ACI_Spec_v_Oct_2011_26_Aug15.doc

(Navy) AIRCRAFT CONDITION INSPECTION

CLASS I

MED (C-12)-065

Oct 2011

SECTION I

GENERAL INSTRUCTIONS

1-1 SCOPE

1-1.1. General:

a. This specification establishes the Aircraft Condition Inspection (ACI) requirements for the U.S. Navy C-12 series aircraft.

b. The ACI requirements are expected to restore aircraft subjected to this process to a condition which can be maintained at the field level to ensure a high level of operational availability for the duration of the designed service period and to provide interim support during total service life. These requirements include, but are not limited to:

(1) A thorough and comprehensive inspection of selected aircraft structure, flight essential systems, and flight critical components by appropriate inspection methods with repair as required to ensure aircraft serviceability until the next sequential ACI induction.

(2) Incorporation of authorized Technical Directives.

(3) Replacement of time change components assigned to depot level at specified replacement intervals.

(4) Repaint the exterior of the aircraft

c. Adjustment, checks, tests, repairs, inspections, and preventive maintenance shall be accomplished in accordance with applicable directives and publications as directed within this specification.

d. This specification will be evaluated on an annual basis for content and effectiveness of each of the inspection criteria and, if required, adjusted to fit the current fleet requirements. If there are mid year requirements Section VIII contains the Functional Reporting Requirements that will be filled out and submitted.

1-1.2. Contents:

a. Section I of this specification provides general instructions relative to: (1) the purpose and scope of ACI, (2) specification revision information, (3) definitions of terminology of ACI, and (4) maintenance publications and documents required to perform ACI.

b. Section II of this specification contains general and specific rework requirements; standards, guidelines, instructions, inspections, tests, and rework to be complied with and accomplished by the rework activity. Each item shall be complied with as an item of scheduled maintenance. At completion of all such repair and rework, the aircraft and its accessories/components shall be completely reassembled, applicable systems rigged, aligned and/or tested in accordance with the specified requirements and the aircraft flight checked in accordance with Section III.

(1) The scheduled maintenance requirements prescribed in this specification comprise the minimum requirements necessary to ensure the timely discovery and correction of actual and/or anticipated defects based on the aircraft class and intended use. Compliance with these requirements is mandatory.

(2) Unscheduled maintenance requirements are those requirements that cannot be directly related to any scheduled requirement. These are only discovered as an incidental result of the following functions which are accomplished as a part of and during the scheduled inspections: (1) review of aircraft logbooks and records, (2) the operational/functional testing of systems or (3) inspection of the aircraft and its components during ACI.

c. Section III describes the functional check flight requirements to be complied with prior to the delivery of the reworked aircraft.

d. Section IV is a tabulated listing by aircraft systems of components requiring replacement as a function of flight hours, or unit operating time or cycles.

e. Section VI is the Aircraft Maintenance History Summary Report Requirements. This section provides general and specific reporting requirements to ensure complete documentation of maintenance performed during ACI.

f. Section VII is the Structural Sampling Report Requirements. These requirements are supplemented by.

(1) Illustrations giving specific locations and,

(2) Forms to report amount and severity of corrosion.

g. Section VIII contains the Functional Reporting Requirements. These requirements are supplemented by forms to report actions taken during testing.

1-1.3. Error! Bookmark not defined. Change Recommendations:

a. Recommendations for additions, deletions, or changes to the requirements of this specification are invited and should be submitted to the Program Manager 207, Attn: Code 207.3C, 46990 Hinkle Circle, Bldg 419, Patuxent River, Maryland 20670-1627.

1-2 AIRCRAFT CONDITION INSPECTION INTERVALS:

1-2.1. Aircraft Condition Inspection for the U. S. Navy C-12 aircraft are prescribed initially as a function of the planned operational service life of the aircraft. Operational service life is measured in terms of operational service months accumulated between periods of rework.

1-2.2. Rework intervals (operational service months per period) and the number of periods of the C-12 are 60 months.

1-3 DEFINITIONS:

1-3.1. The purpose of this Glossary is to establish a mutual basis of communication to avoid misinterpretation and distortion of the terminology, and therefore the intent, of the requirements of this specification.

1-3.2. The terms are defined in the context of their usage as applied to the specification. Generally accepted interpretations and colloquial usage are unacceptable unless in exact agreement.

Abrasion. Abrasion is the condition of wearing away by rubbing or scraping (synonymous with Chafing).

Accessible. Areas exposed by the removal of non‑permanent fasteners, access doors, panels, fairings, etc., or other disassembly required by a maintenance requirement which does not involve destructive disassembly unless otherwise specified.

Accessory. A part, subassembly, or assembly designed for use in conjunction with, or to supplement another assembly, unit, or set that contributes to the effectiveness thereof without extending or varying the basic function of the assembly or set. An accessory may be used for testing, adjusting, or calibrating purposes. Examples are test instrument, recording camera for radar set, headphones, and emergency power supply.

Aircraft Condition Inspection (ACI). Depot level aircraft maintenance accomplished upon an attainment of a specified number of calendar months of service as designated by the operating Service.

Airframe. The structural components, including the framework and skin, of such parts as the fuselage, empennage, wings, control surfaces, landing gear (minus wheels and tires) and engine mounts.

Airframe Accessories. The items of equipment that are required for operation of the aircraft and that cannot be considered an integral part of the airframe or engine, such as wheels, brakes, hydraulic equipment, fuel system, de‑icing equipment, anti‑icing equipment, and other items not an integral part of the airframe, regardless of whether attached to the engine or airframe.

Assembly. Any combination or number of parts or subassemblies joined together to perform a specific function.

Attachment. A part, subassembly, or assembly designed for use in conjunction with another assembly, unit, or set that contributes to the effectiveness thereof by varying the basic function of the assembly or set.

Calibrate. To determine and make required corrections in calibration standards or Precision Measuring Equipment (PME) used in precise measurement or to repair adjust and align equipment so that it functions within assigned tolerances; may consist of the comparison of two instruments, one which is a certified calibration standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the other instrument or PME being compared with the certified calibration standard.

Chafing. The wearing away of material by rubbing or scraping (synonymous with Abrasion).

Check. To compare the characteristics of an item with established standards.

Check Flight; Functional. Airborne operational test performed to determine whether the airframe, power plant, accessories, and other items of equipment are functioning in accordance with predetermined standards when subjected to the intended operating environment.

Checkout. A sequence of functional, operational, and calibration tests to determine the condition and status of a system or element thereof.

Cleanliness. The state of being free from impurities, impediments, and foreign matter not specified to be applied to the surface in question.

Component. A number of parts or subassemblies, or any combination thereof, joined together to perform a specific function.

Component, Scheduled Removal. Components whose overhaul or replacement schedule is established as a function of service use (flight hours, unit operating time or calendar time, cycles, events or OSP intervals).

Composite Material. A material composed of two or more different constituents, the combination of which results in a product superior in some mechanical properties to any of its constituent parts.

Concurrent Component Rework. The removal of a defective component from an aircraft, repair of that item concurrent with ACI processing of the aircraft, and reinstallation of that item on the same aircraft.

Configuration Identification. The current approved or conditionally approved technical document for a configuration item as set forth in specifications, drawings, and associated lists and reference documents.

Corrosion. An action or process which destroys metal by chemical or electrochemical action and converts it into an oxide, hydroxide, or sulfate compound.

Crack. A break, fracture, crevice, or separation in the structure of a part.

Crazing. Fine cracks, which may extend in a network, in plastic material (i.e., windshields, canopy glass, windows, etc.).

Damage. Impairment of an aircraft/item/part by a physical force.

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

Defect, Critical. A defect that constitutes a hazardous or unsafe condition, or as determined by experience or 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.

Defect, Major. A defect, other than critical, that could result in failure, or materially reduce, the usability of the unit or part for its intended purpose.

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.

Defective. The state of possessing a deviation from specified requirements.

Deformation. Any disfiguration or change in form or shape from the intended design configuration.

Delamination. A physical break of the bond between the binder material and any two or more plies of laminated panels fabricated of plastic, metal, composite material, or other material.

Detailed Inspection. A thorough examination of the appliances, the aircraft, and components and systems with such disassembly as necessary.

Deterioration. The breakup, eating away, or decomposition of a substance by the action of weather, corrosion, or other environmental conditions.

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

Distortion. Any disagreement or change in form or shape from the intended design configuration resulting from a twisting or torsional action.

Disturbed System. A system whose installed integrity has been interrupted, broken, or interfered with to the extent that system installation and operational cannot be assured without verification by a functional or operational check or test.

Evidence. Factual data which establishes the possibility of an existing or impending unsatisfactory condition.

Equipment. A collection of items consisting of parts, subassemblies, components, assemblies, units, groups, sets, subsystems, and systems.

Examination. An element of inspection consisting of investigation, without the use of special laboratory appliances or procedures, of supplies and services to determine conformance to those specified requirements that can be determined by such investigations. Examination is generally nondestructive.

Exterior Surface. That part of the airframe exposed to the elements when in a "clean" flight configuration, including wing and stabilizer control surface wells (aileron, flap, rudder, and elevator). Does not include landing gear structure, wheel wells, or areas exposed by deflection of slats, vanes, speed brakes, wing folds, etc., or extension of landing gear.

Failure. The inability of an item to perform within previously specified limits.

Fraying. The wearing away by rubbing, usually of woven, braided, or stranded material, which results in a worn or ragged appearance.

General Electric/Electronic Wiring Circuitry Verification. A test of system wiring and wiring components to verify ability of aircraft wiring to perform its intended function when mated to a set of operational black boxes. May be accomplished by either of the following procedures:

a. Functional or operational test of the system using existing aircraft black boxes, if operable, or "slave" units, if available. Tests shall be limited to the depth required to demonstrate adequacy of system wiring.

b.

Any suitable method of continuity and insulation resistance checks.

Groove. Any narrow furrow, depression, or slit on the surface of a part.

Group. A collection of units, assemblies, or subassemblies that is a subdivision of a set or system, but is not capable of performing a complete operational function (see System).

Inclusion. A void or discontinuity in the molecular structure of metal.

Inspect. To perform critical investigation of an item, unit, component or airframe through the visual, auditory, olfactory and tactile senses, utilizing simple manipulation, gauging and measurements as required for the specific intent of determining its conformance to the assigned specifications within the tolerances permitted and may require partial disassembly of such items.

Inspection. To compare the characteristics of an item with established standards. Inspection includes, but is not limited to, sight, hearing, smell, touch, taste, and other investigations; simple physical manipulation, gauging and measurement. The process may require partial disassembly of the item.

Inspection, Conditional. An unscheduled inspection required as a result of an over limit situation. A logbook entry is required for a conditional inspection of an aircraft and any component/equipment.

Inspection, Scheduled. An inspection with a standard interval such as daily, calendar/phased, major engine or ACI (Aircraft Conditional Inspection). The intervals are specified in the applicable Beech Maintenance Manual and are based on elapsed calendar time, flight hours, operating hours, or number of cycles/events (e.g. 14, 28 days/50, 100, 200 hours etc.). Logbook entries are required.

Major Structural Damage. Damage which requires removal or extensive in‑place repair, and repair or replacement of airframe structural members.

Mission Essential Equipment. All equipment, parts, and accessories necessary to perform a specified mission.

Modify. To alter in appearance, performance, function, position, or effect.

Nick. Any notch, slit, cut, or chip on the surface of a part.

Overhaul, Component. Rework performed on a component which includes disassembly sufficient to inspect all constituent parts, followed by cleaning, repair, replacement of consumables and defective parts as required, servicing reassembly and checks/tests in accordance with applicable overhaul specifications, instructions and procedures.

Part. One piece or two or more pieces joined together, not normally subject to disassembly without destruction of designed use.

Pitting. Any small, approximately circular indentation, depression, hollow, or scar in the surface of a part; generally the result or corrosion of erosive action.

Quality Assurance. A planned program of actions necessary to provide confidence that processing conforms to established standards.

Refinish. To restore an existing surface finish without removal of all the existing finish. The process of refinishing includes cleaning the affected area to remove all loose an scaling paint or other finishing material, soil, and contaminants; featheredging the remaining original finish to a smooth surface; and applying new finish coatings (including chemical conversion coatings).

Refurbish. To repair and renovate aircraft interior furnishings to acceptable standards of appearance and comfort consistent with the assigned mission of the aircraft. Includes replacement of deteriorated, worn, or damaged furnishings.

Reinstall. The reinstallation of a part or component in its former position to accomplish its former function.

Reliability. The probability that material will perform its intended function for a specified period under stated conditions.

Remove. The physical separation of an item from its designed position. Removal is normally required to facilitate a maintenance action on the item or on the area or items exposed by the removal. Implicit in the requirement for removal is the requirement for reinstallation.

Repair. Whatever is required to restore an item to serviceable status, including preparation, disassembly, inspection, fault correction, replacement of parts, adjustment, reassembly, calibration and tests.

Repair as Required. The unscheduled repair of discrepant items when the repair is technically feasible or economically justified and is based on inspections and tests or authorized directives to restore the item to an operable condition.

Replace. To install a like serviceable item in place of the removed item.

Replace as Required. Directs the unscheduled replacement of discrepant items when the replacement is technically feasible or economically justified and is based on inspections and tests or authorized directives.

Rework Activity. The industrial establishment, either government or commercial, designated by the respective Service or Department of Defense as having depot maintenance responsibility for rework of a particular model aircraft or aircraft components.

Sampling Inspection. A depot level inspection for impending failures or specified defects on a designated structurally significant item/component which is performed on less than all of the fleet of a type/model/series aircraft and requires the completion of a sampling report form to document sampling inspection findings.

Sampling Program. A depot level inspection program which uses one or more sampling plans to best evaluate the applicability, effectiveness, or necessity for inspection requirements of designated structurally significant items/components on a type/model/series.

Security Inspection. An inspection to verify that an item is positively and safely attached and secured in the approved manner specified by applicable drawings and specifications.

Service. The performance of any act (other than corrective maintenance) required to maintain an item of equipment in operating condition, such as lubricating, fueling, oiling, cleaning, etc., but does not include periodic replacement of parts or any corrective maintenance task.

Serviceable. The condition of an item in which all requirements of repair, check/test, rework, or modification, as applicable, have been accomplished, making it capable of performing the function or requirements for which originally designed or later modified as directed by approved technical directives. (Synonymous with Ready for Issue.)

Service Life Expectancy. The projected operational usefulness of an aircraft component in terms of operating time, cycles, or calendar age as determined through engineering estimates or actual operational experience. The time or age figure (i.e., 1000 hours, 36 months, etc.) used in relation to service life expectancy represents the point at which continued use of the component would create a high probability of failure within a short period of time.

Set. A unit or units and necessary assemblies, subassemblies and parts connected or associated together to perform an operational function.

Specified. Used to define a definite amount, operation, or limitation which has been established and is contained in applicable directives.

Structure. Load bearing elements that make up the aircraft.

Subassembly. Two or more parts which form a portion of an assembly or a unit, replaceable as a whole, but having a part or parts which are individually replaceable.

Substitute Items. Two or more items possessing such functional and physical characteristics as to be capable of interchangeability for particular applications without alteration of the items themselves.

System (Electrical‑Electronics). A combination of two or more parts, assemblies, or sets generally physically separated when in operation, and such other assemblies, subassemblies, and parts interconnected as necessary to perform an operational function or functions.

System (General). A combination of parts, assemblies, and sets joined together to perform a specific operational function or functions.

Test. Evaluation of aircraft items (e.g., airframe, power plant, accessories, equipment, equipage, etc.) under specified conditions to verify functional conformance to predetermined requirements in accordance with applicable directives.

Test, Bench. Test of individual items using shop equipment.

Test, Functional. The quantitative evaluation of a system or component to assure its ability to perform over the full operating range as designed and within specified limits. Test equipment is normally used to provide precise inputs and to make measurements.

Test, Operational. The exercise of a system or component, within its operating modes, to assure operation without interference and in proper direction and sequence of intended performance. Normal operation is verified through observation of overall performance without resort to measurement.

Unit. An assembly or any combination of parts, subassemblies, and assemblies mounted together normally capable of independent operation in a variety of situations.

Unscheduled Maintenance Checks. A maintenance action required as a result of an over limit condition.

Zonal Inspection. A general visual inspection of all structure and installations contained within the designated boundaries of a zone. Structure and installations within zones that require more extensive inspections are separately identified by specific requirements.

Zone. An area of the aircraft defined by physical boundaries, title, and major installations.

1-4 MAINTENANCE REFERENCES:

The following specification, drawings, directives, and publications form a basic part of this specification. Compliance with the latest issue date of all technical manuals, directives, specifications, and publications is mandatory when:

a.

They are pertinent to the aircraft and installed equipment, and the rework activity is authorized to accomplish the work therein.

b.

The prescribed rework policies, use of materials and procedures for rework.

Several references have multiple numbers assigned (one for each service that uses the manual). All those numbers are listed hereafter but the following text lists only the Navy number. The Air Force does not have similar CNO procedures.

1-4.1. CNO Procedures:

1-4.2 Services Instructions:

1-4.3 Military Publications:

NA 01-1A-1

General Manual for Structural Repair

NA 01-1A-8

Aircraft Structural Repair

NA 01-1A-9

Aerospace Metals General use Factors Engineering Series for Aircraft Repair

NA 01-1A-12

Aircraft Repair Fabrication Maintenance and Repair of Transparent Plastics Engineering Series Handbook

NA 01-1A-16

Nondestructive Inspection Methods, Technical Manual

NA 01-1A-503

Aeronautical Antifriction Bearings for Organizational, Intermediate, and Depot Maintenance Levels, Maintenance of

NA 01-1A-505

Aircraft Electric and Electronic Wiring Installation Practices

NA 01-1A-509

Aircraft Weapons System Cleaning and Corrosion Control for Organizational and Intermediate Maintenance Levels

NA 01-1B-40

Weight and Balance Data

NA 01-1B-50

Aircraft Weight and Balance Control

NA 01-C12AAA-1

NA01-C12AAB-1

NA 01-C12FFF-1

NA 01-C12MMM-1

UC/TC-12B/F/M Aircraft NATOPS Flight Manuals

NA 01-C12FFF-1.1

NA 01-C12MMM-1.1

RC-12F/M Aircraft NATOPS Flight Manuals

NA 16-01-540

Avionics Cleaning and Corrosion Prevention/ Control Technical Manual

1-4.6 Manufacturer Publications

Beech Drawing

101-000042-1 Navy Insignia and Markings

1-4.7 Federal Aviation Regulations:

1-4.8 Advisory Circulars:

1-4.9 Airworthiness Directives:

1-4.10 Miscellaneous:

1-4.11 Federal Specifications:

1-5

APPLICABLE CODES:

1-5.1 Aircraft model applicable codes are used throughout this Specification to indicate the model on which the work requirements shall be performed.

APPLICATION

CODE

All Models A

UC/TC-12B

B

UC-12F/RC-12F

C

UC-12M/RC-12M

D

SECTION II

AIRCRAFT CONDITION INSPECTION (ACI) REQUIREMENTS

1.

GENERAL MAINTENANCE STANDARDS:

This section contains specific rework, inspection and test requirements to be accomplished by the depot level Rework Activity responsible for the Aircraft Condition Inspection of the C-12 series aircraft. Each requirement shall be complied with as an item of scheduled maintenance at each ACI unless otherwise specified.

I. Component nomenclature used herein is in general accordance with that used in the aircraft technical maintenance manuals.

I. The inspection, replacement or other maintenance action required by this specification on specific equipment not installed on particular C-12 aircraft shall be disregarded on those aircraft so affected.

I. Part numbers listed in this section are for reference only. Equivalent parts with different part numbers or identified only by nomenclature, serving the specified or implied function, are subject to the specified maintenance requirements.

I. General Requirements:

I. Aircraft/engine organizational level scheduled maintenance requirements.

I. Phase Inspections: Accomplishment of the requirements of the next aircraft and engine phase inspection is not a requirement of ACI.

I. Daily Inspection: Accomplishment of the requirements of a Daily Inspection is a requirement of ACI. A Daily Inspection will be performed before the first check flight following ACI and before final acceptance of the aircraft.

I. Corrosion Control Inspection: Accomplishment of the requirements of the next aircraft Corrosion Control Inspection is not a requirement of ACI. Complete compliance of all corrosion inspections occurs through equivalent ACI requirements.

I. Unscheduled Maintenance Checks: Accomplishment of the requirements of Unscheduled Maintenance Checks is a requirement of ACI when due. Unscheduled Maintenance Checks are identified in the Beech A200/B200 Maintenance Manual, Chapter 5-50-00.

I. Maintenance Practices: All maintenance and structural repairs shall be accomplished in accordance with the Raytheon Structural Repair Manual, FAA Advisory Circular 43.13-1B and 2 and FAA regulations 43.3, 43.5, 43.7, 43.9, 43.13, and 145. All previously installed repairs which do not conform to Raytheon Aircraft or FAA maintenance practices shall be reworked to the above standards unless otherwise directed by the Navy.

I. Disturbed systems: Aircraft systems, not otherwise assigned a requirement for an operational check/test, that are disturbed during ACI processing to the extent that the systems integrity (i.e., installation and operation) cannot be assured, shall receive an operational check/test as necessary to verify proper installation and operation.

I. Defect Correction Criteria:

I. Critical Defects. All critical defects discovered as a direct result of, or incidental to, compliance with ACI requirements shall be corrected in accordance with applicable documents.

I. Major Defects:

I. All major defects discovered as a direct result of compliance with ACI requirements shall be corrected in accordance with applicable documents.

I. Major defects discovered incidental to compliance with ACI requirements that require skills, tools, or other support available only at depot maintenance, or are located in an area not normally opened or inspected by organizational maintenance, shall be corrected in accordance with applicable documents.

I. Minor Defects: Minor defects located in an area not normally opened or inspected by organizational maintenance shall be corrected in accordance with applicable documents.

I. Defects Caused by Rework Activity: All defects caused by the rework activity shall be corrected in accordance with applicable documents.

I. Classification of Defects: Classification of defects shall be subject to the approval of the cognizant engineering authority or government representative, as applicable.

I. Rework Procedures.

I. Applicable Documents: ACI procedures shall comply with publications listed in Section I, maintenance references, applicable Service CFA directives, aircraft/equipment technical manuals applicable to the processing, rework and repair of specific model aircraft/ equipment. In case of Conflicting instructions the order of precedence is Beech Aircraft Corporation manuals, other applicable manufacturers’ manuals, FAA manuals, then Service manuals.

I. Source Applicable Documents: The commercial rework activity will receive an initial allowance of those Service documents, drawings and specifications that are referenced by this specification. Commercial and FAA publications are to be obtained by the rework activity. The rework activity shall be responsible for obtaining all other publications applicable to ACI processing.

I. Technical Directive Compliance:

I. FAA Airworthiness Directives, Beech/Raytheon Aircraft Service Instructions, Raytheon Aircraft Service Bulletins, Navy Maintenance Engineering Directives and Rapid Action Minor Engineering Changes (RAMEC) shall only be complied with and/or incorporated when directed by the appropriate Service office.

I. Aircraft Records Maintenance:

I. The rework activity shall maintain the power plant logbooks in accordance with AC 43.9 and the aircraft logbook in accordance with Service directives from the date of acceptance of the aircraft from the government to the date of acceptance by the government.

I. Upon completion of each ACI rework, a logbook entry shall be made stating compliance with the requirements of this specification. The total flight time accrued to date shall be entered with the above entry in the aircraft logbook.

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

I. Engineering information on all modifications engineered by the Rework Activity directed by the Service be prepared in general accordance with the format of appropriate Service directives with engineering drawings prepared, as required, in accordance with DOD‑STD‑00100. A copy of all engineering modification/repair directives and drawings shall be forwarded to Program Manager PMA 207, Patuxent River, MD 20670‑5449, ATTN: Code 207.3E4.

I. Inspection Work Sheets:

I. The Commercial Rework Activity shall utilize appropriate inspection work sheets to record aircraft serial number, items of work, Technical Directives accomplished, inspections performed, discrepancies discovered, certifications of work accomplished and other necessary data.

I. Describe each discrepancy discovered through compliance with the inspection requirements of this specification. (Identify as critical, major or minor).

I. List discrepancies reported in aircraft maintenance records.

I. List Technical Directives authorized for accomplishment.

I. Record all accessories and components removed for rework or replacement (cite identity, reason for removal and corrective action/disposition).

I. After the work to be accomplished has been determined and described on the inspection work sheets, the Rework Activity shall correct the discrepancies when required by this specification.

I. Nondestructive Inspection Processes:

I. Nondestructive inspections shall be performed in accordance with the requirements and instructions of this specification.

I. Operators of Magnetic Particle, Penetrant, and radiographic inspection processes shall be examined and qualified in accordance with NAS 410.

I. When visual inspection of components proves insufficient to firmly establish condition and disposition, the appropriate process shall be applied in accordance to establish condition and disposition.

I. Ground Handling, Operation and Safety Precautions:

I. Operating personnel shall be thoroughly versed in the emergency procedures pertaining to the ground operation of the aircraft contained in the applicable aircraft maintenance instructions.

I. Comply with the instructions, procedures and precautions directed to the aircraft fueling operation of the Raytheon Maintenance Manual and as directed by the Cognizant Government Representative.

I. Aircraft servicing, taxiing, towing, parking, jacking, moving and hoisting shall be in accordance with the instructions and precautions of the applicable aircraft maintenance instructions.

I. Ground operation of engines shall be in accordance with the applicable aircraft and engine maintenance instructions. Observe the engine operation precautions specified therein.

I. Structural Repairs:

I. All structural repairs shall be accomplished in accordance with, Raytheon Structural Repair manuals, FAA Advisory Circular 43.13‑1B and 2 and FAA Regulations 43.3, 43.5, 43.7, 43.9, 43.13 and 145 and applicable Maintenance manuals and drawings. The repairs shall be subject to the inspection and approval of the Cognizant Government Representative or Cognizant Field Activity.

I. All previously installed repairs, not authorized by the above publications relative to the standards of repair workmanship enumerated therein, shall be reworked to authorized standards unless otherwise directed by the Cognizant Government Representative or Cognizant Engineering Authority. Cases of this nature shall be brought to the attention of engineering for determining disposition.

I. Weld repairs of structural members and primary components shall be subject to close engineering control of design and welding process.

I. For repairs of a major nature exceeding the depth of the Beech Structural Repair manual the rework activity shall submit to the Cognizant Field Activity, for review and approval, a detailed description of damage, method and details of repair procedures, stress analysis, drawings and specifications.

I. Stress analysis criteria shall be obtained by the commercial rework activity, as required, from the NAVAIR, or prime airframe contractor.

I. The rework activity will certify that each structural repair of a major nature, as defined above, meets the structural strength requirements so specified.

g) Record and submit a Structural Alteration Report to the respective Service.

I. Self‑Locking Nuts:

I. The limitations and usage of self‑locking nuts shall conform to the instructions of AC 43.13-1B & 2, and applicable Aircraft Maintenance Manuals.

I. Self‑locking nuts used in the flight control system and landing gear system dynamic components removed incident to rework, will not be reused and shall be replaced with identical new parts.

I. Torque Requirements:

I. Comply with the standard torque values as specified in AC 43.13-1B & 2 except as specifically required by applicable aircraft maintenance instructions, structural repair manuals, manufacturer’s drawings and other Service directives for all torque‑ required hardware affected by rework.

I. Apply torque stripe on specified torque‑required hardware affected by rework. If torque stripe in areas not affected by rework are obliterated so that determination cannot be made as to whether slippage has occurred, re-torque and reapply torque stripe.

I. Replacement Part and Substitutions:

I. Replacement parts and material shall be of an OEM approved design in accordance with the manufacturer’s maintenance instructions, or illustrated parts catalogues for specific equipment as applicable. PMA parts will not be used.

I. Substitution of these replacement parts and material shall be subjected to positive engineering control to insure that the substitute parts and material possess properties equal to or equivalent to those possessed by the original part.

I. Substitution of parts and material not authorized by applicable maintenance manuals are authorized only when approved by NAVAIR.

I. Lock Wiring:

I. Lock wiring of fasteners and connections shall be in accordance with the aircraft technical maintenance manuals.

I. Lock wiring at electrical and electronic connection shall be in accordance with the aircraft technical maintenance manuals.

I. Anti‑Friction Bearings:

I. All anti‑friction bearings used on mechanisms, control systems, engine control linkages, rod ends, pulleys, etc., shall be inspected when required in accordance with applicable inspection criteria of NAVAIR 01‑1A‑503 unless otherwise specified in subsequent parts of this specification.

I. Defective (dry, rough, damaged, seized, corroded or otherwise unserviceable) bearings shall be removed, inspected, cleaned and processed in accordance with the applicable aircraft maintenance manual.

I. Observe maintenance precautions to protect bearings from dirt, dust, moisture, cleaner and other contaminants.

I. Vapor blasting, vacuum blasting, sandblasting or other uncontrolled application of abrasive material adjacent to or on exposed bearings is prohibited.

I. The use of steam or chlorinated hydrocarbons on bearings is prohibited.

I. Clean and re-lubricate anti-friction bearings immediately following the inadvertent application of corrosive contaminants. Purge sufficiently to assure removal of all contaminants.

I. Tubing:

I. System tubing shall be visually examined when required for security, deterioration, evidence of leakage, chafing, twisting, deformation, corrosion and proper routing, as a minimum requirement. Fabricate, repair, test, clean, inspect and store tubing in accordance with Raytheon Maintenance Manuals and AC 43.13-1B & 2.

I. All replacement tubing shall be identified and marked in accordance with the Raytheon Maintenance Manuals.

I. Flexible Hose Assemblies:

I. Inspect for defective and overage synthetic rubber hose assemblies in accordance with the Beech Maintenance Manuals. Replace all defective and overage hose assemblies in accordance with the applicable maintenance manual.

I. Inspect, fabricate and replace hose assemblies in accordance with the Raytheon Maintenance Manuals.

I. All replacement hoses shall be identified and installation date marked in accordance with the Raytheon Maintenance Manuals. In addition, replacement shall be noted in the Miscellaneous Section of Aircraft Logbook.

I. Protective Closures I. The use of bosses, caps, and lubricating seals on open ports, fittings, and pipes shall be in accordance with the Raytheon Maintenance Manual.

I. Identification of Piping:

I. The identification of replacement pipe, hose and tubing lines shall be in accordance with the manufacture's drawings.

I. Packing, Gaskets, and Seals:

I. The use of packing, gaskets, and seals shall conform to the specifications of the aircraft manufacturer. Leaky, damaged, or deteriorated gaskets, seals, grommets, plugs, or sealing compound shall be replaced.

I. Non-metallic packing, gaskets, and seals removed or exposed by any disassembly required by this specification shall be replaced.

I. Riveting:

I. All riveting shall conform to the practices and procedures of the Raytheon Structural Repair Manual and AC 43.13-1B & 2.

I. Tolerances:

I. Tolerances shall be in accordance with the aircraft technical maintenance manuals, manufacturer's drawings, other configuration identifications, or other authorized directives.

I. Electrical Wiring:

I. Replacement electrical wiring shall conform to the requirements of the applicable aircraft maintenance instructions manual. Replacement electrical wiring shall be fabricated and installed in accordance with Advisory Circular 43.13-1B and the applicable aircraft maintenance instructions manual. Laser marking will be used to identify wiring. Hot Stamping will not be used.

I. Electrical and Coaxial Connectors. Replacement electrical and coaxial connectors shall be identified to those specified in the applicable aircraft maintenance instructions manual or alternate connectors authorized by the applicable aircraft assembly drawing.

I. Solderless Terminals and Splices. Solderless terminals and splices shall be selected, fitted, crimped and connected in accordance with latest FAA approved procedures.

I. Bonding. Bonding for electrical purposes shall be in accordance with latest FAA approved procedures.

I. Usage and Handling of Gases:

I. Observe the hazardous and precautionary notes while using and handling gases.

I. All pneumatic systems and all self‑contained components normally serviced with air shall be serviced with dry nitrogen conforming to Federal Specification BB-N-411, Type I, Class I, Grade B.

I. Unscheduled Component Rework:

I. Items not otherwise scheduled for removal/ replacement shall be subject to rework only on a discrepancy basis, i.e., when determined defective by in place operational and functional checks, tests and inspection. Items removed on a discrepancy basis will normally be replaced by exchanging for Ready For Issue (RFI) units.

I. Engineering Support Requirements:

I. 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/repairs not otherwise provided for in applicable technical publications.

I. Major rework or repair not otherwise provided in applicable technical publications requires a Hawker Beechcraft Inc approved Repair Plan.

I. Thread Compound:

I. Anti-seize and sealing thread compound shall be used on all tapered pipe threads exposed incident to rework and shall conform to specifications in the Beech Maintenance Manual.

I. Non‑Standard Installations:

I. Rework shall not be performed on non‑standard installations, or on standard installations made non‑standard, unless specifically requested by the aircraft custodian and approved by Cognizant Government Representative.

I. When non‑standard installations interfere with authorized rework, they will be removed to the extent necessary to facilitate the designated rework. Cases of this nature shall be referred to the Cognizant Government Representative for disposition.

I. Scheduled Component Removal/Replacement Criteria:

I. Aircraft components listed in Section IV of this specification shall be replaced at flight hour, calendar or operational time limitations specified. Disposition of the removed item shall be as specified.

I. Premature removal of scheduled time change components prior to expiration of the specified replacement interval for repair, modification, economy or technical directive compliance shall be subject to reuse if the operating time remaining is more than ten percent of the specified replacement interval for time controlled or three months for calendar controlled items. Those items which cannot be made serviceable through specific repair or whose operating/calendar life remaining is less than ten percent or three months, as applicable, shall receive disposition specified by the Beech Maintenance Manuals.

I. Weight and Balance:

I. Weight and balance control of the aircraft during ACI shall be accomplished in accordance with the Beech Maintenance Manuals using the latest Air Force Weight & Balance program.

I. A post-ACI weighing of the aircraft in accordance with the Raytheon Maintenance Manual shall be accomplished.

I. Pre-Delivery Requirements (Site Responsibility):

I. Perform "A" profile check flight at least 30 days prior to aircraft delivery.

I. Prior to delivery, remove and retain all unnecessary loose gear and equipment and those items not requiring ACI rework. Miscellaneous equipment necessary for aircraft security and safe ground handling will be delivered with the aircraft. Classified material shall be removed prior to delivery of aircraft to ACI and stored at the Site.

I. Logs and Records. Deliver current and up‑to‑date logbooks and necessary records with the aircraft. Verify that all entries are current as of the date of delivery.

I. Report any discrepancies encountered during delivery of aircraft to the rework activity.

I. Report Requirements:

I. Aircraft Maintenance/History Summary Report. The rework activity shall prepare and submit a Maintenance/History Summary Report in accordance with section VI.

I. Structural Sampling Report. A Sampling Report shall be prepared in accordance with Section VII for all Structural Significant Items (SSI's) as identified and defined in the ACI Specification.

I. Functional Sampling Report. A Sampling Report shall be prepared in accordance with Section VIII for all Functional Significant Items (FSI's) as identified and defined in the ACI Specification.

I. Major Airframe Assemblies/Components Replacement: In the event a major airframe assembly or component (such as the wing, control surfaces, wing attached landing gear, horizontal or vertical stabilizers) requires replacement or is being swapped with another airframe, submit a structural alteration report.

I. INDUCTION INTO ACI REQUIREMENTS:

I. Aircraft Record Analysis:

I. Aircraft logbook and records shall be reviewed to determine the existence and extent of conditions that might affect the planned sequence of aircraft rework. Past historical performance shall be analyzed to determine possible chronic system and component trouble areas on which to apply added emphasis during aircraft examination.

I. Overhaul and Replacement items. Review aircraft logbook and records for any overhaul and replacement item that is high time or will become high time during ACI processing and check flight. Schedule appropriate action during subsequent rework.

I. Determine and document additional items of rework such as the incorporation of outstanding technical directives and other maintenance directives as specified by the Cognizant Government Representative.

I. Document all noted discrepancies, areas requiring special consideration and required rework items. Schedule appropriate action during subsequent rework.

I. Aircraft/engine/component logbook entries shall be compared with aircraft maintenance records and verified. Aircraft technical directive status shall be verified.

I. Aircraft Equipment Inventory I. Conduct an equipment inventory, jointly when possible, with a representative of the delivering activity as soon as possible after receiving the aircraft.

I. Accountability and shortages shall be in accordance with the aircraft inventory records.

I. All inventory equipment removed from an aircraft shall be reinstalled on the same aircraft from which removed or if required, shall be replaced with an equivalent serviceable item at completion of ACI.

I. Loose equipment, including personal survival equipment,…