACF/FCF only under and -6CF requirements will be completed, however, proce- extenuating circumstances, such as when weather delays dures developed by the contractor and approved by the would seriously degrade combat potential or preclude government may be used. meeting operational mission requirements.

4.6. Check flights will:

4.12. Duplication of ACF by the USAF and contractors b. Failure or malfunction of the component or system will be held to a minimum. The USAF should use flight test to be checked would not affect operation of the sampling when a contact’s production quality levels permit. aircraft at night or under IMC, as appropriate.

c. The check flight portion of the flight can be accom-5. AIRCREW REQUIREMENTS.

plished under VMC or VMC conditions above the clouds.5.1. Check flights will be accomplished by aircrew pos-sessing the best qualifications as determined by command

7. FLIGHT DURATION.directives and flying unit commanders. Check flights accomplished on USAF aircraft by contractor personnel in

7.1. ACF/FCF duration for engine changes are specifiedthe performance of contractor maintenance requirements in the -6 inspection manual. These are minimum timeswill be performed by flight crews qualified in accordance based on the time required to accomplish the functionalwith the provisions of DCMA Instruction 8210.1, Contrac-checks prescribed in the applicable ACF/FCF checklist.tors Flight and Ground Operations or earlier version as defined by contract.

7.2. Duration of a flight to complete a specified inspection

is the time necessary to accomplish the checklist, determine5.2. Check flights will be conducted by the minimum the affected equipment is operating properly, and ensureaircrew defined by the technical manual and MAJCOM aircraft is airworthy and capable of missiondirectives plus any personnel designated by the OG/CC or accomplishment.equivalent as required for the mission in accordance with

AFI 11-401, Aviation Management, and applicable

7.3. Duration of flights for other conditions will be deter-MAJCOM supplements. Check flights will be accom-mined by the responsible maintenance officer or pilot butplished without cargo or nonessential passengers/crew must be sufficient duration to accomplish the checks speci-members (as determined by the OG/CC or equivalent).

fied in the check list at specified altitudes.

5.3. Major commands will determine Check Flight crew

7.4. The ACF/FCF should not take off unless sufficientcomplement and certification. These crew members will be time is available to complete the required elements asdesignated in writing.

defined in the -6CF and in accordance with paragraph 6.1.

6. WEATHER REQUIREMENTS.

8. FLIGHT DOCUMENTATION.

6.1. Check flights will normally be conducted in daylight,

8.1. ACF/FCF and release of aircraft for operational useVisual Meteorological Conditions (VMC). Aircraft with are recorded in the AFTO Form 781 series and/or on AFTOfour or more engines may conduct check flights during Form 349 and/or CAMS in accordance with 00-20-2 andhours of darkness if VMC exists at the departure airfield.

00-20-1 series technical manuals.

6.2. The operations group (or equivalent) commander to

8.2. The check pilot is responsible to ensure all discrepan-which the aircraft is assigned (for transient aircraft, the cies noted by the flight crew before, during, and after flightwing or equivalent commander at the transient base) may are recorded on AFTO Form 781A or on the contractorwaive paragraph 6.1 and authorize ACF/FCF under the form approved by the government in accordance with TOfollowing conditions, when required:

00-20-1.

a. Takeoff in VMC to begin the check flight. If the

8.3. The ACF/FCF that have validated airworthiness butaircraft is operating properly in VMC, pilots may must continue to subsequent sortie(s) for additional in-proceed into Instrument Meteorological Conditions flight verification of noncritical systems will still be docu-(IMC) to penetrate cloud cover and complete the mented as an ACF/FCF. The ACF/FCF is not completecheck flight in VMC conditions above the clouds.

until all required items have been verified. Subsequent sortie(s) status will not be changed to ECF status.b. Weather conditions versus the necessity to conduct a check flight must be considered.

9. FLIGHT CHECKLISTS.

6.3. When a flight is required only to check the operation

of auxiliary systems or components, the flight may be 9.1. USAF ACF/FCF checklists are issued for each type, initiated during daylight hours under IMC or during hours model or series aircraft for which a -6 inspection manual of darkness under VMC provided: exists. These checklists specify minimum requirements for accomplishment of ACF/FCF. Use of the entire checklist is

a. The aircraft is known to be operational for night or required only when a complete check flight is accom-

IMC flight as appropriate. plished. Locally developed checklists may be used for aircraft that do not have a published checklist. Units may develop local checklist guides to accommodate local air- check flights. Upon completion of the check flight, the pilot space configuration, weather, etc., to facilitate the smooth in command will sign the checklist to indicate they have flow of the mission. Once the mission is complete, tran- completed the inspection requirements. Government scribe the results into the -6CF published checklists (if approved procedures apply for ACF.

available) for inclusion in the aircraft documentation fold-

9.4. Completed ACF/FCF checklists or approveders. Locally developed ACF/FCF results worksheets must ACF/FCF results worksheets are filed with the aircraftcapture the pertinent information from the ACF/FCF maintenance records for a period of 3 months or untilchecklist and contain all signature and ACF/FCF sign-off replaced by a new ACF/FCF checklist/worksheet, which-information. Contact the applicable TO manager for ever is later. Copies of worksheets used in place of anapproval to use ACF/FCF worksheets.

AFTO Form 781A to report ACF/FCF discrepancies are

9.2. ACF checklists are developed by the contractor and filed and disposed of in accordance with TO 00-20-1.

approved by the government. These checklists specify Checklists containing classified information entries may be minimum requirements for accomplishment of ACF. treated as classified waste immediately following debriefing under the provisions of AFI 31-401, Information

9.3. ACF/FCF checklists are divided into sections pertain- Security Program Management. The responsible crew ing to particular stations and flight crew members. Flight members will sign a certificate stating all required equip-crew members will use the specified symbols to complete ment checks were made and were satisfactory, and the the checklist or section of the checklist applicable to their certificate will be filed instead of the classified checklists.

station and/or equipment. When check flights are accom- Government approved procedures apply for ACF.

plished to check specific equipment or systems, only appli-cable portions of the checklist will be used. The AFTO Form 781A may also be used to record and verify accom-plishment of specific checklist requirements of partial

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