AMXGOI 21-7.pdf

UNCONTROLLED DOCUMENT WHEN PRINTED

DEPARTMENT OF THE AIR FORCE 309AMXG Operating Instruction 21-7

OGDEN AIR LOGISTICS CENTER (AFMC)

th

Aircraft Maintenance Group (309 AMXG)

Hill AFB, Utah 84056 3 December 2008

Maintenance

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY OF

AIRCRAFT PARTS/COMPONENTS

Supersedes: MABOI 21-7, 15 October 2004

OPR: 574 AMXG/ (Ken Songer) Certified by: 309 AMXG/OBR

Distribution: F Pages: 8

This operating instruction (OI) defines the requirements, procedures, and responsibilities within the th

Aircraft Maintenance Group to prevent damage, loss, or deterioration of parts/components removed from aircraft during the depot production process. Detailed instructions are contained in referenced publications. This OI serves to aggregate those publication requirements and other requirements unique to 309 AMXG, and to reflect and portray the overall program. This OI supports the 309 AMXG Quality System.

SUMMARY OF REVISIONS:

This revision changes the office symbols and format. An asterisk (*) indicates revisions from the previous edition.

1. SCOPE:

1.1. This OI is restricted to those requirements, procedures, and responsibilities of 309 AMXG production and support personnel. Procedures and requirements for Defense Logistics Agency (DLA) and OO-ALC/MMXG personnel (including those matrixed to 309 AMXG) are comprehensively documented and fall under these agencies’ jurisdictions.

1.2. The requirements, procedures, and responsibilities for the aircraft, aircraft systems, and installed components are not addressed. They are adequately covered in technical orders (TOs), process orders

(POs), and work control documents (WCDs). All explosives will be identified, handled, removed, packaged, and stored to prevent degradation and will be controlled by the designated personnel in production/SSC in accordance with established TOs and local operating procedures. The inspection, removal, and installation of MK-13/124 MOD O flares, inflation actuators, booster charges, delay cartridges, distress signal kits, reefing line cutters, locking cord cutters, UWARS release, and

SEAWARS release will be performed in accordance with TOs 14D3-10-1, 14D3-11-1, 14S-1-102, 14S1-3-51, 14S1-11-3, 15X11-19-2 and 11P10-6-7. This publication is focused on parts and components that are removed from the aircraft.

2 AMXG OI 21-7 3 December 2008

2. Applicable Technical Orders And Regulations:

2.1. EOI NO. AMXG OI 91-201-01, Storage and Handling of Egress Explosives in Building 223

2.2. TO 1F16 ()-2-95JG-10, F-16 Ejection Seats

2.3. TO 1F16 ()-2-95JG-20, F-16 Canopies

2.4. TO 1A10A-2-95JG-10, A-10 Ejection Seats

2.5. TO 11A-1-46, Uninstalled Explosives

2.6. Air Force Manual 91-201, Explosives Safety Standards

2.7. EO1 NO. AMXG OI 91-201-02, Fire Extinguisher System and Guillotine Squibs

2.8. TO 1A-10A-2-27JG-7, Environmental Control System, Fire Extinguisher System

2.9. TO 1C130H-2-26JG-20-1, FIRE PROTECTION Fire Extinguishing System

2.10. TO 1C-130H-2-28JG20-2, Fuel System Distribution, In-Flight Refueling

2.11. NAVAIR 11-100-1.1, Cartridge Activated Devises (CADS) and Propellant Activated

Devices (PADS)

2.12. EOI NO. AMXG OI 91-201-03, Maintenance of Escape System Assemblies(ACES II

Ejection Seats)

2.13. AFMCI 21-122 HAFB, Supplement 1, Foreign Object Damage (FOD) and Dropped Object

(DO) Awareness and Prevention Program & 309 AMXG Operating Instruction 21-122FOREIGN

OBJECT DAMAGE (FOD)/DROPPED OBJECT PREVENTION (DOP) PROGRAM

2.14. TO 13A5-56-11

2.15. AFOSH STD 91-66

2.16. Applicable 11p and 11a Series TOs

2.17. AFOSH STD 91-501, Air Force Consolidated Occupational Safety Standard

AMXG OI 21-7 3 December2008 3

2.18. EOI NO. AMXG OI 91-201-04, Transportation, Storage, and Handling of Explosive

Devices in Prep For Flight.

2.19. AFMAN 91-201HAFB SUP 1, Explosives Safety Standards

2.20. HAFBI 91-201, Ammunition and Explosives Movement

2.21. EOI NO. AMXG OI 91-201-05, Pylon/Tank Carts

2.22. TO 1F-16 ()-33-1-2, Non-nuclear Munitions Basic Information and Loading Procedures

2.23. TO 1A-10A-33-1-2, Non-nuclear Munitions Basic Information and Loading Procedures

2.24. EOI NO. AMXG OI 91-201-06, F-16 Seat Removal/Installation

2.25. EOI NO. AMXGOI 91-201-07, F-16 Canopy Removal/Installation/Maintenance

2.26. EOI NO. AMXG OI 91-201-08, F-16 ECRL/DTA Lines .

2.27. EOI NO. AMXG OI 91-201-09, Remove and Install A-10 Ejection Seat

2.28. EOI NO. AMXG OI 91-201-10, Transportation of ACES II Ejection Seats and F-16

Canopies

2.29. TO 11N-W80.83-2, Ground Handling Procedures AGM-86 Missile

2.30. T. 11N-W80.85-2, Ground Handling Procedures AGM-129 Missile

2.31. TO 21M-AGM-86-2-1, Maintenance Instructions Organizational-USAF Series AGM-86

Missile

2.32. TO 21-AG129-2-1, Organizational Maintenance Instructions AGM-129 Missile

2.33. TO 21M-AGM-86-23, System Peculiar Corrosion Control, USAF Series AGM-86 Missile

2.34. TO 21-AG129-23, System Peculiar Corrosion Control USAF Series AGM-129 Missile

2.35. TO 11A15-1-437, Ordinance Handling

2.36. EOI NO. AMXG OI 91-201-16, Inspection, Removal and Installation of MK-13/124 MOD O

Flares, Inflation Actuators, Booster Charges, Delay Cartridges, Distress Signal Kits, Reefing Line

Cutters, Locking Cord Cutters, UWARS Release. (This operating instruction prescribes step-by-

4 AMXG OI 21-7 3 December 2008 step instructions for a safe and efficient operation in the process of inspection, repair, removal, and installation of survival kits, parachutes, and life raft accessory kits with installed explosives.)

2.37. AFOSHSTD 91-46, Material Handling and Storage of Equipment

2.38. TO-25-234, General Shop Practice for the Repair, Maintenance and Test of Electrical

Equipment

2.39. TO 1-1A-14 (Section 3, Paragraph 3 – 52 020 00), Protection of Electrical Connectors

Electrical Connector and Waveguide Protection and Stowage

2.40. TO 00- 85-20, Engine Shipping Instructions

2.41. AFMCI 24-201, AFMC Packaging and Materials Handling

2.42. AFMCR 65-8, ESD Control Program & Program309 AMXG Operating Instruction 21-234

AIRCRAFT GROUP ELECTROSTATIC DISCHARGE CONTROL PROGRAM

2.43. AMXG OI 21-12, Condition Tagging and Labeling of Air Force Material

2.44. AMXG OI 21-234, Aircraft Maintenance Group Electrostatic Discharge Program

2.45. AMXG OI 24-301, Vehicle Control

2.46. AMXG OI 21-122, Foreign Object Damage (FOD) Prevention Program

2.47. AMXG OI 31-2, Securing Aircraft Classified Documents

2.48. AMXG OI 21-3, Structure Deficiency Reports, Aircraft/Engines Acceptance Deficiency

Reports and Navy Acceptance Deficiency Reports

2.49. AMXG OI 15-102, Severe Weather and High Wind Conditions

2.50. If conflicting instructions are provided by WCDs, item-specific directives or TOs will take precedence over this OI.

2.51. T.O. 00-20-1, Aerospace Equipment Maintenance Inspection, Documentation, Policies, and

Procedures

2.52. T.O. 00-20-2, Maintenance Data Documentation

2.53. T.O. 00-20-3, Maintenance Processing of Repairable Property and the Repair Cycle Asset

Control System

AMXG OI 21-7 3 December2008 5

3. General Responsibilities and Requirements:

3.1. 309 AMXG production personnel will comply with this OI and referenced publications to ensure all aircraft parts/components are guarded against damage, loss, and deterioration during depot maintenance. Additional requirements for security of classified equipment, electrostatic discharge (ESD) protection (TO 00-25-234), and prevention of foreign object damage (FOD)

(AMXG OI 21-122), are mandatory.

3.2. Procedures described in this OI ensure parts/components removed from aircraft are identified prior to handling and movement IAW AMXG OI 21-12, Condition Tagging and Labeling of Air

Force Material, and AFMCI 21-122 HAFB, Supplement 1, Foreign Object Damage (FOD) and

Dropped Object (DO) Awareness and Prevention Program. Negligent swapping of these items can have an adverse effect on configuration management serially controlled component tracking, historical time change requirements, and aircraft/systems integrity.

3.3. Air Force Occupational Safety and Health Standard (AFOSHSTD) 91-46, Material Handling and Storage of Equipment, details criteria and requirements for manual and powered equipment materials handling. This standard not only establishes personnel safety practices and procedures, but specifies equipment requirements and inspection criteria. AFOSHSTD 91-501, Air Force

Consolidated Occupational Safety Standard, outlines manual lifting requirements. Prevention of personal injury due to improper procedures or equipment failure prevents damage to aircraft parts/components. All 309 AMXG personnel handling materials are required to comply with this instruction.

4. Handling:

4.1. Handling includes part/component removal, storage, transportation, installation, and identification.

4.2. All TO, AFOSHSTD, OI, PO, and WCD instructions will be utilized during all required handling actions. In addition, responsible individuals will ensure:

4.2.1. All ESD-sensitive components are adequately protected during handling actions. These actions include use of prescribed removal and installation requirements or guidance outlined in TOs and/or applicable instructions/publications. Installation of approved ESD caps, plugs, and bags using proper transportation methods, proper equipment, and proper storage units, IAW TO 00-25-234. ESD protection will begin immediately upon component removal and prior to handling procedures.

4.2.2. All exposed lines, fittings, connectors, ducts, tubes, etc., will be capped or appropriately covered immediately upon removal from aircraft or subsystem and prior to any movement or relocation of the part or component IAW AMXG OI 21-122.

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4.2.3. Transportation trailers, dollies, boxes, crates, and pallets that require an AFTO Form

244 card will be inspected to ensure serviceability. Transportation will inspect the condition and presence of padding/bumper material to ensure serviceability. Transportation will ensure items to be moved are clean and free of foreign objects/debris IAW AMXG OI 21-122. The user will perform an inspection prior to use. These inspections are general and diverse in nature and must rely on the judgment of the user.

4.2.4. Parts/components to be transported will be properly secured to prevent movement or contact with other parts/components when they are placed on trailers, pallets, etc. Proper security of the parts/components is the responsibility of the individual securing the items.

When available, parts/components to be routed will be stored in reusable containers.

4.2.5. Aircraft parts/components will be identified. All parts/components removed will be tagged or labeled IAW AMXG OI 21-12. In addition, all parts/components turned into supply will meet the requirements outlined in 00-20 series TOs to include completion of required

AFTO and DD Forms where applicable.

4.2.6. Identification of cannibalized parts will be maintained IAW AMXG OI 21-3.

4.2.7. Prior to installation of parts/components, the user will inspect the condition, serviceability, and remove all caps, plugs, and covers.

4.2.8. The use of lifting devices, hoists, or slings will be accomplished IAW AFOSHSTD 91-

46.

4.2.9. Special handling, tagging and labeling, and transportation requirements for classified equipment, canopies, and external fuel tanks are described in the applicable directives outlined in this OI.

4.2.10. The C-130 Prep and Paint Section personnel will ensure C-130 flight controls, when removed from the aircraft, maintain aircraft identification and are suspended for strip and paint using the designated locally designed and manufactured attachments. These attachments are required to properly secure and prevent structural damage to the flight controls.

4.3. Transportation Reclamation Function:

4.3.1. Transportation personnel provide the required transportation support for 309 AMXG to include the handling and delivery of aircraft components. Personnel will follow AFOSH and

OSHA guidance when operating equipment and vehicles (Refer to AMXG OI 24-301).

4.3.2. Crane, forklift, hoist, and vehicle operators will ensure the serviceability of their equipment or vehicle prior to use. Equipment and vehicle status forms will be checked for

AMXG OI 21-7 3 December2008 7 discrepancies that could affect safety and operation. Any required daily inspections will be performed as required by AMXG OI 24-301 and AFOSHSTD 91-46.

4.3.3. Vehicle operators will visually verify that components or items to be transported are properly secured, boxed, crated, palleted, and padded IAW this instruction to prevent damage or movement during transportation.

5. Storage:

5.1. All parts/components placed in storage cabinets, racks, crates, bins, and boxes will be marked to indicate tail number and part number and maintained in a neat and orderly manner to minimize any damage potential. These storage locations will be kept free of loose hardware, debris, sand, etc., which could present a threat of FOD or contamination and hold only material required to facilitate other maintenance (FOM) on the aircraft on dock. All ESD sensitive components will be properly protected IAW TO 1-1A-14 (Section 3, Paragraph 3 - 52), Protection of Electrical

Connectors, TO 00-25-234, and AFMCR 65-8, ESD Control Program and Local OIs.

5.2. All parts will be protected from damage by the appropriate application of padding or cushioning material to the storage area and/or directly on the parts or components. If parts such as access panels must be stacked, padding material will be placed between the items. Padding and cushioning material used for storage can be bubble pack, polyurethane foam, felt pads, cardboard, paper, plastic, etc. The method and use of these materials will be left to the discretion of the individual storing the parts, unless specific instructions are provided in other directives. Materials used on or around ESD-sensitive components and the storage units must conform to the requirements of TO 00-25-234 (Section 7).

5.3. The individual handling, removing, storing, or routing the item will ensure all hydraulic lines, fittings and openings, electrical connectors, etc., are properly capped, plugged, or covered, and items have had fluids drained and/or wiped down to prevent leakage and/or contamination of the storage location and other stored items.

5.4. Adequate protection will be provided to prevent damage (nicks, scratches, etc.) to machined surfaces. Actuator rods that cannot be retracted will be wrapped to prevent damage.

5.5. RCCs will not store items together which present a potential contamination problem such as oxygen lines/hoses and hydraulic components.

6. Flight Line Operations and Outside Storage:

6.1. All part and component handling and storage requirements apply to flight line operations and outside storage. However, there are additional concerns that must be considered due to exposure to the outside elements and lack of a protective structure.

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6.2. Damage to aircraft parts/components is increased by adverse weather, jet blast/ prop wash, and vehicle traffic. Responsible RCCs will properly store and secure parts /components, secure flight line storage units and items stored at designated outside storage locations.

6.3. Outdoor storage requirements increase the risk of contamination to parts/components. All caps, plugs, and covers will be securely installed to prevent contamination and withstand the elements.

6.4. Hazardous weather conditions require special actions to secure and protect aircraft parts and components. The 309 AMXG Control Center will notify 309 AMXG managers per

AMXG OI 15-102. The type and severity of the weather conditions forecast would dictate what actions are taken. Transportation and responsible RCCs will ensure assets are properly protected before movement to outside storage facilities or when exposure to the elements is possible.

7. Preservation, Packaging, and Delivery:

7.1. Any part or component that is chemically stripped or beadblasted will be treated to prevent corrosion or oxidization, per the WCD and TO requirements.

7.2. Aircraft engines shipped off base are preserved and packaged in accordance with TO 00-85-20, Engine Shipping Instructions, and the applicable engine TOs.

7.3. Preservation, packaging, and delivery requirements are very limited within 309 AMXG since the finished products are operational aircraft that fly back to the owning units. If items are shipped, DLA and Logistics Management Depot Supply Division (OO-ALC/LGS) personnel (except engines) accomplish their preservation, packaging, and delivery.

//signed//

RICHARD A. DUGAN

Deputy Director

309th Aircraft Maintenance Group