BY ORDER OF THE SECRETARY OF THE AIR FORCE AIR FORCE INSTRUCTION 21-101 21 ...

420 Pages·2015·2.71 MB·English

Administrative Changes to AFI21-101 AFRC SUPPLEMENT, Aircraft and Equipment
Maintenance Management

OPR: AFRC/A4MM

Change all reference of “AFI 21-101” to “DAFI 21-101” throughout this AFRC Supplement. 18
April 2022

Change all reference of “Air Force Instruction 21-101” to “Department of the Air Force
Instruction 21-101” throughout this AFRC supplement. 18 April 2022

Change all reference of AFI 33-360 to DAFI 90-160 throughout this publication. 10 November
2022

Change all reference of Air Force Instruction AFMAN 33-361 to DAFMAN 90-161 throughout
this publication. 10 November 2022
BY ORDER OF THE AIR FORCE INSTRUCTION 21-101
SECRETARY OF THE AIR FORCE
16 JANUARY 2020
AIR FORCE RESERVE COMMAND
Supplement
13 AUGUST 2020
Incorporating Change 1, 2 March 2022

Corrective Actions Applied,
4 NOVEMBER 2022
Maintenance
AIRCRAFT AND EQUIPMENT
MAINTENANCE MANAGEMENT
COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available for downloading or ordering on the e-
Publishing website at www.e-publishing.af.mil.
RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AF/A4LM Certified by: SAF/AQD
(Ms. Angela L. Tymofichuk)
Supersedes: AFI 21-101, 1 May 2015; Pages: 419
AFI 21-110, 16 Jun 2016;
AFI 21-123, 3 Feb 2017;
AFI 21-124, 12 Jan 2017; and
AFI 21-136, 3 Feb 2017
OPR: AFRC/A4MM Certified by: AFRC/A4
(Brig Gen William R. Kountz, Jr.)
Supersedes: AFI21-101_AFRCSUP,
Pages: 419
24 August 2015;
AFI21-124_AFRCSUP,
20 January 2016;
AFI21-136_AFRCSUP,
04 January 2018;
AFRCI 21-108,
15 May 2012.
2 AFI21-101_AFRCSUP 13 AUGUST 2020
This publication implements Air Force Policy Directive (AFPD) 21-1, Maintenance of Military
Materiel. It is the basic Air Force Instruction (AFI) for all weapon system and support equipment
maintenance management guidance. It provides the minimum essential guidance and procedures
to safely and effectively maintain, service, and repair weapon systems and support equipment.
This publication applies to all military and civilian members of the Regular Air Force (RegAF),
Air Force Reserve (AFR) and Air National Guard (ANG) and those with contractual obligation to
comply with Air Force publications. Supplements and addendums are written in accordance with
(IAW) AFI 33-360, Publication and Forms Management. Supplements must identify and
document Major Command (MAJCOM), AFR, and ANG required deviations (applicability,
variance, exception and differences in organizational placement of responsibilities/processes) in
their supplement and addendums with the abbreviation “(DEV)”. Place the “DEV” entry after the
Paragraph number and directly preceding the affected text, such as (AMC) (DEV) Use the... or
(ADDED-AMC) (DEV) Use the...). All supplements and addendums are submitted to the Air
Force Maintenance Division (AF/A4LM) @ usaf.pentagon.af-a4.mbx.a4lm-maintenance-
[email protected] for approval and are published in the e-Publishing website. The authorities to
waive wing and unit level requirements in this publication are identified with a Tier (“T-0, T-1, T-
2, T-3”) number following the compliance statement. See AFI 33-360 for a description of the
authorities associated with the Tier numbers. Submit requests for waivers through the chain of
command to the appropriate Tier waiver approval authority, or alternately, to the requestor’s
commander for non-tiered compliance items. For questions on interpreting this instruction, first
contact your MAJCOM maintenance functional activity. Refer recommended changes and
questions about this publication through your MAJCOM, AFR or ANG, to the Office of Primary
Responsibility (OPR) using the Air Force (AF) Form 847, Recommendation for Change of
Publication; route AF Forms 847 from the field through the appropriate functional chain of
command. Ensure all records created as a result of processes prescribed in this publication are
maintained in accordance with AFI 33-322, Records Management and Information Governance
Program, and disposed of in accordance with the Air Force Records Disposition Schedule located
in the Air Force Records Information Management System. The use of the name or mark of any
specific manufacturer, commercial product, commodity, or service in this publication does not
imply endorsement by the AF.
(AFRC) This instruction implements AFPD 21-1, Air and Space Maintenance, and extends
guidance of Air Force Instruction (AFI) 21-101, Aircraft and Equipment Maintenance
Management. This supplement applies to AFRC unit equipped (UE) organizations, as well as
Active Associate units when AFRC is the lead. Classic associate units will follow the guidance of
their host unit MAJCOM except for Administrative Control (ADCON) functions. Paragraph
11.15 applies to all AFRC units that own/utilize GITA/TAA to train. This supplement does not
apply to the ANG. Refer questions for interpreting this supplement and the basic AFI to
AFRC/A4MM ([email protected]), Maintenance Policy and Procedures. Ensure that all
records created as a result of processes prescribed in this publication are maintained in accordance
with AFMAN 33-363, Management of Records, and disposed IAW Air Force Records Information
Management System (AFRIMS) Records Disposition Schedule (RDS). Submit AF Form 847,
Recommendation for Change of Publication for recommended changes concerning this publication
to the field unit commander, then Numbered Air Force maintenance office (NAF/A4M), to HQ
AFRC/A4MM ([email protected]) Units will develop supplements to further extend guidance
in the basic AFI and this supplement. Supplements to this publication and the basic AFI are not
AFI21-101_AFRCSUP 13 AUGUST 2020 3
required to be sent to the OPR for review unless they have deviations. Tier waiver authority to
compliance items are identified as (“T-0, T-1, T-2, T-3”) following the compliance statement.
Process AF Form 679, Air Force Publications Compliant Item Waiver Request/Approval for
compliance waiver request. See AFI 33-360, Publications and Forms Management, for guidance
on waiver approval authorities, waiver process and limitations. HQ AFRC/CC delegates Tier 2
waiver authority to AFRC/A4. The use of the name or mark of any specific manufacturer,
commercial product, commodity, or service in this publication does not imply endorsement by the
Air Force.
SUMMARY OF CHANGES CORRECTIVE ACTION
This corrective action revises paragraph 11.15, by changing “AFI 16-204” to “AFI 16-402.”
SUMMARY OF CHANGES
This publication has been substantially revised and must be completely reviewed in its entirety.
Significant changes include the addition of Maintenance Cyber Discipline requirements,
Decentralized Materiel Support, incorporation of four AFIs superseded above and establishes a
Wing Avionics Manager Position requirement. Additionally, eTool and World Wide Identification
(WWID) management procedures were expanded to provide standardized enterprise requirements.
MAJCOMs/ANG designated to establish Special Certification Roster (SCR) prerequisites to
optimize workforce alignment to mission requirements.
(AFRC) This interim change revises AFI 21-101 AFRC Supplement by add Rapid Crew Swap
(RCS) and Engine Running Crew Change (ERCC) policy and guidance.

Chapter 1—MANAGEMENT OVERVIEW, SUPPORTING CONCEPTS AND
REQUIREMENTS. 13
1.1. Introduction. ............................................................................................................. 13
1.2. Organization. ............................................................................................................ 13
1.3. Maintenance Concept. ............................................................................................. 13
1.4. Aircraft Maintenance Tactics, Techniques and Procedures (TTP). ......................... 14
1.5. Aircraft and Equipment Readiness. ......................................................................... 15
1.6. Maintenance Discipline. .......................................................................................... 15
1.7. Communications Security (COMSEC)/Controlled Cryptographic Item (CCI)
Accountability. ......................................................................................................... 16
Table 1.1. Tiered Interface Examples. ...................................................................................... 17
1.8. Environmental Compliance. .................................................................................... 19
1.9. Publications. ............................................................................................................. 19
1.10. Maintenance Training. ............................................................................................. 19
1.11. Modification Management. ...................................................................................... 19
4 AFI21-101_AFRCSUP 13 AUGUST 2020
1.11. (AFRC) Modification Management. ........................................................................ 19
1.12. Maintenance Information Systems (MIS). ............................................................... 20
1.13. General Safety Guidance. ........................................................................................ 20
1.14. Duty Shifts and Rest Periods. .................................................................................. 20
1.15. Communications. ..................................................................................................... 22
1.16. Maintenance Repair Priorities. ................................................................................. 22
Table 1.2. Maintenance Repair Priority Designators. ............................................................... 23
1.17. Associate Unit Program/Total Force Integration (TFI). .......................................... 25
1.18. Performance-Based Activities. ................................................................................ 25
1.19. Changes to Technical Orders. .................................................................................. 25
Chapter 2—ROLES AND RESPONSIBILITIES 27
2.1. General. .................................................................................................................... 27
2.2. Wing Commander (WG/CC) Responsibilities. ........................................................ 27
2.3. Wing Vice Commander (WG/CV) Responsibilities. ............................................... 28
2.4. Maintenance Group Commander (MXG/CC) Responsibilities. .............................. 29
2.4. (AFRC) Maintenance Group Commander (MXG/CC) Responsibilities. ................ 29
2.5. Deputy Maintenance Group Commander (MXG/CD). ............................................ 35
2.6. MXG Superintendent Responsibilities. ................................................................... 36
2.7. Wing Weapons Manager (WWM). .......................................................................... 36
2.8. Squadron Commander (SQ/CC) Responsibilities. ................................................... 41
2.9. Maintenance Supervision Responsibilities. ............................................................. 42
2.10. Flight Supervision. ................................................................................................... 44
2.10. (AFRC) Flight Supervison/Flight Chief or AMU Officer in Charge/Chief. ............ 44
2.11. Production Superintendent (Pro Super). .................................................................. 47
2.12. Section NCOIC/Chief. ............................................................................................. 47
Chapter 3—AIRCRAFT MAINTENANCE SQUADRON (AMXS). 51
3.1. General. .................................................................................................................... 51
3.2. Maintenance Supervision Responsibilities. ............................................................. 51
3.3. Aircraft Maintenance Unit (AMU). ......................................................................... 51
3.3. (AFRC) Aircraft Maintenance Unit (AMU). ........................................................... 52
3.4. AMU OIC/SUPT Responsibilities. .......................................................................... 52
3.4. (AFRC) AMU OIC/SUPT Responsibilities. ............................................................ 52
3.5. Production Superintendent (Pro Super). .................................................................. 52
AFI21-101_AFRCSUP 13 AUGUST 2020 5
3.6. Flightline Expediter. ................................................................................................ 53
3.7. Aircrew and Maintenance Debrief Section. ............................................................. 54
3.7. (AFRC) Aircrew and Maintenance Debrief Section. ............................................... 54
Table 3.1. Landing Status Codes. ............................................................................................. 55
Table 3.2. System Capability Codes ......................................................................................... 56
Table 3.3. Deviation Cause Codes ............................................................................................ 57
3.8. Aircraft Section. ....................................................................................................... 57
3.9. Specialist Section. .................................................................................................... 58
3.10. Weapons Section. ..................................................................................................... 59
3.11. Support Section. ....................................................................................................... 66
3.12. AMU Decentralized Materiel Support (DMS)..................................................... 67
Chapter 4—MAINTENANCE SQUADRON (MXS) 68
4.1. General. .................................................................................................................... 68
4.2. Maintenance Supervision Responsibilities. ............................................................. 68
4.3. MXS Production Superintendent (Pro Super). ......................................................... 68
4.3. (AFRC) MXS Production Superintendent (Pro Super). ........................................... 69
4.4. Accessories Flight. ................................................................................................... 69
4.5. Aerospace Ground Equipment (AGE) Flight........................................................... 74
4.6. Armament Flight. ..................................................................................................... 77
4.7. Avionics Flight. ....................................................................................................... 79
4.8. Fabrication Flight. .................................................................................................... 81
4.9. Maintenance Flight. ................................................................................................. 84
4.10. Munitions Flight. ..................................................................................................... 88
4.11. Propulsion Flight. ..................................................................................................... 88
4.12. Test, Measurement, and Diagnostic Equipment (TMDE) Flight. ............................ 97
4.12. (AFRC) Test, Measurement, and Diagnostic Equipment (TMDE) Flight. .............. 97
Chapter 5—MAINTENANCE OPERATIONS (MXO). 99
5.1. General. .................................................................................................................... 99
5.2. Maintenance Operations. ......................................................................................... 99
5.3. Maintenance Training (MT). ................................................................................... 111
5.3. (AFRC) Maintenance Training (MT). ..................................................................... 111
5.4. Programs and Resources (P&R). ............................................................................. 112
6 AFI21-101_AFRCSUP 13 AUGUST 2020
Chapter 6—QUALITY ASSURANCE (QA) 114
6.1. General. .................................................................................................................... 114
6.2. Responsibilities. ....................................................................................................... 114
6.3. QA Superintendent (QA SUPT) Responsibilities. ................................................... 115
6.4. Chief Inspector Responsibilities. ............................................................................. 117
6.5. Quality Assurance Inspector Responsibilities.......................................................... 118
6.6. Quality Assurance Inspector Training. .................................................................... 118
6.7. Maintenance Standardization and Evaluation Program (MSEP). ............................ 120
6.8. LEAP QA Database. ................................................................................................ 132
6.9. QA Product Improvement Programs (PIP). ............................................................. 134
6.10. Technical Order Distribution Office (TODO). ........................................................ 135
6.11. One-Time Inspections (OTI) program. .................................................................... 137
6.11. (AFRC) HQ AFRC/A4MA is the MAJCOM OPR for OTIs. .................................. 137
6.12. Functional Check Flights (FCFs) to include Operational Check Flights (OCFs). ... 138
6.13. Inflight Operational Checks. .................................................................................... 140
6.14. High Speed Taxi Checks. ......................................................................................... 140
6.15. Weight and Balance (W&B) Program. .................................................................... 140
Chapter 7—IMPOUNDMENT PROCEDURES 142
7.1. Aircraft and Equipment Impoundment. ................................................................... 142
7.2. Specific Guidance. ................................................................................................... 142
7.3. Impoundment Authorities. ....................................................................................... 142
7.4. Impoundment Official Responsibilities. .................................................................. 143
7.5. Mandatory Impoundments. ...................................................................................... 143
7.6. Impoundment Procedures. ....................................................................................... 144
7.7. Rules of Impoundment Specifically for Explosive-Related Events/Mishaps. ......... 145
Chapter 8—TOOL AND EQUIPMENT MANAGEMENT 147
8.1. Tool and Equipment Management. .......................................................................... 147
8.2. Guidelines for Program Management. ..................................................................... 147
8.3. General Program Guidelines. ................................................................................... 149
8.4. TMDE Management Guidelines. ............................................................................. 152
8.4. (AFRC) TMDE Management Guidelines. ............................................................... 153
8.5. Tool Accountability. ................................................................................................ 153
8.6. Tool and Equipment Marking and Identification. .................................................... 156
AFI21-101_AFRCSUP 13 AUGUST 2020 7
8.7. Locally Manufactured, Developed, or Modified Tools and Equipment. ................. 158
8.7. (AFRC) Locally Manufactured, Developed, or Modified Tools and Equipment. ... 158
8.8. Tool Room Operations and Security. ....................................................................... 159
8.9. Lost Item/Tool Procedures. ...................................................................................... 160
Chapter 9—MATERIEL MANAGEMENT SUPPORT 162
9.1. General. .................................................................................................................... 162
9.1. (AFRC) General. ...................................................................................................... 162
9.2. Decentralized Materiel Support. .............................................................................. 162
9.3. Supply Discipline. .................................................................................................... 163
9.4. Readiness Spares Package Review. ......................................................................... 163
9.5. Bench Stock. ............................................................................................................ 163
9.6. Consumable Readiness Spares Package. ................................................................. 163
9.7. Shop Stock. .............................................................................................................. 164
9.8. Operating Stock. ...................................................................................................... 164
9.9. Work Order Residue. ............................................................................................... 164
9.10. Adjusted Stock Levels. ............................................................................................ 164
9.11. Shelf-life Items. ....................................................................................................... 164
9.11. (AFRC) Shelf-Life Items. ........................................................................................ 164
9.12. Equipment Items. ..................................................................................................... 165
9.13. Special Purpose Recoverable Authorized Maintenance (SPRAM). ........................ 165
9.14. Supply Assets Requiring Functional Check, Calibration, or Operational Flight
Programming. .......................................................................................................... 165
9.15. Time Compliance Technical Order (TCTO) Kit Procedures. .................................. 165
9.16. Supply Points. .......................................................................................................... 166
9.17. Local Manufacture. .................................................................................................. 166
9.18. DIFM Management. ................................................................................................. 166
9.19. Tail Number Bins (TNB). ........................................................................................ 168
9.20. CANN Actions. ........................................................................................................ 168
9.21. Bench Check and Repair Policy. ............................................................................. 168
9.22. Maintenance Turn-Around Record Update Processing. .......................................... 169
9.23. Buildup Items. .......................................................................................................... 169
9.24. DR Exhibits.............................................................................................................. 169
9.25. Destruction of TOP SECRET Material. ................................................................... 169
8 AFI21-101_AFRCSUP 13 AUGUST 2020
9.26. Certifying Items Associated With Explosives. ........................................................ 170
Chapter 10—MUNITIONS POLICY AND WEAPONS LOAD CREW PROGRAM 171
10.1. AF Munitions Policy. ............................................................................................... 171
10.2. Unit Committed Munitions List (UCML), Test/Training Munitions List
(TTML). ................................................................................................................... 172
10.3. Weapons Load Crew Training Program (WLCTP). ................................................ 172
10.4. Loading Standardization Crew (LSC). .................................................................... 175
10.5. Weapons Academic Instructor. ................................................................................ 175
10.6. Squadron Lead Crews. ............................................................................................. 175
10.7. Training Facilities/Aircraft. ..................................................................................... 176
10.8. Weapons Academics. ............................................................................................... 176
10.9. Practical Training. .................................................................................................... 178
10.10. Task Assignment List. ............................................................................................. 178
10.11. Munitions Aircraft Loading Certification/Decertification. ...................................... 179
10.12. Proficiency Review Period. ..................................................................................... 181
10.13. Minimum Required Proficiency Load. .................................................................... 181
10.14. Load Crew Semi-Annual Evaluations (SAE). ......................................................... 182
10.15. Documenting Load Crew Certification/Decertification/Qualification..................... 183
10.16. Weapons Task Qualification. ................................................................................... 183
10.17. Munitions Load Time Standards. ............................................................................. 185
Table 10.1. Fighter Aircraft Munitions Family Group and Munition Load Time Standards (in
minutes). .................................................................................................................. 186
Table 10.2. Bomber Aircraft Munitions Family Group and Munition Load Time Standards. ... 188
Table 10.3. Remote Piloted/Special Mission Aircraft Munitions Family Group and Munition
Load Time Standards ............................................................................................... 190
10.18. (Added-AFRC) Integrated Combat Turnaround (ICT). ........................................... 191
Chapter 11—ADDITIONAL MAINTENANCE REQUIRMENTS AND PROGRAMS 193
11.1. Facility Housekeeping and Contamination Control. ................................................ 193
11.2. Personal Wireless Communications Systems Management. ................................... 193
11.3. MAJCOM/ANG Special Certification Rosters (SCR). ............................................ 193
11.3. (AFRC) Special Certification Roster (SCR). ........................................................... 194
Table 11.1. Mandatory Special Certification Roster and Prerequisites. ..................................... 195
Table 11.1. (AFRC) Mandatory Special Certification Roster (SCR) and Prerequisites (T-2). ... 198
AFI21-101_AFRCSUP 13 AUGUST 2020 9
11.4. Aircraft Grounding. ................................................................................................. 198
11.5. Ramp Inspection Program........................................................................................ 199
11.6. Red Ball Maintenance. ............................................................................................. 200
11.7. Maintenance Recovery Team: ................................................................................. 200
11.7. (AFRC) Maintenance Recovery Team (MRT). ....................................................... 200
11.8. Foreign Object Damage (FOD) Prevention Program. ............................................. 201
11.9. Dropped Object Prevention (DOP) Program. .......................................................... 209
11.10. Aircraft Structural Integrity Program (ASIP). ......................................................... 210
11.11. Identification Friend or Foe (IFF) Program. ............................................................ 210
11.12. Radar Warning Receiver/Radar Threat Warning Testing. ....................................... 211
11.13. Cannibalization Program. ........................................................................................ 212
11.14. Hangar Queen Aircraft. ............................................................................................ 213
11.15. Ground Instructional Trainer Aircraft (GITA)......................................................... 215
11.15. (AFRC) Request and Dispose of GITA/TAA. ......................................................... 215
11.16. Aircraft Inlet/Intake/Exhaust Certification. ............................................................. 219
11.17. Engine Run Training and Certification Program. .................................................... 220
11.18. Engine Blade Blending Training and Certification Program. .................................. 229
11.19. Engine Flexible Borescope Inspection Training and Certification Program. .......... 230
11.20. Flying Crew Chief (FCC) Program.......................................................................... 232
11.21. Maintenance of Flash Blindness Protective Devices. .............................................. 238
11.22. WRM External Nestable Fuel Tank Build-Up. ........................................................ 239
11.22. (AFRC) WRM External Nestable Fuel Tank Build-Up (NFTBU). ......................... 239
11.23. Protective Aircraft Shelters (PAS). .......................................................................... 240
11.23. (AFRC) Protective Aircraft Shelters (PAS). ............................................................ 240
11.24. Combat Sortie Generation........................................................................................ 240
11.25. Hot Refueling Procedures. ....................................................................................... 242
11.25. (AFRC) Hot Refueling Procedures. ......................................................................... 242
Table 11.2. (Added-AFRC) Hot Refueling Training/Certification Requirements (T-2). ........... 247
11.26. Aircraft Rapid/Hot Defueling. ................................................................................. 248
11.27. 406 MHz Emergency Locator Transmitter Systems Program. ................................ 249
11.28. Crashed, Damaged or Disabled Aircraft Recovery (CDDAR) Program. ................ 249
Table 11.3. (Added-AFRC) Minimum CDDAR Bag/Manifold Requirements (T-2)................. 251
11.29. Aircraft Battle Damage Repair (ABDR). ................................................................. 254