TRD.pdf

Technical Requirements Document (TRD) Landing Gear Remanufacture 3 (LGR3)

8 Apr 2015 Air Force Material Command (AFMC) Air Force Sustainment Center (AFSC)

Prepared by: 417 SCMS Hill Air Force Base, Utah 84056

Contents Section I

1. Description of Requirements

1.1. Scope

Section II

2. Requirements

2.1. Transition Phase

2.2. General Work Requirements:

2.3. Remanufacture Requirements

2.4. Deliverable Data Requirements

2.5. Time Compliance Technical Order (TCTO)

2.6. Technical Orders and Other Directives

Section III

3. Government Furnished Property (GFP)

3.1. All items necessary for the performance of this contract not listed in the Appendix B will be the responsibility of the contractor

3.2. Please note, no Government Furnished Equipment (GFE) will be provided

3.3. The contractor must report all condemned GFM items through CAVAF reporting at the time of condemnation IAW CAVAF requirements

Section IV

4. General Information

4.1. Quality Control

4.2. Safety and Health

4.3. Program Management Review (PMR) Frequency

4.4. MICAP, Critical Items and Surge:

4.5. Over and Above Procedures

Section V

5. TERMS EXPLAINED:

Attachment # 1

Attachment # 2

Attachment # 3 – AFTO Form 95

Attachment # 4 – AFTO Form 22

Attachment # 5 – AFMC Form 202

Attachment # 6

Attachment # 7 – SF 364 (Report of Discrepancy)

List of Attachments #1 CAV AF Statement of Work

#2 Contractor Communications Network (CCN)

#3 AFTO Form 95

#4 AFTO Form 22

#5 AFMC Form 202

#6 AFTO Form 43

#7 SF 364 (Report of Discrepancy)

Section I

1. Description of Requirements

1.1. Scope

1.1.1. This TRD defines depot-level maintenance requirements to sustain United States Air Force (USAF) E-3, C-130, and KC-135 aircraft landing gear components. The objective of this contract is to obtain remanufacture of assets to accomplish the work requirements specified herein.

1.1.2. This TRD establishes the minimum work requirements for complete remanufacture necessary to return the C-130, KC-135, and E-3 system landing gear and related components repairable end items(s) to a serviceable condition; specifically, Condition Code A, unless otherwise requested, IAW the latest version of applicable TOs.

1.1.3. All end item remanufacture performed by the contractor will comply with the instructions and technical data requirements contained in this Technical Requirement Document. The United States Government (USG) shall not be held liable for reimbursement for any unauthorized work tasks.

1.1.4. The contractor shall expend no unauthorized effort under this TRD for additional engineering design or development of the end items(s) or components(s).

1.1.5. The functional capabilities for which the end item was designed shall not be changed, modified, or altered without approval from a government engineer via the Request for Deviation (RFD) (see paragraph 2.3.12.).

1.1.6. Mission Impaired Capability Awaiting Parts (MICAPs) will be identified to the contractor and work priorities will be set by direction of the Program Manager to ensure mission needs are prioritized over batch processing. USG will provide the contractor with a weekly priority list detailing (MICAP) and high priority items.

1.1.7. Continuation of Essential DoD Contractor Services During Crisis. Contract performance is not mission essential during crisis situations IAW DoDI 3020.37.

1.1.8. Foreign disclosure restrictions apply to engineering data, which are export controlled.

1.1.9. The disassembly, inspection, complete remanufacture/modification/update, test, and assembly of components parts and equipment shall conform to the instructions in this TRD and all applicable technical data/directives listed in Section II.

1.1.10. Required delivery, as specified in section B of the model contract is clarified as shown below.

1.1.10.1. Start: Remanufacture delivery time begins upon receipt of induction of the F condition end item. Receipt of F condition end item is defined as the end items final Continental United States (CONUS) destination.

1.1.10.2. Finish: Remanufacture delivery time ends upon receipt of the remanufactured end item to its final destination as specified by the delivery order. Early delivery is acceptable for all induction schedules shown below.

1.1.10.3. Contractor shall induct end items utilizing the following instructions:

1.1.10.3.1. If delivery order is identified as a singular order (not quarterly, yearly etc.), then Contractor shall induct immediately upon receipt of F condition end item.

1.1.10.3.2. If delivery order is identified as a quarterly order, then Contractor shall induct utilizing the following induction schedule: The monthly induction amount shall be calculated by dividing the total quantity ordered by three months (i.e. 15 ea / 3 mon = 5 inductions per month). The first induction period will begin immediately upon receipt of F condition end item.

1.1.10.3.3. If delivery order is identified as a semi-annual order, then Contractor shall induct utilizing the following induction schedule: The monthly induction amount shall be calculated by dividing the Total quantity ordered by six months (i.e. 30 ea / 6 mon = 5 inductions per month). The first induction period will begin immediately upon receipt of F condition end item.

1.1.10.3.4. In the event that the schedules above aren’t sufficient for the Government needs, the Contractor shall induct on an expedited schedule provided by the Government on a delivery order basis. This schedule shall not exceed 275 total landing gear remanufactures in a thirty day period.

1.1.10.3.5. Contractor is authorized to induct early in all situations.

Section II

2. Requirements

2.1. Transition Phase

2.1.1. Transition Phase In: In the event that a transition period is needed, a phase-In transition period of six months after contract award will be allowed. During this transition time period, the Contractor will not be required to perform remanufacture work. The purpose of this transition period is to allow for any required Contractor preparation that will allow for successful performance on this LGR3 requirement (facility, equipment, special tooling, staffing etc.).

2.1.2. Transition Phase Out: In the event of this requirement’s workload transferring to a different prime contractor/contract (termination, agreement, or completion of this contract etc.), the LGR3 contractor shall ensure cooperation with the Government and any new contractor(s), if applicable, in conducting joint wall-to-wall inventories, ensuring continuity of ongoing remanufacture operations during the transition period, executing transfer of responsibility and custody of Government Property (if any) to the new contractor and any other transition tasks as directed by the USG. The LGR3 contractor shall cooperate with a succeeding contractor to ensure an orderly transition and shall continue to manage and maintain accountability of all property in the pipeline until delivered and accepted.

2.2. General Work Requirements:

2.2.1. The general work requirements in this landing gear remanufacture effort may include, but are not limited to the following: complete disassembly, cleaning and paint removal, nondestructive inspection, reassembly, testing, repainting, machining, grinding, stripping of plated coatings, and re-plating. Contractor’s facility and equipment shall have a minimum capacity/capability to remanufacture up to 275 landing gear major assemblies per month.

2.2.2. Table 1 lists the general overview of the processes required and the frequency of occurrence. The various technical orders and process specifications listed in section 2.6 will define all of these processes. This table is not a complete list of processes. It is intended to give an idea of the processing required, refer to applicable T.O. for specific requirements.

2.2.3. It is the contractor’s responsibility to identify the affected process and comply with all applicable regulations. Many of these processes are regulated in the United States under Occupational Safety and Health Administration (OSHA) and Environmental Protection Agency (EPA) regulations. Reference to a regulated process under either OSHA or EPA is not intended to be the only regulated processes.

TABLE 1 – Work Requirements Summary

PROCESS OCCURRENCE COMMENT

1.Complete disassembly 100% Disassembly includes removal of bushings unless specifically exempted by the specific component technical order.

May require special tools and equipment to accomplish.

2. Clean and paint removal 100%

May use either abrasive blast or chemical paint removal techniques. Will produce a regulated hazardous waste stream.

3. Chrome, Cadmium, HVOF, LHE zn-ni, and anodize strip

As required Cadmium removal may require compliance with OSHA standards for cadmium exposure.

4.Non-destructive inspection (NDI) 100% initially and as required by additional processing.

The primary inspection methods are fluorescent penetrant for non-ferrous components and fluorescent magnetic particle for ferrous components. Other methods will be as required by specific component technical order. All inspectors shall be certified per NAS410, Level II. Certifying officials shall be level III certified.

4a. Temper etch inspection 100% Following grinding and/or machining of steel heat-treated above 180 ksi.

5. Hydrogen embrittlement and stress relief bakes

100% on steel heat treated over

180,000 psi following processes with potential

Bakes are either 4 or 23 hours depending on the process and usually must start within 4 hours of the embrittling process.

The usual bake temperature is 375+/-25 degrees F. Other bake criteria may be required or authorized by specific hydrogen generation.

process specifications. A bake is required following stressing operations such as grinding.

6. Evaluation 100%

Determines the further processing required. This involves visual examination of the component and various dimensional checks. A temperature controlled inspection area is required. Temperature control must be such that part tolerances can be accurately measured and maintained.

7. The following processes are typical of the processing most parts will require. The requirement is established during the evaluation.

Machining

• Grinding (based metal)

• Stripping of various electroplated and anodic coatings

• Shot peening

• Reapplication of coatings such as:

o Chrome o HVOF o Nickel Sulfamate o Electroless Nickel o Cadmium o IVD o Zn-Ni o Aluminum o Anodize o Phosphate coating o Conversion Coatings o Grinding coating to finish size

As determined by the evaluation step.

Most of these processes are governed by specifications. The process and coating must meet the specifications. The process control requirements of the specifications must be complied with (Reference the general strut technical order 4S-1-182 for use in lieu of process control).

8. Bushings Installation 100% for those components that had bushings removed during disassembly.

New bushings are required except as authorized by the specific component technical order.

9. Assembly 100% as required by the end item.

May require special tools and fixtures.

10. Test As required by the technical data.

May require special test stands and equipment.

11. Paint 100% as required by the end item.

Most components or assemblies require painting. Some minor components do not.

2.3. Remanufacture Requirements

2.3.1. The contractor shall receive, disassemble, inspect, perform complete

Remanufacture/modification/update, and test each end-item and all associated components, when applicable, to restore the item to a serviceable condition; specifically, Condition Code A, unless otherwise requested, IAW the latest version of applicable TOs.

2.3.2. Reworked component parts of the end-item shall meet Condition Code A criteria IAW the applicable technical data.

2.3.3. Serviceable precision matched or mated component parts shall be handled in a manner to ensure their reinstallation as a matched set.

2.3.4. Maintenance on the remanufacturable end-item(s) and component(s) shall be accomplished using only the applicable technical data and shall be completed IAW delivery schedule contained in section B of model contract.

2.3.5. If any applicable technical data is changed, revised, amended, or supplemented after award of contract, and an increase or decrease in work requirements is involved, the ACO and PCO shall be informed. If the change drives increased cost to any of the line items, the remanufacture cost for the affected items may be renegotiated.

2.3.6. The contractor shall check for any unauthorized or unacceptable maintenance performed on the end items by other sources. If unauthorized or unacceptable maintenance is suspected or verified, Contractor shall notify the Government Engineer, PM, ACO, and PCO.

2.3.7. In the event that an item condemns and the contractor desires to retain item, the contractor shall submit request to Government PM. Upon approval from PM, contractor is authorized to retain condemned end items for use in cannibalization down to the Shop Repair Unit (SRU) level for use in the remanufacture process.

2.3.8. Unless specifically prohibited by the controlling T.O., the contractor will be allowed to move components among repairable end items to expedite remanufacture, versus maintaining serial number integrity. When the schedule is critical and the part within the Line Repairable Unit (LRU) in work is unserviceable, the contractor shall receive approval through the Government PM in order to cannibalize SRU from LRU in order to remanufacture the LRU for the purpose of expediting deliveries. Once the cannibalization action has been completed, the unserviceable LRU must be remanufactured back to serviceable condition prior to the next end item induction. The contractor shall not remove components to the point that the end items are not repairable and require condemnation.

Any end item in work with cannibalized components must be placed in Work in Progress (WIP) unserviceable condition until supportable.

2.3.9. The contractor shall be responsible for identification, selection, ordering, and stocking of required parts to support all remanufactured items. All commercially procured parts shall be from approved sources and shall not alter the configuration of the end item. The contractor shall establish a parts control program IAW industry standards. The Government makes no representation that any previous vendor of an item will sell, or agree to sell, such articles to the Contractor. Audit trails for the manufacture of all parts must be maintained for all components procured in support of this contract.

2.3.10. Substitution of parts not listed in the TOs shall be submitted to Government Engineer and PM for approval by the cognizant Government Engineer on a case by case basis.

2.3.11. Replacement of failed parts shall not result in an item’s configuration changing to a less preferred configuration (downgrading/deconfiguration).

2.3.12. Request for Deviation (RFD) - The contractor shall submit requests for all Class I and Class II deviations, waivers, and non-conformances for new and remanufactured parts (see instructions below). Refer to MIL-HDBK-61A table 6-2 for information on criteria used to classify changes. Guidelines for preparing a Request for Deviation (RFD) may be found in MIL-HDBK-61A and ANSI/EIA-649. A RFD shall be prepared in accordance with CDRL A0003 and providing the information using DD form 1694. All changes, both Class I and Class II, must be submitted for review. No shipments of material under this contract shall be authorized until such time as the requests for deviations have been approved by the appropriate office. In the event that a RFD is prepared, the following steps shall be followed:

• Step 1- Contractor shall draft RFD and send to Hill Engineering, PM, ACO, and PCO for review.

• Step 2- Hill Engineering and PM shall review/approve RFD and Contracting Office shall send final approval to Contractor prior to RFD related work commencing.

• Step 3- Contractor shall complete work.

2.3.13. Contractor shall maintain an archive of completed RFDs that may be requested by the government during the contract.

2.3.14. Contractor shall submit a request for T.O. change (Form AFTO22) for items which have been identified as having a recurring non-conformity and have not been incorporated into a T.O. change, IAW (CDRL A001).

2.3.15. Receipt of Property at Contractor Facility

2.3.16. HANDLING: The contractor shall exercise care to prevent damage to GFP while in its possession.

2.3.17. The contractor shall store all GFP in a secure area to provide protection against damage, pilferage, or loss. Storage areas shall provide protection against all adverse environmental conditions. Costs associated with such storage shall be included in the cost of the end item remanufacture.

2.3.18. Reusable shipping containers, packaging, and crating material in which the GFP is received shall be handled with care. The contractor shall package all end items IAW Special Packaging Instructions (SPI) data. The contractor may choose to reuse existing packaging and accomplish any associated repair of such packaging, or build new packaging. The existing container shall be marked with the current NSN configuration (part number) of item being shipped. The contractor shall be responsible for ensuring that containers are in serviceable (reusable) condition. The costs associated with such containers shall be included in the cost of the end item remanufacture.

2.3.19. INVENTORY INSPECTION: An inspection shall be performed on the end-item upon its receipt at the contractor’s facility for the following:

• Proper identity

• Damage

• Completeness (item physical configuration).

• Any deficiencies found as a result of the above inspection shall be brought to the attention of the ACO/PCO and PM, and disposition shall be as directed through the

ACO/PCO (IAW CDRL A005).

2.3.20. The contractor shall capture information from the AFTO 95 attached to the item to include but not limited to; flight hours, installed/removed dates, TCTOs adverse events etc. This information shall be compiled using (CDRL A004).

2.3.21. Condemnations on End Item

2.3.21.1. Authorization to accomplish condemnation shall be obtained through the

Government engineer; however, the ACO, PCO, and PM shall be included in request/approval corrospondance. This applies to any end item(s) determined to be uneconomical to return to a serviceable condition (FAR Part 45.6, DFAR part 245.6, DOD 4160.21-M-1, DOD 4100.39-M). It shall be considered uneconomical to accomplish remanufacture on an end item when the total cost for parts, materials, and labor exceed 75% of the applicable Stock List Price. In some cases the Air Force Engineer and Air Force PM may elect to perform remanufacture efforts that exceed an economical repair cost based on logistics constraints even in cases where this limit is exceeded. If the asset reaches the point where it is beyond economical repair (BER) , the contractor shall submit an RFD to the Engineer. If the engineer concurs and the end item includes salvageable GFM component parts, the PM will provide disposition instructions for the salvageable parts. The contractor will submit the WR to include costs incurred to the point of condemnation and the cost to salvage GFM component parts. Salvaged GFM components shall be identified and reported to Hill AFB Program Office.

2.3.22. Condemnation of Sub-components/GFM Replacement

2.3.22.1. At the completion of the Disassembly and Inspection (D&I) process, certain sub-components of an end item assembly may be condemned. If the sub-component is condemned the condemnation shall be reported in CAVAF. If the condemned sub-components are to be supplied as GFM under the terms of the contract, contractor will requisition the necessary parts through normal USAF procedures (See Appendix B).

The remaining reparable components will proceed through the remanufacture line. If at the end of the remanufacture process, GFM is not available and information received from the PM reveals that the parts will not become available in the near foreseeable future; the remanufactured components of the end item assembly will be boxed, properly marked and returned per disposition instructions provided by the PM or the component part may be remanufactured. This will be handled on a case-by-case basis utilizing the over and above procedures.

2.3.23. Other Direct Costs

2.3.23.1. Receipt, Storage & Shipment of end Items and GFM: All incoming USAF material is received and secured at contractor’s expense at a primary or supplemental address central location. All outgoing USAF shipments will be shipped each week per the direction of the Government utilizing a Government Bill of Lading (GBL) or as otherwise directed. The USAF will only be responsible for shipping costs incurred within the Continental United States (CONUS), all other shipping related costs will be at the contractor’s expense. Additionally, the Government will not ship any GFM or end items Outside the Continental United States (OCONUS). The contractor shall be responsible for any applicable OCONUS shipping.

2.3.23.2. The contractor shall provide any and all parts support other than GFM at their own expense (as Contractor Furnished Material (CFM)).

2.3.23.3. Misdirected and Mis-identified Material: Upon receipt of misdirected or mis-identified material, contractor shall submit a Supply Discrepancy Report (SDR) in the WEB SDR system. In the event that the contractor cannot access WEB SDR, then the Report of Discrepancy (ROD) shall be submitted to the Government PM for disposition.

2.4. Deliverable Data Requirements

2.4.1. REPORTING REQUIREMENTS: Reporting and data requirements are identified in the

Contract Data Requirements Lists (CDRL), DD Forms 1423-1.

2.4.2. The Contractor is required to use the Government system Commercial Asset Visibility Air

Force (CAVAF) in order to provide status of maintenance production, asset management, condemnations, problems encountered, accountability and stock balances of GFP end items and financial accounting and inventory control of GFM. All processes identified in the Commercial Asset Visibility Air Force Contractors Training Guide must be accomplished IAW (CAV-AF Statement of Work) (IAW CDRL A008).

2.4.3. The contractor shall use the AFTO 95 to document remanufacture information to each item

(IAW CDRL A004).

2.4.4. The contractor shall create an Asset Status Report (ASR) that tracks each end item through the remanufacturing line. The ASR should be submitted to the PM weekly (IAW CDRL A002). This report shall include a listing of all National Stock Numbers (NSNs) on hand by condition code [i.e. A = serviceable; F = reparable; G = awaiting parts; M = in work].

2.4.5. The contractor shall establish capability to advise the PM of errors or omissions and other recommended changes to T.O.’s of technical nature, which prevents performance of functions required for mission accomplishment. Submit AFTO Form 22 to PM on a monthly basis, unless a work stoppage is generated, in which case submit report within 24 hours of discovery. (IAW CDRL A001).

2.4.6. The contractor shall seek disposition through the PCO from USAF Engineering when an asset is found to exceed the remanufacture limits established in the applicable T.O. (s) Also see Terms Explained for RFD). (IAW CDRL A003)

2.4.7. Product Quality Deficiency Report (PQDR). The SF 364 form (see attachment #7) or other approved format shall be used to record and transmit product quality deficiency data. This Data is information (based on objective evidence) provided by an activity concerning unsatisfactory (government or contractor) materiel. The data can be as simple as the originating point’s internal report form that initially recorded the deficiency. Of prime importance is the requirement for documentation which is based on direct examination, test, procedural review, etc. (IAW CDRL A005)

2.5. Time Compliance Technical Order (TCTO)

2.5.1. The contractor shall comply with urgent action, immediate action, and safety TCTOs which are due to rescind and are supportable with kits/parts (if applicable) that are outstanding or generate while the landing gear components are in work.

2.5.2. The contractor shall accomplish all TCTOs specified by the Delivery Order.

2.6. Technical Orders and Other Directives

2.6.1. Technical Data Requirements: The contractor shall comply with the latest dated T.O.s and other directives used or issued during the time the work is being accomplished and perform a timely review of all updated T.O.s and other directive changes applicable to the work requirement. The review will consider the impact on work requirements, cost, and schedules with backup data for those changes. Increases or decreases in work, which impact the maintenance facility or the government, will be sent to the PCO. Over and Above procedures may apply in singular type events, or requests for equitable adjustments if it can be shown that there was a significant cost increase due to Government changes to the T.O.s;

however, in the event that the change is not secluded and will apply downstream to more remanufactures, a negotiation may be utilized to update remanufacture pricing for applicable NSNs in basic contract.

2.6.2. General Technical Orders:

TO Table 2 General TOs 4S-1-182 General Overhaul and Maintenance Instruction, Aircraft Landing Gear

Components.

00-35D-54 USAF Deficiency Reporting, Investigation, and Resolution, 33B-1-1 Nondestructive Inspection Methods

33B-1-2 Nondestructive Inspection Methods, General Procedures and Process Controls

1-1-1 Operation Instructions, Cleaning Of Aerospace Equipment

1-1-8 Application and Removal of Organic Coatings Aerospace and Non Aerospace Equip

1-1A-8 Structural Hardware

1-1-691 Cleaning and Corrosion Prevention Control, Aerospace and Non Aerospace Equip

00-5-1 AF Technical Order System

00-20-1 Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures

00-20-2 Maintenance Data Documentation

00-20-5 Covers processing of AFTO 95’s

00-25-260 Asset Marking and Tracking Item Unique Identification (IUID) Marking Procedures

00-25-195 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems

44B-1-2 General Maintenance Instructions – Airframe Antifriction Bearings

00-25-234 General Shop Practice Requirements for the Repair, Maintenance and Test of Electrical Equipment

1-1-4 Air Force Standard Exterior Finishes

1-1-2 Corrosion Control and Treatment for Aircraft and Missiles

2.6.3. Aircraft Specific T.O’s:

TO Table 3 KC-135 Technical Orders

4A4-12-3 Overhaul NG Installation 4A4-12-4 IPB NG Installation

4A4-12-23 Main Landing Gear Installation 4A4-12-24 IPB, Main Landing Gear Installation 4A4-29-4 Illustrated Parts Breakdown 4A4-30-3 Overhaul Instructions, Depot Level, Truck Assembly, Brake Collar

Assembly 4S1-49-3 Maintenance/Overhaul, Intermediate/Depot with IPB, Main Gear Snubber

Assembly 4S1-56-3 Depot Main Gear Oleo Assemblies 4S1-56-4 IPB, Main Gear Oleo Assemblies

4S1-56-13 Depot Level Overhaul, Main Gear Accessories C/KC-135 Aircraft 4S1-56-14 IPB, Main Gear Accessories C/KC-135 Aircraft 4S1-110-3 Overhaul Instructions, Depot Level, Shock Strut Assembly, Torsion Link

Assembly 4S1-118-3 Depot Level, Overhaul Instructions, Side Strut Assembly 4S1-119-3 Overhaul Instructions, Depot Level, Trunnion Assembly 4S-1-182 General Overhaul and Maintenance Instructions, Aircraft Landing Gear and Components 4S2-30-3 Overhaul Nose Gear Strut Assemblies with IPB

4SA3-7-13 Overhaul with IPB Steering Metering Valve Assembly KC-135 Aircraft 4SA6-5-3 Overhaul Instructions with IPB, Nose Gear Drag Brace Assemblies

4SA6-33-3 Overhaul Instructions Depot Level Drag Brace Assembly 9H2-2-39-3 Maintenance/Overhaul and IPB, Main Gear Centering Cylinder Assembly 9H2-3-30-3 Overhaul Instructions with IPB, Nose Wheel Steering Cylinder Assemblies

TO Table 4 C-130 Technical Orders 4S1-37-3 Overhaul Instructions, Strut Assembly MLG shock

4S1-37-4 Strut Assembly, MLG shock

4S1-69-13 Overhaul Instructions, with Parts Breakdown, Strut Assembly MLG Torque

4S2-23-3 Strut Assembly MLG

4S2-23-4 IPB, Strut Assembly NLG

4SA3-26-3 Overhaul with Parts Breakdown, Valve Assembly NLG steering

4SA6-7-3 Overhaul Instructions with Parts Breakdown Brace Assembly NLG

9H2-2-80-3 Overhaul Instructions with Parts Breakdown Cylinder Assembly Drag Strut

NLG

TO

Table 5 E-3 Technical Orders

4A4-24-13 Overhaul Instructions with IPB, Nose Landing Gear Major Assemblies

4A4-25-3 Overhaul Instructions with IPB, Main Gear Truck Assembly

4BA4-116-3 Steering Metering Valve Assembly

4S1-102-3 Overhaul Instructions with IPB Main Gear Oleo Assembly

4S1-103-3 Overhaul Instructions with IPB, main Gear Centering Cylinder and Snubber Assembly

4S1-104-3 Overhaul Instructions with IPB, Main Landing Gear Side Strut Actuator assembly

4S1-105-3 Overhaul Instructions with IPB, Main Gear Actuator Beam Assembly

4S1-106-3 Overhaul Instructions with IPB, Main Gear Side Strut Assembly

4S1-107-3 Overhaul Instructions with IPB, Main Landing Gear Major Assemblies

4S2-78-3 Overhaul Instructions with IPB, Gear Oleo Assembly

4S2-79-3 Overhaul instructions with IPB, Nose Gear Drag Brace Assembly

4SA2-51-3 Overhaul Instructions with IPB, Nose Wheel Steering Cylinder Assembly

44B-1-102 Maintenance Instructions Antifriction Bearings

2.6.4. The contractor shall be responsible to maintain an account with the applicable Technical

Order systems with electronic access. Tech data may be kept in paper and/or electronic versions. Refer to TO 00-5-1 for directions on maintaining a technical order account. See below paragraphs for procedures on accessing this system.

2.6.5. The contractor must establish a TODO account by processing an AFTO Form 43, (TODO) Assignment or Change Request. The IBM Lotus version of the AFTO Form 43 can be downloaded at http://www.e-publishing.af.mil/. Air Force Portal access procedures are found at https://my.af.mil, including the need for, at a minimum, a favorable National Agency Check (NAC).

2.6.6. Because ETIMS access is required to establish and manage TODO accounts, prospective TODO POCs must first obtain a CAC or an External Certificate Authority (ECA) with a minimum of a favorable national agency check (NAC) to establish Air Force Portal access needed for ETIMS. Procedures for contractors to obtain an ECA certificate are found at:

16C1-12-10-

Hydraulic Brake Assembly, MLG

16G1-151-3 Overhaul Instructions with Parts Breakdown MLG Gear Box Assembly

16G1-152-3 Overhaul Instructions with Parts Breakdown Manual Gear with Brake

16G1-182-

3WA-1

Gear Box Assembly MLG

16G3-2-87-

Overhaul Instructions with Parts Breakdown MLG Ball Screw Assembly and Ski Ball Assembly

9H2-3-12-3 Overhaul Instructions Nose Landing Gear Steering Cylinder Assembly

9H2-3-12-4 IPB, Nose Landing Gear Steering Cylinder Assemblies http://www.e-publishing.af.mil/ https://my.af.mil/ http://iase.disa.mil/pki/eca/certificate.html The AF portal ID of the prospective, primary TODO POC is entered into block 6 of the AFTO Form 43. The designated Contracting Officer representative must confirm an approved DD Form 2345, Militarily Critical Technical Data Agreement (AFI 61-204, Disseminating Scientific and Technical Information) is on file prior to approving the AFTO Form 43. The approved AFTO Form 43 is then submitted to the AFLCMC/EZGTP using the following email address:

aflcmc.ezgtp.afto43@us.af.mil. If government support contractors maintain a separate company-owned TO library, the company shall process a separate AFTO Form 43 to establish the contractor owned and operated TODO. NOTE: Once contractor TODO accounts are established, the contractor TODO uses ETIMS to directly order and receive the TOs required under the contract.

2.6.7. TODO Actions(per TO 00-5-1 4.3.4.1 and .2): Upon receipt of the approved AFTO Form 43, the primary TODO should access and use the ETIMS account associated with the JCALS TM account number on the AFTO Form 43 to establish and manage their unit’s TO/eTO requirements.

2.6.8. The contractor shall be responsible to acquire technical drawings as required. This data may be acquired by request through the contracting officer.

2.6.9. Technical order/manuals, technical directives and other applicable publications required to accomplish the work effort, but not in possession of the contractor, shall be acquired as authorized and directed by the ACO. NOTE: Primary source for military specifications and standards is: https://assist.daps.dla.mil/quicksearch

2.6.10. High Velocity Oxygenated Fuel (HVOF) Requirement

2.6.11. HVOF coating is preferred in each instance where it is indicated as optional in the applicable TO. The applicable current drawings are listed below:

-AF Drawing 200310641 (98747) Coatings, Tungsten Carbide on High Strength Steel Using High Velocity Oxygen Fuel (HVOF) Process -AF Drawing 200310642 (98747) Grinding of High Velocity Oxygen Fuel (HVOF) Sprayed Tungsten Carbide Coatings.

https://assist.daps.dla.mil/quicksearch

Section III

3. Government Furnished Property (GFP)

3.1. All items necessary for the performance of this contract not listed in the Appendix B will be the responsibility of the contractor.

3.2. Please note, no Government Furnished Equipment (GFE) will be provided.

3.3. The contractor must report all condemned GFM items through CAVAF reporting at the time of condemnation IAW CAVAF requirements.

Section IV

4. General Information

4.1. Quality Control

4.1.1. Quality Control Program. In compliance with the clause entitled “Inspection of Supplies”, FAR 52.246-2, the contractor shall establish a complete Quality Control Program to ensure the requirements of this contract are provided as specified.

4.1.2. Higher-Level Contract Quality Requirement. In compliance with clause FAR 52.246-11, the Contractor’s Quality Control Program shall comply with ISO 9001and/or AS 9100 compliance or equivalent.

4.1.3. Quality Deficiencies: The quality deficiency rate shall be < 5% of total assets remanufactured in 1 year . The contractor shall provide full cooperation with USAF personnel when Quality Deficiency Rates (QDRs) are identified. No instances of substantiated reports of interference from the contractor with QA inspections conducted by USAF/DCMA personnel will be allowed.

4.1.4. Prior to shipment of completed remanufactured end items, each asset shall pass 100% Acceptance Test Specifications. In the event of failure affecting delivery schedule, notify DCMA liaison and Hill AFB Procuring Contracting Officer (PCO) and the Hill AFB Program Manager (PM) of schedule changes within 24 hours.

4.1.5. Product Quality Deficiency Reports (CDRL A005) PQDRs: The contractor will comply with instructions contained in chapter 3, TO 00-35D-54, USAF Deficiency Reporting, Investigation, and Resolution, and the Joint DLAD 4155.24/AR 702-7/SECNAVINST 4855.5B/AFI 21-115, Product Quality Deficiency Report Program. These documents provide the policy and procedures for reporting, receiving, investigating, and resolving PQDRs. This directive implements Federal Acquisition Requirements for the reporting of product quality deficiency data as required by 41 C.F.R. 101. This directive establishes a system for feedback of product quality deficiency data across Military Service, Defense Logistics Agency, and Government Services Administration (GSA) lines in order to conduct reporting, investigation, cause correction, and management of individual product quality deficiencies, as well as to identify problems, trends, and recurring deficiencies. The contractor will cooperate fully with USAF and DCMA personnel in the investigation of all quality deficiencies. In addition, the contractor will track and measure all quality deficiency reports for the weapon systems involved in this acquisition.

4.2. Safety and Health

4.2.1. 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 Government Representative (GR), 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.

4.2.2. Mishap notifications shall contain, as a minimum, the following information:

• Contract, Contract Number, Name and Title of Person(s) Reporting

• Date, Time and exact location of accident/incident

• Brief Narrative of accident/incident (Events leading to accident/incident)

• Cause of accident/incident, if known

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

• Nomenclature of equipment and personnel involved in accident/incident

• Corrective actions (taken or proposed)

• Other pertinent information

4.2.3. If requested by the designated GR, the contractor shall immediately secure the mishap scene/damaged property and impound pertinent maintenance and training records, until released by the Procuring Safety Office.

4.3. Program Management Review (PMR) Frequency

4.3.1. A PMR will be held bi-annually, as dictated by the PM and may involve alternate venues.

The purpose of the PMR is to review cost/schedule/performance metrics and address significant program/technical issues. The agenda shall be prepared by contractor and coordinated with the USAF. The agenda shall be provided NLT fourteen days prior to meeting; minutes/action items shall be provided within seven working days after the meeting. All action items shall be tracked until closure or resolution. The PMR must address program risks and avenues or alternatives for mitigation. (Ref CDRLs A006 & A007).

4.3.2. Program Status Reporting will be bi-weekly at a minimum and the contractor shall conduct teleconferences with USAF/DCMA personnel to address any/all relevant issues. The agenda shall be prepared by the contractor and coordinated with USG. The agenda shall be provided twenty-four hours in advance; the minutes shall be provided within two working days after the conclusion of the teleconference. The Weekly Status Report (Ref CDRL A002) shall be delivered NLT the last week day of each month, highlighting program progress, status, and risk/problem areas.

4.4. MICAP, Critical Items and Surge:

4.4.1. In the event that the DoD experiences an unplanned spike, sudden increase in demand due to major theater warfare, or a national emergency (also known as surge), the contractor shall work to meet and sustain this demand for quantity levels above and beyond normal peacetime requirements. After being notified of the surge demand in writing, the contractor will allow the DoD to place additional orders and/or elevate the priority status of current orders.

4.4.2. USAF will provide contractor with a weekly priority list detailing (MICAPs) and Joint Chief of Staff (JCS) or other high priority backorders. In response, contractor shall provide the USG PM with a weekly projected 4-week production delivery schedule (Ref CDRL A002). Contractor shall to the maximum extent possible comply with Government priority list.

4.4.3. The Surge contract line item will be used to support Accelerated Delivery Requests (ADRs) for MICAP, JCS and other high-priority backorders that cannot wait for the normal remanufacture CLIN delivery time frames of 60 days ARO induction. The contract line items will be funded when there exists a need to expedite remanufacture through the contractor facility in order to support ADR requirements as directed by the government.

Upon activation of the ADR procedures, contractor will provide USG with an Estimated Delivery Date (EDD) for each item within one working day. The contractor shall, to the maximum extent possible, expedite delivery. If the EDD is not satisfactory, the PM will request contractor to provide an amended schedule.

4.5. Over and Above Procedures

4.5.1. In accordance with DFARS PGI 217.77, negotiations shall be in IAW DFARS Clause

252.217.7028. Request for consideration of over and above shall be made in writing utilizing procedures identified below.

4.5.2. Work Requests (WRs): Contractor shall identify any work that is required which would qualify as “over and above” IAW DFARS 252.217-7028. In the event that over and above work is identified, the Contractor shall prepare a Work Request (WR). The following steps shall be followed:

• Step 1- Contractor shall prepare a Work Request.

o Each Work Request shall include at a minimum the following: Contract/delivery order, description of the work to be completed, estimated additional cost and hours, justification for WR.

• Step 2- Contractor shall send Work Request to Hill Engineering, PM, ACO, and PCO for review.

• Step 3- Hill Engineering and PM shall review/approve work request(s) and Contracting Office shall send final approval to Contractor prior to O&A related work commencing.

Section V

5. TERMS EXPLAINED:

Accelerated Delivery Request (ADR): AFMC Form 200, used to process accelerated delivery requirement to support high-priority backorders and MICAPs.

Acceptance Test Specifications (ATS): as spelled out in applicable Technical Orders.

Administrative Contracting Officer (ACO): Contracting officer who performs actions delegated by the Procurement Contracting Officer at the initiating activity.

Assembly: Two or more parts or subassemblies joined together to form a complete unit, structure, or other article.

Air Force Technical Order (AFTO): Authorized manual directing and providing instructions for performing work on Air Force assets.

Batched Repairs: Repaired items are not reported as complete or shipped until a pre-determined quantity of items is produced.

Beyond Economical Repair (BER): When the total cost for parts, materials, and labor exceed 75% of the applicable Stock List Price

Cannibalization: Removal of a specific assembly, subassembly, or part from one weapon system, support system, or equipment end-item for installation on another end-item to meet priority mission requirements with an obligation to replace the removed item.

Class I Change: Any change to the design of an item that affects form fit or function. Any ambiguity concerning defining a change as Class I or Class II shall be decided by the government engineer.

Class II Change: No change to form fit or function of an item. Any ambiguity concerning defining a change as Class I or Class II shall be decided by the government engineer.

Commercial Asset Visibility Air Force (CAVAF): The primary system of record under this contract for providing status of all Government owned assets located at contractor repair facilities.

CAV AF allows commercial contract repair facilities to report End Item repair and GFM transactions on a daily basis. CAV AF shall be the management control authority (MCA) for contract repair End Items and GFM located at contractor facilities. The connection between CAV AF and commercial facilities shall be via the internet.

Condition Code A: Serviceable asset.

Condition Code F: An asset that is repairable to code A.

Contract Line Item Number (CLIN): Contracts may identify the items or services to be acquired as separately identified line items. Line items may be further subdivided or stratified for administrative purposes (e.g., to provide for traceable accounting classification citations).

Contracting Officer (CO): means a person with the authority to enter into, administer, and/or terminate contracts and make related determinations and findings.

Component: Subsystem, assembly, subassembly or other major element of an end item.

Contractor Furnished Material (CFM): Contractor furnished material to complete remanufacture of end items.

Defect: Any nonconformance to specified requirements.

Disassemble: To remove the components that make up the end-item in accordance with disassembly instructions in the government approved contractor technical data.

Disassembly & Inspection (D&I): Process to determine what is required for repair of the end item or repair/replacement of components.

Electronic Technical Order (eTO): See Technical Order, electronic version.

Engineering Change Proposal (ECP): See Non Conformity Report.

Estimated Delivery Date (EDD): Estimated date of asset delivery.

External Certificate Authority (ECA): Certificate required in order to process government AFTO Form 43 (to set up a Technical Order Distribution Office).

Federal Supply Classification (FSC): First 4 numeric digits of the NSN.

Government Furnished Equipment (GFE): Tangible asset that is functionally complete for its intended purpose, durable, and nonexpendable. (see FAR part 45.101). For the purpose of this TRD, GFE are items such as machinery, tooling, fixtures, booths etc.

Government Furnished Material (GFM): “Material” means property that may be consumed or expended during the performance of a contract, component parts of a higher assembly, or items that lose their individual identity through incorporation into an end-item. Material does not include equipment, special tooling, and special test equipment (see FAR part 45.101).

Government Furnished Property (GFP): Property in the possession of, or directly acquired by, the Government and subsequently furnished to the contractor for performance of a contract (see FAR part 45.101). For the purposes of this TRD, property Includes materials, equipment, carcasses provided to the contractor.

Government Quality Assurance Representative (GQAR): Quality inspector for government.

Joint Chief of Staff (JCS): JCS backorders are not MICAPs, but carry a very high priority and require treatment as with MICAPs.

Line Repairable Unit (LRU): A line repair unit at the end item level.

Landing Gear Repair 2 (LGR3): Title used to refer to competitive effort.

Mission Impaired Capability Awaiting Parts (MICAP): The status of a weapon system, as determined by its ability to accomplish its assigned mission. MICAP situations are a grounded aircraft in need of an immediate serviceable asset or repair.

National Agency Check (NCA): A form of documentation involved in setting up a Technical Order Distribution Office.

National Item Identification Number (NIIN): Last nine numeric digits in the NSN

National Stock Number (NSN): The 13-digit stock number replacing the 11-digit Federal Stock Number. It consists of the 4-digit Federal Supply Classification code and the 9-digit National Item Identification Number. The National Item Identification Number consists of a 2-digit National Codification Bureau number designating the central cataloging office (whether North Atlantic Treaty Organization or other friendly country) that assigned the number and a 7-digit (xxx-xxxx) nonsignificant number. The number shall be arranged as follows: 9999-00-999-9999.

Nondestructive Inspection (NDI): Methods for investigating the quality, integrity, properties, and dimension of material and components without damaging or impairing their serviceability.

Remanufacture: The restoration of an item to a completely serviceable condition as prescribed by applicable technical data.

Product Quality Deficiency Report (PQDR): A tool to report or respond to deficiencies found with either repair/remanufacture or new manufacture of the end product.

Program Management Review (PMR): Biannual review with contractor and government personnel to review contract status and to address all issues from both sides.

Program Manager (PM): Government Individual responsible for the overall program or project.

Quality Assurance (QA): Policies and procedures adopted by the government to ensure that supplies and services acquired under government contracts conform to the contract’s quality and quality requirements.

Quality Deficiency Report (QDR): Report citing the details of any quality deficiency.

Repairable: Capable of being restored to serviceable condition.

Repair to Demand: Contractor reports and ships repaired items as they are completed, rather than “batching up” larger quantities and waiting to ship until the larger quantity is produced.

Request for Deviation (RFD): A report provided to the USAF engineer when a disposition is required because a part is not in conformance with the specifications defined in the Technical Order (reported via DD form 1694).

Safety of Flight (SOF): When a failure or malfunction would present a hazardous condition to equipment or personnel during preflight, in-flight, or post flight operations. Safety of Flight (SOF) is An Agency imposed requirement, and pertains to aircraft items whose absence or failure would likely result in the loss of and/or serious damage to the aircraft and/or serious injury or death to the occupants during pre-flight, flight, or post flight operations.

Serviceable (Condition Code A): New, used, repaired, remanufactured or reconditioned material which is serviceable and issuable to all customers without limitation or restriction. Includes material with more than 6 months of shelf life remaining.

Shop Repairable Unit (SRU): A shop repair unit at the component level

Stock List Price (SLP): Refers to the cost to buy a brand new item.

Support Equipment: Tooling or equipment utilized by personnel during the servicing, repair or manufacture of a component or an end item that does not become part of the component or end item.

Technical Data: All government and contractor drawings, specifications, standards, Technical Orders (T.O.s), technical manuals, and all other technical publications necessary to restore an item to a serviceable condition.

Technical Order (TO): See Air Force Technical Order (AFTO)

Technical Order Distribution Office (TODO): Function required to maintain records on TOs received and distributed

Time Compliance Technical Order (TCTO): Authorized method of providing instructions for modifying equipment, and performing or initially establishing one-time inspections.

Unserviceable: An item in a condition unfit for use but which can be restored to a serviceable condition after repair, rework, or Remanufacture. This condition includes items requiring calibration, test, modification, assembly, or the addition of components.

Wide Area Work Flow (WAWF): is a paperless contracting DoD-wide application designed to eliminate paper from the receipts and acceptance process of the DoD contracting life cycle.

Work Request (WR):…