1

Table oI Contents

Chapters

I. Applicability

II. Purpose

III. Scope

IV. Objectives

V. Revisions

VI. Organization and Responsibilities

A. Maintenance Manager
B. Team Lead
C. Maintenance Supervisor
D. Maintenance Test Pilots
E. A&P Mechanic (Technician)

VII. General InIormation & Procedures
A. Production Control Section
1. Daily Status Report
2. PC Meetings
3. Work order management and tracking (WOTS)
4. Controlled Exchange

B. Quality Control Section
1. QC Inspection Procedures
2. Tool Control Procedures
3. TM Familiarization Chart
4. Technical Publications
5. Weight and Balance
6. FOD Program
7. Oil Analysis Program
8. Calibration Program
9. Corrosion Control Program
10. Technical InIormation
11. Technical AIIairs
12. Maintenance and Shop SaIety Program
13. Forms and Records Program
14. TBO and SLL Program
2


C. AircraIt Maintenance Section
1. AircraIt Induction into 2
nd
Line Maintenance
2. Routine maintenance and repair oI mission equipment (ROLE)
3. MTF Procedures
4. Deployment Procedures
5. AircraIt Recovery
6. Security/Accountability
7. FOD and SaIety check list
8. AircraIt Jacking
9. AircraIt ground Handling
10. Training/Recurrent
11. Daily Operating Procedures

D. Workshops Section
1. Back shops support
2. Aviation LiIe Support System (ALSS)
3. Ground Support Equipment (GSE)

Aviation Logistics Section
1. Demand Procedures
2. Issue Procedures
3. Turn-in Procedures
.
E. SaIety Section
1. General InIormation
2. Risk Assessment and Hazard Management
3. Initial Training
4. SaIety Bulletin Board
5. First Aid
6. Injury Report
7. Incident/Accident Reports
a. Special Occurrence Report (SOR)
b. Ground Occurrence Report (GOR)
c. Hazard Report
d. Discrepancy Record
8. Evacuation Plan
9. Fire Extinguisher SaIety/Fire Prevention
10. Personal Protective Equipment (PPE)
11. Hearing Conservation
12. Respiratory Protection
13. Hazardous Communication (HAZCOM)
14. Environmental Protection
15. Material Handling (Housekeeping)
16. Permit Required ConIined Spaces
17. Lockout/Tagout
3

18. Radio Frequency (RF) Hazards

F. Training Section

G. Non Aviation Stores Section
1. Purchase Order Requests
2. Facilities Maintenance

H. HR Section

I. Hazard Communications

VIII. ReIerences & Forms
A. List oI ReIerences
B. Forms
1. Controlled Exchange Form
2. DeIect Report
3. Form 4-25

8. MMIR Form
9. SB/SL Review Sheet















** Areas to be expanded




4


I. Applicability:

This SOP applies to all oI Maintenance personnel in direct support oI the maintenance
contract. Any deviation Irom these procedures will require a written, deviation authorization,
Irom the Maintenance Manager.

II. !:7pose:

The purpose oI this SOP is two-Iold. First, is to outline the step by step procedures by which
we conduct our daily duties. Second, is to ensure standardization oI all the maintenance and
quality procedures, which maintains and improves the saIety and working conditions oI
every mechanic supporting the maintenance contract.

III. $cope:

This SOP applies to both garrison and Iield locations or while deployed to a theater oI
operations. II speciIic instructions are to be used while on deployment status,
commanders/leaders may convey additional instructions or policies in this section.

General note: No SOP can cover every possible contingency; thereIore, in the absence oI
guidance Irom this document, "common sense applies". When in doubt ask your supervisor.

IV. Objectives:

To establish standardization within the maintenance program, and to ensure its
implementation in accordance with all applicable policies and directives as per assigned
contracts.

V. Revisions:

The Maintenance Manager is responsible Ior the revisions, reviews and dissemination oI this
SOP as applicable. At a minimum, annual reviews should be completed to ensure compliance
with amended contracts, SOP`s and any other ruling document. All Maintenance personnel
are encouraged to submit a revision notice anytime a discrepancy or conIlict with this
document is discovered.

VI. O7anization and Responsibilities:

In general, it is advised that all personnel involved in the execution oI the maintenance
contract, understand our local organizational structure, its Iunctions, and how they work
together to accomplish our joint objectives.

Within the maintenance contract, our organization is divided into six levels. The lower Iive
levels are divided into the Iollowing sections; Production, Quality, Maintenance, Workshops,
5

Logistics (Aviation and Non-Aviation), SaIety, Training and although not directly part oI the
maintenance organization, the IT and H/R sections are also important to understand.

Within each section operational levels are typically broken down as Iollows; Manager level,
Team Lead level, Supervisor level, and Technician level.
The important thing to keep in mind is the communication path between levels, especially iI
you are communicating outside oI the maintenance section. The objective here is to pass
inIormation to the right person at the right time in the right order. Not doing so, can have
serious adverse eIIects on our saIety and eIIiciency. Most oI you will recognize this as
Iollowing the 'Chain oI Command, both up and down the chain. Ask questions iI you are
ever in doubt.

Lastly, to assist in understanding the organizational layout oI the Maintenance Section, below
is a list oI the Iive operational levels within the section and their associated basic
responsibilities. To understand the operational levels oI another section, such as Quality
Control, please see their appropriate SOP.

A. aintenance anae7

1. The basic responsibility oI the Maintenance Manager is the overall management oI
manpower, equipment, inIormation and procedures used in the execution oI the
assigned contract, as it relates to the 2
nd
Line Maintenance Section.

2. Reports to the Aviation Maintenance Program Manager (P.M.) on all maintenance
operations.

. Team Lead

1. The basic responsibilities oI a Team Lead are to manage all material planning,
maintenance planning and all section activities (programs) pertaining to the mission
design series aircraIt assigned.
2. Ensures that all aircraIt inspections and scheduled maintenance is timed correctly, Ior
maximum availability oI assigned aircraIt and systems. Also, ensures that all parts,
tools, equipment, and inIormation are on hand and in serviceable condition when
needed.
3. Reports directly to and works closely with the 2
nd
Line Maintenance Manager on all
issues pertaining to his assigned Team(s).

. $:pe7viso7

1. The basic responsibilities oI a Supervisor are to coordinate maintenance support
through 'work orders and manage assigned manpower, tools, equipment, and
inIormation to accomplish assigned maintenance tasks.

D. aintenance Test !ilot

6

1. The basic responsibilities oI the Maintenance Test Pilot are to ensure the
airworthiness oI assigned aircraIt and ensure the quality and eIIiciency, oI all
maintenance procedures within his assigned aircraIt section.
2. Assist the Supervisor and works closely with all levels on issues pertaining to his
assigned aircraIt and or additional tasks.

. A&! echanic (Technician)
1. The basic responsibilities oI a Technician are to complete all tasks assigned in the
most saIe and eIIicient way possible.
2. Reports directly and works closely with the Supervisor and Team Lead on all issues
pertaining to the Team assigned.


VII. Gene7al Info7mation & !7oced:7es

Close coordination between the Maintenance Manager, Team Leads, Supervisors,
Maintenance Test Pilots, Technicians, Maintenance Planners and supporting personnel
within the organization is essential to the success oI a well-organized maintenance program.
ThereIore, this chapter is divided into separate sections outlining, the purpose, Iunctions and
procedures that cover speciIic areas oI aircraIt maintenance. All Maintenance section
personnel should become Iamiliar with this document and conduct their daily maintenance
operations according to guidance contained within this SOP.

a:tion: the procedures listed below Ior sections other than the Maintenance Section may
not be all inclusive. The procedures are intended to be used Irom the Maintenance Section`s
point oI view.


A. !7od:ction ont7ol $ection

!:7pose:
To act as the single point oI contact Ior coordinating all actions on the Ilight line or at the
support Iacility in order to maintain, repair, overhaul, and apply modiIication work
orders, saIety-oI-Ilight messages, or any other mandated maintenance Iunctions.

F:nctions:
1. Establish priorities oI work across the Ileet.
2. Maintaining and reporting aircraIt status reports.
3. Maintaining the production control status board and Ilow charts.
4. Maintaining maintenance man-hour estimates & MAC charts.
5. Maintaining minimum equipment lists (MEL).
6. Work order, management and tracking (WOTS).
7. Manage the controlled exchange program.
8. Manage the repairable component exchange program (LRU`s).
9. Manage unscheduled maintenance across the Ileet.
10. Manage scheduled maintenance across the Ileet.
7

11. Manage deIerred maintenance scheduling across the Ileet.
12. Manage phase/periodic maintenance scheduling across the Ileet.
13. Coordinate maintenance test Ilights and operational checks.
14. Maintain Operational Readiness Rates (Goals)

!7oced:7es:
1. Daily $tat:s Repo7ts
Daily status is reported to Production Control by the Team Lead assigned to each
mission design series aircraIt Ior 2
nd
Line aircraIt and by the 1
st
Line Supervisor Ior
1
st
line aircraIt, no later than 07:00 hours daily.

2. ! eetins (p7io7ities and inte7nal coo7dination).
REF: TC 04.3-7
a. Production Control meetings will be conducted in the GAL production control
oIIice, Sunday through Thursday at 0800 hrs on the summer schedule and 0830 hrs
on the winter schedule. Attendance by the Iollowing is mandatory: 2
nd
Line
Maintenance Manager, Team Lead (all sections) Maintenance Supervisor (all
sections), MTP`s when necessary. The PC Manager/PC Technician will chair the
meeting.

b. The PC meeting is a way oI planning, adjusting, and Iorecasting maintenance and
logistics actions.

c. The PC meeting ensures that eIIorts oI managers, team leads, supervisors, MTP`s
and other maintenance personnel are synchronized.

d. The PC meeting is most eIIective when there is strong two-way communication
between the PC section and all members representing each section, and 1
st
Line
companies.

3. ont7olled chane

A. !:7pose:
The purpose oI this SOP is to establish procedures Ior the removal oI serviceable
components Irom an unserviceable, economically repairable aircraIt, to be installed on an
unserviceable, repairable aircraIt, to return it to an FMC (Fully Mission Capable) status.

. $cope:
This SOP pertains to all parts, components, assemblies, and sub-assemblies removed
Irom one aircraIt Ior use on another aircraIt.

. Responsibility:
1. The Commander, or the Commander`s designated representative Ior approving
controlled exchanges, is responsible Ior the approval oI all controlled exchanges. The
Commander`s designated representative shall be on unit orders. All Controlled
8

Exchanges, Irom aircraIt work ordered to 2
nd
Line Maintenance Ior inspection or
repair, will be approved by the Aviation Maintenance P.M.

2. Production Control is responsible to ensure the Controlled Exchange has been
registered and a Production Control Number assigned to the Controlled Exchange
Iorm. Production Control will ensure all Controlled Exchange actions are reported on
DA Form 1352 during the reporting period. The Production Control copy oI the
Controlled Exchange Iorm will be attached to the DA Form 1352 as supporting
documentation.

3. The 2
nd
Line Team Lead / Maintenance Supervisor Ior the aircraIt type is
responsible Ior the initiation oI the Controlled Exchange process and that all
Controlled Exchange actions are I.A.W TM 1-1500-328-23, AR 700-138, AR 750-1,
local directives, and this SOP.

4. The Technical Supply/Sub-Store Technician is responsible Ior veriIying that the
component is not available in stores and that the component has been demanded, with
an AOG status, Ior the donor aircraIt.

5. Quality Control is responsible Ior ensuring that proper entries in the donor and
receiving aircraIt logbooks are entered, and that the donor and receiving aircraIt
historical records reIlect the Controlled Exchange.

6. The Mechanic/Technician is responsible Ior the timely completion oI the
Controlled Exchange task. This includes the maintenance tasks I.A.W the applicable
Technical Manual, logbook entries in the donor and receiving aircraIt logbooks, and
Iollowing the established procedures Ior the turn-in oI any unserviceable parts.

D. ont7olled chane:

a. The Controlled Exchange will be perIormed when:
1. It is within the maintenance authority and capability oI the unit activity or
organization perIorming the exchange, in accordance with published equipment
manuals.
2. All means to obtain the required parts, in a timely manner to meet operational
readiness requirements, through direct exchange channels, maintenance repair and
return, normal supply channels or other sources oI supply have been exhausted.
3. The aircraIt Irom which the parts are removed is non mission capable supply
(NMCS), or Partial Mission Capable (PMC).
4. It is the only means oI eliminating an adverse eIIect on the operational readiness oI
the organization concerned.
5. It will immediately restore an aircraIt that is coded NMCS (Non Mission Capable
Supply) to a FMC (Fully Mission Capable) status.
6. It will not degrade the donor aircraIt to an uneconomical repairable condition.
7. It will not be conducted on aircraIt that have been grounded more than 25 calendar
days, (recommended).
9

. Fo7ms and Reco7ds:

F. ont7olled chane !7ocess:

a. The Team Lead / Maintenance Supervisor Ior the aircraIt type will notiIy his Team
Lead/Manager and Production Control, that a Controlled Exchange is required. He will
then assign a Maintenance Technician to obtain a Controlled Exchange Iorm (see Iorms
chapter VIII) Irom the Production Control oIIice.

b. The Maintenance Technician will then ensure the 'Maintenance section oI the
Controlled Exchange Iorm is completed.

c. The Maintenance Technician will deliver the Controlled Exchange Iorm to the
Technical Supply/Sub-Store Technician Ior the type aircraIt. The Technical Supply/Sub-
Store Technician will ensure the component is not available in stores, and that the
component is demanded (AOG) Ior the donor aircraIt. He will enter the 'requisition
number Ior the demand on the Controlled Exchange Iorm.

d. The Maintenance Technician will then deliver the Controlled Exchange Iorm to the
Commander`s designated representative Ior approving Controlled Exchange (the
Aviation Maintenance P.M.) Ior approval

e. Under certain circumstances, the P.M. may give a 'Verbal authorization. The
Controlled Exchange Iorm must be signed by the P.M. as soon as practical, Ior a period
not to exceed 48 hours.

f. The Maintenance Technician will then deliver the Controlled Exchange Iorm to
Production Control. Production Control will register the Controlled Exchange and assign
a Production Control Number to the Iorm

. Upon receipt oI the 'approved Controlled Exchange Iorm, the Maintenance
Supervisor will then assign Mechanics/Technicians to perIorm the maintenance
procedures applicable Ior the Controlled Exchange. The Mechanics/Technicians will
ensure proper entries in the donor and receiving aircraIt logbooks speciIying the
Controlled Exchange.

h. The Maintenance Technician notiIies Quality Control upon completion oI the
maintenance actions. Quality Control inspects the work, ensures proper entries in the
donor and receiving aircraIt logbooks, places one copy oI the controlled exchange Iorm
in each aircraIt logbook, sends one copy to P.C. and places one copy in the historical
records.



10



Flow ha7t

$ta7t nd


























aintenance $ection
1. Starts process with verbal notiIication
to P.C. and Team Lead/Manager.
2. Initiates controlled exchange Iorm.

":ality ont7ol
1. Inspects work.
2. Ensures proper entries in both log
books.
3. Updated historical records.
4. Makes Iour copies oI Iorm.
5. Places one copy in each log book.
6. Sends one copy to P.C.
7. Files Iorth copy in Q.C.
Technical $:pply
1. Receives part(s) request.
2. Ensures part is not avaiable
3. Issues requisition number.
4. Maint. Technician takes Iorm to
aintenance $:pe7viso7
1. Assigns technicians to
complete maintenance tasks.
2. Maint. Technicians takes Iorm
to
! / O
1. PM approves and signs Iorm.
2. Maint. Technician takes Iorm to

!7od:ction ont7ol
1. Register the controlled exchange.
2. Issues a control number.
3. Maint. Technician takes Iorm to
11

. ":ality ont7ol $ection

!:7pose:
The purpose oI the Quality Control Section is to ensure high-quality maintenance and
saIety oI assigned aircraIt.
Meticulous quality control procedures oI our assigned aircraIt decreases unscheduled
maintenance, which can disrupt mission requirements and reduce combat readiness.
Quality assurance lessens the possibility oI maintenance error or inadequate aircraIt
inspections, which can lead to aircraIt damage, personal injury, or death.

F:nctions:
1. Manage Delegation oI Authority Orders.
2. Manage the AircraIt Inspections Program.
3. Manage the Tool Control Program.
4. Manage the Calibration Program (TMDE).
5. Manage the Weight & Balance Program.
6. Manage the Technical Publications Program.
7. Manage the Forms and Records Program.
8. Manage the Technical InIormation Program.
9. Manage the Technical Assistance Program.
10. Manage the Oil Analysis Program.
11. Manage the FOD Program
12. Manage the TBO & SLL Program.
13. Manage the Maintenance and Shop SaIety Inspection Program

!7oced:7es:
1. " Inspection p7oced:7es
TIs (technical inspectors on orders) and the Group Commander are the only personnel
allowed to clear a 'status symbol X, grounding condition or 'circle X condition. A
TI must be present whenever a complex component is reassembled. A TI will be
present whenever a pre-closure inspection is required. TI's are not allowed to sign oII
their own work no matter what level oI involvement. II there is any doubt about a
conIlict oI interest, or concern, oI authorization (stamp) abuse, voice your concerns
up the 'chain oI command immediately. Prior to perIorming an inspection, QC
personnel must review the latest applicable maintenance manual and regulatory
policies to ensure that inspection meets current requirements. As a double check, ask
politely.

2. Tool cont7ol p7oced:7es
a. The Tool Control Program is applicable to all employees working on the contract,
including remote Iacilities and operations.

b. All sections will maintain compliance within Tool control
SOP.

12

c. The Tool Control Program has established procedures ensuring eIIicient operations
oI the tool rooms, shops and 100 percent accountability oI assigned/personal tools
and special repair equipment.

d. QC Technical Inspectors will conduct random toolbox inspections. These
inspections will be completed, at a minimum, on a monthly basis with a report oI
discrepancies being given to the Section Supervisor. A Iollow up inspection will then
be completed within a timely manner to ensure any discrepancies have been
corrected.

e. Section Supervisors will ensure that all Technicians are Iamiliar with the Tool
Control Program to include, but not be limited to:
1. Daily toolbox inventories.
2. FOD inspections.
3. Lost tool procedures.
f. Maintenance Technicians will:
1. Familiarize them with the Tool Control Program and acknowledge their
understanding by initialing the InIormation Reading File.
2. Conduct a comprehensive visual inventory oI any assigned toolboxes at
the beginning and at the end oI their shiIt utilizing Daily Toolbox
Inventory Log. Further, it is recommended that all tools are accounted Ior at the
completion oI any on airIrame task.
3. Any discrepancies or missing tools will be immediately reported to the
Section Supervisor.
4. PerIorm FOD checks oI areas where maintenance has been perIormed at the
completion oI a task.

3. T Familia7ization ha7t
A TM Familiarization Chart ensures all personnel are Iamiliarized with the most
common publications relevant to their tasks. This chart will include all applicable
TM`s, TO`s, AMM`s and SOP`s required to conduct business on a daily basis. The
Familiarization Charts will be updated and reviewed quarterly; upon receipt oI a
change, or whenever a publication is replaced.

`` 4. Technical !:blications

a. Reporting minor discrepancies: Technicians are encouraged to report any error or
discrepancy Iound in any Technical Manual (TM), to their Supervisor. The
Technician should keep one copy as will the Section Supervisor. The Supervisor is
responsible Ior Iorwarding the third copy to the Technical Publications section Ior
processing. Team Leads / Supervisors are responsible to Iollow up on the issue in a
timely manner to ensure quality inIormation is available Ior the technicians.

b. Reporting crucial discrepancies: All personnel utilizing technical publications
should be on the lookout Ior discrepancies that can or could aIIect the airworthiness
condition oI the aircraIt, its systems, sub-systems and or the saIety oI personnel.
13


c. Replacement oI unserviceable publications: Replacement oI unserviceable
publications can be accomplished by submitting a Iorm to the Tech. Pubs Section.
Don`t Iorget to keep copies and to Iollow up.

d. First issue publications: First issue publications can also be requested.

e. Missing pages and review request: Missing pages can be replaced by the tech pubs
section, between Supervisors. II any publication is Iound to be in signiIicant disarray,
a review request Ior that publication can also be requested. Again, don`t Iorget to
keep copies and Iollow-up.

5. Weiht and alance

AircraIt weight and balance is designated an AVIM task, Maintenance section
will provide assistance to Quality Control Ior accomplishment.

`` 6. FOD !7o7am
a. The Foreign Object Damage/Debris (FOD) Prevention Program has been
established to minimize the risk oI damage to aircraIt and equipment Irom
extraneous debris.

b. The FOD prevention program is applicable to all employees working on the
airIield and Iacilities to include remote locations and operations.

c. The Aviation Maintenance P.M. is the approving authority Ior the FOD
prevention program.

d. The SaIety Manager is tasked with developing and implementing the FOD
prevention program. Additionally the SaIety Manager will ensure that
discrepancies are corrected in an eIIicient and timely manner.

e. The Quality Control Manager will ensure that the FOD prevention program is
being complied with through the use oI random on and oII aircraIt inspections and
documented FOD checks.

f. Team Leads/Supervisors will ensure that Technicians are aware oI and comply
with the requirements oI the FOD prevention program.

. A mandatory weekly FOD walk will be held on the Iirst working day oI the
week Ior all Maintenance personnel.

h. Section Supervisors will ensure that all available personnel within their section
actively participate in the FOD walk.

14

i. The Maintenance Manager will assign speciIic FOD walk areas to each
maintenance section as required.

j. The P.M. or Maintenance Manager can increase the Irequency oI the FOD walk
as required to address conditions.


7. Oil Analysis !7o7am

a. The Quality Manager is responsible Ior implementing the Oil Analysis
Program. This program is a quality management tool to enhance saIety, conserve
resources and to extend the liIe oI major assemblies and components. All matters
relating to the OAP to include resolution, procedures, research and development
and requests Ior assistance are processed through the Quality Manager

b. AMC-R 11-47, and AR 750-1 outline AOP policy and assigns responsibilities
Ior the OAP. The OAP is MANDATORY Ior all aircraIt.

c. It is the responsibility oI the Maintenance Supervisor to ensure all sampling
intervals are adhered to in accordance with TB 04-211.

8. alib7ation !7o7am (TD)

a. Gene7al
1All shop tools/equipment will be incorporated into
and comply with the Test Measuring and Diagnosed
Equipment (TMDE) program established by the Quality
Control Department.
2. The Maintenance Supervisor will ensure that all tools
requiring calibration are turned in to the TMDE Monitor/Calibration
Shop prior to the calibration expiry date marked on the tool.
3. All calibrated tools/equipment will have a selI
adhesive label indicating the calibration due date placed on the
tool/equipment. II the label is no longer legible, contact the
Calibration Shop Supervisor.
4. When a calibrated tool`s accuracy is in question, report
it immediately to the Section Supervisor. Any suspect tool
will be removed Irom service and turned in Ior calibration. Under no
circumstances will the tool be used prior to being re-
calibrated.
5. II a tool or piece oI equipment requiring calibration is accidentally
dropped, it will be immediately reported to the Section Supervisor. The
tool will be removed Irom service and turned in Ior calibration. Under no
circumstances will the tool be used prior to being re-calibrated.
15

6. No tool/equipment will be used aIter its calibration due date has
expired. Under special circumstances, an extension to the calibration due
date can be granted. All extensions must be approved in writing by the
QC Department and will be addressed on a case-by-case basis.
7. It is the responsibility oI the Technician using a tool or piece oI
equipment to ensure it is in compliance with the established calibration
requirements.

b. T:7n in !7oced:7es
1. The maintenance supervisor will monitor the
Maintenance calendar on a daily basis to ensure calibration time schedules
are adhered to.
2All equipment shall have a Work Order
426A completed as deIined by Production Control (PC), and a DD FORM
1577-2 (Green Unserviceable Tag) which has been completed as per
TAMMS 738- 751.
3. When a tool or piece oI equipment is turned in, the maintenance
supervisor, or his/her designee will ensure that 2 ea copies oI DA Form 2062
(hand receipt) have been Iilled out to reIlect all items turned in.
4. Turn in items MUST be signed Ior by the TMDE Lab supervisor or
his/her designee utilizing DA Form 2062.
5. One copy oI the completed DA Form 2062 will be retained with
the toolbox paperwork to which the turned-in item/items are assigned.

c. efo7e-Use inspections
1. It is the responsibility oI the Technician using a tool or piece oI
equipment to perIorm a BeIore-Use inspection on calibrated items.
2. At a minimum, the BeIore-Use inspection will include the Iollowing:
a. The physical condition oI tool, checking Ior any
obvious damage.
b. Ensure the calibration sticker is within date and
that the part number and serial number are legible.


`` 9. o77osion !7evention !7o7am

1. Preventive control measures must be conducted as soon as possible per the applicable
Technical Manual (TM) when aircraIt or associates equipment are suspected oI being
expose to any type oI environmental or atmospheric condition that could contribute to
any type oI corrosion.

2. The corrosion prevention program will include thorough cleaning, inspection,
preservation, and lubrication at the speciIic intervals in accordance with appropriate
aircraIt & equipment TM, TM 1-1500-344-23, chapters 3, 4, and Appendices D, & E

16

3. All inspections and scheduled or unscheduled maintenance / servicing activities will
include checks Ior corrosion damage and the integrity oI the protective Iinishes on
aircraIt and equipment.


10. Technical Info7mation
a. !"DR !7ocess
1. The Shop Supervisor will inIorm the QC Department oI any repeated
equipment malIunctions, materiel deIects, and maintenance procedure
discrepancies in the Technical Manuals.
2. All PQDR reports will be submitted in writing by the maintenance supervisor,
or MTP on. Maintenance section is responsible Ior completing sections I and II
beIore Iorwarding to technical aIIairs.
3. All PQDRs will be in accordance with policies and procedures established by
the QC Department.

. $/$L/TLX/OD Review $heet !7oced:7e

Note:
maintenance has submitted a revision suggestion to this process which is currently under review by the
Quality Manager.

1. The SB is received by tech pubs, and logged in by tech aIIairs and Iorwarded
to the applicable airIrame QC.

2. QC veriIies the aircraIt conIiguration and applicability to concerned Ileet and
then Iorwards to the maintenance supervisor Ior evaluation and analysis.

3. Mandatory SB's: Maintenance supervisor will evaluate the required parts /
kits required to accomplish the bulletin, and complete / attach parts request sheet
(this sheet will also state the drop dead date / time, oI bulletin to aid logistics
personnel). The bulletin then is submitted to stores / material planning Ior
processing. At the completion oI the logistics phase, the SB will be submitted to
QC Ior logbook entries and record keeping purposes. It is the responsibility oI
the logistics department to track the shipping / due in dates Ior Bulletin items. It
is the responsibility oI the QC department to administer Bulletin compliance.

4. Optional SB's: Maintenance supervisor will evaluate
SB data, and make a recommendation Ior compliance / non compliance based
on cost, and the eIIects oI downtime on Ileet. The SB is then returned to QC, to
be Iorwarded to Group 18 Ior authority approval. At no time will the
Maintenance Supervisor request parts Ior an optional SB beIore it is approved
by Group 18 / SOC. II an optional SB is approved, the same process will be
implemented as with a mandatory Bulletin (see Para. 2.1 above).
17

See below Flow Chart. (Figure 1)












Optional Mandatory
































Tech !:bs
1. Receives document.
2. Logs receipt.
3. Pass to Tech aIIairs.
Tech Affai7s
1. Reviews document.
2. Determines platIorm applicability.
3. Determines routing (optional or mandatory).
4. Initiates Iorm.

G18
1. Determines whether to
implement.
2. Passes Iorm back to Tech
AIIairs.
":ality ont7ol
1. Logs required action in log book.
2. ConIirm applicability.
3. Forward to Maint. Sup.
aintenance $:pe7viso7
1. Analyzes Ior manpower and parts requirements.
2. Takes Iorm to Supply


Tech $:pply
1. Issues document number.
2. Orders part/s.
3. Returns Iorm to Maint. Sup.
aintenance $:pe7viso7
1. Completes task
2. Takes Iorm to Q.C.
":ality ont7ol
1. Inspects work
2. Ensures logbook and records properly completed.
3. Takes Iorm to Tech AIIairs.
Tech Affai7s
1. Closes out records.
2. InIorms G18 task accomplished.
18


11. Technical Affai7s
The technical aIIairs section and its operational procedures are managed and
directed by the Quality Department. It is the responsibility oI the Maintenance
Supervisor, or his designated appointee to coordinate with Technical AIIairs with
reIerence to the Iollowing maintenance procedures and activities:
a. Technical Record Activities per TAMMS-A and TM 1-
1500-328-23.
b. ModiIication / repair issues which require OEM support.
c. Technical Publication revision requests.
d. Review / approval oI all TO's, SB's, SL's, AD's etc. issued by OEM's or
aviation authorities.
e. Oil Analysis Program scheduling and activities.
f. Weight / Balance Program.
. Corrosion Control Prevention program.
h. AircraIt deIerment or request oI extension Ior
maintenance.
i. QDR issues and reports.

12. aintenance and $hop $afety !7o7am
a. QC inspections oI maintenance and shop areas are perIormed with the
overall goal oI establishing sound, disciplined and saIe maintenance procedures and
practices. It is important to remember that a maintenance or shop area that is
overcrowded and unsaIe cannot produce eIIicient, quality work.

b. QC inspections Iocus on two main areas, ensuring established maintenance and
saIety practices are being adhered to.
1. The maintenance Iacility, to include maintenance and shop areas.
2. The test, measurement, and diagnostic equipment (calibration)
Iacility.
c. TIs are charged with perIorming maintenance and shop area saIety and
equipment inspections. These inspections will include but are not limited to the
Iollowing:
1. Cleanliness oI maintenance and shop areas.
2. Serviceability oI and absence oI corrosion on AGSE.
3. Accessibility oI and lack oI obstructions to Iire extinguishers.
4. Serviceability and saIe use oI cranes/hoisting equipment and liIting
devices.

13. Ai7c7aft/6:ipment Fo7ms and Reco7ds !7o7am
a. TIs manage and monitor all Iorms and records Ior accuracy and completeness.
They monitor aircraIt historical records, weight-and-balance records, aircraIt
maintenance records, blank Iorms, and PQDRs.

19

b. TIs, aircrew members, aviation maintainers, maintenance managers, record
clerks, supervisors, and commanders at all levels oI maintenance support
activities, have an equal stake in maintaining Iorms and records.

14. TO and $LL !7o7am
a. QC department updates the TBO list at 1 year or 300 hours
out.
b. QC department alerts the Maintenance Section Supervisor that an update has
been made.
c. The Section Supervisor checks stock availability oI the aIIected part.
1. II the part is available, the Section Supervisor will request the
part in ADMISS.
2. The part will be placed on the TBO shelI in the section sub-store.

Note:
II the part is removed Irom the TBO shelI, the sub-store tech will alert the Section Supervisor that the
part has been utilized and that a demand Ior a replacement is required.

3. II the part is not available through the Main or Sub-Store, check iI
there is an open requisition Ior the part.
4. II no open requisition Ior the part exists, make a demand in AADMIS
Ior the part. Add demand number to the TBO list.
5. II the part can be overhauled get with Technical Follow up to see iI
there is an open repair contract Ior the TBO item. Check Ior a turnaround
time.

d. The Section Supervisor will advise material planner when a requisition has been
made Ior a TBO part.

f. Material Planner alerts Maintenance Planner that the TBO parts list has been
updated.

. The TBO list will be checked during log book recon.

. Ai7c7aft aintenance $ection
!:7pose:
The purpose oI the Maintenance Section is to service, inspect, repair and occasionally
modiIy assigned aircraIt, systems and sub-systems in accordance with approved manuals,
instructions, policies and contracts.

F:nction:
1. Manage and coordinate manpower within the Maintenance Section
20

2. Manage workload assignments within the Maintenance Section.
3. Manage assigned programs.
4. Maintain accountability oI assigned personnel, inIormation and equipment.
5. Coordinate outside support when applicable.

!7oced:7es
1. Ai7c7aft ind:ction into aintenance
The maintenance instructions and procedures contained in this section are general
and applicable to hangar and shop operations. Maintenance instructions that are
speciIic to a particular aircraIt are contained in the applicable maintenance
manuals and will be used in conjunction with general inIormation contained in
TM 1-1500-204-23-1. The Iollowing steps should be complied with whenever an
aircraIt is inducted into Maintenance.

a. !a7in of Ai7c7aft in Hana7s

AircraIt parked in hangars shall be spaced a suIIicient distance apart to provide adequate clearance Ior
maintenance and servicing, while keeping Iine lanes clear at all times. All Iuel cells should be Iull in
order to minimize the presence oI Ilammable vapors within the Iuel cell (Ior saIety) and additionally to
minimize water condensation and subsequent microbiological growth which results in contamination oI
the Iuel. Accordingly, aircraIt will be serviced with Iuel prior to being parked or stored in a hanger.

b. G7o:ndin
All aircraIt parked in a hangar must be grounded (earthed) at all times.

c. D7ip pans
Drip pans shall be placed under aircraIt to collect oil and will be emptied daily.

d. !7otective ove7s
Ensure that air inlet and exhaust covers are installed when engines are not being operated, unless the
engine will be operated again shortly Iollowing shutdown. Cover all open lines, ports etc., whenever
they are opened or disengaged.

e. hocs/!a7in 7ae
AIter parking aircraIt, chock securely and apply parking brake as required.

f. !a7ts sto7ae d:7in maintenance
When serviceable components; such as seats, panels, and stanchions, are removed Irom an aircraIt and
temporarily stored to Iacilitate maintenance, a DD Form 1574, Serviceable Tag, does not need to be
completed Ior each item. A plain manila tag may be used to mark these items. Each tag must have, as a
minimum, the last three digits oI the aircraIt serial number and the part nomenclature/location entered on
the tag. This does not delete the requirement to tag unserviceable items, items in storage, or items turned
into supply activities. Some panels and major parts may have the ACFT SN permanently marked.

. Ref:el - Def:el Ope7ations
21

Servicing aircraIt with Iuel and deIueling aircraIt requires the utmost precaution due to the highly
Ilammable characteristics oI Iuel. Personnel perIorming Iueling and deIueling operations must be
thoroughly Iamiliar with applicable maintenance manuals, FM 10-68,
. (cont.) AircraIt Fueling, and FM 10-69, Petroleum Supply Point Equipment and Operations.
Personnel must also be completely Iamiliar with the aircraIt being serviced.

h. Oyen $e7vicin
Oxygen servicing requires the utmost precautionary measures due to the highly explosive and
Ilammable capabilities oI oxygen. Prior to servicing an aircraIt oxygen system, personnel shall
Iamiliarize themselves with the system, precautions, and instructions Ior handling gaseous oxygen,
operation oI servicing equipment, and potential hazards involved.

#
Do not allow petroleum base products to come in contact with oxygen system components, as an
explosion or fire may result.
Do not use masking tape to seal openings in oxygen regulators. Masking tape constitutes a safety ha:ard
when used on either serviceable or repairable oxygen equipment.
Do not use dry cleaning solvent, Federal Specification P-D-680, near oxygen storage or transfer
systems, the combination of these two will form a highly explosive mixture.

Oxygen servicing requires the utmost precautionary measures due to the highly explosive and
flammable capabilities of oxygen. Prior to servicing an aircraft oxygen system, personnel shall
familiari:e themselves with the system, precautions, applicable maintenance manuals, and instructions
for handling gaseous oxygen, operation of servicing equipment, and potential ha:ards involved.

&%O
Only qualified personnel shall be authori:ed to operate equipment for servicing of an aircraft oxygen
system. Damage to system may otherwise result.

a. SaIety Precautions. AircraIt shall not be serviced with oxygen when any oI the Iollowing conditions
prevail.
AircraIt electrical switches are on.
Ground powered equipment is operating within 50 Ieet oI the servicing area.
AircraIt is being serviced with Iuel, oil, or anti icing Iluids.
Any combustible items, such as Iluid, etc., are evident around oxygen
servicing equipment.
b. Servicing. General servicing procedures Ior oxygen systems are explained in the Iollowing
paragraphs.

&%O
Oxygen equipment shall be kept clean at all times. No organic matter or flammable substance of any
nature shall be allowed to contact oxygen. Ensure that all components of the systems are free of
moisture, oil and grease at all times. Oxygen is a nonflammable gas, however, it supports combustion
and lowers the flash ignition point of all combustible materials. Oxygen shall be handled as a flammable
gas.

22

hen an aircraft is being serviced with oxygen within 50 feet of an area where smoking is permitted,
NO SMOKING signs shall be placed at a 50-foot radius around the servicing area. A spark in the
servicing area could cause an explosion and damage to equipment.


1. To prevent overIilling oI tanks, personnel shall observe aircraIt oxygen system gauges at all times
during servicing operation.

2. Personnel shall be stationed at the oxygen servicing unit at all times during servicing operation to shut
oII unit valves immediately upon receiving a command Irom personnel watching aircraIt system gauge.

3. Service aircraIt Irom cylinders clearly Labeled DRY or AVIATOR'S BREATHING OXYGEN. Other
oxygen may have moisture which could cause Ilow stoppage at temperatures below Ireezing.

4. Always use a pressure-reducing device when servicing low-pressure oxygen system Irom high
pressure bottles.
5. Fill oxygen system slowly to prevent explosion resulting Irom heat generated by Iilling too Iast.

6. An aircraIt oxygen system not equipped with shutoII devices at cylinders shall be completely
discharged oI all pressure prior to removing components. All electrical power shall be turned oII during
oxygen discharge operations.

7. ReIer to the applicable aircraIt maintenance manual Ior additional inIormation and maintenance
procedures.

2. Ro:tine aintenance and Repai7 of ission
6:ipment (ROL)
O All mission equipment inspections, maintenance and repairs will
be completed IAW applicable maintenance manuals.

3. aintenance Test Fliht !7oced:7es

ote:
During actual aircraft operations, this document is intended to infer that mission, design series, aircrew
or Maintenance Test Pilots are adhering to current national airspace and local airfield operating
procedures and practices to include compliance with flight routes, ATC procedures etc. as per
applicable regulatory documents.

a. Gene7al Info7mation
Maintenance Test Flights, Functional Check Flights,
and Maintenance Operational Checks will be
conducted in accordance with TM 1-1500-
328-23 and applicable aircraIt manuals as per
contract statement, see paragraph 3 (m). Details on
DeIinitions, General InIormation,
Maintenance Test Flight Accomplishment,
23

Maintenance Test Flight Check Sheets, Maintenance
Operational Check Requirements and Maintenance
operational Check Accomplishment can be Iound in
TM 1-1500-328-23 section III.

b. A:tho7ization/aintenance Test Fliht
Accomplishment
To be sure that test and check Ilights are properly
conducted. Only aviators that are AircraIt
Maintenance Test Flight Course graduates, or have
qualiIied as stated below, will be selected to perIorm
maintenance test Ilights. All pilots must meet the
requirements oI SOC GFR (Flight Regulation) and
local policies beIore being appointed by the Unit
Commander and SOC Command as a 'Maintenance
Test Pilot Ior speciIic Mission, Design, and Series
aircraIt. Maintenance test Ilights will be
accomplished with assistance as necessary Irom the
most proIicient Ilight crew available, such as: (1)
copilots, (2) Ilight engineers, (3) technical
inspectors, and (4) observers. Aviators who are not
graduates oI a aircraIt maintenance test Ilight course
may be appointed as a 'Maintenance Test
Pilot upon completion oI an evaluation
administered IAW GFR and local policies.

c. Ai7c7ew and maintenance checlists
1. The publications and Iorms required by DA
Pam 738-751 will be in each aircraIt during
Ilight operations.
2. Operator and crew member checklists to
include MTF checklist procedures will be
used Ior beIore starting engines through
beIore leaving aircraIt checks.
3. Checklists will be used while perIorming
Maintenance Operational Checks,
Maintenance Test Flights, Functional Check
Flights, and preventive maintenance
inspections.
4. Only approved Operator`s Manuals and
Checklists will be used, unless otherwise
speciIied by Command, such as
Functional Check Flights.

d. aintenance test fliht ve7ification of ai7c7aft
on a Red ~X stat:s symbol.
24

1. When an in-Ilight deIiciency, with a Red
'X status cannot be duplicated during ground
tests and a maintenance test Ilight Ior
veriIication is deemed appropriate with an
acceptable degree oI risk, the Commander and
or assigned Maintenance Test Pilot may
authorize the Iollowing actions:
a. Enter in the Correcting InIormation
block, 'Status symbol changed to a Red
'', see entry below. The person
making this entry will enter his or her signature aIter
the statement, TIPID in the PID and TIPID block, and
last name initial over the Red 'X
in the Status box in the Fault
InIormation block oI the DA Form 2408-
13-1.
b. Enter in the next open Fault
InIormation block, 'AircraIt cleared Ior
a maintenance test Ilight to veriIy
(reason Ior test Ilight), sign your name Iollowing the entry,
and complete all portions oI the Fault
InIormation block that apply, to include PID.
c. Enter a Red '- in the Status box oI
the Fault InIormation block oI the DA
Form 2408131 and in the SYSTEM
STATUS symbol block on the DA
Form 240813.
2. II the condition does not recur during the
test Ilight, the maintenance test pilot will:
a. Enter in the Correcting InIormation
block, 'Could not duplicate, test Ilight
completedaircraIt released Ior
Ilight, complete all portions oI the
Correcting InIormation blocks that
apply, to include PID.
b. Put his or her last name initial over
the status symbol in the Status box in
the Fault InIormation block.
3. II the test Ilight conIirms that the in-Ilight
Iault or deIiciency exists, the test pilot will
enter in the Correcting InIormation block:
a. 'Test Flight Completed see entry
below.
b. Complete all portions oI the
Correcting InIormation block that
apply, to include PID.
25

c. In the next Fault InIormation block
reenter the Iault or deIiciency, the
proper status symbol, all inIormation
needed in the Fault InIormation
block, to include PID, and any
other inIormation noted
during the test Ilight.


4. R:n-:p and Taiin !7oced:7es
a. Gene7al
1. AircraIt run-up and ground taxi procedures
shall only be conducted by authorized
personnel and will be on unit orders IAW
GFR/local policy.
2. Standard Ilight line operational procedures
will be Iollowed in accordance with TM 1-
1500-204-23-1, chapter three.
3. Standard signals to aircraIt procedures will
be Iollowed in accordance with FM 21-60,
chapter Iive. (See Iigure 5-1 thru 5-22 Ior arm
and hand signals).
b. $afety
General saIety procedures Ior run-up and taxiing are
provided in the Iollowing steps.
1. Chock aircraIt securely beIore attempting
an engine run-up.
2. Check run-up area careIully to prevent rotor
or propeller blast Irom throwing sand and debris on other
aircraIt.
3. Ensure an adequately sized, serviceable Iire
extinguisher is on hand.

ote:
hen available, have the base fire truck standing by when starting a new or untested engine.

5. Ai7c7aft Recove7y
a. Gene7al
In the event oI an assigned aircraIt requiring recovery Irom
an oII station landing the Maintenance Section may
be tasked to assist in its recovery. The
Maintenance Manager shall ensure that each
design series aircraIt assigned, has a properly
equipped team identiIied and available Ior quick assembly. Each
team shall include, but not limited to, a SaIety
Representative, Maintenance Test Pilot, Technical Inspector and
26

necessary Maintenance Technicians. Also, the Maintenance
Manager shall consider the need Ior security, transportation
and additional logistic support and coordinate as
appropriate.

b. vac:ation of ai7c7aft on a Red ~X stat:s symbol
II it is deemed possible, with an acceptable degree oI
risk, to evacuate an aircraIt while the condition status is a
Red 'X, the Commander, or an equal management or
supervisory person in a SOC contract maintenance support
activity or their designated representative (usually a
maintenance oIIicer) may authorize a one-time evacuation
mission as Iollows:

ote:
One-time evacuation mission (recovery mission) is intended to allow the commander the flexibility,
during deployment in austere conditions, to authori:e more than one fuel stop to return the aircraft to
the first available maintenance facility. The commander is responsible for risk assessment of each leg of
the mission. The recovery mission terminology is not intended to allow return of a Red 'X` aircraft to
home station unless it is the first available maintenance facility.

1. Enter this statement in the Correcting InIormation block
oI the DA Form 2408131, 'Status symbol downgraded to
a Circled Red `X,` see entry below. The person making
this entry will enter his or her signature aIter the statement,
PID in the PID block that applies (PID or TIPID block),
and last name initial over the Red 'X in the Fault
InIormation block.
a. Enter a Circled Red 'X in the next Fault
InIormation status block and change the SYSTEM
STATUS symbol block on the DA Form 240813.
b. Enter this statement in the Circled Red 'X Fault
InIormation block: 'AircraIt cleared Ior a one-time
evacuation mission Irom .... to ...., sign your name
Iollowing the entry and complete all portions oI the
Fault InIormation block that applies to include the
PID block.
2. AIter completion oI the one-time evacuation mission the
pilot, authorized by the commander or designated
representative to perIorm the one-time evacuation mission,
will enter in the Correcting InIormation block: 'One-time
evacuation mission completed, status symbol upgraded to a
Red 'X. (see entry below.)
a. The pilot will enter his or her PID in the
Correcting InIormation PID block. A technical
27

inspector`s PID must be entered in the TIPID block
Ior units using the ULLS-A or LAS program.
b. The pilot will enter his or her last name initial
over the Circled Red 'X status symbol in the Fault
InIormation block.
c. The pilot will enter a Red 'X status symbol in the
SYSTEM STATUS block on the next open box on
the DA Form 240813 and the Status box in the
Fault InIormation block oI DA Form 2408131.
Reenter the original Iault and the pilot`s PID in the
Fault InIormation PID block.

6. $ec:7ity/Acco:ntability
a. !e7sonnel Repo7tin Each supervisor within
Maintenance will complete the daily attendance Ior their
section no later than 0830 daily to maintain
accountability oI assigned personnel.
b. Info7mation Dist7ib:tion and anaement
1. Technical Manual (TM) Familiarization ReI TC 3-04.7,
Para 9-32 to 9-35
A. QC, Shops and Maintenance Personnel will
maintain a technical data publications Iorm (TM
Familiarization Chart) to ensure maintenance
personnel understand changes to publications
relevant to their duties.
. All publications used to maintain supported
aircraIt and related aviation equipment, and the
names oI maintenance personnel will be listed on the
Iamiliarization chart.
. QC, Shops and Sections Supervisors are
responsible Ior tracking and announcing pertinent
inIormation updates requiring Iamiliarization.
D. Section Supervisors will ensure that assigned
personnel are Iamiliar with all changes aIIecting
supported aircraIt maintenance TM's and
publications.
. Maintenance personnel will validate and record
their Iamiliarization by initialing in the block
corresponding to each publication to indicate
currency. Validations are deleted as new
changes are received and announced.
F. QC will ensure validations are updated quarterly
or when a publication is changed.
G. QC checks the records during publication review
to ensure:
28

1. All publications used by maintenance
sections or shops are listed and
current to include the latest
changes.
2. All maintenance section or shop
personnel are listed.
3. All personnel have validated their
Iamiliarization with the latest change or
revision to the publications.

2. InIormation Reading File
a. The InIormation Reading File should be
divided into general and speciIic Iunctional
areas containing reIerence material on
regulations, directives, SOP's, saIety and
other appropriate topics.
1. General InIormation is to include but
not be limited to company inIormation
letters, memos and other pertinent
inIormation.
2. SaIety InIormation will include
monthly saIety topics, daily "toolbox
talk" subjects, quarterly SaIety Council
inIormation and other pertinent saIety
related inIormation.
b. New inIormation should be maintained in
the Iront section oI each general and speciIic
Iile area until the inIormation expires or is
permanently incorporated into a publication or
SOP.
c. The Section Supervisor will designate an
individual to monitor and update the
InIormation Reading File.
d. Section personnel must read the InIormation
Reading File upon initial employment within the
section and quarterly thereaIter. More Irequent
review may be necessary dependant on inIormation
being added to the Iile.

7. FOD and $afety heclist
Will be conducted daily 016 Discrepancies will be
corrected immediately iI possible. Issues which cannot be
dealt with straight away will be Iorwarded to the GSO Ior Iurther
action. A FOD and SaIety Checklist will be turned in
weekly to the 2
nd
Line Maintenance SaIety Council
Member and kept on Iile Ior 90 days.
29


8. Ai7c7aft 1acin
a. To ensure the saIety oI both aircraIt and personnel all
persons involved in aircraIt maintenance operations shall
be trained and certiIied on jacking operations. Training will
be documented utilizing the SaIety QualiIication
Training / CertiIication.
b. All personnel involved in jacking operations will review
and be thoroughly Iamiliar with the aircraIt jacking
procedures as stated in the speciIic technical manuals.
AircraIt jacking operations shall be perIormed IAW
applicable T.O.s, AMM`s, SaIety Letter (aircraIt
jacking) and T.M.s.
c. AircraIt jacks shall be maintained inspected and tested
IAW the applicable T.O., AMM and TM`s.
d. Maintenance technicians will inspect jacks prior to use to
veriIy liIting capacity, proper Iunctioning oI saIety locks,
condition oI pins and general serviceability.
e. When an aircraIt is supported by jacks, the area around
the aircraIt shall be secured (ropes and/or traIIic cones),
hangar doors closed, and warning signs posted
'AircraIt On Jacks.

9. Ai7c7aft G7o:nd Handlin
a. Towing aircraIt is not a hazardous operation when done
properly. Mishaps usually occur when personnel Iail to
Iollow established procedures or when team coordination
and attention lapse.
b. All personnel occupying a cockpit position (riding the
brakes), driving the tow vehicle or acting as the tow team
supervisor/leader shall be trained, qualiIied and certiIied
with documentation using SaIety QualiIication
Training / CertiIication.
c. Wing walkers and tail walkers require no specialized
training, but will be thoroughly brieIed by tow team
supervisor prior to each towing operation on areas
oI responsibilities, verbal, hand and emergency stop
signals and the route oI travel.
d. All aircraIt ground handling personnel shall be Iamiliar
with all published procedures (T.O.s, SaIety Letter
and T.M.s) pertaining to the type oI aircraIt being towed.
e. The Required minimum number oI tow team members to
saIely move aircraIt, including tow team supervisor is; CH-
47 aircraIt 5 members, all other airIrames 4 members).

10. T7ainin/Rec:77ent
30

a. Initial training is required Ior all personnel new to
the organization.
b. Recurrent training is a time based requirement to
renew either initial or specialized training.
c. The Section Supervisor will ensure that personnel
within the section receives initial training and
recurring training as required.
d. Documentation will be added to each employees
personnel Iile Iollowing successIul completion oI
training.
e. The SaIety Manager has overall responsibility Ior
ensuring that the SaIety training program is
implemented.
f. The SaIety Manager shall provide all personnel
with initial and recurring saIety related training,
such as; SaIety Program, Hearing Conservation,
Introduction to Personnel Protective Equipment
(PPE), Hazardous Communication, Flight line SaIety
and Fire Prevention.


11. Daily Ope7atin !7oced:7es
On a daily basis Supervisors will ensure that the
Iollowing is completed.
a. Daily FOD and SaIety check list is completed
b. Tool box inventories are completed at the start
and end oI each shiIt
c. Daily attendance is completed no later than 0830
d. Attend the daily PC meeting at 0800 (summer
shiIt) and 0830 (winter shiIt)
e. Update WOTS at the end oI their shiIt.
f. Appointed Technicians will complete daily beIore
use inspections on all GSE.
. Check Maintenance Calendar Ior daily
and monthly reminders

D. Wo7shop !7oced:7es
!:7pose:
Workshop sections perIorm preventive maintenance oI aircraIt components and
structures that require specialized technical skills. In addition, technicians assigned to
these sections perIorm scheduled and unscheduled maintenance, troubleshoot Iaulty
components, remove, replace and repair aircraIt components and LRUs and manage
bench stock at the shop level.


31


F:nctions:
Workshops comprises the Iollowing sections: Turbomeca Engine, Blade, Mission
Equipment, Armament, ALSE, NDI, Electronic WarIare, Rescue Hoist, Battery, GSE,
Paint, power train, structural (airIrame), pneudraulics (hydraulics), and avionics/electrical
sections. These sections are in place to support all aircraIt, systems and equipment.

!7oced:7es
1. ac shops $:ppo7t
a. All supported sections must initiate work orders when seeking workshop
support. The maintenance work order must be processed and accepted by the PC
oIIice beIore maintenance support or component repair can commence.
b. Maintenance work orders must be authorized by the PC oIIice to include a
priority designator. Once accepted by the PC oIIice and a high-priority designator
(01 through 03) has been assigned to work orders by the PC oIIice, they must be
distributed by the PC clerk to the supporting shop immediately. For other than 01
through 03 priority designator maintenance work orders, work orders will be
placed in the corresponding shops in-box in WOTS or given to the shops team
lead iI a manual work order is needed aIter the PC meeting. The shops Team Lead
will routinely check with the PC oIIice and WOTS Ior work orders.

2. Aviation Life $:ppo7t $ystem (AL$$)
a. All personnel assigned ALSE equipment will ensure their
equipment is maintained in a serviceable condition.
b. ALSE Scheduled inspections will be perIormed by authorized
ALSE personnel. Crew members are responsible Ior turning in
their own Ilight gear on time. The minimum turn in time Ior
ALSE inspections is one week prior the due date. Exceptions
may be granted on a case-by case basis but will not be considered iI
it is due to a lack oI responsibility. Items will be turned in with a
work order when due Ior inspection. Crew members can expect
a three day turn around on personal equipment periodic
inspections.
c. Aircrew member's helmets and vest shall be inspected
concurrently and the next inspection date shall be indicated on
tape on the side oI the visor assembly.

`` 3. G7o:nd $:ppo7t 6:ipment (G$)
a. A UAE Drivers License and Operator`s CertiIicate is required to operate the
Iollowing GSE on Group 18 airIield Iacilities; Tug, Personally Owned Vehicle
(POV), ForkliIt, Gator, Floor Sweeper and any other motorized, selI propelled
vehicle.
b. Operator`s CertiIicate is required to operate the Iollowing GSE and Hanger
Equipment: Electric Power Cart, Hydraulic Power Cart, Nitrogen Cart, AircraIt
Jacks, Hanger Doors and Overhead Hoists.
32

c. All training will be documented on a SaIety QualiIication Training /
CertiIication and this document will be entered into the employees training
Iolder.
d. BeIore use Inspections will be perIormed by the technician utilizing the
equipment. Work stands, jacks, cranes, and hoists will be inspected Ior proper
Iunctioning saIety items, i.e.., saIety locks, valid load test dates, guards, etc; any
discrepancy will be annotated on a work order, DA 2404 and submitted
immediately to the Ground Support Equipment shop Ior corrective action
e. All equipment and or compressed gas bottles requiring inspection, repair or
service will have a repairable tag (green) attached and a work order assigned
beIore sending items to the GSE shop.

`` . Aviation Loistics
!:7pose
The purpose oI the Aviation Logistics Section is to provide quality aviation parts
and material to the end user in a timely manner.

F:nction
1. Storage oI aviation parts and material.
2. Manage and maintain war stock quantities.
3. Manage and maintain non-war stock quantities.
4. Issue and receive parts and material in a timely manner.
5. Drive the rest oI us poor saps crazy.

!7oced:7es
1. Gene7al: Logistics procedures Irom the maintenance technician`s
perspective can be divided into three Iunctional areas which
are: 1) Requesting (demanding) items, 2) Receiving items
and
3) Turning in items.

2. Demand !7oced:7es
a. Manual Demand Procedures: Demand procedures
breakdown into three possibilities; 1) Stock available at the sub store, 2)
Stock not available at the sub store but available at the main
store, and 3) Stocks not available at the SOC.
1. For stocks available at the main store the Maintenance
Technician is required to check stock availability in the sub
store prior to requisitioning any item. II the item is
available at the sub store the sub store Logistics Technician
will issue the item without a requisition. The technician
will sign the issue voucher Ior historical records
Regardless oI classiIication oI item.
2. II the item is available at the Main Store a Parts Request
Form will be completed and signed by the person
requisitioning the item and the Section Supervisor (or other
33

authorized personnel). Once the Logistics Technician
retrieves the item Irom the main store, the item will be
issued and an issue voucher will be signed.
3. II no stock is available a 'Parts Request
Form authorized and approved by the Maintenance
Supervisor will be submitted to the sub store technician.







F. $afety !7oced:7es

!:7pose
The health and saIety oI the personnel within the organization is everyone's
responsibility. It is the saIety policy oI this organization to eliminate injuries to personnel
and damage to equipment due to preventable accidents. This will be accomplished by
minimizing risk and eliminating the conditions which could lead to an unsaIe or
unhealthy environment.

F:nction
This section oI the Maintenance SOP contains additional inIormation and guidance Ior
maintenance personnel, in support oI the SaIety Management Program.

!7oced:7es
1. Gene7al Info7mation
a. Army Regulation 385-10 adopts all Department oI Labor standards, including
the Occupational SaIety and Health (OSHA) Act oI 1970 as Army saIety
standards to be complied with in Army workplaces. Ref AR385-10, Pg (i), Para 2
b. The Section Supervisor has the responsibility oI ensuring that the workplace is
Iree oI known hazards and that procedures are being Iollowed by all maintenance
personnel. Ref DA Pam385-10, Chap 8, Para 8-2c
c. All personnel have the responsibility to report unsaIe or unhealthy working
conditions that they may uncover in their day-to-day activities. ReI DA Pam385-
10, Chap 8, Para 8-2c
d. The Section Supervisor will ensure a list oI all emergency numbers is posted in
various areas throughout the Iacilities and visible to all personnel. Ref
29CFR1910.165 (b) (4)
e. The Maintenance SaIety Council Member will liaise with the Section
Supervisors Ior the purpose oI designating in writing, an Additional Duty SaIety
Representative Ior each section.



34


2. Ris Assessment and Haza7d anaement
a. The key to a successIul saIety program is the identiIication oI hazards, potential
hazards and likely situations Iollowed up with careIul assessment and
management oI the risks associated with them.
b. Hazard Report Iorms are available beneath the yellow submission boxes on all
hanger saIety boards and can be Iiled anonymously iI desired.
c. It is everyone`s responsibility to identiIy and eliminate hazards. II a hazard
cannot be rectiIied immediately or iI an unsaIe act or condition is observed, an
Operational Hazard Report should be submitted to the GSO.
Ref 29CFR1960.28, 46
d. Following receipt oI the Operational Hazard Report, the GSO will investigate,
with a written report to the submitting party, iI known, no later than 10 days aIter
submission.
Ref AR385-10, Para 4-4(d)
e. The GSO will maintain a hazard log with supporting documentation in order to
properly track hazards and the steps taken to eliminate them.

2. Initial $afety T7ainin
a. The SaIety Manager will brieI all New-Hire personnel on the general saIety
procedures and policies utilized by the organization. This will include, but not be
limited to the GAL SaIety program, Hearing Conservation, Introduction to PPE,
Hazardous Communication, Flight line SaIety, Fire Prevention and FOD
Prevention.
b. Section Supervisors or their designated representative will brieI all New-Hire
personnel on the worksite speciIic saIety programs and requirements.
c. $ection $:pe7viso7s will maintain a training Iolder Ior each individual
assigned to his/her section




3. $afety :lletin oa7d
a. SaIety Boards should be as big as needed to hold all the items required,
including a Iirst aid kit and whenever possible, they will be centrally located in
the hanger.
b. They should be painted white with a two-inch green border. The words 'SaIety
Board should be painted in white letters on a green rectangle.
c. The SaIety Board will have the saIety equipment necessary based on the hazard
assessment, mission and work environment.
d. The minimum relevant inIormation to be posted on the SaIety Board shall
include the Name and duty phone number oI the SaIety Manager and Aviation
SaIety Advisor, SaIety Policy Letter, A completed Hazard Report, Blank
incident/ accident Iorms and SaIety awareness literature.
e. Access to saIety boards will remain clear oI obstructions. In an emergency,
even the Iew seconds it takes to move clutter could cost a liIe.
35

f. Monthly saIety board inspections will be carried out to ensure all items are on
available and in good condition.
. Initial and recurring saIety equipment Iamiliarization training will be provided
Ior all employees working in the hangar, to include all items listed on the saIety
board.

Fi7st Aid
a. All sections/shiIts should have at a minimum, one person trained to render Iist
aid. Ref 29CFR1910.151, 156

ote:
Federally accepted response time for first aid in a location where serious infuries are possible is 3-4
minutes.

b. Any employee tasked with providing Iirst aid will comply with the Blood borne
Pathogens regulation.
Ref 29CFR1910.1030 (g) (2)
c. Each section will maintain a Iirst aid kit with all the necessary medical
equipment needed to assist immediately and eIIiciently in the event oI an accident
in the work place.
Ref 29CFR 1910.151 (b).
d. The Iirst aid kit will be in accordance to the level oI hazard in the hangar or as
speciIied by the GSO.
Ref 29CFR1910.151 (b)
e. Each section will maintain an inventory list with the Iollowing inIormation:
Nomenclature, Expiration dates, Quantity, Inventory date, name oI the person
who conducted the inventory.
f. Any item used or missing Irom the Iirst aid kit will be noted and a request Ior
immediate replacement sent to the GSO. Expired items will be turned in to the
GSO with an itemized list oI required replacement items.
. The Iirst aid kit will be maintained in a sanitary condition and inspected
monthly or immediately aIter use. First aid kits will have a break-away seal to
indicate use.
h. Fixed continuous Ilow or portable eyewash stations will be provided in each
Iacility where eye injuries are possible.
Ref 29CFR1910.151(c)
i. Eyewash stations will be cleaned and inspected weekly, with the Section
Supervisor and GSO being notiIied oI any discrepancies. Replacement portable
eyewash bottles will be ordered through the GSO.

3. Inj:7y Repo7t
a. All accidents and injuries will be reported through the chain oI command,
including the GSO, to the 2
nd
Line Maintenance Manager as soon as possible
b. Written accident Iorms will be completed within 24 hours and submitted to the
2
nd
Line Maintenance Manager with a copy going to the GSO.

36

4. Incident/Accident Repo7ts
a. NotiIication oI incidents and accidents is the responsibility oI the individuals
involved and any witnesses to the event.
b. NotiIication will utilize the Iollowing Iorms; Special Occurrence Report
(SOR), Ground Occurrence Report (GOR), Hazard Report, Discrepancy Record.
1. $pecial Occ:77ence Repo7t
The completed Pilot Initial Report element oI the SOR will be given to the
GSO within 24 hours oI the incident. The SOR will be completed and
submitted within 10 days Ior any incident occurring during the period oI
operation oI an aircraIt as speciIied by the regulations and GSO.
Additionally, any Ilight-related aircrew or ground crew error that occurs
which reduces the normal level oI saIety will require a completed SOR.
2. G7o:nd Occ:77ence Repo7t
The GOR Initial Report should be sent within 24 hours oI the incident
occurrence and will be identiIied by a tracking number consisting oI the
Company/Time/Date/ number (48 / 1330 / 30-09-07 / 01). Ground
Occurrences will be classiIied as Iollows:
a. ajo7: Occurrences involving the loss oI liIe or permanent
disability or where the incident causes an absence Irom work in excess oI
5 days. Damage to property or equipment such that the item(s) is
destroyed or beyond reasonable repair and the item(s) are essential in the
operation oI the section where used.
b. ino7: Occurrences involving injuries oI a minor nature not
requiring specialized medical attention. Damage to property or equipment
such that the item(s) can be repaired or replaced within normal working
conditions.
3. Haza7d Repo7t
A Hazard Report will be Iilled out whenever a hazard is noticed that
cannot be immediately corrected or is a recurring incident.
4. Disc7epancy Reco7d
A Discrepancy Report is generated when a system or process is in place
but is not being Iollowed. The discrepancy is noted and passed to the
relevant supervisor or manager Ior correction.
c. In case oI doubt, the SaIety Section should be asked Ior advice on completing
these Iorms.

5. vac:ation !lan
a. The hangar and shops used by Maintenance must have a written Emergency
Action Plan, to include a Fire Prevention Plan and an Evacuation Plan Ior all
personnel to Iamiliarize themselves with and to review as necessary.
b. The Evacuation Plan should be located in a visible area, and describe the
precise route oI evacuation and designated gathering point Ior all personnel within
that section. This document will be part oI the publications included in the
InIormation Reading File.
c. The Section Supervisor or a delegated individual will ensure that all employees
are accounted Ior Iollowing an evacuation. Ref 29CFR1910.38(c) (4).
37

d. All Designated Emergency Exits must be highly visible to all personnel and
correctly marked to aid in the rapid evacuation oI the hanger. Ref 29CFR1910.37
(b) (1) & (2)
e. All doors along exit route that could be mistaken Ior exits must be marked 'Not
an Exit. Alternately, each door will be marked as to its purpose or Iunction (i.e.
Closet).
Ref 29CFR1910.37 (b) (5).
f. All hangar and shop Egress Lanes must be Iree and unobstructed. No equipment
or materials may be placed, either temporarily or permanently within the exit
route. Any obstacle in the exit route could prevent personnel Irom evacuating the
area in case oI an emergency. Ref 29CFR1910.37 (a) (3).
. The Name or job title oI every employee who may be contacted by employees
needing more inIormation regarding the Emergency Action Plan, Fire Prevention
Plan and Evacuation Plan or an explanation oI their duties under the plans will be
posted. Ref 29CFR1910.38(c) (5).

6. Fi7e tin:ishe7 $afety/Fi7e !7evention
a. Monthly Fire SaIety Surveys will be conducted by the Maintenance SaIety
Council Member to assist in identiIying potential risk Iactors. Completed surveys
will be signed by each Section Supervisor and kept on Iile Ior a period oI 12
months.
b. Section Supervisors and maintenance personnel will assist in correcting any
hazard identiIied during the Monthly Fire SaIety Survey.
c. A discrepancy report detailing hazards which cannot be immediately corrected
will be Iorwarded to the Maintenance Manager on a monthly basis.
d. Fire extinguishers must be Iully charged and in serviceable condition, visible,
and in the designated area, access to which is unobstructed. Ref
29CFR1910.157(c)(1),(4)
e. Fire extinguishers must be inspected on a monthly basis or as per
manuIacturer`s recommendations. Additionally all portable Iire extinguishers will
be subjected to an annual maintenance check. Ref 29CFR1910.157 (e) (3)
f. All personnel must be properly trained in the proper use oI the Iire
extinguishers.
. Training will be given upon initial employment and at least annually thereaIter.
Ref 29CFR1910.157 (g) (1)
h. Supervisors will request this training Irom the unit GSO. A record oI training
will be added to the personnel training Iiles.
I. All hangars will have Iire extinguishers compatible with the materials used in
the work area. Ref 29CFR1910.157(c) (2), (d) (1)
j. All Iire extinguishers will meet the requirements established by an approved
saIety standard or as per GSO guidance.
Ref 29CFR1910.157(c) (2).
. Maintenance personnel will utilize extinguishers and Iire Iighting apparatus
only to the extent that they have been trained. This training will then only be used
to Iight small, selI contained Iires.
38

l. At no point will maintenance personnel risk injury or loss oI liIe to contain
Iires.

7. !e7sonal !7otective 6:ipment (!!)
a. In accordance with the requirements oI the Workplace Hazard Assessment, all
Maintenance personnel will wear the proper PPE assigned to the section and/or
the individual to protect him/her Irom injuries at the work place. Ref
29CFR1910.132 (d) (1), (1) (i)

b. Section Supervisors will ensure that all Maintenance personnel comply with
this requirement.
c. Training in the use oI (PPE) will be conducted on initial employment and on an
annual basis thereaIter. Additional training may be required upon the receipt oI
new machinery or equipment or when a new task or procedure is utilized, which
could expose personnel to the risk oI injury.
Ref 29CFR1910.132 (f) (1)
d. All PPE training will be documented with a copy included in the personnel
training Iiles. Ref 29CFR1910.132 (f) (4)
e. The Section Supervisor will ensure all PPE is maintained in good sanitary and
working order. Ref 29CFR1910.132 (a), (b)
f. All deIective PPE will be replaced immediately.
Ref 29CFR1910.132 (e)
. All Maintenance personnel using power tools/machinery will wear saIety
goggles/Iace shield and noise attenuating devices. Goggles and Iace shields will
meet or exceed the saIety standard established by the GSO.
Ref 29CFR1910.133 (a) (1)
h. The work area will display all the necessary saIety signs indicating the use oI
the required PPE, i.e. gloves, glasses, mask, etc., and they will be visible to all
shop personnel.
Ref 29CFR1910.145 (a), (b), (c), TM1-1500-204-23-4, Para4-1a
i. All employees will wear the company`s authorized work clothing during
working hours. All protective clothing will be managed through Non-Aviation
Stores under the Protective Clothing and Equipment Program. Ref GAL-QC-SOP-
005, Para 12.6

8. Hea7in onse7vation
a. All Group 18 maintenance Iacilities have the potential Ior noise exceeding
85db. To avoid hearing degradation, all assigned personnel will use the
appropriate hearing protection when exposed to high level oI noise.
b. All maintenance personnel will abide by the hearing conservation program
established by the GSO
9. Respi7ato7y !7otection
a. In the control oI those occupational diseases caused by breathing air
contaminated with harmIul dusts, Iogs, Iumes, mists, gases, smokes, sprays, or
vapors, the primary objective will be to protect maintenance personnel Irom
respiratory injuries. Ref 29CFR1910.134 (a) (2)
39

b. Supervisors will ensure all personnel comply with the Respirator Program
established by the GSO or designated personnel.
c. Supervisors will ensure the technician is provided with respirators that are
applicable and suitable Ior the purpose intended. ReIer to the manuIacturer`s
instructions Ior more details.
d. Supervisors will regularly consult employees required to use respirators to
assess the eIIectiveness on the program and to identiIy deIiciencies. Any
problems that are identiIied during this assessment will be brought to the attention
oI the relevant manager and/or GSO Ior immediate action.

10. Haza7do:s omm:nication (HAZO)
a. All maintenance personnel will Iamiliarize themselves with the company
Hazard Communication Program.
b. All HAZCOM training will be Iacilitated through the GSO and
HAZMANT/POL Supervisor.
c. A list oI all known hazardous chemicals utilized in each Iacility will be posted
and available to maintenance personnel. Ref 29CFR1910.1200 (e) (1) (i)
d. Chemical warning labels will be utilized when decanting hazardous chemicals
into secondary containers. This does not apply to secondary containers Irom
which the contents will be immediately and completely utilized and will not
require storage. Ref, 29CFR1910.1200 (f) (7)
e. Material SaIety Data Sheets (MSDS) will be maintained in each Iacility
utilizing hazardous chemicals.
Ref 29CFR1910.1200 (g) (1)
f. Training will be provided to all maintenance personnel covering categories oI
hazards, speciIic chemicals and the use MSDS sheets. Ref 29CFR1910.1200 (h)
(1)
. Any chemical in the workplace that does not have a corresponding MSDS sheet
will not be used until one is available. Contact the HAZMAT/POL Supervisor to
obtain the required MSDS documentation.

11. nvi7onmental !7otection
RF: GAL-"-$O!-001
a. All maintenance personnel will make every eIIort to avoid contaminating the
environment. When in doubt, ask the Section Supervisor, unit HAZMAT/POL
technician, GSO or designated personnel Ior proper disposal procedures.
b. In the event oI a spill, containment will be perIormed. The Section Supervisor,
HAZMAT/POL supervisor, GSO and the 2
nd
Line Maintenance Manager will be
notiIied as soon as possible.
c. All HAZMAT/POL waste will be placed in the designated disposal area.
HAZMAT/POL personnel will be notiIied to arrange Ior collection.
d. SaIety Program Manager (Environmental Protection) HAZMAT/POL
Supervisor will develop and implement Iurther environmental protection plans.
ate7ial Handlin (Ho:seeepin)
RF: GAL-"-$O!-001
40

a. Materials, equipment, tools, etc. will be stored in such a way that they do not
create a hazard. Aisles, passageways, exits and access to emergency alarms and
equipment will be kept clear oI obstructions. Ref 29CFR1910.176 (a), (b)
b. In order to maintain good housekeeping in the workplace, the technicians will
clean as they go to ensure all work areas are properly maintained. Ref DA
Pam385-90, Para 2-8d (3) (c), 29CFR1910.176(c)
c. Inspect and clean work areas at the end oI each shiIt. When completed, the
person perIorming the check will initial the corresponding area on the FOD and
SaIety Checklist. All sections oI the Checklist will be completed prior to the end
oI the shiIt/day.
d. Spills will be cleaned up as soon as practical with the appropriate absorbent
cleaning kit and disposed accordingly in the hazmat waste, not in the regular
garbage.
e. Dripping oil and/or hydraulic Iluids will be collected in drip pans, which will be
wiped clean daily.
f. All personnel will comply with all applicable installation requirements and
guidelines Ior the disposal oI waste products such as water, soap, and solvents.
When in doubt ask the GSO Ior guidance.

12. !e7mit-Re6:i7ed onfined $paces

a. A conIined space is deIined as any space large enough that a person can enter
and perIorm a task, but has limited or restricted means oI entry or exit and is not
designed Ior continuous occupancy. Ref 29CFR1910.146 (b)
b. Entry into these conIined spaces will utilize a 'Permit-Required ConIined
Space Program. A written permit (GAL Form # TBA) veriIying that the space is
saIe Ior entry will be completed prior to any person entering the space.
Ref 29CFR1910.146 (b), (c)
c. The permit will include: The date; Location and description oI the space;
Purpose oI entry; Authorized duration oI the permit; Authorized entrants; Name
oI attendants; Name oI the person serving as Entry Supervisor; Hazards oI the
space; Measures used to eliminate hazards: The name and signature oI the
approving Manager/Supervisor.
Ref 29CFR1910.146(c) (5) (ii) (H), 29CFR1910.146 (f) (1)-(f) (8)
e. Permits will be retained Ior a minimum oI 1 year to Iacilitate the review oI the
Permit-Required ConIined Space Program. Any problems encountered during an
entry operation shall be noted on the pertinent permit so that revisions to the
program can be made. Ref 29CFR1910.146 (e) (6)
f. Prior to any person entering a permit-required conIined space, the atmosphere
will be tested with a calibrated direct-reading instrument to check oxygen content,
Ior Ilammable gases and vapors and Ior any toxic air contaminants, in that order.
Ref 29CFR1910.146(c) (5) (ii) (B)
. Continuous Iorced air ventilation shall be used to eliminate any hazardous
atmosphere prior to entry and will continue until the space is no longer occupied.
Ref 29CFR1910.146(c) (5) (ii) (E) (2)
41

h. The atmosphere within the space shall be periodically tested as necessary to
ensure that the continuous Iorced air ventilation is preventing the accumulation oI
a hazardous atmosphere.
Ref 29CFR1910.146(c) (5) (ii) (F)
i. Prior to entering the space, the individuals involved have the right to see both
the approved permit Ior entry and any atmospheric test results. Ref
29CFR1910.146(c) (5) (ii) (C) & (H)
j. The Authorized Entrant will:
1. Be trained and knowledgeable oI the hazards oI entry, to include the
mode, signs or symptoms and consequences oI exposure. They will be in
the use oI and be Iamiliar with all required PPE.
Ref 29CFR1910.146 (h) (1), (h) (2)
2. Have an Attendant and be able to communicate as necessary to enable
the Attendant to monitor the Entrants` status as well as alerting him/her oI
the need to evacuate the space. Ref 29CFR1910.146 (h) (3)
. The Assigned Attendant will:
1. PerIorm no duties that might interIere with his/her primary duty to
monitor and protect the Authorized Entrants. Ref 29CFR1910.146 (i) (10)
2. Remain outside the conIined space until all Entrants have leIt the space
or until relieved by another designated Attendant. Ref 29CFR1910.146 (i)
(4)
3. Be trained and knowledgeable oI the hazards oI entry, to include the
mode, signs or symptoms and consequences oI exposure and oI possible
behavioral eIIects oI exposure. Ref 29CFR1910.146 (i) (1)
4. Monitor the activities inside and outside the conIined space to
determine iI it is saIe Ior Entrants to remain inside. II a determination is
made that a hazardous condition exists, either inside, outside or with the
Entrant, the Attendant will immediately order that the space be evacuated.
Ref 29CFR1910.146 (i) (6)
l. The Entry Supervisor will:
1. Be trained and knowledgeable oI the hazards oI entry, to include the
mode, signs or symptoms and consequences oI exposure and oI possible
behavioral eIIects oI exposure. Ref 29CFR1910.146 (f) (1)
2. VeriIy by checking that the appropriate entries have been made on the
permit, that all tests speciIied by the permit have been conducted and that
all procedures and equipment required are in place beIore endorsing the
permit and allowing entry to begin.
Ref 29CFR1910.146 (f) (2)
3. Terminate the entry and cancel the permit when entry operations
covered by the permit have been completed or when a condition that is not
allowed under the permit arises in or near the permit space.
Ref 29CFR1910.146 (f) (3), (e) (5)

13. Loco:t/Tao:t !7o7am
a. In order to prevent injury to personnel and/or damage to equipment, a
Lockout/Tagout Program has been established. This program is designed to
42

prevent the unexpected energizing or startup oI a piece oI equipment undergoing
maintenance.
Ref 29CFR1910.147 (a) (3) (i)
b. Due to the limits oI airIrame design a physical lockout is usually not possible,
thereIore a Tagout system will be utilized. An approved Tag will be used to
indicate that the isolating device and the equipment being controlled may not be
operated until the Tagout device is removed.
Ref 29CFR1910.147 (b), (c) (2) (i)
c. Tagout devices, including their means oI attachment, shall be substantial
enough to prevent inadvertent or accidental removal. Attachment oI the Tagout
device will utilize all environment-tolerant nylon cable ties. Ref
29CFR1910.147(c) (5) (ii) (C) (2)
d. Tagout devices will be standardized throughout the organization and will
consist oI a 30cm x 30cm White Sign with Red Block-Style Letters 6cm Tall.
These devices will be used to warn against a speciIic hazard condition, Ior
example; 'NO ELECTRIC POWER and 'NO HYDRAULIC POWER.
Ref 29CFR1910.147(c) (5) (ii) (B)
e. Tagout devices will indicate the identity oI the individual applying the device.
Ref 29CFR1910.147(c) (5) (ii) (D)
f. When the Tagout device is attached it is not to be removed without
authorization Irom the person responsible Ior it and it is never to be bypassed,
ignored or otherwise deIeated.
Ref 29CFR1910.147(c) (7) (ii) (B)
. The Tagout device shall be removed by the individual who applied it. In the
event that the person who applied it is unavailable, the Section Supervisor can
authorize removal oI the device aIter ensuring that the removal poses no threat oI
injury to personnel and/or potential damage to the equipment.
Ref 29CFR1910.147 (e) (3)
h. AIIected maintenance personnel will be notiIied by the Supervisor or an
authorized employee oI the application or removal oI a Tagout device.
NotiIication shall be given prior to the Tagout device being applied and aIter it
has been removed.
Ref 29CFR1910.147(c) (9)
i. All aIIected employees will be trained to ensure that the purpose and Iunction oI
the Lockout/Tagout Program is understood and that the knowledge skills required
Ior the saIe application, usage and removal oI the Lockout/Tagout devices are
acquired by employees. Ref 29CFR1910.147(c) (7) (i)
j. An inspection and review oI the Lockout/Tagout Program will be perIormed at
least annually to ensure that the procedures and requirements oI the program are
Iollowed and remain relevant. Ref 29CFR1910.147(c) (6) (i)
. The inspection is to be perIormed by an authorized individual who is not
involved in the program and the resultant outcomes are to be used to correct
deIiciencies in the program.
Ref 29CFR1910.147(c) (6) (i) (A), (B)

14. Radio F7e6:ency (RF) Haza7ds
43

a. When perIorming maintenance tasks it is essential that personnel are aware oI
the potential hazards associated with Radio Frequency (RF) energy transmissions.
b. Exposure to RF energy can cause serious immediate and long term injuries to
personnel.
c. Various types oI RF systems are in current use. These can include, but are not
limited to Radar, Forward Looking InIra-Red (FLIR), High Frequency (HF), Very
High Frequency (VHF) and Ultra High Frequency (UHF) systems. It is important
to note that additional tactical systems are oIten Iitted to aircraIt.
d. No RF system will be operated while the aircraIt is being Iueled or deIueled.
e. No personnel will be in the immediate area oI an antenna when transmitting.
f. The Section Supervisor will ensure that all applicable warning signs are in place
and that maintenance personnel are brieIed about the relevant hazards prior to
working on or around an RF system.
. It is the responsibility oI the maintenance personnel working on an aircraIt to
Iamiliarize themselves with the identiIied RF hazards, to include associated
warnings and cautions, through the use oI the operations and maintenance
manuals Ior that speciIic aircraIt.

`` G. T7ainin !7oced:7es

``H. Non Aviation $to7es !7oced:7es

!:7pose: To supply the end user with quality tools, equipment
and material in a timely manner.

F:nctions:
1. Storage oI non aviation parts and material.
2. Manage and maintain property books
3. Manage and maintain HAZMAT and POL supplies.
4. Issue and receive parts and material in a timely manner.
5. Provide a single point oI contact Ior Facilities
Maintenance.
6. Issuing procedures Ior clothing supplies which Iall
under the Protective Clothing and Equipment Program.
7. Issuing procedures Ior non-aviation supplies.

!7oced:7es:
1. Purchase Order Request: Items needed oI the non aviation type can be request through
the Non Aviation Store using the Purchase Request Iorm, see chapter VIII. Describe the
items to the best oI your ability using publications and pictures iI available. The
signatures are as Iollows:
a. The requesting Manager / Supervisor.
b. The Calibration Shop Manager iI a calibrated item.
c. Logistics Supervisor


44

eep copies and follow :p weely.

2. Facilities Maintenance requests can be submitted utilizing the Maintenance Work
Order Form, see Iorm reIerence. Complete one request Ior each area oI expertise, such as
one Ior plumbing and another Ior electrical work. Also keep copies and Iollow up
weekly.

``I. HR !7oced:7es

ReIer to GAL Employee Handbook, Revision 1

. Haza7d omm:nication
1. Supervisors will ensure all personnel comply with all the
policies and procedures established in the Hazard Communication
2. All HAZMAT items will be marked with the appropriate
label indicating the risk Iactor, and the PPE required Ior saIe-
handling oI said chemical. These chemicals will be stored in an appropriate
HAZMAT locker with a visible warning sign that reads 'FLAMMABLE
KEEP FIRE AWAY. All corrosive chemicals will be stored in an
appropriate locker, separate Irom HAZMAT locker, with a visible warning
sign that reads 'CORROSIVE. All incompatible chemicals will be used
and stored at a distance Irom each other (e.g. bleach and ammonia).
3. A Material SaIety Data Sheet (MSDS) will be maintained Ior
every chemical in the work place. They will be Iiled in an appropriate
yellow and black MSDS binder nearby the HAZMAT cabinet, and
must be readily available to all personnel. The MSDS will be part oI the
most common publications in the Familiarization Chart.
4. The section will maintain an up-to-date inventory oI all the
items in the HAZMAT locker.






XII. Refe7ences
AMC-R 11-47
AR 25-400-2
AR 385-10
AR 700-138
AR 750-1
DA PAM 38-751
DA Pam 385-90
FM 3.04-500
FM 10-68
FM 10-69
45

TB 04-211
TC 3.04.500
Title 29, Code oI Federal Regulation (CFR) 29CFR1910, 29CFR1960
TM 1-1500-204-23
TM 1-1500-204-23-1
TM 1-1500-204-23-4
TM 1500-328-23