RFP-Attachment1PSISpecNov2007.doc

Attachment 1 (11/26/07) HSCG38-08-R-H00006

USCG HC-130H SERIES PROGRESSIVE

STRUCTURAL INSPECTION

BASIC (PSI) SPECIFICATION

SECTION I: GENERAL

1.1 Information

1.2 Terms Explained

1.3 Data

1.3.1 Maintenance Records, Forms and Publications

1.3.7 Reporting Requirements

1.3.11 Technical Data

1.4 Security—Unclassified

1.5 Reserved

1.6 Condemnation and Repair

1.7 Nonstructural Accessories, Components, Re-Use, Repair & Replacement

1.8 Pollution Prevention Program

TECHNICAL ORDERS AND OTHER DIRECTIVES

1.9 Technical Specifications

1.9.1 General

1.9.2 Applicable Time Compliance Technical Orders

1.9.3 Applicable AF Directives

1.9.3.1 AF Instructions

1.9.3.2

1.9.3.3 AFMC Instructions

1.9.4 Specifications (Military)

1.9.5 Military Standards

1.9.6 Military Handbook

1.9.7 Federal Specifications

1.9.8 Federal Standards

1.9.9 National Aerospace Standards (NAS)

1.9.10 Commercial Standards and Specifications

1.9.11 Drawings

SECTION II: RECEIPT OF AIRCRAFT AT FACILITY

2.1 Handling

2.2 Inventory

2.3 Preservation

SECTION III: WORK REQUIREMENTS

3.1 Aircraft General

3.2 Specific Work Requirements

3.2.1 Depot Maintenance

3.2.1.1 Fuselage

3.2.1.1.1 Forward Fuselage Forward of FS 245

3.2.1.1.2 Center Fuselage (WL 146 and Lower)

3.2.1.1.3 Center Fuselage, FS 245-FS 737

3.2.1.1.4 Vertical Beams and Landing Gear Support Structure

3.2.1.1.5 Upper Fuselage Pressure Bulkheads

3.2.1.1.6 Aft Fuselage, FS 737-FS 1041

3.2.1.1.7 Cargo Ramp and Aft Fuselage

3.2.1.1.8 Latrine Areas

3.2.1.1.9 Fuselage Pressurization System

3.2.1.1.10 GTC/APU Access Panel

3.2.1.2 Wing

3.2.1.2.1 Center Wing

3.2.1.2.2 Outer Wing

3.2.1.3 Empennage

3.2.1.4 Hydraulic and Pneumatic Systems

3.2.1.5 Instruments

3.2.1.6 Power Plant (Engine)

3.2.1.7 Propellers

3.2.1.8 Electrical

3.2.1.9 Flight Controls

3.2.1.10 Fuel System

3.2.1.11 Communication, Navigation and Radar Equipment

3.2.1.12 Landing Gear System

3.2.2 Depot Level Modifications

3.2.3 Negotiated Maintenance

3.2.4 Special Depot Requirements

3.2.4.2 Throttle and Condition Cable Inspection/Replacement

3.2.4.3 Oxygen System

3.2.4.4 Additional Non Destructive Inspections (NDI)

3.2.4.5 Addl Aircraft Computerized Maintenance System (ACMS) Cards

SECTION IV: FINAL PROCESSING OF AIRCRAFT

4.1.

Finishing of Aircraft

4.2 De-preservation

4.3 Servicing

4.4 Weight and Balance

4.5 Functional Ground Check

4.6 Pre-Flight

4.7 Acceptance/Functional Check Flight

4.8 Thru Flight Inspection

4.9 Post Flight

4.10 Preparation for Ferry

4.11 Forms Preparation

4.12 Government Acceptance

SECTION V: PAINT HC-130 AIRCRAFT

5.1 General

5.2 Determination of Finish Maintenance Requirements

5.3 Control Surfaces

5.4 Antennas and Radomes

5.5 Complete Repaint/Repaint Requirements

5.6 Touch Up Paint

5.7 Sealing

5.8 Markings

5.9 Quality Inspection and Acceptance Criteria

SECTION VI: HC-130 SUPPORT EQUIPMENT

APPENDIX A

Non-Destructive Inspection Report

A-1

Table I Method of Detection Designation A-3

Table II Material Designation

A-3

Table III Size Designation

A-4

Table IV Nature Designation

A-4

Table V Category Designation

A-5

Table VI Type Designation

A-5

Non-Destructive Inspection Report Form A-6

APPENDIX B

Corrosion Inspection Report

B-1

SECTION I: GENERAL

1.1 Information:

1.1.1 This specification establishes the depot maintenance requirements necessary to baseline Coast Guard HC-130H aircraft for transition to a Progressive Structural Inspection Program (PSI). This specification includes the minimum work requirements for inspection, flight test and preparation for delivery of Coast Guard C‑130 aircraft by the depot facility. It is designed to return C‑130 aircraft to a serviceable but not like new condition. Any work requirements beyond the tasks identified in this specification will be documented and approved as added scope of work on appropriate contractor generated documents to verify proposed repair action and document the man-hours and materials expended.

1.1.1.1 The PSI Baseline requirements contained herein are designed to accurately establish the current condition of the airframe with respect to corrosion, wear and physical damage, and return it to a more serviceable condition. This effort constitutes the minimum requirements to ensure reliability and operational availability of the aircraft at minimum cost for the duration of the established service period.

1.1.1.2 The maintenance requirements prescribed in this specification comprise the minimum requirements necessary to ensure the timely discovery and correction of actual and/or anticipated defects. Compliance with these requirements is mandatory.

NOTE

This project is unclassified; however, no data, technical or otherwise concerning this project, shall be released through publication or in any manner except with specific written authorization by USCG.

1.1.2 The aircraft shall be returned to the assigned organization in the same configuration as received, with the same type components, accessories and special equipment installed except as modified, removed, or added by requirements of this work specification. Specifically equipped, instrumented or configured aircraft are subject to being worked under the requirements of this work specification.

1.1.3 Special tools and test equipment are required and are listed in Section VI to this work specification.

1.1.4 Nonstructural accessories or components shall not be overhauled, except as authorized in this specification, paragraph 1.7, but shall be repaired as limited to base level repair restrictions as listed in TO 1C‑130A‑6.

1.1.4.1 Unless otherwise directed in this specification, or authorized by the Coast Guard, accessories or components shall not be replaced due to expiration of time, but shall be replaced upon failure only.

1.1.5 Items listed below shall be accomplished as directed by the Contracting Officer. Any additional work requested by the USCG and listed on form AFTO 103 shall be accomplished as approved by the CONTRACTING OFFICER.

1.1.5.1 Accomplishment of work not specifically directed in this specification.

1.1.5.2 Correction of Safety of Flight discrepancies (Critical defects) and Major defects.

1.1.5.3 Any discrepancies that require extensive disassembly or shoring of the aircraft for accomplishment.

1.1.5.4 Depot level discrepancies of systems listed on aircraft 4377/5181 forms submitted by the incoming flight crew that are not otherwise directed for accomplishment by this specification.

1.1.5.5 The correction of any discrepancy found, that because of access to that discrepancy during PSI Baseline, or because of availability of tools or spares required to correct the discrepancy, is more economical to accomplish during PSI-B shall be corrected.

1.1.6 Structure cracks and corrosion in the following areas are safety of flight: TO 1C-130A-3; Center Wing, Section 57-10-00; Outer Wing, Section 57-10-00; Stabilizer, Section 55-00-01; Fuselage, Section 53-10-00; Nacelle, Section 54-10-00. On site engineering shall determine safety of flight fasteners.

1.1.7 Discrepancies found which do not require correction by this specification shall be recorded in aircraft historical records IAW COMDTINST M13020.1 series and documented in the Noted But Not Corrected report per paragraph 1.3.7.5.1.

1.1.8 Only those systems worked by a specific requirement or disturbed by other requirements of this specification shall be made operational unless a safety of flight condition exists or it is an overseas requirement as required by Section III, paragraph 3.1.6.

1.1.9 If replacement of T-56 power sections, gearboxes, torque meters, propellers and GTC/APU are required, these items shall be replaced only with CONTRACTING OFFICER approval and shall be furnished by the USCG. (Return repairable items to USCG)

1.1.10 Cannibalization of parts, components and/or accessories shall be accomplished only as authorized by the CONTRACTING OFFICER through the USCG representative.

NOTE

The contractor will notify and coordinate with the CONTRACTING OFFICER through the USCG representative, the procurement of any ATS serial number tracked components requiring replacement.

1.1.11 Any deviations from this specification must be approved by the CONTRACTING OFFICER as directed on the AFTO 103.

1.1.12 The PSI Baseline shall include a corrosion control program. For the purpose of this work specification, corrosion treatment is defined as cleaning, removal of corrosion and deteriorated coatings, chemical treatment of metals, repair and finishing in accordance with applicable technical orders. Missing or deteriorated coating systems shall be considered a discrepancy.

1.2 Terms Explained:

NOTE

Items listed below shall not be interpreted to delete or minimize any work requirements of technical orders listed in paragraph 1.9 of this specification.

1.2.1

Accessible: Applies to areas of equipment that may be inspected or worked without disassembly other than required by this specification.

1.2.2

Accessory: A mechanism or device employed in conjunction with a major item of equipment or installed as part of a system.

1.2.3

Reserved 1.2.4

AFMC: The abbreviation for Air Force Material Command.

1.2.5

Aircraft Exterior: Aircraft outer skins and outer skins of components, such as flaps, ailerons, elevators, rudder, ramp, cargo door, nose gear doors and main landing gear doors.

1.2.6

Airframe: The structural components of an airplane including the framework and skin of such parts as the fuselage, empennage, wings and engine mounts (does not include landing gear and engine).

1.2.7

Avionics Tracking System (ATS): Coast Guard computer based system for tracking select avionics components. Components enrolled in this program are identified by barcode tag.

1.2.8

Basic Maintenance Instructions: The appropriate section of the applicable aircraft handbooks and manuals listed in paragraph 1.9 of this specification.

1.2.9

Bench Check: Visual inspection, physical test and functional check using shop facilities, equipment, procedures and test parameters, as set forth in applicable technical publications to determine the exact condition.

1.2.10

Calibration: A comparison between two instruments, one of which is a standard of known accuracy, to detect and correlate or adjust any variation in accuracy of the instrument being compared.

1.2.11

Component: A separate identifiable part of an end item, which performs a function within the system or subsystem and is necessary for the proper operation of that end item.

1.2.12

Contract Field Team: A group of contractor maintenance personnel who are provided with Government furnished special tools, equipment and supplies to accomplish maintenance/modification onsite at operational bases. The work involves depot level, organizational and intermediate level tasks. The contractor provides supervision, people and hand tools.

1.2.13

Correct Defects/Discrepancies: The accomplishment of all necessary work and testing to restore the part, component or aircraft to a serviceable condition status. Categorized as Fixed Price Basic, Fixed Price Over & Above, or Negotiated Over & Above IAW 1.2.30, 1.2.31, or 1.2.39 as applicable.

1.2.14

Data: All management, scientific engineering and logistics information, reports and documentation that is required.

1.2.15 Defect: Any nonconformance of a unit or part with specified requirements (synonymous with Discrepancy).

1.2.16 Defect, Critical: A defect that constitutes a hazardous or unsafe condition, or as determined by experience and judgment could conceivably become so, relative to its deleterious effect on the prime intended function, safety of flight, or mission capability of the aircraft or its operating personnel.

1.2.17 Defect, Major: A defect, other than critical that could result in failure, materially reduce, or if not corrected will degrade the usability of the unit or part for its intended purpose.

1.2.18 Reserved 1.2.19 Defect, Minor: A defect that does not materially reduce or if not corrected will not degrade the usability of the unit or part for its intended purpose, or is a departure from standards which has no significant bearing on the effective use or operation of the unit or part.

1.2.20 Defects, Noted But Not Corrected (NBNC): Minor discrepancies that were discovered during PSI Baseline but not required to be corrected per this specification.

1.2.21

Depot Level or Maintenance Facility: An industrial type facility established to perform overhaul functions or modification and maintenance in support of field and using organizations. This includes AFMC assigned installations and commercial contractors who are engaged in performing depot level work on weapon systems or equipment under contracts issued and managed by AFMC.

1.2.22

Deteriorated Finish: When the finish no longer provides the protection for which it was intended.

1.2.23

Direct Parts and Material: Material that is installed and remains installed on the aircraft.

1.2.24

Disassembly: Teardown of the item or parts sufficient to permit the type and amount of inspection and work required.

1.2.25

Disturbed System: Any system of which the whole or component part has been removed, disassembled, repaired, adjusted, modified, disconnected, or altered.

1.2.26

ECO: The abbreviation for Engineering Change Order.

1.2.27

Economical Repair: The correction of any discrepancy found, that because of access to that discrepancy during PSI Baseline, or because of availability of tools or spares required to correct the discrepancy, is more economical to accomplish during PSI-B.

1.2.28

End Item: A recoverable article of equipment listed in a procuring activity supply catalog.

1.2.29

Engine: The complete engine as specified in applicable technical order (TO) handbooks listed in the work specification.

1.2.30

Engine Accessories: All external items contained in the fuel, ignition and control systems that are normally removed for rework or replaced without disassembly of the engine.

1.2.31

Fixed Price Basic: In general, the application of a Firm Fixed Price applies to the tasks of this specification that are performed essentially on every aircraft or series of aircraft.

1.2.32

Fixed Price Over & Above: In general, the application of a Firm Fixed Price to tasks, other than Fixed Price Basic to this specification, which are performed contingent upon aircraft/component condition and typically associated with special inspections, specified repairs, component removal and replacement.

1.2.33

Functional Check: A check or test of the designed function operation of a specified unit using equipment procedures and limits specified in applicable TOs.

1.2.34 Functional Check Flight (FCF): Airborne functional checks to establish if an airframe or equipment, when subjected to design environment, is operating properly. Generally, areas checked on test flights are equipment or systems whose failure would adversely affect flight safety.

1.2.35

IAW: The abbreviation for In Accordance With.

1.2.36

Indirect Parts and Material: Material used to perform depot maintenance but is not installed and/or does not remain installed on aircraft.

1.2.37

Inspect Or Check: An examination of an item to determine identity, condition and proper installation.

1.2.38

Loose Fastener: As defined in TO 1-1A-8.

1.2.39

Modification: A change in the physical configuration or in the functional characteristics of system or equipment.

1.2.40

N/A: The abbreviation for not applicable.

1.2.41

Negotiated Over & Above: In general, the application of negotiated labor hours to a fixed hourly rate for tasks, other than Fixed Price Basic to this specification or Fixed Price Over & Above, which are performed contingent upon aircraft/component condition, including economic repairs

1.2.42

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

1.2.43

OMMS: Organizational Maintenance Manual Set are Air Force technical orders comprised of those manuals which are necessary to support on-vehicle maintenance to the C-130 airplane and it’s various systems.

1.2.44

Overseas: Outside the North American Continent.

1.2.45

O & I: Organizational and Intermediate Level Maintenance.

1.2.46 Over and Above: Work requirements not covered by this specification or elsewhere in the contract, which are determined and authorized by the CONTRACTING OFFICER and necessary to accomplish the requirements of PSI-B.

1.2.47

Overhaul: The disassembly, cleaning, inspection, repair or replacement of parts or components, reassembly and test of any item or accessory IAW applicable TOs, directives, or authorized manufacturer's publications to provide an operationally safe, serviceable and reliable item.

1.2.48

Parts: Essential elements, components, or subassemblies of an item.

1.2.49

Preventive Maintenance: The normal inspection, upkeep and lubrication of equipment required to maintain the serviceability of equipment subjected to usage, wear and deterioration.

1.2.50

Programmed Depot Maintenance (PDM): Depot level maintenance normally applied to aerospace vehicle scheduled on a time cycle basis.

1.2.51

PSI-B: Abbreviation for Progressive Structural Inspection – Baseline.

1.2.52

Reclamation: The process of recovering serviceable or reparable spare parts.

1.2.53

Reinstall: The reinstallation of a part or component on an aircraft after it has been removed to facilitate inspection, repair, or for military security purposes.

1.2.54

Repair: The restoration or replacement of parts or components of an item as necessitated by wear and tear, damage or failure of part in order to maintain the specific item in serviceable condition.

1.2.55

Repair Finish: The coating system which is required to be applied to an area after replacement of components or accomplishment of any work which deteriorates the corrosion protection of the area after inspection shows coatings to be nonexistent or deteriorated.

1.2.56

Reparable: An unserviceable item that can be repaired and restored to a serviceable condition.

1.2.57

Replace: The replacement of items that are determined by the Government to be beyond economical repair, or as otherwise specifically directed.

1.2.58

Safety Of Flight: A failure or malfunction that would present a hazardous condition to equipment or personnel during pre‑flight, in‑flight, or thru‑flight operations.

1.2.59

Serviceable: Capable of meeting the requirement and performing the function for which designed or modified, and meets all test requirements established by the work specifications.

1.2.60

SCHR: Significant Component History Report, a USCG computer generated report, which maintains a record of significant maintenance actions on serial number tracked items (comparable to the Air Force AFTO 95).

1.2.61

Special Inspection: As used herein shall be interpreted to mean those inspections performed as required IAW applicable TO 1C‑130A‑6.

1.2.62

Technical Orders (TO): A publication that gives specific technical directives and information with respect to the inspection, storage, operation and maintenance of given items and equipment. Reference to TOs herein will include supplements and latest published changes.

1.2.63

Time Compliance Technical Order (TCTO): An authorized directive issued to provide instructions for accomplishing 'one‑time' changes, modifications, installation of new equipment, or inspection of equipment.

1.2.64

Touch‑Up: The repainting of a local area or marking to provide legibility or protection and to meet quality standards.

1.2.65

USCG Aircraft Computerized Maintenance System (ACMS): Database, which performs the basic function of maintenance scheduling and tracking. ACMS supports the preparation of centralized Significant Component History Reports (SCHR) and ACMS cards.

1.2.66

USCG Aircraft Computerized Maintenance System (ACMS) Cards: ACMS cards are documents with written instructions for accomplishment of maintenance requirements, each of which is assigned a unique ACMS code number.

1.2.67

USCG ARSC C-130 Product Line Manager (PLM): U.S. Coast Guard C-130 Product Line Manager directs and is responsible for issues pertaining to the C-130 aircraft, for ensuring best value to the Government and that sound business practices are balanced against operational requirements.

1.2.68

USCG ASIP: United States Coast Guard Aircraft Structural Integrity Program.

1.2.69 Visual Inspection: Consists of visually inspecting for cracks, distortion, corrosion, fastener security, pulled rivets, undue wear and damage. When inspecting items for corrosion, particular attention must be given to areas of dissimilar metal‑to‑metal contact (bushing, fasteners, etc.).

1.2.70

Workbook: A listing of aircraft serial numbers, the equipment or systems to be modified, work to be accomplished and provisions for indicating that the work has been accomplished.

1.2.71

Office Symbols:

ARSC C-130 PLM

USCG C-130 Production Cell Leader Work: (252) 335-6560

USCG Aircraft Repair & Supply Center Cell: (252) 202-4309

C-130 Division, Heavy Maintenance Facility

FAX: (252) 335-6452

Elizabeth City, NC 27909-5001

E-MAIL: Andrew.W.Eriks@uscg.mil

ARSC C-130 PLM

USCG C-130 PLM Chief Work: (252) 335-6837

E-MAIL: Thomas.S.MacDonald@uscg.mil

USCG C-130 Engineering Branch Chief Work: (252) 335-6621

Cell: (252) 202-1321

E-MAIL: Gene.H.Lupton@uscg.mil

Nancy DeBerry – C130 PCO Work: (252) 335-6291

E-MAIL: Nancy.DeBerry@uscg.mil

Bill Kingsley – C130 Contract Specialist Work: (252) 384-7283

Cell: (407) 766-7287

E-MAIL: william.t.kingsley@uscg.mil

1.3

Data:

(Fixed Price Basic)

1.3.1 Maintenance Records, Forms and Publications:

1.3.2 The depot facility shall maintain the forms and publications listed in subparagraph 1.3.4 below. If records are not received or are illegible, the depot facility shall obtain them from the reporting custodian through the USCG representative or as directed by the Contracting Officer IAW the applicable directive set forth in subparagraph 1.3.4.

1.3.3 Record each technical order compliance in the aircraft historical records furnished with each aircraft IAW COMDTINST M13020.1 series.

1.3.4 These forms and publications shall be maintained from the date the aircraft is received until the date the aircraft departs.

1.3.5 A notation shall be made in the Significant Historical Data Column of SCHR, indicating the day, month, year and aircraft time and facility that PSI Baseline was accomplished IAW TOs 00-20-2, 00-20-5 and COMDTINST. M13020.1 series. This shall certify that prescribed requirements of this specification were accomplished. A notation of paint application shall be made as directed in Section V, paragraph 5.10.1.7. Also SCHR entries are required for the following: PSI/UDLM accomplishment, TCTO accomplishment, aircraft paint application, MLG track replacement, rudder support bearing replacement, aircraft critical structure‑removed & replaced, aircraft critical structure‑damage repair, severe corrosion, special service test equipment installed or removed, aircraft alignment and symmetry results, removal of stabilizers, wing removals; replaced FS 737 longeron fitting, replaced sloping longeron, replaced FS 1041 fittings, replaced throttle & condition cables, removed engines, removed struts, replaced ballscrews, removed vertical & horizontal stabilizers, removed flight controls, accomplished wing bolt inspection, accomplished bleed air checks, replacement of bleed air ducts, removed bladder cells, removal of bolts at the following locations: FS 245 and FS 737 splice fittings, FS 737 and FS 1041 longeron end fittings and FS 477 and FS 617 upper tension tie fitting; truss mount replacement, MLG vertical beam replacement and installation of FS 517 MLG vertical beam splice repair. Annotate SCHR of any new flapper drain valves installed and at what FS and BL locations.

1.3.6 TO 1C‑130A‑6 and ACMS special inspections accomplished under requirements of this specification shall be recorded on applicable forms of the aircraft historical records.

1.3.7 Reporting Requirements:

1.3.7.1 Reported Defect Analysis. The depot facility shall perform reported defect analysis as shown below:

1.3.7.1.1 Reported Defects. List defects reported by the reporting custodian, those reported by the ferry pilot and those recorded in aircraft logbook and associated records.

1.3.7.1.2 Verify Defects.

1.3.7.1.2.1 Perform operational and functional tests or visual inspections of the aircraft, systems and power plants, as necessary, to identify and verify all defects within 30 days of induction. Record additional information, as necessary, to assist in correction of applicable defects. As soon as possible after receiving the aircraft, perform an operational check of the systems and flight reference instruments specified in paragraph 3.2.1.11. Components of specified systems found to be inoperable on receipt should be returned to the reporting custodian via the USCG representative for replacement. Components of multiple systems or COM/NAV systems not listed but found inoperable during aircraft rework should be noted in the NBNC list.

1.3.7.1.2.2 Before the aircraft has been cleaned and preserved, the depot facility shall conduct a thorough inspection of the airframe to document any indications of structural degradation, working fasteners or other damage. If corrosion damage is evident or suspected at skin laps, clearly mark or note the suspect area for further inspection.

1.3.7.1.3 Determine Action. Within 60 days of induction, the depot facility shall schedule all verified and discovered defects for corrective action, as applicable, at an appropriate repair sequence. List those applicable minor defects on the NBNC List.

1.3.7.3 Repairable Item Processing Tag.

IAW COMDTINST 13020 (Series), CH4 and CH7. (Fixed Price Basic)

1.3.7.4 Defective or inadequate Parts/Specification Notification.

IAW TO 00‑35D‑54.

1.3.7.5

PSI-B Work Cards.

The PSI-B work cards shall be a contractor developed set of work cards containing all the elements detailed in Appendix A of this specification. Work cards used to execute this specification shall be provided to the Coast Guard at no additional cost.

1.3.7 – 1.3.10 Reserved

1.3.11

Technical Data:

NOTE

The requirements called out in applicable Organizational Maintenance Manual Set take precedence over –2 tech orders.

1.3.12 The removal, disassembly, inspection, repair, adjustment, modification, test, assembly and reinstallation of components and equipment shall conform to the maintenance instruction manuals and other applicable TOs listed in paragraph 1.9 of this work specification.

1.3.13 Structural repairs installed while accomplishing the requirements of this specification shall conform to TO 1C‑130A‑3, 1C‑130A‑23 and contractor engineering instructions as directed by the CONTRACTING OFFICER. Shoring is required when major structural components require replacement as depicted in TO 1C‑130A‑3.

NOTE

Special jacking and shoring for structural repairs shall be determined by the depot facility’s engineering based on the work and repairs to be accomplished on a particular aircraft if the requirements of TO 1C-130A-3 are not appropriate.

1.3.14 Replacement parts and materials used in the repair of the aircraft or any other equipment shall be those authorized in USAF and USCG approved publications.

1.3.15 Obtain and use approved torque values and safety methods from publications listed below.

1.3.15.1 Organizational Maintenance Manual Set maintenance instructions and manuals and TO 1C-130A-3 structural repair manuals.

1.3.15.2 If not listed in Organizational Maintenance Manual Set manuals or TO 1C-130A-3 manuals, refer to accessory maintenance manuals.

1.3.15.3 If not listed in 1.3.15.1 or 1.3.15.2 above see TOs 1‑1A‑1 and 1‑1A‑8.

1.3.16 Identification, installation and replacement of flexible hose and fittings shall conform to TOs 1‑1A‑1, 1‑1A‑8, 42E1‑1‑1 and 44H3‑1‑3. Low pressure hoses having radial cracks on the end, minor cracks or lack of manufacturer's date shall not be rejected unless found unserviceable.

1.3.17 Reserved.

1.3.18 Color-coding of new tubing shall be IAW the basic maintenance handbook for applicable aircraft and TO 1-1-8.

1.3.19 All fluids, fuel, oils, grease and compounds used in servicing the aircraft shall be specified in the individual workbook for each C‑130 aircraft.

1.3.20 Nondestructive Inspection (NDI): Requirements for NDI shall be obtained from TO 1C‑130A‑36 and 33B‑1‑1.

1.3.20.1 Nondestructive Inspection (NDI) methods in TOs 33B‑1‑1 and 1C‑130A‑36 shall be utilized when:

1.3.20.1.1 Directed by TOs or this specification.

1.3.20.1.2 Questionable indications of defects are noted.

1.3.20.1.3 Parts are reworked in any way that could adversely affect the quality of parts such as milling, welding, machining, plating, grinding and heat-treating.

1.3.20.2

Non-Destructive Inspections:

1.3.20.2.1 Magnetic particle inspection shall be accomplished as directed by TO 33B‑1‑1, AMST E1444 and TO 1C‑130A‑36. Procedures specified in the general TO and specification shall not supersede those of the overhaul handbooks unless so stipulated.

1.3.20.2.2 When the condition of metal parts and material indicates unserviceability, such parts and material shall be inspected using methods and equipment prescribed in specification MIL‑I‑6870 or equivalent specification.

1.3.20.2.3 Fluorescent penetrant inspection shall be accomplished IAW TOs 1C‑130A‑36, 33B‑1‑1 and ASTM E 1417 or equivalent specification.

1.3.20.2.4 Radiographic inspection shall be accomplished IAW TOs 33B‑1‑1, 1C‑130A‑36 and ASTM E 1742 or equivalent standard. Procedures specified in the general TO and specification shall not supersede those of the overhaul handbooks unless so stipulated.

1.3.20.2.5 When inspection techniques not listed in TO 1C‑130A‑36 are used, they shall be reported using AFTO Form 202 IAW TO 33B‑1‑1. The information reported shall be sufficient to enable maintenance personnel with training in the use of NDI to accomplish the reported inspection.

1.3.20.2.6 Personnel performing the nondestructive inspections required by this specification shall have had formal training in the usage of the inspection equipment and shall possess certification of such training. NDI inspectors shall meet the training standards and/or qualifications for Level II inspectors as detailed in NAS-STD-410 and MIL-STD-453 or equivalent standards.

1.3.20.2.7 NDI inspections shall be performed utilizing NDI equipment authorized for use IAW TO 1C‑130A‑36.

1.3.20.2.8 The Vendor shall certify that the NDI techniques performed on each structural item have been performed successfully under the conditions and circumstances specified in TO 1C‑130A‑36.

1.3.21 Shot peening shall be accomplished IAW AMS-S-13165 or equivalent.

1.3.22 Cadmium plating, anodizing and ion vapor depositation shall be accomplished IAW TO 1C-130A-23 and specification listed there in.

1.3.23 Abrasive blasting shall be accomplished IAW MIL-STD-1504 or equivalent standard.

1.3.24 Heat treat of steel alloys shall be accomplished IAW SAE-AMS-H-6875 or equivalent specification. Heat treat of aluminum alloys shall be accomplished IAW AMS 2770 and AMS 2772 or equivalent specification.

1.3.25 All deviations from technical and engineering data must be approved by certified onsite engineering and cleared through the Coast Guard prior to implementation.

1.4 Security – Unclassified:

NOTE

In the event an aircraft should arrive at the depot facility with classified equipment, immediately notify the on-site USCG representative or the CONTRACTING OFFICER.

1.5

Reserved.

1.6 Condemnation and Repair:

The depot shall not repair condemned items without prior approval of the Contracting Officer. The depot facility shall not repair items where the cost of parts and labor exceeds 75% of the replacement cost of the item unless authorized by the Contracting Officer. The contractor shall advise the Contracting Officer of the criticality of items.

1.6.1 Under conditions other than those listed above, no item is to be repaired if serviceable assets are available.

1.7 Nonstructural Accessories, Components, Re‑Use, Repair and Replacement:

1.7.1 When determined from inspection, operational test, or bench check that overhaul is required to ensure serviceability of serial number tracked/ATS items, items shall be replaced with serviceable accessories or components. The Contractor shall notify the Contracting Officer through the USCG representative and request the needed component from ARSC inventory. In the event the Contracting Officer and cognizant Item Manager cannot provide serviceable accessories or components in sufficient time to avoid work stoppages, the Contracting Officer shall provide the Contractor with detailed instructions. (Fixed Price Basic)

1.7.2 Cannibalization of parts, components and accessories required to prevent schedule slippage is authorized, as coordinated by the USCG representative and approved by the Contracting Officer.

1.7.3 No item is to be repaired if serviceable assets are available and/or if estimated delivery date does not affect production critical path.

1.8 Pollution Prevention Program:

1.8.1 The depot facility shall implement a Hazardous Material Management and Pollution Prevention Programs, IAW National Aerospace Standard (NAS) 411 or local government rules and regulations if those rules and regulations are more restrictive than NAS 411 requirements, that integrates all pollution prevention efforts. The depot facility shall document their approach for managing hazardous materials, pollutants and potential pollutants associated with activities specified in this contract and the contractor's proposal. This program shall also apply to elimination, reduction and minimization of hazardous materials, pollutants and potential pollutants by subcontractors. All of this information shall be provided in a Hazardous Material Management Plan (HMMP). (Fixed Price Basic)

TECHNICAL ORDERS AND OTHER DIRECTIVES

1.9 Technical Specifications:

1.9.1

General

All referenced TOs, directives, regulations, U.S. Government specifications or standards, drawings and other documents (including revisions) are those in effect October 31, 2007. Any change or revision dated after October 31, 2007 shall be negotiated and approved by the CONTRACTING OFFICER prior to implementation.

1.9.1.1 Compliance with all technical orders and all other documents (e.g. specifications, drawings) listed is mandatory when applicable to the aircraft or installed equipment and to work requirements IAW this specification.

1.9.1.2 Technically illustrated parts breakdown and general information TOs pertaining to the aircraft, aircraft engine and installed aircraft and aircraft engine accessories are listed in TO 1C‑130H‑10. Referenced technical manuals, illustrated parts breakdown and general information TOs listed herein are made a part of this work specification.

1.9.1.3 The depot facility shall use USAF and USCG regulations, manuals, instructions; Military Standards, Specifications and Handbooks; Federal Standards and Specifications; and National Aerospace Standards listed in this specification to perform maintenance on USCG C-130 aircraft. The depot facility may use an equivalent or alternative document to perform specific requirements as approved by the CONTRACTING OFFICER. If the depot facility chooses to use an equivalent or alternative document to perform specific maintenance tasks, then the depot facility shall submit the portion of the technical document that identifies the exact alternative steps/procedures that they propose to use, past performance data, cost data, reference USAF and USCG regulations, manuals and instructions being replaced. Any alternative procedure, process, specification, or standard approved by the government will be incorporated into government technical and engineering data as required. They should not include procedures, processes, materials, specifications, or standards that require research, development and/or testing or proprietary processes/materials that would degrade the government’s ability to maintain the aircraft at a later date at a government or another contractor’s depot facility.

1.9.1.3.1 Technical orders, specifications, standards and other documents identified as reference documents may be replaced and the depot facility may use an alternative document/standard, if approved by the government.

1.9.1.4 The depot facility shall control and maintain all TOs and other technical directives applicable to the work requirement in an updated and current status IAW TO 00‑5‑1. This requires compliance with the latest dated TOs and directives, regulations, U.S. government specifications and standards, drawings and other documents issued during the time the work requirement is being accomplished. The depot facility shall accomplish a timely review of all updated TOs and all other documents applicable to the work requirement. The review shall consider the impact on other work requirements, costs, schedules and any other relevant factors. Written evaluation along with specific back‑up data for those changes which impact the performance of the depot facility shall be forwarded to the CONTRACTING OFFICER within ten working days after receipt. The depot facility shall not begin work until changes have been approved by the CONTRACTING OFFICER.

TO

NUMBER

CGTO

16 W14-12-3

TO

NUMBER

Organizational Maintenance Manual Set MANUALS

* Update Jan 05

GROUND HANDLING

1C-130(A)H-2-05JG-00-1

Ground Handling

GROUND HANDLING

AIR CONDITIONING

AUTOFLIGHT

1C-130H-2-22JG-10-1-2

AP-105 Autopilot

TO

NUMBER

COMMUNICATIONS

ELECTRICAL

EQUIPMENT AND FURNISHINGS

*1C-130H-2-25FI-60-1

Emergency System

*1C-130H-2-25FI-80-1

Aerial Delivery Systems

FLIGHT CONTROLS

FLIGHT CONTROLS

FUEL

HYDRAULIC

ICE AND RAIN PROTECTION

LANDING GEAR

LIGHTING

(33FI-00-1-1-1)

(33FI-00-1-1-2)

(33FI-00-2-2)

NAVIGATION

OXYGEN

APU/GTC

1C-130E-2-49JG-00-1-1

GTC JGM

1C-130E-2-49JG-00-1-2

GTC JGM

APU/GTC

STRUCTURES

1C-130(A)H-2-51JG-00-1

Structures JGM

STRUCTURAL DOORS

WINDOWS

PROPELLERS

POWER PLANT

POWER PLANT

1C-130(A)H-2-71JG-00-1

Engine Operating Limits