TO 00-20-1.pdf

TO 00-20-1

TECHNICAL MANUAL

AEROSPACE EQUIPMENT MAINTENANCE INSPECTION,

DOCUMENTATION, POLICIES, AND PROCEDURES

(ATOS-HILL)

THIS MANUAL SUPERSEDES TO 00-20-1, DATED 1 APRIL 2016.

FOR QUESTIONS CONCERNING TECHNICAL CONTENT OF THIS TECHNICAL MANUAL, CONTACT THE APPLICABLE TECHNICAL CONTENT MANAGER (TCM) LISTED IN THE ENHANCED TECHNICAL INFORMATION MANAGEMENT SYSTEM (ETIMS). HQ

AFMC/A4FI, WPAFB, OH IS THE APPROVAL AND WAIVER AUTHORITY FOR THIS TECHNICAL MANUAL.

DISTRIBUTION STATEMENT A: Approved for public release; distribution unlimited. HQ AFMC/PA Certificate Number AFMC PAX-04-329.

Submit recommended changes or problems with this technical order to the applicable TO Manager (TM) listed in ETIMS using the Recommended Change Process outlined in accordance with (IAW) TO 00-5-1.

Published under authority of the Secretary of the Air Force

11 JULY 2016

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . 11 July 2016

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 126, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - v vi Blank 1-1 - 1-2 2-1 - 2-10 3-1 - 3-5 3-6 Blank 4-1 - 4-5 4-6 Blank 5-1 - 5-45 5-46 Blank 6-1 - 6-5 6-6 Blank 7-1 - 7-11 7-12 Blank 8-1 - 8-8 9-1 - 9-7 9-8 Blank 10-1 - 10-3 10-4 Blank A-1 - A-3 A-4 Blank B-1 - B-2 C-1 - C-4

*Zero in this column indicates an original page

A USAF

TABLE OF CONTENTS

Chapter Page

FOREWORD ...................................................................................................................................................................... v

1 GENERAL .......................................................................................................................................................................1-1

1.1 Purpose...............................................................................................................................................................1-1

1.2 Recommendations for Technical Order Changes.............................................................................................1-1

1.3 Contract Maintenance Operations.....................................................................................................................1-1

2 AEROSPACE VEHICLE INSPECTIONS .....................................................................................................................2-1

2.1 General...............................................................................................................................................................2-1

2.2 Inspection Requirements ...................................................................................................................................2-1

2.2.2 Inspection Concepts...........................................................................................................................................2-1

2.2.3 Inspection Cycle ................................................................................................................................................2-2

2.3 Specified Flying Period.....................................................................................................................................2-2

2.4 Pre-Flight Inspections (PR)...............................................................................................................................2-2

2.5 End-of-Runway Inspection (EOR)....................................................................................................................2-3

2.6 Thru-Flight Inspection (TH)..............................................................................................................................2-3

2.7 Quick Turn Inspection (QT) .............................................................................................................................2-3

2.8 Basic Post-Flight (BPO) Inspection..................................................................................................................2-3

2.9 Combined Pre-Flight/Basic Post-Flight (PR/BPO) Inspection ........................................................................2-4

2.10 Hour Post-Flight Inspection (HPO) ..................................................................................................................2-4

2.11 Periodic Inspection (PE)....................................................................................................................................2-4

2.12 Phase Inspections (PH)......................................................................................................................................2-4

2.13 Isochronal Inspection (ISO) ..............................................................................................................................2-4

2.14 Minor (MIN) ISO..............................................................................................................................................2-5

2.15 Major (MAJ) ISO..............................................................................................................................................2-6

2.16 Home Station Check (HSC) Inspection............................................................................................................2-6

2.17 Programmed Depot Maintenance (PDM) .........................................................................................................2-6

2.18 Aerospace Vehicle Manufacturer Inspections ..................................................................................................2-6

2.19 No-Fly Calendar Inspections.............................................................................................................................2-6

2.20 Transfer Inspections ..........................................................................................................................................2-7

2.21 Acceptance Inspections .....................................................................................................................................2-7

2.22 One Time Inspections (OTI).............................................................................................................................2-7

2.23 In Process Inspection (IPI)................................................................................................................................2-8

2.24 Aerospace Vehicles in Storage .........................................................................................................................2-8

2.25 Inspection Work Cards (AFTO Form 26) ........................................................................................................2-9

2.26 Inspection Responsibility for Work Accomplished by Depot or Contractor Field Teams (DFT/

CFT) ..............................................................................................................................................................2-9

2.27 Service Life Extension Program (SLEP)..........................................................................................................2-9

3 AEROSPACE EQUIPMENT FORMS DOCUMENTATION.......................................................................................3-1

3.1 General...............................................................................................................................................................3-1

3.2 Maintenance Information Systems (MIS).........................................................................................................3-1

3.3 Automated Forms ..............................................................................................................................................3-2

3.4 Forms Entries.....................................................................................................................................................3-2

3.5 Standard Date Format........................................................................................................................................3-2

3.6 Minimum Signature...........................................................................................................................................3-2

3.7 Informational Notes...........................................................................................................................................3-2

3.8 Transfer of Documents......................................................................................................................................3-2

3.9 Filing ..................................................................................................................................................................3-3

3.10 Disposition of Documents.................................................................................................................................3-3 i

3.11 Maintenance of Documents During Extended Storage ....................................................................................3-3

3.12 Air Card/Fuel Identiplate ..................................................................................................................................3-4

3.13 Use of USAF Aerospace Vehicle by Bailment Contractors and Air Carrier Contract Operators .................3-4

3.14 Processing of Documents During Depot Maintenance ....................................................................................3-4

3.15 Safeguarding/Documenting Classified Equipment ...........................................................................................3-5

4 SYMBOLS AND THEIR USE .......................................................................................................................................4-1

4.1 General...............................................................................................................................................................4-1

4.2 Red X.................................................................................................................................................................4-1

4.3 Red Dash............................................................................................................................................................4-2

4.4 Red Diagonal .....................................................................................................................................................4-2

4.5 Clearing Red Symbol Entries............................................................................................................................4-2

4.6 Changing Symbols After an Original Entry.....................................................................................................4-3

4.7 Downgrading a Red X for One-Time Flight....................................................................................................4-4

4.8 Red W (ICBM ONLY) .....................................................................................................................................4-5

4.9 RED C................................................................................................................................................................4-5

5 AFTO FORM 781 SERIES.............................................................................................................................................5-1

5.1 General Purpose of AFTO Form 781...............................................................................................................5-1

5.2 Training Device Forms......................................................................................................................................5-1

5.3 Forms Within the Binder ..................................................................................................................................5-1

5.4 Documenting Operational Checks and Functional Check Flights (FCF)........................................................5-1

5.5 Recording Engine Storage.................................................................................................................................5-2

5.6 AFTO Form 781, ARMS Aircrew/Mission Flight Data Document (Figure 5-1 and Figure 5-2) .................5-2

5.7 AFTO Form 781A, Maintenance Discrepancy and Work Document (Figure 5-3 and Figure 5-4) .............5-6

5.8 AFTO Form 781B, Communications Security (COMSEC) Equipment Record (Figure 5-5)......................5-13

5.9 AFTO Form 781C, Avionics Configuration and Load Status Document (Figure 5-6 and

Figure 5-7) ..................................................................................................................................................5-15

5.10 AFTO FORM 781E, ACCESSORY REPLACEMENT (Figure 5-8 and Figure 5-9)..................................5-18

5.11 AFTO FORM 781F, AEROSPACE VEHICLE IDENTIFICATION DOCUMENT (Figure 5-10) ...........5-19

5.12 AFTO Form 781G, General Mission Classification-Mission Symbols (Figure 5-11 and

Figure 5-12) ................................................................................................................................................5-24

5.13 AFTO Form 781H, Aerospace Vehicle Flight Status and Maintenance Document (Figure 5-13 and Figure 5-14) .........................................................................................................................................5-27

5.14 AFTO Form 781J, Aerospace Vehicle Engine Flight Document (Figure 5-15 and Figure 5-16) ...............5-33

5.15 AFTO Form 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection, and

Delayed Discrepancy Document (Figure 5-17 and Figure 5-18) .............................................................5-37

5.16 AFTO Form 781M, Status Symbols and Functional System Codes (Figure 5-19 and

Figure 5-20) ................................................................................................................................................5-41

5.17 AFTO FORM 781P, SUPPORT GENERAL DOCUMENTATION (Figure 5-21) .....................................5-44

6 ACCESSORY REPLACEMENT AND REUSE PROCEDURES.................................................................................6-1

6.1 Accessory Replacement and Reuse ..................................................................................................................6-1

6.2 Time-Change Item (TCI) Replacement Policies ..............................................................................................6-1

6.3 Time-Change Item Reuse Policies....................................................................................................................6-3

7 SUPPORT EQUIPMENT (SE) .......................................................................................................................................7-1

7.1 Purpose...............................................................................................................................................................7-1

7.2 Forms Location..................................................................................................................................................7-2

7.3 Inspection Requirements ...................................................................................................................................7-2

7.4 War Reserve Material (WRM) or Mobility Equipment...................................................................................7-4

7.5 Support Equipment Document Administration ................................................................................................7-4

7.6 AFTO Form 244, Part I ....................................................................................................................................7-4

7.7 AFTO Form 244, Part II ...................................................................................................................................7-5

7.8 AFTO Form 244, Part III..................................................................................................................................7-5

7.9 AFTO Form 244, Part IV .................................................................................................................................7-5 ii

7.10 AFTO Form 244/245, Part V............................................................................................................................7-5

7.11 AFTO Form 245................................................................................................................................................7-6

7.12 Disposition Instructions.....................................................................................................................................7-6

7.13 Closing Out AFTO Form 244/245....................................................................................................................7-6

8 TRANSFER, STORAGE, AND DEPOT MAINTENANCE.........................................................................................8-1

8.1 Transferring Aerospace Vehicles ......................................................................................................................8-1

8.2 AFTO Form 290, Aerospace Vehicle Delivery Receipt ..................................................................................8-3

8.3 Preparation of Aerospace Vehicles for Delivery to a Depot/Contractor Facility ...........................................8-8

8.4 Preparation of Aerospace Vehicle for Transfer by One-Time Flight..............................................................8-8

8.5 Preparation of Aerospace Vehicle to be Transferred Sold or Disposed .........................................................8-8

9 MAINTENANCE HISTORICAL DOCUMENTATION ...............................................................................................9-1

9.1 General Maintenance Historical Documentation Requirements ......................................................................9-1

9.2 Non-Automated Procedures ..............................................................................................................................9-3

9.3 AFTO Form 95, Significant Historical Data Record (Figure 9-1) ..................................................................9-4

9.4 AFTO Form 95 Entries .....................................................................................................................................9-4

9.5 AFTO Form 95, Special Applications..............................................................................................................9-4

9.6 Maintenance and Disposition of Historical Records........................................................................................9-4

10 ICBM FACILITY AND SUPPORT EQUIPMENT INSPECTIONS..........................................................................10-1

10.1 General.............................................................................................................................................................10-1

10.2 Inspection Requirements .................................................................................................................................10-1

10.3 Inspection Types..............................................................................................................................................10-1

10.4 Documentation.................................................................................................................................................10-2

10.5 Deviations ........................................................................................................................................................10-3

A MAINTENANCE TERMS.............................................................................................................................................A-1

A.1 Description of Frequently Used Maintenance Terms .....................................................................................A-1

B APPLICABLE TECHNICAL ORDERS AND SUPPORTING DIRECTIVES........................................................... B-1

B.1 Applicable Technical Orders............................................................................................................................ B-1 B.2 Supporting Directives ....................................................................................................................................... B-1

C LIST OF ACRONYMS .................................................................................................................................................. C-1

LIST OF ILLUSTRATIONS

Number Title Page

2-1 AFTO Form 26, Aerospace Vehicle Inspection Work Card.................................................................................2-10 5-1 AFTO FORM 781, ARMS Aircrew/Mission Flight Data Document (Front) ........................................................5-4 5-2 AFTO FORM 781, ARMS Aircrew/Mission Flight Data Document (Reverse)....................................................5-5 5-3 AFTO FORM 781A, Maintenance Discrepancy and Work Document................................................................5-11 5-4 AFTO FORM 781A, Maintenance Discrepancy and Work Document (Reverse) ...............................................5-12 5-5 AFTO FORM 781B, Communication Security (COMSEC) Equipment Record.................................................5-14 5-6 AFTO FORM 781C, Avionics Configuration and Loads Status Document ........................................................5-16 5-7 AFTO FORM 781C, Avionics Configuration and Load Status Document (Reverse).........................................5-17 5-8 AFTO FORM 781E, Accessory Replacement Document.....................................................................................5-21 5-9 AFTO FORM 781E, Accessory Replacement Document.....................................................................................5-22 5-10 AFTO FORM 781F, Aerospace Vehicle identification Document.......................................................................5-23 5-11 AFTO FORM 781G, General Mission Classifications-Mission Symbols ............................................................5-25 iii

5-12 AFTO FORM 781G, General Mission Classifications-Mission (Reverse) ..........................................................5-26 5-13 AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document..........................................5-31 5-14 AFTO FORM 781H, Aerospace Vehicle Flight Status and Maintenance Document (Reverse).........................5-32 5-15 AFTO FORM 781J, Aerospace Vehicle Engine Flight Document ......................................................................5-35 5-16 AFTO FORM 781J, Aerospace Vehicle Engine Flight Document (Reverse)......................................................5-36 5-17 AFTO FORM 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection and Delayed

Discrepancy Document ......................................................................................................................................5-39 5-18 AFTO FORM 781K, Aerospace Vehicle Inspection, Engine Data, Calendar Inspection and Delayed

Discrepancy Document (Reverse) .....................................................................................................................5-40 5-19 AFTO FORM 781M, Status Symbols and Functional System Codes..................................................................5-42 5-20 AFTO FORM 781M, Status Symbols and Functional System Codes (Reverse).................................................5-43 5-21 AFTO FORM 781P, Support General Documentation .........................................................................................5-45 7-1 AFTO FORM 244, Industrial/Support Equipment Record .....................................................................................7-8 7-2 AFTO FORM 244, Industrial/Support Equipment Record (Reverse) ....................................................................7-9 7-3 AFTO FORM 245, Industrial Support Equipment (Continuation) .......................................................................7-10 7-4 AFTO FORM 245, Industrial Support Equipment (Continuation) .......................................................................7-11 8-1 AFTO FORM 345, Aerospace Vehicle Transfer Inspection Checklist and Certification (Front) .........................8-5 8-2 AFTO FORM 345, Aerospace Vehicle Transfer Inspection Checklist and Certification (Reverse).....................8-6 8-3 AFTO Form 290, Aerospace Vehicle Delivery Receipt .........................................................................................8-7 9-1 AFTO FORM 95, Significant Historical Data (Front) ............................................................................................9-6 9-2 AFTO FORM 95, Significant Historical Data (Back) ............................................................................................9-7 10-1 IMDS ''Verify Equip Status'' ..................................................................................................................................10-2

LIST OF TABLES

Number Title Page

6-1 Red Symbol Entries for Installed Aerospace Equipment Time Change Items.........................................................6-4 6-2 Processing Time Change Items Where Previous Operating Time is Unknown or Known to be Invalid...............6-5 iv

FOREWORD

1. PURPOSE.

This technical manual provides a description of the Aero-space Equipment Maintenance Inspection, Documentation, Policies, and Procedures. Instructions for safe and proper storage, handling, inspection, testing, maintenance, and preparation for use are also provided.

2. USE OF THIS MANUAL.

The table of contents indicates chapter, paragraph, title, and page numbers to facilitate location of information. Illustra-tions, tables, and diagrams, when applicable, are located throughout the publication to supplement the text material.

A list of illustrations and a list of tables indicate the number, title, and location. Abbreviations, phrases, and words which are on a decal, a placard or an engraving are set forth in the text exactly as they appear on the decal, the placard or the engraving.

3. DEFINITIONS.

The word SHALL is used to express a provision that is binding. The words SHOULD and MAY are used when it is necessary to express nonmandatory provisions. WILL may be used to express a mandatory declaration of purpose or when it is necessary to express a future event.

4. ABBREVIATIONS AND ACRONYMS.

All abbreviations used in this manual are in accordance with abbreviations per ASME Y14.38M, Abbreviations and Acronyms for use on drawings and related documents:

NOTE

Acronyms used only once in the TO are not included in this list.

Use acronym list from Appendix C, paragraph C.1

5. LIST OF RELATED PUBLICATIONS.

These publications contain information in support of this technical manual. Use List of Related Publications from Appendix B, paragraph B.1.

v/(vi blank)

CHAPTER 1

GENERAL

1.1 PURPOSE.

1.1.1 This Technical Order (TO) establishes the policies and procedures for use of the 00-20 series TOs and provides weapon system and equipment maintenance inspection and documentation guidance. It also implements the policies of AFI 21-101, Aircraft and Equipment Maintenance Management; AFI 11-301, Aircrew Flight Equipment (AFE) Program, and AFI 21-102, Depot Maintenance Management.

1.1.2 Unless otherwise specified, the term “AEROSPACE EQUIPMENT” in this technical order refers to weapon systems and equipment such as aerospace vehicles, equipment, missiles, nuclear weapons, Test Measurement and Diagnostic Equipment (TMDE), trainers, training equipment, engines, Flight Support Equipment (FSE), industrial plant equipment, and all related Support Equipment (SE). This technical order is applicable to all organizations maintaining this equipment.

1.1.3 MAJCOMs may supplement 00-20 series TOs as required. For the purpose of the 00-20 series TOs, the term AFMC Single Manager (SM) includes System Program Directors (SPD), Product Group Managers (PGM), and Supply Chain Managers (SCM).For the purpose of maintenance policy, the Lead Commands are Air Combat Command, Air Mobility Command, Air Force Special Operations Command, Air Education and Training Command, Air National Guard, Air Force Reserve Command, Air Force Space Command, Global Strike Command and Air Force Materiel Command.

1.1.4 Air Force agencies will not furnish maintenance data in any form to contractors unless the applicable Lead Command, Field Operating Agency or Weapon System Manager, as appropriate, has granted approval. Operating activities will not perform any additional documentation requirements above those outlined in this TO without MAJCOM/Lead Commandand HQ USAF/A4LM approval.

1.1.5 In the 00-20-series TOs, the designation, GP/CC is used to represent the Maintenance Group Commander. At test sites or activities which do not have a GP/CC, it will be the responsibility of the Chief of Maintenance, Chief of Test Force Teams, Air Mobility Squadron Commander, Installation Team Chief or equivalent (as determined by the MAJCOM/A4) to ensure that the criteria of this TO is complied with.

1.1.6 Forward requests for waivers to this TO through MAJCOM maintenance policy to HQ AFMC/A4FI.

1.1.7 For all Air-To-Air and Air-To-Ground missiles and munitions tracked in Reliability Asset Monitoring System (RAM)/Tactical Munitions Reporting System (TMRS), serviceability and maintenance documentation procedures are managed through the use of AFTO Form 244 and other forms identified in TO 21M-1-101.

1.2 RECOMMENDATIONS FOR TECHNICAL ORDER CHANGES.

All changes to this TO must be forwarded through users MAJCOM. Submit change requests using AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply, IAW TO 00-5-1, AF Technical Order System.

1.3 CONTRACT MAINTENANCE OPERATIONS.

1.3.1 The contractor will provide the Air Force contract administration office with a list of personnel who are authorized to certify that Aerospace Equipment is safe for flight or use. This certification list should be kept to a minimum to meet mission requirements. Any changes to the list will be immediately forwarded to the contract administration office. The listing will specifically identify the personnel who are authorized to:

1.3.1.1 Sign exceptional releases.

1.3.1.2 Downgrade Red X or Red W conditions.

1.3.1.3 Sign off Red X or Red W symbol.

1.3.1.4 Certify operational capability.

1.3.1.5 Perform functional check flights (if applicable).

1-1

1.3.1.6 Update weight and balance records IAW TO 1-1B-50, Aircraft Weight and Balance.

1.3.2 The contractor will develop and maintain a program to ensure that personnel are trained in the areas specified in the contract. The program will have provisions for contractor certification/recertification of personnel authorized to perform the specific functions or to operate various SE IAW AFI 21-101 and other applicable directives.

1.3.3 The contract administration office will ensure that the contractor performs the maintenance management and documentation requirements prescribed in applicable TOs. In addition, the contract administration office will ensure that the applicable TOs are referenced as provisions in the contract.

1-2

CHAPTER 2

AEROSPACE VEHICLE INSPECTIONS

2.1 GENERAL.

2.1.1 Inspection intervals required for Air Force aerospace vehicles are prescribed in applicable Mission Design Series (MDS) specific -6 TO maintenance manuals, item technical orders, inspection work cards, checklists, commercial manuals or depot engineering data. All requirements pertaining to inspections will normally be accomplished concurrently to avoid complications in scheduling and controlling the required maintenance. The inspection concepts for aerospace vehicles are periodic, phase, isochronal, programmed depot maintenance (PDM), and aerospace vehicle manufacturer maintenance. The GP/CC establishes necessary controls to ensure that the periodic, phase, or isochronal inspections are accomplished at or near the scheduled due time as authorized in applicable TOs or approved waivers. GP/CC may increase the frequency or scope of scheduled inspections or individual inspection requirements, when required for temporary situations. Scheduling deviations of periodic, phase, or isochronal inspections beyond what is authorized in aerospace vehicle specific technical manuals, must be approved through the SM in coordination with the Owning MAJCOM. Scheduling deviations that effect PDM or aerospace vehicle manufacturer maintenance, must be approved through the SM, Lead Command, and Owning MAJCOM.

2.1.2 When new inspection requirements are levied and the age or accrued time of the aerospace vehicles, systems, and components is less than the specified inspection interval, begin accomplishment of the new requirements at the prescribed interval. If the age or time is beyond the specified interval, accomplish initial inspections as soon as practical and regulate subsequent inspections accordingly. When requirements are added or changed for accessory items, determine operating time in accordance with Chapter 6.

2.2 INSPECTION REQUIREMENTS.

2.2.1 Each Single Manager (SM)/Program Manager (PM) determines the inspection concept, establishes a recurring maintenance cycle and ensures adequate scheduling flexibility to bundle/align recurring maintenance requirements to the maintenance cycle.

2.2.1.1 Recurring maintenance requirements are published in MDS specific -6 TO’s and/or inspection workcard decks, (e.g.

pre-flight, basic post-flight, thru-flight, etc.). After the initial publication, the SM/PM may, in conjunction with applicable Lead Command, delete Section I from MDS specific TO if Section I contains the same inspection requirements as published in the inspection work cards.

2.2.2 Inspection Concepts. The basic sub-elements for the periodic, phase, isochronal, PDM, and aerospace vehicle manufacturer inspection concepts are as follows:

2.2.2.1 PERIODIC CONCEPT:

Pre-flight (PR) Basic Post-Flight (BPO)

Pre-Launch Inspection (PLI) or Walk-Around (WAI) Combined Pre-Flight (PR/BPO)

End-of-Runway (EOR) Hourly Post-Flight (HPO)

Thru-Flight (TH) Periodic (PE)

Quick Turn (QT) Pre-Departure Service Check (PDSC)

2.2.2.2 PHASE CONCEPT:

Pre-flight (PR) Basic Post-Flight (BPO)

Pre-Launch Inspection (PLI) or Walk around (WAI) Combined Pre-Flight (PR/BPO)

End of Runway (EOR) Hourly Post-Flight (HPO)

Thru-Flight (TH) Phase (PH)

Quick Turn (QT)

2-1

2.2.2.3 ISOCHRONAL CONCEPT:

Pre-flight (PR) Hourly Post-Flight (HPO)

End-of-Runway (EOR) Home Station Check (HSC)

Thru-Flight (TH) Minor (Min)

Quick Turn (QT) Major (Maj)

Basic Post-Flight (BPO) Combined Pre-Flight (PR/BPO)

2.2.2.4 PROGRAMMED DEPOT MAINTENANCE (PDM)

12 Month 48 Month

24 Month 54 Month

36 Month 60 Month

2.2.2.5 AEROSPACE VEHICLE MANUFACTURER INSPECTION CONCEPT

A Check C Check

B Check D Check

2.2.3 Inspection Cycle. Lead Commands may authorize aerospace vehicles to use a modified inspection work card deck during contingencies, and increased readiness conditions. The SM designates and publishes work cards in conjunction with the Lead Command for use during these periods. Construct contingency decks to ensure all items impacting aerospace vehicle safety and reducing aerospace vehicle reliability are inspected. Accomplish the normal inspection work card deck upon termination of this period.

2.2.4 Periodic, isochronal, phase, HSCs, HPOs, and commercial equivalent inspections are scheduled at equal intervals throughout the total inspection cycle, regardless of when inspections were actually completed. Do not exceed inspection intervals unless authorized by the MDS specific -6 TO, or approved by the Lead Command and SM to meet mission essential requirements. If the interval is exceeded, use the appropriate Red symbol (specific exceptions will be in the appropriate TOs).

Inspection interval extensions must be annotated using the Red Dash unless authorized for service tests and special projects by the SM and the Lead Command. Changes to prescribed inspection intervals, concepts or requirements will be made by the SM only after thorough analysis of data obtained from the Maintenance Information System (MIS) and from appropriate Reliability Centered Maintenance Analysis (RCMA).

2.2.5 Scheduled inspection requirements specified in publications other than MDS specific -6 TO are not applicable to components in an installed status. Inspection requirements for components not installed are contained in commodity and equipment manuals. If inspection requirements for installed items are listed in publications other than -6 (or -2 for missiles) TO, bring them to the attention of the SM, who will take action to integrate them into the applicable -6 (or -2) scheduled inspection and maintenance manuals. Aircrew Flight Equipment (AFE) not in an installed status and therefore not listed in MDS specific -6 TO, as defined in Appendix A, are exempt from these requirements.

2.3 SPECIFIED FLYING PERIOD.

2.3.1 The specified flying period begins with the first flight and continues for a period of hours as specified by the MAJCOM not to exceed 72 hours, unless authorization is granted by the PM and MDS specific -6.

2.4 PRE-FLIGHT INSPECTIONS (PR).

2.4.1 The pre-flight inspection is a flight preparedness inspection done in accordance with the MDS specific -6 TO or maintenance requirements manual (as applicable). The pre-flight inspection includes visually examining the aerospace vehicle and operationally checking certain systems and components to ensure there are no serious defects or malfunctions.

2.4.2 A preflight will be required prior to the first flight of the flying period, or when the preflight validity period has expired.

2.4.3 If not already specified in the MDS specific TO, MAJCOMS may select a 24-, 48- or 72-hour pre-flight validity period.

2-2

2.4.4 The pre-flight validity period ends when the selected time period in paragraph 2.4.3. has expired or when the specified flying period expires, whichever occurs first. MAJCOMs or MDS specific technical orders may be more restrictive.

2.4.5 When an aerospace vehicle is mobilizing for contingency operations, units are authorized to place the aerospace vehicle on alert status. It must be prepared in accordance with established TOs, accepted by an aircrew, remain under the control of operations and be monitored by maintenance.

2.4.5.1 Accomplish a complete preflight inspection prior to sealing the aircraft.

2.4.5.2 A new pre-flight is not required during the alert period or as long as the aircraft is launched directly from alert status regardless of the pre-flight validity period.

2.4.5.3 Upon termination of alert status, accomplish a preflight if the preflight validity period expired.

2.4.6 Pre-Launch Inspection (PLI) or Walk-Around Inspection (WAI). The PLI and WAI are abbreviated pre-flights and will be accomplished as required by MDS-specific -6 TO and/or MAJCOM supplement to this TO.

2.5 END-OF-RUNWAY INSPECTION (EOR).

2.5.1 The EOR inspection is a final visual and/or operational check of the aerospace vehicle. The SM in coordination with the Lead Command will list minimum inspection requirements in the applicable -6 TO and publish in an existing work card deck.

2.5.2 EOR is performed immediately prior to take-off at a designated location.

2.5.3 The purpose of the inspection is to detect critical defects that may have developed or have become apparent during ground operation of the aerospace vehicle.

2.5.4 Aerospace vehicles launched from alert status do not require this inspection. Alert Force Evaluations will not require an EOR inspection and will be treated as Active Air Defense scrambles. However, Alert aircraft launched for training missions from Alert status will require an EOR inspection.

2.6 THRU-FLIGHT INSPECTION (TH).

2.6.1 The TH inspection is a ''between flights'' inspection and will be accomplished after each flight when a turnaround sortie or a continuation flight is scheduled and a basic post-flight inspection is not required. A TH is not required when aircraft are hot-pitted and immediately accomplish a turnaround or continuation sortie. This inspection is applicable when prescribed by applicable MDS specific -6 TO or maintenance manual. The TH inspection consists of checking the aerospace vehicle for flight continuance suitability by performing visual examination and/or operational checks of certain components, areas, or systems, according to established TOs to ensure no defects exist which would be detrimental to further flight.

2.6.2 Certain aerospace vehicles have thru-flight inspection requirements identified by special characters in applicable work card decks. Other aerospace vehicles have separately published thru-flight inspection work card decks.

2.7 QUICK TURN INSPECTION (QT).

2.7.1 QTs are abbreviated thru-flight inspections authorized by MDS specific -6 TOs.

2.7.2 MAJCOMs will publish QT guidance and may authorize QT inspections for aerospace vehicles resuming alert after flight or placing aerospace vehicles on alert at alert site locations.

2.8 BASIC POST-FLIGHT (BPO) INSPECTION.

2.8.1 The BPO inspection is a more thorough check than the pre-flight or the thru-flight inspections and is accomplished in accordance with the MDS specific -6 TO or maintenance manual for the aerospace vehicle.

2.8.2 This inspection will consist of checking the aerospace vehicle condition by performing visual examination or operational checks of certain components, areas, or systems to assure that no defects exist that would be detrimental to flight.

2.8.3 Maintenance personnel will perform a BPO after the last flight of a specified flying period or a combined pre-flight/BPO prior to the next flying period if the aerospace vehicle has flown.

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2.9 COMBINED PRE-FLIGHT/BASIC POST-FLIGHT (PR/BPO) INSPECTION.

2.9.1 This inspection consolidates the requirements of the pre-flight and basic post-flight inspections into a single inspection accomplished at the end of the specified flying period or prior to the first flight of the next specified flying period. It has the same validity period as the PR.

2.10 HOUR POST-FLIGHT INSPECTION (HPO).

2.10.1 The HPO inspection is accomplished at equally spaced intervals as specified in the applicable MDS specific -6 TO.

2.10.2 Determine the due time for all HPO inspections at the completion of each periodic/PHASE inspection. Reference applicable -6 TO for impact of early/late completion of HPO.

2.11 PERIODIC INSPECTION (PE).

2.11.1 The PE is due upon accrual of the number of flying hours, operating hours, or at the expiration of a calendar period specified in the applicable MDS specific -6 TO. The periodic inspection is more extensive in scope than the HPO or BPO inspections as the PE inspection is a thorough inspection of the entire aerospace vehicle.

2.12 PHASE INSPECTIONS (PH).

2.12.1 For the purpose of this section, the term phase refers to both Periodic and Phase inspections. These inspections are cumulative for the life of an aerospace vehicle. The number of the next due periodic inspection should be the same as the number obtained by dividing the aerospace vehicle hours at which the next PH is due by the hourly inspection interval. The number obtained may vary from the actual PH number due because of transfers and premature or overdue flying hour inspections.

2.12.2 Accomplish PH upon accrual of the number of flying hours specified in the applicable MDS specific -6 TO and maintenance manual. The PH concept involves consolidation of the BPO, periodic inspection and/or HPO requirements into work deck(s) having approximately the same work content and approximately the same number of clock hours for accomplishment. The primary objective of the PH concept is to minimize the length of time that an aerospace vehicle is out-of-commission for any given scheduled inspection. The PH concept does not apply to those aerospace vehicle types for which the inspection requirements cannot be divided into reasonably equal work decks.

2.12.3 Schedule PH at equal intervals throughout the total inspection cycle regardless of when the inspections are actually accomplished.

2.12.4 When aerospace vehicles under the phase concept are required for extended missions, phases may be accomplished in advance to cover the period of the extended mission, when authorized by the MAJCOM and SM. Upon completion of the extended mission, normal scheduling of the phase packages will be resumed.

2.13 ISOCHRONAL INSPECTION (ISO).

2.13.1 The ISO concept translates flying hour utilization rates into calendar periods, usually expressed in days. The SM ensures the calendar period is properly established to meet maintenance and engineering requirements. In the event programmed flying hours are changed, adjust inspection interval as specified in the MDS specific -6 TO. The SM, in conjunction with the Lead Command, determines necessary adjustments. The Lead command will notify Owning MAJCOMs of adjustments.

2.13.2 To manage the ISO concept properly, schedule inspections as far in advance as possible for each aerospace vehicle.

2.13.3 The interval time frame is from the completion of the post-dock from the last ISO to the start of the next ISO. The ISO concept allows for the time an aerospace vehicle is programmed to be in an inspection status.

2.13.4 MAJCOMs, with SM concurrence, approve deviations to schedules when ISO cannot be met. Criteria for deviations should be, but are not limited to, aerospace vehicles removed from service for extended periods of time (e.g. depot level maintenance IAW TO 00-25-107, Maintenance Assistance), extended fuel repair and Time Compliance Technical Order (TCTO) kit verification.The GP/CC establishes procedures to ensure these aircraft are placed in storage in accordance with TO 1-1-17, Storage of Aircraft and Missile Systems, when required.

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2.13.4.1 Send requests for ISO schedule deviations to the MAJCOM functional manager. Units will not request an ISO deviation unless the deviation exceeds the overfly authorized by the MDS-specific -6 TO (if applicable). Provide the following information when requesting ISO deviations:

2.13.4.1.1 MDS

2.13.4.1.2 Serial Number

2.13.4.1.3 Reason for Request

2.13.4.1.4 Type of Inspection (e.g., #4 Major, #1 Minor)

2.13.4.1.5 Actual Inspection Due Date

2.13.4.1.6 Requested Inspection Date

2.13.4.1.7 Completion Date of the post-dock for the last Isochronal Inspection

2.13.4.1.8 Number of PDM Days Since Last Inspection

2.13.4.1.9 Total days in Unscheduled Depot Level Maintenance (UDLM)

2.13.4.1.10 Special Inspections Due

2.13.4.1.11 Time Change Items Due (Item, Date Due/Time Remaining)

2.13.4.1.12 Outstanding TCTOs (only those affected by the extension)

2.13.4.1.13 Airframe Hours Since Last Inspection

2.13.4.1.14 Flying hours since last major (i.e. ISO) inspection

2.13.5 Aerospace vehicles in Purpose Identifier Code ''DJ'' (as determined by Air Force Data Dictionary, ADE AE-710), awaiting depot input, or undergoing UDLM, do not accrue -6 inspection days. Refer to the MDS-specific -6 TO (if applicable) for stipulations as to when the ISO clock stops.

2.13.6 Isochronal inspections for Intercontinental Ballistic Missile (ICBM) and their trainers, and their SE will be due at equal intervals throughout the total inspection cycle, regardless of when the inspections were actually accomplished.

Isochronal inspections are based on calendar intervals using the following due periods:

TYPE INTERVAL DUE PERIOD

Major Semi-annual or greater Within due month

Minor Semi-monthly, bi-monthly, Quarterly Within due week

Minor Weekly Due date ± one work day

Minor Daily On due date

Minor Semi-monthly, monthly, bi-monthly, Within due week Quarterly

NOTE: Weekly intervals will begin on Sunday and semi-monthly intervals will begin on the first and sixteenth of each month.

2.14 MINOR (MIN) ISO.

2.14.1 The MIN consists of checking certain components, areas, or systems of the aerospace vehicle to determine if conditions exist, if uncorrected, could result in failure or malfunction of a component prior to the next scheduled inspection.

2.14.2 The MIN inspection is due upon accrual of the number of calendar days established as the inspection interval in the

MDS.

2.14.3 Compute this date from the post dock of the last isochronal inspection.

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2.15 MAJOR (MAJ) ISO.

2.15.1 The MAJ inspection is a thorough inspection of the entire aerospace vehicle, and individual requirements may be more extensive in scope than previous inspection items.

2.15.2 The MAJ inspection is due upon accrual of the number of calendar days established as the inspection interval in the MDS specific -6 TO.

2.16 HOME STATION CHECK (HSC) INSPECTION.

The HSC is an inspection arranged and designed for accomplishment upon expiration of a specified short-term calendar interval. This inspection is due at the calendar interval specified in the MDS specific -6 TO. Send HSC schedule deviation requests to the MAJCOM functional manager. Units will not request an HSC deviation unless the deviation exceeds the overfly authorized by the MDS-specific -6 TO (if applicable). Refer to paragraph 2.13.4.1 thru 2.13.4.1.14 for submittal requirements. Since the HSC is an integral part of the isochronal concept, compute this date from the completion of the last HSC/isochronal inspection. Accomplish the inspection in conjunction with minor and major inspections.

2.17 PROGRAMMED DEPOT MAINTENANCE (PDM).

2.17.1 PDM is an inspection requiring skills, equipment, and/or facilities not normally possessed by operating locations.

Individual areas, components and systems are inspected to a specific -6 TO requirements.