Atch_5_-_T.O._1C-130A-23.PDF

1C-130A-23S-1

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O O O O O O O OOPERATIONAL SUPPLEMENT

OPERATIONAL SUPPLEMENT

TECHNICAL MANUAL

MAINTENANCE INSTRUCTIONS

DEPAINT OF REPAIRS IN HEATSHIELD AREA, W-10

LOWER EXTERIOR SURFACE OF WING, AND METAL

REMOVAL LIMITS FOR WING STRUCTURE.

USAF SERIES

C-130 AIRCRAFT

This publication supplements TO 1C-130A-23 dated 1 April 2013, change 3 dated 1 April 2015. Reference to this supplement will be made to the title page of the basic manual by personnel responsible for maintaining the manual in current status.

COMMANDERS ARE RESPONSIBLE FOR BRINGING THIS SUPPLEMENT TO THE ATTENTION OF ALL

AFFECTED PERSONNEL

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use) (30 December 2015). Refer other requests for this document to AFLCMC/WIUEG, Robins AFB, GA 31098.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE – Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

30 DECEMBER 2015

1. PURPOSE:

The purpose of this operational supplement is to provide corrections to the basic publication as listed below.

2. INSTRUCTIONS:

a. Amend Chapter 1 Section XIII, by updating existing data on pages 1-53 and 1-54 Figure 1-21 Bonded Repair with data on pages 2 and 3 of this supplement.

b. Amend Chapter 2 Section 1 Page 2-18, Para 2.10 Item No.W-10 Lower Exterior Surface of Wings and sub para. 2-10.1 by updating existing data with data on page 4 through 10 of this supplement.

c. Amend Chapter 8 Page 8-48, Figure 8-3 Metal Removal Limits for Wing Structure Sheet 6 by updating existing data with data on page 11 of this supplement.

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SECTION XIII PAINTING, DEPAINTING, AND MARKING OF BORON/EPOXY

COMPOSITE REPAIR AND METAL BOND REPAIR LOWER WING PANELS

ABOVE THE HEAT SHIELDS

1.51 BORON/EPOXY COMPOSITE AND METAL

BOND REPAIRS

Corrosion damage on the lower wing panels above the heat shields (in particular for the No. 2 and No.

3 engines) is caused by water intrusion into the area.

Repair of the damage is accomplished by adhesively bonding a boron/epoxy composite patch or metal bond patch over the damaged area. This repair is a DEPOT ONLY repair.

Do not allow chemical paint strippers to come in contact with the boron/epoxy repair as they will severely damage the c om p o s i t e r epa i r . Do not allow chemical strippers to come in contact with the bondline around metal bond patches.

Mask off the repair d u r i n g a n y paint removal and repaint operations IAW TO 1-1-8.

1.51.1 Surface Preparation of Repair and

Surrounding Area When repainting the lower wing panels in the area of the boron/epoxy composite repair or metal bond repair, prepare the surface of the repair and the surrounding area as follows:

a. After removing the masking from the repair, lightly scuff sand and feather edge the paint on the repair with an A-A-58054, Class 1, Type I, Grade B (fine) abrasive mat.

b. Solvent wipe the surface with a clean, lint-free cloth wet one of the wipe solvents listed in Chapter 3 of TO 1-1-8.

c. Apply MIL-DTL-5541/MIL-DTL-81706, Class 1A, Form III, Method B or Form VI, Method D conversion coating per Section II in Chapter 5 of TO 1-1-691 or PreKote SP per Chapter 3 of TO 1-1-8 and Section X in Chapter 1 of this manual to the metal wing surface areas surrounding the bonded repair.

1.51.2 Sealing, Priming and painting of

area and Surrounding Area

a. Apply a neat fillet seal of MIL-PRF-81733 Class B- 1 or -1/2 (ref. P/N PS870B) sealant around the edges of the patch.

b. Sealant should extend 0.25-0.50” on either side of patch boundary.

c. Apply one coat of MIL-PRF-23377, Type I, Class C2 epoxy primer per Chapters 4, 5, and 6 of TO 1-1-8 to the surrounding metal wing surface area and the composite repair.

d. Apply one coat of MIL-PRF-85285, Type IV, Class H polyurethane topcoat, Color No.

16473 (gray) of FED-STD-595, over the epoxy primer per Chapters 4, 5, and 6 of TO 1-1-8.

1.51.3 Marking of the Repair.

a. Apply a one inch wide outline on the edges of the composite repair with MIL-PRF-85285, Type IV, Class H polyurethane in Color No.

37038 (black) of FED-STD-595 per Chapters 4, 5, and 6 of TO 1-1-8. Outline to be outside of the sealant on edges of patch.

NOTE

Use of stick on vinyl material letters in lieu of paint is authorized.

b. Stencil the words; ‘‘BONDED REPAIR - DO

NOT USE CHEMICAL STRIPPERS ON THIS

AREA’’ inside outline on the field of the composite repair with MIL-PRF-85285, Type IV, Class H poly- urethane in Color No. 37038 (black) of FED-STD- 595 per Chapters 4, 5, and 6 of TO 1-1-8 using Figure 1-21 as a guide.

1.51.4 Depainting of the Repair and Surrounding Area.

a. Mask around the repair area and sealant IAW TO 1-1-8 and Figure 1-21 of this manual prior to depainting.

b. Wet abrasive blasting may be used IAW TO 1- 1-691 to remove finish of area surrounding the repair up to 3 inches outside of sealant edge as shown in Figure 1-21.

c. The remaining 3 inches must be removed up to the edge of the sealant by hand using approved hand held abrasives from TO 1-1-8.

CAUTION

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Figure 1-21. Bonded Repair

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2.10 ITEM NO. W-10. LOWER EXTERIOR SURFACE OF

SURFACE OF WING.

2.10.1 General. (See Figure 2-9.) The lower surface of both

the center and outer wing consist of machined aluminum panels of 7075 aluminum alloy material. The center wing lower surfaces of C-130A/D airplanes not modified by Center Wing Replacement TO 1C-130-1340, TO 1C- 130-1899, and TO 1C-130-1914 and the outer wing lower surfaces of airplanes prior to AF73-01580 not modified by TO 1C-130-1039, are heat treated to the -T6 condition.

The center wing lower surfaces of C-130B airplanes and subsequent airplanes modified by Center Wing Replacement TO 1C-130-1340, TO 1C-130-1899, and TO 1C-130-1914 and the outer wing lower surfaces of airplanes AF73-01580 and up, and airplanes modified by TO 1C-130-1039, are heat treated to the - T73 condition. The -T73 panels are slightly thicker because of a lower tensile strength; however, this latter condition offers greater resistance to stress corrosion cracking and intergranular attack.

Corrosion of the lower surfaces of the wing can be severe in areas that are in proximity to or washed by engine exhaust gases.

Corrosion also results from concentrations of soils washed down from upper surfaces. Figure 2-9 illustrates the corrosion rework required of fastener attachments and also the corrosion damage sustained under paint on lower wing surfaces

2.10.2 Types of Corrosion. Lower panels of all airplanes are

susceptible to pitting, uniform etch, filiform, and galvanic types of corrosion, but only the lower surfaces panels made from 7075- T6 aluminum alloy are likely to develop exfoliation type corrosion.

2.10.2.1 Other Defects. Fatigue cracks may originate in the

lower wing panel at fastener holes common to the nacelle fairing attach angle, engine drag angle and wing attach cover fairing. If steel bushings have been installed at the attach hole locations, stress corrosion cracking may also originate in the aluminum material in contact with the steel bushings. Knife marks, tool marks, scratches, gouges, grindouts, or other maintenance-induced damage may also be found.

2.10.3. Corrosion Inspection.

2.10.3.1 Aircraft Preparation. Refer to Safety Precautions in 15- 20-00 of TO 1C-130A-36 and TO 33B-1-1 for precautions to be observed during nondestructive inspection of aircraft. Ensure aft heat shields are removed IAW TO 1C-130H-2-51JG-00-1 prior to inspection.

2.10.3.2 Access. Access is gained to the inspection area using appropriate ground support equipment.

2.10.3.3 Preparation of Part. Ensure inspection area is cleaned per 15-10-00 of TO 1C-130A-36. Ensure area under heat shields is thoroughly clean of all soot, dirt and other contaminates. Remove loose sealant/loose paint using a non-metallic sealant scraper IAW TO 1-1-691. This is performed to allow the areas to be inspected for corrosion or damage in the area where the paint and sealant has been damaged. For depot level inspection, the inspection area (Reference Figures 2-9.1 and 2-9.2) shall be completely depainted IAW TO 1-1-

8. Reference Section XIII for depainting around existing bonded repairs.

2.10.3.4 Inspection. Using a flashlight, conduct a detailed

visual inspection (DVI) IAW 15-10-07 of TO 1C-130A-36 of all visible surfaces of the structure for any corrosion or structural damage on the lower wing surface, particularly under the heat shield footprint, as shown in Figures 2-9.1, 2-

9.2 and areas listed in 2.10.3.4.1. Visually examine the surfaces for lifting paint, oxide buildup along seam lines and around fasteners, broken fasteners, blisters in the paint and in the metal. Check for eruptions of the metal, particularly around gaps, protrusions and broken paint.

Examine exhaust exposure areas for pinpoints of corrosion products, which are indicative of pitting activity. Note rusty fasteners and the condition of the surrounding aluminum skin. Document all observed damage, including corrosion, cracks, gouges, dings, abrasions, scratches, and any other defects. Scratches are defined as marks penetrating the surface that reduce the structural cross section of the material but do not penetrate the complete thickness. Reference TO 1-1A-1.

Mark all damage with a blue, red, or black permanent marker and take a photograph of all existing damage prior to further fastener removal and blending. Photographs shall include an overview of the area inspected, as well as a close-up of the individual damage site. Photographs should be taken facing forward on the wing. Overview photograph should show entire lower surface at each engine, followed by several photos that zoom in to the individual damage site. Once damage site location is documented, then photos from other orientations may be taken to adequately show the damage.

Document inspection findings with pictures in accordance with C-130 Inspection, Crack/Corrosion and Repair Reporting (ICARR) Program. See Section IX for instructions. For depot level inspections, existing bonded repairs shall be inspected IAW depot work specification requirements and results included in this report.

2.10.3.4.1 Inspection Areas with High Incidences of

Corrosion and Damage. The following areas have high incidences of corrosion and maintenance induced damage that could lead to corrosion. When conducting the inspection of the entire lower wing surface per the preceding paragraph, pay particular attention to the areas detailed below. Reference Figures 2-9.1 through 2-9.4.

I. Left/Right OWS 160.0 to OWS 200.0:

a. Panels 1-3 adjacent to Outboard/Inboard drag

& attach angles

b. Outboard/Inboard drag angle

c. Panels 3-4 at Outboard/Inboard stud row

d. Panels 1-4 adjacent to Outboard/Inboard drain troughs

e. Panels 1, 2, 3, 4

f. Fwd edge of Panel 1 at fwd nacelle

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II. Left/Right CWS 174.0 to CWS 220.0:

a. Panels 1-2 adjacent to Outboard/Inboard drag & attach angles

b. Outboard/Inboard drag angle

c. Panels 2-3 at Outboard/Inboard stud row

d. Panels 1-3 adjacent to Outboard/Inboard drain troughs

e. Panels 1, 2, 3

f. Panels 1-3 at Wing-to-Fuselage Panel (Armpit)

g. Rainbow Fittings

h. Fwd edge of panel 1 and spar cap at fwd nacelle

i. Fwd and aft corner fittings

III. Left/Right Upper Surface Rainbow Fitting CWS 215.0 to OWS 5.0

a. Center Wing upper surface Panels 1-4

b. Center Wing rainbow fitting

c. Outer Wing rainbow fitting

d. Center/Outer wing fwd and aft corner fittings

Do NOT use steel tools to remove drag angles, attach angles, drain troughs, and sealant. Doing so causes additional damage to the wing plank. Use a non-metallic or phenolic wedge or scraper IAW 1-1- 691.

2.10.4 Corrosion Removal. For all corrosion, scratches, and

gouges within metal removal limits listed in Figure 8-3, mechanically blend out using Blue/fine grit (220 or greater) Scotch-brite disks or Abrasive cloths with bonded aluminum oxide grit per A-A-1048. Do not remove any more material than is required to remove defects. Submit an AFMC 202 (Depot) or AFTO 107 (Field units) to C-130 Engineering for disposition if damage exceeds metal removal limitations from Figure 8-3 of this manual.

Blend individual damages leaving well defined divots as opposed to making large gentle divots that incorporate multiple damages.

Knife marks and other shallow damage along drag or attach angles may be blended using cratex rods or sandpaper to avoid removal of drag or attach angles. Do not leave step shaped grindouts along drag or attach angles from effort to avoid removing items. If drag or attach angles inhibit proper blending of knife marks and other shallow damage IAW Chapter 5 of TO 1-1-691 and Figure 8-3 of this manual when using cratex rods, then these angles shall be removed (which requires removal of engine) to allow the use of Scotch-brite disks.

Mechanically remove exfoliation and intergranular corrosion in accordance with instructions contained in Chapter 5 of TO 1-1-

691. Pitting corrosion may be removed either mechanically by vacu-blasting or by chemical means as outlined in Chapter 5 of TO 1-1-691. Chemical means shall not be used if fluids are likely to become trapped in crevices.

Measure and annotate the depth of any blend-outs using a depth gauge with a long straight flat edge attachment. Note:

Wing planks may have waviness which will interfere with depth measurement. Observe fit of straight edge on wing plank and adjacent intact areas of greenish anodize coating to ensure plank surface is flat. Do not include depth of waviness in damage measurement. Adjust length of straight edge to take into account any waviness in the damage area.

Areas with waviness tend to be under engines 2 and 3 between drag angles, and at inboard end of rainbow fitting at center wing planks. The contact point shall be a carbide ball of less than .100” diameter but not a needle point. Ensure all writing is oriented in the same direction and is legible. Write depth of divot on wing in thousandths of an inch and mark edges of divots. Annotate final damage depths and locations with additional pictures in ICARR. Reworked areas shall be Roto-Peened per SAE AMS-2590 using procedures in Section III in Chapter 5 of TO 1-1-691 and Figure 8-3 of this manual. Finish blended areas IAW Paragraph 2.10.7. Blend-outs exceeding the depth limitations outlined in Figure 8-3 will require a repair.

2.10.5 Corrosion Damage Limits. Refer to Chapter 8, Figure 8-4 of this manual for metal removal limits.

2.10.6 Classification of Structure. Critical

2.10.7 Finish.

• MIL-PRF-85285 polyurethane is flammable and toxic. Good general ventilation is normally adequate. Skin and eye protection and an organic vapor type respirator are required. Avoid all sources of ignition.

• Conversion coating, MIL-DTL-5541/MIL- DTL-81706 is toxic to skin, eyes, and respiratory tract. Skin and eye protection required. Avoid all contact. Good general ventilation is normally adequate.

CAUTION

WARNING

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The center wing lower surface panels of airplanes prior to AF64- 14855 not modified by Center Wing Replacement TO 1C-130- 1340, TO 1C-130-1899, and TO 1C-130-1914, have an inorganic finish of MIL-DTL-5541/MIL-DTL- 81706, Class 1A, Form I or II, Method C conversion coating or a gray chromic acid anodized coating per MIL- A-8625, Type I, Class 1.

Wing lower surfaces of airplanes AF64-14855 and up, and airplanes modified by Center Wing Replacement TO 1C-130-1340, TO 1C-130-1899, and TO 1C-130-1914, have an inorganic finish of MIL-A- 8625, Type II, Class 1 sulfuric acid anodize. The current repair/refinish system consists of a conversion coating per MIL-DTL-5541/MIL-DTL-81706, Class 1A, Form III, Method B or Form VI, Method D, one coat of TT-P-2760, Type I, Class C polyurethane primer and two coats of MIL- PRF-85285, Type IV, Class H (APC) polyurethane APC topcoat in Color No. 36173 (gray) of FED-STD-595. The skin under the aft nacelle (heat shields) repair/refinish system consists of conversion coat per MIL-DTL-5541/MIL-C-81706, Class 1A, Form III, Method B or Form VI, Method D, one coat of MIL- PRF-23377 Type I, Class C2 epoxy primer, and two coats of MIL-PRF-85285, Type I, Class H topcoat in Color No. 16473 (gloss gray) of FED- STD-595. Apply conversion coating per Section II in Chapter 5 of TO 1-1-691 and Chapter 3 of TO 1- 1-8 and primer and topcoat per Chapters 4, 5, and 6 of TO 1-1-

8. The exterior surface of the heat shields aft of each engine shall be finished with MIL-DTL-5541/MIL-DTL-81706, Class 1A, Form III, Method B conversion coating applied per Section II of Chapter 3 in TO 1-1-691 or PreKote SP applied per TO 1- 1-8; and one coat of MIL-PRF-23377, Type I, Class C2 Epoxy Primer and two coats of MIL-P-14105 Heat Resistant Paint (Color No. 37030, Flat Black of FED-STD-595) both applied per Chapters 4, 5, and 6 of TO 1-1-8.

2.10.8 Sealing.

MIL-PRF-81733 sealant is flammable and toxic to the skin, eyes, and respiratory tract. Skin and eye protection are required. Avoid all contact. Good general ventilation is normally adequate. Keep away from open flames and all other sources of ignition.

The faying surfaces of outer wings on C-130A/D airplanes were not sealed in production; however, most of these airplanes have since been sealed during refurbishment programs. The faying surfaces of wings on all subsequent airplanes have been sealed in production. Refurbishment of outer wings provides fay surface sealing and wet installation of fasteners using MIL-PRF-81733, class 1, Grade A, Type I or IV corrosion inhibiting polysulfide sealant. Additionally, MIL-PRF-81733, Class 1, Grade A, Type II sealant is used in gaps and fillets on the exterior surfaces to resist entry of maintenance chemicals. Repair sealing shall conform to these same requirements.

WARNING

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Figure 2-9.1. View of Inspection Area for Engine #1, OWS 160.00 to OWS 200.00

PRIMARY INSPECTION AREA

INDICATED BY DASHED LINES

SHALL BE DEPAINTED IAW 1-1-8

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Figure 2-9.2. View of Inspection Area for Engine #2, CWS 174.00 to CWS 220.00

PRIMARY INSPECTION AREA

INDICATED BY DASHED LINES

SHALL BE DEPAINTED IAW 1-1-8

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Figure 2-9.3. FWD Corner Fittings Inspected at Engine #2, CWS 174.00 to CWS 220.00 and Left Side Armpit

1C-130A-23S-

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Figure 2-9.4. Left Wing Upper Rainbow Inspection Area and Aft Corner Fittings

PRIMARY INSPECTION AREA

INDICATED BY DASHED LINES

SHALL BE DEPAINTED IAW 1-1-8

P age 11

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O O

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O O

O O

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O O O O O O O OOPERATIONAL SUPPLEMENT

Figure 8-3. Metal Removal Limits for Wing Structure (Sheet 6)

Page 11/(12 Blank)

TO 1C-130A-23

TECHNICAL MANUAL

SYSTEM PECULIAR CORROSION CONTROL

USAF SERIES

ALL C-130 SERIES AIRCRAFT

(EXCEPT C-130J)

(ATOS)

This change supports systems/equipment modified by TO 1C-130(A)U-662 and TO 1C-130(M)H-649.

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C: Distribution authorized to U.S. Government agencies and their contractors (Administrative or Operational Use) (1 April 2013). Refer other requests for this document to AFLCMC/WIUEG, Robins AFB, GA 31098.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751,et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Comply with distribution statement and destroy by any method that will prevent disclosure of the contents or reconstruction of the document

Published under authority of the Secretary of the Air Force

1 APRIL 2013 CHANGE 3 - 1 APRIL 2015

CURRENT

SUPPLEMENTS

BASIC AND ALL UPDATES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . 1 April 2013 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . . . . . . .1 July 2013

Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . 15 October 2014 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 1 April 2015

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 588, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A - B C Blank i - ii iii - v vi vii viii ix x x.1 - x.2 Added x.3 Added x.4 Blank Added xi xii - xiv xv xvi xvii xviii - xxii xxiii - xxiv xxv xxvi Blank 1-1 - 1-2 1-3 - 1-4 1-4.1 Added 1-4.2 Blank Added 1-5 - 1-6 1-7 - 1-8 1-9 - 1-10 1-10.1 - 1-10.2 Added 1-11 - 1-13 1-14 1-15 - 1-16 1-17 1-18 - 1-26 1-27 1-28 - 1-30 1-31 1-32 - 1-37 1-38 - 1-39

1-40 1-41 1-42 1-43 1-44 1-45 - 1-46 1-47 - 1-54 2-1 - 2-2 2-3 - 2-4 2-5 2-6 2-7 2-8 - 2-10 2-11 2-12 2-13 - 2-14 2-15 2-16 2-17 2-18 2-19 - 2-20 2-21 - 2-22 2-23 2-24 2-25 2-26 2-27 - 2-29 2-30 2-31 - 2-32 2-33 - 2-34 2-35 - 2-36 2-37 2-38 2-39 2-40 2-41 2-42 2-43 - 2-44 2-45 2-46

2-47 2-48 2-49 - 2-51 2-52 2-53 - 2-60 3-1 3-2 - 3-3 3-4 3-5 3-6 3-7 3-8 3-9 3-10 3-11 3-12 3-13 3-14 3-15 - 3-16 3-17 3-18 3-19 3-20 3-21 - 3-22 3-22.1 Added 3-22.2 Blank Added 3-23 - 3-26 3-27 - 3-29 3-30 3-31 3-32 3-33 3-34 3-35 3-36 - 3-37 3-38 3-39 3-40 3-41 3-42 - 3-44

*Zero in this column indicates an original page

A Change 3 USAF

LIST OF EFFECTIVE PAGES

Page *Change Page *Change Page *Change No. No. No. No. No. No.

3-45 3-46 3-47 3-48 - 3-52 3-53 3-54 3-55 3-56 3-57 3-58 3-59 3-60 - 3-62 3-63 3-64 3-65 3-66 3-67 3-68 - 3-70 3-71 - 3-73 3-74 - 3-75 3-76 3-77 - 3-78 3-79 3-80 3-81 3-82 3-83 3-84 - 3-85 3-86 3-87 3-88 3-89 3-90 - 3-91 3-92 - 3-95 3-96 3-97 3-98 3-99 3-100 3-101 3-102 3-103 - 3-104 3-104.1 Added 3-104.2 Blank Added 3-105 3-106 3-106.1 - 3-106.7 Added 3-106.8 Blank Added 3-107 - 3-115 3-116 3-117 - 3-135 3-136 Blank 4-1 4-2

4-3 - 4-4 4-4.1 Added 4-4.2 Blank Added 4-5 - 4-7 4-8 4-9 - 4-13 4-14 - 4-15 4-16 5-1 5-2 5-3 5-4 - 5-5 5-6 - 5-7 5-8 5-9 - 5-11 5-12 - 5-13 5-14 5-15 5-16 - 5-19 5-20 5-21 - 5-23 5-24 Blank 6-1 - 6-10 6-11 6-12 7-1 - 7-2 7-3 - 7-27 Added 7-28 Blank Added 8-1 - 8-5 8-6 8-6.1 Added 8-6.2 Blank Added 8-7 - 8-8 8-9 - 8-10 8-10.1 Added 8-10.2 Blank Added 8-11 - 8-12 8-13 - 8-18 8-18.1 Added 8-18.2 Blank Added 8-19 - 8-20 8-21 - 8-22 8-22.1 Added 8-22.2 Blank Added 8-23 8-24 8-25 8-26 - 8-27 8-28 - 8-32 8-33 - 8-34 8-34.1 Added 8-34.2 Blank Added 8-35 - 8-38 8-39

8-40 - 8-42 8-42.1 Added 8-42.2 Blank Added 8-43 - 8-80 8-81 - 8-83 8-84 - 8-91 8-92 - 8-93 8-94 - 8-149 8-150 Blank 9-1 - 9-4 A-1 - A-3 A-4 Blank B-1 - B-10 Glossary 1 - Glossary 3 Glossary 4 Blank Index 1 Index 2 - Index 22

*Zero in this column indicates an original page

Change 3 B/(C blank)

TABLE OF CONTENTS

Chapter Page Chapter Page

INTRODUCTION......................................................xv

SAFETY SUMMARY.............................................xxv

1 GENERAL PREPARATION ...................................1-1

SECTION I PREPARATION OF SUR-

FACES FOR CORROSION INSPEC-

TION.....................................................................1-1

1.1 CLEANING THE AIRPLANE..................1-1

1.2 CLEANING EQUIPMENT PE-

CULIAR ITEMS ...................................1-1

1.3 AIRPLANE COMPONENT RE-

MOVALS REQUIRED .........................1-1

1.4 MASKING TO PREVENT

WATER ENTRY...................................1-2

1.5 EXTERIOR WASHING SE-

QUENCE ...............................................1-3

1.6 LOCAL INTERIOR CLEANING .............1-3

1.7 PAINT REMOVAL PROCE-

DURES PECULIAR TO THE

AIRPLANE............................................1-4

1.7.1 Paint Remover Compounds........................1-4

1.7.2 Masking....................................................1-4.1

1.7.3 Paint Removal.............................................1-7

1.8 SEALANT REMOVAL .............................1-7

SECTION II CORROSION INSPEC-

TION METHODS..............................................1-14

1.9 GENERAL................................................1-14

1.10 VISUAL INSPECTION ...........................1-14

1.11 NONDESTRUCTIVE INSPEC-

TION TECHNIQUES..........................1-14

1.11.1 Fluorescent Penetrant Inspection .............1-14

1.11.2 Eddy Current Inspection...........................1-14

1.11.3 Magnetic Particle Inspection....................1-14

1.11.4 Ultrasonic Inspection................................1-14

1.11.5 Radiographic Inspection ...........................1-14

SECTION III POST CLEANING LU-

BRICATION ......................................................1-15

1.12 GENERAL................................................1-15

SECTION IV INSPECTING, CLEAN-

ING, AND STERILIZING FUEL

TANKS...............................................................1-16

1.13 GENERAL................................................1-16

1.14 DEFUELING ............................................1-16

1.15 PURGING.................................................1-16

1.16 TANK ENTRY.........................................1-16

1.17 LIMITED ENTRY INSPEC-

TION ....................................................1-16

1.17.1 First Phase Removals ...............................1-16

1.17.2 Depuddling of Integral Fuel

Tanks ....................................................1-16

1.17.3 Second Phase Removals...........................1-16

1.18 CLEANING FUEL TANKS ....................1-17

1.19 DECONTAMINATION ...........................1-17

1.19.1 Microbial Decontamination or

Tank Sterilization.................................1-17

SECTION V CORROSION REMOVAL

PROCEDURES FOR INTEGRAL FU-

EL TANKS.........................................................1-21

1.20 GENERAL................................................1-21

1.21 MECHANICAL REMOVAL

METHODS ..........................................1-21

1.22 CHEMICAL-MECHANICAL

REMOVAL METHOD........................1-21

SECTION VI SEALING FOR CORRO-

SION PROTECTION IN INTEGRAL

FUEL TANKS ...................................................1-22

1.23 PROTECTIVE COATINGS IN

INTEGRAL FUEL TANKS................1-22

1.24 INSPECTION FOR CORRO-

SION UNDER SEALANT..................1-22

1.25 SEALING REPAIRS................................1-23

SECTION VII SEALING FOR COR-

ROSION PROTECTION OF AIR-

PLANE STRUCTURE.......................................1-26

1.26 GENERAL................................................1-26

1.27 TYPES OF SEALANT ............................1-26

1.27.1 SAE AMS-3284 (PR-1773), Low

Adhesion Sealing Compound for Removable Panels and Fu-el Tank Inspection Plates ....................1-26

1.27.2 SAE AMS-S-8802, Sealing Com-

pound, Temperature Resistant, Integral Fuel Tanks and Fuel Cell Cavities, High Adhesion..............1-26

1.27.3 MIL-S-38249 (SAE AMS-3374),

Firewall Sealing Compound................1-27

1.27.4 MIL-PRF-81733, Class 1, Grade

A Corrosion Inhibitive Sealing and Coating Compound.......................1-27

1.27.5 MIL-A-46146, Room Tempera-

ture Vulcanizing (RTV) Sili-cone Sealants ......................................1-27

Change 2 i

1.27.6 POLYURETHANE (PU)

‘‘HITAK TUFSEAL’’ SEAL-

ANT TAPE ..........................................1-27

1.27.7 POLYURETHANE (PU)

‘‘HITAK’’ SEALANT TAPE .............1-28

1.27.8 POLYURETHANE (PU)

‘‘HITAK’’ SEALANT CON-

DUCTIVE GASKETS.........................1-29

1.27.9 POLYURETHANE (PU) SEAL-

ANTS, INJECTABLE .........................1-30

1.28 MIXING OF SEALANTS .......................1-31

1.29 STORAGE OF SEALANTS....................1-31

1.30 PRE-MIXING, FREEZING,

AND REFRIGERATED

STORAGE OF SEALANTS ...............1-31

1.31 SEALANT APPLICATION LIFE...........1-32

1.32 TRANSPORTING SEALANTS

TO AND MAINTAINING

SEALANTS AT THE WORK

SITE .....................................................1-32

1.33 SURFACE PREPARATION

AND SEALANT APPLICA-

TION ....................................................1-32

SECTION VIII CORROSION CON-

TROL OF ELECTRICAL COMPO-

NENTS ...............................................................1-33

1.34 GENERAL................................................1-33

1.35 ELECTRICAL SYSTEM PECU-

LIAR CORROSION AREAS..............1-33

1.35.1 Avionic Equipment Rack, FS 245 ...........1-33

1.35.2 Electrical Connectors................................1-33

1.35.3 Landing Gear Wheel Well Area ..............1-35

1.35.4 High Frequency (HF) Radio An-

tenna .....................................................1-35

1.35.5 Engine Nacelle Junction Box...................1-36

1.36 INSPECTION FOR CORRO-

SION ....................................................1-36

1.37 CORROSION REMOVAL ......................1-36

1.38 PRESERVATION.....................................1-36

SECTION IX C-130 INSPECTION,

CORROSION AND REPAIR RE-

CORDING (ICARR) PROGRAM.....................1-38

1.39 GENERAL................................................1-38

SECTION X C-130 EXTERIOR FIN-

ISH REQUIREMENTS .....................................1-39

1.40 GENERAL................................................1-39

1.40.1 Field Level Touch-Up and Main-

tenance .................................................1-39

1.41 FINISH REQUIREMENTS FOR

COMPLETE STRIP AND

REPAINT OF EXTERIOR

SURFACE............................................1-39

1.41.1 General Exterior Finish ............................1-40

1.41.2 Upper Center and Outer Wing

In-Spar Walkway .................................1-40

1.41.3 Fuselage Walkway and Horizon-

tal Stabilizer Walkway ........................1-40

1.41.4 Control Surfaces .......................................1-40

1.41.5 Control Surface Wells and Coves ...........1-40

1.41.6 Radomes and Antennas ............................1-40

1.41.7 Propeller Tips ...........................................1-41

1.41.8 Wing and Horizontal and Verti-

cal Stabilizer Leading Edges...............1-41

1.42 ALTERNATE SURFACE PREP-

ARATIONS FOR ALUMI-

NUM ALLOY SURFACES

(PREKOTE SP) ...................................1-41

1.42.1 Surface Preparation...................................1-41

1.42.2 Application of PreKote SP.......................1-42

1.42.3 Removal of Fuel and Hydraulic

Fluid .....................................................1-43

1.43 FINISH REQUIREMENTS FOR

SCUFF SAND AND OVER-

COAT...................................................1-43

1.43.1 Primer Coating..........................................1-43

1.43.2 Topcoat .....................................................1-43

1.43.3 Soil Barrier Coating Application .............1-43

1.44 QUALITY INSPECTION AND

ACCEPTANCE CRITERIA................1-43

1.44.1 Wet Tape Test Inspection ........................1-43

1.44.2 Wet Tape Test Acceptance Crite-

ria .........................................................1-44

1.45 UNIT LEVEL POST PRO-

GRAMMED DEPOT MAIN-

TENANCE (PDM)

ACCEPTANCE INSPEC-

TION REQUIREMENTS....................1-44

1.45.1 Visual ........................................................1-44

1.45.2 Wet Tape Tests.........................................1-44

1.45.3 Reporting Requirements ...........................1-45

SECTION XI PLASTIC MEDIA

BLASTING ........................................................1-46

1.46 PURPOSE.................................................1-46

1.46.1 General......................................................1-46

1.46.2 Equipment .................................................1-46

1.46.3 Media ........................................................1-46

1.46.4 Media Contamination ...............................1-46

1.46.5 Training.....................................................1-46

1.47 PRE-BLAST PREPARATION ................1-46

1.47.1 Cleaning ....................................................1-46

1.47.2 Masking.....................................................1-46

1.48 BLASTING OPERATIONS.....................1-46

1.48.1 Parameters.................................................1-46

1.48.2 Operation Guidelines................................1-46

1.49 POST BLASTING OPERA-

TIONS..................................................1-46

ii Change 2

SECTION XII APPLICATION AND

REMOVAL OF 3MTM 8730HT HIGH

TEMPERATURE POLYURETHANE

PROTECTIVE TAPE FO R LEAD-

ING EDGES.......................................................1-48

1.50 POLYURETHANE PROTEC-

TIVE TAPE .........................................1-48

1.50.1 Installation of 3M™ 8730HT

High Temperature Poly-urethane Protective Tape .....................1-48

1.50.2 Repair of Damaged Area .........................1-51

1.50.3 Application of Edge Sealer ......................1-51

1.50.4 Tape Removal...........................................1-52

SECTION XIII PAINTING AND

MARKING OF BORON/EPOXY

COMPOSITE REPAIR LOWER

WING PANELS ABOVE THE HEAT

SHIELDS............................................................1-53

1.51 BORON/EPOXY COMPOSITE

REPAIR ...............................................1-53

1.51.1 Surface Preparation of Repair

and Surrounding Area..........................1-53

1.51.2 Priming and Painting of Repair

and Surrounding Area..........................1-53

1.51.3 Marking of the Repair ..............................1-53

2 WING ........................................................................2-1

SECTION I CORROSION PRONE AR-

EAS.......................................................................2-1

2.1 ITEM NO. W-1. CENTER

WING UPPER SKIN

PANELS.................................................2-1

2.1.1 General........................................................2-1

2.1.2 Types of Corrosion.....................................2-1

2.1.3 Corrosion Inspection...................................2-1

2.1.4 Corrosion Removal.....................................2-1

2.1.5 Corrosion Damage Limits ..........................2-1

2.1.6 Classification of Structure..........................2-1

2.1.7 Finish...........................................................2-1

2.1.8 Sealing.........................................................2-2

2.2 ITEM NO. W-2. OUTER WING

UPPER SKIN PANELS ........................2-2

2.2.1 General........................................................2-2

2.2.2 Types of Corrosion.....................................2-2

2.2.3 Corrosion Inspection...................................2-2

2.2.4 Corrosion Removal.....................................2-2

2.2.5 Corrosion Damage Limits ..........................2-2

2.2.6 Classification of Structure..........................2-3

2.2.7 Finish...........................................................2-3

2.2.8 Sealing.........................................................2-3

2.3 ITEM NO. W-3 OUTER WING

ATTACHMENT AT WING

STATION 220 .......................................2-5

2.3.1 General........................................................2-5

2.3.2 Types of Corrosion.....................................2-5

2.3.3 Corrosion Inspection...................................2-5

2.3.4 Corrosion Removal.....................................2-5

2.3.5 Corrosion Damage Limits ..........................2-5

2.3.6 Classification of Structure..........................2-5

2.3.7 Finish...........................................................2-5

2.3.8 Sealing.........................................................2-5

2.4 ITEM NO. W-4 WING AT-

TACH BOLTS, C-130 AIR-

PLANES.................................................2-5

2.4.1 General........................................................2-5

2.4.2 Types of Corrosion.....................................2-5

2.4.3 Corrosion Inspection...................................2-7

2.4.4 Corrosion Removal.....................................2-7

2.4.5 Classification of Structure..........................2-7

2.4.6 Finish...........................................................2-7

2.4.7 Sealing and Reinstallation..........................2-7

2.5 ITEM NO. W-5. WING JOINT

ATTACHMENT FITTINGS .................2-7

2.5.1 General........................................................2-7

2.5.2 Types of Corrosion.....................................2-7

2.5.3 Corrosion Inspection...................................2-7

2.5.4 Corrosion Removal.....................................2-7

2.5.5 Corrosion Damage Limits ..........................2-7

2.5.6 Classification of Structure..........................2-7

2.5.7 Finish...........................................................2-9

2.5.8 Sealing.........................................................2-9

2.6 ITEM NO. W-6. WING BEAM

CAP (CORNER) FITTINGS,

WING STATION 220 ...........................2-9

2.6.1 General........................................................2-9

2.6.2 Types of Corrosion...................................2-11

2.6.3 Corrosion Inspection.................................2-11

2.6.4 Corrosion Removal...................................2-11

2.6.5 Corrosion Damage Limits ........................2-11

2.6.6 Classification of Structure........................2-11

2.6.7 Finish.........................................................2-11

2.6.8 Sealing.......................................................2-13

2.7 ITEM NO. W-7. DRY BAY AC-

CESS DOORS ON WING

UPPER SURFACE..............................2-13

2.7.1 General......................................................2-13

2.7.2 Types of Corrosion...................................2-13

2.7.3 Corrosion Inspection.................................2-13

2.7.4 Corrosion Removal...................................2-13

2.7.5 Corrosion Damage Limits ........................2-13

2.7.6 Classification of Structure........................2-13

2.7.7 Finish.........................................................2-13

2.7.8 Sealing.......................................................2-14

2.8 ITEM NO. W-8. DRY BAY AC-

CESS OPENINGS IN WING

UPPER SURFACE..............................2-14

2.8.1 General......................................................2-14

2.8.2 Types of Corrosion...................................2-14

2.8.3 Corrosion Inspection.................................2-14

2.8.4 Corrosion Removal...................................2-14

2.8.5 Corrosion Damage Limits ........................2-14

2.8.6 Classification of Structure........................2-16

2.8.7 Finish.........................................................2-16 iii

2.8.8 Sealing.......................................................2-16

2.9 ITEM NO. W-9. OVER-THE-

WING HOIST MOUNTING

BRACKET BOLT HOLES .................2-16

2.9.1 General......................................................2-16

2.9.2 Types of Corrosion...................................2-18

2.9.3 Corrosion Inspection.................................2-18

2.9.4 Corrosion Removal...................................2-18

2.9.5 Corrosion Damage Limits ........................2-18

2.9.6 Classification of Structure........................2-18

2.9.7 Finish.........................................................2-18

2.9.8 Sealing.......................................................2-18

2.10 ITEM NO. W-10. LOWER EX-

TERIOR SURFACE OF

WING...................................................2-18

2.10.1 General......................................................2-18

2.10.2 Types of Corrosion...................................2-21

2.10.3 Corrosion Inspection.................................2-21

2.10.4 Corrosion Removal...................................2-21

2.10.5 Corrosion Damage Limits ........................2-21

2.10.6 Classification of Structure........................2-21

2.10.7 Finish.........................................................2-21

2.10.8 Sealing.......................................................2-21

2.11 ITEM NO. W-11. WING PAN-

EL RISERS AT ‘‘H’’ CLIP

ATTACHMENTS................................2-21

2.11.1 General......................................................2-21

2.11.2 Types of Corrosion...................................2-22

2.11.3 Corrosion Inspection.................................2-22

2.11.4 Corrosion Removal...................................2-22

2.11.5 Corrosion Damage Limits ........................2-22

2.11.6 Classification of Structure........................2-22

2.11.7 Finish.........................................................2-22

2.11.8 Sealing.......................................................2-22

2.12 ITEM NO. W-12. ENGINE

MOUNT DRAG ANGLES,

LOWER SURFACE OF

WING...................................................2-24

2.12.1 General......................................................2-24

2.12.2 Types of Corrosion...................................2-24

2.12.3 Corrosion Inspection.................................2-24

2.12.4 Corrosion Removal...................................2-24

2.12.5 Corrosion Damage Limits ........................2-24

2.12.6 Classification of Structure........................2-24

2.12.7 Finish.........................................................2-24

2.12.8 Sealing.......................................................2-26

2.13 ITEM NO. W-13. WING LEAD-

ING EDGES ........................................2-26

2.13.1 General......................................................2-26

2.13.2 Types of Corrosion...................................2-26

2.13.3 Corrosion Inspection.................................2-26

2.13.4 Corrosion Removal...................................2-26

2.13.5 Corrosion Damage Limits ........................2-26

2.13.6 Classification of Structure........................2-26

2.13.7 Finish.........................................................2-26

2.13.8 Sealing.......................................................2-28

2.14 ITEM NO. W-14. BLEED AIR

AND ANTI-ICING DUCTS ...............2-28

2.14.1 General......................................................2-28

2.14.2 Types of Corrosion...................................2-28

2.14.3 Corrosion Inspection.................................2-28

2.14.4 Corrosion Removal...................................2-28

2.14.5 Corrosion Damage Limits ........................2-28

2.14.6 Classification of Structure........................2-28

2.14.7 Finish.........................................................2-28

2.14.8 Sealing.......................................................2-28

2.15 ITEM NO. W-15. HINGES ON

WING LEADING AND

TRAILING EDGES.............................2-30

2.15.1 General......................................................2-30

2.15.2 Types of Corrosion...................................2-30

2.15.3 Corrosion Inspection.................................2-30

2.15.4 Corrosion Removal...................................2-30

2.15.5 Corrosion Damage Limits ........................2-30

2.15.6 Classification of Structure........................2-30

2.15.7 Finish.........................................................2-30

2.15.8 Sealing.......................................................2-30

2.16 ITEM NO. W-16. WING BEAM

(SPAR) CAPS......................................2-33

2.16.1 General......................................................2-33

2.16.2 Types of Corrosion...................................2-33

2.16.3 Corrosion Inspection.................................2-33

2.16.4 Corrosion Removal...................................2-33

2.16.5 Corrosion Damage Limits ........................2-33

2.16.6 Classification of Structure........................2-33

2.16.7 Finish.........................................................2-33

2.16.8 Sealing.......................................................2-34

2.17 ITEM NO. W-17. IR SHIELD

ATTACH FITTINGS (AC-

130U ONLY) .......................................2-34

2.17.1 General......................................................2-34

2.17.2 Types of Corrosion...................................2-34

2.17.3 Corrosion Inspection.................................2-34

2.17.4 Corrosion Removal...................................2-34

2.17.5 Corrosion Damage Limits ........................2-34

2.17.6 Classification of Structure........................2-34

2.17.7 Finish.........................................................2-34

2.17.8 Sealing.......................................................2-34

2.18 ITEM NO. 2-18. HIGH FRE-

QUENCY (HF) PROBE AN-

TENNA ATTACH FITTINGS

(AC-130U ONLY)...............................2-37

2.18.1 General......................................................2-37

2.18.2 Types of Corrosion...................................2-37

2.18.3 Corrosion Inspection.................................2-37

2.18.4 Corrosion Removal...................................2-37

2.18.5 Corrosion Damage Limits ........................2-37

2.18.6 Classification of Structure........................2-37

2.18.7 Finish.........................................................2-37

2.18.8 Sealing.......................................................2-37

2.19 ITEM NO. W-19. BEAM WEBS ...........2-37

2.19.1 General......................................................2-37

2.19.2 Types of Corrosion...................................2-37

2.19.3 Corrosion Inspection.................................2-39

2.19.4 Corrosion Removal...................................2-39

2.19.5 Corrosion Damage Limits ........................2-39

2.19.6 Classification of Structure........................2-39

2.19.7 Finish.........................................................2-39

2.19.8 Sealing.......................................................2-39 iv

2.20 ITEM NO. W-20. BONDED-

BEADED TRAILING EDGE

SKINS ..................................................2-41

2.20.1 General......................................................2-41

2.20.2 Types of Corrosion...................................2-41

2.20.3 Corrosion Inspection.................................2-41

2.20.4 Corrosion Removal...................................2-41

2.20.5 Corrosion Damage Limits ........................2-41

2.20.6 Classification of Structure........................2-41

2.20.7 Finish.........................................................2-41

2.20.8 Sealing.......................................................2-43

2.21 ITEM NO. W-21. AILERONS ................2-43

2.21.1 General......................................................2-43

2.21.2 Types of Corrosion.....................