Well Done Award AMC Commander to KC-135 Crews: “I Could Not Be More Proud.”

For more than 60 years, the KC-135 Stratotanker has been a useful enhancement to the U.S. Air Force’s global reach by providing refueling support to Air Force aircraft (as well as to Navy, Marine Corps, and allied nations’ aircraft) and assisting with aeromedical evacuations. Recently, the KC-135 aircrews have faced some difficult obstacles on their missions. Some of the obstacles the crews of the KC-135 have encountered include issues with the Block 45 Autopilot system and flight delays due to defective vertical stabilizer tail pins.

The Block 45 Autopilot system has had several issues over the years, including two forms of uncommanded climbs and engagements, and the inability to disconnect. Because of the autopilot restrictions, crews have been faced with flying longer sorties. Pilots have had to operate the aircraft in all weather conditions without the aid of an autopilot, which is not only mentally and physically fatiguing but cognitively taxing as well. This situation is concerning because flying in this condition increases the crew’s fatigue. Another problem is that the aircraft tail securing pins in some KC-135s were not built to aircraft specifications. In an abundance of caution, the program office recommended grounding aircraft until the correct pins could be installed. Despite all these challenges, Mobility Airmen have managed to keep tankers in the air and have continued to fly critical missions around the world.

Pulling off an aerial refueling maneuver is extremely difficult, even in ideal conditions. The crew has to take many simultaneous steps, not to mention the pressure of the receiving aircraft running out of fuel mid-air. Maintaining distance from the receiving aircraft, maintaining speed and stability within a shared airspace, and keeping the filler device connected during refueling are just a few of the challenges the crew of the KC-135 faces. Successfully confronting these issues without an accurate autopilot system increases the complexity of the missions and demonstrates the skill and preciseness of the crew.

Gen Michael A. “Mike†Minihan, commander of Air Mobility Command (AMC), recognizes the expertise required to meet these challenges and is extremely proud of the KC-135 crew. He praised their accomplishments, stating, “The efforts of our Airmen have been nothing short of valiant in continuing to operate and employ this weapon system without a reliable autopilot at the times they need it most. I could not be more proud of the professionalism and airmanship of our KC-135 aircrews.â€

AMC implemented restrictions of autopilot use in Block 45-equipped KC-135 Stratotankers below 10,000 feet and during air refueling. These regulations became a challenge to both the KC-135 crews and the crews of the receiving aircraft. AMC continues to work with the KC-135 Program to resolve these issues and restore full use of the Block 45 Autopilot. “We owe our aviators a fully capable weapon system,†Minihan stated.

Maj Travis Cord, of AMC Flight Safety, recounted a specific instance where the crew had to deal with the limitations caused by the autopilot system. “In one specific flight, a crew shared with me the challenges of hand flying [autopilot disengaged] the aircraft in instrument meteorological conditions [clouds] while in formation with another KC-135. This, compounded with the language barriers of communicating with foreign air traffic controllers and supervising an upgrading co-pilot, was extremely challenging/mentally taxing. Situations such as these are where crews wish they had an autopilot to give them back some of that ability/thinking capacity.†Although the flight crew faced drawbacks without an autopilot system, they still demonstrated great competence and completed the flight.

Cord offered a couple of metaphors on what it is like to fly the KC-135. “A common analogy is that it feels as if you are controlling an old pick-up truck that lacks power steering. There is resistance in the flight controls as you are actuating physical cables that run all the way to the wings and tail. The flight controls feel very heavy. Imagine going around a racetrack in an old pickup truck for several hours. This scenario is how it might feel to be flying multiple practice approaches and landings in the KC-135.†Cord continued, “Refueling without an autopilot requires an extreme amount of focus. You are attempting to fly a smooth platform for the receiver behind you by making small movements to the controls, but not jolting or quick. Think of it as balancing an egg on a plate while walking up and down stairs … for an hour.â€

The Airman Safety Action Program (ASAP) enables any crew member, at any level within the command, to communicate directly with AMC staff to identify safety concerns while operating the aircraft in the air and during ground operations. AMC uses this tool as the primary method for tracking autopilot issues, advising the submitter, and relaying potential issues across the fleet. Crews have had to reassess their operational risks with each mission as the added duration and complexity of operating without the autopilot increases the risks of these missions. Crewmembers have had to practice their crew resource management skills to assess and reassess each other to identify the hazards and formulate ways to mitigate them. Crewmembers must have quick thinking and analyzation skills to assess risks and execute solutions.

The AMC Standards and Evaluations and Safety teams maintain regular contact with flying units to assess their operability and proactively address future challenges. With the issues KC-135 crews have reported, AMC’s maintenance team has had to spend more time analyzing autopilot malfunctions. When an aircraft has an autopilot malfunction, it often cannot be used immediately on a subsequent flight, so maintenance must work extra hours to ready another aircraft for flight. Minihan would like to see the Block 45 Autopilot system corrected. “My #1 operational priority is the KC-135 Block 45 Autopilot, and I intend to see it through to full completion.â€

The tanker fleet has many aircraft with different functions that are used to meet United States Transportation Command requirements. The KC-135 is part of a broader enterprise of the tanker mission to include the KC-46A, the KC-10, and Air Reserve Component tanker capacity support. Combined, our tanker fleet provides sufficient capability and capacity to fulfill refueling and cargo missions to joint allies and partners around the globe at a moment’s notice. Air Mobility Command has approximately 395 Stratotankers in its fleet.

The KC-135 crews have shown great adaptability and technical skills when faced with the challenges the Stratotankers have presented. Minihan holds the Mobility Airmen of the KC-135 Stratotankers in high regard. “I’m incredibly proud of the skill and professionalism our KC-135 crews have demonstrated in the face of recent challenges associated with the KC-135. Not only are our Airmen dealing with the problems, but they have also become part of the solution. Our Stratotanker team exemplifies the best of our Air Force. They are dedicated to their craft, passionate about the mission, and always ready to go.â€