76 MXW OPERTING INSTRUCTION 21-203.doc

BY ORDER OF THE COMMANDER 76 MXW OPERATING INSTRUCTION 21-203

76 MAINTENANCE WING

26 FEBRUARY 2010

Incorporating Change 2011-1, 9 August 2011

Maintenance

EQUIPMENT MAINTENANCE/

INSPECTION AND DOCUMENTATION

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: This publication is available digitally at:

https://org.eis.afmc.af.mil/sites/76MXW/pubs/Operating%20Instructions/Forms/AllItems.aspx.

If you lack access, contact your 76 MXW Publications and Forms Manager.

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: 76 MXSS/MXDEAB Certified by: 76 MXSG/DD (David Goss)

Pages: 66

This instruction establishes responsibilities and procedures for the Air Force Technical Order

(AFTO) Form 244/245, Industrial/Support Equipment Record or computer-generated equivalent, for equipment delayed discrepancies, corrective actions, record service, periodic and special inspections, record inspection status and historical data in accordance with (IAW) Technical

Orders (T.O.s), Air Force Occupational Safety and Health (AFOSH) Standards and local directives. This instruction prescribes responsibilities and provides general instructions for

Preventive Maintenance (PM) and Predictive Maintenance (PdM) of Support Equipment (SE).

This includes recording the cost of equipment repair and modification IAW Air Force Materiel

Command Instruction (AFMCI) 21-127, Depot Maintenance Plant Management. The instruction applies to all personnel within the 76th Maintenance Wing. In the event of conflicting guidance, the most stringent requirements will take precedence.

SUMMARY OF REVISIONS.

This interim change addresses requirements in higher level directives T.O. 00-20-1, Aerospace

Equipment Maintenance Inspection, Documentation, Policies, and Procedures, AFOSH STD 91-

46, Materials Handling and Storage Equipment, and T.O. 35D6-1-106, Aircraft and Engine

Slings (General) and Restraining Devices. The affected paragraphs have only been slightly changed. A margin bar indicates newly revised material.

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Chapter 1— AFTO FORM 244 DOCUMENTATION REQUIREMENTS

1.1. AFTO Form 244 General Information and Documentation Requirements

1.2. AFTO Form 244 Block Identification …………………

1.3. AFTO Form 244 Symbols

1.4. AFTO Form 244 Maintenance and Disposition Instructions………………………

Chapter 2— EQUIPMENT MAINTENANCE 12

2.1. Maintenance Concept

2.2. Maintenance Program Determination

2.3. Preventive Maintenance

2.4. Predictive Maintenance Work

2.5. Responsibilities………………………………………………………………..………15

Chapter 3— FACILITIES AND EQUIPMENT MAINTENANCE SYSTEM 25

3.1. FEM System Definition ……………………………………………………….… 25

3.2. FEMWEB System Definition ……………………………………………………….25

3.3. FEMWEB Unscheduled Outage ………………………………..………………

3.4. FEMWEB Scheduled Outage………………………………………………………. 25

3.5. Responsibilities………………………………………………………………………25

Chapter 4— LOCALLY MANUFACTURED OR DEVELOPED/MODIFIED 27

SUPPORT EQUIPMENT

4.1. General

4.2. Duties and Responsibilities:

Chapter 5—HOIST INSPECTION AND DOCUMENTATION 31

5.1. General

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5.2. Duties and Responsibilities

5.3. Inspection……………………………………………………………………………..32

5.4. Annual Certification/Inspections……………………………………………………...32

5.5. Removal and Installation of Fixed Hoists……………………………………………32

5.6 Use of Hoists…………………………………………………………………………32

Chapter 6—LIFTING AND RESTRAINING DEVICES INSPECTION AND 33

DOCUMENTATION

6.1. General……………………………………………………………………………….33

6.2. Responsibilities………………………………………………………………………33

6.3. Certification Procedures……………………………………………………………...35

6.4. Non-Destructive Inspection (NDI) Requirements …………………………...………36

Chapter 7—TRAILER INSPECTION AND DOCUMENTATION 38

7.1. Background ………………………….. ………………………………...………… 38

7.2. Description of Preventive Maintenance…………………………………………… 38

7.3. Operator Preventive Maintenance (PM)..…………………………………………….38

7.4. Monitor Maintenance……………………………………………………………… 38

7.5. Six Month Scheduled Preventive Maintenance (PM)……..…………………………38

7.6. Unscheduled Maintenance or Wheel Bearing Pack (WBP)………………………….39

7.7. Primary Repair Center………………………………………………………………..39

7.8. Trailer Configuration Changes or Modifications…………………………………….39

7.9. Trailer Painting Requirements………………………………………………………..39

7.10. Responsibilities…………………………………………………………………… 39

Chapter 8 —MOBILE MAINTENANCE STANDS/FIXTURES/CARTS/ 41

PLATFORMS/ TABLES/CABINETS AND DEXION CARTS SECURING

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8.1. General……………………………………………………………………………… 41

8.2. Push Carts……………………………………………………………………………41

Chapter 9— OVERHEAD CRANE OPERATIONS 42

9.1. Roles and Responsibilities………………………………………………………....….42

9.2. Maintenance of Overhead cranes……………………………………………………...45

9.3. Safe Practices…………………………………………………………………….……46

9.4. Historical Records……………………………………………………………………..48

9.5. Training/Safety Briefings…………………………………………………………..….48

Chapter 10 —FORMS ADOPTED AND/OR PRESCRIBED 49

Attachment 1—GLOSSARY OF REFERENCES AND 50

SUPPORTING INFORMATION

Attachment 2—COMPLETION INSTRUCTIONS FOR AFMC FORM 388, 56

MACHINE TOOL AND EQUIPMENT HISTORICAL RECORD

Attachment 3—SUPPORT EQUIPMENT CLASSIFICATION, PREVENTIVE 57

MAINTENANCE AND FORMS DETERMINATION GUIDE

Attachment 4—DEPOT INDUSTRIAL PLANT EQUIPMENT (DIPE) REPAIR AND 58

DOCUMENTATION GUIDE

Attachment 5—NON-DEPOT INDUSTRIAL PLANT EQUIPMENT (NON-DIPE) 59

REPAIR AND DOCUMENTATION GUIDE

Attachment 6—ON-CONDITIONAL MAINTENANCE (OCM) REPAIR AND 60

DOCUMENTATION GUIDE

Attachment 7—SAMPLE 76 MXW FORM 105 OVERHEAD CRANE 61

OPERATOR INSPECTION CHECKLIST

Attachment 8—OVERHEAD CRANE MAINTENANCE AND 62

INSPECTION SCHEDULE

Attachment 9—OVERHEAD CRANE OPERATOR ANNUAL SAFETY 63

BRIEFING OUTLINE

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Chapter 1

AFTO FORM 244 DOCUMENTATION REQUIREMENTS

1.1. AFTO Form 244 General Information and Documentation Requirements.

1.1.1. Overdue TMDE. Owning work centers shall not use the AFTO Form 244/245 to document overdue calibrations. Use the AFTO Form 350, Repairable Item Processing Tag for this purpose.

1.1.2. AFTO Form 244/245 entries will only be in black (pencil or ballpoint pen), unless otherwise specified.

1.1.3. Minimum signature will be first name initial, last name, and employee number.

1.1.3.1. Oklahoma City Air Logistics Center may use a production stamp in place of the employee number.

1.1.3.2. Contractors will use their Federal Avionics Administration (FAA) certification number or equivalent in place of the employee number.

1.1.4. All “SYMBOL” block entries will be made in RED.

1.1.5. RED symbol entries will NEVER be erased even when entered in error.

1.1.6. All “DATE” entries will be eight digits in order of year, month, day (YYYYMMDD) i.e. 20010306.

1.1.7. Documents will be maintained legible, complete, correct and clean.

1.1.8. AFTO Form 244 will be attached to equipment. EXCEPTION: ONLY when equipment use or size makes it hazardous or impractical for the form to accompany the equipment. The GP/CC must designate in writing permission for such forms to be maintained in a separate file. It is the user’s responsibility to review equipment documentation prior to use to ensure that all inspections are current and any discrepancies have been identified on the AFTO Form 244, part V.

1.1.9. Specific inspection criteria for any equipment will be in accordance with

Equipment/General T.O.s, Original Equipment Manufacture’s (OEM) manual, Air Force

Occupational Safety and Health (AFOSH) Standards, Engineering Documents, similar equipment inspection work cards or local operating instructions (OI).

1.1.10. Entries will be documented in a sequential order (i.e. either “top-to-bottom” or “leftto-right”).

1.2. AFTO Form 244 Block Identification.

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1.2.1. AFTO Form 244, part I, provides a means to identify the SE for which the form is maintained.

1.2.1.1. Block 1. Enter the nomenclature/model number (e.g. Air Compressor/MC2A).

1.2.1.2. Block 2. Enter the assigned AF registration/serial number. Leave blank if not applicable.

1.2.1.3. Block 3. Enter the identification number (a locally defined equipment-type

Identifier, for DIPE enter the OC number), if assigned. Leave blank if not assigned.

1.2.1.4. Block 4. Enter the field number. Leave blank if not applicable.

1.2.1.5. Block 5. Enter the Work Unit Code (WUC) if one is assigned. Leave blank if not applicable.

1.2.1.6. Block 6. Enter the assigned organization/work center (e.g., 76

AMXG/MXAATA).

1.2.1.7. Block 7. Enter the date the form was initiated to the ‘left” of the word “TO.”

Once the form is closed out or the equipment is turned into supply/salvage enter the close out date to the right of the word “TO” (e.g., “20040430 TO =” new/current form, “20040430 TO 20041230” = closed out form).

1.2.1.8. Block 8. Leave blank if not applicable. This block may be used for MXG/CC specific requirements.

1.2.2. AFTO Form 244, part II, provides a means to document the accomplishment of daily or prior to use (Daily/PU) specific operator maintenance (OM) inspections as outlined on the

AFMC Form 306 (or equivalent) or applicable technical order. Daily/PU is defined: These actions are to be reviewed prior to use. Signing off on these actions means you have accomplished all actions required prior to the use of the equipment and you have read, understand, and will accomplish those actions required during and after use. These actions are to be reviewed by each shift using the equipment with appropriate actions being accomplished as directed by the AFMC Form 306. These actions and associated sign offs need only be accomplished once per calendar day on those days the equipment is used regardless of multiple shift use.

1.2.2.1. Time Column. Enter the time (in 24-hour military time) the service/prior to use inspection was accomplished. If the unit is equipped with a running time meter, the metered time may be entered in place of the time of day. For SE inspected at hourly intervals, enter the daily/accumulated time.

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1.2.2.2. Inspector’s Initials Column. Enter the first initial, last initial of the individual completing the inspection.

1.2.2.3. Date Column. Enter the date (YYYYMMDD) the inspection was accomplished.

1.2.3. AFTO Form 244, part III, provides a means to document the accomplishment of specific operator inspections/maintenance as outlined on the AFMC Form 306 (or equivalent) or applicable technical order other than daily/prior to use. These actions must be accomplished at their set interval regardless of equipment usage. Due-by dates are defined by the last time the action was accomplished plus the defined interval. Actions are required to be accomplished within that interval.

1.2.3.1. Inspection Requirement. In this column, enter the type of inspection due

(e.g., weekly, monthly, etc.), periodic inspection, special wheel bearing packing, lubing etc. Any specific operator inspections/maintenance, other than daily/prior to use, will be documented in part III. Initials for the technician performing specific OM will not be required in part III.

1.2.3.2. Interval. In this column, enter the next scheduled inspection interval (e.g., 30-

, 60-, and 180-day, or 500-hour, etc.).

1.2.3.3. Date Due. In this column, enter the next inspection due in the next open date due block.

1.2.3.4. Date Completed. Enter the hour/date inspection was completed. Enter a new inspection due date in next DATE DUE block.

1.2.4. AFTO Form 244, part IV. Provides a means to document a quality control or supervisory review of the form. Supervisors may also designate, in writing, an individual who will satisfy the review requirement. The letter will be maintained by the work center supervisor. Ensure all the applicable blocks are filled out correctly, operator specific PM inspections are being accomplished on time and documented, and discrepancies corrected are signed off correctly. The interval for this review is every 6 months. This section will not be used for documenting inspection of completed maintenance actions.

1.2.4.1. Employee Number. Enter first name initial, last name and grade (preferred method) or production stamp or employee number.

1.2.4.2. Date. Enter the date (YYYYMMDD e.g., 20010306) the review was accomplished.

1.2.5. AFTO Form 244/245, part V. Provides a means to document equipment discrepancies and corrective actions. The following conditions will be recorded in this part of the form.

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1.2.5.1. Delayed discrepancies that cannot be corrected as part of the maintenance actions in progress will be scheduled for follow-on maintenance actions.

1.2.5.2. Use a Red X when an inspection renders the SE unsafe or unserviceable.

1.2.5.3. Overdue inspection, including portions of inspections not accomplished during the scheduled inspection (e.g., work card and/or work card items not completed by the end of the due period).

1.2.5.4. Overdue time change, Master Configuration Lists (MCLs) and Time

Compliance Technical Orders (TCTOs).

1.2.5.5. Discrepancies discovered by the operator during operation of the system/equipment.

1.2.5.6. Part V will be completed as follows:

1.2.5.6.1. Block 9—TO. Enter the TO number or manufacturer’s manual number/title that covers the item identified in block 1.

1.2.5.6.2. Block 10—NSN. Enter the assigned national stock number or part number for item identified in block 1. Leave blank if not applicable.

1.2.5.6.3. Block 11 and Block 12. These blocks are left blank, unless approved for use by Major Command (MAJCOM).

1.2.5.6.4. Date Discovered. In this column, enter the date the discrepancy is discovered; the original date is brought forward to the new form when entries are carried forward from an old form.

1.2.5.6.5. Discovered By. In this column, the individual discovering the discrepancy will include his/her minimum signature.

1.2.5.6.6. Sup Doc Number. In this column, enter the base supply document number(s). This block is not required for units using Maintenance Information

Systems (MIS) or if directed by the Maintenance Group Commander. When two or more supply document numbers are needed to adequately define base supply support for repairing a discrepancy, add all additional supply document numbers needed to correct the discrepancy after the statement of the discrepancy. If necessary, use of the next open DISCREPANCY block is authorized. If the next block is used all adjacent blocks will be lined through. As these requisitions from base supply are received by the requester, draw a single line through the document number to show its receipt.

1.2.5.6.7. Symbol. In this column, enter the applicable Red symbol for the discrepancy.

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1.2.5.6.8. Discrepancy. In this column, enter the discrepancy or maintenance action required. Only one defect will be entered in each block for each job control or work order number; however, use as many blocks as necessary to completely describe a single discrepancy.

1.2.5.6.9. Job CON/W.O. Number. In this column, enter the job control or work order number assigned to the discrepancy.

1.2.5.6.10. Corrective Action—In this column, enter the description of the corrective action taken. For Red X and Red Dash discrepancies, include technical order (T.O.) reference (including page and paragraph/figure number or function number), if applicable, or equivalent, in the “CORRECTIVE ACTION” block and enter the date in the “DATE CORRECTED” block. DIPE is excluded from this requirement since the T.O. reference is listed on the equipment. Maintenance

Group Commanders may specify additional minimum T.O. reference. If more space is needed to make this entry, use the next open block.

1.2.5.6.11. Date Corrected. In this column, enter the date (YYYYMMDD e.g., 20010306) the discrepancy is corrected.

1.2.5.6.12. Corrected By. In this column, the individual who corrects the discrepancy will sign his/her signature in this block.

1.2.5.6.13. Inspected By. In this column, the individual clearing a red - (dash) or

Red X will enter his/her minimum signature in this block and last name initial over the Red symbol in the symbol column.

1.2.6. AFTO Form 245. This form provides a continuation to part V of the AFTO Form

244. This form will be completed using the same instructions as provided for part V of the

AFTO Form 244.

1.3. AFTO Form 244 Symbols.

1.3.1. Symbol entries will be made in RED to make the important warning signals stand out clearly. All manually entered symbols must be entered in RED, except black name initials placed over the RED symbol.

1.3.2. Red X entries on the AFTO Form 244, for support equipment, can only be cleared by the shop supervisor/work leader or appointee (designated in writing).

1.3.3. RED (X) Symbol.

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1.3.3.1. A Red X indicates that the support equipment (SE) is considered unsafe or unserviceable and will not be used until the unsatisfactory condition is corrected and symbol is cleared.

1.3.3.2. Exception: SE with a Red X condition may be operated as necessary to troubleshoot or repair the discrepancy.

1.3.4. RED – (Dash) Symbol.

1.3.4.1. A RED Dash indicates that a required scheduled inspection, special inspection or operation check is overdue.

1.3.4.2. Also used to indicate that the condition of the equipment is unknown and a more serious condition may exist.

1.3.5. RED / (Diagonal) Symbol.

1.3.5.1. A RED Diagonal indicates that an unsatisfactory condition exists on the equipment but is not sufficiently urgent or dangerous to warrant discontinuing use of the equipment.

1.3.6. Changing RED Symbols (After an Original Entry).

1.3.6.1. Symbols/Initials once entered will NEVER be erased even if entered in error.

1.3.6.2. Reasons for changing a RED symbol:

1.3.6.2.1. Condition is more serious than previously entered.

1.3.6.2.2. Condition is less serious than previously entered.

1.3.6.2.3. Symbol/Initials were entered in error.

1.3.7. Clearing RED Symbols:

1.3.7.1. The black last name initial entered over the symbol in the “SYMBOL” block indicates that the individual whose name appears in the signature block related to the particular entry has accomplished the required maintenance or has inspected the equipment, work accomplished, or system specified and has found the deficiency cleared.

1.3.7.2. The individual who signs off a RED symbol for a specific maintenance task must be authorized, familiar with the task, and knowledgeable of the technical orders required to accomplish the task.

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1.3.7.3. When the initial is entered, consider the discrepancy indicated by the symbol cleared and discrepancy has been corrected.

1.3.7.4. When a Red Dash or Red Diagonal is entered in error on a discrepancy or work document, the individual discovering the incorrect entry enters the following statement in the “CORRECTIVE ACTION” block: “Symbol/Initial entered in error, discrepancy and correct symbol/initial reentered on page ___, item ____,” or

“Symbol entered in error, no discrepancy exists,” and enter their minimum signature.

When required, re-enter the discrepancy, and correct symbol in the next open

“DISCREPANCY” block on the form.

1.3.7.5. If the erroneous symbol is a Red X, the individual discovering the incorrect entry will enter the applicable statement identified in paragraph 1.3.7.4. If they are authorized to clear these symbols, they will complete the “INSPECTED BY” block and initial over the symbol. If they are not authorized to clear these symbols, they will sign the “CORRECTED BY” block. The individual authorized to clear these symbols will place their last name initial over the symbol and complete the “INSPECTED BY” block.

1.3.7.6. If the erroneous item is an initial, clear the discrepancy by entering “Initial entered in error, see Page ___Item___,” sign the “CORRECTED BY” block and re-enter the discrepancy in the next open block.

1.4. AFTO Form 244 Maintenance and Disposition Instructions.

1.4.1. When carrying the “DISCOVERED BY” block forward, print the first initial, last name and grade of the individual that originally discovered the discrepancy.

1.4.2. When closing out the AFTO Form 244, the current date will be entered in block 7

(following the “TO”) and carried forward (CF) will be entered in the DATE COMPL block of part III followed by the closer’s initials. For each open discrepancy, enter in the corrective action block CF and the closer’s first name initial, last name, and grade.

1.4.3. Completed AFTO Form 244/245 or computer-generated equivalent will be kept on file by the shop supervisor for 1 year. AFTO Form 244/245 or computer-generated equivalent will be destroyed after 1 year.

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