Huey Depot Spec revised 8-17-11.docx

BACKGROUND

The INL/A Bell Helicopter rotary wing aircraft perform a variety of missions. At times the aircraft operate from forward operating base locations under primitive conditions and at other times from international airports executing instrument approaches. The primary mission is to transport passengers and cargo into and out of austere and established areas located throughout the theater of operation.

This mission requires that the aircraft meet or exceed the performance requirements set forth below for personnel and cargo carrying capacity, long range and flight endurance. Operations are often flown in very rugged, high mountainous terrain in brown out conditions that requires optimum take off, climb, and turn performance at high and high-density altitudes. These aircraft serve in remote areas with few bases from which to operate aircraft.

Current location, density and types of aircraft are as follows: Afghanistan - ten (10) Huey II's; Iraq - eighteen (18) UH-1N/ST's; Pakistan - fourteen (14) Huey II's; Colombia - thirteen (13) Huey II's; Peru - twenty four (24) Huey II's; Guatemala - six (6) Huey II's; Bolivia - eight (8) UH-1H's; Florida - two (2) Huey II's and one (1) UH-1N.

Secondary missions include, but are not limited to, armed convoy escort, hostile force reconnaissance, medical evacuation, external hoist, and external load operations. Further, the aircraft and crews are subject to being targeted by hostile fire. Depending on the region where these aircraft have been deployed, these aircraft may have defensive aircrew and aircraft survivability systems installed. Other INL aircraft may have an ATK AN/AAR-47 missile warning system combined with the Symetrics AN/ALE-47 countermeasures dispensing system and defensive armor for cockpit crew protection.

CLIN 0001, Optional CLINS 1001, 2001, 3001, and 4001 – UH-1 Program Depot Maintenance. This is a firm fixed price line item. The contractor shall provide all necessary labor and material to complete program depot maintenance of the USG provided UH-1 in accordance with the below statement of work.

AIRCRAFT CONDITION INSPECTION

Department of State

UH-1

March 2011

SCOPE

General:

This specification establishes the Aircraft Condition Inspection (ACI) requirements for the U.S. Department of State UH-1 series aircraft.

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. In addition the requirements in this SOW are expected to enhance the aircraft reliability. These requirements include, but are not limited to:

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

Incorporation of authorized Technical Directives and Modifications.

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

Strip and repaint the exterior and paint interior of the aircraft.

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

This specification will be evaluated after ACI completion on each aircraft for content and effectiveness of each of the inspection criteria and, if required, adjusted to fit the current fleet requirements.

Inspect and evaluate aircraft for airworthiness. Develop and execute any required repair procedures using established technical data. In case(s) where established procedures do not exist, the Offeror shall have the engineering capability to develop and execute all levels of airworthy repairs for aircraft involved in accidents, incidents, and battle damage requiring major or specialized structural repair.

Change Recommendations: Recommendations for additions, deletions, or changes to the requirements of this specification are invited and should be submitted to the DoS Chief of Aircraft Maintenance, 1038 South Patrick Drive, Patrick AFB, FL 32920.

AIRCRAFT CONDITION INSPECTION INTERVALS:

Aircraft Condition Inspection for the U. S. Department of State UH-I aircraft is 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.

ACI interval (operational service months per period) for the DoS UH-I series aircraft is 60 months.

PROGRAM MANAGEMENT

The contractor shall develop a program management plan which includes schedule, costs, and risk management.

SECTION II

AIRCRAFT CONDITION INSPECTION (ACI) REQUIREMENTS

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 UH-1 series aircraft. Each requirement shall be complied with as an item of scheduled maintenance at each ACI unless otherwise specified.

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

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

Part numbers listed in this specification are for reference only.

General Requirements: Aircraft/engine organizational level scheduled maintenance requirements.

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.

Corrosion Control Inspection: Accomplishment of the requirements of the next aircraft Corrosion Control Inspection is a requirement of ACI. Complete compliance of all corrosion inspections occurs through equivalent ACI requirements and requirements of the UH-1 scheduled corrosion control inspection.

Maintenance Practices: All maintenance and structural repairs shall be accomplished in accordance with the applicable aircraft 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 applicable SRM or documented engineering approval shall be reworked to the above standards unless otherwise directed by the DoS.

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.

Prior approval by the DoS Chief of Aircraft Maintenance and Contracting Officer’s Representative (COR) are required for work beyond the scope of the ACI.

Defect Correction Criteria:

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.

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

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.

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

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

Classification of Defects: Classification of defects shall be subject to the approval of the DoS representative, as applicable.

Rework Procedures.

Applicable Documents: ACI procedures shall comply with publications listed in Section I, maintenance references, applicable Service 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 UH-I Maintenance manuals, other applicable manufacturers’ manuals, FAA manuals, then Service manuals.

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.

Technical Directive Compliance:

FAA Airworthiness Directives, U.S. Army Safety of Flight, US Army Aviation Safety Action messages and modification, and DoS Modifications shall only be complied with and/or incorporated when directed by the DOS Maintenance Director.

Aircraft Records Maintenance:

The rework activity shall maintain the aircraft records in accordance with DA PAM 738-751, and AC 43.9 directives from the date of acceptance of the aircraft from the government to the date of acceptance by the government.

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.

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

Engineering information on all modifications engineered by the Rework Activity directed by the DoS shall be prepared in accordance with FAA and/or DoD directives with engineering drawings prepared, as required, in accordance with ASME Y.14-100 and AFI 21-402. A copy of all engineering modification/repair directives and drawings shall be forwarded to Chief of Aircraft Maintenance, DoS Office of Aviation, 1038 South Patrick Drive, Patrick AFB, FL 32925.

Inspection Work Sheets:

The 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.

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

List discrepancies reported in aircraft maintenance records.

List Technical Directives authorized for accomplishment.

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

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.

Nondestructive Inspection Processes:

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

All personnel performing Nondestructive inspections shall be examined and qualified in each method for type of inspection performed in accordance with NAS 410 E or American Society for Non destructive Testing (ASNT).

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.

Ground Handling, Operation and Safety Precautions:

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.

Comply with the instructions, procedures and precautions directed to the aircraft fueling operation of the applicable servicing manual and as directed by the DoS Representative.

Aircraft servicing, taxiing, towing, parking, jacking, moving and hoisting shall be in accordance with the instructions and precautions of the applicable aircraft maintenance instructions and AR 95-20.

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

Structural Repairs:

All structural repairs shall be accomplished in accordance with, UH-I Maintenance manuals. Repairs not authorized per the UH-I manuals maybe repaired in accordance with procedures in BHT-MED-SRM-1 with prior approval of DOS engineering. The repairs shall be subject to the inspection and approval of the DoS Representative.

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 DoS Representative. Cases of this nature shall be brought to the attention of engineering for determining disposition.

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

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

Stress analysis criteria shall be obtained by the rework activity, as required, from the airframe OEM or DoS approved engineering analysis.

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

Upon completion of repairs record and submit a Structural Alteration Report to the DOS engineering staff.

SelfLocking Nuts:

The limitations and usage of selflocking nuts shall conform to the instructions of UH-I Maintenance manuals and TM 1-1500-204-23-6.

Selflocking 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.

Torque Requirements:

Comply with the standard torque values as specified in applicable aircraft maintenance instructions, structural repair manuals, manufacturer’s drawings and other Service directives for all torque required hardware affected by rework.

Apply torque stripe as required by aircraft maintenance manual for specific torquerequired 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, retorque and reapply torque stripe.

After completion of required torque the value that the item was torqued to and the torque wrench serial number will be entered in the maintenance corrective action block.

Replacement Part and Substitutions:

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 without DoS approval.

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.

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

Lock Wiring:

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

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

AntiFriction Bearings:

All antifriction 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 UH-I maintenance manuals and TM 55-1500-322-24 unless otherwise specified in subsequent parts of this specification.

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.

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

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

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

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

Tubing:

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 applicable Maintenance Manuals and TM 1-1500-204 series.

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

Flexible Hose Assemblies:

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

Inspect, fabricate and replace hose assemblies in accordance with the UH-I Maintenance Manuals or applicable FAA or DOD specifications.

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

Protective Closures

The use of bosses, caps, and lubricating seals on open ports, fittings, and pipes shall be in accordance with the UH-I Maintenance Manual and Rework Activity FOD prevention procedures.

Identification of Piping:

The identification of replacement pipe, hose and tubing lines shall be in accordance with the manufacture's drawings or applicable FAA or DOD specification.

Packings, Gaskets, and Seals:

The use of packings, 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.

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

Riveting:

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

Tolerances:

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

Electrical Wiring:

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/or the applicable aircraft maintenance instructions manual. Laser marking will be used to identify wiring. Hot Stamping will not be used.

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.

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

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

Usage and Handling of Gases:

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

All pneumatic systems and all selfcontained components normally serviced with air shall be serviced with dry nitrogen conforming to Federal Specification A-A-59503A, Type I, Class I, Grade B.

Unscheduled Component Rework:

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.

Engineering Support Requirements:

The rework activity shall provide engineering capability to perform continuous surveillance of the rework processes; to solve problems and to develop rework procedures/processes/repairs not otherwise provided for in applicable technical publications.

Major rework or repair not otherwise provided in applicable technical publications requires a Repair Plan approved by the DoS representative.

Thread Compound: 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 UH-1 Maintenance Manual.

NonStandard Installations:

Rework shall not be performed on nonstandard installations, or on standard installations made nonstandard, unless specifically requested by the DoS representative.

When nonstandard 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 DoS Representative for disposition.

Scheduled Component Removal/Replacement Criteria:

Components which are predicted to obtain time limitations during ACI or prior to Phase Inspection following ACI shall be determined on a case-by-case basis during the pre-delivery records review.

Aircraft Components after completion of ACI shall have sufficient time remaining to insure that component replacement is not required prior to next Phase inspection. DoS may direct replacement of components on a case-by-case basis.

Inspection Requirements

Aircraft Phase Inspection shall be completed during the ACI inspection. All material costs not associated to the ACI SOW, but required for the phase inspection will be charged to unscheduled maintenance.

All scheduled Special Inspection that will come due prior to next scheduled Phase Inspection, or within one year after completion of ACI shall be complied with.

Weight and Balance

Weight and balance control of the aircraft during ACI shall be accomplished in accordance with AR 95-1 and TM 1-1500-342-23. A post-ACI weighing of the aircraft after completion of maintenance shall be accomplished.

Pre-Delivery Requirements:

Aircraft transfer from the delivering activity to the rework activity shall be in accordance with TM 1-1500-328-23, Section VII and Section XII, Table 12-1, Requirements for the Transfer of Operational Aircraft within or Between Non-Combat Theaters.

Prior to delivery, the delivering activity shall 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.

Logs and Records. The delivering activity shall deliver current and uptodate logbooks and necessary records with the aircraft. Verify that all entries are current as of the date of delivery.

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

Report Requirements:

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

Structural Sampling Report. N/A

Functional Sampling Report. N/A

Major Airframe Assemblies/Components Replacement: In the event a major structural airframe assembly or component (such as the pylon) requires replacement or is being swapped with another airframe, submit a structural alteration report.

INDUCTION INTO ACI REQUIREMENTS:

Aircraft Record Analysis:

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.

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.

Determine and document additional items of rework such as the incorporation of outstanding technical directives, modifications and other maintenance directives as specified by the DoS Representative.

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

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

Aircraft Equipment Inventory:

Conduct an equipment inventory, jointly when possible, with a representative of the delivering activity as soon as possible after receiving the aircraft. Provide a copy of the inventory to the DoS representative.

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

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.

Loose equipment, including personal survival equipment, personnel oxygen equipment, and other items shall not be repaired, but shall be properly tagged and stored to prevent damage and deterioration during the ACI processing.

Preservation:

Engines shall be preserved in accordance with the UH-I Maintenance and Engine Manuals, as follows:

Engines scheduled for replacement shall be given Type I preservation.

Engines scheduled for continued service shall be given Type II preservation.

Aircraft and components shall receive preservation in accordance with the applicable UH-1 Maintenance Manual.

Drain fuel tanks and lines in accordance with the applicable UH-I Maintenance Manual instructions.

Purge the aircraft fuel tanks and apply preservation in accordance with the applicable UH-I Maintenance Manual.

Batteries: Aircraft batteries shall be removed, stored and maintained in accordance with the applicable UH-1 Maintenance Manual.

Operational Test:

Preliminary examinations and operational tests shall be performed on each aircraft to validate reported discrepancies and to aid in the determination of unscheduled rework. The scope of the examination shall be of sufficient depth to avoid unscheduled rework from occurring at an inappropriate rework sequence.

Note all discrepancies discovered during the performance of preliminary examinations and operational test, those discrepancies reported by the delivering activity, and those discrepancies recorded in the aircraft logbook and associated records.

Preliminary examinations and operational tests:

During the Receiving Inspection, service all systems, accomplish engine run-up, inspect and perform operational checks as necessary to determine the condition and extent of adjustment or repairs required of all systems.

Perform functional/operational checks of aircraft systems in accordance with the applicable aircraft maintenance instructions.

Perform hydraulic fluid and oil contamination checks in accordance with the UH-1 Maintenance Manual. Standard JOAP analysis is acceptable.

Fuel samples shall be inspected for contamination in accordance with the criteria of the UH-1 Maintenance Manual.

Drained fluids shall be disposed of as contaminated property.

An Engine performance recovery wash shall be conducted in accordance with the UH-I Maintenance Manual Manual preparatory to preservation.

All discrepancies documented during aircraft checks shall be scheduled for corrective action at an appropriate rework sequence.

SURFACE CONDITIONING:

Cleaning:

Metal Surfaces: Clean aircraft external and accessible internal metal surfaces using methods and materials specified by applicable UH-1 Maintenance Manuals. After cleaning, take special precautions to assure thorough draining of all liquids from between facing surfaces, crevices and inspection doors. Re-clean all areas as necessary.

Transparent and Reinforced Plastic Surfaces: Clean transparent and reinforced plastic surfaces using methods and materials specified by the UH-I Maintenance Manual.

Vinyl and Rubber Surfaces: Clean and treat upholstery, floors, vinyl and rubber surfaces and trim using methods and materials specified by the UH-1 Maintenance Manual.

Stripping:

Examine the exterior surface of the aircraft for defective paint finish, excessive thickness, spalling, cracking and progressive detachment (loss of adhesion). Examine for defective sealant. All stripping operations shall be stripped using approved commercial methods except composite surfaces (e.g. antennae).

Examine accessible interior surfaces of the aircraft for defective paint finishes. Interior finishes shall be stripped only to the extent necessary to inspect for corrosion and defects or to restore protective coatings.

Take adequate precautions during stripping and subsequent cleaning operations to prevent ingress of moisture, stripping and cleaning compounds to engine inlet/exhaust openings, static, pitot, and vent openings, bearings, bearing surfaces, electrical switches, relays, connectors, wires and all other electrical and electronic components. Protect plastic glass and rubber parts during stripping and cleaning. Comply with all applicable safety precautions/procedures when using stripping compounds.

Corrosion Removal and Surface Treatment:

Corrosion removal:

Inspect for corrosion in accordance with the detailed requirements of this specification and UH-1 Maintenance Manuals.

NOTE

Removal of fasteners at seams and lap joints is not required unless visual examination indicates corrosion of faying surfaces.

Remove all corrosion. Replace corroded parts when the corrosion damage (after corrosion removal) exceeds the limits allowed by applicable overhaul or structural repair manuals. To prevent water intrusion seal between skin seams using approved sealants listed in UH-I Maintenance Manual.

Only those materials and methods specified by the UH-1 Corrosion Prevention Instructions, FAA or DoD Corrosion Control processes are authorized.

Protect parts and components from corrosion during rework.

Surface treatment:

Reapply surface treatment to all metal surfaces from which previously applied organic coatings have been removed as specified by the UH-1 maintenance manuals.

Apply appropriate surface treatment to all newly fabricated metal parts. During assembly of components, parts and subassemblies, insulate dissimilar metals as specified by the manufacturers’ maintenance publications.

Surface Restoration:

Seam sealing:

Remove all loose or deteriorated sealant and contamination from the seams. Remove corrosion products by one of the mechanical methods. Replace sealant in accordance with the applicable Structural Repair Manual and the UH-1 Maintenance Manuals.

CAUTION

Do not use chemical corrosion removers.

Seal all seams to comply with applicable structural repair manual and UH-1 Maintenance Manual.

Aircraft Interior:

Finish interior metal surfaces in inhabited areas in accordance with the applicable structural repair manual.

Finish interior metal surfaces in uninhabited areas using methods and paints required in UH-1 maintenance manuals and TM 55-1500-345-23 (Painting and Marking of Army Aircraft). Apply the number of coats specified by manufacturer’s structural repair manual.

Finish battery boxes and battery bay areas using the materials specified by the UH-1H II Maintenance Manual.

Apply interior markings in accordance with UH-1 applicable maintenance instructions, TM 55-1500-345-23 (Painting and Marking of Army Aircraft), illustrated parts breakdown, and structural repair manuals.

Aircraft Exterior

For DoS aircraft apply primer coat and finish coat in accordance with UH-1 Maintenance Manuals and TM 55-1500-345-23 (Painting and Marking of Army Aircraft).

Protect plastics and rubber components during painting. Apply standard exterior finish colors, markings and insignia in accordance with DOS UH-I configuration. National insignia, branch of service, radio call sign, and multi-colored caution and warning markings must be applied by in accordance with the UH-1 Maintenance manual and TM 55-1500-345-23 (Painting and Marking of Army Aircraft). Application of aircraft serial number or registration number will be determined by DoS representative.

Conduct at least one wet tape adhesion test on the completed base finish system. The test may be conducted on a test panel carried through processing with the aircraft or on an easily repainted access panel.

DISASSEMBLY:

Disassembly, General:

The aircraft shall be disassembled to the extent required to accomplish planned examination, restoration, rewiring, modification and test and shall include the following:

Remove engine. Engines that are deemed economically repairable, shall undergo cleaning, inspection, repair and troubleshooting IAW applicable engine manual.

Main Rotor Blades

Main Rotor Hub

Scissors and Sleeve, Swashplate.

Main Transmission.

All Drive Shafting

42 Degree Gearbox

90 Degree Gearbox

Tail Rotor Hub And Blade Assembly

Tail Boom

NOTE

Disassembly will normally be limited to the extent permitted by the removal of bolts and screws. This does not preclude the removal of rivets or high strength fasteners to permit inspection for suspected damage, to make repairs or, when necessary, to accomplish modification.

Examination During Disassembly:

Examine the aircraft during disassembly for the following: Loose or missing rivets and fasteners, cracks, corrosion, damaged controls, excessively worn hinges, attach fittings, bearings, bushings and bolts, distortion and elongation of bolt holes and any signs that may lead to inspection and/or disassembly to a greater depth.

If corrosion damage is evident or suspected at skin laps, remove rivets and peel back skin progressively in the immediate area for further inspection to determine the extent of corrosion progression.

Particular emphasis shall be placed on examination of items that may require special examination and correction as a result of aircraft service record information; on items specifically requested by the reporting custodian, agreed to by the rework activity and authorized by the aircraft controlling custodian; and on items where past experience or analytical inspection has proven to be deficient or which may lead to discrepancies in associated parts or subassemblies. This shall include areas subject to known or suspected structural fatigue, deterioration or corrosion.

It is intended that the disassembly examination be accomplished by sufficiently qualified personnel to preclude the possibility of overlooking structural deficiencies that may escape detection by less skilled personnel.

AIRCRAFT MODIFICATIONS:

Aircraft modifications shall be designed and installed in accordance with FAA or DOD standards.

Modifications may be incorporated during the ACI if directed by DoS Chief of Aircraft Maintenance.

Examples of possible modifications:

Install ELT 406 modification

DMR 500 Installation

Cross Tube Support Bracket

Sky Connect Installation

Installation of "Diamond J" Mgt, Torque and Oil Pressure/Temperature Indicators

Rewire and Avionics Upgrade:

(1) Rewire will consist of all new wiring harnesses throughout the entire aircraft.

(2) Adel clamps and hardware will be inspected and replaced, if necessary. Stand offs, spiral wrap and plastic edge protectors will be used as required to prevent chaffing.

(3) Circuit breakers will be inspected and replaced, if necessary.

(4) Engine wiring from engine to firewall shall be inspected and replaced as necessary. Engine wiring on airframe side of firewall shall be replaced.

(5) Specific equipment identification and layout will be provided upon modification authorization.

STRUCTURAL AND ZONAL INSPECTION REQUIREMENTS

General: Structural and zonal inspections shall be conducted in accordance with UH-1 Phase Inspection Checklists. Inspections shall include those special inspections identified during the Aircraft Records Analysis.

SECTION III

ACI CHECK FLIGHT AND ACCEPTANCE REQUIREMENTS

FINAL PROCESSING:

Weight and Balance

Weigh the aircraft in accordance with the Handbook of Weight and Balance Data and Complete Weighing Record DD Form 365-2.

Inventory the aircraft and complete Chart A, Basic Weight Check List, DD Form 365-1, to reflect the actual equipment inventory.

Update Chart C (DD 365-3), Basic Weight and Balance record, DD Form 365-3, to reflect the actual inventory of Chart A (DD 365-1), plus the effect of any technical orders/ directives or modifications incorporated during ACI.

Update DD 365-1 and DD365-3, as required, to reflect the effect of any technical orders/directives or modifications incorporated during ACI.

Complete Weight and Balance Clearance Form F, DD Form 365-4, to reflect actual load disposition for test or ferry flight.

Logs and Records

Conduct aircraft inventory and annotate aircraft records, DD Form 365-2, Chart A, to reflect the actual inventory.

Complete a Shortage Form DD Form 365-2, Chart A for all items marked as "missing" in the inventory record.

Annotate the Aircraft Log Book in accordance with the specified instructions to reflect:

Accomplishment of ACI.

Accomplishment of applicable inspections.

Incorporation of compliance with Technical Directives.

Replacement of assemblies, accessories and major components.

Accrual of flight time during the period of aircraft custody by Rework Activity.

Applicable aircraft records shall be annotated showing the month, year and aircraft time that ACI was accomplished. The entries shall also reflect the Rework Activity name and the contract number.

Servicing and Lubrication

After completion of rework as specified herein, the aircraft and engines shall be depreserved, checked for structural and mechanical completeness and integrity, proper assembly and all systems serviced and lubricated in accordance with applicable Maintenance Manuals.

Power Plant Turn-Up

Perform all required checks for maintenance performed during the ACI inspection utilizing applicable checkout procedures. All discrepancies are to be corrected prior to flight.

Compass Calibration

Calibration of compasses will be required after completion of ACI.

Record logbook entry in miscellaneous history section after accomplishment of compass swing in accordance with requirements of the appropriate Service's directives. Place working half copy of compass card into the historical record logbook.

Disturbed Systems

Aircraft systems, not otherwise assigned a requirement for a functional/operational check/test, that are disturbed during ACI processing to the extent that the system's integrity, i.e., installation and operation, cannot be assured shall receive a functional/operational check/test as necessary to verify proper installation and operation.

Pitot-Static System Calibration: Perform a Leak and Functional check and system calibrations in accordance with the applicable Maintenance Manual.

Fuel System Leak Check and Calibration: Perform a Leak and Functional check and system calibrations in accordance with the applicable Maintenance Manual.

SmartCycle ‘Manual Trend Check’ shall be completed during the MTF phase. Calibration shall be completed prior to MTF.

CHECK FLIGHT

Daily/Turnaround Inspection

Prior to the first check flight of the day, perform a Daily Inspection in accordance with UH-I Daily Checklist and perform a turnaround inspection in accordance with UH-I Operators Checklist before each subsequent flight.

Acceptance Check Flight and Acceptance:

Acceptance Check Flight:

An acceptance maintenance check flight shall be performed with a minimum of one (1) qualified Maintenance Test Pilot. The acceptance check flight shall be accomplished IAW the UH-1 Maintenance Test Flight Procedures manual and the appropriate Flight Manuals. Acceptance check flight may be a joint flight between delivering activities and rework activity.

Aircraft mission equipment/systems are included in flight check requirements.

Acceptance Processing:

The DoS representative shall verify that all special, loose and miscellaneous equipment and furnishings and publications reflected as "installed" in the aircraft inventory record are appropriately stowed and that all required logbook entries have been accomplished in accordance with appropriate directives.

Post ACI Maintenance:

The rework activity shall be responsible for the post-ACI maintenance of the aircraft until returned to DoS.

Acceptance:

The DoS representative will indicate acceptance of the aircraft upon completion of ACI by signature on the applicable documents and records.

SECTION IV

COMPONENT REMOVAL/REPLACEMENT SCHEDULE

GENERAL:

The scheduled component removal/replacement requirements are contained in UH-I Maintenance Manuals.

Items not specifically addressed shall be processed in accordance with TM 1-1500-328-23, Section XII, Table 12-1, Requirements for the Transfer of Operational Aircraft within or Between Non-Combat Theaters.

Components removed/replaced as specified herein shall be properly recorded in accordance with appropriate Service directives.

SECTION V

ACI REPORT REQUIREMENTS

MAINTENANCE HISTORY SUMMARY REPORT:

General: Reports shall be prepared and submitted for all aircraft processed under the ACI requirements of the specification.

Specific Report Requirements:

Reports shall contain the following data elements.

Accurate location of the defect.

Description of corrective action taken.

Man-hours to repair defect.

ACI task number when defect discovered.

Additionally, for corrosion, report type and severity as defined in tables 6-1 and 6-2.

Aircraft identification and flight hours including:

Tail number, base location, and ACI number.

Induction date and completion date.

Total flight hours and operational months.

Flight hours and operational months since last ACI.

Inspection man-hours, defect man-hours, and total ACI man-hours.

Describe any special work requested by the DoS, any difficulties encountered while performing the work, and the number of man-hours to complete.

Reports shall be type written on letter size paper. A form may be developed and used for all or part of the above elements if desired. Electronic submission of reports is preferred.

Forward copy of reports to: Chief of Aircraft Maintenance, DoS Office of Aviation, 1038 South Patrick Drive, Patrick AFB, FL 32925. Reports shall be forwarded not later than thirty days subsequent to Government acceptance of aircraft.

TABLE 6-1 TYPE DESIGNATION

TABLE 6-2 SEVERITY DESIGNATION

Appendix A DEFINITIONS:

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.

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 nonpermanent 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, deicing equipment, antiicing 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…