Attachment_016_SEMA_Appendix_L_PWS

W58RGZ-15-R-0045 APPENDIX L to SEMA PWS

Appendix L

Interior Refurbishment

For

SEMA Aircraft

TABLE OF CONTENTS

SECTION I General Instructions

1.1. Scope

1.1.1 General:

1.1.2 Contents:

1.1.3 Change Recommendations:

1.2 Definitions

1.3 Maintenance References:

1.3.1 Military Specifications:

1.3.2 Federal Aviation Regulations (FAA Regs):

1.3.3 Advisory Circulars:

1.3.4 Federal Specifications:

SECTION II Aircraft Interior Refurbishment Requirements

2.1 General Maintenance Standards:

2.1.1 General Requirements:

2.1.2 C-12 Requirements:

2.1.3 RC-12 Requirements:

2.1.4 EO/TO-5, MC-12S and RO-6A Requirements

2.1.5 Defect Correction Criteria:

2.1.6 Rework Procedures:

2.1.7 Aircraft Records Maintenance:

2.1.8 Ground Handling, Operation and Safety Precautions:

2.1.9 Engineering Support Requirements:

2.1.10 Non-Standard Installations:

2.1.11 Weight and Balance:

2.1.12 Report Requirements:

2.2 Induction Requirements:

2.2.1 Aircraft Equipment Inventory:

2.2.2 Preservation:

SECTION III Aircraft Refurbishment Acceptance Requirements

3.1 Final Processing

3.1.1 Weight and Balance

3.1.2 Logs and Records

3.1.3 Power Plant Turn-Up:

3.1.4 Disturbed Systems:

3.2 Delivery

3-2.1 Daily/Turnaround Inspection:

3.2.2 Maintenance Test Acceptance:

3.2.3 Acceptance Processing:

3.2.4 Acceptance:

SECTION I General Instructions

1.1. Scope

This appendix applies to Army C-12, RC-12, EO/TO-5, MC-12S and RO-6A aircraft.

1.1.1 General:

a. This specification establishes the Aircraft Interior Refurbishment requirements for the C-

12/RC-12, EO/TO-5, MC-12S and RO-6A Series Aircraft. The goal is a high quality interior standardized by aircraft type.

Note: If the aircraft is in a facility for a strip and repaint then the task may be performed concurrently with the strip and repaint.

b. The requirements included within this Appendix provide for removal, inspection, refurbishment and reinstallation of all interior components.

(1) Burn certificates required for material (carpet, leather etc.)

(2) Documentation (8130, Yellow Tag, etc.) required for parts used

1.1.2 Contents:

This appendix has sections that are a guide to the minimum requirements for interior standardization/refurbishment of the C-12/C-12J, RC-12, EO/TO-5, MC-12S and RO-6A.

1.1.3 Change Recommendations:

Recommendations for additions, deletions, or changes to the requirements of this specification are invited and should be submitted to:

PEO Aviation, Fixed Wing Project Office (FW PO) Attn: AMSAM-AC-AR-C (Program Contracting Officer) Redstone Arsenal, 35898-5280.

1.2 Definitions

Definitions are contained in the manuals, any questions concerns can be discussed on a case by case basis

1.3 Maintenance References:

The following specifications, drawings, directives, and publications are provided for guidance.

Best commercial practices shall be followed.

1.3.1 Military Specifications:

MIL-DTL-64159 Chemical & Biological Resistant Polyurethane Coating

MIL-C-91706 Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys

MIL-F-7179 Finishes, Coatings and Sealants for the Protection of Aerospace Weapons Systems

TM-55-1500-345-23 Painting and Marking of Army Aircraft

MIL-L-81352 Lacquer, Acrylic

MIL-P-23377 Primer Coatings: Epoxy Polyamide, chemical and Solvent

Resistant

TM 405-9 Weight and Balance Control Data

1.3.2 Federal Aviation Regulations (FAA Regs):

FAR 43.3 Persons Authorized to Perform Maintenance, Preventative Maintenance, Rebuilding and Alterations

FAR 43.5 Approval for Return to Service after Maintenance, Preventative

Maintenance, Rebuilding and Alterations

FAR 43.7 Persons Authorized to Approve Aircraft Airframes, Aircraft Engines, Propeller, and Appliances for Return to Service after Maintenance, preventive Maintenance, Rebuilding and Alterations

FAR 43.9 Content, Form and Disposition of Maintenance, Rebuilding and Alteration Records (except 100-hour, annual and progressive inspections)

FAR 43.13 Performance Rules (General)

FAR 65 Certification of Airmen Other Than Flight Crew Members (See applicable sections)

FAR 91.417 Maintenance Records

FAR 145 Repair Stations

1.3.3 Advisory Circulars:

AC 43.9 Maintenance Records, General Aviation Aircraft

AC 43.13 Acceptable Methods, Techniques and Practices: Aircraft

Inspection and Repair

1.3.4 Federal Specifications:

MIL-STD-973 Configuration Management

SECTION II Aircraft Interior Refurbishment Requirements

2.1 General Maintenance Standards:

This section contains specific instructions for the Interior Refurbishment of the C-12/RC-12, EO/TO-5, MC-12S and RO-6A series aircraft.

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

b. No additional charges for Interior removal and reinstallation when an aircraft is in a facility for any effort that requires the removal of the interior.

2.1.1 General Requirements:

The Interior Refurbishment is an ongoing effort of the FW PO to provide the end user of the SEMA aircraft a standardized, high quality and durable interior.

2.1.2 C-12 Requirements:

1. Seats (includes armrests & seat belt reels): ensure move and lock in all directions as designed. Discrepancies should be corrected before seats are reupholstered

2. Remove and inspect all interior components

3. Cabin headliner; Recover

4. Cabin seats & Divan if installed; Reupholster seats to include armrests, install new foam cushions and paint seat frames

5. Cabin sidewall panels; recover and install new foam

6. Cabin window panels, recover panels and paint reveals to match

7. Cargo bay; reupholster and paint trim panels to match

8. Cargo door; Reupholster trim panels, paint trim panels, replaces wind laces and paint cargo door frame

9. Carpet; Replace throughout the aircraft and install runner for center aisle

10. Center spar cover; Install new aeromat

11. Crew seats; Reupholster seats to include armrests, install new foam cushions and paint seat frames

12. Entrance door; Install new aeromat on steps, replace wind laces and paint door trim panels

13. Flight deck; Paint headliner, paint window trim panels, recover lower sidewall panels and replace aeromat on center pedestal cover

14. Glare Shield; Recover

15. Laminate; Replace with new throughout the aircraft, stain hardwood nosing to match, replace cork in cup-holders

16. Lavatory; Seat, reupholster and install new foam cushions and replace curtain

17. Sound proofing; install kits

18. Install Interior components

19. Provide sheep skin covers for pilot and copilot seat.

2.1.2.1 C-12 Material:

• Carpet, Velvet Gray - AZ3403

• Leather, Ambassador Charcoal - 1501076

• Laminate, Bronze Ribbon Mahogany - 2613V-G

• Entry Steps, Gray Aeromat - 45R91897230R/54

• Lower side walls, Waypoint Light Gray - WP860

• Headliner, Aertrim/Schneller - 14JBS12251695R54

• Glare Shield, Mirage GS Ebony - 210790

• Divider Curtain – Cavalier/Pewter

• Insulation, Scandia - KA200/Over ESCS

2.1.3 RC-12 Requirements:

1. Seats (includes armrests & seat belt reels): ensure move and lock in all directions as designed. Discrepancies should be corrected before seats are reupholstered

2. Remove and inspect all interior components

3. Cabin headliner; Install new blanket

4. Cabin seats; Reupholster seats to include armrests, install new foam cushions and paint seat frames

5. Cabin sidewall; Install new blankets

6. Cabin window panels; paint reveals

7. Cargo bay; install new blankets and paint trim panels to match

8. Cargo door; Recover panel, paint plastic trim panels to match headliner, replace wind laces and paint cargo door frame black

9. Center spar-cover; Install new aeromat

10. Crew seats; Reupholster seats, install new foam cushions and paint seat frames

11. Provide sheep skin covers for pilot and copilot seats.

12. Entrance door; Install new aeromat on steps, replace wind laces and paint door trim panels

13. Flight deck; Paint headliner, paint window trim panels, recover lower sidewall panels, replace aeromat on center pedestal cover and install new carpet

14. Glare Shield; Reupholster

15. Lavatory; Seat, reupholster and install new foam cushions and replace curtain

16. Floor; Paint

17. Sound proofing; install kits

18. Install Interior components

2.1.3.1 RC-12 Material:

• Crew seats: Moore and Giles Olympia Slate Grey, Leather and Sheepskin Overlays, Silver

Grey.

• Seat foam: Skandia HR551.0X36X72, HR701.0X36X, HR1501.X36X72, HR1502.0X36X72.

• Step Tread: Perrone Aerospace ST-4112 Black.

• Cabin and aft cargo: Quilted Blanket Avio-Diepen 64027.

• Velcro on blanket: Skandia hook and loop.

• Cockpit carpet: Vasi Aerospace Elevation Carpets- Slipstream Matterhorn Grey.

• Insulation: Skandia SK-7000 RP Aerotherm.

• All seatbelts were sent to Aviation Safety Products and re-webbed.

2.1.4 EO/TO-5, MC-12S and RO-6A Requirements

The Government will elect to utilize the elective improvement clause for interior refurbishments on EO/TO-5, RO-6A and MC-12S aircraft.

2.1.5 Defect Correction Criteria:

a. Critical Defects. All critical defects discovered as a direct result of, compliance with aircraft interior refurbishment requirements shall be corrected in accordance with the OEM, FAA, and Part 145, Repair Station Criteria.

b. Major Defects:

(1) All major defects discovered as a direct result of compliance with aircraft interior refurbishment requirements shall be corrected in accordance with FAA, Part 145, Repair Station Criteria and the OEM specific approved data.

(2) Major defects discovered during aircraft interior refurbishment that require skills, tools, or other support available only at depot maintenance shall be corrected in accordance with FAA, Part 145, Repair Station Criteria, FAA guidance and OEM instructions.

c. Minor Defects: Minor defects shall be corrected IAW applicable document.

d. Defects caused by Rework Activity. All defects caused by the rework activity shall be corrected in accordance with FAA, Part 145, Repair Station Criteria.

e. Classification of Defects: Classification of defects shall be subject to the approval of the PCO as applicable.

2.1.6 Rework Procedures:

a. Applicable Documents: aircraft interior refurbishment procedures shall comply with publications listed in Section I, maintenance references, applicable Army 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 OEM Maintenance Manuals, FAA Manuals, and then Army/DOD Manuals.

b. Source Applicable Documents: The Contractor will provide commercial rework activity an initial allowance of those Military/DOD 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 applicable to aircraft interior refurbishment processing.

2.1.7 Aircraft Records Maintenance:

a. The rework activity shall maintain the aircraft logbook in accordance with FAA Regulations and Army directives.

b. All certifications for parts and materials will be kept with the aircraft historical records if at the facility or sent to the aircraft home Site.

a. Upon completion of each aircraft interior refurbishment, a logbook entry shall be made stating compliance with the requirements of this specification. The date, total flight time, aircraft hours and landings accrued to date shall be entered with the above entry in the aircraft historical logbook. The weight and balance, will be updated prior to departure.

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

c. Engineering and modifications directed by the FWPMO shall be IAW the Army format with engineering drawings prepared. A copy of all engineering modification/repair directives and drawings shall be forwarded to the FW PO, ATTN: SFAE-AV.AS-FW, Redstone Arsenal, AL 35898-5280

d. Inspection Work Sheets:

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

(a) Describe each task accomplished

(b) List discrepancies reported in aircraft maintenance records.

2.1.8 Ground Handling, Operation and Safety Precautions:

a. 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.

b. Comply with the instructions, procedures and precautions directed to the aircraft fueling operation of the OEM Maintenance Manual.

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

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

2.1.9 Engineering Support Requirements:

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

2.1.10 Non-Standard Installations:

a. Rework shall not be performed on non-standard installations unless approved by an Airworthiness Release or on standard installations made nonstandard, unless specifically requested by the aircraft custodian and approved by the PCO.

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

2.1.11 Weight and Balance:

a. Weight and balance control of the aircraft during aircraft interior refurbishment shall be accomplished in accordance with Army Regulation 95-1 with an updated forms provided and installed in the aircraft weight and balance manual

2.1.12 Report Requirements:

A detailed report/book will be provided for each aircraft identifying the work scope accomplished.

2.2 Induction Requirements:

2.2.1 Aircraft Equipment Inventory:

a. A facility representative will conduct an equipment inventory with a representative of the delivering activity immediately after receiving the aircraft.

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

c. 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 heavy maintenance processing.

2.2.2 Preservation:

a. Engines shall be preserved in accordance with applicable OEM Manuals.

(1) Engines scheduled for replacement shall be given Type I preservation.

(2) Engines scheduled for continued service shall be given Type 11 preservation.

b. Aircraft and components shall receive preservation in accordance with Applicable OEM

Manuals and manufacture instructions.

c. Batteries: Aircraft batteries including the INS battery assembly shall be removed, stored, charged and maintained in accordance with the OEM and Battery Manufacturer Instructions.

d. All static sensitive components removed and stored will be placed in static sensitive packaging during storage.

SECTION III Aircraft Refurbishment Acceptance Requirements

3.1 Final Processing

3.1.1 Weight and Balance

a. Weigh the aircraft in accordance with AR 95-1 series and the Handbook of Weight and Balance Data and Complete Weighing Record Form 365-2.

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

c. Update Chart C, Basic Weight and Balance Record, DD Form 365-3, to reflect the actual inventory of Chart A, plus the effect of a technical orders/directives or modifications incorporated during heavy maintenance.

d. Update Chart E, as required, to reflect the effect of any technical orders/directives or modifications incorporated during heavy maintenance.

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

3.1.2 Logs and Records

a. Conduct aircraft inventory and annotate aircraft records to reflect the actual inventory.

b. Complete a Shortage Form for all items marked as "missing" in the inventory record.

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

(1) Accomplishment of Aircraft Interior Refurbishment

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

(3) Applicable aircraft records shall be annotated showing the month, year and aircraft time that Aircraft Interior Refurbishment was accomplished. The entries shall also reflect the Rework Activity name and the contract number.

(4) Uncorrected discrepancies will be entered in the logbook appropriate form.

3.1.3 Power Plant Turn-Up:

Perform power plant turn-up following the procedures and making the checks required by the preflight check list. Engine limits and parameters will be correct prior to completion of heavy maintenance. Grounding discrepancies will be referred to the Government for action.

3.1.4 Disturbed Systems:

Aircraft systems, not otherwise assigned a requirement for a functional/operational check/test that are disturbed during Aircraft Interior Refurbishment 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.

3.2 Delivery

3-2.1 Daily/Turnaround Inspection:

Prior to the delivery flight and subsequent flights as (if) required, perform a Daily Inspection, in accordance with OEM Daily/Turnaround Checklist.

3.2.2 Maintenance Test Acceptance:

1. Install aircraft battery and INS battery.

2. Perform a ground run and perform a functional check of the environmental system airflow.

Wemacs: ensure directional movement and airflow.

3. Seats (includes armrests & seat belt reels): ensure move and lock in all directions as designed.

4. Seat Belts and reels: visual inspection and operational check.

5. Window Shades: ensure proper operation.

6. Lights: check all lights and switches for proper operation.

7. Dividers: open, close and latch as designed.

3.2.3 Acceptance Processing:

The cognizant Government representative shall verify that all special, loose and miscellaneous equipment and furnishings and publications reflected as "installed" in the aircraft inventory record is appropriately stowed and that all required logbook entries have been accomplished.

3.2.4 Acceptance:

The reporting activity shall indicate acceptance of the aircraft upon completion of aircraft interior refurbishment by signature on the applicable documents and records.