PERFORMANCE-BASED WORK STATEMENT (PWS) FOR PACAF A-10 IN-THEATER DEPOT
PURCHASE REQUEST NO.: F2DCAQ8324B001
22 February 2019
Prepared By Mr. Jerome Savikis OCONUS Depot Program Manager A-10 System Program Office (801) 777-4153 [email protected]
A-10 System Program Office (WWA) Air Force Life Cycle Management Center (AFLCMC) 6058 Aspen Road, Bldg. 1285 Hill Air Force Base (AFB), UT 84056
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Record of Revisions
Revision Number Date Description Basic 22 February 2019
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TABLE OF CONTENTS
1. PERFORMANCE WORK STATEMENT (PWS) 5
2. DESCRIPTION OF SERVICES 5
2.1. Scope 5 2.2. General Contractor Requirements 5 2.3. Facilities for Government Use 6 2.4. Terms Explained 7 2.5. Condemnation and Limitation on Repair 8 2.6. Accessory and Component Reuse, Repair, and Replacement 9 2.7. Contractor’s Workbook 10 2.8. Receipt of Aircraft at Contractor Facility 10 2.9. General Work Requirements 13 2.10. Specific Work Requirements 13 2.11. Final Processing of Aircraft 18 2.12. Over and Above Work Procedures 19
3. DATA 20
3.1. Maintenance Records, Forms, and Publications 20 3.2. Reporting Instructions 21
4. TECHNICAL ORDERS (TOS) AND OTHER DIRECTIVES 23
4.1. Technical Data 23 4.2. Compliance with Listed Publications 24 4.3. Applicable TOs 24
5. SERVICES SUMMARY 25
6. MANAGEMENT OBJECTIVES 26
6.1. General Objectives 26 6.2. Program Status Reporting 27 6.3. Program Management Reviews 27 6.4. Program Kick-Off Meetings 28 6.5. Master Program Plan and Schedule 28
7. GENERAL INFORMATION 29
7.1. Security / Operations Security Requirements 29 7.2. Quality Control 30 7.3. Quality Assurance 30 7.4. Configuration Management 31 7.5. Environmental Controls 31 7.6. Government Observations 32 7.7. Safety Requirements 32 7.8. Training 32 7.9. Special Qualifications 33
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TABLE OF CONTENTS
7.10. Phase Out 34 7.11. Publications 34 7.12. Government Furnished Property and Services 35 7.13. Government Inspection and Acceptance of Deliverables 35 7.14. Data Ownership 35
APPENDIX 1 – ACRONYMS AND ABBREVIATIONS LIST 36
APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES 39
APPENDIX 3 – A-10C STRUCTURAL COMPONENT S/N VERIFICATION 47
APPENDIX 4 – A-10C PAINT SPECIFICATIONS 48
APPENDIX 5 – A-10C SCHEDULED STRUCTURAL INSPECTION (SSI) 52
APPENDIX 6 – ENHANCED WING ASSEMBLY (EWA) 66
APPENDIX 7 – EIGHT YEAR CORROSION (8YC) 70
APPENDIX 8 – LEGACY WING SCHEDULED STRUCTURAL INSPECTION (SSI) 75
APPENDIX 9 – PYLON REWIRE 93
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PERFORMANCE WORK STATEMENT (PWS)
1. PERFORMANCE WORK STATEMENT (PWS)
1.1. This Performance Work Statement (PWS) is prepared in accordance with (IAW) the Defense Acquisition Guidebook (DAG) 14.3.1.5.
2. DESCRIPTION OF SERVICES
2.1. SCOPE: This PWS defines depot-level maintenance required to sustain United States Air Force (USAF) A-10 aircraft. The objective of this contract is to acquire in-theater Contractor Maintenance Support to accomplish the work requirements specified herein. This PWS is a binding agreement between the U.S. Government (USG) and the contractor. The scope of this contract remains in effect under the terms of the basic contract and all applicable modifications until completion of the contract’s duration or exhaustion of the contract ceiling. The following general tasks are to be completed under this effort:
2.1.1. Acronyms and Abbreviations List – Appendix 1 2.1.2. Technical Orders and Other Directives – Appendix 2 2.1.3. A-10C Structural Component S/N Verification – Appendix 3 2.1.3. A-10C Paint Specifications – Appendix 4 2.1.4. A-10C Scheduled Structural Inspection (SSI) – Appendix 5 2.1.5. Enhanced Wing Assembly (EWA) – Appendix 6 2.1.6. Eight Year Corrosion (8YC) – Appendix 7 2.1.7. Legacy Wing Scheduled Structural Inspection – Appendix 8 2.1.8. Pylon Rewire – Appendix 9 2.1.9. Additional depot-level inspection, repair, and modification programs may arise in the future. All additional work requirements will be negotiated or accomplished using over-and- above work procedures. Revisions or supplements to this PWS will be added as needed through bi-lateral contract modifications.
2.2. GENERAL CONTRACTOR REQUIREMENTS
2.2.1. The contractor shall provide all facilities, equipment, Contractor Furnished Equipment/Contractor Furnished Material (CFE/CFM), and manpower to accomplish all work activities.
2.2.2. The contractor facility shall be located at an airport capable of receiving and servicing A- 10C. Facility shall be located within 400 nautical miles of Osan Air Base, South Korea.
2.2.3. The contractor shall furnish all parts and materials except USAF managed items supplied as Government Furnished Equipment/Government Furnished Material GFE/GFM as authorized in Appendix B of the contract see Government Furnished Property and Services paragraph 7.13. CFE/CFM shall be requisitioned using the MILSTRIP system. When required parts/materials are not available in MILSTRIP, the contractor shall requisition the CFE/CFM from USG approved sources or local manufacture in accordance with the technical data package. The contractor shall be responsible for ensuring all aircraft (A/C) parts meet flight worthiness standards and certification.
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2.2.4. The contractor shall possess local manufacturing capability for material and support equipment necessary to complete work requirements in cases when such material/equipment is not available from USG approved sources and local manufacture is authorized by the Administrative Contracting Officer (ACO).
2.2.5 The contractor shall furnish all parts and materials except USAF managed items supplied as GFE/GFM as identified in Appendix B of the contract. CFE/CFM may be requisitioned using the MILSTRIP system. When required parts/materials are not available in MILSTRIP, the contractor shall requisition the CFE/CFM from USG approved sources or local manufacture in accordance with the technical data package. The contractor shall be responsible for ensuring all aircraft parts meet flight worthiness standards and certification. Local manufacture requests shall be submitted using the AFMC Form 202 process for parts listed in the Illustrated Parts Breakdown (IPB) with a Source, Maintenance, and Recoverability (SMR) Code of procurable with no assets available through MILSTRIP or surplus. For parts with an SMR Code of Manufacture (starting with MO, MF, MD or XC) an AFMC Form 202 is not required. Reference Technical Order (TO) 00-25-195 AF Technical Order System Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and Equipment for SMR code breakdown. Local manufacture requests shall be submitted using the Air Force Material Command (AFMC) Form 202 process IAW paragraph 4.1.3. Submission of additional 202 requests is not required on locally manufacture parts that have been approved with an AFMC Form 202 by the A-10 SPO Engineering Group during the current contract.
2.2.6. The contractor shall be capable of meeting all applicable requirements in order to accept first A/C induction and begin work within six (6) months of contract award. Minimum requirements include facility preparation/upgrade, equipment acquisition, technical order library, compliance with all personnel training and certification requirements, approved safety, security, quality, and management plans, and compliance with Ground and Flight Risk contract clause (252.228-7001). The contractor shall coordinate closely with the USG Program Manager to ensure required GFE/GFM is received and develop mitigation options for items not readily available.
2.3. FACILITIES FOR GOVERNMENT USE
2.3.1. The primary work site is the Contractor’s facility.
2.3.2. The Contractor grants to the U.S. Government the right to utilize office space, together with light, heat, office furniture, local telephone service, and other services required, for administrative purposes associated with this contract. All of the space, utilities, and services mentioned herein will be furnished at no additional cost to the U.S. Government.
2.3.3. The Contractor is responsible for all facility maintenance directly related to A-10 contract.
2.3.4. Government Plant Representatives/Government Ground Flight Representative (GGFR) Office: The Contractor shall make office and working spaces available to the Government for Contract Administration Services (CAS) functions at its aircraft and maintenance facility (if not already established), as follows:
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PERFORMANCE WORK STATEMENT (PWS)
2.3.4.1. Custodial services to include trash removal, sweeping, vacuuming, mopping, dusting and waxing of floors surfaces. Custodial services provided shall coincide with Contractor’s daily schedule for similar services.
2.3.4.2. Telecommunication Services (Voice/Phone). The designated DCMA office will be provided voice/phone line service for calls that does not incur any costs such as emergency response (119 or equivalent), international toll-free connections, and local calls. The Contractor shall receive written approval from the PCO before incurring any costs associated with long-distance or international calling. For U.S. Government personnel outside of the DCMA agency that requires use of long-distance or international calling, the designated unit shall pay for incurred telecommunication service charges, as applicable.
2.3.4.3. Telecommunication Services (Data/Peripheral). The designated DCMA office will provide their own data/peripheral network connections in accordance with DCMA instructions. If Contractor networks are available for use, DCMA personnel will exercise existing DCMA instructions to initially receive approval to connect to these networks. The Contractor shall receive written approval from the PCO before incurring any costs associated with data/peripheral services. For U.S. Government personnel outside of the DCMA Agency that require data connection to the Contractor’s network and applicable peripherals such as printing and facsimiles, the designated unit shall pay for incurred telecommunication service charges, as applicable.
2.4. TERMS EXPLAINED For the purpose of the work specification, the terms used herein are explained as follows:
2.4.1. Defect: Any nonconformance of a characteristic with specified requirements. The classes of defects are minor, major, and critical.
2.4.1.1. Minor Defect: A defect that is not likely to materially reduce the usability of the end item or part for its intended purpose, or is a departure from established standards.
2.4.1.2. Major Defect: A defect, other than critical, that is likely to result in failure, or materially reduce the usability of the end item or part for its intended purpose.
2.4.1.3. Critical Defect: A defect that judgment and experience indicate is likely to result in hazardous or unsafe conditions for individuals using, maintaining, or depending upon the end item or part.
2.4.2. Disturbed Systems: Any system, of which the whole or a component part has been removed, disassembled, repaired, adjusted, modified, disconnected, or altered.
2.4.3. Accessible Areas: Those areas of equipment that may be inspected or worked without disassembly other than that required by this work specification.
2.4.4. End Item: The specific Aircraft for which this work specification is written.
2.4.5. Limited Access Area: An area which would not normally be opened during organizational and intermediate level maintenance or during a phase inspection excluding riveted or stress panels.
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2.4.6. Maintenance Facility: A maintenance facility is determined as an organic or contract facility capable of performing depot level, technical maintenance.
2.4.7. Inspection or Check: An examination of an item to determine identity, condition, and proper installation.
2.4.8. Examination: Determining the conformance of an item or part to specific requirements by simple physical (i.e., visual, auditory, tactile, etc.) means, manipulation, gauging, or measurement without the use of special laboratory appliances or procedures.
2.4.9. Modification: A change in the physical configuration or in the functional characteristics of a system or equipment.
2.4.10. Operational Check: A functional test of an accessory, component or system accomplished in its installed environment to assure proper installation and operation.
2.4.11. Repair: The process to remove defects, restore strength or replace parts and components using authorized TO methods as necessitated by wear and tear, damage or failure of parts to maintain the specific item of material in efficient operating condition.
2.4.12. Reparable: An unserviceable item that can be repaired and restored to a serviceable condition.
2.4.13. Serviceable: Capable of meeting the requirement and performing the function for which designed or modified.
2.4.14. Maintenance Paint: Touch-up painting as necessary, to provide adequate corrosion protection.
2.4.15. Nondestructive Inspection (NDI): Methods for investigating the quality, integrity, properties, and dimension of material and components without damaging or impairing their serviceability.
2.4.16. Critical Safety Item: Pertains to aircraft items whose absence or failure would likely result in the loss of and/or serious damage to the aircraft and/or serious injury or death to the occupants during pre-flight, flight, or post flight operations.
2.5. CONDEMNATION AND LIMITATION ON REPAIR
2.5.1. Condemnation: Any item deemed unserviceable by the Administrative Contracting Officer (ACO) shall be condemned administratively IAW the Equipment Repair Recoverability Code (ERRC) criteria in TO 00-25-195 and processed IAW Air Force Instruction (AFI) 23-101. Contact the ACO for disposition on disposal or return of condemned items.
2.5.2. Limitation on Repair: When the estimated cost to the USG for repair of an item or part, including labor and material, is in excess of 75 percent of the new acquisition/ exchange cost, the maintenance facility shall not repair the item or part without approval of the ACO.
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2.6. ACCESSORY AND COMPONENT REUSE, REPAIR, AND REPLACEMENT CRITERIA
2.6.1. Reuse: Serviceable accessories and components removed solely for work accessibility shall be identified by A/C serial number, protected, and properly stored to prevent damages or loss. Such accessories and components shall be reinstalled on the same A/C unless otherwise authorized by the ACO.
2.6.2. Repair: Accessories and components that have defects shall be repaired provided the repair does not exceed the base level repair authorized by TO 1A-10C-6 and the maintenance facility has the necessary support equipment to accomplish the required repairs. Those accessories and components requiring repairs that exceed base level repair restrictions or for which the necessary support equipment is not available, shall be replaced with a serviceable like item.
2.6.3. Replacement: Unserviceable accessories and components shall be replaced with a serviceable like item, or by cannibalization IAW AFI 21-102 and AFI 21-101 para 9.23. when authorized by the ACO.
2.6.3.1. Replacement parts shall comply with "Usable on Code" contained in the applicable 1A-10C-4 series Illustrated Parts Breakdown (IPB) technical order.
2.6.3.2. Candidates for cannibalization shall be reviewed for TO changes and updated Time Compliance Technical Order (TCTO) requirements affecting the required item configuration. Cannibalization actions must be approved by the ACO prior to the cannibalization action.
2.6.3.3. Any parts that are cannibalized or replaced that are serially controlled by 1A-10C- 06 Work Unit Code (WUC) Manual shall be documented in the aircraft records.
2.6.4. Time changes: Accessories and components installed on incoming A/C should have sufficient remaining time to exceed the number of days the A/C will be in depot. A/C received with accessories/components requiring time change replacement will be referred to the ACO.
2.6.4.1. Accessories/components becoming overdue for time change during depot possession due to original output date being exceeded will be referred to the ACO. The ACO will coordinate with the using command for disposition of the time change requirement.
2.6.4.2. Time change item replacements, if accomplished by the contract depot facility, shall be recorded in the affected A/C Work Control Document (WCD)/records immediately after installation of the item.
2.6.4.3. When Cartridge Actuated Device / Propellant Actuated Device (CAD/PAD) items come due during time of depot possession, the owning unit is responsible for providing serviceable replacements to the contractor for install.
2.6.4.4. Prior to departure of the A/C, all time change items recorded in the maintenance WCDs shall be transcribed to the A/C records.
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2.7. CONTRACTOR’S WORKBOOK The contractor shall develop and maintain a workbook to provide specific and uniform step-by-step instructions for accomplishing work accurately, economically, and safely.
2.7.1. Workbooks must specify component removals, inspections, and reinstallations that affect quality and must include warning and caution notes where failure to follow prescribed procedures could result in injury to personnel or damage to USG property. Removal and reinstallation of items (including lines, fittings, components, etc.), when required to gain access to another component, shall be listed as separate entries in the workbook.
2.7.2. Include quantitative criteria (dimensions and tolerances) in the workbook, either by actual values or by references to the drawing or TO.
2.7.3. Include criteria essential for determining the acceptability of work performed.
2.7.4. Maintain and retain workbooks and other pertinent records IAW the contract requirement. Sufficient documentation must be maintained by the contractor until the A/C’s next induction, incident, or action to assist in any accident investigation that may be conducted by the USG. Records remaining at the end of the contract shall be prepared and transferred to the USG or the follow-on contractor.
2.8. RECEIPT OF AIRCRAFT AT CONTRACTOR FACILITY
Aircraft Delivery/Induction Requirements:
2.8.1. Aircraft:
2.8.1.1. A/C engines that are removed shall be reinstalled in the same A/C unless an exception is authorized by the ACO. These engines should not have inspections or time change items due within the next 25 operating hours or equivalent cycles.
2.8.1.2. Aircraft Munitions: A/C should be delivered to depot with all munitions and externals stores removed. A/C weight and balance will be maintained by use of ballast. A/C should not be delivered to depot with spent casings loaded.
2.8.1.3. Survival Packs: When delivered with the A/C to depot, survival packs should have a minimum of 90 days remaining prior too due date of 180-day inspection requirement prescribed in TO 14S1-3-51.
NOTE: This requirement is waived for A/C inducted for SSI
2.8.1.4. External Tanks: A/C being input to depot should be delivered without external tanks unless previously negotiated with depot using Air Force Technical Order (AFTO) Form 103.
2.8.1.5. A/C Records: The using activity will ensure that required forms are complete prior to delivery of A/C to depot.
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2.8.1.6. Review of A/C records should include verification of TCTOs and Engineering Change Proposal (ECP). A thorough review of each A/C fuselage and wing AFTO Form 95s for engineering derived re-inspection requirements shall be accomplished and documented on appropriate WCD. Copies of required forms will be IAW TO 00-20-1. Include engine historical records containing last five (5) flights of take-off Trim Data (NF Trim).
2.8.2. Handling:
2.8.2.1. The contract depot maintenance facility shall service, tow, park, moor, and make the A/C safe for maintenance IAW the applicable sections of TO 1A-10C-2-4JG-1.
2.8.2.2. Accomplish spectrometric oil sampling of each engine (except Auxiliary Power Unit [APU]) IAW AFI 21-124, TO 33-1-37-1, -2, -3, and 1A-10C-2-12JG-1. A data collection sheet should arrive with the A/C forms. File the completed sheet with the A/C forms along with a copy of the laboratory results printout. In addition, provide an electronic copy of the laboratory results to the using organization unit within 15 days of A/C arrival IAW Contract Data Requirements List (CDRL) A/B/C/D/E/F/G/H/J/K 001, Oil Analysis Report.
2.8.2.3. Download Turbine Engine Monitoring System/Airborne Data Recorder TEMS/ADR data IAW TO 1A-10C-2-31JG-1 and provide data to the using organization within 15 days of A/C arrival IAW CDRL A/B/C/D/E/F/G/H/J/K 002, Turbine Engine Monitoring System.
2.8.3. Inventory:
2.8.3.1. Receipt of the A/C shall be acknowledged on AFTO Form 290, Aerospace Vehicle Delivery Receipt IAW TO 00-20-1.
2.8.3.2. Inventory each A/C to ascertain the accuracy of the equipment installed in the A/C and all -21 equipment IAW 1A-10C-21. Document inspection results using an AF Form 2692 and maintain with the A/C forms.
2.8.3.2.1. If a discrepancy is noted, notify the ACO within (1) hour. The ACO will contact the unit organization to determine whether the missing equipment warrants a Report of Survey or replacement. Where safety of flight is affected, the owning unit will be responsible for providing the missing equipment.
2.8.3.3. Accomplish an inventory inspection of disturbed system/areas using this work specification and TO 1A-10C-6 as a guide. Visual inspection will continue throughout the entire disassembly phase and be performed in all areas accessed in the accomplishment of this work specification.
2.8.3.4. Incoming A/C and serialized component AFTO 95, AFTO 44 shall be reviewed for engineering inspection requirements on A/C driven by previous depot inductions or field repairs. All engineering inspection requirements documented into AFTO 95 from previous maintenance activities shall be incorporated and documented into current maintenance activity.
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2.8.3.5. Record A/C major structural components IAW Appendix 3 of the PWS: A-10 Structural Component Serial Number Verification and provide information IAW CDRL A/B/C/D/E/F/G/H/J/K 003. Note: The NLign program will be used to record incoming serialized components and also to capture the outgoing aircraft configuration information. Delivery of the information back to SPO engineering will also be through the NLign program.
2.8.3.5.1. Record data as detailed below for each A-10 induction: 2.8.3.5.1.1. Configuration Status (incoming / outgoing) 2.8.3.5.1.2. Depot 2.8.3.5.1.3. Tail Number 2.8.3.5.1.4. Induction (arrival / departure) 2.8.3.5.1.5. A/C Hours (COT) 2.8.3.5.1.6. Serial Number 2.8.3.5.1.7. Left Nacelle 2.8.3.5.1.8. Right Nacelle 2.8.3.5.1.9. Horizontal Stabilizer 2.8.3.5.1.10. Left Vertical Fin 2.8.3.5.1.11. Right Vertical Fin 2.8.3.5.1.12. Wing Center Panel 2.8.2.5.1.13. Left Outer Wing Panel and type 2.8.2.5.1.14. Right Outer Wing Panel and type 2.8.2.5.1.15. Forward Main Fuel Foam (date replaced) 2.8.2.5.1.16. Aft Main Fuel Foam (date replaced) 2.8.2.5.1.17. Vent Fuel Foam (date replaced) 2.8.2.5.1.18. Main Wing Fuel Foam (date replaced)
2.8.3.5.2. Using the NLign program upload the information and deliver electronic file at time of induction process.
2.8.4. Preservation:
2.8.4.1. Remove A/C battery, store, maintain and perform capacitance check IAW TO 8D2-3-1.
2.8.4.2. Defuel A/C and Purging/Draining of Fuel Cells/Tanks IAW TO 1A-10C-2-12JG-1 and TO 1-1-3.
2.8.4.3. Preserve engines IAW TO 2J-TF34-101 Chapter 3 as required.
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2.9. GENERAL WORK REQUIREMENTS
2.9.1. Comply with urgent action, immediate action, and safety TCTOs which are due to rescind and are supportable with kits/parts (if applicable) that are outstanding or generated while the A/C is in work.
2.9.2. All A/C systems shall be returned to the using command in the same condition as received, or better as determined by USG acceptance inspection. The USG reserves the right to require the contractor to remedy these problems at the contractor’s expense before USG acceptance or at a later time if the defect is proven to be latent. Any item(s) missing or inoperable upon receipt, that is/are necessary to perform system checks, shall be installed for test purposes and removed prior to delivery, unless directed otherwise by the ACO. Missing Critical Safety Item will be replaced with items furnished by the using commands. System checks, if required, shall be accomplished as directed by TOs identified in Appendix 2.
Exceptions to the above paragraph are A/C requiring over water delivery routes. All required systems shall be made operational to the point of passing the system operational checks as specified in AFI 11-207.
2.9.3. Markings: The contractor shall be responsible for replacing all markings removed or otherwise affected during any maintenance task. Units will supply the required stencils for individual unit logos and any additional markings requested by AFTO Form 103. All markings shall comply with TO 1A-10C-23.
2.9.4. When aircraft components or equipment require shipment they will be packaged IAW the Special Packaging Instructions (SPI) developed for that specific component. SPIs are available at https://spires.wpafb.af.mil.
2.10. SPECIFIC WORK REQUIREMENTS
2.10.1. Depot Maintenance: After an A/C has been received and inducted into the depot facility, accomplish specific work requirements as specified by the task order. Specific work requirements for individual depot work packages are contained in Appendices 1 through 9 of this PWS.
2.10.1.1. Perform disassembly IAW applicable TO/maintenance manuals.
2.10.1.2. Recording of Defects: All noted defects which are not part of a project requirement shall be recorded in the affected A/C 781 series forms IAW TO 00-20-1. Any repaired defects should be annotated on the AFTO 95s and in the applicable Maintenance Systems (MIS).
2.10.1.3. Corrosion Treatment and Painting: Treat corrosion IAW TOs 1-1-691 and 1A-10C-23. Painting shall be IAW TOs 1-1-691, 1-1-8, and 1A-10C-23 unless otherwise specified.
2.10.1.4. All panels, doors, and covers opened or removed for access or compliance with work requirements herein shall be reinstalled by the maintenance facility IAW applicable TOs.
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2.10.1.5. Functional Check: The contract depot maintenance facility shall accomplish an operational check of each disturbed system. Each disturbed system shall be repaired/adjusted to meet the operational parameters specified in the applicable A-10C A/C job guide manuals.
2.10.1.5.1. Operational tests of disturbed systems will be performed when support/test equipment becomes available.
2.10.1.6. Critical Safety Item Systems are:
1. All Flight Instrument and Standby Instrument Systems 2. All Engine Performance Instruments 3. Communication/Navigation a. Head Up Display - (required for Low Altitude Safety and Targeting Enhancement System/Ground Collision Avoidance System (GCAS)/Autopilot) b. Very High Frequency/Frequency Modulation Radio c. Instrument Landing System d. Embedded Global Positioning System/Inertial Navigation System (EGI) (required for GCAS) e. Radar Altimeter (required for GCAS) f. Ultra-High Frequency/Amplitude Modulation radio (Air Force/Navy/Airborne Radio Communication (ARC) 164(V)) g. ARC-210 Radio #1 radio, ARC-210 Radio #2 if installed h. Intercommunication (AIC 18) i. Identification Friend-or-Foe (AN/APX 101) j. Tactical Air Navigation (AN/ARN 118(V)) k. Control Display Unit l. Multifunction Color Display 4. Egress System (Visual Check, by certified personnel) 5. Ground Safety Pin Assembly (pilot's emergency canopy release) 6. Pin, Ejection Seat Safety 7. Parachute (Visual Check) 8. Survival Kit (Visual Check) 9. Canopy Breaker Tool (Visual Check) 10. Circuit Breakers (Visual Check) 11. Auxiliary Power Unit 12. Oxygen Supply and Regulation 13. Pitot Heat 14. Lighting System a. Landing b. Taxi c. Position d. Strobe Anti-collision e. Instrument and Cockpit 15. Flight Control System a. Primary and Secondary Controls b. Manual Reversion c. Stability Augmentation System d. Speed Brakes e. Primary Trim Control System
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16. Environmental Control System a. Cockpit Temperature Control (manual) b. Canopy Defogging c. Windshield Temp/Heat d. Cabin Pressure 17. Fuel Quantity 18. Fuel Transfer and Vent System 19. Primary and Utility Hydraulic Pressure Indicating System 20. Normal and Anti-Skid Wheel Braking System 21. Nose Wheel Steering 22. Landing Gear Retraction 23. Overheat and Fire Detection 24. Electrical Power Supply and Controls 25. Low Altitude Safety and Targeting Enhancement System
2.10.1.7. All non-safety of flight defects, reflected in the incoming A/C records or as listed on the AFTO Form 103 shall be corrected only when authorized by the ACO.
2.10.2. Depot Modification:
2.10.2.1. Accomplishment of depot level modifications will be performed as negotiated between the depot facility and ACO.
2.10.2.2. If an A/C is received for SSI that has not previously been modified with the TEMS re- wire, Pylon re-wire, or TCTO 1A-10C-544/553/554/555/604 but is not specified as a required task by the Task Order, notify the ACO for disposition.
2.10.2.3. When specified by the Task Order, comply with the Enhanced Wing Assembly (EWA) installation on scheduled A/C with TCTO 1A-10C-520 and applicable program guidance. Specific instruction is provided in Appendix 6 of this PWS.
2.10.2.4. When specified by the Task Order, install the following modifications, listed by current, applicable TCTO, as part of the Consolidated Modification Installation. This modification package may be installed as a stand-alone effort as determined by USAF requirements.
Negotiated TCTO:
2.10.2.4.1. TCTO 1A-10C-520 – Replacement of Wing Assembly with Enhanced Wing Assembly 2.10.2.4.2. TCTO 1A-10C-544 – Replacement of Upper Longeron Plates, Crown Skin Fuselage Repairs 2.10.2.4.3. TCTO 1A-10C-553 – Installation of Repair Straps at FS 405 2.10.2.4.4. TCTO 1A-10C-554 – Installation of Fuselage Fuel Cavity Drain Tube Assemblies 2.10.2.4.5. TCTO 1A-10C-555 – Installation of Upper Longeron Repair Straps at FS 268 2.10.2.4.6. TCTO 1A-10C-604 – Replacement of Left Hand Lower Longeron, Hydraulic Drive Fittings, and Associated Brackets
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2.10.3. TCTO Accomplishment:
2.10.3.1. Accomplish all TCTO’s specified by the Task Order. Individual TCTO accomplishment will be negotiated separately or accomplished as over-and-above. If missing (unaccomplished) TCTO’s are discovered on an A/C, submit an AFMC Form 202 and notify the ACO for disposition.
2.10.4. Additional Maintenance Requirements:
2.10.4.1. AFTO Form 103 defects shall be corrected when authorized by the ACO, as feasible, without negative impact to the A/C schedule. If authorized, repair shall be accomplished under over-and-above work procedures. For AFTO Form 103 requests requiring upfront parts support, owning unit shall supply such parts.
2.10.4.2. For A/C discrepancies not covered by the PWS and referenced documents the contractor shall annotate AFTO Form 781A IAW TO 00-20-1 and notify the ACO for disposition.
2.10.4.3. From time-to-time, the using unit may request that an A/C part be cannibalized from an A/C while it is inducted at the contract depot facility. When directed by the ACO, the contractor shall remove the requested part and ship to the requesting unit. If special packaging instructions are not provided or directed, the contractor shall be responsible for ensuring proper packaging to prevent damage. Coordinate with using unit to ensure a replacement part is received. Shipping, packaging, and work effort for component removal and reinstallation shall be accomplished under over-and-above work procedures.
2.10.4.4. From time-to-time, A/C may be inducted for stand-alone number I or II Phase Inspections that are not in-conjunction with SSI. Accomplish Phase Inspection IAW TO 1A-10C-6.
2.10.5. Special Depot Requirements:
2.10.5.1. Drop-in Maintenance: From time to time, the USG may request to drop in additional A-10C for emergency repair and maintenance. To the extent feasible, based on the contractor's facilities and experience, the contractor shall accept such A/C for repair and maintenance. The contractor shall obtain prior authority for such inputs from the ACO. The ACO shall, provided funds are available, authorize such preliminary work sufficient for the contractor to develop and submit an estimate for completion of the required repairs or maintenance. When sufficient funding is available and the Procuring Contracting Officer (PCO) grants authorization for completion of the work, the ACO shall authorize completion of the work by issuance of a funded over and above work request. The over and above rates of the contract shall apply to all such work.
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2.10.5.2. Surge Requirements: When PACAF or CONUS based A-10 aircraft or aircraft assemblies (i.e. wings, nacelles) are inducted into the depot facility for emergency drop-in repair and maintenance, the contractor shall coordinate with the ACO and the A-10 System Program Office (SPO) to establish workload priorities for drop-in aircraft / assemblies and aircraft already in-work (i.e. SSI). The surge requirement should also extend to the local manufacture of structural components or other parts that may need to be manufactured as determined by the requirement. When directed by the ACO, the contractor shall, to the maximum extent feasible, increase production rate and / or capacity to accomplish drop-in and / or other over-and-above work requirements IAW the USG’s delivery schedule objectives / requirements. The contractor shall take efforts to minimize delays to the delivery schedule of aircraft already in-work. In addition, the ACO may direct surge operations to accelerate delivery of in-work aircraft and / or induct additional aircraft above and beyond the standard induction schedule. Surge requirements will be negotiated on a case by case basis and will be billed to the CLIN X017 (SURGE Requirement) of the contract.
2.10.5.3. Contract Field Team (CFT): The contractor shall have the capability to deploy a CFT off-site to accomplish depot-level maintenance separate from their primary facility in cases where an A-10 is not safe for flight or when a Task order is negotiated to accomplish A/C modifications off-site. Repairs of this type are primarily for the purposes of allowing for a one-time flight back to the main contractor depot facility or to accomplish modifications on an A/C already in work by the CFT. The USG will request a proposal from the contractor prior to issuing a Task Order for CFT services.
2.10.5.3.1. The AFLCMC/WWAE Engineering will make the determination if a repair will require a CFT.
2.10.5.3.2. The AFLCMC/WWA Program Manager shall notify the AFLCMC/WWAK contract negotiator, Defense Contract Management Agency (DCMA) ACO, and the contractor of the requirement via email.
2.10.5.3.3. The contractor shall acknowledge receipt of the requirement within two (2) working days to the DCMA ACO, the Program Manager, and the PCO (or his/her delegate). If the contractor requires further information, the contractor shall send this request to the DCMA ACO prior to travel.
2.10.5.3.4. The contractor shall coordinate with the operational unit, AFLCMC/WWAE Engineering, Pacific Air Forces (PACAF) Functional Manager, Program Manager and DCMA ACO, as required, until all technical and logistical issues are resolved, understood and in hand.
2.10.5.3.5. The contractor shall then provide the ACO a detailed written work proposal. The ACO will then provide written authorization to the contractor for the CFT to proceed.
2.10.5.3.6. The contractor shall coordinate a start work date with the PACAF Functional Manager, the operational unit, and owning MAJCOM with emphasis being to commence work as soon as possible. The contractor shall inform the ACO of the start work date.
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2.10.5.3.8. Any suggested additions, deletions, or deviations from written work proposal shall be coordinated in writing with the ACO prior to any changes taking effect.
2.10.5.3.9. Once the CFT work is completed, the contractor shall then provide the ACO the detail of cost incurred, in such a way that the ACO can approve and allow for the issue of the proper invoicing of said CFT work.
2.11. FINAL PROCESSING OF AIRCRAFT
2.11.1. Finishing:
2.11.1.1. The contract depot maintenance facility shall clean the exterior and interior of the A/C in those areas opened for access/rework. Remove all filings, chips, loose hardware, debris, and trapped moisture. Also remove any moisture which has been trapped in any of the lower compartments of the A/C.
2.11.1.2. Accomplish maintenance painting IAW TOs 1-1-691, 1-1-8, and 1A-10C-23.
2.11.1.3. Environmental sealing, shall be accomplished IAW TOs 1A-10C-3-1 and 1A-10C-2- 27MS-1
2.11.1.4. White Area Closure Sealing shall be accomplished IAW TO 1A-10C-2-27MS-1
2.11.2. De-preservation: De-preserve engines IAW TO 1A-10C-2-71JG-2 if required.
2.11.3. Servicing:
2.11.3.1. The contract depot maintenance facility shall service all systems IAW TO 1A-10C- 2-12JG-1.
2.11.3.2. The contract depot maintenance facility shall install serviceable battery IAW TO 1A-10C-2-24JG-3.
2.11.4. Weight and Balance: Accomplish weight and balance IAW TOs 1A-10C-2-4JG-1, 1A- 10C-5, and 1-1B-50 when required.
2.11.5. Preflight: The contract depot maintenance facility shall accomplish preflight inspection IAW TO 1A-10C-6WC-5. Correct all Critical Safety Item and critical defects. All functional checks performed shall meet operational procedures contained in applicable job guide manuals.
2.11.6. Functional Check Flight (FCF): An FCF, if required, shall be accomplished IAW TO 1A- 10C-6CF-1. A USAF FCF pilot will be furnished by the individual unit. Unit must be contacted at least 10 working days prior to scheduling FCF to arrange for travel. Notify unit immediately of all changes to FCF schedule. Coordinate all FCF arrangements with the ACO.
2.11.7. Post Flight: Accomplish Post Flight Inspection IAW TO 1A-10C-6WC-5. Provide Oil Sample analysis and TEMS/ADR data to owning units as specified in paragraph 2.7.2.2 and 2.7.2.3.
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2.11.8. Preparation for Ferry:
2.11.8.1. Service all systems IAW TO 1A-10C-2-12JG-1.
2.11.8.2. Reinstall/replace all loose equipment received with A/C.
2.11.8.3. Accomplish preflight/post flight inspections IAW TO 1A-10C-6WC-5.
2.11.8.4. A/C will not be accepted for delivery with equipment/parts shortages that affect Critical Safety Item.
2.11.9. Forms Preparation: Complete the AF Form 2692 IAW AFI 21-103. Equipment removed/relocated shall be recorded on AF Form 2692. If applicable, annotate the A/C records to reflect the phase inspection that was accomplished.
2.11.10. For the outgoing configuration, record the serial numbers for A/C major structural components IAW Appendix 3: A-10C Structural Component Serial Number Verification and provide data IAW CDRL A/B/C/D/E/F/G/H/J/K 003.
2.12. OVER AND ABOVE WORK PROCEDURES
2.12.1. Prior to first A/C induction, the contractor shall work with the USAF A-10 SPO and the ACO to develop a comprehensive Over and Above Management Procedure mutually acceptable to the contractor and the USG. It is the contractor’s responsibility to ensure that this procedure is developed. The intent of this procedure is to minimize the response time to over and above work requests.
2.12.2. Any additional tasks directed to be accomplished beyond those tasks covered in the negotiated work packages will be handled under the over and above work procedures. All over-and-above work requests must be authorized by the ACO prior to accomplishment. The USG shall not be held liable for reimbursement for any unauthorized work tasks.
2.12.3. Cannibalization: If parts or component shortages will delay delivery of A/C, serviceable parts or components which are readily exchangeable may be removed from another A/C by cannibalization. The ACO must authorize all such actions prior to removal. Compensation shall be limited to extra man-hours associated with cannibalizing when the required parts cannot be supplied in a timely manner and work stoppage would occur. No compensation shall be made for labor hours required to effect original removal or replacement action, nor to remove a part which would have required removal during the normal rework process, nor cannibalization as a result of fault or negligence of the contractor.
2.12.4. USAF engineering or System Program Manager (SPM) dispositions requiring repairs/replacement beyond negotiated program requirements will funded through Over and Above procedures. All such repairs/replacements must be authorized by the ACO in advance.
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3. DATA
3.1. MAINTENANCE RECORDS, FORMS, AND PUBLICATIONS. The contract depot maintenance facility shall maintain the forms listed below as applicable, during the time the A/C is at the facility:
Form Number Form Title Directive DD Form 365 Series Record of Weight and Balance TO 1-1B-50 and 1A-10C-5 AF Form 2692 Aircraft/Missile Equipment Property AFI 21-103 Record AFTO Form 44 Turbine Wheel Historical Record TO 00-20-5-1-2 AFTO Form 95 Significant Historical Data TO 00-20-Series AFTO 781 Series Aerospace Vehicle TO 00-20-1
3.1.1. AFTO Forms 350: The maintenance facility shall prepare and process AFTO Form 350, Repairable Items Processing Tag, IAW AFI 21-101, Aircraft and Equipment Maintenance Management, and 00-20-2 Series Technical Orders.
3.1.2. Record on AFTO Form 95 IAW TO 00-20-1 and the applicable Maintenance System (MIS)
3.1.2.1. Enter the induction date and flight hours (COT) for each aircraft into the depot. Enter dates that maintenance was performed and the serial numbers for the following components if removed from A/C whether it will be installed onto original A/C or not:
1. Wing Center Panel (WCP) 2. Left Hand (LH) Wing Outer Panel (WOP) 3. Right Hand (RH) Wing Outer Panel (WOP) 4. LH Nacelle 5. RH Nacelle 6. LH Vertical Fin 7. RH Vertical Fin
Enter dates that maintenance was performed and the serial numbers for the following components if installed onto A/C:
1. Wing Center Panel (WCP) 2. Left Hand (LH) Wing Outer Panel (WOP) 3. Right Hand (RH) WOP 4. LH Nacelle 5. RH Nacelle 6. LH Vertical Fin 7. RH Vertical Fin
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3.1.2.2.1. Use AFTO Form 95 and 781 series forms to document all engineering generated re-inspection requirements for any repair to include but not limited to; bushings, oversize of fastener holes, repair straps. This must include exact location of repair, oversized or bushed holes, layers affected, material used to make bushings and/or straps and size of bushings and/or straps.
Close loop on every AFMC Form 202 for each A/C. Engineering shall be informed and AFTO Form 95 shall be documented with geometry and dimension of final maintenance actions used to repair A/C. Do not use max allowable values from the AFMC Form 202 engineering disposition unless it was the actual final value used to repair the A/C. Include final size of hole prior to any cold work. The statement “prior to any cold working” does not imply cold working is required, only that reported diameters after cold work processes have occurred are not required. Include data about bushed holes, i.e. number of the hole and/or its location, layers bushed, bushing size and material, etc. Document the exact fastener holes that were cold-worked and what repair option was used. Document areas where blends were used and the remaining thicknesses after blending procedures.
NOTE: AFTO Form 95s are required for each serialized component.
3.1.2.2. Each white area inspection completed by the contract depot maintenance facility shall be recorded to include the date, reason, and time of entry and closing.
3.1.2.3. Entries shall be made in the A/C records of date of paint Removal/repainted.
3.1.2.4. Entries shall be made for any maintenance accomplished IAW TOs 00-20-1, Aerospace Equipment Inspection, Documentation, Policy and Procedures and 00-20-2, maintenance Data Documentation.
3.1.2.5. Results of cabin pressurization testing will be annotated.
3.1.3. Record A/C major structural components IAW TO 1A-10C-36 Chapter 7. The data will be delivered to the A-10 ASIP Office using the NLign Program IAW CDRL A/B/C/D/E/F/G/H/J/K 003. Component information shall be completed and sent for both incoming inspection and outgoing forms preparation. Incoming information shall be delivered no later than (NLT) 30 days after A/C induction to allow for ASIP review. Copies of the outgoing form shall be delivered to the gaining unit as part of the A/C documentation.
3.2. REPORTING INSTRUCTIONS:
3.2.1. Material Deficiency Reporting: The contract depot maintenance facility shall submit Material Deficiency Reports and Production Quality Deficiency Report (PQDR) IAW TO 00-35D- 54. Deficiency reports shall be submitted IAW CDRL A/B/C/D/E/F/G/H/J/K 006, Deficiency Report, and CDRL A/B/C/D/E/F/G/H/J/K 007, Teardown Deficiency Report.
3.2.2. AFTO Form 22: When inadequacies are found to exist in technical publications or engineering data specified herein, they shall be reported on AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply, IAW TO 00-5-1. Reports shall be submitted IAW CDRL A/B/C/D/E/F/G/H/J/K 008, Technical Order Improvement Report.
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3.2.3. USAF Engineering Data Deficiencies: Whenever deficiencies are found on drawings or other engineering data provided, an AFMC Form 202 shall be submitted to USAF engineering. For all other deficiencies in USG provided data including illegible, inconsistent, defective, non- usable, late, or otherwise non-delivered information that will prevent the contractor from proceeding with work, submit a deficiency report IAW CDRL A/B/C/D/E/F/G/H/J/K 009, Government Furnished Information Deficiency Report.
3.2.4. The contract depot maintenance facility shall maintain a system for reporting maintenance and operational status of all possessed A-10C aircraft. Reporting procedures shall be IAW Air Force Material Command Instruction (AFMCI) 21-118 paragraph 5.2.4. All reports shall be submitted IAW CDRL A/B/C/D/E/F/G/H/J/K 010, Maintenance Data Collection Record.
3.2.5. IAW TO 1A-10C-36 Chapter 7, as part of the SSI program, the contract depot maintenance facility shall:
3.2.5.1. Aircraft Structural Integrity Program: It is the responsibility of the contract depot maintenance facility personnel to fully understand how to use the NLign program and the data capture requirements. A fully detailed description and example of the data capture process is available in TO 1A-10C-36 chapter 7, and Appendix 3 of the PWS. For questions regarding data submission, contact A-10 ASIP Office via e-mail to [email protected]
3.2.5.2. Using the NLign program, the contractor will provide the following information to SPO ASIP Engineering. NLign is to be used as the primary reporting system when sending data to SPO engineering.
3.2.5.2.1. Contractor will document the appropriate serial number for each serialized component inspected.
3.2.5.2.2. Contractor will document the incoming initial and pre-cold work “crack like” clean- up of oversized diameter holes, crack direction and affected layer/layers for all numerically labeled holes. The holes are uniquely identified and documented on the SSI illustration sheets. Diameter and crack direction data is required for holes oversized to clear “crack like” defects.
3.2.5.2.3. Contractor will document the estimated length and direction of all “crack like” defects for each uniquely identified and documented surface scan inspection region.
3.2.5.2.4. At completion of SSI inspections export the completed inspection information to the A-10 ASIP office for approval.
3.2.6. Contractor Manpower Requirement:
3.2.6.1. In accordance with FY11 NDAA Section 8108, the Contractor shall report ALL contractor labor hours (including subcontractor labor hours) required for performance of services provided under this contract for the A-10 System Program Office via a secure data collection site. The Contractor is required to completely fill in all required data fields at http://www.ecmra.mil.
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3.2.6.2. Reporting inputs will be for the labor executed during the period of performance for each Government fiscal year (FY), which runs 1 October through 30 September. While inputs may be reported any time during the FY, all data shall be reported no later than 31 October of each calendar year. Contractors may direct questions to the Contractor Manpower Reporting Application (CMRA) help desk.
3.2.6.3. Uses and Safeguarding of Information: Information from the secure web site is considered to be proprietary in nature when the contract number and contractor identity are associated with the direct labor hours and direct labor dollars. At no time will any data be released to the public with the contractor name and contract number associated with the data.
3.2.6.4. User Manuals: Data for Air Force service requirements must be input at the Air Force CMRA link. However, user manuals for government personnel and contractors are available at the Army CMRA link at: http://www.ecmra.mil.
4. TECHNICAL ORDERS (TOs) AND OTHER DIRECTIVES
4.1. TECHNICAL DATA:
4.1.1. The contract depot maintenance facility shall accomplish removal, disassembly, inspection, repair, replacement, adjustment, modification, test, assembly and installation of accessories and equipment shall conform to directives and supplements listed in Appendix 2-1 of this PWS.
4.1.2. The following order of precedence shall apply when conflicting requirements exist in the listed TOs and other directives shown in Appendix 2 – I. of this PWS:
1. USAF TOs and USG Specifications. 2. This PWS. 3. USG Approved Contractor Publications. 4. USG Approved Commercial Publications. 5. USG Approved Commercial Practices.
4.1.3. All existing or proposed structural repairs which do not conform to TOs 1A-10C-3, 1A- 10C-3-1, 16C1-30-10-3, 16C1-30-12-3, or the USAF approved engineering standards shall be submitted to A-10 SPO Engineering, using AFMC Form 202, Nonconforming Technical Assistance Request and Reply. A copy of AFMC Form 202s will be provided in the A/C forms to the unit when the A/C is delivered Document IAW TOs 00-20-2, and 00-20-1.
4.1.4. Replacement parts and material used in the repair of the A/C or any other equipment will be those authorized by the USG in approved/authorized publications.
4.1.5. Nondestructive Inspections (NDI):
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4.1.5.1. NDI methods described in TO 33B-1-1 and 33B-1-2 shall be utilized when:
(a) Directed by TO 1A-10C-36 or other overhaul handbook/commodities TOs.
(b) Directed by engineering (based on AFMC Form 202 actions).
4.1.5.2. All defects and reject-able indications shall be documented in the WCD and also on an AFMC Form 202 by the contract depot maintenance facility for engineering disposition to obtain further instructions and guidance.
4.1.5.3. Magnetic particle, radiographic, eddy current, and ultrasonic inspections shall be accomplished by the contract depot maintenance facility IAW TOs 1A-10C-36, 33B-1-1, 33B- 1-2, and/or applicable overhaul handbook. Procedures specified in TO 33B-1-1 and American Society for Testing and Materials (ASTM) E1444-93 shall not supersede those of the overhaul handbook unless so stipulated.
4.1.5.4. The contract depot maintenance facility shall accomplish dye penetrant inspections IAW TOs 1A-10C-36, 33B-1-1, and 33B-1-2.
4.1.5.5. The contract depot maintenance facility shall accomplish radiographic inspections IAW TOs 1A-10C-36, 33B-1-1, and 33B-1-2.
4.1.5.6. The contract depot maintenance facility shall accomplish eddy current and ultrasonic inspections IAW TOs 1A-10C-36, 33B-1-1, and 33B-1-2.
4.2 COMPLIANCE WITH LISTED PUBLICATIONS. The maintenance facility shall comply with all publications listed in Appendix 2 - I. of this PWS when:
4.2.1. The publication(s) pertain to the equipment whose maintenance is described herein and where the contract depot maintenance facility is authorized by this work specification to accomplish the work specified therein.
4.2.2. The publication(s) prescribe Air Force policies, use of material, procedures, and processes applicable to the work requirements.
4.3. APPLICABLE TOs:
4.3.1. The contract depot maintenance facility shall control and maintain all TOs and other technical directives applicable to the work requirements in an updated and current status IAW TO 00-5-1.
4.3.2. Compliance with Revised Publications: When a USG provided publication listed in Appendix 2 – I. is subsequently revised, supplemented, replaced, or rescinded, the contract depot maintenance facility, upon receipt, shall immediately provide the ACO with a Rough Order of Magnitude (ROM) estimate on the impact to cost and schedule, if work scope is affected. All changes to work scope resulting from publication changes will be considered for equitable adjustment.
4.3.3. USG documents: Applicable documents are listed in Appendix 2 – I. of this PWS.
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5. SERVICES SUMMARY
Performance PWS Performance Threshold Objective Para A/C receipt at depot 2.8.2. All ground handling conducted in strict accordance with facility: ground handling TO 1A-10C-2-4JG-1. Zero instances of safety violations or damage to A/C due to improper handling. Functional checks 2.10.1.5. Functional operations check performed on all disturbed on disturbed systems systems. All discrepancies corrected/repaired to meet operational parameters specified in the associated A- 10C job guide manuals. Contract Field Teams 2.10.5.3. ROM for CFT support provided within five (5) working days of receipt of request. Final processing of A/C: 2.11.1.1. Exterior & interior of A/C carefully cleaned to remove all finishing debris & trapped moisture. Zero instances of Foreign Object Damage noted during acceptance inspections. Final processing of A/C: 2.11.3. A/C serviced in strict accordance with servicing TO 1A-10C-2-12JG-1. Zero instances of improper servicing prior to A/C acceptance. Final processing of A/C: 2.11.5., Conduct preflight/post flight inspections in strict preflight/post flight 2.11.7. accordance with TO 1A-10C-6WC-5. 100% of Critical Safety Item & other critical discrepancies corrected. Over-&-Above work 2.12. All over-&-above work requests authorized in writing by procedures & ACO prior to accomplishment. 100% of work accomplishment accomplished within scope of ACO authorization for specific tasks. Maintenance Records, 3.1. Correctly maintain, prepare, and process all required Forms, & Publications A/C forms and records. 100% of noted discrepancies corrected and returned to the USG within 48 hours of notification. Compliance with Technical 4.1., 100% compliance with all published Technical Data Data 4.2., 4.3. procedures, instructions, and directives. Requests for deviations must be approved by the USG prior to deviation. All work performed using latest version of the publication. Replacement 4.1.4. 100% of all replacement parts/material installed on A/C parts/materials approved/authorized by USG A-10C technical publications. Program Status Reporting 6.2. Team coordination/status telecom led by contractor held at a minimum every two (2) weeks. Agenda provided 24 hours in advance; minutes provided within two (2) working days. Monthly status report delivered NLT last calendar day each month highlighting program progress, status, and risk/problem areas. Program Management 6.3. PMR conducted at least annually to review Reviews (PMR) cost/schedule/performance metrics & address significant program/technical issues. Agenda prepared by contractor; coordinated with USG. Agenda provided NLT 14 days prior to meeting; minutes/action items provided within seven (7) working days. All action items tracked until closure or resolution. PMR must address program risks and mitigation. FISCAL YEAR 19 Page 25 of 101
Performance PWS Performance Threshold Objective Para Master Program Plan & 6.5. Initial copy of Integrated Master Schedule (IMS) Schedule provided within 30 days of contract award. Updates provided once per month. Security 7.1. Zero security-related incidents for duration of contract period where integrity of USG property or data is compromised. All security incidents reported to ACO within one (1) hour of identification. Quality Control 7.2. Quality Control Program in compliance with ISO 9001:2015/SAE AS9100. Upon request, records of inspections furnished to USG within 24 hours. Quality Assurance 7.3. Full cooperation with USG quality assurance (QA) personnel. Zero substantiated reports of Interference with QA inspections by DCMA. Environmental Controls 7.5. 100% compliance with all local environmental laws, regulations, & requirements. Safety 7.7. Zero instances of damage to USG property exceeding 2.92,000 USD. All safety mishaps over reporting threshold reported within one (1) hour. Government Inspection & 7.14. 100% inspections & correction of all Critical Safety Item. Acceptance of Deliverables
6. MANAGEMENT OBJECTIVES
6.1. GENERAL OBJECTIVES
6.1.1. The management objective is to allow the contractor the maximum flexibility to innovatively manage the program plan, schedule, and risk to efficiently and effectively accomplish the specified work under this effort to deliver A/C free of quality defects under the shortest possible flow-time. The contractor is encouraged to participate in, and provide input to A/C induction schedule planning discussions. However, the actual induction quantity and schedule is at the sole discretion of the USG pursuant to all contractual agreements and obligations. Any induction schedules provided to the contractor are for planning purposes only and in no way constitute any contractual agreement or obligation on behalf of the USG.
6.1.2. The contractor shall provide a single Point of Contact (POC) for this effort. POC must read, speak, and write the English language and shall serve as the primary interface between the USAF Program Manager and ACO and the contractor regarding all programmatic and technical matters concerning the execution of this effort.
6.1.3. The Management Plan shall detail the management processes pertaining to program scope, schedule, cost, quality, safety, process improvement, staffing, communication, training, and risk. The plan will detail the dependencies among these processes, team roles and responsibilities, program reporting, and conduct of management reviews. The Management Plan will include cost, schedule, and quality baselines, demilitarization / disposal plan, and a risk management plan. Submit plan IAW CDRL A/B/C/D/E/F/G/H/J/K 011, Technical and Management Work Plan.
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6.1.4. The Management Plan shall include a production surge plan to detail the processes that will be implemented to achieve the surge requirements as defined in PWS Para 2.10.5.2.
6.2. PROGRAM STATUS REPORTING
6.2.1. At a minimum, a status telecom shall be hosted by the contractor every two weeks utilizing a call-in number provided by the USAF A-10 SPO. The specific time for such meetings will be negotiated between the contractor and the USAF Program Manager.
6.2.2. Topics addressed shall include current A/C status in progress, upcoming Inductions, technical issues, supply/supportability issues, and any other issues affecting Task order execution.
6.2.3. Additional telecoms may be requested by either the contractor or the USAF as necessary to address time-critical issues.
6.2.4. The contractor shall coordinate with the USAF Program Manager to identify and notify required participants for each telecom meeting. An agenda or pre-brief shall be provided by the contractor to all participants at least 24 hours in advance of each meeting.
6.2.5. The contractor shall provide meeting minutes within two (2) working days of each telecom. An Electronic-Mail distribution list for minutes will be coordinated with the USAF Program Manager. Provide minutes IAW CDRL A/B/C/D/E/F/G/H/J/K 012, Report, Record of Meeting/Minutes.
6.2.6. A written program status report shall be delivered by the last day of each calendar month IAW CDRL A/B/C/D/E/F/G/H/J/K 013, Contractor’s Progress, Status, and Management Report. The content shall include cost, schedule, and performance metrics for each individual Task order and an overall program assessment that indicates the progress of work, status of the program, and informs of existing or potential problem areas.
6.3. PROGRAM MANAGEMENT REVIEWS
6.3.1. A Program Management Review (PMR) shall be conducted at least annually. The time and location of meetings shall be determined by the USAF A-10 SPO. Location may be USAF A-10 Program Office, contractor facility, or other designated location. For meetings held at the contractor facility, the contractor shall be responsible for providing meeting space and making all other facility/access arrangements. In order to capitalize on the experience of other depots, USAF may opt to schedule PMR activities involving multiple depot organizations.
6.3.2. Required participants for program reviews shall be coordinated between the USAF Program Manager, ACO, and the contractor.
6.3.3. Regardless of location, contractor shall be responsible for preparing meeting agenda, presentations, materials, minutes, and action items. The contractor shall submit a draft agenda to the USAF, and request USAF agenda inputs, NLT 30 calendar days prior to meeting. The USAF will provide agenda inputs NLT 14 calendar days prior to meeting. Final agenda shall be provided by contractor NLT seven (7) calendar days prior to meeting. The contractor shall make a reasonable attempt to accommodate last minute agenda changes. Provide agenda IAW CDRL A/B/C/D/E/F/G/H/J/K 014, Conference Agenda.
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6.3.4. Agenda topics shall be negotiated between the contractor and the USAF. At a minimum, program review shall address cost, schedule, and performance metrics as well as current production status and significant program/technical issues. Specific attention shall be afforded to identifying program risks and risk mitigation. Contractual issues shall only be discussed when a USG Contracting Officer is present.
6.3.5. The contractor shall provide meeting minutes within seven (7) working days of each program review. An Electronic-Mail distribution list for minutes will be coordinated with the USAF Program Manager. Provide minutes IAW CDRL A/B/C/D/E/F/G/H/J/K 012, Report, Record of Meeting/Minutes.
6.3.6. The contractor shall be responsible for recording and tracking actions items, including interim developments, until closure and/or resolution of each item. NOTE: Action Items are intended to assist the contractor with the execution of work requirements to fulfill contractual obligations. The assignment of actions items does not change contractual agreements or obligations. The contractor shall notify the ACO of any action item request that falls outside of the scope of the negotiated contract. The USG will not reimburse or be held financially liable for any work effort expended by the contractor towards the resolution of an action item unless written authorization is provided in advance by the ACO.
6.4. PROGRAM KICK-OFF MEETINGS
6.4.1. A Program Kick-off meeting will be held at the contractor’s facility prior to the first A/C induction. All requirements outlined in PWS Para 6.3 Program Management Reviews and sub- paragraphs will apply to the Program Kick-off meeting to include tracking and providing minutes and action items. Agenda topics will be tailored to assess contractor readiness to perform the work effort specified within this PWS.
6.4.2. Additional Kick-off meetings for new programs/workloads may be required by the USAF A-10 SPO for individual modification programs and other significant new workloads added to the contract. The purpose of such meetings is to assess the contractor’s readiness level to perform the additional work effort.
6.5. MASTER PROGRAM PLAN AND SCHEDULE
6.5.1. The contractor shall be responsible for developing and maintaining the Integrated Master Schedule (IMS) IAW CDRL A/B/C/D/E/F/G/H/J/K 015. The IMS shall be used to verify attainability of contract objectives, to evaluate progress toward meeting program objectives, and to integrate the program schedule activities with all related components. Update IMS after each A/C induction to show projected delivery date.
6.5.2. The IMS shall contain contract milestones, accomplishments, and discrete tasks / activities to include all program management meetings/reviews and status report due dates. A/C induction forecasts will be developed with coordination from the USG. Induction forecasts are for planning purposes only and to do not obligate or commit the USG to induct A/C beyond contractual obligations.
6.5.3. A copy of the IMS shall be provided to the USG within 30 days of contract award and updates provided monthly thereafter.
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7. GENERAL INFORMATION
7.1. SECURITY / OPERATIONS SECURITY REQUIREMENTS
7.1.1. The contractor shall be responsible for safeguarding all USG property in the contractor’s possession. At the close of each work period, USG property and materials shall be secured. The contractor shall ensure that only authorized contractor and USG personnel or other authorized persons as determined by the ACO have access to USG property (equipment, material, publications) to include all work and storage areas. Specific security procedures shall be identified in the contractor’s management plan
7.1.2. The contractor shall not handle any USG classified material. If classified items arrive with an A/C or are suspected to have arrived, the contractor must secure the A/C and notify the ACO immediately. If ACO or other DCMA representative cannot be immediately reached, the A/C Flying Unit shall be notified. Classified items shall be removed only by an authorized USG representative and stored in a secure vault location at the contractor facility or as directed by the ACO. Storage area/container must comply with Department of Defense (DOD) 5220.22-M, Chapter 5 and be certified by USG personnel prior to first A/C induction. Storage container shall only be accessible to authorized USG personnel as determined by the ACO.
7.1.3. All contractors, subcontractors, their employees, associates, and consultants who have access to critical information must comply with the Air Force-sponsored Operations Security (OPSEC) program.
7.1.3.1. OPSEC is a systematic means of identifying and protecting information which an adversary could use to their advantage or to our disadvantage. Critical Information (CI) is generally unclassified but sensitive information which has been identified by the OPSEC program as requiring protection. OPSEC Measures (OM) are control standards with which all personnel must comply in order to protect critical information. Critical information list is provided in Attachment 6.
7.1.3.2. Responsibilities: The contractor must ensure all personnel working on the contract or having access to critical information attend initial and annually recurring refresher training and that the approved curriculum is presented. Training must be provided before personnel are allowed access to critical information.
7.1.3.3. All personnel must comply with OPSEC standards and practices as trained. Additional training may be required based on updates to critical information, OPSEC measures, intelligence threat, or other fundamental changes to the OPSEC program.
7.1.3.4. The contractor must track OPSEC training statistics to include the personnel working on the contract, when each individual received the required OPSEC training, and when refresher training is due. Training statistics must be forwarded to AFLCMC/WWA OPSEC Coordinator annually or upon request. OPSEC Training is provided in Attachment 6
7.1.3.5. Prior to seeking approval through Hill AFB Public Affairs, any information to be released outside of official U.S. Government channels, via any media, must be approved through an OPSEC review by OPSEC Coordinator. All personnel must promptly report OPSEC related incidents, issues, and concerns to OPSEC Coordinator. The OPSEC coordinator is: Matthew Wallace at [email protected] or through the program manager
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7.2. QUALITY CONTROL
7.2.1. Quality Control Program: In compliance with the clause entitled “Inspection of Services”, Federal Acquisition Regulation (FAR) 52.246-4, the contractor shall establish a complete Quality Control Program to ensure the requirements of this contract are provided as specified. The contracting officer will notify the contractor of acceptance or required modifications to the plan before first A/C induction. The contractor shall make appropriate modifications (at no additional cost to the USG) and obtain acceptance of the plan by the contracting officer before the start of the first operational performance period.
7.2.2. Complete records of all inspection work performed by the contractor shall be maintained and made available to the USG during contract performance.
7.2.3. Higher-Level Contract Quality Requirement. In compliance with clause FAR 52.246-11, the contractor’s Quality Control Program shall comply with ISO 9001:2015/SAE AS9100.
7.3. QUALITY ASSURANCE
7.3.1. The USG will periodically evaluate the contractor’s performance by appointing a representative(s) to monitor performance to ensure services are received. The point, frequency, and intensity of quality control inspections are at the sole discretion of the USG and may be changed at any time.
7.3.2. DCMA Product Assurance (PA) personnel shall determine the most appropriate methods and techniques for performing PA surveillance. PA Methods are System Audit, Process Review, and Product Examination. Process review techniques consist of a review and incremental reviews. Product examination techniques include inspect, witness, test and verification for product examination. These methods and techniques apply to all PA personnel.
7.3.3. Quality Assurance Personnel (QAP):
7.3.3.1. The Quality Assurance Personnel (QAP(s)) is the authorized USG representative(s) who will perform assessments of the contractor’s performance. Subsequent to contract award, the identity of the QAP(s), with a letter defining their duties and authority will be promptly furnished to the successful bidder/offeror.
7.3.3.2. The QAP(s) or alternate(s) will inform the contract manager in person when discrepancies occur and will request corrective action. The QAP(s) or alternate(s) will make a notation of the discrepancy on their assessment checklist with the date and time the discrepancy was noted and will request the contract manager (or authorized representative) to initial the entry on the checklist
7.3.3.3. Any matter concerning a change to the scope, prices, terms or conditions of this contract shall be referred to the Contracting Officer and not to the QAP(s).
7.3.3.4. The services to be performed by the contractor during the period of this contract shall at all times and places are subject to review by the Contracting Officer or authorized representative(s).
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7.4. CONFIGURATION MANAGEMENT
7.4.1. The contractor shall accomplish Configuration Management (CM) tasks in accordance with the Configuration Management Plan and Data Management Plan Dated 6 April 2018, utilizing MIL-HDBK-61A as a guide. CM shall include procedures, responsibilities for configuration identification, change control, audits, status accounting, interface management and subcontractor management. The contractor shall establish a process to assure that configuration control is maintained and documented in functional, allocated and product baseline configuration identification. (DI-SESS-80640D/T Request for Variance, DI-SESS- 80643D/T Specification Change Notice (SCN) use in conjunction with DI-SESS-80639D/T Engineering Change Proposal (ECP) and DI-SESS-80642D/T NOR. DI-SESS-81253C /T Configuration Status Accounting (CSA) Information, DI-ADMN-81249B/T Conference Agenda, DI-ADMN-81250B/T Conference Minutes) The contractor shall prepare contract change proposals and engineering change proposals as required. (DI-SESS-80639D/T Engineering Change Proposals, DI-ADMN-81401B/T Contract Change Proposals (CCP)).
7.4.2. The contract depot maintenance facility shall accomplish all installations/repairs in strict accordance with published TOs, Drawings, procedures, and instructions as specified by this PWS. All non-conforming repairs must be requested and approved using the AFMC Form 202 process and must be made in strict accordance with the guidance provided.
7.4.3. Existing installations/repairs which do not conform to established technical data, procedures, or instructions will not be reworked if the following conditions exist: the installation/repairs are serviceable, do not interfere with structural modifications required by this PWS, and do not present Critical Safety Item conditions. For any existing non-conforming installation/repair discovered, the contract depot maintenance facility shall notify the ACO for disposition.
7.4.4. Request for Deviation: The contractor shall submit a written request for deviation from any contractual requirement with a Contractor Request for Deviation (RFD) letter to the PCO. The contractor shall ensure that RFD identifies the status of the A/C and the potential impact to schedule if RFD is not approved. The contractor shall ensure a single RFD is submitted for each occurrence identifying affected A/C. RFDs shall be submitted IAW CDRL A/B/C/D/E/F/G/H/J/K 016.
7.5. ENVIRONMENTAL CONTROLS
7.5.1. Compliance with Laws and Regulations: The contractor shall know and comply with all applicable local laws, regulations, and requirements regarding environmental protection. In the event environmental laws/regulations change during the term of this contract, the contractor is required to comply as such laws come into effect. If there is an increase or decrease in cost as a result of the change, the contractor shall inform the contracting officer pursuant to notice requirements and negotiate a modification to the contract.
7.5.2. Material Storage and Use: The contractor shall follow manufacturer’s guidelines and professional recommendations for control of humidity, temperature, cleanliness, and materials handling. This includes hazardous materials.
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7.5.3. Hazardous Material Disposal: The contractor shall be responsible for disposing of all hazardous materials associated with this work effort, to include fuels and lubricants, IAW all local laws, regulations and manufacturer’s disposal guidelines.
7.5.4. Compliance with Air Force Environmental Impact Analysis Process (EIAP) Requirements: The contractor shall fully cooperate to ensure the Air Force’s compliance with EIAP requirements, as detailed in 32 Code of Federal Regulations (C.F.R.) 989.37 and 989.38, and 32 C.F.R. Part 187. The contractor shall not begin any work or action which would require EIAP analysis until after the EIAP process is complete to the satisfaction of the Air Force, to include the signing of a Record of Decision, Finding of No Significant Impact, or other EIAP decision document.
7.6. GOVERNMENT OBSERVATIONS
7.6.1. In addition to contracting officers and QAP(s), other USG personnel may from time to time, with ACO coordination, observe contractor operations. However, these personnel may not interfere with contractor performance or make any changes to the contract.
7.7. SAFETY REQUIREMENTS
7.7.1. In performing work under this contract, the contractor shall provide protection to USG property to prevent damage during the period of time the property is under the control or in possession of the contractor. Specific safety requirements are contained in Appendix C of the contract/solicitation.
7.7.2. A safety plan meeting the requirements defined in Appendix C of the contract / solicitation shall be included in the contractor’s Management Plan for approval by the USG. Any changes or modifications to the safety plan must be submitted to the ACO for approval.
7.7.3. In the event of an accident / mishap, take reasonable and prudent action to establish control of the accident/mishap scene, prevent further damage to persons or property, and preserve evidence until released by the accident/mishap investigative authority through the ACO.
7.7.4. The contractor shall notify the USG within one (1) hour of all mishaps as required by the mishap notification requirements in Appendix C of the contract/solicitation.
7.7.5. If the USG elects to investigate the accident/mishap, the contractor shall cooperate fully and assist USG personnel in the conduct of investigation until the investigation is completed.
7.8. TRAINING
7.8.1. The contractor shall be responsible for training all contractor personnel on the correct processes and procedures to ensure maintenance personnel are qualified to perform assigned tasks IAW applicable technical data and commercial best practices and standards. All expenses related to training of contractor personnel will be the responsibility of the contractor unless otherwise authorized by the ACO. Employee training requirements shall be addressed in the contractor’s Management Plan, reference PWS Para 6.1.3.
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7.8.2. The contractor shall coordinate with the USAF to receive any specialized A-10 training required by regulation or best practice. Training will be conducted at the contractor’s facility or a USAF installation as deemed appropriate by the USAF. Such training may include:
7.8.2.1. A-10 Familiarization Training 7.8.2.2. Egress System 7.8.2.3. Canopy System Maintenance 7.8.2.4. Flight Control Rigging 7.8.2.5. Engine removal/installation 7.8.2.6. Engine Trim Check 7.8.2.7. Ammo Drum removal/installation 7.8.2.8. Gun System removal/installation 7.8.2.9. White Area Maintenance and Inspector certification 7.8.2.10. Engine Run certification (annual re-certification)
7.8.3. Individual employee training documentation must be maintained for each maintenance personnel and made available upon request to DCMA and USG QAP personnel. Documentation must provide evidence that employee has met all initial training, re-training, certification, and proficiency requirements to satisfy the requirements of the approved contractor’s training plan.
7.8.4. Contractor personnel may be required to travel and attend A-10 instructional events to ensure maintenance personnel are familiarized and qualified to perform specific tasks to minimize delays in aircraft delivery. In the event that additional modifications are deemed necessary or if the USG determines modifications require additional A-10 specific instruction, the USG would cover the travel and related expenses of contractor personnel to attend. Events will be conducted at a facility or installation as deemed most appropriate by the USAF.
7.9. SPECIAL QUALIFICATIONS
7.9.1. Contractor personnel who perform ground operations on A/C and those personnel who operate and maintain ground support equipment used in support of A/C shall be trained and certified IAW Defense Contract Management Agency Instruction (DCMA - INST) 8210.2, Chapter 5 Ground Operations.
7.9.2. Personnel performing NDI shall be qualified IAW AF and AFMC policies. Personnel performing NDI at OCONUS contract depot maintenance facilities shall be qualified and certified IAW AIA/NAS 410. Such inspections shall be performed by certified Level II NDI as specified in the TO.
7.9.3. The contractor is responsible for gaining access to all required electronic information systems required for the performance of this contract to include obtaining the necessary access permissions such as Public Key Infrastructure (PKI) certificates.
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7.10. PHASE OUT
7.10.1. The USG reserves the right to conduct site visits in all contractor operated facilities in conjunction with the solicitation of offers for the follow-on contract. In the event the follow-on contract is awarded to other than the incumbent, the incumbent contractor will cooperate to the extent required to permit an orderly changeover to the successor contractor. The contractor shall develop and provide with the Management Plan a transition approach to phase-out of the contract. The contractor shall ensure the following transition phase-out requirements are accomplished:
7.10.1.1. Cooperate fully to permit an orderly changeover of workload.
7.10.1.2. Allow recruitment notices to be placed in the work areas.
7.10.1.3. Provide a final inventory of all GFE/GFM and a projected availability schedule to identify when specific items will be available for transfer to the follow-on contractor.
7.11. PUBLICATIONS
7.11.1. Compliance with all publications, regulations and operating instructions provided by the USG is required when:
7.11.1.1. They pertain to the procedures for materials expediting herein and where the contractor is authorized by the statement of work to accomplish the work specified in the publication, regulation or operating instructions.
7.11.1.2. The publications prescribe USAF policies, use of materials, procedures and processes applicable to the work requirements.
7.11.1.3. The contractor is required to acquire and work from the latest version of the publication.
7.11.2. Technical Order Library
7.11.2.1. The contractor shall acquire, maintain, control, and dispose of all TO data IAW TO 00-5-1, Chapter 5, including managing access to digital TO files on servers, laptops, and desktop computers. Prior to receiving any TO data, a DD Form 2345, Militarily Critical Technical Data Agreement, must be on file with the USG.
7.11.2.2. All contractor personnel handling or utilizing TO data must be trained IAW with TO 00-5-1, Chapter 11.
7.11.2.3. At a minimum, the contractor shall be responsible for TO Library Custodian duties. Assignment of the TO Distribution Office (TODO) will be negotiated between the contractor and the USG. Reference TO 00-5-1, Chapter 4. It is the objective of the USAF A-10 SPO to have the contractor qualify for and establish a TODO account.
7.11.2.4. If a USG TODO account is utilized, the contractor shall support all spot and periodic TO library inspections by USG TODO personnel.
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7.12. GOVERNMENT FURNISHED PROPERTY AND SERVICES
7.12.1. The contractor shall be responsible for providing and maintaining a complete and current list of all equipment and material required to complete the work effort specified within this PWS. When surplus equipment and/or material are available within the USAF supply system, these items may be supplied as GFE/GFM. All GFE/GFM available for requisition will be documented in Appendix B of the contract/solicitation and will be finalized at the time of contract award and updated as necessary. The contractor shall be responsible for providing all other equipment and materials not provided as GFE/GFM.
7.12.2. All GFM will be requisitioned through the Commercial Asset Visibility (CAV) AF system IAW Appendix B of the contract/solicitation and reporting shall be submitted IAW CDRL A/B/C/D/E/F/G/H/J/K 018 and Appendix B.
7.12.3. Requests for specialized test equipment loans to support work requirements will be handled through the ACO. Such equipment will only be provided when surplus items are available and will not negatively impact USAF operational requirements. All equipment loans shall be returned to the USG as soon possible or as negotiated under the terms of the loan agreement.
7.12.4. The quantity, status, and supply condition data for all GFE will be reported on a quarterly basis IAW CDRL A/B/C/D/E/F/G/H/J/K 017, Status of Government Furnished Equipment Report.
7.13. GOVERNMENT INSPECTION AND ACCEPTANCE OF DELIVERABLES
7.13.1. The DCMA Quality Assurance Specialist (QAS) will accept deliverables from the contractor when there is a basis of confidence products conform to requirements.
7.13.2. For Critical Safety Item, 100% inspection shall be conducted prior to USG acceptance. Independent inspections/tests, or witness of the contractor performing the inspection/tests are the primary methods of product examination used for SOF surveillance. The contractor shall fully cooperate with all inspections performed by authorized USG personnel. When extreme confidence exists in the contractor’s abilities and controls over SOF operations, DCMA may authorize less frequent and or less intense surveillance. If a reduction in confidence and/or escape occurs, the authorization for reduced surveillance shall be revoked.
7.13.3. Deliverables will be accepted using the Procurement Integrated Enterprise Environment (PIEE) system. It is the responsibility of the contractor to gain access to PIEE, prepare, submit for acceptance, and make distribution of all required documents.
7.14. DATA OWNERSHIP: All data produced under performance of this contract to include all data deliverables shall be the sole property of the USG and shall not contain proprietary markings. Exceptions must be approved in writing by the USG PCO.
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APPENDIX 1 – ACRONYMS AND ABBREVIATIONS LIST
Acronym/Abbreviation Definition A/C Aircraft ACI Aircraft Condition Inspection ACO Administrative Contracting Officer ACSG Aircraft Sustainment Group ADR Automatic Data Recorder AECI Automatic Eddy Current Inspection AF Air Force AFI Air Force Instruction AFMAN Air Force Manual AFMC Air Force Material Command AFMCMAN Air Force Material Command Manual AFMCI Air Force Material Command Instruction AFTO Air Force Technical Order APU Auxiliary Power Unit ARC Air Force/Navy/Airborne Radio Communication ASIP Aircraft Structural Integrity Program ASSY Assembly ASTM American Society for Testing and Materials CAD Cartridge Actuated Device CAV Commercial Asset Visibility CDRL Contract Data Requirements List CFE Contractor Furnished Equipment CFM Contractor Furnished Material CFR Code Federal Regulation CFT Contract Field Team CO Contracting Officer CSI Critical Safety Items DCMA Defense Contract Management Agency DFARS Defense Federal Acquisition Regulation Supp. DoD Department of Defense DoDI Department of Defense Instruction DTA Damage Tolerance Analysis ECP Engineering Change Proposal EGI Embedded GPS/Inertial Navigation System EIAP Environmental Impact Analysis Process ERRC Equipment Repair Recoverability Code EWA Enhanced Wing Assembly 8YC Eight Year Corrosion FAR Federal Acquisition Regulation FCF Functional Check Flight FMSP Force Maintenance Structural Plan GCAS Ground Collision Avoidance System GFM Government Furnished Material GFE Government Furnished Equipment IAW In Accordance With IPB Illustrated Parts Breakdown IMS Integrated Master Schedule
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APPENDIX 1 – ACRONYMS AND ABBREVIATIONS LIST
Acronym/Abbreviation Definition ISO International Organization for Standardization LARS Lightweight Airborne Recovery System LH Left-Hand LRU Line Replaceable Unit LT Left MAJCOM Major Command MTBR Mean Time between Repairs NDI Non-Destructive Inspection NLT No Later Than NSN National Stock Number O&I Organizational & Intermediate OML Outer Mold Line OS Outboard Stringers OWP Outer Wing Panel PA Product Assurance PACAF Pacific Air Forces PAD Propellant Actuated Device PBSA Performance Based Service Acquisition PCO Procuring Contract Officer PE Precision Engagement PIEE Procurement Integrated Enterprise Environment PKI Public Key Infrastructure PM Program Manager PMB Plastic Media Blast PMR Program Management Review POC Point of Contact PQDR Production Quality Deficiency Report PWS Performance-Based Work Statement QA Quality Assurance QAP Quality Assurance Personnel QAS Quality Assurance Specialist R&I Remove and Inspect RFD Request for Deviation RH Right-Hand ROM Rough Order of Magnitude RT Right SCU Station Control Unit SLEP Service Life Extension Program SMR Source, Maintenance, and Recoverability SPAECI Surface Probe Automatic Eddy Current Inspection SPM System Program Manager SPO System Program Office SPI Special Packaging Instruction SSI Scheduled Structural Inspection TCTO Time Compliance Technical Order TEMS Turbine Engine Monitoring System TM Technical Manual
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APPENDIX 1 – ACRONYMS AND ABBREVIATIONS LIST
Acronym/Abbreviation Definition TO Technical Order TODO TO Distribution Office USAF United States Air Force USG United States Government WCD Work Control Document WCP Wing Center Panel WOP Wing Outer Panel WS Wing Station WUC Work Unit Code
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
I. APPLICABLE TECHNICAL ORDERS TO NUMBER TITLE 00-5-1 AF Technical Order System 00-20-1 Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures 00-20-2 Maintenance Data Documentation 00-20-3 Maintenance Processing of Reparable Property and Repair Cycle Asset Control System 00-20-5-1-2 Instructions for Jet Engine Parts Tracking and Historical Documentation 00-25-4 Depot Maintenance of Aerospace Vehicles and Training Equipment 00-25-107 Maintenance Assistance 00-25-172 Ground Servicing of Aircraft and Static Grounding/Bonding 00-25-195 AF Technical Order System Source, Maintenance, and Recoverability Coding of AF Weapons, Systems and Equipment 00-25-257-3 Engine Health Management (Engine Diagnostics) 00-35D-54 USAF Deficiency Reporting, Investigation, and Resolution 1-1-3 Inspection and Repair of Aircraft Integral Tanks and Fuel Cells 1-1-8 Application and Removal of Organic Coatings 1-1-19 Inspection, Test, and Replacement of Vibration Isolators 1-1-300 Maintenance Operational Checks and Check Flights (FCF) 1-1-689-1 Cleaning & Corrosion Control Volume I Corrosion Program 1-1-689-3 Cleaning & Corrosion Control Volume III Avionics & Electronics 1-1-691 Cleaning & Corrosion Prevention & Control Aerospace & Non-Aerospace Equipment 1-1A-8 Aircraft & Missile Repair - Structural Hardware 1-1A-14 Installation and Repair Practices - Aircraft Electric and Electronic Wiring 1-1B-50 Aircraft Weight & Balance 1A-10C-01 List of Applicable Publications, A-10C 1A-10C-1 Flight Manual, A-10C 1A-10C-1-1 Flight Manual, Performance Data, A-10C 1A-10C-1-3 Pilot’s Guide For the Suite 8 Software, IFF/SIF Mode 5, & Improved Data Modem Upgrades, A-10C 1A-10C-1CL-1 Flight Crew Checklist – Pilot, A10C 1A-10C-2-1-1 General Aircraft Equipment 1A-10C-2-1-2 Job Guide Manual (JGM) index, A-10C 1A-10C-2-4JG-1 Job Guide Manual, Ground Handling, A-10C 1A-10C-2-12JG-1 Job Guide Manual, Servicing, A-10C 1A-10C-2-12MS-1 Maintenance Support Manual, Ground Handling, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-2-15JG-1-1 Job Guide Manual, Software Loading Procedures Utilizing PATS-70, A- 10C 1A-10C-2-15JG-1-2 Job Guide Manual, Software Loading Procedures Utilizing PATS-70, Vol 2, A-10C 1A-10C-2-15JG-2-1 Job Guide Manual, Windows 7 Software Loading Procedures Utilizing PATS- 70, Vol 1, A-10C 1A-10C-2-15JG-2-2 Job Guide Manual, Windows 7 Software Loading Procedures Utilizing PATS- 70, Vol 2, A-10C 1A-10C-2-15JG-3 Job Guide Manual, Operational Checkout Utilizing PATS-70, A-10C 1A-10C-2-21JG-1 Job Guide Manual, Environmental Control System (ECS), Cockpit Pressurization, A-10C 1A-10C-2-21JG-2 Job Guide Manual, Environmental Control System (ECS), Bleed Air System, A-10C 1A-10C-2-21JG-3 Job Guide Manual, Environmental Control System (ECS), Comp Cooling, A-10C 1A-10C-2-21JG-4 Job Guide Manual, Environmental Control System (ECS), Rain Removal & Defog Systems, A-10C 1A-10C-2-21JG-5 Job Guide Manual, Environmental Control System (ECS), Windshield Deicer Systems, A-10C 1A-10C-2-21JG-7 Job Guide Manual, Environmental Control System (ECS), Fire Extinguisher System, A-10C 1A-10C-2-21JG-8 Job Guide Manual, Environmental Control System (ECS), LOX System 1A-10C-2-21MS-1 Maintenance Support Manual (MSM), Environmental Control System 1A-10C-2-21TS-1 Troubleshooting Manual (TM), Environmental Control System, A10C 1A-10C-2-23JG-1 Job Guide Manual, Communications VHF/FM, A-10C 1A-10C-2-23JG-2 Job Guide Manual, Communication UHF, ADF Intercom & LARS Systems, A-10C 1A-10C-2-23JG-3 Job Guide Manual, Communication IFF/SIF, A-10C 1A-10C-2-23JG-4 Job Guide Manual, Communication, Secure Speech (Fairchild) 1A-10C-2-23JG-5 Job Guide Manual, Situational Awareness Link, (SADL)/Enhanced Position Location Reporting System (EPLRS) and Improved Data Modem (IDM) USAF Series A-10C Aircraft 1A-10C-2-23JG-6 Job Guide Manual, Communications, AN/ARC-210(V) Radio Systems-USAF Series A-10C Aircraft 1A-10C-2-23JG-7 Technical Manual, Org Maintenance-Job Guide-Crypto Loading-USAF Series 1A-10C Aircraft 1A-10C-2-23MS-1 Organizational Maintenance-Maintenance Support-Communications System, USAF Series A-10 Aircraft 1A-10C-2-23TS-1 Organizational Maintenance-Troubleshooting-Communications, USAF Series A-10C 1A-10C-2-24JG-1 Job Guide Manual, Electrical System A/C Generator & Drive, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-2-24JG-2 Job Guide Manual, Org Maintenance -Electrical System, DC Power-USAF Series 1A-10C Aircraft 1A-10C-2-24JG-3 Job Guide Manual, Electrical System Emergency, External, and APU Power 1A-10C-2-24JG-4 Job Guide Manual, Org Maintenance -Electrical System Power Distribution- USAF Series 1A-10C Aircraft 1A-10C-2-24JG-5 Job Guide Manual, Org Maintenance -Electrical System-Exterior/Interior Lighting-USAF Series A-10C Aircraft 1A-10C-2-24JG-6 Job Guide Manual, Org Maintenance -Electrical System-Master Caution-USAF Series 1A-10C Aircraft 1A-10C-2-24MS-1 Technical Manual, Org Maintenance-Maintenance Support-Electrical System- USAF Series A-10C Aircraft 1A-10C-2-24TS-1 Organizational Maintenance-Troubleshooting-Electrical System-USAF Series A-10C Aircraft 1A-10C-2-27JG-1 Job Guide Manual, Org Maintenance – Flight Controls, Flaps/Slats 1A-10C-2-27JG-2 Job Guide Manual, Org Maintenance – Flight Controls, Speed Brakes 1A-10C-2-27JG-3 Job Guide Manual, Org Maintenance – Flight Controls, Stability 1A-10C-2-27JG-4 Job Guide Manual, Org Maintenance – Flight Controls, Pitch 1A-10C-2-27JG-5 Job Guide Manual, Flight Controls, Roll, A-10C 1A-10C-2-27JG-6 Job Guide Manual, Flight Controls Yaw, A-10C 1A-10C-2-27MS-1 Maintenance Support Manual Flight, Flight Controls, A-10C 1A-10C-2-27TS-1 Organizational Maintenance-Troubleshooting-Flight Controls-USAF Series 1A- 10C Aircraft 1A-10C-2-28JG-1 Job Guide Manual, Fuel System Fuel Feed/Vent System, A-10C 1A-10C-2-28JG-3 Job Guide Manual, Fuel System Single Point/In-Flight, Refueling System 1A-10C-2-28JG-4 Job Guide Manual, Fuel System, External Fuel System 1A-10C-2-28JG-5 Job Guide Manual, Fuel System, Fuel Qtr. Indication & Warning System 1A-10C-1-28MS-1 Maintenance Support Manual, Fuel System, A-10C 1A-10C-2-28TS-1 Troubleshooting Manual Fuel System, A-10C 1A-10C-2-29JG-1 Job Guide Manual, Pneudraulics, A-10C 1A-10C-2-29MS-1 Maintenance Support Manual, Pneudraulics, A-10C 1A-10C-2-29TS-1 Technical Manual, Org Maintenance-Troubleshooting- Pneudraulic System, USAF Series 1A-10C Aircraft 1A-10C-2-31JG-1 Job Guide, Org Maintenance – Data Recording System, Turbine Engine Monitoring System 1A-10C-2-31JG-2 Job Guide, Org Maintenance – Data Recording System, Airborne Data Recording System 1A-10C-2-31MS-1 Maintenance Support, Org Maintenance – Recording Systems 1A-10C-2-31TS-1 Troubleshooting, Org Maintenance – Data Recording 1A-10C-2-32JG-1 Job Guide Manual, Landing Gear System Main & Nose, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-2-32JG-2 Job Guide Manual, Landing Gear System Landing Gear Warning & Control, A- 10C 1A-10C-2-32JG-3 Job Guide Manual, Landing Gear System Nose Wheel Steering 1A-10C-2-32JG-4 Job Guide Manual, Landing Gear System Anti-Skid & Brake, A-10C 1A-10C-2-32MS-1 Maintenance Support Manual, Landing Gear System, A-10C 1A-10C-2-32TS-1 Troubleshooting Manual, Landing Gear System, A-10C 1A-10C-2-34JG-1 Job Guide Manual Instruments, Navigation Instruments, A-10C 1A-10C-2-34JG-2 Job Guide Manual, Instruments System, Pilot Static & Angle 1A-10C-2-34JG-3 Job Guide Manual, Navigation System HARS, A-10C 1A-10C-2-34JG-4 Job Guide Manual, Navigation System TACAN, A-10C 1A-10C-2-34JG-6 Job Guide Manual, Instrument System, ILS-USAF 1A10C-Aircraft 1A-10C-2-34JG-9 Technical Manual, Job Guide-Organizational Maintenance-Data Transfer System (DTS) 1553 MUX BUS-USAF Series A-10C Aircraft 1A-10C-2-34JG-10 Job Guide Manual, Embedded Global Positioning System-Inertial Navigation Unit (EGI) Navigation System, USAF Series A-10C Aircraft 1A-10C-2-34MS-1 Maintenance Support Manual, Navigation Instruments, A-10C 1A-10C-2-34TS-1 Troubleshooting Manual, Navigation/Instruments, A-10C 1A-10C-2-40MS-1 Maintenance Support 1A-10C-2-40TS-3 Organizational Maintenance-Troubleshooting-Avionics Integrated System (Navigation System) USAF Series 1A-10C Aircraft 1A-10C-2-40TS-7 Organizational Maintenance Instructions-Integrated Avionics System (LASTE)- USAF Series 1A-10C Aircraft 1A-10C-2-40TS-8 Organizational Maintenance-Troubleshooting-Avionics Integrated Systems, A- 10 Data Bus System-USAF Series 1A-10C Aircraft 1A-10C-2-40TS-9 Troubleshooting Avionics Integrated Systems, Integrated Data and Weapons Management System (IDWMS), A-10C 1A-10C-2-51JG-1 Job Guide Manual, Airframe & Misc. 1A-10C-2-51JG-2 Job Guide Manual, Airframe, Wing Fuselage & Empennage, A-10C 1A-10C-2-51JG-3 Job Guide Manual, Fuselage Panels, A-10C 1A-10C-2-51JG-4 Job Guide Manual, Panel Removal Installation Empennage and Nacelle 1A-10C-2-51JG-5-1 Job Guide Manual, Wing Panels—Vol 1, A-10C 1A-10C-2-51JG-5-2 Job Guide Manual, Wing Panels—Vol 2, A-10C 1A-10C-2-51MS-1 Maintenance Support Manual, Airframe, A-10C 1A-10C-2-51TS-1 Technical Manual, Troubleshooting-Organizational Maintenance-Airframe- USAF Series A-10C Aircraft 1A-10C-2-56JG-1 Job Guide Manual, Canopy Windshield & Ladder. 1A-10C-2-56MS-1 Maintenance Support Manual, Canopy, Windshield, and Ladder, A-10C 1A-10C-2-56TS-1 Troubleshooting Manual, Canopy, Windshield, and Ladder, A- 10C 1A-10C-2-71JG-1 Job Guide Manual, Power Plant, Fire Detecting & Overheat Warning System, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-2-71JG-2 Job Guide Manual, Power Plant APU Operation, A-10C 1A-10C-2-71JG-2CL-1 Organizational Maintenance Checklist-Power Plant-Power Plant/APU OPR- USAF Series 1A-10C Aircraft 1A-10C-2-71JG-3 Job Guide Manual, Power Plant APU Removal & Installation, A-10C 1A-10C-2-71JG-4 Job Guide Manual, Power Plant APU Accessory Removal & Installation, A- 10C 1A-10C-2-71JG-5 Job Guide Manual, Power Plant Accessory Removal & Installation, A-10C 1A-10C-2-71MS-1 Maintenance Support Manual, Power Plant, A-10C 1A-10C-2-71TS-1 Troubleshooting Manual, Power Plant, A-10C 1A-10C-2-93JG-2-1 Job Guide, Org Maintenance – Electronic Warfare ALQ 1A-10C-2-93JG-4-1 Job Guide, Org Maintenance – Countermeasure Set, ALQ-213(V) RHAW 1A-10C-2-93JG-5-1 Job Guide, Org Maintenance – Countermeasure Set System AN/ALE-40(V) 1A-10C-2-93JG-6-1 Job Guide, Org Maintenance – Countermeasure Set System ALQ-213(V)2 1A-10C-2-93JG-7-1 Job Guide, Org Maintenance – Airborne Instrumentation System (AIS) Pods Installation and Removal 1A-10C-2-93MS-1 Maintenance Support, Org Maintenance – Electronic Warfare 1A-10C-2-93TS-2-1 Troubleshooting, Org Maintenance – Countermeasure Set AN/ALQ-213(V)-2 1A-10C-2-94JG-1 Job Guide Manual, Fire Control, Heads-Up Display, A-10C 1A-10C-2-94JG-2 Job Guide Manual, Fire Control, Laser Spot Seeker, A-10C 1A-10C-2-94JG-3 Job Guide, Organization Maintenance – Fire Control, TV Monitoring System 1A-10C-2-94JG-4 Job Guide Manual, Fire Control, Gun Camera, A-10C 1A-10C-2-94JG-5 Job Guide Manual, Armament Alignment Verification, A-10C 1A-10C-2-94JG-6 Job Guide Manual, Armament 30MM Gun System, A-10C 1A-10C-2-94JG-7 Job Guide Manual, Armament Control System, A-10C 1A-10C-2-94JG-8 Job Guide Manual, Armament, Pylons, A-10C 1A-10C-2-94JG-10 Organizational Maintenance-Fire Control Head Up Display/IFFCC (LASTE) System-USAF Series 1A-10C Aircraft 1A-10C-2-94JG-11 Organizational Maintenance-Fire Control-AN/AAQ-28 Targeting Pod System- USAF Series A-10C Aircraft 1A-10C-2-94JG-12 Organizational Maintenance-Fire Control-AN/AAQ-33-Targeting Pod System- USAF Series A-10C Aircraft 1A-10C-2-94MS-1 Technical Manual, Organizational Maintenance-Maintenance Support-Fire Control-USAF Series 1A-10C Aircraft 1A-10C-2-94MS-2 Maintenance Support Manual, Armament, Verify Sight, 30MM Gun Sys, Control, A-10C 1A-10C-2-94TS-1 Troubleshooting Manual, Displays & Image Recording, A-10C 1A-10C-2-95JG-1 Job Guide Manual, Egress System Canopy/Seat, A-10C 1A-10C-2-95JG-2 Job Guide Manual, Egress, Emergency Canopy Release, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-2-95MS-1 Technical Manual-Organizational Maintenance-Job Guide-Egress System, Canopy/Seat-USAF Series 1A-10C Aircraft 1A-10C-2-95TS-1 Troubleshooting Manual, Egress System, A-10C 1A-10C-2-110-1 Wiring Diagrams, A-10C 1A-10C-2-110-1-1 Supplemental Manual Wiring Diagrams, A-10C 1A-10C-3 Structural Repair Manual, Depot Level, A-10C 1A-10C-3-1 Structural Repair, A-10C 1A-10C-3-1-1 Supplemental Manual - Depot Tooling Structural Repair Manual, A-10C 1A-10C-3-3 Technical Manual-Depot Level Maintenance-Removal and Replacement of Forward and AFT Fuselage Sections-USAF Series 1A-10C Aircraft 1A-10C-4-1 IPB, Numerical index and Reference Designation Index-USAF Series 1A- 10C Aircraft 1A-10C-4-2 IPB, Ancillary Equipment 1A-10C-4-21 IPB, Environmental Control System 1A-10C-4-23 IPB, Communications 1A-10C-4-24 IPB, Electrical System 1A-10C-4-27 IPB, Flight Controls 1A-10C-4-28 IPB, Fuel System 1A-10C-4-29 IPB, Pneudraulics 1A-10C-4-31 IPB, Data Recording System 1A-10C-4-32 IPB, Landing Gear System 1A-10C-4-34 IPB, Instrument System 1A-10C-4-51 IPB, Airframe 1A-10C-4-56 IPB, Canopy, Windshield, and Ladder 1A-10C-4-71 IPB, Power Plant 1A-10C-4-93 IPB, Electronic Warfare 1A-10C-4-94-1 IPB, Fire Control 1A-10C-4-94-2 IPB, Armament 1A-10C-4-95 IPB, Egress System 1A-10C-5 Basic Weight Checklist & Loading Data, A-10C 1A-10C-06 Work Unit Code (WUC) Manual, A-10C 1A-10C-6 Scheduled Inspection and Maintenance Requirements, A-10C 1A-10C-6CF-1 Acceptance and Functional Check Flight, A-10C 1A-10C-6CL-1 Acceptance and/or Functional Check Flight Checklist, A-10C 1A-10C-6WC-1 Inspection Workcards Launch Recovery, Thruflight, Quickturn Inspection Workcards-USAF Series A-10C Aircraft-SERNO 78-0582 and Subsequent 1A-10C-6WC-2 Phased Inspection Work cards, A-10C
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
TO NUMBER TITLE 1A-10C-6WC-3 Inspection Workcards Over G Inspection Workcard-USAF Series A-10C Aircraft-SERNO 78-0582 and Subsequent 1A-10C-6WC-5 Preflight-Post Flight Inspection, A-10C 1A-10C-6WC-6 End of Runway Inspection Workcards-USAF Series 1A-10C Aircraft 1A-10C-6WC-7 After Aircraft Wash Lubrication Requirements, A-10C 1A-10C-8-1 Technical manual-Software Configuration Manual-USAF Series A-10C Aircraft 1A-10C-10 Power Package Build-Up & Teardown TF34-GE-100A Engine, A10C 1A-10C-11 Power Package Build-Up (Auxiliary Power Unit), A-10C 1A-10C-21 Aircraft Inventory Record Master, A-10C 1A-10C-23 Corrosion Control, A-10C 1A-10C-36 Non-Destructive Inspection Manual, A-10C 1A-10C-38 Aircraft Structural integrity Program Service Life Monitoring Program-USAF Series 1A-10C Aircraft 1A-10C-39 Technical Manual-Battle Damage Repair-USAF Series A-10C Aircraft 2J-TF34-9 Non-Destructive Inspection Procedures 2J-TF34-101 Corrosion Control, TF34-GE-100 2J-TF34-116-1 Intermediate Main Instruments, TF34-GE-100 2J-TF34-116-5 Cleaning, Inspection and Repair-Turbofan Engine, Model TF34-100A 2J-TF34-116-8 Maintenance Instructions-On Condition maintenance, Turbofan Engine, Model TF34-100A 8D2-3-1 Operation, System & Repair Instructions, NI-CAD Batteries 14S1-3-51 Survival Kit Components and Survival Kit Container Assembly 16C1-30-10-3 Overhaul Instructions w/Illustrated Parts Breakdown, Wing Center Panel 16C1-30-12-3 Overhaul Instructions w/Illustrated Parts Breakdown, Wing Outer Panel 16W12-55-3 Engine Nacelle Center Section, A-10C 33-1-37-1 Joint Oil Analysis Program Manual, Vol I 33-1-37-2 Joint Oil Analysis Program Manual, Vol II 33-1-37-3 Joint Oil Analysis Program Manual, Vol III 33B-1-1 Non-Destructive Inspection Methods 33B-1-2 Non-Destructive Inspection General Procedures & Process Controls 42B-1-1 Quality Control of Fuels 42E-1-1 Elastic Shock Absorber Cord & Elastic Exerciser Cord 44H3-1-3 General Use of Boss, Cap and Tubing Seals
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APPENDIX 2 – TECHNICAL ORDERS AND OTHER DIRECTIVES
II. APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS (TCTO): TCTO NUMBER TITLE 1A-10C-520 Enhanced Wing Assembly (EWA) 1A-10C-544 Replacement of Upper Longeron Plates, Crown Skin, and Fuselage Repairs 1A-10C-553 Installation of Repair Straps at FS 405 1A-10C-554 Installation of Fuselage Fuel Cavity Drain Tube Assemblies 1A-10C-555 Installation of Upper Longeron Repair Straps at FS 268 1A-10C-604 Replacement of Lower Left Hand Longeron PN 160D113004-139 1A-10C-622 Relocation of Canopy Seal Check Valve from Upper Gun Bay Bulkhead to Bay F101 1A-10C-633 Removal of Pylons at Weapons Station 3 and 9 to Accomplish TCTO 16W6- 28-525 1A-10C-634 Removal of Assembly on Stations 4 and 8 Pylons to Accomplish TCTO 16W6-28-524 1A-10C-635 Removal of Pylons at Weapons Station 5 and 7 to Accomplish TCTO 16W6- 28-523
III. APPLICABLE DIRECTIVES: AIR FORCE MANUALS AND INSTRUCTIONS NUMBER TITLE AFI 11-207 Combat Aircraft Delivery, Flying Operations AFI 21-101 Aircraft and Equipment Maintenance Management AFI 21-103 Equipment Inventory, Status, and Utilization Reporting AFI 21-124 Oil Analysis Program AFI 23-101 Air Force Material Management AFPD 10-36 Contracted Air Support for Adversary Air & Close Air Support Training
AIR FORCE MATERIAL COMMAND MANUALS AND INSTRUCTIONS NUMBER TITLE AFMCI 21-102 Analytical Condition Inspection Programs AFMCI 21-118 Aircraft Maintenance Production/Compression Report (AMREP) AFMCI 21-201 Overseas Workload Program DCMAI 8210.2 Aircraft Operations
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APPENDIX 3 – A-10C STRUCTURAL COMPONENT S/N VERIFICATION
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APPENDIX 4 – A-10C PAINT SPECIFICATIONS
SECTION PAGE
1. GENERAL……………………………………………………………………………………4 9
1.1. Information…………………………………………………………………………….4 9 1.2. Special Depot Requirements………………………………………………………..4 9
2. PMB DEPAINTING, CORROSION INSPECTION AND TREATMENT, AND REPAINTING REQUIREMENTS…………………………………………………………………………49
2.1. General Information……………………………….………………………………….49 2.2. Aircraft Parts Removals………………………….…………………………………..49 2.3. Weight and Balance ..…………………………….………………………………….50 2.4. Lubrication ..……………………………………….………………………………….50 2.5. Sealant …………………………………………….………………………………….50 2.6. Water Break Test……………………………………………………………………..50 2.7. Wet Tape Test………………………………………………………………………...50 2.8. Flight Control Operational Checks………………………………………………….50 2.9. Gloss Meter Reading…………………………………………………………………50
3. SCUFF SANDING, CORROSION INSPECTION AND TREATMENT, AND REPAINTING REQUIREMENTS…………………………………………………………………………..50
3.1. General Information………………………………………………………………….50 3.2. Aircraft Parts Removal ...……………………………………………………………50 3.3. Weight and Balance …………………………………………………………………50 3.4. Lubrication…………………………………………………………………………….50 3.5. Sealant ………………………………………………………………………………..50 3.6. Water Break Test ……………………………………………………………………51 3.7. Wet Tape Test ……………………………………………………………………….51 3.8. Flight Control Operational Checks …………………………………………………51 3.9. Gloss Meter Reading ………………………………………………………………..51
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APPENDIX 4 – A-10C PAINT SPECIFICATIONS
1. GENERAL
1.1. Information: This Appendix establishes requirements for both the Plastic Media Blast (PMB) and Scuff Sand Paint Programs. Procedures for PMB are in Section 2, procedures for Scuff Sand are in Section 3 of this Appendix.
1.2. Special Depot Requirements:
1.2.1. For both the PMB and Scuff Sand Paint Programs, (for aircraft not modified by TCTO 1A- 10C-520) inspect for loose jo-bolts in the leading edge of the upper skin outer wing panel from Wing Station (WS) 110 through WS249. Replace all jo-bolts that are loose IAW TO 1A-10C-3- 1.
1.2.2. Perform Scuff Sand, Corrosion Inspection and Treatment, and Repainting of the Enhanced Wing Assembly.
1.2.2.1. The paint thickness shall not exceed a dry film thickness 0.007-inch.
1.2.2.2. If a total coating failure is identified on the wing assembly, submit an AFMC 202 request for authorization to perform PMB De-painting, Corrosion Inspection and Treatment, and Repainting of the Enhanced Wing Assembly.
2. PMB DEPAINTING, CORROSION INSPECTION AND TREATMENT, AND REPAINTING REQUIREMENTS
2.1. General Information: Prepare and perform aircraft wash, paint stripping, corrosion treatment, masking, priming, repainting, special coatings application, and marking placement for the A-10C aircraft. All work will be accomplished IAW TOs 1A-10C-23, 1-1-691, 1-1-3, 1-1-8, 1A-10C-27JG series Job Guides, and 1A-10C-3-1.
2.2. Aircraft Parts Removals: Removal of specific parts prior to de-paint must be complied with IAW 1A-10C-23. Any exceptions must be coordinated through ACO. Parts removed from aircraft will be de-painted and cleaned IAW TOs 1-1-691, 1A-10C-23, and 1A-10C-3-1. Remove corrosion, chemically treat, prime and paint all removed parts IAW TOs 1A-10C-3-1, 1-1-691, 1-1- 8, 1A-10C-23 and applicable engineering drawings.
2.2.1. Flight Controls are removed/routed for repair to back shop/paint/weight & balance IAW 1A- 10C-3-1 Section 1 (Control Surface Balancing) and installed on aircraft.
2.2.1.1. Rudders will be replaced 100% on all programs and will be returned to supply upon removal.
2.2.1.2. Elevators will continue removal/routed for repair/paint/weight & balance/install. Once supportability is confirmed elevators will be replaced 100% on all programs and will be returned to supply.
2.2.1.3. Incoming Inspection required on Flight Controls Surfaces (Flaps, Slats, Decelerons) to determine type of flight controls installed, not modified by TCTO 1A-10C-520 or modified by TCTO 1A-10C-520.
2.2.1.3.1. Not modified by TCTO 1A-10C-520 (part numbers beginning with “160”) will require routes to back shop for repairs, repaint and weight/balance.
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APPENDIX 4 – A-10C PAINT SPECIFICATIONS
2.2.1.3.2. Aircraft modified by TCTO 1A-10C-520 (part numbers beginning with “162”) will not require routes to back shop for repairs, repaint and weight/balance.
2.3. Weight and Balance: After painting, perform weight and balance on those flight control surfaces that require it (prior to installation) IAW TO 1A-10C-3-1 after painting the aircraft, perform weight and balance IAW TO 1A-10C-5.
2.4. Lubrication: Perform lubrication of aircraft as required IAW TO 1A-10C-6WC-7.
2.5. Sealant: Remove and replace all deteriorated, damaged, loose and missing sealant around all exterior seams and permanent skin panel joints IAW TOs 1A-10C-23, 1A-10C-3-1, and 1-1- 691.
2.6. Water Break Test: Water break tests shall be conducted on representative areas to be treated immediately prior to the application of corrosion removal pre-paint solutions as directed in TO 1-1-8, section 3.
2.7. Wet Tape Test: Perform wet tape test to determine coating adhesion IAW TO 1-1-8.
2.8. Flight Control Operational Checks: Perform operational checks on all removed / reinstalled flight controls IAW TOs 1A-10C-2-27JG series Job Guides.
2.9. Gloss Meter Reading: Perform gloss meter reading IAW TO 1-1-8 and 1A-10C-23.
3. SCUFF SANDING, CORROSION TREATMENT AND INSPECTION, REPAINTING REQUIREMENTS
3.1. General Information: Prepare and perform aircraft wash, scuff sanding, corrosion treatment, masking, priming, repainting, special coatings application, and marking placement for the A-10C aircraft. All work will be accomplished IAW TOs 1-1-691, 1-1-3, 1A-10C-23, 1A-10C-3-1, 1A-10C- 27JG series Job Guides, and 1-1-8.
3.2. Aircraft Parts Removal: Removal of specific parts prior to de-paint must be complied with IAW 1A-10C-23. Any exceptions must be coordinated through the PCO or ACO. Parts removed from aircraft will be de-painted and cleaned IAW TOs 1-1-691, 1A-10C-23, and 1A-10C-3-1. Remove corrosion, chemically treat, prime and paint all removed parts IAW TOs 1A-10C-3-1, 1-1- 691, 1-1-8, 1A-10C-23 and applicable engineering drawings.
3.3. Weight and Balance: After painting, perform weight and balance on those flight control surfaces that require it (prior to installation) IAW TO 1A-10C-3-1, Section 1 (Control Surface Balancing)
3.3.1. After painting the aircraft, perform weight and balance IAW TOs 1-1B-50 and 1A-10C-5.
3.4. Lubrication: Lubricate aircraft as required IAW TO 1A-10C-6WC-7.
3.5. Sealant: Remove and replace all deteriorated, damaged, loose and missing sealant around all exterior seams and permanent skin panel joints IAW TOs 1A-10C-23, 1A-10C-3-1, and 1-1- 691.
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APPENDIX 4 – A-10C PAINT SPECIFICATIONS
3.6. Water Break Test: Water break tests shall be conducted on representative areas to be treated immediately prior to application of corrosion removal pre-paint solutions as directed in TO 1-1-8, section 3.
3.7. Wet Tape Test: Perform wet tape test to determine coating adhesion IAW TO 1-1-8.
3.8. Flight Control Operational Checks: Perform operational checks on all removed/reinstalled flight controls IAW TOs 1A-10C-2-27JG series Job Guides.
3.9. Gloss Meter Reading: Perform gloss meter reading IAW TO 1-1-8 and 1A-10C-23.
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APPENDIX 5 – A-10C SCHEDULED STRUCTURAL INSPECTION (SSI)
SECTION PAGE
1. GENERAL ...... 53
1.1. Background ...... 53 1.2. Past Analysis Guidance ...... 53 1.3. Other Sources...... 53 1.4. Current Analysis Guidance ...... 54 1.5. Purpose ...... 54
2. GENERAL REQUIREMENTS ...... 54
3. FUSELAGE REQUIREMENTS ...... 57
4. ADDITIONAL INSPECTIONS...... 61
4.1. Systems ...... 61 4.2. Phased Inspection...... 61 4.3. Flight Control System Inspections/Replacements...... 61 4.4. Replacements ...... 62
5. LEGACY WING AIRCRAFT..…...... 63
6. EWA AIRCRAFT..………………...... 64
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APPENDIX 5 – A-10C SCHEDULED STRUCTURAL INSPECTION (SSI)
1. GENERAL
1.1. Background
1.1.1. Currently the A-10 fleet has surpassed the end of its second design requirement of 8,000 flight hours. The Aircraft Condition Inspection (ACI) program, used previously to manage the structural health of the A-10, and the SLEP program provides engineering cracking history of some problem areas in the fleet, but are inadequate in providing a fleet-wide assessment that could be used to validate the structural health of the aircraft. The SLEP program includes structural inspections and a number of repairs intended to extend the life of the aircraft. Ongoing periodic inspections as provided by SSI are still necessary to maintain the structural health of the aircraft. The SSI program is anticipated to be an ongoing dynamic process of inspection as new data is received and interpreted.
1.1.2. Engineering has developed and is currently developing structural fatigue critical areas from past current and ongoing analyses and other sources. The resultant inspection requirements are a vital component throughout the extended service requirement of the aircraft. This dynamic inspection requirement is one element of the overall plan to re-establish the A-10 Aircraft Structural Integrity Program (ASIP) with the goal of fulfilling Air Force requirements and supporting the airworthiness certification. These structural inspections are and will be derived from:
1.2. Past Analysis Guidance:
1.2.1. Force Structural Maintenance Plan (FSMP) – SA220R0241, November 1993
1.2.2. Damage Tolerant Analysis – SA220R0207, January 1993
1.2.2.1. The Damage Tolerant Reassessment (SA220R0207) reports damage tolerant analysis for fatigue critical locations that were derived from analysis and tests. This report is based on the second 6000 hour usage spectrum.
1.2.2.2. Details included in the SSI program are those with short lives or high crack growth rates relative to 24,000 flight hours.
1.3. Other Sources:
1.3.1. Wing Fatigue Test Findings
1.3.2. Teardown Results
1.3.3. Fleet Experience
1.3.4. TCTOs, SLEP and ACI Inspections
1.3.4.1. All SLEP inspections are included.
1.3.5. Repair History
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APPENDIX 5 – A-10C SCHEDULED STRUCTURAL INSPECTION (SSI)
1.4. Current Analysis Guidance
1.4.1. Force Structural Maintenance Plan, 06-A10DOC-6260, December, 2008. Damage Tolerance Re-Assessment: Reconfigured Post Desert Storm Severe Spectrum, SA220R0207 Rev B, September, 2008.
1.4.1.1. New fatigue critical locations were derived from test, teardown, and fleet data. Analysis updated to reflect current aircraft usage.
1.4.1.2. Engineering is in the process of updating SSI inspection locations, procedures and schedule based on this recent analysis.
1.4.2. The proposed SSI plan requires these structural fatigue critical areas be inspected on a given timeline to ensure flight safety of the airframe throughout the remainder of the service objective. The inspections were lumped into packages (SSIs) to facilitate maintenance and financial planning. The FSMP currently outlines different inspection intervals for each area. However, the new Damage Tolerance Analysis (DTA) and FSMP requirements may significantly alter SSI. It is planned to add numbers to every hole inspection illustration. This will add fidelity to the inspections findings reporting process. There will be several new and altered inspections. As these inspections are completed they will be delivered accordingly. The maximum number of flight hours between inspections that engineering can allow, based on current information will be either 2000 or 4000 flight hours.
1.5. Purpose
1.5.1. The purpose of this Appendix is to define the requirements for completion of the A-10 SSI Program (including wing rework and fuselage inspections and repairs).
1.5.2. All additional work not included in this attachment shall be limited to SOF.
1.5.3. If defects are indicated during inspection, repair in accordance with (IAW) TO 1A-10C-3 and TO 1A-10C-3-1. If defects are outside of tech data submit AFMC Form 202 for engineering disposition.
1.5.4. Any additional repairs outside TO limits and this Appendix shall first be approved in writing by the PCO or ACO.
2. GENERAL REQUIREMENTS
2.1. Perform a visual inspection for corrosion and defects in all areas of work associated with these inspections IAW TO 1A-10C-23 and 1A-10C-3-1.
2.1.1. Visually inspect fuselage forward and aft fuel bladder cavity structure for corrosion and cracks IAW TO 1A-10C-3-1 and 1A-10C-23.
2.1.2. Visually inspect the canopy actuator lower support fitting PN 160D117219-11 for damage. Replace/repair as required IAW TO 1A-10C-3-1.
2.2. Review AFTO 95 for any additional inspection requirements. Submit AFMC Form 202 request for any items inspected that are outside of prescribed limits or any items with re- inspection requirements
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2.3. Nacelles
2.3.1. Remove and visually inspect all access panels for damage (REF TO 1A-10C-2-51JG-4).
2.3.2. When supportable, remove and replace center section of nacelles 100%. Until Nacelle center sections become 100% supportable perform the following:
2.3.2.1. Remove Thrust Mount Fitting, inspect and Measure bore IAW 16W12-55-3.
2.3.2.2. Visually check hinge tangs (center section side, PN 160D412023-31/-32) for cracks and missing tangs. Reference TO 1A-10C-3-1.
2.3.2.3. Inspect nacelle lower hinge IAW 1A-10C-36, chapter 5, NACELLE DOOR LOWER HINGE LH/RH NS 132.00-210.0-EDDY CURRENT. If damage is found repair IAW TO 1A- 10C-3-1, chapter 6. If damage exceeds limits of TO, submit a 202 for further disposition.
2.3.2.4. Inspect T-angle IAW TO 1A-10C-36, chapter 5, LH & RH Nacelle T-Angle Eddy Current P/Ns 160D412008-35/-36, 160D412009-39/-40, 160D412010-29, 160D412011-43, 16D412012-29, 16D412013-43/-44, and 16D412014-61/-62 IAW 1A-10C-3-1.
2.3.2.5. Install N3 repair, PN 160J412035.
2.3.2.6. Perform visual inspection IAW 1A-10C-3-1, Section I, VISUAL INSPECTION.
2.3.3. Visually inspect and repair FWD and AFT nacelle cowls as required.
2.4. Perform inspection of three gun and four ammo drum mount fittings as follows:
2.4.1. Perform inspection of the three gun and four ammo drum mount fittings IAW TO 1A-10C- 3-1 “Evaluation of Gun and Ammo Drum Support Fitting Mount Holes for Damage.”
2.4.2. Visually inspect the three gun and four ammo drum fittings for corrosion and defects IAW TO 1A-10C-3-1 (7 each):
2.4.2.1. Forward gun support fitting P/N 160D116004-19. 2.4.2.2. Left aft gun support fitting P/N 160D116005-13. 2.4.2.3. Right aft gun support fitting P/N 160D116022-13. 2.4.2.4. Left forward ammo drum support fitting P/N 160D116006-15 or -17. 2.4.2.5. Left aft ammo drum support fitting P/N 160D116016-21. 2.4.2.6. Right forward ammo drum support fitting P/N 160D116007-23. 2.4.2.7. Right aft ammo drum support fitting P/N 160D116007-21.
2.5. Perform the SSI inspections as outlined in the tables below.
2.5.1. SSI will be required at intervals determined by the A-10 ASIP office and scheduled by the A-10 Depot Support Section, AFLCMC/WWA
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2.5.2. SSI Table 1. Fuselage Inspection F1 F1 Repaired F2 F3 F3 Repaired F4 F4-Repaired F5 F7 F8 F8 Repaired F9 F10 F11 F12 F13 F14 F15 G3 H1 N1 N3 N3-Repaired N4 N5 V1
For Aircraft receiving the Hogback (TCTO 1A-10C-544) the following SSI inspections will be performed:
2.5.3. SSI Table 2. Fuselage Inspection Hogback FUSELAGE:
Hogback non-numbered forward fuselage section Hogback non-numbered center fuselage section Hogback non-numbered aft fuselage section Hogback Region A Hogback Region B Hogback Region C Hogback Region D Hogback Region E C1 F1 Hogback F2 Hogback F3 Hogback F4 Hogback F5 FISCAL YEAR 19 Page 56 of 101
F6 Hogback F8 Hogback F9 Hogback F10 Hogback F11 Hogback F12 F13 F14 F15 G3 H1 N1 N3 N3-Repaired N4 N5 V1
2.6. Supplemental wing inspections may be required, wing serial number specific. These inspections will be identified and provided by SPO engineering prior to induction.
2.7. The following tasks shall be performed on all aircraft:
2.7.1 Remove and replace all landing gear and drag strut actuators with zero-time, condition code “B” assets. If unavailable, serviceable, condition code “A” assets shall be installed
3. FUSELAGE REQUIREMENTS
3.1. Fuselage fuel tank foam replacement:
3.1.1. Foam shall be 100% replaced if aircraft records do not show 100% replacement in the last 12 years.
3.1.2. Upon 100% fuel foam replacement, annotate AFTO 95 as follows: “Fuselage tank fuel foam was 100% replaced on MM/DD/YYYY (MRT Transfer Date)”. Additionally, record IAW Appendix 3 of the PWS: A-10 Structural Component Serial Number Verification
3.1.3. Remove/replace uncoated and/or damaged ballistic foam (void filler) in all accessed areas IAW TO 1A-10C-3-1.
3.1.3.1. Replace ballistic foam (Void Filler) in all accessed areas unless previously CW with new coated foam IAW 1A-10C-3-1.
3.1.4. Perform inspections IAW inspection s listed in SSI Table 1. For aircraft receiving TCTO 1A-10C-544 (Hogback), inspection requirements are listed in SSI Table 2.
3.1.5. SSI inspections are listed and defined below. A-10 Engineers may add or delete SSI inspections as necessary through the Program Manager (PM).
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Hogback SSI Region A: Inspection of “J” extrusion FS 343-FS 381 IAW TCTO 1A-10C-544.
Hogback SSI Region B: Inspection of “J” extrusion FS 381-FS 436 IAW TCTO 1A-10C-544.
Hogback SSI Region C: Inspection of “J” extrusion and FS 468 fuselage frame at FS 436-FS 481 IAW TCTO 1A-10C-544.
Hogback SSI Region D: Inspection of “J” extrusion FS 481-FS 524.3 IAW TCTO 1A-10C-544.
Hogback SSI Region E: Inspection of “J” extrusion FS 524.3-FS 546 IAW TCTO 1A-10C-544.
Hogback Non-numbered Forward Fuselage Section: All holes that have fasteners removed that are fatigue and fracture critical in the forward fuselage area.
Hogback Non-numbered Center Fuselage Section: All holes that have fasteners removed that are fatigue and fracture critical in the center fuselage area.
Hogback Non-numbered Aft Fuselage Section: All holes that have fasteners removed that are fatigue and fracture critical in the aft fuselage area.
F1: Inspection of upper longeron splice support FS 268 IAW TO 1A-10C-36.
F1 Repaired: Inspection of repair of upper longeron splice support FS 268 IAW TO 1A-10C-36.
F1 Hogback: Inspection of LH/RH upper longeron splice and support at FS 268 IAW TCTO 1A-10C-555.
F2: Inspection of center fuselage upper longeron strap/frame FS 468/BL 12 IAW TO 1A-10C-36.
F3: Inspection of lower, auxiliary longeron splice strap, and fuselage frame FS 405/WL 89.5 IAW TO 1A-10C-36
F3 Hogback: Inspection of LH/RH lower auxiliary longer, FS 405.21 frame, FS 389.44-FS 418.21, and WL 89.50 IAW TCTO 1A-10C-553.
F3 Repaired: Inspection of lower, auxiliary longeron splice strap, and fuselage frame FS 405/WL 89.5 IAW TO 1A-10C-36.
F4: Inspection of FS 524.3 upper longeron strap IAW TO 1A-10C-36.
F4 Hogback: Inspection of upper longeron “J” extrusion and FS 524.30 frame FS 513.28-531.9 LH/RH IAW TCTO 1A-10C-544.
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F5: Inspection of aft gun support fitting at FS 239 IAW TO 1A-10C-36.
F6 Hogback: Inspection of LH/RH forward fuselage support at FS 314, crown skin removed IAW TCTO 1A-10C-544.
F7: Inspection of forward fuselage upper crown skin at FS 314-365 IAW TO 1A-10C-36.
F8: Inspection of lower auxiliary longeron and splice strap, FS 405.21 frame WL 89.5.
F8 Hogback: Inspection of LH/RH lower auxiliary longeron, splice strap, FS 405.21 frame, and FS 386-416 IAW TCTO 1A-10C-553.
F8 Repaired: Inspection of lower auxiliary longeron and splice strap, FS 405.21 frame WL 89.5, repair installed (PN 264J213005).
F9: Inspection of upper longeron strap and “J” extrusion FS 405 IAW TO 1A-10C-36.
F9 Hogback: Inspection of Upper longeron at FS 405.21 frame IAW TCTO 1A-10C-544.
F10: Inspection of upper longeron strap and “J” extrusion FS 535 IAW TO 1A-10C-36.
F10 Hogback: Inspection of upper longeron “J” extrusion FS 530-FS 541 IAW TCTO 1A-10C-544.
F11: Inspection of upper longeron strap and “J” extrusion FS 365 IAW TO 1A-10C-36.
F11 Hogback: Inspection of upper longeron “J” extrusion FS 352-FS 391 IAW TCTO 1A-10C-544.
F12: Inspection of FS 280 Ammo Drum Support Fittings LH/RH.
F13: Inspection of wing attach lugs, fuselage side. SSI F13 is only required when the tapered pin and bushings are removed as a result of other requirements, i.e., a wing drop. If the pin/bushing is not removed, then no inspection is required.
F14: Inspection of FS 365 Bulkhead.
F15: Inspection/Repair of FS524 Upper Auxiliary Longeron Strap.
G3: Inspection of nose landing gear drag brace fitting IAW TO 1A-10C-36.
H1, V1: Inspection of horizontal stabilizer upper and lower mid spar cap, BL 109 Inspection of vertical stabilizer rear spar splice fitting, IAW TO 1A-10C-36.
N1: Inspection of aft nacelle hanger frame attach lug (fuselage and nacelle) IAW TO 1A-10C-36.
N3/N3 repaired: Inspection of nacelle aft hanger frame lower attach flanges, NS 200 IAW TO 1A-10C-36.
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N4: Inspection of nacelle forward hanger frame lug (fuselage and nacelle side) IAW TO 1A-10C-36.
N5: Inspection of LH and RH FWD/UPPER engine mount link assembly.
3.1.6. If not previously accomplished, install FS 524.3 upper longeron repair straps (PN 160J213011-11 / –12) on aircraft not modified by TCTO 1A-10C-544 upper longeron & crown skin. Outer mold line straps PN 264J213001-15/-16 will be installed during TCTO 1A-10C-544 upper longeron & crown skin.
3.1.7. Replacement of left and right nacelle aft engine mount thrust fitting with P/N 160D412006-1/-3 will be accomplished. For aircraft which have had the new thrust fitting, National Stock Numbers (NSN’s) 1560-01-483-8806 (RH) and 1560-01-483-8807 (LH) installed, comply with inspection N2, if applicable.
3.1.8. If not previously performed, maintenance facilities shall perform a complete re-wire of the Turbine Engine Monitoring System (TEMS) (CLIN X020). Reference drawings 160D141340, 160D141360, 160D145295, 8735229, 8735230, and 8735251 for more detail on location of wires requiring removal and replacement.
3.1.9. If not previously accomplished, install 160K211101-1/-2 repair at FS365 IAW drawing 160K211101.
3.1.10. If not previously accomplished, install FS 268 longeron repair straps IAW TCTO 1A-10C- 555 (CLIN X027). Local manufacturing is authorized until repair strap is supportable through Air Force supply system.
3.1.11. Install FS405 lower aux longeron repair straps IAW TCTO 1A-10C-553 if applicable (CLIN X025).
3.1.12. If not previously accomplished, install fuel cavity drain IAW TCTO 1A-10C-554 (CLIN X026).
3.1.13. Install upper longeron strap and crown skin IAW TCTO 1A-10C-544 if applicable (CLIN X024).
3.1.14. Install turtledeck support repair doubler at FS 314 IAW TCTO 1A-10C-544 if applicable (CLIN X024).
3.1.15. When supportable, accomplish replacement of lower longeron PN 160D113004-139 IAW TCTO 1A-10C-604 if applicable (CLIN X0028)
3.1.16. If not previously accomplished, Accomplish nacelle thrust fitting bore repair IAW drawing 160J412004.
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3.1.17. Empennage flight controls will be handled in the following manner:
3.1.17.1. Rudders will be replaced 100% on all programs. If available from supply Rudders will be returned to supply upon removal. If not available from supply they will be routed for repair/paint/weight & balance/install.
3.1.17.2. Elevators will be replaced 100% on all programs. If available from supply Elevators will be returned to supply upon removal. If not available from supply they will be routed for repair/paint/weight & balance/install.
4. ADDITIONAL INSPECTIONS / REPLACMENTS
4.1. Systems: Replace all O-rings in the disturbed fuel system.
4.2. Phased Inspection: Perform first and second phase inspections IAW TO 1A-10C-6WC-2.
4.3. Flight Control System Inspections: The following fuselage inspections listed in Table 1 shall be accomplished on all SSI aircraft regardless of flight hours. (Ref: TO 1A-10C-6)
Table 1. Flight control fuselage special inspection requirements: Work Unit Special Inspections Code 14CCB REMOVE AND INSPECT ROLL FORWARD FUSELAGE CRANK ASSEMBLY NO. 2 (PN 160D122140), FOR WEAR OF THE BOLT, BUSHINGS, AND BUSHING CAVITIES, INCLUDING ATTACHING PUSH RODS AND HARDWARE. (REF: TO 1A-10C-2-27JG-5 AND TO 1A-10C-3-1) 14ECB REMOVE AND INSPECT PITCH FORWARD FUSELAGE CRANK ASSEMBLY NO. 2 (PN 160D121260), FOR WEAR OF THE BOLT, BUSHINGS AND BUSHING CAVITIES, INCLUDING ATTACHING PUSH RODS AND HARDWARE. (REF: TO 1A-10C-2-27JG-4 AND TO 1A-10C-3-1) 14AA0 CONTROL STICK PITCH OUTPUT CRANK (PN 160D120130), AT THE BOBWEIGHT OUTPUT CONTROL ROD FOR WEAR OF THE BOLT, BUSHINGS, AND CRANK, INCLUDING ATTACHING PUSH RODS AND HARDWARE. (REF: TO 1A-10C-3-1) 14EC1 ELEVATOR ACTUATOR OUTPUT LINK BUSHINGS, BOLTS, AND LINK FOR WEAR. INSPECT ELEVATOR HORN, BEARING, BUSHINGS, AND BOLT FOR WEAR. (REF: TO 1A-10C-3-1) 14GB3 LH YAW CRANK ASSEMBLY BUSHINGS, FS 683.78 (PN S5005-4-268, S5006-3- 100, S5005-4-160, S5006-3-170), CRANK ASSEMBLY (PN 160D323120) AND SUPPORT ASSEMBLY (PN 160D323151). (REF: TO 1A-10C-3-1)
14GB3 RH YAW CRANK ASSEMBLY BUSHINGS, FS 683.78 (PN S5006-3-100, S5005-4- 160, S5006-3-185 OR S5005-4-270) CRANK ASSEMBLY (PN 160D323125) AND SUPPORT ASSEMBLY (PN 160D323143). (REF: TO 1A-10C-3-1) 14GBS YAW IDLER SUPPORT ASSEMBLY, FS 236.07 (PN 160D123250 OR 160D123270) AND YAW CRANK SUPPORT ASSEMBLY, FS 264.0 (PN 160D123240 OR 160D123260). (REF: TO 1A-10C-3-1) 14GBA REMOVE LT RUDDER PEDAL CARRIAGE ASSEMBLY AND INSPECT JOINTS FOR WEAR IAW TO 1A-10C-2-27JG-6 AND TO 1A-10C-3-1.
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14GBH REMOVE RT RUDDER PEDAL CARRIAGE ASSEMBLY AND INSPECT JOINTS FOR WEAR IAW TO 1A-10C-2-27JG-6 AND TO 1A-10C-3-1. 14GB0 ADJUSTMENT RACK FOR WEAR, PN 160D123162-11. (REF: TO 1A-10C-3-1) 14GB0 ADJUSTMENT LOCK ASSEMBLY FOR OVERTRAVEL TOLERANCE. (REF: TO 1A-10C-2-27JG-6) 14GB0 CABLE CONDUIT ASSEMBLIES FOR PROPER INSTALLATION/SECURITY IN THE CAP AND BLOCK ASSEMBLY. (P/N 160D123065)(REF: TO 1A-10C-2-27JG-6) 14GB0 PROPER TORQUE ON RETENTION CAP SCREW ON THE RUDDER PEDAL CONTROL ADJUSTMENT CONTROL BOX. (REF: TO 1A-10C-2-27JG-6)
4.4. Replacements: The following fuselage repairs/replacements listed in Table 2 shall be accomplished on all SSI aircraft regardless of flight hours. ( Ref: TO 1A-10C-6)
Table 2. Flight control system repair/replacement requirements: Work Unit Repair/Replacement Code 14CCD BEARINGS, IN RT AND LT ROLL IDLER CRANK ASSEMBLY, FS 275.20, PN 160D122220. CHECK CRANK SUPPORT. (REF: TO 1A-10C-3-1) 14CCL BEARINGS, IN RH AND LH ROLL CABLE CRANK, FS 282.72, PN 160D120310, CHECK CRANK SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14GBZ BEARINGS, IN LH YAW CABLE CRANK FS 282.72, 160D120310, CHECK CRANK SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14ECN BEARINGS IN RH AND LH PITCH CABLE CRANK ASSEMBLY, FS 274.86, PN 160D121250. CHECK CRANK SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CCD BEARINGS, IN LH AND RH ROLL CABLE CRANK, FS 465.12, PN 160D222114. CHECK CRANK AND SUPPORT AND BUSHINGS. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14GBC BEARINGS, IN LT YAW CONTROL BEARING RETAINER ASSEMBLY, FUS. STA. 208.14, PN 160D123212-1. (REF: TO 1A-10C-3-1) 14GBK BEARINGS, IN RT YAW CONTROL BEARING RETAINER ASSEMBLY, FUS. STA. 208.14, PN 160D123212-1. (REF: TO 1A-10C-3-1) 14EAB BEARINGS, IN LT ELEVATOR MID AND OUTBOARD HINGES. (REF: TO 1A-10C-2-27JG-4 and 1A-10C-3-1) 14EAJ BEARINGS, IN LT ELEVATOR INBOARD AND OUTBOARD TAB HINGES. (REF: TO 1A-10C-2-27JG-4 and 1A-10C-3-1) 14EBB BEARINGS, IN RT ELEVATOR MID AND OUTBOARD HINGES. (REF: TO 1A-10C-2-27JG-4 and 1A-10C-3-1) 14EBJ BEARINGS, IN RT ELEVATOR INBOARD AND OUTBOARD TAB HINGES. (REF: TO 1A-10C-2-27JG-4 and 1A-10C-3-1) 14GBD LT BOLT, RUDDER CARRIAGE, PN 160D123127-11. (REF: TO 1A-10C-2-27JG-6) 14GBL RT BOLT, RUDDER CARRIAGE, PN 160D123127-11. (REF: TO 1A-10C-2-27JG-6) 14G11 SPRING, LT RUDDER PEDAL RETURN, PN 160D123146-11. (REF: TO 1A-10C-2-27JG-6) 14G22 SPRING, RT RUDDER PEDAL RETURN, PN 160D123146-11. (REF: TO 1A-10C-2-27JG-6) 14ECU PITCH FEEL CONTROL SPRINGS, PN 160D521116-11. (REF: TO 1A-10C-2-27JG-4)
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APPENDIX 5 – A-10C SCHEDULED STRUCTURAL INSPECTION (SSI)
5. LEGACY WING AIRCRAFT
5.1. For legacy wing aircraft receiving an Enhanced Wing Assembly IAW TCTO 1A-10C-520, contractor shall submit Form 202 requesting disposition of the removed legacy wing assembly.
5.1.1. If required, ensure the complete legacy wing assembly (including all flight controls) is returned to the supply system for storage.
5.1.2. Remove fuel foam from legacy wing assembly prior to returning wing to supply.
5.1.3. Do not plastic media blast flight controls, pods, etc.
5.1.4. Flight controls will be returned to supply upon removal – do not route for repair.
5.1.5. Ensure the same MLG torque arm fairings, strut fairing assemblies, aft door and mechanisms, and all attaching hardware from the “original” MLG and wings are shipped with each original wing set when returned to supply, or when the wing set is returned to supply after accomplishment of SSI requirements.
5.2. For legacy wing aircraft that will NOT be receiving a EWA IAW TCTO 1A-10C-520.
5.2.1. Remove the center wing wiring harness, inspect and repair as required, and reinstall.
5.2.2. Replace aluminum slat bell cranks with steel slat bell cranks if found.
5.2.3. Wing tank fuel foam shall be 100% replaced.
5.2.3.1. Foam shall be 100% replaced if aircraft records do not show 100% replacement in the last 12 years.
5.2.3.2. Upon 100% fuel foam replacement, annotate AFTO 95 as follows: “Wing tank fuel foam was 100% replaced on MM/DD/YYYY (MRT Transfer Date)”. Record IAW Appendix 3 of the PWS: A-10 Structural Component Serial Number Verification
5.2.4. Flight control surfaces (Flaps, Slats, and Decelerons) shall be inspected to determine type of flight controls installed.
5.2.4.1. Flight control surfaces not modified by TCTO 1A-10C-520 (part numbers beginning with “160”) shall be routed to back shops for repairs and weight/balance.
5.2.4.2. Flight control surfaces modified by TCTO 1A-10C-520 (part numbers beginning with “162”) do not require routing to back shop for repairs, repaint, or weight/balance.
5.2.5. Flight control system repair/replacements inspections listed in Tables 4-2 and 4-3 of Appendix 8 shall be accomplished on aircraft wings. Additional special inspections listed in Table 5-1 of Appendix 8 shall also be accomplished on all aircraft wings regardless of hours. (REF TO 1A-10C-6)
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5.3. Pylons, if installed, should be prepped, painted and stenciled (REF: TO 1A-10C-23-1 and TO 1-1-8).
6. EWA AIRCRAFT
6.1. The following requirements apply to aircraft that are inducted for SSI with an Enhanced Wing Assembly previously installed (aircraft modified by TCTO 1A-10C-520).
6.2. Flight control system special inspections listed in Table 3 shall be accomplished on aircraft wings. Flight control system repair/replacements listed in Table 4 shall also be accomplished on aircraft wings regardless of hours. (REF TO 1A-10C-6)
Table 3. EWA aircraft wing flight control system inspection requirements: Work Unit Special Inspection Code 14CD0 REMOVE AND INSPECT LT AND RT ROLL TRIM MECHANISM MAIN PIVOT SHAFT BUSHING (PN S5044-9-115), PLUG (PN 160D622220-19, 162D622220- 2007) AND SUPPORT (PN 160D622230, 162D622230). REPLACE AS REQUIRED. (REF:TO 1A-10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM BOLTS (PN 160D725151-11, 162D725151- 2001), BUSHINGS (PN 160D725160-11, -13, 162D725160-2005, -2001), AND CRANK ASSEMBLY (PN 160D725110-1, -5, 162D725110-1001). (REF: TO 1A- 10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM SHAFT (PN 160D725152-5, 162D725152- 2005). (REF: TO 1A-10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM BOLT (PN 160D725151-15), BUSHINGS (PN 160D725160-17, 162D725160-2007), AND CRANK ASSEMBLY (PN 160D725110-5, 162D725110-1003). (REF: TO 1A-10C-3-1) 14N00 REMOVE AND NDI LEADING EDGE SLAT STEEL BELLCRANKS, PN 160D627110-5 OR 162D627110-1001(REF:TO1A-10C-36 AND TO 1A-10C-3-1)
Table 4. EWA aircraft wing flight control system repair/replacement requirements: Work Unit Repair/Replacement Code 14CDE BEARINGS, IN LH ROLL CABLE CRANK, WS 30.62, PN 160D622110-1, 162D622110-1001 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDR BEARINGS, IN RH ROLL CABLE CRANK, WS 30.62, PN 160D622110-1, 162D622110-1003 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDY BEARINGS, IN LH ROLL CABLE CRANK, WS 167.00, PN 162D622120-1001, 160D622120 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDZ BEARINGS, IN RH ROLL CABLE CRANK, WS 167.00, PN 162D622120-1002, 160D622120 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDK BEARINGS, IN LH ROLL CABLE CRANK, WS 175.26, 160D622130-1, 162D622130-1001. INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) FISCAL YEAR 19 Page 64 of 101
14CDW BEARINGS, IN RH ROLL CABLE CRANK, WS 175.26, 160D622130-1, 162D622130-1001. INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14NCA LT SLAT ACTUATORS. (REF: TO 1A-10C-2-27JG-1) 14NCC RT SLAT ACTUATORS. (REF: TO 1A-10C-2-27JG-1) 14NCG LT SLAT RESTRICTORS. (REF: TO 1A-10C-2-27JG-1) 14NCK RT SLAT RESTRICTORS. (REF: TO 1A-10C-2-27JG-1) 14CDK BEARINGS, LH AILERON DRIVE TAB SHIFTER CRANK ASSEMBLY (PN 160D622325-1 or 162D622325-1001 and 160D622330-1 or 162D622330-1001 and 160D622321-1 or 162D622321-1001). (REF: TO 1A-10C-3-1) 14CDR BEARINGS, RH AILERON DRIVE TAB SHIFTER CRANK ASSEMBLY (PN 160D622325-1 or 162D622325-1001 and 160D622330-1 or 162D622330-1001 and 160D622321-1 or 162D622321-1001). (REF: TO 1A-10C-3-1) 14CDH SHAFT, LT AILERON SHIFTER MECHANISM PIVOT, W.S 200.40, (PN 162D622333-2001, 160D622333-13) (REF: TO 1A-10C-2-27JG-5) 14CDU SHAFT, RT AILERON SHIFTER MECHANISM PIVOT, W.S 200.40, (PN 162D622333-2001, 160D622333-13). (REF: TO 1A-10C-2-27JG-5)
6.3. If defects are identified on the center fuselage with limited access for repair, authorize removal of the Enhanced Wing Assembly to facilitate maintenance IAW TO 1A-10C-2-51JG-2. Prior to reinstallation of the Enhanced Wing Assembly, SSI W49 and F13 shall be performed on wing/fuselage attach lugs IAW TO 1A-10C-36.
6.4. Flight control surfaces (Flaps, Slats, and Decelerons) shall be inspected to determine type of flight controls installed.
6.4.1. Flight control surfaces not modified by TCTO 1A-10C-520 (part numbers beginning with “160”) shall be routed to back shops for repairs and weight/balance.
6.4.2. Flight control surfaces modified by TCTO 1A-10C-520 (part numbers beginning with “162”) do not require routing to back shop for repairs, repaint, or weight/balance.
6.5. Pylons, if installed, should be prepped, painted and stenciled (REF: TO 1A-10C-23-1 and TO 1-1-8).
6.6. Perform scuff sand, corrosion inspection and treatment, and repainting of the Enhanced Wing Assembly 100%.
6.6.1. The paint thickness shall not exceed a dry film thickness of 0.007-inch.
6.6.2. If a total coating failure is identified on the wing assembly, submit an AFMC 202 request for authorization to perform PMB de-painting, corrosion inspection and treatment, and repainting of Enhanced Wing Assembly.
6.7. For Enhanced Wing Assembly serial #’s 1-55, accomplish TCTO 1A-10C-568 for the inspection and replacement of incorrect wire harnesses, identification markers, and connector Reference Designator Indicators (RDIs). (Any such additional requirements will be over-and- above tasks.)
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APPENDIX 6 – ENHANCED WING ASSEMBLY (EWA)
SECTION PAGE
1. GENERAL …...... 67
1.1. Purpose …...... 67 1.2. General Requirements………………………………….……………….……………67
2. EWA INSTALLATION…………………………………….……………….…………….67
3. AIRCRAFT PAINT REQUIREMENTS…………………………….….………………..68
3.1. General Information ...... 68 3.2. Aircraft Parts Removals …...... 68 3.3. Flight Control Surfaces……………………………….…………….………………….68 3.4. Weight and Balance………………………………….…………….…………………..68 3.5. Lubrication……………………………………….………………….…………………..68 3.6. Sealant………………………………………………….………….……………………69 3.7. Water Break Test………………………………………………….….………………..69 3.8. Wet Tape Test…………………………………………………….……………………69 3.9. Gloss Meter Reading……………………………………………….………………….69
4. OPERATIONAL CHECKS……………………………………………………………….69
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APPENDIX 6 – ENHANCED WING ASSEMBLY (EWA)
1. GENERAL
1.1. Purpose
1.1.1. The purpose of this Appendix is to define the depot work requirements for installation of EWAs IAW TCTO 1A-10C-520, on A-10 aircraft with legacy wings installed and scheduled to receive a EWA. All additional work not included in this Appendix shall be limited to Critical Safety Item (CS). Any additional repairs outside TO limits shall first be approved in writing by the PCO or ACO.
1.2. General Requirements
1.2.1. Ensure complete removal of (old) wing assembly, to include flight controls, from the aircraft. The A10 SPO will provide the appropriate disposition of the entire wing assembly.
1.2.2. Review AFTO 95 for any additional inspection requirements. Submit AFMC Form 202 request for any items inspected that are outside of prescribed limits or for re-evaluation of any items requiring a 2,000 hour re-inspect cycle.
1.2.3. Replace fuel bladders as required when unserviceable.
1.2.4. Fuselage fuel foam will be 100% replaced unless aircraft records already indicate 100% replacement of fuselage fuel foam within the last 12 years.
1.2.4.1. Upon completion, annotate AFTO 95 to indicate that “Fuselage/wing tank fuel foam was 100% replaced on MM/DD/YYYY (MRT Transfer Date)”. Record IAW Appendix 3 of the PWS: A-10 Structural Component Serial Number Verification.
1.2.5. Replace ballistic foam (Void Filler) in all accessed areas unless previously CW with new coated foam IAW 1A-10C-3-1.
1.2.6. Replace all O-Rings and seals in the disturbed fuel systems.
1.2.7. If not previously accomplished, install 160K211101-1/-2 repair at FS365 IAW drawing 160K211101.
1.2.8. If 160J213011 (F4 Repair) and/or 264H213005 (F11 Repair) repair straps are installed, no further inspection is required until next SSI induction. If 160J213011 (F4 Repair) and/or 264H213005 (F11 Repair) repair straps are not installed perform SSI F4 and or F11 IAW TO 1A-10C-36 and even if no defects are found, repair straps shall be installed IAW TO 1A-10C-3.
2. EWA INSTALLATION
2.1. Install EWA IAW instructions provided in TCTO 1A-10C-520.
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APPENDIX 6 – ENHANCED WING ASSEMBLY (EWA)
2.2. As required by the aircraft schedule, perform the following TCTO
2.2.1. Install forward and aft fuel cell cavity drains IAW TCTO 1A-10C-554, if applicable (CLIN X026).
3. AIRCRAFT PAINT REQUIREMENTS
3.1. General Information
3.1.1. In conjunction with EWA install scuff sanding and paint of the fuselage will be the preferred paint option during EWA install to maintain a consistent finish over the entire aircraft. EWA will be received by contractor already in a primed condition. Fuselage PMB for a EWA install will only be accomplished if scheduled in conjunction with an 8YC, SSI, or via AFTO Form 103 request.
3.1.2. Prepare and perform aircraft wash, scuff sanding, corrosion treatment, masking, repainting, special coatings application, and marking placement for the A-10C aircraft. All work will be accomplished IAW TOs 1A-10C-23, 1-1-691, 1-1-3, 1-1-8, 1A-10C-27JG series Job Guides, 1A-10C-3-1, and 1A-10C-2-1-1.
3.2. Aircraft Parts Removals
3.2.1. Removal of specific parts prior to de-paint must be complied with IAW 1A-10C-23 any exceptions must be coordinated through ACO. Parts removed from aircraft will be scuff sanded and cleaned IAW TOs 1-1-691, 1A-10C-23, and 1A-10C-3-1. Paint all removed parts IAW TOs 1A-10C-3-1, 1-1-691, 1-1-8, 1A-10C-23 and applicable engineering drawings.
3.3. Flight Control Surfaces
3.3.1. Flaps, Slats, and Decelerons will be turned into supply. New flight controls are provided in TCTO 1A-10C-520 kit
3.3.2. Rudders will be replaced 100% on all programs and will be turned into supply upon removal.
3.3.3. Elevators will continue removal/route for repair/paint/weight & balance/install. Once supportability is confirmed elevators will be replaced 100% on all programs and will be turned into supply upon removal.
3.4. Weight and Balance
3.4.1. After painting, perform weight and balance on those flight control surfaces that require it (prior to installation) IAW TO 1A-10C-3-1, Chapter 1. After painting the aircraft, perform weight and balance of the entire aircraft IAW TO 1A-10C-5.
3.4.2. Flight controls delivered with Enhanced Wing Assembly shall be already painted
3.5. Lubrication: Perform lubrication of aircraft as required IAW TO 1A-10C-6WC-7.
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APPENDIX 6 – ENHANCED WING ASSEMBLY (EWA)
3.6. Sealant: Remove and replace all deteriorated, damaged, loose and missing sealant around all exterior seams and permanent skin panel joints IAW TOs 1A-10C-23, 1A-10C-3-1, and 1-1- 691.
3.7. Water Break Test: Water break tests shall be conducted on representative areas to be treated immediately prior to the application of corrosion removal pre-paint solutions as directed in TO 1-1-8, Section 3.
3.8. Wet Tape Test: Perform wet tape test to determine coating adhesion IAW TO 1-1-8.
3.9. Gloss Meter Reading: Perform gloss meter reading IAW TO 1-1-8.
4. OPERATIONAL CHECKS
4.1. Perform rigging and operational checks on all removed/reinstalled flight controls IAW TOs 1A-10C-2-27JG-1, 2, 3, 4, 5, and 6.
4.2. Perform FCF on aircraft as required by 1A-10C-6.
FISCAL YEAR 19 Page 69 of 101
APPENDIX 7 – EIGHT YEAR CORROSION (8YC)
SECTION PAGE
1. GENERAL ...... ……..71
1.1. Purpose ...... 71 1.2. General Requirements ...... 71
2. PMB DEPAINTING, CORROSION INSPECTION AND TREATMENT, AND REPAINTING REQUIREMENTS ...... 72
2.1. General Information ...... 72 2.2. Special Inspection Requirement During Paint ...... 72 2.3. Aircraft Parts Removal ...... 72 2.4. Weight and Balance ...... 73 2.5. Lubrication ...... 73 2.6. Sealant...... 73 2.7. Water Break Test ...... 73 2.8. Wet Tape Test ...... 73 2.9. Gloss Meter Reading ...... 73
3. CORROSION INSPECTION REQUIREMENTS...... 73
3.1. General ...... 73 3.2. Fuel Cell Cavity Inspection and Repair...... 73 3.3. Left and Right Wing Fuel Adapter Port Inspection (WS85) ...... 74 3.4. WS 90 to WS 106 (Hell Hole) Inspection (legacy wing assemblies) ...... 74 3.5. Wing Fuel Tank Access Opening Inspection (legacy wing assemblies) ...... 74
4. TCTO REQUIREMENTS ...... 74
5. OPERATIONAL CHECKS ...... 74
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APPENDIX 7 – EIGHT YEAR CORROSION (8YC)
1. GENERAL
1.1. Purpose
1.1.1. The purpose of this Appendix is to define the specific requirements for completion of 8 year corrosion inspection on all A-10 aircraft requiring 8YC. All additional work not included in this Appendix shall be limited to Critical Safety Item (CSI). Any additional repairs outside TO limits shall first be approved in writing by the PCO or ACO.
1.2. General Requirements
1.2.1. Review AFTO 95 for any additional inspection requirements. Submit AFMC Form 202 request for any items inspected that are outside of prescribed limits or for re-evaluation of any items requiring a 2,000 hour re-inspect cycle.
1.2.2. For aircraft receiving Enhanced Wing Assembly IAW TCTO 1A-10C-520, ensure complete wing assembly (including all flight controls) is returned to supply for storage.
1.2.2.1. Do not Plastic Media Blast flight controls, pods, etc. on old wing assembly prior to turn-in.
1.2.2.2. Remove Fuel Foam from old center wing assembly prior to returning old wing to supply.
1.2.3. For .8.2.2 PCW TCTO 1A-10C-520, perform scuff sand, corrosion inspection and treatment, and repainting of the Enhanced Wing Assembly.
1.2.3.1. The paint thickness shall not exceed a dry film thickness of 0.007-inch.
1.2.3.2. If a total coating failure is identified on the wing assembly, submit an AFMC 202 request for authorization to perform PMB De-painting, Corrosion Inspection and Treatment, and Repainting of the Enhanced Wing Assembly.
1.2.4. Replace fuel bladders as required when unserviceable.
1.2.5. Fuselage Fuel Foam will be 100% replaced unless aircraft records already indicate 100% replacement of fuselage fuel foam within the last 12 years.
1.2.5.1. If not receiving a EWA wing IAW TCTO 1A-10C-520, wing tank fuel foam will be 100% replaced unless aircraft records show 100% replacement of wing tank foam within the last 12 years.
1.2.5.2. Upon completion, annotate AFTO 95 to indicate that “Fuselage/wing tank fuel foam was 100% replaced on MM/DD/YYYY (MRT Transfer Date)”. .
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APPENDIX 7 – EIGHT YEAR CORROSION (8YC)
1.2.6. Replace all ballistic foam (Void Filler) in all accessed areas IAW TO 1A-10C-3-1.
1.2.7. Replace all O-Rings and seals in the disturbed fuel systems.
1.2.8. If 160J213011 (F4 Repair) and/or 264H213005 (F11 Repair) repair straps are installed, no further inspection is required until next SSI induction. If 160J213011 (F4 Repair) and/or 264H213005 (F11 Repair) repair straps are not installed perform SSI F4 and or F11 IAW TO 1A-10C-36 and even if no defects are found, repair straps shall be installed IAW TO 1A-10C-3.
1.2.9. For aircraft which do not have FS524 repair straps installed, Install FS 524 straps (PN 160J213011-11 and -12).
1.2.9.1. Install only on those A/C that do not have the Hogback repair. OML straps P/N 264J213001-15/-16 will be installed in this area during Hogback.
2. PMB DEPAINTING, CORROSION INSPECTION AND TREATMENT, AND REPAINTING REQUIREMENTS
2.1. General Information: Prepare and perform aircraft wash, paint stripping, corrosion treatment, masking, priming, repainting, special coatings application, and marking placement for the A-10C aircraft. All work will be accomplished IAW TOs 1A-10C-23, 1-1-691, 1-1-3, 1-1-8, 1A-10C-27JG series Job Guides, 1A-10C-3-1, and 1A-10C-2-1-1.
2.2. Special Inspection Requirement during Paint
2.2.1. Inspect for loose jo-bolts in the leading edge of the upper skin outer wing panel from WS 110 through WS 249. Replace all jo-bolts that are loose IAW TO 1A-10C-3-1.
2.3. Aircraft Parts Removal
2.3.1. Removal of specific parts prior to de-paint must be complied with IAW 1A-10C-23, any exceptions must be coordinated through ACO. Parts removed from aircraft will be de-painted and cleaned IAW TOs 1-1-691, 1A-10C-23, and 1A-10C-3-1. Remove corrosion, chemically treat, prime and paint all removed parts IAW TOs 1A-10C-3-1, 1-1-691, 1-1-8, 1A-10C-23 and applicable engineering drawings.
2.3.2. Flight Controls are removed/routed to back shop/paint/weight & balance and installed on aircraft.
2.3.2.1. Rudders will be replaced 100% on all programs and will be turned into supply upon removal - do not route for repair.
2.3.2.2. Elevators will continue removal/route for repair/paint/weight & balance/install. Once supportability is confirmed elevators will be replaced 100% on all programs and will be returned to supply upon removal.
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APPENDIX 7 – EIGHT YEAR CORROSION (8YC)
2.3.2.3. Incoming Inspection required on Flight Controls Surfaces (Flaps, Slats, Decelerons) to determine type of flight controls installed, not modified by TCTO 1A-10C-520 or modified by TCTO 1A-10C-520.
2.3.2.3.1. Aircraft not modified by TCTO 1A-10C-520 (part numbers beginning with “160”) will require routes to back shop for repairs, repaint and weight/balance.
2.3.2.3.2. Aircraft modified by TCTO 1A-10C-520 (part numbers beginning with “162”) will not require routes to back shop for repairs, repaint and weight/balance.
2.4. Weight and Balance
2.4.1. After painting, perform weight and balance on those flight control surfaces that require it (prior to installation) IAW TO 1A-10C-3-1.
2.4.2. After painting the aircraft, perform weight and balance IAW TO 1A-10C-5.
2.5. Lubrication: Perform lubrication of aircraft as required IAW TO 1A-10C-6WC-7.
2.6. Sealant: Remove and replace all deteriorated, damaged, loose and missing sealant around all exterior seams and permanent skin panel joints IAW TOs 1A-10C-23, 1A-10C-3-1, and 1-1-691.
2.7. Water Break Test: Water break tests shall be conducted on representative areas to be treated immediately prior to the application of corrosion removal pre-paint solutions as directed in TO 1-1-8.
2.8. Wet Tape Test: Perform wet tape test to determine coating adhesion IAW TO 1-1-8.
2.9. Gloss Meter Reading: Perform gloss meter reading IAW TO 1-1-8.
3. CORROSION INSPECTION REQUIREMENTS
3.1. General
3.1.1. Perform a visual inspection for corrosion and defects in all areas of work associated with these inspections IAW TO 1A-10C-23 and 1A-10C-3-1 and repair as necessary.
3.2. Fuel Cell Cavity Inspection and Repair
3.2.1. Remove forward and aft fuel bladders. Visually inspect, repair and treat fuselage forward and aft fuel bladder cavity structures for corrosion and cracks IAW TOs 1A-10C-3-1 and 1A- 10C-36.
3.2.2. NDI forward fuel cavity floor at boost pump mount flange for cracks and corrosion IAW 1A-10C-36.
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APPENDIX 7 – EIGHT YEAR CORROSION (8YC)
3.3. Left and Right Wing Fuel Adapter Port Inspection (WS85)
3.3.1. Remove fuel adapter ports (P/N 457-226) from left and right wing center panel.
3.3.2. Inspect upper skin area around and under adapter and fuel adapter port hole for corrosion. Repair and treat as necessary IAW TO 16C1-30-10-3 for thick skin wings
3.4. WS 90 to WS 106 (Hell Hole) Inspection (legacy wing assemblies)
3.4.1. Remove panels W17 and W18 and door assembly (P/N 160D611309) IAW TO 1A-10C-2-51JG-5.
3.4.2. Inspect lower forward and aft skin and all lower spar caps for corrosion and cracking IAW TO 1A-10C-23. Repair and treat as necessary.
3.5. Wing Fuel Tank Access Opening Inspection (legacy wing assemblies)
3.5.1. Remove panels W1 and W2 and fuel tank access doors W3, W4, W5, W6, W7, W8, W9, and W10 from lower aft wing IAW TO 1A-10C-2-51JG-5.
3.5.2. Inspect fuel tank access openings and seal surfaces for corrosion. Repair and treat as necessary IAW 1A-10C-3-1.
4. TCTO REQUIREMENTS
4.1. As required by the aircraft schedule, perform the following TCTO
4.1.1. Install forward and aft fuel cell cavity drains IAW TCTO 1A-10C-554 if applicable (CLIN X026)
5. OPERATIONAL CHECKS
5.1. Perform operational checks on all removed/reinstalled flight controls IAW TOs 1A-10C-2- 27JG-1, 2, 3, 4, 5, and 6.
5.2. Perform FCF on aircraft as required by 1A-10C-6CF-1.
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APPENDIX 8 – LEGACY WING SSI
SECTION PAGE
1. GENERAL...... 76
1.1. Purpose……...... 76
2. REQUIREMENTS ………………...... 76
3. WING ASSEMBLY REQUIREMENTS ...... 76
3.1. General ...... 76
4. ADDITIONAL INSPECTIONS...... 90
4.1. Systems ...... 90 4.2. Phased Inspection Tasks ...... 90 4.3. Flight Control Systems Inspections/Replacements ...... 90 4.4. Additional Flight Control Systems Inspections …………………..……………….91
5. SPECIAL INSPECTION TASKS ...... 92
5.1. Special Inspections..…………………….……………………………………..…....92
FISCAL YEAR 19 Page 75 of 101
APPENDIX 8 – LEGACY WING SSI
1. GENERAL
1.1. Purpose
1.1.1. The purpose of this Appendix is to define the responsibilities of the contract depot facility involved with the A-10 SSI Scheduled Structural Inspection Program (including wing rework, inspections and repairs). All additional work not included in this Appendix shall be limited to SOF. Any additional repairs outside TO limits shall first be approved in writing by the ACO.
1.1.2. Unless specifically identified as an over-and-above task, all tasks in this Appendix are to be completed as part of the negotiated work package. In general, repair or replace tasks denoted “as needed” or “as required” will be accomplished using over and above work procedures.
2. REQUIREMENTS
2.1. Perform a visual inspection for corrosion and defects in all areas of work associated with these inspections IAW TO 1A-10C-23 and 1A-10C-3-1.
2.2. Ensure the same MLG torque arm fairings, strut fairing assemblies, aft door and mechanisms, and all attaching hardware from the “original” MLG and wings are removed from the original MLG and shipped with each original wing set when turned into supply for SSI, and when the wing set is sold to supply after accomplishment of SSI requirements.
2.3. Review AFTO 95 for any additional inspection requirements. Any such additional requirements will be over-and-above tasks.
2.4. Perform the SSI inspections as outlined in the tables below.
3. WING ASSEMBLY REQUIREMENTS
3.1. General
3.1.1. Follow the wing portion of the inspection plan as outlined in SSI Table 3-1, Table 3-2, and Table 3-3 as briefly described below. Perform repairs, if necessary, IAW the appropriate TOs 16C1-30-10-3, 16C1-30-12-3, 1A-10C-3, and 1A-10C-3-1. Resulting repairs will be over-and- above tasks.
3.1.2. Perform the inspections specified in Paragraphs 3.1.3, and 3.1.4 within this document. Submit AFMC Form 202 to request the newest revision of TO’s for each serial number of wing panel.
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APPENDIX 8 – LEGACY WING SSI
3.1.3. Wing Center Panel (WCP) Scheduled Structural Inspection (SSI). The Scheduled Structural Inspection (SSI) program requires Nondestructive Inspection (NDI) of fatigue critical and corrosion prone areas. Early detection and repair of defects extends the service life of the WCP and ensures safety of flight.
3.1.3.1. Perform scheduled structural inspections as specified in Table 3-1 and Table 3-3 in accordance with TO 1A-10C-36.
Table 3-1. SSI Wing Center Panel: SSI TO 1A-10C-36 Title and Inspection (WCP) Number W1 SSI INSPECTION W1 - WING CENTER PANEL (WCP) LH/RH WS 23 LOWER FORWARD WING ATTACH LOCATION - EDDY CURRENT. W2 SSI INSPECTION W2 - WING CENTER PANEL (WCP) LH/RH WS 23 LOWER FORWARD WING ATTACH LOCATION - EDDY CURRENT W3 SSI INSPECTION W3 - WING CENTER PANEL (WCP) LH/RH WS 23 LOWER AFT WING ATTACH LOCATION - EDDY CURRENT W4 SSI INSPECTION W4 - WING CENTER PANEL (WCP) LH/RH WS 23 LOWER AFT WING ATTACH LOCATION - EDDY CURRENT W5 SSI INSPECTION W5 - WING CENTER PANEL (WCP) FUEL TRANSFER HOLES, LOWER FORWARD STRINGERS, CENTER AND AUXILIARY SPAR CAPS, LH/RH WS 0.00 - 90.00 - EDDY CURRENT W6 SSI INSPECTION W6 - WING CENTER PANEL (WCP) PYLON STUD HOLES AT CENTER SPAR LH/RH WS 0, 23, 66 LOWER SKIN - EDDY CURRENT W7 SSI INSPECTION W7 - WING CENTER PANEL (WCP) CENTER SPAR WEB FUEL TUBING HOLES AT LH/RH WS 46.50 - EDDY CURRENT W8 SSI INSPECTION W8 - WING CENTER PANEL (WCP) LOWER AFT WING SKIN TRAILING EDGE FROM LH/RH WS 23.00 TO WS 90.00 – EDDY CURRENT W9 SSI INSPECTION W9 - WING CENTER PANEL (WCP) LOWER AUX SPAR ATTACH HOLES TO AFT SKIN FROM LH/RH WS 44.50 TO WS 110.00 – EDDY CURRENT W10 SSI INSPECTION W10 THICK SKIN WCP - WING CENTER PANEL (WCP) LOWER AUX SPAR CAP TO AFT SKIN ATTACH HOLES FROM LH/RH WS 00.00 TO WS 44.50 - EDDY CURRENT W11 SSI INSPECTION W11 - WING CENTER PANEL (WCP) LOWER WING SKIN AT MIDSPAR, ATTACH HOLES TO LOWER SKIN AT LH/RH WS 66.00 TO 110.00 - EDDY CURRENT W12 SSI INSPECTION W12 - WING CENTER PANEL (WCP) FRONT SPAR WEB, LH/RH WS 00.00 TO WS 04.00 - EDDY CURRENT W13 SSI INSPECTION W13 THICK SKIN WCP - WING CENTER PANEL (WCP) LOWER CENTER SPAR CAP TO LOWER COVER ATTACH FASTENERS AND HOLES, LH/RH WS 28.00 - EDDY CURRENT W14 SSI INSPECTION W14 - WING CENTER PANEL (WCP) FORWARD LOWER SKIN, LH/RH WS 44.00 TO WS 90.00 - EDDY CURRENT W15 SSI INSPECTION W15 - WING CENTER PANEL (WCP) LOWER AFT WING TO LOWER REAR SPAR ATTACHMENT FASTENERS FROM LH/RH WS 44.50 TO WS 90.00 - EDDY CURRENT W17 SSI INSPECTION W17 - WING CENTER PANEL (WCP) DRAIN HOLES, LH/RH WS 90.00 - WS 110.00 - EDDY CURRENT W18 SSI INSPECTION W18 - WING CENTER PANEL (WCP) LOWER FRONT SPAR CAP AND WEB, LH/RH WS 90.00 - WS 97.00 - EDDY CURRENT W21 SSI INSPECTION W21 - WING CENTER PANEL (WCP) LOWER FORWARD SKIN AT WS 00.00 - EDDY CURRENT FISCAL YEAR 19 Page 77 of 101
W23(1) SSI INSPECTION W23(1) - CENTER WING SPLICE FITTING AT LH/RH WS 110.00 – EDDY CURRENT W24(1) SSI INSPECTION W24(1) - WING CENTER PANEL (WCP) LOWER SPLICE ANGLE, CENTER SPAR CAP, AND SKIN/STRINGER HOLES IN VICINITY OF LH/RH WS 110.00 - EDDY CURRENT W25(1) SSI INSPECTION W25(1) - WING CENTER PANEL (WCP) LOWER FRONT WING SKIN INTEGRAL STRINGER AND SPLICE ANGLES LH/RH WS 98.00 AND WS 101.00 - EDDY CURRENT W26(1) SSI INSPECTION W26(1) - WING CENTER PANEL (WCP) SPLICE TABS AT FRONT SPAR, CENTER SPAR AND REAR SPAR LH/RH WS 110.00 - EDDY CURRENT W27 SSI INSPECTION W27- WING CENTER PANEL (WCP) CENTER SPAR WEB ACCESS DOOR CUTOUTS AND ACCESS DOORS (A, B, C, D) FROM LH/RH WS 110.00 - WS 110.00 - EDDY CURRENT W29 SSI INSPECTION W29 - WING CENTER PANEL (WCP) LOWER FWD WING SKIN AT LH/RH WS 90.00 - EDDY CURRENT W30 SSI INSPECTION W30 - WING CENTER PANEL (WCP) REAR SPAR WEBS AND LOWER REAR SPAR CAPS AT LH/RH WS 44.00 - WS 90.00 - EDDY CURRENT • If a repair is present within the inspection area, perform W30R. W30R SSI INSPECTION W30 REPAIRED - WING CENTER PANEL (WCP) REAR SPAR WEBS, LOWER REAR SPAR CAPS, AND REPAIR DOUBLER(S) AT LH/RH WS 44.00 TO WS 90.00 - EDDY CURRENT W31A SSI INSPECTION W31A - WING CENTER PANEL (WCP), CENTER SPAR CAP REPAIR AT LH/RH WS 0 - 29.50 - EDDY CURRENT • SSI W31A was designed to a nominal installation of the 264J611306 repair. If the fastener pattern or required follow-on repair configuration does not match the configuration provided in SSI W31A, contact A-10 Engineering via AFMC Form 202 with annotated images of the non-conformances attached. Engineering will provide inspection requirements for non-conformances on a case-by-case basis due to the wide variability in repair configurations.
W31B SSI INSPECTION W31B - CENTER SPAR LOWER CAP VERTICAL FLANGE WS 23.00 - 90.00 - EDDY CURRENT W32 SSI INSPECTION W32 THICK SKIN WCP - WING CENTER PANEL (WCP) FRONT SPAR WEB AND LOWER FRONT SPAR CAP FROM LH/RH WS 23.00 TO WS 90.00 - EDDY CURRENT W34 SSI INSPECTION W34 - WING CENTER PANEL (WCP) TRAILING EDGE SKIN TO REAR SPAR AT LH/RH WS 97.00 - EDDY CURRENT W35A SSI INSPECTION W35A - WING CENTER PANEL (WCP) RIB LH/RH AT WS 90.00 - EDDY CURRENT W35B SSI INSPECTION W35B - WING CENTER PANEL (WCP) MAIN LANDING GEAR TRUNNION MOUNTING HOLES AT LH/RH WS 90.00 - 110.00 - EDDY CURRENT W36 SSI INSPECTION W36 - WING CENTER PANEL (WCP) FUEL ACCESS PANEL FLANGES AND REINFORCEMENT RINGS LH/RH WS 90.00 - WS 90.00 - EDDY CURRENT W37 SSI INSPECTION W37 - WING CENTER PANEL (WCP) FRONT SPAR WEB ELECTRICAL CONNECTOR PORT CUTOUT AND DOUBLER, LH/RH WS 44.50 TO WS 52.30 - EDDY CURRENT W39 SSI INSPECTION W39 - WING CENTER PANEL (WCP) UPPER SKIN, STRINGERS/CENTER SPAR CAP FUEL VENT HOLES FROM WS 00.00 TO LH/RH WS 90.00 - EDDY CURRENT • If a repair is present within the inspection area, perform W39R.
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W39R SSI INSPECTION W39 REPAIRED - WING CENTER PANEL (WCP) UPPER SKIN, STRINGERS/CENTER SPAR CAP FUEL VENT HOLES FROM WS 00.00 TO LH/RH WS 90.00 - EDDY CURRENT W40 SSI INSPECTION W40 – LH AND RH WING CENTER PANEL FORWARD SPAR WEBS, P/Ns 160D611301 AND 160D611304 FROM WS 90.00 TO WS 110.00 – EDDY CURRENT • If a repair is present within the inspection area, perform W40R. W40R SSI INSPECTION W40 REPAIRED - WING CENTER PANEL (WCP) FRONT SPAR WEBS, LH/RH WS 90.00 TO WS 110.00 - EDDY CURRENT W42 SSI INSPECTION W42 - WING CENTER PANEL (WCP) FRONT SPAR AT LH/RH WS 23.00 TO WS 44.50 - EDDY CURRENT W49 SSI INSPECTION W49 - FWD AN AFT WING TO FUSELAGE FITTING LUGS AT LH/RH WS 23.00 - EDDY CURRENT W51 SSI INSPECTION W51 - WING CENTER PANEL (WCP) UPPER AND LOWER SPLICE FITTING VERTICAL FLANGES AT LH/RH WS 110.00 - EDDY CURRENT W52 SSI INSPECTION W52 - INBOARD AND OUTBOARD FLAP TRACKS LH/RH AT WS 38.00 AND WS 110.00 - EDDY CURRENT W53 SSI INSPECTION W53 - WING SLAT SUPPORT RIB ASSEMBLIES BELLCRANK AND IDLER PIVOT HOLES AT LH/RH WS 40.50, WS 44.50, WS 68.00 AND WS 72.00 - EDDY CURRENT W54 SSI INSPECTION W54 - WING CENTER PANEL (WCP) UPPER FRONT SPAR CAP AND SPAR WEB AT LH/RH WS 42.50 AND WS 70.00 - EDDY CURRENT W57 SSI INSPECTION W57 - WING CENTER PANEL (WCP), UPPER AFT SKIN DOME NUT PLATE FASTENER HOLES WS 28.00 - WS 33.00 - EDDY CURRENT
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APPENDIX 8 – LEGACY WING SSI
3.1.4. Wing Outer Panel (WOP) Scheduled Structural Inspection (SSI). The Scheduled Structural Inspection (SSI) program requires Nondestructive Inspection (NDI) of fatigue critical and corrosion prone areas. Early detection and repair of defects extends the service life of the WOP and ensures safety of flight.
3.1.4.1. Perform scheduled structural inspections as specified in Table 3-2 in accordance with TO 1A-10C-36.
Table 3-2. SSI Outer Wing Panel: SSI TO 1A-10C-36 Title and Inspection (OWP) Number W19, SSI INSPECTION W19 AND W20 - OUTER WING PANEL (OWP), LOWER WING W20 SKIN AT LH/RH WS 118.00 AND WS 126.00 - EDDY CURRENT W23(2) SSI INSPECTION W23(2) - OUTER WING SPLICE FITTINGS AT LH/RH WS 110.00 - EDDY CURRENT W24(2) SSI INSPECTION W24(2) - OUTER WING PANEL (OWP), LOWER CENTER SPAR CAP, STRINGERS, SPLICE ANGLES, SPLICE FITTING, AND WING SKIN ATTACH HOLES LH/RH WS 110.00 - EDDY CURRENT W24(3) SSI INSPECTION W24(3) - OUTER WING PANEL, (OWP) UPPER FRONT, CENTER, AND REAR SPAR CAPS, SPLICE ANGLE AT STRINGERS, WS 110 SPLICE FITTING, AND WING SKIN ATTACH HOLES LH/RH WS 110.00 - EDDY CURRENT W25(2) SSI INSPECTION W25(2) - OUTER WING PANEL (OWP) LOWER FORWARD WING SKIN, INTEGRAL STRINGER, AND SPLICE ANGLES LH/RH WS 117.00 AND WS 122.00 - EDDY CURRENT W26(2) OUTER WING PANEL (OWP) SPLICE TABS AT FRONT SPAR, CENTER SPAR, AND REAR SPAR LH/RH WS 110.00 W28(1) SSI INSPECTION W28(1) - OUTER WING PANEL (OWP) LOWER SKIN STRINGERS LH/RH WS 135.00 - EDDY CURRENT W28(2) SSI INSPECTION W28(2) - OUTER WING PANEL (OWP) LOWER SKIN AT FRONT SPAR FROM LH/RH WS 172.00 TO WS 187.00 - EDDY CURRENT
W28(3) SSI INSPECTION W28(3) - OUTER WING PANEL (OWP) LOWER SKIN FROM LH/RH WS 127.00 TO WS 143.00 - EDDY CURRENT W33R SSI INSPECTION W33 REPAIRED - OUTER WING PANEL (OWP) CENTER SPAR WEB AND DOUBLER, LH/RH WS 110.00 TO WS 144.00 - EDDY CURRENT W45 SSI INSPECTION W45 - OUTER WING PANEL (OWP) LOWER WING REAR SPAR CAP AND REAR WEB AT LH/RH WS 118.00 - WS 126.00 - EDDY CURRENT W46 SSI INSPECTION W46 - OUTER WING PANEL (OWP) PYLON STUD HOLES IN CENTER SPAR CAPS AT LH/RH WS 144.00 - EDDY CURRENT W50 SSI INSPECTION W50 - OUTER WING PANEL (OWP) FRONT SPAR CAP AND WEB, LH/RH WS 110.00 TO WS 135.00 - EDDY CURRENT W56 SSI INSPECTION W56 - OUTER WING PANEL, LEADING EDGE RIB AT WS 121.00 - EDDY CURRENT
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APPENDIX 8 – LEGACY WING SSI
Table 3-3. Additional Inspection Requirements: Noun Requirement Repair-Replace-Inspect Visually inspect hydraulic tubing TO 1A-10C-3-1, paragraph 9.16, for chafing, dents, damage, or REPAIR OR REPLACEMENT OF 21-6- signs of leakage. Repair 9 TUBING. identified defects.
Splice repairs of hydraulic tubing TO 1A-10C-2-29MS-1, Chapter 3, shall not be located between WS HYDRAULIC TUBING INSTALLATION 28-RH and WS 28-LH. AND CLEARANCE REQUIREMENTS
Hydraulics
Visually inspect clearance TO 1A-10C-2-24MS-1, Chapter 3, between wiring and hydraulic CLEARANCE REQUIREMENTS FOR tubing. Repair identified defects ELECTRICAL HARNESS to prevent chafing. INSTALLATIONS
TO 1-1A-14, Section 010 00, HARNESS INSTALLATION Visually inspect the integral fuel TO 1-1-3, Chapter 6, INTEGRAL tank from WS 90-RH to 90-LH for TANKS contaminants such as water or microbial growth, sediment, foreign objects, top coat peeling, structural or fastener damage and overall sealant condition.
Clean and repair identified TO 16C1-30-10-3, paragraph 5.3.5, defects. INSPECTION FOR FUEL TANK Fuel System REPAIRS
Perform a pressure leak test of TO 16C1-30-10-3, paragraph 9.2, AIR the integral fuel tank to verify tank PRESSURE LEAK-TESTING integrity. PROCEDURES or paragraph 9.2.2, VACUUM LEAK TESTING PROCEDURE or paragraph 9.2.3, FLUID PRESSURE LEAK TESTING PROCEDURE
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Visually inspect and clean fuel TO 1A-10C-2-28MS-1, Chapter 6, system components: INSPECTION AND CLEANING OF AIRFRAME FUEL SYSTEM 1. Pumps 2. Probes 3. Shutoff valves 4. Pilot valves 5. Fuel lines 6. Couplings and fittings 7. Boost pump covers 8. Fuel quantity harness
Identify dents, nicks, scratches, cracking, and contamination. Repair or replace if defects are identified.
Remove and visually inspect fuel TO 1-1A-14, Section 004 01, probes and fuel quantity harness AIRCRAFT WIRING SYSTEM assembly. INSPECTION
Verify the pig tails on fuel probe- REF DWG 160C950906-25 electrical leads have required splices made outside of the fuel tank or conduit.
Verify the length of fuel probe electrical leads are 12-inches (minimum) outside of the fuel tank.
Visually inspect the wiring for fuel pilot valves and shutoff valves. Wires shall be cut long enough to accommodate a splice outside of the conduit.
Visually inspect the components TO 1A-10C-3-1, paragraph 1.113, common to the aircraft flight DETECTION OF FAULTY BEARINGS. controls (i.e. slat system, flap system...)
Remove and replace damaged TO 1A-10C-3-1, paragraph 1.114, Flight Controls bearings and bushings. REPLACEMENT OF BEARINGS RETAINED BY CIRCUMFERENTIAL Remove and replace damaged LINE STAKING IN FLIGHT CONTROL flight control components. COMPONENTS INCLUDING BELL CRANKS, CRANKS, IDLERS, AND RETAINERS.
Visually inspect electrical wiring TO 1A-10C-2-24MS-1, Chapter 3, and components along the CLEARANCE REQUIREMENTS FOR Electrical leading and trailing edge of the ELECTRICAL HARNESS INSTALLATIONS
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wing. If defects are indicated, repair or replace.
Ensure wire harness clamps are TO 1-1A-14, Section 010 00, secure and retaining. HARNESS INSTALLATION Installations hardware are not deteriorated, corroded, loose or REF DWGS: missing and are properly torqued. 160D641101 Replace as necessary. 160D641102 160D641103 160D641104
Check electrical connectors, REF PRECISION ENGAGEMENT grounding receptacles, and other Drawing: 262A696 components for security, damage, and cleanliness.
Perform continuity checks on wing electrical harnesses to verify serviceability.
Visually inspect the leading edge for installation of precision engagement wiring harness assembly.
If the precision engagement wiring harness assemblies are not installed, install harnesses IAW installation drawing.
Visually inspect the leading edge DWG 160D611501, LEADING EDGE rib assemblies for evidence of INSTL CENTER PANEL previous repairs, oversized bushings or structural defects. Leading Edge –
Ribs If previous repairs, oversized
bushings, or structural defects are detected, remove and replace the leading edge rib.
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Visually inspect the leading edge TO 16C1-30-10-3, paragraph 7.16.1, skin assemblies for evidence of REMOVAL/INSTALLATION previous repairs or damage. PROCEDURES FOR THE LEADING EDGE SKIN ASSEMBLY (LH/RH) NOTE: Cracks may be located in the upper skin at WS 34.16, WS 50.76, WS 56.35, WS 62.00, or WS 79.28.
If previously repaired or Leading Edge – damaged, remove and replace Skins the leading edge skin assembly.
If a replacement asset is not TO 1A-10C-3-1, Chapter 9, TYPICAL available, repair the leading edge STRUCTURAL REPAIRS AND skin assembly. Document wing APPLICATIONS serialized records (AFTO 95) to direct replacement of the repaired skin at the next scheduled structural inspection.
Remove and replace the Slat TO 16C1-30-10-3, paragraph 3.2.12, Fences (100%). REMOVAL OF SLAT FENCE, LH/RH.
Slat Fences TO 16C1-30-10-3, paragraph 8.2.5, INSTALLATION OF SLAT FENCE, LH/RH.
Remove and visually inspect the TO 16C1-30-10-3, paragraph 3.3.1, Slat Cylinder Support Fittings. REMOVAL OF SLAT CYLINDER SUPPORT FITTING.
Replace aluminum-Slat Actuator TO 16C1-30-10-3, paragraph 5.3.7, Support Fittings (REF 160D6271 INSPECTION OF SLAT CYLINDER Slat Cylinder l l-l) with steel-Slat Actuator SUPPORT FITTING Support Fittings Support Fittings (REF 160D6271 TO 16C1-30-10-3, paragraph 8.2.1, l l-5/-7). INSTALLATION OF SLAT CYLINDER SUPPORT FITTING. Replace damaged Slat Cylinder Support Fittings.
Visually inspect the upper- TO 16C1-30-10-3 forward skin (upper and lower surfaces, WS 85-RH/LH) at the fuel adaptor ports for corrosion Upper-Skin and previous blends. (WS 85-RH/LH) Repair identified defects.
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Visually inspect the upper- TO 16C1-30-10-3, paragraph 7.1.2.5.2, forward and upper-aft skin- FORCEMATE BUSHING REPAIR stringers and the upper-center PROCEDURES spar cap for installation of Force Upper-Skin Mate bushings from WS 40-RH to (WS 40-RH to WS 40-LH. WS 40-LH)
Install Force Mate bushings if not previously installed.
Visually inspect the interior and TO 1A-10C-23, Chapter 2, WING exterior surfaces of the lower- GROUP CORROSION-PRONE AREAS forward and lower-aft skin panels for corrosion (Hellhole).
Lower-Skin Remove corrosion and repair TO 16C1-30-10-3, paragraph 7.12.1, (WS 90-106 damage. METAL REMOVAL LIMITS - RH/LH) FORWARD LOWER SKIN
TO 16C1-30-10-3, paragraph 7.13.4, METAL REMOVAL LIMITS - AFT LOWER SKIN
Lower-Skin Fuel Inspect and repair fuel tank For repair submit AFMC Form 202 to Tank Access access doors (W3-Wl0). A-10 Engineering, request most current Doors tech data, FUEL TANK ACCESS (W3-Wl0) OPENING/DOOR INSPECTION
Visually inspect the front spar DWG 2641611305, WING CENTER web to determine if the current PANEL REPAIR FRONT SPAR-WS 90- repair configuration (REF 110 2641611305) is installed.
Front Spar Web If the current repair configuration TO 16C1-30-10-3, paragraph 7.9.3.1, (WS 90-110 is not installed (to include FORWARD SPAR WEB REPAIR WS RH/LH) installation of rivet less nut 90 TOWS 110 plates), remove the existing repair and install the current configuration.
Inspect the lower-forward spar TO 16C1-30-10-3, paragraph 5.3.4, cap at WS 92-104 RH/LH for INSPECTION FOR Lower-Forward corrosion damage. CORROSION AT WS 92-WS104, Spar Cap LH/RH, LOWER FORWARD SPAR (WS 92-104 If corrosion is identified, remove CAP RH/LH) corrosion and repair defects.
Inspect the lower-forward and TO 16C1-30-10-3, paragraph 5.3.6, lower-aft spar caps for installation INSPECTION FOR OVERSIZE Lower Spar Caps of oversized rivets. FASTENERS, FRONT AND REAR (WS 44.5-66 SPARS, WS 44.50 - WS 66.00, LH/RH RH/LH) If defects are indicated, repair the spar caps as directed.
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Visually inspect the center spar DWG 2641611306, REPAIR-MID SPAR web to determine the current CAPS, WG CTR PNL, WG STA 17 repair configuration.
Submit AFMC Form 202 to A-10 Center Spar Web Engineering and request (WS 17 RH/LH) additional repair procedures. Attach photographs of the current configuration. Identify fastener hole diameters/edge margins.
Inspect the fasteners attaching TO 16C1-30-10-3, paragraph 5.3.3, WS the WS 110 wing splice fittings to 110 SPLICE FITTING FASTENER the upper and lower skins and INSPECTION spar caps. If defects are identified, remove and replace the damaged fasteners.
Visually inspect the surfaces of TO 16C1-30-10-3, Chapter 7.3, RIB the upper and lower wing splice AND SPLICE FITTING, WS 110 Wing Splice fittings for evidence of cracks, Fittings corrosion, worn finish, and (WS 110 RH/LH) damage. If defects are identified, repair damaged surface.
Perform precision optical measurements to verify the wing splice fittings meet drawing specifications for flatness and node thickness.
Visually inspect the outboard flap TO 16C1-30-10-3, paragraph 5.3, tracks for installation of a bathtub ADDITIONAL INSPECTION repair fitting. REQUIREMENTS, Figure 5-2
If a repair is installed, remove TO 16C1-30-10-3, paragraph 7.14.2, and replace the flap track. REMOVAL/REPLACEMENT OF Flap Tracks, OUTBOARD FLAP Outboard TRACK (WS 109.88) (WS 109.88 RH/LH)
Visually inspect the inboard and DWG 160D611631, FLAP TRACK outboard flap track - liners, upper ASSEMBLY, INBD, BL 37.68 and lower (REF 160D611624). If Flap Track- Liners defects are indicated, remove DWG 160D611632, FLAP TRACK and replace the flap track-liner. ASSEMBLY, INBD, WS 109.88
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Visually inspect the trailing edge- For repair submit AFMC Form 202 to upper panel assembly, RH/LH. A-10 Engineering, request most current Trailing Edge – tech data, REPLACEMENT OF UPPER Upper Panel TRAILING EDGE PANEL Assembly Replace the trailing edge-upper panel assembly if one of the DWG 160D611535, UPPER PANEL following conditions exist: INSTL TRAILING EDGE PANEL, WS 37.55 TOWS 110.00 - SPARE 1. Damage is identified 2. Existing repair installed 3. Honeycomb configuration installed (REF 160D611513)
Visually inspect the trailing edge For repair submit AFMC Form 202 to wedge assembly, RH/LH. A-10 Engineering, request most current tech data, REPLACEMENT OF TRAILING EDGE WEDGE
Trailing Edge - Replace the trailing edge wedge Wedge assembly if damage is detected or a previous repair is identified.
Visually inspect Access Panels TO 1A-10C-3-1, Figure 1-10, for cuts, discontinuities, high Aerodynamic Smoothness Criteria spots, and damage which would impair sealing. Verify TO 1A-10C-3-1, Paragraph 1.66, aerodynamic smoothness criteria AERODYNAMIC SMOOTHNESS will be met. TO 1A-10C-3-1, Paragraph 1.81, Repair identified defects. AIRFRAME SEALING (NONFUEL AREAS)
Access Panels TO 16C1-30-10-3, Figure 1-5, Wing Fuel Access Doors
TO 16C1-30-10-3, paragraph 7.13.1, 1139 (W36) CORROSION REMOVAL AND NEW FLANGE INSTALLATION PROCEDURES FOR THE EIGHT FUEL TANK OPENING SEAL SURFACES
Visually inspect the LB-outboard TO 16C1-30-10-3, paragraph 5.1.1, flap track at WS 38.00 for UID UNIQUE IDENTIFICATION (UID) Label. LABEL
UID Label Install label if not previously installed. TO 16C1-30-10-3, Appendix A, UNIQUE IDENTIFICATION (UID) SUPPORTING INFORMATION
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APPENDIX 8 – LEGACY WING SSI
3.1.5. After completion of inspection (SSI W31) repair and/or install the WS 17 repair 264J611306 on both sides LH/RH of every wing if not previously completed. Reference TO 16C1-30-10-3 (Section 7), and TO 1A-10C-36. This is an over-and-above task.
3.1.6. After completion of inspection (SSI W39) repair and/or install FORCEMATE bushings in all fuel transfer holes in upper forward and aft skins between LH/RH WS 44.5 ribs if not previously completed. This shall be accomplished for every fuel transfer hole in indicated region. Cracked fuel transfer holes can be bushed if within tech data bushing limits. If cracked fuel transfer holes are outside of bushing limits, additional repairs are necessary. Reference TO 16C1- 30-10-3 (Section 7), TO 1A-10C-36. This is an over-and-above task.
3.1.7. After completion of inspection (SSI W40) repair and/or install the WS 90-110 “Hellhole” repair 264J611306 on every wing if not previously completed. Remove any configuration other than repair 264J611306 and install repair 264J611306, this is an over-and- above task.
3.1.8. Inspect the RH and LH Inboard Flap Outer Flap Tracks for a bathtub repair fitting shown in TCTO 1A-10-1531. If a repair is present, the repaired flap track shall be removed and replaced with a new flap track. Replacement is an over-and-above task.
3.1.9. Perform continuity checks on electrical harnesses 160D641101, 160D641102, 160D641103, and 160D641104 on the wings. Reference TO 1A-10C-110-1-1.
3.1.10. Inspect all wiring in the WOPs/WCP for chaffing and damage under the leading edge skins and at the trailing edge. No chafing or damage is allowed. Repair IAW TO 1-1A-14. Repair is an over-and-above task
3.1.11. Remove, inspect Fuel Probes and Fuel Quantity harness assembly P/N 160C950906-25 and replace as required. Ensure Fuel Probe electrical leads pig tails are of sufficient length to splice outside of fuel tank or conduit. Length should be at least 12 inches. Reference TOs 8-1- 1 and 1-1A-14.
3.1.12. Inspect wiring for fuel Pilot Valves and Shut-off Valves to ensure wires are of sufficient length to accommodate a splice outside of the conduit. No splices are allowed inside wing tank or conduit. Reference TOs 8-1-1 and 1-1A-14.
3.1.13. Remove, inspect and clean panels W3, W4, W5, W6, W7, W8, W9 and W10. If panels are the composite type they shall be replaced with aluminum alloy panels, these panels shall be re-installed and painted with the wing. Replacement (material only) is an over-and-above task.
3.1.14. Inspect the Jo-bolts for looseness at WOP forward spar cap from WS110 outboard. Replace all Jo-bolts that are loose IAW 1A-10C-3-1.
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APPENDIX 8 – LEGACY WING SSI
3.1.15. Install mid spar web doubler IAW 160J612461 on SSI wings if not previously installed. This is an over-and-above task.
3.1.16. Inspect the Jo-bolts for looseness at WOP forward spar cap from WS110 outboard. Replace all Jo-bolts that are loose IAW 1A-10C-3-1.
3.1.17. Install mid spar web doubler IAW 160J612461 on SSI wings if not previously installed. This is an over-and-above task.
3.1.18. Submit an AFMC Form 202 for WS90 repair fitting on all WCPs IAW 160J611435 that were not previously repaired. Inspection of WS 90 rib auxiliary spar cap cutouts complied with by SSI W35 (was TCTO 1A-10-1439). If damage found in ribs 160D611408-11, -12 or 160D611410-11, - 12 is within repair limits set by 1A-10C-3-1, Para 4.31 and engineering generated supplemental WS 90 repair strategy then install modification/repair 160J611435. This is an over-and-above task.
3.1.18.1. If damage found in ribs 160D611408-11, -12 or 160D611410-11, -12 is NOT within repair limits set by 1A-10C-3-1 Para 4.31 and engineering generated supplemental WS 90 repair strategy then that rib shall be replaced with 160D611408-13, -14 or 160D611410-13, - 14. This is an over-and-above task.
3.1.18.2. If cracking is found around the periphery of repair 160J611435 in ribs 160D611408- 11, -12 or 160D611410-11, -12 that rib shall be replaced with 160D611408-13, -14 or 160D611410-13, -14. This is an over-and-above task.
3.1.18.3. Any WS 90 rib removed from aircraft must be replaced with 160D611408-13, - 14 or 160D611410-13, -14. DO NOT install modification/repair 160J611435 onto 160D611408-13, - 14 or 160D611410-13, -14.
3.1.19. Replace ballistic foam (Void Filler) in all accessed areas unless previously CW with new coated foam IAW 1A-10C-3-1.
3.1.20. Remove main landing gear trunnion fitting and hardware (1A-10C-3-1). Perform NDI inspection on trunnion wing mounting holes. Inspect and repair trunnion fitting IAW 1A-10C-3-1. All new hardware will be installed on replacement trunnion fitting.
3.1.21. Replace the skin (P/N160D611502-5/-6) on center wing under leading edge slats that have previous repairs. Perform repairs as required to structural members within this area (ribs, etc.). Reference TO 1A-10C-4-51-JG-1. This is an over-and-above task.
3.1.22. Perform inspection of installed false flaps (wedges) to ensure serviceability. Repair as required IAW 1A-10C-3-1. Repair is an over-and-above task.
3.1.23. Perform inspection of installed P/N 160D611511-17/18 panels to ensure serviceability. Replace as required IAW 1A-10C-3-1. Replacement is an over-and-above task.
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APPENDIX 8 – LEGACY WING SSI
3.1.24. Inspect all hydraulic lines for chafing, damage or signs of leakage, taking special note under phenolic blocks. REF TO 1A-10C-2-29MS-1.
3.1.25. Replace aluminum slat actuator support fittings P/N 160D627111-1 with the new steel fittings P/N 160D627111-5 or -7, NSN 1560-01-102-3773. Install IAW TO 1A-10C-3-1. This is an over-and-above task.
3.1.26. Inspect and replace deceleron attach bushings, as required. Reference TO 1A-10C-3-1. Replacement is an over-and-above task.
3.1.27. Accomplish wing fuel tank pressure check IAW EPN 99C-10-FU-8213 or equivalent and 1A-10C-3-1, Wing Tank Pressure Checks.
3.1.28. Inspect and repair taper pin bore IAW 1A-10C-3-1 and 1A-10C-3-1-1.
3.1.29. Ensure wing serial number data plate is secure and in place on the WCP and WOPs. If old tag is missing, obtain serial number from USAF A-10 engineering. Serial number is required for annotation on the Form 95.
3.1.30. Wing Tank Fuel Foam will be 100% replaced. Upon completion, annotate in AFTO 95 form that “Wing tank fuel foam was 100% replaced on MM/DD/YYYY (MRT Transfer Date)”. Do not replace wing foam if aircraft records show 100% replacement in last 12 years.
4. ADDITIONAL INSPECTIONS:
4.1. Systems: Replace all O-rings in the disturbed fuel system.
4.2. Phased Inspection Tasks: Perform first and second phase inspection IAW TO 1A-10C-6WC- 2.
4.3. Flight Control Systems Inspections/Replacements: Accomplish the following inspections on all SSI aircraft. REF: 1A-10C-6. Note: These replacements shall be accomplished as part of the negotiated work package. Any necessary repairs will be over-and-above tasks.
Table 4-2. Legacy aircraft wing flight control system repair/replacement requirements. Work Unit Repair/Replacement Code 14CDE BEARINGS, IN LH ROLL CABLE CRANK, WS 30.62, PN 160D622110-1, 162D622110-1001 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDR BEARINGS, IN RH ROLL CABLE CRANK, WS 30.62, PN 160D622110-1, 162D622110-1003 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDY BEARINGS, IN LH ROLL CABLE CRANK, WS 167.00, PN 162D622120-1001, 160D622120 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDZ BEARINGS, IN RH ROLL CABLE CRANK, WS 167.00, PN 162D622120-1002, 160D622120 INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) FISCAL YEAR 19 Page 90 of 101
14CDK BEARINGS, IN LH ROLL CABLE CRANK, WS 175.26, 160D622130-1, 162D622130-1001. INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14CDW BEARINGS, IN RH ROLL CABLE CRANK, WS 175.26, 160D622130-1, 162D622130-1001. INSPECT CRANK AND SUPPORT. REPAIR AS NECESSARY. (REF: TO 1A-10C-3-1) 14NC0 SLAT ACTUATORS. (REF: TO 1A-10C-2-27JG-1) 14NCG SLAT RESTRICTORS. (REF: TO 1A-10C-2-27JG-1) 14CDK BEARINGS, LH AILERON DRIVE TAB SHIFTER CRANK ASSEMBLY (PN 160D622325-1 or 162D622325-1001 and 160D622330-1 or 162D622330-1001 and 160D622321-1 or 162D622321-1001). (REF: TO 1A-10C-3-1) 14CDR BEARINGS, RH AILERON DRIVE TAB SHIFTER CRANK ASSEMBLY (PN 160D622325-1 or 162D622325-1001 and 160D622330-1 or 162D622330-1001 and 160D622321-1 or 162D622321-1001). (REF: TO 1A-10C-3-1) 14CDH SHAFT, LT AILERON SHIFTER MECHANISM PIVOT, W.S 200.40, (PN 162D622333-2001, 160D622333-13) (REF: TO 1A-10C-2-27JG-5) 14CDU SHAFT, RT AILERON SHIFTER MECHANISM PIVOT, W.S 200.40, (PN 162D622333-2001, 160D622333-13). (REF: TO 1A-10C-2-27JG-5)
4.4. Additional Flight Control Systems Inspections: Accomplish the following inspections on all SSI aircraft. Ref: 1A-10C-6C. Note: These replacements shall be accomplished as part of the negotiated work package. Any necessary repairs will be over-and-above tasks. Table 4-3. Legacy aircraft wing flight control system inspection requirements: Work Unit Special Inspection Code 14CD0 REMOVE AND INSPECT LT AND RT ROLL TRIM MECHANISM MAIN PIVOT SHAFT BUSHING (PN S5044-9-115), PLUG (PN 160D622220-19, 162D622220- 2007) AND SUPPORT (PN 160D622230, 162D622230). REPLACE AS REQUIRED. (REF:TO 1A-10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM BOLTS (PN 160D725151-11, 162D725151- 2001), BUSHINGS (PN 160D725160-11, -13, 162D725160-2005, -2001), AND CRANK ASSEMBLY (PN 160D725110-1, -5, 162D725110-1001). (REF: TO 1A-10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM SHAFT (PN 160D725152-5, 162D725152- 2005). (REF: TO 1A-10C-3-1) 14LB0 SPEEDBRAKE CONTROL SYSTEM BOLT (PN 160D725151-15), BUSHINGS (PN 160D725160-17, 162D725160-2007), AND CRANK ASSEMBLY (PN 160D725110-5, 162D725110-1003). (REF: TO 1A-10C-3-1) 14N00 REMOVE AND NDI LEADING EDGE SLAT STEEL BELLCRANKS, PN 160D627110-5 OR 162D627110-1001(REF:TO1A-10C-36 AND TO 1A-10C-3-1)
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APPENDIX 8 – LEGACY WING SSI
5. SPECIAL INSPECTION TASKS
5.1. Special Inspections: Perform the following on all SSI aircraft (Ref: TO 1A-10C-6 Ch. 2, Section 1). Resulting repairs and replacements are over-and-above tasks.
Table 5-1. Additional special inspections: Work Item Unit Special Inspection (all SSI) Number Code WSSI SI 1 11000 WHEN WING ASSEMBLY CENTER PANEL IS REMOVED FROM AIRFRAME: INSPECT HYDRAULIC TUBING UNDER PHENOLIC AND ALUMINUM TUBE BLOCKS ATTACHED TO THE FORWARD AND AFT CENTER WING SECTION FOR CHAFE DAMAGE. EVALUATE CHAFING AND REPAIR AS NECESSARY. (REF: TO 1A-10C-2-29MS-1) WSSI SI 2 11000 WHEN WING ASSEMBLY CENTER PANEL IS REMOVED FROM AIRFRAME: INSPECT WING / FUSELAGE ATTACHEMENT FITTINGS. (REF: TO 1A-10C-36 AND TO 1A-10C-3-1) WSSI SI 3 11000 WHEN WING ASSEMBLY CENTER PANEL IS REMOVED FROM AIRFRAME: INSPECT WING / FUSELAGE ATTACH TAPER PINS AND BUSHINGS. (REF: TO 1A-10C-36)
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APPENDIX 9 – PYLON REWIRE
SECTION PAGE
1. GENERAL………………………………………………………………………..94
1.1. Scope…………………………………………………………………………..94 1.2. Purpose………………………………………………………………………..94 1.3. Past Modifications………………………………………………..94 1.4. Additional Repairs………………………………………………..94 1.5. Paint Condition…………………………………………………….94 1.6. Aircraft Area to be Modified ………………………………………………….94 1.7. General Information…………………………………………………………..94
2. COMPLIANCE DOCUMENTS…………………………………………………95
3. WORK PERFORMANCE REQUIREMENTS…………………………………95
3.1. Aircraft Preparation ……………………………………………………………95 3.2. Modification Procedures………………………………………………………95 3.3. Technical Directives……………………………………………………………95
TECHNICAL DATA PACKAGE PAGE
Pylon 1 and 11 Technical Data Package…………………………………………96 Pylon 2 and 10 Technical Data Package…………………………………………97 Pylon 3 and 9 Technical Data Package…………………………………………..98 Pylon 4 and 8 Technical Data Package…………………………………………..99 Pylon 5 and 7 Technical Data Package…………………………………………..100 Pylon 6 Technical Data Package………………………………………………….101
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APPENDIX 9 – PYLON REWIRE
1. GENERAL
1.1. Scope: The Pylon Re-Wire modification is a small upgrade to the A-10C aircraft. During the A-10 Precision Engagement (PE) Modification program the pylons were modified and many new wires and components were added. There are many original wires and components still in place after the PE modification that are creating maintenance issues due to their age. The wiring has become fragile and prone to breakage resulting in increased maintenance time and decreased MTBR. This effort shall remove and replace all wires, connectors, splices and related electrical components not replaced/installed during the PE modification.
1.2. Purpose: The purpose of this attachment is to define the responsibilities of the contract depot facility performing the A-10 Pylon rewire. All additional work not included in this attachment shall be limited to Critical Safety Item (CSI). Any additional repairs outside TO limits shall first be approved in writing by the ACO.
1.3. Past Modifications: During the Precision Engagement (PE) Modification each pylon was modified by engineering order and drawing numbers as listed below up to a new dash number. The contractor shall remove and replace all wires, connectors and other components listed in the previous dash numbers of each pylon that were not removed as part of the PE mod. The contractor is encouraged to remove and replace any PE modified wiring and components if it makes the overall effort easier or more efficient.
1.4. Additional Repairs: During the rewire a visual inspection should be done on the overall structural condition of each pylon. Any discrepancies or non-standard repairs found during the re- wire such as repairs or replacement of items not covered by the scope of 1.1 through 1.3 shall be negotiated with the ACO. This is an over-and-above task.
1.5. Paint: Pylons, if installed on aircraft or stand alone, should be prepped, painted and stenciled (REF: TO 1A-10C-23-1 and TO 1-1-8).
1.6. Aircraft area to be modified:
1.6.1. Aircraft Pylons: The modification requires removal of internal components and wiring and the re-installation of new wiring and internal components.
1.6.2. Affected Pylons: Stations; 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, and 11.
1.6.3. Change the data plate to add: “Rewired MM/YR".
1.6.4. Other areas to be modified: NONE.
1.7. General Information
1.7.1. Rewire in conjunction with other maintenance: Aircraft that have station pylons installed and are inducted for SSI or 8YC. The rewire will be performed in conjunction with work being performed on the aircraft. If pylons were not previously picked up by owning unit, they will be reinstalled on aircraft and operational checks completed prior to aircraft delivery. CLIN X030 will be used.
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APPENDIX 9 – PYLON REWIRE
1.7.2. Rewire as maintenance standalone (drop off): The owning unit would deliver the pylons to the contractor facility and no aircraft would be associated with delivery of the pylons. Once rewire is accomplished the owning unit will pick up the pylons at the contractors facility. The drop off and pick up dates and times are to be coordinated between the unit and the contractor. Pylon operational checks will not be performed by contractor. CLIN X029 will be used.
1.7.3. The Armament Circuit Preload Test Set is required for the operational checks. This set has been included in the list of authorized GFE and will either be provided or funded on the order that contains the initial pylon rewire effort.
2. COMPLIANCE DOCUMENTS
Document Name Description A-10C TOs All applicable Technical Orders Pylon Drawings All applicable Pylon Drawings Engineering Data All applicable Engineering Data Technical Data Package All applicable Technical Data Packages
3. WORK PERFORMANCE REQUIREMENTS
Note: It is suggested the contractor create a step-by-step work performance requirement for each pylon to ensure standardization of the rewire effort. There may be future revisions to this attachment as requirements change or are updated.
3.1. Aircraft Preparation: Ensure Aircraft is safe for maintenance TO 1A-10C-2-4JG-1.
3.2. Modification Procedures: a. Perform internal component and wire removal. b. Perform visual inspection of pylon structure and paint / corrosion. c. Perform re-wire of each pylon assembly. d. Perform internal component re-installation. e. Perform functional check IAW TO 1A-10A-2-94JG-7 f. Perform Operational checkout of disturbed systems. Checkout shall be accomplished IAW A- 10C TOs prior to returning the aircraft to normal operation.
3.3. Technical Directives: TOs, Drawings, Engineering Data, and Technical Data Packages.
3.3.1. Refer to Technical Data Package (TDP):
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APPENDIX 9 – PYLON REWIRE
Pylon 1 and 11 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylons 1 and 11 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the Contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 1 and 11 TDP Document List Drawing No. Rev # Title Comments 160D845829 G ELEC INSTL Pylon STA 1&11 160D845829 PL G ELEC INSTL Pylon PL, STA 1&11 EO: 08A1411, 87C4826, 160D845830 D ELEC INSTL Pylon STA 1&11 88C1344 160J944111 A Harness Assembly, W8011 EO: 96C0098 160D841011 E Harness Assembly, W8011 TO INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED 16W6-28-2 PARTS BREAKDOWN STATION 1 AND 17 April 2017 11 PYLON ASSEMBLY PART NO. 160D891121-111 TO Reference Table 4-1. Continuity Checkout
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APPENDIX 9 – PYLON REWIRE
Pylon 2 and 10 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylons 2 and 10 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 2 and 10 TDP Document List Drawing No. Rev # Title Comments 160D845887 G Electrical Installation, Pylon STA 2 & 10 160D845887 PL G Electrical Installation PL, Pylon STA 2 & 10 Electrical Installation, Pylon STA 2 & 10 EO: 08A1217, 160D845889 D BL187 88C3116 EO: 08A1211, 160D841002 F Harness Assembly, W8002, Pylon 2 & 10 87C0691 160D841050 B Harness Assembly, W8050, Stations 2 & 10 Harness Assembly PL, W8050, Stations 2 & 160D841050 PL B 10 160D841051 B Harness Assembly, W8051, Stations 2 & 10 Harness Assembly PL, W8051, Stations 2 & 160D841051 PL B 10 TO INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED 18 SEPTEMBER 16W6-28-12 PARTS BREAKDOWN STATION 2 AND 10 PYLON ASSEMBLY PART NO. 2017 160D891221-111 TO Reference Table 4-1. Continuity Checkout Ref Drawings 262A700 J System Installation PE (PL available) 264A652 H Pylon Assembly, BL 187 EO: 12A1343 264A652 G Pylon Assembly PL, BL 187 264A669 D Wiring Diagram, Left Wing Outboard 264A668 D Wiring Diagram, Right Wing Outboard EO: 10A1152 264A575-1 A List, Wire Removals, Pylon 2 & 10 264A575-1 A Wire Removals PL, Pylon 2 & 10
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APPENDIX 9 – PYLON REWIRE
Pylon 3 and 9 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylons 3 and 9 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 3 and 9 TDP Document List Drawing No. Rev # Title Comments EO: 03C0689, 160D845845 H Electrical Installation Drawing 88C3634, 08A1085 EO: 08A1046, 160D841003 H Harness Assembly, W8003 Pylon 3 & 9 87C0690, 87C5086, 88C3092, 15A0007 160D841052 B Harness Assembly, W8052 Pylon 3 & 9 Harness Drawing PL, W8052 Pylon 3 & 160D841052 PL B 9 TO INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED 16W6-28-22 PARTS BREAKDOWN STATION 3 AND 31 JANUARY 2018 9 PYLON ASSEMBLY PART NOs 160D891321-117 AND 160D891321-119 TO Reference Table 4-1. Continuity Checkout Ref Drawings 264A654 G Pylon Assembly, Pylon 3 & 9, BL 144 264A654 G Pylon Assembly PL, BL 144 264A576 B List, Wire Removals - Pylon 3 & 9 262A700 J System Installation PE (PL available) 264A669 D Wiring Diagram, Left Wing Outboard
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APPENDIX 9 – PYLON REWIRE
Pylon 4 and 8 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylons 4 and 8 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 4 and 8 TDP Document List Drawing No. Rev # Title Comments 160D845866 G Electrical Installation Pylon, STA 4&8, BL66 160D845866 PL G Electrical Installation Drawing PL, STA 4&8 EO: 88C3230 160D845867 F Electrical Installation Pylon, STA 4&8, BL66 EO: 08A1218 EO: 05A0819, 160D841004 H Harness Drawing, W8004, Pylon, STA 4&8 08A1088, 0205E, 16A0264 TO INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED 16W6-28-32 PARTS BREAKDOWN STATION 4 AND 8 31 JANUARY 2018 PYLON ASSEMBLY PART NO 160D891401-213 TO Reference Table 4-1. Continuity Checkout Ref Drawings 262A700 J System Installation PE (PL available) 264A656 D Pylon Assembly, BL66 EO: 12A1338 264A656 PL C Pylon Assembly PL, BL66 EO: 09A2071 264A669 D Wiring Diagram, Left Wing Outboard 264A668 D Wiring Diagram, Right Wing Outboard EO: 10A1152 264A577 A List, Wire Removals, Pylons 4&8 264A577 PL A List, Wire Removals PL, Pylons 4&8 160D841057 C Harness Assembly, Pylons 4&8, W8057 160D841057 PL C Harness Assembly PL, Pylons 4&8, W8057
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APPENDIX 9 – PYLON REWIRE
Pylon 5 and 7 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylons 5 and 7 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 5 and 7 TDP Document List Drawing No. Rev # Title Comments 160D845823 K Electrical Installation, Pylon STA 5 & 7 160D845824 G Electrical Installation, Pylon STA 5 & 7 EO: 08A1124 160D841005 G Harness Assembly, W8005, Pylon 5 & 7 EO: 04A3158, 08A1093, 87C0689 TO 16W6-28-42 INTERMEDIATE MAINTENANCE 12 DECEMBER INSTRUCTIONS WITH ILLUSTRATED 2017 PARTS BREAKDOWN STATION 5 AND 7 PYLON ASSEMBLY PART NO. 160D891501-215, 160D891501-217 TO Reference Table 4-1. Continuity Checkout Ref Drawings 262A700 J System Installation PE (PL available) 264A658 B Pylon Assembly, BL 23 EO: 09A1974 264A658 B Pylon Assembly, BL 23 PL 264A717 C Harness Assembly, 1760 Umbilical 264A578 B List, Wire Removals, Pylons 5&7 264A578 PL B List, Wire Removals PL, Pylons 5&7 160D841053 A Harness Assembly, Pylons 5&7 160D841053 PL A Harness Assembly PL, Pylons 5&7, W8053
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APPENDIX 9 – PYLON REWIRE
Pylon 6 Technical Data Package The following is a list of the drawings and the TO that are needed to create a requirements work sheet for the contractor to do the rewire of pylon 6 “C” version. The TDP can be used in place of the missing process order.
Note: 1. All drawings have the proper distribution statement and can be released to the contractor, as they are government property, released from LMSI at the end of the Precision Engagement project. 2. Drawings have been checked for latest EO’s (listed as a reference). 3. The wiring tables are in the new TO and can be referenced in place of the process order.
Pylon 6 TDP Document List Drawing No. Rev # Title Comments 160D845810 K Electrical Installation, Pylon STA 6 160D845810 PL K Electrical Installation PL, Pylon STA 6 Electrical Installation, Pylon STA 6 EO: 08A1250, 160D845811 F (Drawing includes PL) 88C3641, 85C0538 EO: 08A1135, Harness Assembly, W8006, Pylon STA 6 160D841006 G 87C0688, 87C5085 TO INTERMEDIATE MAINTENANCE INSTRUCTIONS WITH ILLUSTRATED 31 January 2018 16W6-28-52 PARTS BREAKDOWN STATION 6 PYLON ASSEMBLY PART NO. 160D891601-213 TO Reference Table 4-1. Continuity Checkout Ref Drawings 160D841106 Wiring Diagram for Harness 160D845811-7
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