PWS3_F-16 Aircraft Wash Procedures.docx

FOR REFERENCE ONLY

Homestead Air Reserve Base – F-16 Aircraft Wash Procedures

1. AIRCRAFT EXTERIOR/INTERIOR CLEANING.

CAUTION

The use of robotic washing systems is prohibited. Failure to observe this caution may result in damage to aircraft. Contact F-16 SPO Engineering for disposition on any deviation from technical data listed herein.

NOTE

The following areas shall be cleaned with scheduled aircraft wash cycles: engine air inlet duct, nose radome, gun port, landing gear, and wheel well areas.

Aircraft exterior and interior cleaning may be accomplished in total or in part as requirements demand. The definitions of exterior and interior surfaces are listed in TYPES OF SURFACES (3) (WP 007 00).

1.1 Materials and Equipment. Materials and equipment required to accomplish aircraft cleaning functions are listed in SPECIAL TOOLS, CONSUMABLES AND EXPENDABLE ITEMS (WP 003 00).

NOTE

Numerous references to “tape” occur in the following cleaning sections. Refer to SPECIAL TOOLS, CONSUMABLES AND EXPENDABLE ITEMS (WP 003 00) to identify the necessary tape for specific uses. For wash equipment and usage, refer to TO 1-1-691 Chapter 3 unless otherwise specified.

1.2 Exterior Cleaning.

CAUTION

Landing gear and speedbrake surfaces shall have lubrication removed during cleaning, deicing, or paint removal operations. After cleaning and inspecting these areas, reapply proper lubricant.

Exterior cleaning methods may vary, depending upon whether the entire aircraft is to be cleaned or only specific areas require cleaning. The following cleaning procedures detail the steps needed to satisfy actual aircraft cleaning and environmental conditions. Exterior cleaning methods vary depending on finish system used (urethane coating, FMS-2026 spectrally selective coating, or FMS-3600 coating).

1.2.1 Preparation of Aircraft for Exterior Surface Cleaning.

Preparation for aircraft cleaning must be accomplished as follows:

a. Download all external munitions.

CAUTION

Failure to download all aircraft pods and inlet hard point pylons may cause serious damage to pods or equipment.

b. Download all aircraft pods and inlet hard point pylons.

c. Ensure aircraft is safe for maintenance.

d. Using barrier material and tape, mask quick access doors on door number 2101.

e. Ensure aircraft conform to maintenance restrictions on explosive-loaded aircraft.

f. Manually open speedbrake and lower arresting hook.

g. Mask arresting hook uplock switch.

WARNING

Install barrier material and masking tape over access door 3308 and Liquid Oxygen (LOX) vent tube to prevent cleaning agents and water from being introduced into LOX converter and possible explosion. Failure to observe this warning may cause serious injury or death.

CAUTION

Safety-approved soft-soled shoes must be worn during operations which require walking on aircraft surface to prevent surface damage. Do not use unauthorized tape on the canopy surface; canopy damage may result. 38 Ensure engine oil breather pressurization valve drain is sealed prior to cleaning. Failure to observe this caution results in contamination of engine oil and serious damage.

h. Install barrier material and masking tape in all locations as shown in Figure 1. Use tape as required to seal small areas.

1) Using masking tape, mask off 0.5-inch diameter, centered within 0.03 inch, around ambient sensing port clusters.

2) Using approved barrier material and tape, mask upper wing fuel covers (5415 and 6416).

3) Using barrier material and tape, mask threat warning antennas on the vertical stabilizer and rudder fairing.

4) 32 Using barrier material and tape, mask upper AIFF antenna and lower AIFF.

i. Install masking tape over exposed electrical connectors under wing and around engine air inlet area if electrical access covers and pylons are not installed.

j. Install barrier material and masking tape over openings under rudder at lower forward edge to prevent cleaning solution from entering fuselage and damaging amplifier detectors. Refer to Figure 1.

k. Rinse canopy with clear water using low pressure (no more than 250 psi) spray to remove dust particles.

CAUTION

Do not apply tape to the surface of the transparency. Any peeling force may damage the transparency coating.

Remove rings and watches and roll up sleeves prior to accomplishing the following canopy protective covering procedures to prevent scratching of canopy.

l. To prevent water intrusion, apply masking tape around the entire circumference of the canopy frame to seal all gaps between canopy frame and aircraft fuselage, Figure 1 detail C.

m. To protect canopy transparency, place a sheet of polyethylene film over entire canopy transparency and secure it in place with masking tape by attaching it to canopy frame. Ensure masking tape and polyethylene film cover the canopy frame surrounding the canopy transparency and the circumference of the canopy assembly, Figure 1 detail C.

n. Mask all openings in the nose and main landing gear wheel wells that may allow wash solution and rinse water to enter equipment bays. Refer to Figure 2.

o. Install barrier material and masking tape over nose wheel steering feedback potentiometer J1 and J2 electrical connectors.

2. Cleaning of Aircraft Exterior Surfaces with FMS3600 Coating.

General cleaning of aircraft exterior surfaces with FMS-3600 coating shall be accomplished as follows to maintain coating appearance and function:

a. Ensure aircraft has been prepared for cleaning. Refer to PREPARATION OF AIRCRAFT FOR EXTERIOR SURFACE CLEANING (1.2.1).

CAUTION

· Aircraft with FMS-3600 coating shall only be cleaned using Re-Gel cleaning compound or MIL-PRF-87937 Type IV alkaline cleaners. No solvents are to be used to clean FMS-3600 coating. Failure to observe this caution may result in damage to the coating both in appearance and function.

· MIL-PRF-87937 Type I cleaning compound is not approved for cleaning FMS-3600 coating.

· Use of unauthorized scrub pads or solvent cleaners will result in damage to FMS-3600 coating.

b. The following cleaning compound solutions and dilution ratios are authorized for use on FMS-3600 coating:

1) For general aircraft cleaning, Re-Gel cleaning compound can be used.

2) For moderate soils, Re-Gel cleaning compounds can be used with a diluted mix ratio of 1 part cleaner to 4 parts waters.

3) For heavy soil, it is permissible to use undiluted Re-Gel cleaning compound. This practice shall only be used on a limited basis in localized areas.

4) For general aircraft cleaning, MIL-PRF-87937 Type IV alkaline cleaning compounds can be used.

c. To facilitate cleaning, the following approved cleaning pads/brushes shall be used. These items may be mounted on a threaded pole to assist cleaning:

1) Aero safe Melamine cleaning pad

2) 3M Easy Erase Jet Pad

3) NIB cleaning pad

4) Nonabrasive soft bristle brush

NOTE

Re-Gel cleaning compound and MIL-PRF87937 Type IV alkaline cleaners shall be applied to wet surfaces only.

d. Standard aircraft wash:

1) Prior to applying cleaning solutions, rinse aircraft surfaces to reduce contaminants that may be present on the aircraft skins.

CAUTION

Do not allow cleaner to dry on surface. Failure to observe this caution results in surface contamination residue.

2) Prepare Re-Gel cleaning compound or MIL-PRF87937 Type IV alkaline cleaner with appropriate dilution ratio defined in Step b.

3) Apply the prepared cleaning compound solution with a foam generator spray. Allow cleaner to remain on surface for up to one minute without scrubbing. Heavily soiled areas may be cleaned by scrubbing the area using a circular motion for up to 15 seconds with an approved pad or brush.

4) Rinse the loosened soil and cleaner with fresh water using a fan spray nozzle directed at an angle between 15 and 30 degrees from the surface. Continue rinsing with fresh water until all evidence of cleaner and soils have been removed from the aircraft. Blot dry using clean cheesecloth.

e. Spot cleaning: FMS-3600 coating may be spot cleaned as follows:

1) Prepare Re-Gel cleaning compound or MIL-PRF87937 Type IV alkaline cleaner with an appropriate dilution ratio defined in Step b.

CAUTION

Do not allow cleaner to dry on surface. Failure to observe this caution results in surface contamination residue.

2) Apply the cleaning solution using an approved cleaning pad or nonabrasive soft bristle brush saturated with water and let stand for approximately 2 to 3 minutes.

3) Remove cleaning solution from all affected surfaces by flooding with water (if local regulations permit) or by wiping areas with a clean cheesecloth saturated in water.

4) After removing cleaning solution from area, immediately wipe dry using a clean cheesecloth.

5) If spot cleaning does not remove all soil, go to Step f.

f. Stubborn soils:

NOTE

For stubborn soil, it is permissible to use undiluted Re-Gel cleaning compound, but this practice should be used on a limited basis only.

1) Apply Re-Gel cleaning compound.

CAUTION

Do not allow cleaner to dry on surface. Failure to observe this caution results in surface contamination residue.

2) Allow cleaning compound to remain on surface for up to 15 minutes. Scrub soiled area using a circular motion for up to 30 seconds with an approved pad or brush.

3) Rinse thoroughly. Blot dry using a clean cheesecloth.

g. Remove all masking and barrier material installed on aircraft.

h. Ensure speedbrakes are wiped dry with clean, dry cheesecloth as required.

i. Manually close speedbrake and raise arresting hook.

NOTE

· Inspect and verify integrity of cover (5415 and 6416) gaskets when removed.

· Inspect integrity of sealant around upper surface of wing rib pylon attach fitting, and pay particular attention to area between attach fitting and wing rib. Look for voids in sealant.

j. Remove upper wing fuel covers (5415 and 6416) and inspect for presence of moisture. If moisture is found, dry using compressed air (10 to 15 psi) to aid in drying, and replace cover gasket.

k. Install upper wing fuel covers (5415 and 6416) using four bolts, and torque bolts 50-70 inch-pounds.

l. Accomplish post aircraft wash inspection.

2.1 Nose Radome Cleaning. Cleaning of nose radome must be accomplished in accordance with the following procedure:

a. Ensure aircraft is safe for maintenance.

NOTE

MIL-PRF-87937 and MIL-PRF-85570 cleaning compound solutions may be heated up to 130 (±10)°F if water heater is available for more effective cleaning of nose radome surfaces if the necessary facilities are available. Care should be taken to prevent skin contact with hot solution.

b. Apply MIL-PRF-87937 Type IV cleaning compound or MIL-PRF-85570 Type II cleaning compound to radome surface with a nonabrasive soft bristle brush, cheesecloth, sponge, or spray bottle. Allow cleaner to remain on surface for up to five minutes before scrubbing. Clean with a nonabrasive soft bristle brush scrubbing briskly for up to 30 seconds.

c. Rinse radome thoroughly with clean water until all evidence of cleaner and soils have been removed from the radome surface. Blot dry using clean cheesecloth. Do not allow cleaner to dry on surface.

d. Radomes remaining streaked or discolored may be cleaned as follows:

CAUTION

Unless otherwise directed, utilize manufacturer’s recommended dilution ratio. Failure to observe this caution may result in possible damage to coating and/or skin irritation.

NOTE

Unless otherwise specified by manufacturer, mix heavy duty/stubborn dilution ratio as follows.

1) Apply MIL-PRF-87937 Type I cleaning compound or MIL-PRF-87937 Type III cleaning compound to soiled radome surface with a clean sponge or cheesecloth. Allow the Type I cleaning compound to remain on surface for up to one minute before scrubbing. Allow the Type III cleaning compound to remain on surface for up to 15 minutes before scrubbing. Scrub the radome surface with a nonabrasive soft bristle brush using a circular motion for up to 15 seconds.

2) Rinse radome thoroughly with clean water until all evidence of cleaner and soils have been removed from the radome surface. Blot dry using clean cheesecloth.

3) Repeat procedure until streaking and discoloration have been removed from radome.

e. Inspect cleaned area for evidence of corrosion or finish damage.

2.1.1 Gun Port Cleaning with FMS3600 Coating. The gun bay area and gun port with FMS3600 coating must be cleaned as follows:

a. Ensure aircraft is safe for maintenance.

b. Remove access cover 2407.

c. Apply barrier material over gun and exterior surface around gun port and tape in place securely. Refer to Figure 1.

d. Clean surface as outlined in the steps for cleaning stubborn soils.

e. Inspect cleaned area for evidence of corrosion or finish damage.

f. Remove barrier material and tape.

g. Install access cover 2407.

2.1.2 Nose Gear and Wheel Well Area Cleaning. The nose gear and wheel well area must be cleaned as follows:

a. Ensure aircraft is safe for maintenance.

b. Apply polyethylene film or barrier material and/or tape over all holes or openings in wheel well boundary structure to prevent cleaning solution from entering other areas of the aircraft. Also apply tape over lube holes of both the nose gear door actuator and the nose gear retract and extend actuator. Refer to Figure 2.

c. Protect nose wheel steering feedback potentiometer and the two connectors using barrier material and tape.

d. Protect nose landing gear downlock switch and connector using barrier material and masking tape.

e. Protect nose landing gear uplock switch and connector using barrier material and masking tape.

WARNING

Do not mix MIL-PRF-87937 or MIL-PRF85570 cleaning compounds with any solvent (degreasing solvent, acetone, MEK, etc.). The added solvents will create a fire hazard, a serious disposal problem, and damage to nonmetallic materials. Failure to observe this warning will create potential fire hazard and could result in injury to personnel or damage to equipment.

NOTE

MIL-PRF-87937 and MIL-PRF-85570 cleaning compound solutions may be heated up to 130 (±10)°F for more effective cleaning of nose gear and wheel well area surfaces if the necessary facilities are available. Care should be taken to prevent skin contact with hot solution.

f. Apply MIL-PRF-87937 Type IV cleaning compound or MIL-PRF-85570 Type II cleaning compound with a nonabrasive soft bristle brush, cheesecloth, sponge, or spray bottle.

g. Allow cleaner to remain on surface for up to five minutes before scrubbing.

NOTE

Do not allow cleaning solution to dry before rinsing, since less effective cleaning and streaking will result.

h. While keeping area wet with cleaning solution, scrub area with a nonabrasive soft bristle brush until surface appears clean.

CAUTION

Do not direct high pressure hose into nose landing gear wheel well area or damage to electrical connectors in nose landing gear wheel may result.

i. Thoroughly rinse with clean water, applied by spray method at low pressure, to remove cleaner and soils. Blot dry using clean cheesecloth.

j. If area is not sufficiently clean, apply MIL-PRF87937 Type I cleaning compound or MIL-PRF-87937 Type III cleaning compound with a clean sponge or cheesecloth.

k. Allow the Type I cleaning compound to remain on surface for up to one minute before scrubbing. Allow the Type III cleaning compound to remain on surface for up to 15 minutes before scrubbing. Scrub the surface with a nonabrasive soft bristle brush using a circular motion for up to 15 seconds.

l. Thoroughly rinse with clean water, applied by spray method at low pressure, to remove cleaner and soils. Blot dry using clean cheesecloth.

WARNING

Use of compressed air or nitrogen creates an environment of propelled foreign particles which may cause serious eye injury. Protective equipment consisting of industrial goggles is required. Failure to observe this warning may result in serious injury to personnel.

m. Allow area to dry. Use clean, dry cheesecloths or compressed air or nitrogen (10 to 15 psi) to aid in drying cavities.

n. Inspect cleaned area for evidence of corrosion or finish damage.

o. Remove barrier material and tape from nose wheel well areas.

2.1.3 Main Gear and Wheel Well Area Cleaning. The main gear and wheel well area must be cleaned as follows:

a. Ensure aircraft is safe for maintenance.

CAUTION

Ensure all vent holes on strut cylinder are taped to prevent cleaning solution from entering vent holes or damage to inner cylinder will occur. Also ensure barrier material and/or tape is covering wheel and brake assembly to prevent damage to brake disc and rotor assembly caused by cleaning solution.

b. Apply polyethylene film or barrier material and/or tape over any holes or openings in boundary structure to prevent cleaning solution from entering other areas of the aircraft. Refer to Figure 2.

c. Protect left and right main landing gear downlock and uplock switches using barrier material and tape.

CAUTION

Ensure aircraft battery and aircraft battery harness are masked prior to aircraft cleaning. Failure to observe this caution may result in formation of corrosion, an electrical short, or wheel well fire.

d. Apply barrier material and tape to aircraft battery and aircraft battery harness as shown in Figure 2.

WARNING

Ensure Electronic Countermeasures (ECM) power harness connector is masked prior to aircraft cleaning. Failure to observe this warning may result in wheel well fire, injury to personnel, or damage to equipment.

e. Apply barrier material and tape to ECM power harness connector in right main landing gear wheel well as shown in Figure 2.

f. Apply barrier material and tape to Station 5 harness connectors in right main landing gear wheel well as shown in Figure 2.

g. Apply barrier material and/or masking tape to mechanical strain recorder as shown in Figure 2.

WARNING

Do not mix MIL-PRF-87937 or MIL-PRF85570 cleaning compounds with any solvent (degreasing solvent, acetone, MEK, etc.). The added solvents will create a fire hazard, a serious disposal problem, and damage to nonmetallic materials. Failure to observe this warning will create potential fire hazard and could result in injury to personnel or damage to equipment.

NOTE

MIL-PRF-87937 and MIL-PRF-85570 cleaning compound solutions may be heated up to 130 (±10)°F for more effective cleaning of main gear and wheel well area surfaces if the necessary facilities are available. Care should be taken to prevent skin contact with hot solution.

h. Apply MIL-PRF-87937 Type IV cleaning compound or MIL-PRF-85570 Type II cleaning compound with a nonabrasive soft bristle brush, cheesecloth, sponge, or spray bottle.

i. Allow cleaner to remain on surface for up to five minutes before scrubbing.

NOTE

· Do not allow cleaning solution to dry before rinsing since less effective cleaning and streaking will result.

· Assure keel beam pockets and drain holes are clean and drain freely.

j. While keeping area wet with cleaning solution, scrub area with a nonabrasive soft bristle brush until surface appears clean.

CAUTION

Do not direct high pressure hose into main landing gear wheel well area or damage to electrical connectors in main landing gear wheel may result.

k. Thoroughly rinse with clean water, applied by spray method at low pressure, to remove cleaner and soils. Blot dry using clean cheesecloth.

l. If area is not sufficiently clean, apply MIL-PRF87937 Type I cleaning compound or MIL-PRF-87937 Type III cleaning compound with a clean sponge or cheesecloth.

m. Allow the Type I cleaning compound to remain on surface for up to one minute before scrubbing. Allow the Type III cleaning compound to remain on surface for up to 15 minutes before scrubbing. Scrub the surface with a nonabrasive soft bristle brush using a circular motion for up to 15 seconds.

n. Thoroughly rinse with clean water, applied by spray method at low pressure, to remove cleaner and soils. Blot dry using clean cheesecloth.

WARNING

• Use of compressed air or nitrogen creates an environment of propelled foreign particles which may cause serious eye injury. Protective equipment consisting of industrial goggles or faceshield is required. Failure to observe this warning may result in serious injury to personnel.

• Do not allow pressure to exceed 15 psi. Failure to observe this warning may result in damage to equipment or injury to personnel.

o. Allow area to dry. Use clean, dry cheesecloth or compressed air or nitrogen (10 to 15 psi) to aid in drying cavities.

p. Inspect cleaned areas for evidence of corrosion or finish damage.

q. Remove barrier material and tape from main wheel well/wheel and brake assembly. Clean wheel assembly with cheesecloth moistened with a cleaning compound from Step h or Step l, being careful to keep solution from contacting brake disc and rotor assembly. Rinse using low pressure water spray. Blot dry with a clean cheesecloth.

r. Remove barrier material and tape from ECM power harness connector in right main landing gear wheel well.

s. Remove barrier material and tape from Station 5 harness connectors in right main landing gear wheel well.

t. Remove barrier material and/or masking tape from mechanical strain recorder.

NOTE

Compressed air has a high moisture content and shall not be used to remove moisture from electrical connectors.

u. Using pressurized nitrogen gas, dry centerline pylon electrical connectors as follows:

(1) Disconnect electrical connectors that require drying. If centerline pylon is not installed, remove dust caps on centerline electrical connectors requiring drying.

(2) Set up nitrogen servicing trailer to 15 psi.

(3) Place nitrogen air outlet end on top of connector allowing nitrogen to flow into the backside of the electrical connector.

(4) Place nitrogen air outlet 1.5 to 2.0 inches from front end of electrical connector allowing nitrogen to flow into connector.

(5) Repeat Step u(3) and Step u(4) until electrical connectors are free of moisture.

v. Replace protective caps, if removed, on all centerline pylon electrical connectors, if disconnected.

w. Reconnect all centerline pylon electrical connectors, if disconnected.

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