SOW updated 6-16-2020.pdf

Appendix A

PR Number: FD2030-19-02358 SOW Form Rev 4: 9 MARCH 2017 i

DEPARTMENT OF THE AIR FORCE

AIR FORCE SUSTAINMENT CENTER

TINKER AIR FORCE BASE, OKLAHOMA 73145

PR NO: FD2030-19-02358 DATE: 16 June 2020

AF CONTRACT NO:

STATEMENT OF WORK (SOW)

TYPE OF WORK: Remanufacture of F-15 Float Valve, F-15 Interconnect Valve, and C-

130 Float Valve

TABLE OF CONTENTS

PREFACE SHEET......................................................................................................................... iii REVISION SHEET ....................................................................................................................... iv

SECTION 1 GENERAL INFORMATION

1.1. DEFINITIONS

1.2. PRE-AWARD SURVEY REQUIREMENTS

1.3. INITIAL PRODUCTION EVALUATION REQUIREMENTS

1.4. REPORTING REQUIREMENTS

1.5. QUALITY PROGRAM AND INSPECTION SYSTEM REQUIREMENTS

1.6. TOOLS AND SUPPORT EQUIPMENT

1.7. PRECIOUS METALS RECOVERY PROGRAM

1.8. NUCLEAR HARDNESS REQUIREMENTS

1.9. PARTS CONTROL PROGRAM

1.10. OZONE DEPLETING SUBSTANCES

1.11. TECHNICAL ORDER MAINTENANCE

1.12. CONTRACTOR EMPLOYEES

1.13. SAFETY AND HEALTH STATEMENT

1.14. SURGE……………………………………………………………………………………8

SECTION 2 DESCRIPTION OF WORK

2.1. GENERAL

2.2. SPECIFIC WORK REQUIREMENTS

2.3. DELIVERY SCHEDULE

SECTION 3 APPLICABLE DOCUMENTS

3.1. APPLICABLE TECHNICAL ORDERS

3.2. OTHER PUBLICATIONS FOR INFORMATION PURPOSES ONLY

3.3. CONTRACTOR DOCUMENTS

ii

SECTION 4: GOVERNMENT PROPERTY

4.1. GOVERNMENT PROPERTY

4.2. DISPOSITION OF GOVERNMENT PROPERTY

4.3. OTHER

SECTION 5: CONSUMABLE PARTS REPLACEMENT REQUIREMENTS

5.1. 100% CONSUMABLE PART REPLACEMENT REQUIREMENTS

iii

PREFACE SHEET

END ITEM

RECEIVED AS

END ITEM

TO BE DELIVERED AS

END ITEM

NUMBER

NATIONAL

STOCK NUMBER

PART

NUMBER

NATIONAL

STOCK NUMBER

PART

NUMBER

0001 2915-01-140-5873RK 765900-211 2915-01-140-5873RK 765900-211

0002 2915-01-140-5983RK 766900-213 2915-01-140-5983RK 766900-213

0003 2915-01-081-6534RK 32900-105 2915-01-081-6534RK 32900-105

iv

REVISION SHEET

When a revision is received, it should be inserted into this Statement of Work (SOW). The superseded pages should be retained as a record.

NOTE: The portion of the text of this specification affected by the current revision is indicated by a black underscore for figures, words, or phrases within a given paragraph, and by a black vertical line in the outer margin where the change constitutes a whole paragraph.

After the revised pages have been inserted into the SOW, the revised title page should be inserted in front of the existing title page. This revision page is placed under the basic title page.

DATES OF ISSUE FOR ORIGINAL AND CHANGED PAGES ARE:

SECTION 1 GENERAL INFORMATION

1.1. DEFINITIONS

1.1.1. The following definitions are applicable to this SOW:

a. End Item: An end item is a complete piece of Government equipment as listed in Government supply catalogs and suitable for Government storage and issue. End items may contain one or more Shop Replaceable Unit (SRUs). End items are also referred to as Line Replaceable Units (LRUs). End items covered by work under this SOW are listed on the preface sheet.

b. Initial Production Evaluation (IPE): An IPE is a planned Government review of early production items and processes to evaluate a Contractor’s ability to complete the work in accordance with (IAW) the contract, applicable technical orders, and other guidance required by this SOW.

c. Remanufacture: An end item remanufacture as described within this SOW is the action taken to return the end item to a like-new condition. This remanufacture process is consistent with the provisions of Federal Acquisition Regulation (FAR) 22.1003-6(a)(1).

d. Administrative Contracting Officer (ACO): A contracting officer assigned the responsibility for the post award functions related to the administration of a Government contract in the field. The ACO is normally located in the Defense Contract Management Agency (DCMA). The ACO is responsible for ensuring the Contractor performs in accordance with the terms of the contract.

e. Procuring Contracting Officer (PCO): The individual authorized to enter into contracts for supplies on behalf of the Government by formal advertising or negotiation and who is responsible for overall procurement of the contract.

f. Technical Order (TO): An Air Force publication that gives specific technical directives and information with respect to the inspection, storage, operation, modification, and maintenance of Government equipment.

g. Support Equipment (SE): All equipment called out in applicable TOs required for LRU, SRU, and component test, remanufacture, and/or modification.

h. Serviceable: An item is considered serviceable if it is capable of meeting the functional and test requirements for which designed or modified as established by the applicable technical documentation in section 3.

i. Repair: An end item repair is the action taken to return the end item to a serviceable condition by replacing all exposed consumable items and only the damaged recoverable parts that do not meet the TO inspection criteria. Repair consists of end item testing to determine deficiencies, disassembly as required to support maintenance actions required, thorough cleaning, refurbishment or replacement of all disturbed components not meeting inspection criteria, replacement of all soft parts (seals, gaskets, etc.) exposed during repair, re-assembly of assemblies and subassemblies, performance of all adjustments and alignments, test and calibration of subassemblies and end items, and final inspection (e.g. safety wiring, painting, affixing decals) IAW the applicable TO and approved test documentation.

j. Defect: A characteristic that does not conform to the specified requirements.

k. Product Quality Deficiency: Any defect or nonconforming condition. Included are deficiencies in design, specification, material, manufacturing, and workmanship.

l. Product Quality Deficiency Report (PQDR): The SF 368 form or format used to record and transmit product quality deficiency data.

m. Consumable Part: Piece parts that are not typically reused during remanufacture.

n. Re-usable Component: Non-accountable, expendable part or assembly that may be re-installed in an end item after inspection/repair and deemed serviceable.

o. Recoverable Component: Accountable, non-expendable part or sub-assembly of an end item. Also referred to as a Shop Replaceable Unit (SRU). SRUs may be re-installed in an end item after inspection/repair and deemed serviceable. If applicable to the scope of this SOW, SRUs will be listed on the preface sheet.

1.2. PRE-AWARD SURVEY REQUIREMENTS

1.2.1. A Pre-Award Survey (PAS) shall be required but may be waived by the Government at the time of award.

1.2.2. At the time of the PAS the prospective Contractor shall meet the following technical requirements (additionally, there are many other business capabilities that may be evaluated) IAW contract requirements. Failure to do so shall result in PAS disapproval and disapproval of the prospective Contractor for this procurement action.

a. Provide data to include Contractor facility capabilities, all subcontractor facility capabilities (if subcontracting is proposed), and an explanation of how Contractor and subcontractor facilities will fulfill the Government’s requirements.

b. Prior to PAS, the prospective Contractor shall provide a list of all special tooling and SE required and shall comply with the requirements detailed in paragraph 1.6.

c. Prior to PAS, the prospective Contractor shall provide a test plan for each end item as specified in the preface sheet. The test plan shall include all testing required by the applicable acceptance test procedure and will detail how the testing will be accomplished utilizing the prospective Contractor’s SE.

d. The prospective Contractor shall provide the above to the PCO via email in the form of a word processing document or spreadsheet, viewable by Microsoft Office programs.

1.3. INITIAL PRODUCTION EVALUATION REQUIREMENTS

1.3.1. IPE shall be completed within sixty (60) calendar days of receipt of first delivery order.

The IPE requirement may be waived by the Government at the time of contract award.

1.3.2. The IPE shall be conducted on three (3) units of each line item. The condition of the items at IPE will be as follows: one (1) each open and ready to be disassembled to follow the entire remanufacture procedure, one (1) each fully disassembled, cleaned, and ready for assembly and testing, and one (1) each assembled and ready for functional testing. The Contractor shall furnish written notice to the PCO through the ACO within fifteen (15) business days after the required quantity of end items are available for the IPE.

1.3.3. The PCO shall notify the Contractor of the projected dates that the Government IPE Evaluation Team will arrive at the Contractor’s facilities to conduct the IPE. The Contractor shall permit entrance to the Evaluation Team into its facilities. This includes access to Contractor telephones and other communication devices that will allow the Evaluation Team to consult with appropriate Government personnel in the accomplishment of the IPE evaluation.

1.3.4. Under no circumstances shall the Contractor accomplish remanufacture on any other quantity of items on order or through any Induction-at-Risk/Early Induction contractual provision, other than the three (3) IPE units that will be evaluated by the Evaluation Team prior to the accomplishment of the IPE. Only after the approval notice from the PCO shall the Contractor proceed with remanufacture on the remaining items on order or items under Induction-at-Risk/Early Induction provisions. The Government’s delivery schedule shall be held in abeyance until approval of the IPE by the Evaluation Team.

1.4. REPORTING REQUIREMENTS

1.4.1. Data requirements are specified in the Contract Data Requirements List (CDRL DD Form 1423) found in Part 1, Section B, The Schedule.

1.4.2. In addition, the Contractor shall maintain for five years a document package containing the following documentation for each end item produced:

a. Maintenance Data Sheet

b. Test Data Sheet

c. Quality Acceptance Review Documentation

d. Parts replaced listed by each serial numbered end item remanufactured

1.5. QUALITY PROGRAM AND INSPECTION SYSTEM REQUIREMENTS

1.5.1. The Contractor shall establish, document, and maintain a quality system as a means of ensuring that the end item conforms to specified requirements. The quality system shall be in accordance with contract requirements.

1.5.2. When a Deficiency Report is received for an end item remanufactured under the terms of this contract, the Contractor shall comply with the ACO’s directions. Guidance is provided in TO 00-35D-54, USAF Deficiency Reporting, Investigation, and Resolution.

1.5.3. The Contractor shall report any Government furnished material, for the work accomplished as outlined in this SOW, that is damaged or otherwise unsuitable for use to the ACO using a Supply Discrepancy Report (SDR), SF Form 364.

1.5.4. The Contractor shall support quality audits as required by the ACO. These audits could require that one or more end items be removed from the production line and subjected to any combination of inspection, testing, disassembly, or assembly to determine that the standards of performance and technical conformance meet the requirements of this SOW. The Contractor shall be required to correct a deficient process to eliminate the cause(s) of any defects as directed by the ACO.

1.5.5. The Contractor shall support quality assurance reviews to be conducted at the site of remanufacture at the request of the Government throughout the contract period.

1.5.6. The Contractor shall support a quality acceptance review by the DCMA representative at the site of work as specified in this SOW for each end item generated under the terms of this contract.

1.5.7. Requests for deviation/waiver shall be submitted to the PCO through the ACO. Work shall not be initiated on assemblies/components affected by deviation/waiver pending approval/disapproval. Requests shall include the contract number, NSN, and part number (P/N) of the end item and lowest part/assembly affected, effect on cost/price and delivery schedule, description of deviation waiver, justification for deviation/waiver, and proposed corrective action taken.

1.6. TOOLS AND SUPPORT EQUIPMENT

1.6.1. The SE required to accomplish the scope of work to be completed on end items under this contract are listed in the TOs or original equipment manufacturer (OEM) remanufacture procedures listed in section 3 of this SOW. If the equipment specified in the TO or OEM remanufacture procedures are not designated as Government furnished in this contract, the Contractor is responsible for furnishing identical or substitute SE from commercial sources.

1.6.2. If the Contractor intends to substitute SE, a list of the proposed substitute SE shall be provided to the PCO with the proposal. At the time of the PAS conference, the Contractor shall demonstrate to the PAS team that suitable substitute SE can be acquired and meets the standards stipulated in the technical data by the following actions:

a. Displaying drawings, schematics, or specifications which illustrate that the prospective Contractor understands the exact nature of the work to be performed and the SE required to perform the tasks.

b. Explaining the capabilities of substitute SE to ensure that it is adequate to perform the specified testing requirements.

c. Defining how substitute SE will be designed, built, and calibrated without assistance from the Government, by an internal engineering capability, or the services of a recognized outside engineering agency as approved by the cognizant engineering activity.

1.6.3. The equipment shall be in possession of the Contractor prior to the IPE team visit.

1.6.4. The Contractor shall show documentation certifying the accuracy of all calibrated SE to the ACO prior to work performed as outlined in this SOW.

1.6.5. Support Equipment Calibration Requirements. The Contractor shall ensure documentation certifying the accuracy of all calibrated SE is made available to the ACO prior to work being performed. The Contractor shall ensure SE calibration is maintained throughout performance of this contract. Upon request, the Contractor shall show calibration data to the ACO for each SE item as follows:

a. SE part number and serial number

b. Date calibrated

c. Calibration due date

d. Calibration source

e. Calibration procedure used

f. Is and Was data

g. Facsimile of the current stamped calibration sticker affixed to SE item

h. Verification of full performance compliance IAW this SOW for SE items not requiring calibration

i. Traceability to the National Institute of Standards and Technology

1.7. PRECIOUS METALS RECOVERY PROGRAM

1.7.1. The Precious Metals Recovery Program is not applicable to this SOW. The handling and control of precious metals shall be IAW AFI 23-101, Air Force Materiel Management, if necessary.

1.8. NUCLEAR HARDNESS REQUIREMENTS

1.8.1. The Contractor shall notify the PCO if the work degrades the nuclear hardness of the item within one (1) business day of determination. The Contractor shall not continue maintenance actions until Government approval is obtained from the PCO.

1.9. PARTS CONTROL PROGRAM

1.9.1. The Contractor shall establish, document, and maintain a parts control program for the work associated with this SOW.

1.9.2. The Contractor shall establish the Parts Control Program for an end item from the applicable Illustrated Parts Breakdown (IPB) TO or Government engineer approved OEM parts list.

1.9.3. Approval from the PCO is required for the Contractor to use any parts not contained in the IPB. The Contractor shall maintain configuration of items worked under the scope of this contract as identified in the applicable IBP or this SOW. The Contractor shall notify the PCO in writing of any configuration discrepancies noted between the applicable IPB, engineering drawings, and the current configuration of the end item. The Contractor shall obtain written authorization from the cognizant engineering activity via the PCO for configuration deviations prior to implementation.

1.9.4. The IPB shall serve as the current baseline for an end item or system unless otherwise stated in this SOW.

1.9.5. The Contractor shall only use replacement parts purchased directly from the end item OEM or purchased from DLA. In the event that parts are not available from either of these two sources for a pending remanufacture operation, the Contractor shall request permission to utilize an alternate source. The cognizant engineering authority shall provide written authorization via the PCO for any deviations from the aforementioned sources. In the instance that surplus components are available, the cognizant engineering activity reserves the right to approve or disapprove the material. Written authorization for surplus material use shall be obtained from the cognizant engineering activity via the PCO.

1.9.6. The Contractor shall keep records to allow traceability of sourcing of replacement parts for each end item remanufactured. These records shall be furnished for inspection up Government request.

1.9.7. The Contractor shall be required to perform work as specified by this SOW for all end items unless written disposition instructions are provided by the PCO through the ACO.

Requests for condemnation shall be submitted by the Contractor in writing through the ACO to the PCO.

1.10. OZONE DEPLETING SUBSTANCES

1.10.1. This SOW is not explicitly requiring the use of a Class 1 ozone depleting substance (ODS) in the performance of this contract. The Contractor is authorized to use a suitable substitute for any Class 1 ODS which may be required by the engineering or technical data specified by this SOW. The Contractor shall immediately identify the substitute in writing to the PCO when a substitute has been determined.

1.11. TECHNICAL ORDER MAINTENANCE

1.11.1. The Contractor shall maintain all TOs and other technical directives applicable to the work requirements in an updated and current status according to TO 00-5-1, Technical Order System, and TO 00-5-3, Technical Order Life Cycle Management.

1.11.2. In the event of a TO change during the contract, the Contractor shall evaluate the impact of the change on the Contractor’s performance. The Contractor shall consider the impact of this change on costs, schedules, and any other pertinent factors. The Contractor shall provide a written evaluation, along with specific justification/applicable data documenting the impact on the Contractor’s performance, to the PCO within ten (10) business days after receipt of the change. The Contractor shall not incorporate these technical order changes until approved by the PCO.

1.12. CONTRACTOR EMPLOYEES

1.12.1. Contractor employees shall identify themselves by introducing themselves or being introduced as Contractor personnel and displaying distinguishing badges or other visible identification for meeting with Government personnel. In addition, Contractor personnel shall appropriately identify themselves as Contractor employees in telephone conversations and in formal and informal written correspondence.

1.13. SAFETY AND HEALTH STATEMENT

1.13.1. While performing work under this contract the contractor shall comply with all applicable federal, state and local regulations regarding occupational safety and health. The contractor shall notify the PCO, within eight (8) hours of any damage to government property where the dollar value exceeds $500,000.00 and within two workdays, for any damage to government property less than $500,000.00 during the execution of the contract. Mishap notifications shall contain, as a minimum, the following information:

a. Contractor, contract number, name and title of person(s) reporting

b. Date, time and exact location of accident/incident

c. Brief narrative of accident/incident (events leading to accident/incident)

d. Cause of accident/incident, if known

e. Estimated cost of accident/incident (material and labor to repair/replace)

f. Nomenclature of equipment and personnel involved in accident/incident

g. Corrective actions (taken or proposed)

h. Other pertinent information

1.13.2. If requested by the designated PCO, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office. Contractors will not dispose of contract data related to a mishap until notified to do so by the PCO.

1.14. SURGE:

1.14.1 In the event that the DoD experiences an unplanned spike or sudden increase in demand, due to major theater warfare or a national emergency (also known as surge, reference DFARs 217.208-70 and DFARs 252.217.7001), and invokes surge: The Contractor is willing to work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. The Contractor is required to provide the Government a surge plan. A CDRL and DID are associated with the surge requirement. After being notified of the surge demand in writing, the Contractor may see additional orders and/or will see the priority status elevated on current orders. The Contractor may do one or more of the following to fill the demand:

a. The Contractor will maintain a certain level of safety stock of components to draw from to perform additional repair.

b. Add additional shifts to increase production within the Contractor and with suppliers.

c. The Contractor will work with the various manufacturing sites and their supply chains to expedite production. The contractor will be notified in advance of, and be given the opportunity to negotiate; any expedite charges that might apply at the time of surge.

Contractual requirements for production of this contract are addressed in Part I. The schedule and surge requirements will be on a best-effort basis.

1.14.2 Surge plans have four basic phases (assessment, execution, sustainment, exit/termination) and the plan associated with the surged items requested need to address those phases. The Government will provide, in writing, the items on contract that are requested to be surged. That request will include the item, the quantity, and timeline with respect to delivery schedule with estimated termination dates when known.

1.14.3 Contractors will provide a plan that includes the identified surge items, how they are going to meet the requirement, timeline to implement the plan, ability to sustain the surge through termination, identify any limiting factors or supply chain risks that will impact current surge production and future requirements for identified items.

SECTION 2 DESCRIPTION OF WORK

2.1. GENERAL

2.1.1. The work performed under this contract is to remanufacture the end item(s) specified in the preface sheet of this SOW. The work shall be accomplished IAW documents as specified in section 3. In the event that a situation develops where these instructions conflict with the documents listed in section 3, this SOW shall take precedence. The work encompasses the disassembly, cleaning, inspection, maintenance, re-assembly, testing, and finishing actions required to return the end item to a like new condition.

2.1.2. When a particular remanufacture is constrained for lack of remanufacture materials that are not and will not be immediately available, the Contractor may request authorization to remove components or subassemblies from other inducted assets (the donor) prior to full disassembly for remanufacture in order to expedite remanufactures. Component removal requests shall be subject to review and approval/disapproval by the cognizant engineering activity. Such component removal actions should only be considered upon exhaustion of all other sources of remanufacture materials. The Contractor shall not initiate any component removal action unless such action shall satisfy all remanufacture material requirements for the recipient end item. The Contractor shall not remove any piece parts from serviceable units.

At the Contractor’s expense, the Contractor shall replace all removed donor subassemblies with remanufactured or new subassemblies and all component parts with new component parts. The Contractor shall ensure the contract delivery schedule is not negatively affected by the removal of any components or subassemblies from any inducted assets. The Contractor shall not condemn donor end items or subassemblies.

2.2. SPECIFIC WORK REQUIREMENTS

2.2.1. Basic remanufacture requirements. The end item shall be cleaned, disassembled, components inspected, assembled, and tested according to applicable TOs and OEM specifications. If any component part does not meet inspection requirements as specified in the applicable TO, or if there is any doubt as to its serviceability or longevity, the Contractor shall replace the component if it cannot be restored to the original life expectancy, or nearly

so. The Contractor is advised to include the cost of replacing a percentage of re-usable and recoverable components, as identified above, in their remanufacture cost proposal. Certain parts shall be replaced one-hundred percent (100%) of the time during each remanufacture event and are specified in section 5. The pricing for these items shall be included in the remanufacture cost.

NOTE: If the Contractor desires to replace or modify an existing remanufacture process with a Contractor developed process, the Contractor shall provide to the PCO all technical data or other information related to the proposed change for review and approval by the cognizant engineering authority. The Contractor must receive written authorization from the cognizant engineering authority via the PCO prior to making any process change or modification.

2.2.2. Over and Above shall only be considered for missing components or for components damaged due to causes unrelated to the normal use of the end item. Identification of missing and/or damaged components must be revealed within two (2) business days after the asset is removed from the shipping container and reported to the PCO through the ACO in the form of an SDR. Approval from the PCO shall be obtained prior to performing any over and above work. The Government shall be the sole authority to determine whether over and above is appropriate.

2.2.3. End Item Identification and Marking. Permanently and legibly mark each remanufactured end item with the Contractor’s CAGE and date of remanufacture. This identification shall be permanently affixed to the end item by stamp, stencil, or similar means.

2.2.4. Quality Acceptance and Processing.

a. Quality acceptance of each end item shall be performed prior to packaging and transportation. Quality acceptance shall be performed by DCMA at the remanufacture site. Quality acceptance documentation for each end item shall be maintained by the Contractor as part of the item document package.

b. Each end item identified as serviceable shall be delivered to the Government defect free.

c. Following quality acceptance by DCMA, the Contractor shall notify the Production Management Specialist (PMS) in writing of the completion of remanufactured end items. The PMS will provide shipping instructions to the Contractor in writing for each end item produced. Within one day of shipment, the Contractor shall provide proof of shipment through delivery of an accepted WAWF Receiving Report to the PMS. The Receiving Report shall include the carrier and tracking number.

2.2.5. Shipping Documentation.

a. The Contractor shall ensure the appropriate tag is attached to each serviceable end item generated.

i. Serviceable tags/labels are DD 1574/1574-1 (Yellow)

ii. Unserviceable (repairable) tags/labels are DD 1577-2/1577-3 (Green)

iii. Unserviceable (condemned) tags/labels are DD 1577/1577-1 (Red)

iv. Suspended tags/labels are DD 1575/1575-1 (Brown)

b. Shipments under this contract shall be by Commercial Bill of Lading (CBL) by the fastest traceable means.

c. Items remanufactured as a result of a quality deficiency shall be shipped at the Contractor’s expense.

2.3. DELIVERY SCHEDULE

2.3.1. One hundred percent (100%) of end items listed in the preface sheet shall be delivered IAW the contractual delivery schedule. The Contractor shall meet the delivery schedule.

SECTION 3 APPLICABLE DOCUMENTS

3.1. APPLICABLE TECHNICAL ORDERS

3.1.1. Specific Technical Orders

PART NUMBER REMANUFACTURE

MANUAL/TO

NUMBER

TITLE/REVISION AND/OR OTHER

DIRECTIVES (AFTO FORM 252)

765900-211 6J15-18-5-3 Technical Manual 32900-105 6J15-3- 154-3 Technical Manual 766900-213 6J15-3-157-3 Technical Manual

3.1.2. General Technical Orders

TO NUMBER DATE TITLE

00-5-1 14 JUNE 2016 AF TECHNICAL ORDER SYSTEM

00-5-3 1 APRIL 2016 AF TECHNICAL ORDER LIFE CYCLE

MANAGEMENT

00-35D-54 1 SEPT 2015 USAF DEFICIENCY REPORTING,

INVESTIGATION AND RESOLUTION

3.2. OTHER PUBLICATIONS FOR INFORMATION PURPOSES ONLY

NOTE: These publications are for information purposes only.

3.2.1. Air Force Manuals

DOCUMENT NUMBER DATE TITLE

AFI 23-101 12 DEC 2016 AIR FORCE MATERIAL

MANAGEMENT

AFMAN 23-215 6 AUG 2001 REPORTING OF SUPPLY

DISCREPANCIES

3.2.2. DoD/Air Force Forms

FORM NUMBER TITLE

SF 364 REPORT OF DISCREPANCY

SF 368 QUALITY DEFICIENCY REPORT

DD1574

DD1574-1

SERVICEABLE TAG – MATERIEL

SERVICEABLE LABEL – MATERIEL

DD1577-2

DD1577-3

UNSERVICEABLE (REPAIRABLE) TAG – MATERIEL

UNSERVICEABLE (REPAIRABLE) LABEL – MATERIEL

DD1577

DD1577-1

UNSERVICEABLE (CONDEMNED) TAG – MATERIEL

UNSERVICEABLE (CONDEMNED) LABEL – MATERIEL

DD1575

DD1575-1

SUSPENDED TAG – MATERIEL

SUSPENDED LABEL – MATERIEL

AFMC FORM 158 PACKAGING REQUIREMENTS

3.3. CONTRACTOR DOCUMENTS

PART NUMBER DRAWING

NUMBER

TITLE AND DATE

N/A N/A N/A

SECTION 4: GOVERNMENT PROPERTY

4.1. GOVERNMENT PROPERTY

4.1.1. The Contractor shall furnish all material, support equipment, tools, test equipment, and services. Government Furnished Equipment (GFE) will not be provided.

4.2. DISPOSITION OF GOVERNMENT PROPERTY

4.2.1. These instructions apply to all Government owned property. Within ninety (90) business days prior to contract expiration, the Contractor shall submit a letter to the managing ALC requesting disposition instructions in the transfer of Government furnished property (GFP). A list identifying GFP shall include the NSN, part number/CAGE, noun, quantity, condition code, and dollar value shall be submitted through the ACO to the PMS for disposition instructions.

4.2.2. If a follow-on contract is being awarded or is in the negotiation or solicitation stage, the existing GFP may be retained to the extent required to support the current contract and/or follow-on contract.

4.2.3. The Contractor shall comply with preservation, packaging, and packing instructions as specified in the basic contract and/or on the AFMC Form 158, Packaging Requirements.

4.3. OTHER

4.3.1. The Contractor shall not obtain GFP through the utilization of requisition codes assigned exclusively to this contract for any other contracts.

4.3.2. The Contractor shall not transfer GFP charged to this contract to any other contract, Contractor, or activity without the advance approval of the PMS through the PCO.

4.3.3. The Government reserves the right to withdraw any GFP in possession of the Contractor to supply other urgent USAF requirements. If any item so removed by the Government is still required to complete the contract, the Contractor shall take appropriate action to replace the removed item.

SECTION 5: CONSUMABLE PARTS REPLACEMENT REQUIREMENTS

5.1. 100% CONSUMABLE PART REPLACEMENT REQUIREMENTS

5.1.1. For remanufacture of a NSN 2915-01-140-5873, PN 765900-211 valve, the following parts should be inspected but may be reused if serviceable. All references are from Figure 9- 1 of T.O. 6J15-18-5-3.

T.O.

Index

Part Number

Description #

Per

765906-2 Not stocklisted.

No drawings available.

Housing Inspect per section 5 and reuse if serviceable.

Contractor may request over-and-above or permission to condemn end item (and salvage usable parts) if damaged beyond repair.

NAS1352C08-8

5305-00-988-7602

CAP SCREW

May be inspected and reused if serviceable.

NAS620C8L

5310-01-627-9283

FLAT WASHER

Consists of index 5,6,7,8,9,10, 11 & 12 below

765926-1 6150-01-572-3602 Not DLA supported.

SWITCH & HARNESS ASSY

serviceable. Use of surplus is acceptable.

765715-1 6150-01-572-3603 Not DLA supported.

HARNESS ASSY

COMMENT: May be made per sample. See section 6 of T.O.

for guidance.

765928-1 3040-01-572-3604 Not DLA supported.

No drawing available.

END FITTING ASSY

Contractor may request over-and-above or permission to condemn end item (and salvage usable parts) if damaged.

10-550598-98P

SCD ST5M1473-11-98P

5935-01-146-9081 Not DLA supported.

May be available from

AMPHENOL.

CONNECTOR ASSY

Inspect per section 5 and reuse if

MS27512-8E or equivalent 5915-01-098-4587 Not supported by DLA.

NUT

10-499494 AMPHENOL, alternate

10-499494TAS

5310-01-044-0773 Replacement may be made per sample.

KEY WASHER

10-550599 AMPHENOL

Not stocklisted.

May be available from

AMPHENOL

SHELL, Receptacle

765927-1 5930-01-572-3606 Not DLA supported.

No drawing available.

SWITCH ASSY

May be inspected and reused if serviceable.

Contractor may request over-and-above or permission to condemn end item (and salvage usable parts) if damaged beyond repair.

765902-1 2915-01-139-0294 No drawing available.

POPPET ASSY

Consists of index 17,18,19,20, 21 & 22

765905-1 2915-01-138-6834 Assembly is not DLA supported.

No drawing available.

RETAINER, Piston Assy Disassemble and inspect parts.

AS106-2-5 or equivalent 5315-01-500-5570

PIN

Pin is removed for disassembly of piston retainer but may be reused if serviceable.

0.3125 overall nominal length 0.0610 –

0.0615 inches diameter 304 CRES material Both ends have 0.01” radius

765931-1 2915-01-500-9660

PISTON ASSY

Slip seals on PN 765931-1 piston assembly may be replaced with locally manufactured seals made per sample. Suitable seal stock is

0.010 inch thick PTFE-coated fiberglass cloth (McMaster-Carr 8577K84 or equivalent). Drill out rivet heads of piston assembly to allow removal of old seals and install new ones.

Reassembly piston assembly in reverse order of disassembly. Replace rivets with suitable rivets or steel screws and self-locking nuts."

765920-1 4810-01-572-3605 Not DLA supported. No drawings available.

Replacement may be made per

RETAINER, Spring

765918-1 5360-01-500-5576 No drawing available.

Replacement may be made per sample and/or Haystack tech data.

Spring, Helical Compression Inspect per section 5 and reuse if serviceable.

Haystack data: ID 1.076 nominal Spring OD 1.190 – 1.210 inches (free length) Free length 2.470 inches

4.056 lb/in deflection rate (nominal)

765911-1 2915-01-501-0243 Limited rights drawing.

Shaft assembly Contractor may request over- and-above to purchase DLA or surplus shaft, or to local manufacture replacement per sample.

765930-1 2915-01-149-3887 Not DLA supported. No drawing available.

RETAINER ASSY

Contractor may request over- and-above to purchase surplus retainer or to local manufacture replacement per sample.

765904-1 Not DLA supported. No drawing available.

Replacement may be made by contractor per sample.

FOAM GUARD ASSY

765903-1 2050-01-572-3607 Not DLA supported.

No drawing available.

FLANGE ASSY

Inspect per section 5 and reuse if serviceable.

Replacement seals may be installed if necessary by removing old seals and applying Mil-C-5541 alodine to bare metal. Attach replacement AS568A-035 nitrile O-Ring in the groove on the face within the four legs. Install replacement AS568A-037 nitrile O-Ring in the groove on the opposite face using AMS-S-8802 adhesive.

MS21209C08-15

5325-00-815-4929

INSERT, Self-Locking Replace only if damaged.

MS21209F4-15

5325-00-829-2141

INSERT, Self-Locking Replace only if damaged.

NOTE : Parts from DLA are generally not available for this valve due to the low numbers of PN 765900-211 remanufactured. (Field/Depot Turn-ins: 2011-6, 2012-5, 2013-0, 2014-1, 2015-4, 2016- 6, 2017-2, 2018-1, 2019-2, 2020-1.) However surplus piece parts and entire PN 765900-211 valve assemblies are listed as available on ILS. Surplus parts, whether procured as new-and-used or “as removed” may be used for remanufacture of PN 765900-211 valve provided they are inspected IAW criteria provided in T.O. 6J15-18-5-3.

5.1.1. For remanufacture of a NSN 2915-01-140-5873, PN 765900-211 valve, the following parts must be replaced 100 percent. All references are from Figure 9-1 of T.O. 6J15-18-5-3.

Description Units

Per Assy

M25988-2-116 5331-01-120-9438

PACKING

Replace with new packing.

M25988-1-034 5331-01-007-1617

AS101-4-11 or equivalent 5315-01-500-5582

PIN, straight, round head Replace with new pin.

Haystack data:

0.122 – 0.124” diameter shank

0.155 – 0.175” head diameter

0.037 – 0.057” head height

0.6725 – 0.7025” under head length 303 CRES material

MS28774-139

5330-01-288-7161

The parts below must be replaced 100% with new parts during remanufacture of the NSN 2915-01- 081-6534, Rogerson PN 32900-105 valve. All references are from Figure 9-1 of T.O. 6J15-3-154- 3.

Description

Units Per Assy

13 M25988-1-012 5331-00-759-1687

41711-1 5945-01-090-8767 0 in DLA supply.

New solenoids may be procured from directly from OEM (Rogerson), or their distributors.

SOLENOID, Primary Solenoids are normally sent in from field with most of lead wires cut off.

Contractors may procure new solenoids or have solenoids repaired by sources/methods approved by USAF engineering. Valves/solenoids must be shipped with 105” wire leads. No splices are allowed on wire leads.

Electrical connection of lead wires to solenoids must be made inside hermetically sealed solenoids to prevent electrical arcing inside fuel tanks.

Sources approved by the USAF to repair solenoids include Aircraft Electrical Electronic of Riverside MO. Other potential sources may be approved by demonstration/history of repair of similar solenoids.

41711-3 5945-01-107-1773 0 in DLA supply.

New solenoids may be procured from directly from OEM (Rogerson), or their distributors

SOLENOID, Secondary Solenoids are normally sent in from field with most of lead wires cut off.

Contractors may procure new solenoids or have solenoids repaired by sources/methods approved by USAF engineering. Valves/solenoids must be shipped with 105” wire leads. No splices are allowed on wire leads. Electrical connection of lead wires to solenoids must be made inside hermetically sealed solenoids to prevent electrical arcing inside fuel tanks.

22 M25988-1-013 5331-00-759-2022

PACKING 2

23 M25988-1-022 5331-00-279-9309

25 MS24665-26 or equivalent 5315- 00-234-1852

PIN, COTTER

33 M25988-1-012 5331-00-759-1687

37 M25988-1-010 5331-00-343-1035

M25988-1-010 5331-00-343-1035

MS19060-4

3110-00-052-7825

BALL

PR Number: FD2030-19-02358 SOW Form Rev 3: 24 APRIL 2015

For remanufacture of a NSN 2915-01-081-6534, Rogerson PN 32900-105 valve, the following parts should be inspected but may be reused if serviceable. All references are from Figure 9-1 of T.O. 6J15-3-154-3.

Description

Units Per Assy

32940 1680-01-056-4287

SHIELD, UPPER

Contractor may make replacement per sample.

MS35275-242

5305-00-939-9222

SCREW, FILLISTER HEAD

NAS620C8

5310 -00-069-5291

WASHER

4 32914

1680-01-056-0727

FLANGE ASSEMBLY

Contractor may request over-and-above if damaged beyond repair.

MS35275-244

5305-00-939-9231

NAS620C8

32912 2915-01-090-8757

PISTON ASSEMBLY, PRIMARY

above if replacement is required.

8 32906 1680-01-090-7315

PISTON ASSEMBLY,

SECONDARY

Contractor may request over-and-above if replacement is required

MS21042-3

5310-00-807-1467

AN960C10

5310-00-167-0801

32905 5360-01-057-4045 Not DLA supported. No surplus listed.

SPRING

32904 1680-01-056-0724 Replacement made be made per

PIN, METERING

above if damaged.

15 MS35275-244

5305-00-939-9231

16 MS35275-246 5305-00-939-9232

17 NAS620C8

19 MS35275-243

5305-00-939-9230

SCREW, FILLISTER HEAD 2

21 MS35275-243

5305-00-939-9230

SCREW, FILLISTER HEAD 4

41710, 41710TAS or equivalent 1680-01-090-8766 Replacement may be machined per sample, FITTING, Machine Contractor may request over-and-above if damaged.

32936-1 5315-01-058-7243

PIN, FLAT HEAD

Contractor may identify and request permission from USAF to use suitable sub pin.

32936-3 5315-01-058-7244

PIN, FLAT HEAD

Contractor may identify and request permission from USAF to use suitable sub pin.

5300-3 or equivalent Not stocklisted.

41707-1 1680-01-090-7339

FLOAT ASSEMBLY,

SECONDARY

41707-2 2915-01-090-8761

FLOAT ASSEMBLY, PRIMARY

32931 2915-01-091-2104

VALVE ASSEMBLY, PILOT

above if damaged.

32 MS24693C26

5305-00-958-2918

SCREW, FLAT HEAD

41712 5340-01-095-2187 Surplus available. Not DLA supported

COVER

Contractor may make replacement

MS35275-243

32927 5340-01-057-8404

RETAINER

32944 5360-01-092-7709

SPRING, COMPRESSION

32939 1680-01-056-4286

POPPET ASSEMBLY, THERMAL

RELIEF

32923-1

NAMEPLATE

Replacements may be locally made

MS35275-243

32928 1680-01-056-0732

COVER

Contractor may request permission to make replacements per sample.

32925 1680-01-056-0730 Not DLA supported.

GUIDE

ALUMINUM ALLOY 6061-T6,QQ-

A-225/8,

0.358 IN. DIA,0.350 IN. LG,1

HOLE IN CENTER

0.104 IN. DIA WITH 6- 32UNC-2B

THD 0.175 IN. DEEP

32929

SPRING

41703

BODY

Contractor may request permission to condemn end item if damaged.

NOTE : When remanufacturing a 2915-01-081-6534, PN 32900-105 valve, replacement parts are more available due to the higher numbers of valves remanufactured annually. (Field/Depot Turn-ins: 2011-105, 2012-100, 2013-32, 2014-38, 2015-58, 2016-29, 2017-17, 2018-25, 2019- 24, 2020-5).

100% CONSUMABLE PART REPLACEMENT REQUIREMENTS

For remanufacture of a NSN 2915-01-140-5983, Transdigm PN 766900-213 valve, 100 percent of the following parts must be replaced. All references are from Figure 9-1 of T.O. 6J15-3-157-

Index Part Number Description

Units Per Assembly

M25988/2-116 5331-01-120-9438

PACKING

Haystack data:

0.943” OD

0.10” cross section 1

766912-1 or equivalent 5310-01-500-7411 Replacements may be made per sample and/or Haystack data.

TEFLON WASHER

Haystack data:

.037–.043” thick, 0.562” ID, 0.750” OD 1

CR3245-4-1 or equivalent 5320-01-158-7848 Rivets are drilled out to remove cover assembly in para 3-3.a. RIVETS 8

765705-1 3120-01-143-3168.

Replacements may be made per sample and/or Haystack data.

Bushings are drilled out in para 3- 3.c.

BUSHING

Haystack data:

0.2800” nominal length 0.3690” nominal OD 0.3450” nominal ID 0.6200” flange nominal OD 0.0400” flange nominal width Aluminum alloy 1100

AS101-3-18 or equivalent 5315-00-296-6324

. PIN, STRAIGH 1

766910-1 2915-01-138-9109 Replacement may be made per sample.

POPPET ASSEMBLY

Aluminum Alloy 6061

766903-1 4820-01-138-8890

SEAT

Aluminum Alloy 6061 Anodize overall

For remanufacture of a NSN 2915-01-140-5983, Transdigm PN 766900-213 valve, the following parts should be inspected but may be reused if serviceable.

All references are from Figure 9-1 of T.O. 6J15-3-157-3

T.O.

Index Part Number Description

Units Per Assembly

766908-1 5945-01-155-6289 Solenoids may be remanufactured by sources approved include Aircraft Electrical Electronic of Riverside MO. Other potential sources may be approved by demonstration/history of repair of similar solenoids.

SOLENOID

Fully enclosed, 0.625” max (pull) stroke length, 0.35 lb linear force, 1 amp nominal current.

1 coil

NAS1291C04M or equivalent 5310-00-845-2359

SELF LOCKING NUT 1

10-550598-98P (Amphenol Corp, CAGE 77820)

ALTN ST5M1473-11-98F

5935-01-572-3993

CONNECTOR ASSY,

Electrical, Hermetic 1.922” nominal length

MS27512-8E or equivalent 5935-01-098-4587

Steel, 1.125-18 UNEF, 1.312” across flats

10-499494 (Amphenol Corp) 5310-01-044-0773

KEY WASHER

CRES, 0.884” – 0.894” ID, 0.063”

thick

766905-1 4820-01-501-9181

COVER ASSEMBLY

765708-1 2915-01-500-7412 sample. COVER PLATE 1

765706-1 5310-01-500-7318

SPACER

AN960PD616L

5310-00-187-2395

765705-1 3120-01-143-3168 sample and/or Haystack data.

BUSHING, SLEEVE

0.2800” nominal length, 0.3690” nominal OD 0.3450’ nominal ID 0.06200’ nominal flange OD 0.0400’ nominal flange width Aluminum 1100, QQ-A-225 2

766904-1 2915-01-138-9107

FLOAT

Polyurethane foam per MIL-P- 26514 Contractor may request over-and-above if replacement required. 1

NAS620C4 or equivalent 5310-00-057-0573

0.032” thick, CRES, 0.115 – 0.125”

ID, 0.204 – 0.224” OD

766901-1 Not stocklisted.

No drawing.

NOTE – If body is damaged beyond repair, contractor may request permission from USAF to condemn end item. HOUSING, PILOT VALVE 1

NOTE: Due to low numbers of NSN 2915-01-140-5983, Transdigm PN 766900-213 valves remanufactured annually, new replacement parts may not be readily available. (Field/Depot Turn-ins: 2011-2, 2012-3, 2013-0, 2014-2, 2015-3, 2016-2, 2017-3, 2018-2, 2019-1, 2020-0).

However surplus piece parts and entire PN 766900-213 valve assemblies are listed as available on ILS. Surplus parts, whether procured as new-and-used or “as removed” may be used for overhaul of PN 766900-213 valve provided they are inspected IAW criteria provided in T.O.

6J15-3-157-3