C-9 SDLM Specification Rev 2011-08-19.docx

NAVAIR C-9B DEPOT SPECIFICATION

C-9B DEPOT LEVEL MAINTENANCE

SPECIFICATION

NAVY MODEL

C-9B

AIRCRAFT

PUBLISHED BY NAVAIR C-9B PROGRAM MANAGER PMA-207

This document is a complete revision and supersedes all previous editions.

All previous editions shall be destroyed.

15 August 2011 2-2

DEPARTMENT OF THE NAVY

NAVAL AIR SYSTEMS COMMAND

PATUXENT RIVER, MD 20670

Depot Level Maintenance Requirements for Navy and Marine C-9B aircraft.

1. This specification has been approved by the Naval Air Systems Command and is published to prescribe the Depot requirements for C-9B series aircraft.

2. Any recommendations for corrections, additions, or deletions should be addressed to:

Commander, Naval Air Systems Command (PMA-207) 46990 Hinkle Circle, Bldg 419 Attn: C-9B Engineering Patuxent River, MD 20670-1627

NAVAIR C-9B/DC-9 SDLM

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TABLE OF CONTENTS

Section/Paragraph Page

1-2. DEPOT INTERVALS/STRUCTURAL SERVICE LIFE LIMITS 1-2

1-3. MAINTENANCE REFERENCES 1-3

1-4. AIRCRAFT EFFECTIVITY CODES 1-8

NAVAIR C-9B DEPOT SPECIFICATION

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Section/Paragraph Page

ii

Section/Paragraph Page

2-9. DELETED

2-10. DELETED

III. PMI-1 THROUGH PMI-4 FUNCTIONAL FLIGHT CHECK AND GOVERNMENT ACCEPTANCE

3-2. FUNCTIONAL CHECK FLIGHT 3-4

IV. COMPONENT REMOVAL AND REPLACEMENT

4-1. DELETED 4-1

4-2. DELETED 4-1

NAVAIR C-9B DEPOT SPECIFICATION

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Section/Paragraph Page

5-2. NOTED BUT NOT CORRECTED REPORT 5-1

5-5. STRUCTURAL ALTERATION REPORT 5-7

VI. APPENDIX

6-3. ACRONYMS 6-12

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LIST OF TABLES

Table No.

NAVAIR C-9B DEPOT SPECIFICATION

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THIS PAGE INTENTIONALLY LEFT BLANK

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SECTION I: GENERAL INSTRUCTIONS

1-1 SCOPE. This specification establishes the depot level maintenance requirements for the PMI-1, PMI-2, PMI-3, PMI-4, and the Structural Integrity Assessment Program (SIAP) for Navy/Marine C9B aircraft.

1-1.1 The Planned Maintenance Interval (PMI)-1 through PMI-4 requirements defined herein provide for airframe, systems and component inspection, defect correction, preventive maintenance, and technical directive compliance. These requirements include, but are not limited to:

a. A comprehensive inspection of selected aircraft structures, flight essential systems, flight critical components, and subsequent repair and preventive maintenance as required ensuring serviceability until the next sequential Depot Level Maintenance or PMI induction.

b. Replacement of depot level time-change components, which will exceed the specified replacement intervals prior to the next scheduled depot visit.

c. Compliance with all approved technical directives, with the exception of deviations specified herein.

1-1.2 Adjustments, checks, tests, repairs, modifications, inspections, preventive maintenance, and rework shall be accomplished in accordance with the latest revision (unless otherwise specified) of applicable directives and publications as directed by this specification. Nonstandard repairs shall be developed when required by contractor's engineering in accordance with FAA requirements and approval of NAVAIR C-9B Engineering.

1-1.3 Section I of this specification provides general instructions relative to:

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1-1.4 Section II of this specification provides PMI-1 through PMI-4 and structural integrity program requirements relative to specific rework, inspection, and test requirements to be accomplished by the depot level rework activity responsible for the standard depot level maintenance of the C-9B aircraft.

1-1.6 Section IV of this specification is a compilation of the Component Removal and Replacement requirements contained in Section II of PMI-1 through PMI-4 requirements and specifies the authorized disposition of replaced components.

1-1.8 Section VI of this specification contains the Appendices that contain the paint specs and aircraft drawings and list of definitions and acronyms.

1-2 DEPOT INTERVALS/STRUCTURAL SERVICE LIFE LIMITS. Depot level maintenance for the C-9B aircraft is composed of repetitive rework at specified time intervals over the planned operational service life of the weapon system.

Periods Planned Operational Period (Mos) Operational Service Life (Mos.)

1-2

1-2.1 The depot level maintenance program consists of four scheduled depot level maintenance inductions during one operational service period cycle. These inductions are identified as PMI-1 at 20 months, PMI-2 at 40 months, PMI-3 at 60 months, and PMI-4 at 80 months. Specification inspection requirements which have an 80 month interval will be accomplished during the PMI-4 visit. Specification inspection requirements which have a 40 month interval will be accomplished during both the PMI-2 and PMI-4 visits. Specification inspection requirements which have a 20 month interval will be accomplished during the PMI-1, PMI-2, PMI-3 and PMI-4 visits. A complete Operational Service Period (OSP) will consist of a 20 month PMI-1, 40 month PMI-2, 60 month PMI-3, and 80 month PMI-4. Aircraft are not taken out of reporting during PMI events.

1-2.2 The operating service periods, planned operational service life (OSL), and authorized extensions are established by OPNAVINST 3110.11 (Series).

1-3 MAINTENANCE REFERENCES. To obtain maximum benefits available from the commercial sector, the use of commercial maintenance regulations, standards, etc. shall be used, when possible, in lieu of Navy documents normally required in these types of specifications. Therefore, commercial maintenance regulations, standards, etc. that are equivalent to the references listed below and annotated by "*" shall be used as an authorized substitution. Refer to paragraph 2-2.1 (Rework Requirements) of this specification for additional information.

PUBLICATIONS

TITLE

* Denotes Navy maintenance references; commercial maintenance regulations that are equivalent to these references can be used as a substitute to utilize best commercial practices

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PUBLICATIONS (cont’d)

TITLE

* Denotes Navy maintenance references; commercial maintenance regulations that are equivalent to these references can be used as a substitute to utilize best commercial practices

1-4

PUBLICATIONS (cont’d)

TITLE

* Denotes Navy maintenance references; commercial maintenance regulations that are equivalent to these references can be used as a substitute to utilize best commercial practices

NAVAIRINST

3710.1 (Series) Contractors Flight and Ground Operations

OPNAVINST

3710.7 (Series) NATOPS, General Flight and Operating Instructions

OPNAVINST

3750.6 (Series) Naval Aviation Safety Program

NAVAIRINST

4790.3 (Series) Aeronautical Time Cycle Management Program

OPNAVINST

5442.4 (Series) Aircraft and Training Devices Material Condition, Definitions, Mission Essential Subsystems Matrices (MESM) and Mission Descriptions

* Denotes Navy maintenance references; commercial maintenance regulations that are equivalent to these references can be used as a substitute to utilize best commercial practices

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MILITARY

SPECIFICATIONS

TITLE

* Denotes Navy maintenance references; commercial maintenance regulations that are equivalent to these references can be used as a substitute to utilize best commercial practices

MANUALS/

DIRECTIVES

TITLE

DoD Manual

5220.22 (Series) Industrial Security Manual for Safeguarding Classified Information

1-6

OPNAV Form 3760/2 Navy Aircraft Flight Record Discrepancy Report (Yellow Sheets)

OPNAV Form 4790/23A Repair/Rework Record

OPNAV Form 4790/24A Technical Directives

OPNAV Form 4790/27A Inventory Record

OPNAV Form 4790/28A Scheduled Removal Component Cards

OPNAV Form 4790/29 Aeronautical Equipment Service Record

OPNAV Form 4790/65 SDLM Special Work Request Form

OPNAV Form 4790/104 Aircraft Inventory Record Transfer Certification

1-7 1-4 AIRCRAFT EFFECTIVITY CODES. The effectivity code consists of four alphanumeric characters (i.e., A10K, B24K, etc.). The left alpha character is the application code. The numerical characters and the right alpha character identifies the threshold. In addition, a cross reference chart which incorporates the effectivity codes and corresponding BUNOs. The application code and threshold are further described below:

a. Effectivity code. Effectivity codes A through D are listed on page 1-27 identifying the aircraft bureau number(s) affected by the requirement.

b. An “X” preceding the effectivity code means that these tasks are Service Action [i.e. Service Bulletin (SB) or FAA Airworthiness Directive (AD)] related and could require repetitive action or terminating action and shall be accomplished only if directed by PMA 207.

C24K FLTHRS - Applies to BUNOs 161266, 161529, and 161530 and is initiated when those aircraft have reached or will exceed prior to the next scheduled depot visit a total accumulation of 24,000 flight hours.

XB - Applies to BUNOs 159113 thru 159116, 159118, and 160046 thru 160051 which are listed in the effectivity section of the referenced service action. These service actions may or may not have had terminating action therefore; they are listed in paragraph 2-11.1 or 2-11.2.

NAVAIR C-9B DEPOT SPECIFICATION

NAVAIR C-9B DEPOT SPECIFICATION

C - Applies to BUNOs 159266, 160529 and 160530.

1-

1-9

AIRCRAFT APPLICABILITY CHART

C-9B EFFECTIVITY CROSS REFERENCE LIST

2-1

SECTION II: DEPOT REQUIREMENTS

2-1 GENERAL. This section of the Depot Specification contains specific rework, inspection, test, and preventive maintenance requirements to be accomplished by the depot level rework activity responsible for accomplishing the PMI-1 at 20 months, PMI-2 at 40 months, PMI-3 at 60 months, PMI-4 at 80 months of Navy/Marine C9B aircraft. Each requirement shall be complied with as an item of scheduled maintenance at each depot visit, unless otherwise specified.

a. Nomenclature. Component nomenclature used in this specification is in general agreement with that used in the aircraft technical Maintenance Instruction Manuals. Inspection requirements for items identified by nomenclature are applicable to the entire class of part numbers for that item.

b. Specific Equipment. The inspection, replacement, or other maintenance actions required by this specification on specific equipment not installed on a particular C-9B aircraft shall be disregarded.

c. Part Numbers. Part numbers listed in this section are identifying the item for which a specific inspection exists.

2-2 GENERAL MAINTENANCE STANDARDS. This paragraph contains maintenance requirements and related instructions applicable to the rework of the aircraft weapons system. These standards do not establish inspection requirements. The information in this paragraph is necessary knowledge prior to the actual induction of the aircraft into depot level maintenance.

2-2.1 REWORK REQUIREMENTS. Contractor shall comply with the latest version (update, revision, change, Rapid Action Change (RAC), etc.) of publications, specifications, handbooks changes, bulletins, directives, and other publications listed in paragraphs 1-3, 2-6, and 2-8 of this specification and other applicable C-9B Engineering/NAVAIR directives, drawings, and publications, as required. The dates and update issues shown in the maintenance reference section are current as of the issue date of this specification and are to be used as a baseline only.

a. Applicable Documents. All maintenance practices and structural repairs shall be accomplished in accordance with applicable Federal Aviation Administration and Federal Aviation Regulations; NAVAIR 01-C9B-2 (Series) Maintenance Instruction Manuals; Boeing Commercial Aircraft DC-9 Series 30 Structural Repair Manual; Boeing Commercial Aircraft DC-9 Series 30 Overhaul Manual; and Navy instructions, manuals, standards, and specifications as required and listed in paragraph 13. When a conflict exists between C-9B specific publications and general Navy publications, the C-9B specific publication will take precedence.

(1) Contractor shall ensure that all installed TDs and terminating FAA and commercial directives are maintained and not removed during the PMI-1 through PMI-4 process.

b. Rework Procedures Approval. Rework procedures for the accomplishment of rework requirements shall be subject to inspection and approval by the Cognizant Government Representative or C-9B Engineering Department, as applicable.

c. Previous Improper Repairs. All previously installed repairs, which do not conform to FAA-approved maintenance practices, shall be identified and submitted for O&A rework to FAA standards in accordance with maintenance references listed in paragraph 1-3.

2-2.2 AIRCRAFT RECORDS MAINTENANCE. The Rework Activity shall maintain aircraft logbooks and records in accordance with COMNAVAIRFORINST 4790.2 (Series) from the date of acceptance of the aircraft into Rework/Repair to the date of acceptance by the aircraft custodian or his designated representative (see paragraph 3-1 for details).

a. PMI-1 through PMI-4 Compliance. A logbook entry shall be made stating compliance with the requirements of this specification upon completion of each depot visit. The total flight times accrued to date shall be entered with the above entry in the aircraft logbook.

b. TD Incorporation. All aircraft changes, bulletins, and other directives and modifications accomplished by the rework activity shall be properly reported and recorded in the applicable section of the aircraft logbook.

c. Entries and Insertions. Other logbook entries or page insertions shall be recorded in the aircraft logbook as specified by the requirements of this specification and as specifically directed by the Cognizant Government Representative or the C-9B Engineering Department.

NAVAIR C-9B DEPOT SPECIFICATION

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d. Unauthorized Entries. Terminating action for Airworthiness Directives (ADs), Service Bulletins (SBs), and All Operator Letters (AOLs) that are contained in the requirements of this specification shall be entered into the Aircraft Logbook Miscellaneous History Section. Repetitive inspection requirements shall not be entered into the Navy/USMC logbook unless specifically authorized by the C-9B Engineering Department.

2-2.3 TECHNICAL DIRECTIVE COMPLIANCE. All effective U.S Navy Technical Directives (TDs) not a part of this specification shall only be complied with and/or incorporated when directed by the Procurement Contracting Officer/Administrative Contracting Officer (PCO/ACO).

2-2.4 DEFECT CORRECTION CRITERIA. Defect classification shall be subject to the approval of the Cognizant Government Representative. The correction criteria for each classified defect are as follows:

a. Critical Defects. A defect that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the product; or a defect that judgment and experience indicate is likely to prevent performance of the tactical function of the aircraft. All critical defects discovered as a direct result of or incidental to, compliance with PMI-1, PMI-2, PMI-3, or PMI-4 requirements shall be corrected in accordance with documents listed in paragraph 1-3.

b. Major Defects. A defect, other than critical, that is likely to result in failure, or to reduce materially the usability of the unit of product for its intended purpose. All major defects discovered as a direct result of compliance with PMI-1, PMI-2, PMI-3, or PMI-4 requirements shall be corrected in accordance with documents listed in paragraph 1-3.

c. Minor Defects. A defect that is not likely to reduce materially, the usability of the unit or product for its intended purpose, or is a departure from established standards having little bearing on the effective use or operation of the unit. Minor defects shall be corrected in areas not normally accessible at the squadron level only if approved by local TYCOM liaison representative. Minor defects not corrected shall be annotated on the NBNC Report.

2-2.4.1 REDUCTION OF INSPECTION INTERVAL. In cases where a defect would cause a reduction in the inspection interval (i.e. less than 80, 60, 40, or 20 months), this reduction must be approved by the NAVAIR C-9B Engineering Department.

2-2.5 SCHEDULED COMPONENT REMOVAL/REPLACEMENT CRITERIA. Removal/replacement of components or accessories to be replaced with a new or overhauled item at scheduled aircraft flight hours, unit operating time, maintenance interval or calendar time not specified in Section 4.1 of this specification shall be accomplished only when ordered by the PCO/ ACO. Disposition of any such item shall also be specified by the PCO/ ACO. These items are identified in the C-9B Periodic Maintenance Information Cards (PMIC), NA 01-C9B-6.

2-2.6 UNSCHEDULED ACCESSORY AND COMPONENT REWORK CRITERIA. Unscheduled removal of components shall only be accomplished on an as required basis. Disposition of removed repairable components shall be specified by the PCO/ACO. Repairable accessories and components not otherwise scheduled for removal/replacement shall be subject to rework only on a discrepancy basis; i.e., determined defective by in-place operational checks/tests and inspections. Items removed on a discrepancy basis will normally receive specific repair in accordance with the following process:

a. Checks/test/examinations, as necessary, to isolate and identify the discrepancy.

b. Disassembly and rework only to the extent necessary to correct the discrepancy.

c. Correction of major and critical defects discovered coincidental to work.

d. Checks/tests only as necessary to validate the rework performed.

e. Installed operational checks/tests to validate proper operation in the design environment.

NAVAIR C-9B DEPOT SPECIFICATION

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2-2.8 ECONOMICAL REPAIR DETERMINATION. Economical repair determination shall be in accordance with local government procedures. This requirement may be waivered on individual basis by the PCO/ACO due to non-availability of replacement items.

2-2.9 AIRCRAFT ORGANIZATIONAL LEVEL SCHEDULED MAINTENANCE REQUIREMENTS.

a. Aircraft Phase/Special Inspections. Aircraft Phase/Special inspection requirements shall be accomplished, when due and if applicable, to the specific BUNO inducted when requested by the reporting custodian on the SWR and approved by NAVAIR.

b. Aircraft Conditional Inspections. Conditional inspections, when due, shall be performed during each scheduled depot visit.

2-2.10 CORROSION CORRECTION CRITERIA. Corrosion detected as a result of, or incidental to, compliance with Depot specification requirements shall be corrected in accordance with NA 01-1A-509 or NA 16-1-540, NA 01C9B2 (Series) Maintenance Manual and the Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual.

2-2.11 GROUND HANDLING, OPERATION, AND SAFETY PRECAUTIONS. Personnel involved in the ground handling and operation of an aircraft shall be thoroughly familiar with the emergency procedures of applicable documents listed in paragraph 1-3.

NAVAIR C-9B DEPOT SPECIFICATION

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a. Aircraft Fueling Operation. The instructions, procedures, and precautions of aircraft fueling operations shall be as specified by applicable documents and as directed by the Cognizant Government Representative or C-9B Engineering Department.

b. Aircraft Servicing. Aircraft servicing, taxiing, towing, parking, jacking, moving, and hoisting shall be conducted in accordance with COMNAVAIRFORINST 4790.2 (Series), OPNAVINST 3710.7 (Series), and equivalent commercial procedures as directed by the Cognizant Government Representative or C-9B Engineering Department.

c. Ground Operation of Engines. Ground operation of engines shall be in accordance with COMNAVAIRFORINST 4790.2 (Series) and OPNAVINST 3710.7 (Series) or equivalent commercial procedures.

2-2.12 STRUCTURAL REPAIRS. All structural repairs shall be accomplished in accordance with Boeing Commercial Aircraft DC-9 Series 30 Structural Repair Manual, NA 01C9B (Series) Manuals, and other applicable documents. These repairs shall be subject to inspection and approval of the Cognizant Government Representative or the C-9B Engineering Department.

a. Extent of Corrosion. When corrosion is detected by an inspection requirement or otherwise suspected and the extent cannot be determined, the adjacent structure shall be disassembled; i.e., the skin shall be peeled back, fittings or other structural members removed to determine the extent required.

b. Previous Repairs. All previous repairs that are not authorized by or do not meet the standards of quality, security, or strength of the applicable maintenance references shall be brought to the attention of the C-9B Engineering Department or the Cognizant Government Representative for disposition.

c. Major Structural Repairs. For repairs of a major nature exceeding the depth of coverage of the applicable maintenance reference, rework activities shall submit a detailed description of damage, method and details of recommended repair procedures, stress analysis, drawings, and specifications to the Cognizant Government Representative and C-9B Engineering Department.

d. Stress Analysis Criteria. The rework activity shall certify that each major structural repair meets the structural strength requirements specified by applicable documents.

NAVAIR C-9B DEPOT SPECIFICATION

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e. Welding. Weld repairs of structural members and primary components shall be performed in accordance with Boeing Commercial Aircraft DC-9 Series 30 Structural Repair Manual.

f. Invalidated Non-Destructive Inspection (NDI) Requirements. An NDI requirement of an area may be invalidated by a previous structural repair contained within that area. When a requirement or any portion cannot be accomplished due to a previous repair, the rework activity shall contact the Cognizant Government Representative for disposition. Resulting changes to requirements shall be documented in the Maintenance History Summary Report.

2-2.13 REPLACEMENT PARTS AND SUBSTITUTIONS. Replacement parts and material substitutions shall be in accordance with applicable NAVAIR 01-C9B (Series) Maintenance Manuals, FAA documents, NAVAIR TD, or C-9B Engineering Department direction.

2-2.14 UNAUTHORIZED INSTALLATIONS. All unauthorized installations or configuration shall be restored to an authorized configuration in accordance with applicable aircraft technical manuals.

a. Exceptions. Aircraft Controlling Custodian (ACC) authorized prototype Airframe Change (AFC), or Research, Development, Test & Evaluation (RDT&E) special installations shall only be restored or reworked when specifically requested by the ACC and approved by the Cognizant Government Representative or NAVAIR as applicable.

b. Interference with Depot Level Rework. When any of the above listed exceptions interferes with depot level or authorized work, the Cognizant Government Representative or NAVAIR shall be consulted for disposition.

2-2.15 DISTURBED SYSTEMS. Aircraft systems that are not inspected and are disturbed during the depot level maintenance process shall be operationally checked as necessary to verify proper installation and operation.

2-2.16 DEPOT TEST EQUIPMENT. All required test equipment shall be provided by the Commercial Rework Activity and shall be maintained with current calibration cycles and tags.

NAVAIR C-9B DEPOT SPECIFICATION

2-7 2-2.17 WEIGHT AND BALANCE. Weight and balance control of the aircraft during each depot visit shall be accomplished in accordance with NA-01-1B-50, NAVAIR 01-1B-40, and COMNAVAIRFORINST 4790.2 (Series), Volume II. When available, the preferred method is to utilize the Automated Weight and Balance System (AWBS) software available at (https://awbs.hill.af.mil/). A list of Chart "A" (DD Form 365-1) items not in the aircraft at time of weighing shall be provided in Chart "B" (DD Form 365-2) excluding items listed for compartment E through L (passenger/cargo rigging).

2-2.18 REPORT REQUIREMENTS. All rework activities shall prepare and submit required reports in accordance with Section VI of this specification.

2-2.19 ENGINEERING SUPPORT REQUIREMENTS. The rework activity shall provide engineering capability as required to perform continuous surveillance of the rework process, to solve problems, and to develop rework procedures, processes, or repairs not provided by applicable technical publications.

2-3 INDUCTION INTO DEPOT. This paragraph presents responsibilities of the reporting custodian prior to induction of the aircraft, procedures for conducting the aircraft equipment inventory, procedures for performing the aircraft records analysis, and the procedures for preservation.

2-3.1 REPORTING CUSTODIAN RESPONSIBILITIES PRIOR TO EACH DEPOT VISIT. With delivery of the aircraft to the depot facility, the reporting custodian shall provide:

a. Current Aircraft/Engine Logs and Records.

b. Aircraft Discrepancy Book

c. Mission-Essential Equipment.

d. Ferry Flight Discrepancy List.

2-3.2 AIRCRAFT EQUIPMENT INVENTORY. The rework activity shall conduct an equipment inventory jointly with the designated representative of the delivery activity as soon as possible after receiving the aircraft. The rework activity shall inventory aircraft equipment against property listed in the latest Aircraft Inventory Record, DD Form 7801/2 and OPNAV Form 4790/104. Accountability and shortages shall be documented in accordance with the aircraft inventory records.

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a. Classified Equipment. The rework activity shall inspect for the presence of classified equipment. If classified equipment is discovered that is not recorded on DD Form 254 in accordance with DoD 5220.22 (Series), the rework activity shall contact the local cognizant government representative for disposition.

2-3.3 PRESERVATION.

a. Scheduled /Unscheduled Maintenance

(1) Aircraft and Components. Aircraft and components shall receive preservation in accordance with requirements of COMNAVAIRFORINST 4790.2 (Series), NA 15-01-500 Preservation Manual and NA 03-105BC-39 APU Maintenance Manual.

(2) Aircraft Engines. Power plants shall be preserved in accordance with requirements of COMNAVAIRFORINST 4790.2 (Series) and NA 02BJT8D61 Maintenance Manual.

2-4 SURFACE CONDITIONING. In this paragraph, an overview for aircraft cleaning, condition evaluation, stripping of painted surfaces, corrosion removal, treatment, and painting are presented. In an effort to adhere to industry specifications to the highest extent possible, NAVAIR has authorized the use of commercial painting and stripping procedures outlined in the industry aircraft paint specifications using the contractor’s reference, Aircraft Exterior Coatings document. Former guidance was outlined in Maintenance Engineering Directive (MED) 05, Aircraft Paint System. General guidance is available in Appendix 6-1 and specific guidance can be obtained by contacting C-9B Engineering, PMA 207.

2-4.1 CLEANING.

a. Metal Surfaces. Clean external and accessible internal metal surfaces, equipment, and furnishings using methods and materials in the Aircraft Exterior Coatings document. General guidelines for the Aircraft Paint Specifications are included in section 6-1 of the Appendix.

b. Plastic Surfaces. Clean transparent and reinforced plastic surfaces using methods and materials specified by NA 011A509 and NA 01-C9B-2 (Series) Maintenance Instruction Manuals.

NAVAIR C-9B DEPOT SPECIFICATION

2-9 2-4.2 EXTERIOR SURFACE REPAINT REQUIREMENTS. On aircraft undergoing PMI-4 inspection frequency, the exterior surface of the aircraft shall be completely stripped and repainted IAW industry specific painting and stripping reference, Aircraft Exterior Coatings.

2-4.3 EXAMINATION AND REPAIR OF BARE SURFACES.

a. All surfaces shall be examined for corrosion, defective sealant, and/or missing fasteners.

b. Corrosion shall be removed and the affected areas treated or repaired in accordance with Aircraft Exterior Coatings (Associated Painters, Inc., July 2007), NA 01-1A-509, and applicable NA 01C9B2 (Series) Maintenance Instruction Manuals.

2-4.4 SURFACE RESTORATION.

a. Aircraft Exterior.

(1) All exterior seams and access panels shall be sealed with the exception of doors and panels routinely opened for maintenance and servicing (See NA 01C9B63 and 01-C9B64).

(2) Defective sealants shall be replaced in accordance with procedures in Aircraft Exterior Coatings (Associated Painters, Inc., July 2007) and Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual.

(3) Prepare the surface for painting in accordance with the procedures in Aircraft Exterior Coatings (Associated Painters, Inc., July 2007).

(4) Apply the exterior finish, markings, and insignias per current C9B paint drawing and NAVAIR 01-C9B-2-11.

(5) The finished paint system shall be evaluated in accordance with the quality criteria in Aircraft Exterior Coatings (Associated Painters, Inc., July 2007).

(6) Touch-up shall be accomplished per instruction in Aircraft Exterior Coatings (Associated Painters, Inc., July 2007).

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(7) Anti-chafe coatings and Mylar tape shall be applied in areas specified by in accordance with NA 01-C9B-2 (Series) Maintenance Instruction Manuals and Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual, Chapter 51. Restore stabilizer rub area, anti-chafe coating, and fairing rub strips as follows:

(a) Remove all horizontal stabilizer fairings. Inspect fairing for damaged and/or missing rub strips. Remove and replace defective parts.

(b) Inspect vertical stabilizer skin in rub area for evidence of chafing (scratches and gouges). Restore surface in accordance with Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual.

(c) Apply anti-chafe coating to vertical stabilizer surface areas which are covered by horizontal stabilizer fairings at both full nose up/down trim positions. Use gray anti-chafe coating number 7X83 paint kit consisting of 7-X-83 base material, 10-C-81 catalyst, and 60-C-20 thinner manufactured by Dexter Corporation, Haywood, California. Prepare surface, mix and apply paint, cure, and observe safety precautions in accordance with Boeing/Douglas Process Standards (DPS) 4.50-131F. If the above standard is not available, refer to Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual, Section 51-10-8, pages 1 through 4 with the following changes that reflect newer paint (7-X-83 vice 7-X-75).

1) Use mixing ratios, paragraph 2A:

66.6 Parts by Weight: Base

18.5 Parts by Weight: Catalyst

14.9 Parts by Weight: Thinner

Mix only amount of paint to be consumed in four (4) hours.

2) Allow five (5) minutes drying time between coats of anti-chafe paint.

3) Total cure time at ambient temperature is 24 hours.

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(d) Reassemble and shim horizontal fairings in accordance with NA 01-C9B-2 (Series) Maintenance Instruction Manual.

b. Interior Surfaces. Interior finish shall be applied in accordance with Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual.

(1) Finish battery boxes and bay areas using materials specified in Boeing Commercial Aircraft DC9 (Series) 30 Structural Repair Manual.

(2) Finish interior metal surfaces in inhabited areas, as required. Ensure Mylar Tape is applied to lavatory floors.

(3) Finish interior metal surfaces in uninhabited areas as required. Apply interior markings in accordance with NA 01-C9B-2 (Series) Maintenance Instruction Manuals and Illustrated Parts Manuals, Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual, DS-3902A-C and DS3933, Navy LMAC Report No. C9B2511 Revision B, and Marine LMAC Report No. C9B-DFSM 01 Detail Specifications.

c. Main and Nose Landing Gear Wheel Wells. Interior surfaces of these areas will receive selective touch-up. Determinations for touch up efforts will be made by inspecting wheel well areas for corrosion, flaking, and alligatored paint surfaces. These conditions, if present, will be corrected by feathering the adjacent paint surface treatment, primer, and application of a top coat in accordance with Boeing Commercial Aircraft DC-9 (Series) 30 Structural Repair Manual.

d. Flaps and Slats. All exposed areas of fully extended flaps and slats shall be stripped, treated, primed, sealed, and painted using the same procedure that applies to aircraft exterior surfaces. Flap wells shall be cleaned and inspected for corrosion and flaking or alligatored paint surfaces. Selective touch-up as necessary.

e. Wing Fillets. Wing fillets shall be removed and the interior side and exposed wing/fuselage areas shall be cleaned, inspected, and paint surfaces restored by selective touch-up. Corrosion preventative compound DINOL AV-30 or equivalent per DMS 2150 shall be maintained in accordance with NA 01-1A-509.

f. Servicing and Routinely Opened Panels. Inspect for general condition and paint deterioration. Clean, sand, seal, and touch up paint as necessary.

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g. Fiberglass Surfaces. Exterior fiberglass surfaces including antennas shall be cleaned and inspected for cracks. All fiberglass surfaces shall be scuff sanded and feathered prior to aircraft painting.

h. Access Panels. Panels not routinely opened shall be maintained with a coating of DINOL AV-30 or equivalent with approval from C-9B Engineering PMA 207 per DMS 2150 corrosion preventative compound in those areas susceptible to corrosion.

i. Stairwell. Stairwells shall be maintained with a coating of DINOL AV-30 or equivalent with approval from C-9B Engineering PMA 207 per DMS 2150 corrosion preventative compound.

j. Fuselage Bilge. Interior fuselage structure between longerons 26L to 26R shall be maintained with DINOL AV-30 or equivalent with approval from C-9B Engineering PMA 207 per DMS 2150 corrosion preventative compound.

2-5 DISASSEMBLY. In this paragraph, installation of safety devices, safety procedural requirements, the criteria for disassembly, the extent of disassembly, and defects discovered during disassembly are presented.

2-5.1 INSTALLATION OF SAFETY DEVICES AND PROCEDURES. Ensure safety devices are installed in accordance with applicable NAVAIR and Boeing/DAC documents.

2-5.2 GENERAL.

a. Criteria for Disassembly. Disassemble the aircraft sufficiently to perform the inspection requirements of paragraphs 2-4, 2-6, and 2-8, required restoration, authorized modifications, and tests.

(1) It is intended that the disassembly examination be accomplished by the highest quality personnel to preclude the possibility of overlooking structural deficiencies that may escape detection by less skilled personnel.

NAVAIR C-9B DEPOT SPECIFICATION

2-13

2-5.2.1 ADDITIONAL SPECIFIC DISASSEMBLY AND PROCESSES.

MAP ALL FLOOR BOARDS AND PROVIDE DOCUMENTATION TO NAVAIR VIA WEB-BASED INFORMATION SYSTEM (WIS). MAPS WILL BE TAIL NUMBER AND BUNO SPECIFIC. VALIDATE AT EACH PMI.

ST113

PMI-1Thru 4

2-6 STRUCTURAL AND ZONAL REQUIREMENTS. The inspection and rework requirements listed in this paragraph shall be accomplished during PMI-1 through PMI-4 processing.

a. Structural Inspection Requirements. The structural inspection requirements are listed in this paragraph in ascending zone sequence. Each item listed shall be inspected, tested, reworked, or replaced as specified, at the designated frequency.

b. Zone Description. The descriptions of the boundaries of each zone are covered in paragraph 2-7 of this specification.

c. Corrosion Inspections. Perform all specified corrosion inspections in accordance with NA 01-1A-509, NA 01-C9B-2 (Series) Maintenance Instruction Manuals.

d. Visual and Non-Destructive Inspections (NDIs). The zone inspection requirements specified in this part provide for visual inspection and NDIs to be performed on selected parts of the aircraft. When cracks or defects are suspected, the subject part shall be inspected using NDI methods in accordance with Boeing Commercial Aircraft (Series) 30 Structural Repair Manual/NDI Manual. Unless otherwise specified, all inspections are performed visually with sufficient lighting. Areas inspected shall be cleaned as necessary to accomplish the inspection.

2-6.1 EXPLANATION OF HEADINGS. The columns in the STRUCTURAL AND ZONAL REQUIREMENTS table are explained as follows:

a. Task Identification (ID) Number. This is a unique reference for each inspection requirement in sequential order and is located in the extreme left hand column of the structural and zonal requirements listing. The task "ID" number consists of five or six alpha-numeric characters (i.e., ST002, ST002A, SY032, SY180B). The first two characters are alpha characters which identify the requirement category. In this section are "Structural and Zonal" requirements which are identified by "ST". The middle three characters are numbers sequentially assigned starting with 001 for each requirements category. The last character is an alpha character used to denote that a requirement has been added following a basic sequence number.

b. Zone Number. This is the location on the aircraft where the inspection is to be performed. See paragraph 2-7 for zone locations and inspection scope.

c. Effectivity. This identifies specific aircraft bureau numbers and any applicable threshold for which a given inspection task applies. See paragraph 1-4 of this specification for code/aircraft bureau number and threshold identification.

d. Requirement. This identifies the zone for the requirements, the nomenclature of the items in the zone to be inspected, the inspection requirement, and the identification of applicable sampling…