TO 1C-130A-23 - Attachment - 5.pdf

TO 1C-130A-23

TECHNICAL MANUAL

SYSTEM PECULIAR

CORROSION CONTROL

USAF SERIES

ALL C-130 SERIES

AIRCRAFT

ATOS/DLDSS

This change supports systems/equipment modified by TO 1C-130-1914 and TO 1C-130(A)H-671.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government agencies and their contrac-tors (Administrative or Operational Use) (15 May 2001). Other requests for this document shall be referred to 580 ACSG/GFEAH, 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

15 MAY 2001

CHANGE 24 - 15 MAY 2009

BASIC AND ALL CHANGES 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 DESTROY SUPERSEDED PAGES.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 miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original........................... 0................. 15 May 2001 Change...........................14........... 1 February 2006 Change............................ 1...........10 January 2002 Change...........................15................ 15 June 2006 Change............................ 2.............15 August 2002 Change...........................16..........1 November 2006 Change............................ 3.......30 September 2002 Change...........................17................. 15 May 2007 Change............................ 4.................. 1 June 2003 Change...........................18.........1 September 2007 Change............................ 5............15 October 2003 Change...........................19..........1 November 2007 Change............................ 6........15 November 2003 Change...........................20........... 1 February 2008 Change............................ 7.............1 January 2004 Change...........................21.................. 1 June 2008 Change............................ 8......... 15 February 2004 Change...........................22..........1 November 2008 Change............................ 9................. 15 May 2004 Change...........................23......... 15 February 2009 Change...........................10...............1 August 2004 Change...........................24................. 15 May 2009 Change...........................11..............1 October 2004 Change...........................12..........1 November 2004 Change...........................13........15 November 2005

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 544, CONSISTING OF THE FOLLOWING:

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

Title .......................................24 1-33 ..........................................0 2-46 - 2-47 A - B ......................................24 1-34 ..........................................4 2-48 C Blank ...................................9 1-34.1 .....................................24 2-49 - 2-50 i ..............................................15 1-34.2 Blank Added................4 2-51 ii ...............................................2 1-35 ........................................24 2-52 - 2-53 iii ............................................24 1-36 ..........................................0 2-54 iv - v.......................................17 1-37 ..........................................2 2-55 vi ............................................24 1-38 - 1-39 ...............................0 2-56 vii - viii Deleted ......................2 1-40 Blank...............................0 2-57 ix - xv.......................................0 2-1 ..........................................17 2-58 xvi ..........................................17 2-2 ............................................0 2-59 xvi.1 Added ...........................17 2-3 ..........................................17 2-60 xvi.2 Blank Added ................17 2-4 - 2-5 ...................................0 2-61 - 2-66 xvii .........................................17 2-6 ..........................................17 2-67 xviii ........................................24 2-7 - 2-14 .................................0 2-68 Blank 1-1 ............................................0 2-15 ........................................17 3-1 1-2 ..........................................18 2-16 ..........................................0 3-2 - 3-3 1-3 - 1-4 .................................24 2-17 - 2-18 .............................24 3-4 1-5 - 1-6 ...................................0 2-19 ..........................................0 3-5 1-7 ..........................................17 2-20 ........................................17 3-6 1-8 - 1-10 .................................0 2-21 - 2-22 ...............................0 3-7 - 3-24 1-10.1 Added .........................14 2-23 ........................................24 3-25 1-10.2 .....................................24 2-24 ..........................................0 3-26 1-11 ........................................24 2-25 ........................................24 3-27 - 3-28 1-12 - 1-22 ...............................0 2-26 - 2-30 ...............................0 3-29 - 3-30 1-23 - 1-24 .............................19 2-31 ........................................17 3-31 1-24.1 Blank Added..............19 2-32 - 2-35 ...............................0 3-32 - 3-35 1-24.2 Added .........................19 2-36 ........................................17 3-36 - 3-37 1-25 - 1-28 ...............................0 2-37 ..........................................0 3-38 1-29 - 1-30 ...............................5 2-38 ..........................................9 3-39 - 3-40 1-30.1 - 1-30.4 Added .............5 2-39 ........................................24 3-41 1-31 - 1-32 .............................15 2-40 - 2-44 ...............................0 3-42 - 3-50 1-32.1 - 1-32.2 Added ...........15 2-45 ........................................17 3-51

*Zero in this column indicates an original page

A Change 24 USAF

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES (CONT)

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

3-52 - 3-53 ...............................0 4-10 - 4-14 ...............................0 7-74.2 Blank Added 3-54 ..........................................4 5-1 - 5-2 .................................24 7-75 3-55 ..........................................0 5-3 ............................................0 7-76 3-56 ........................................17 5-4 ............................................4 7-77 - 7-87 3-57 ..........................................0 5-5 - 5-6 ...................................5 7-88 - 7-90 3-58 ..........................................8 5-7 ............................................0 7-91 - 7-96 3-59 - 3-74 ...............................0 5-8 ............................................4 7-97 - 7-98 3-75 - 3-76 .............................17 5-9 ..........................................17 7-99 - 7-102 3-76.1 Added .........................17 5-10 - 5-12 ...............................0 7-103 3-76.2 Blank Added..............17 5-13 ........................................13 7-104 3-77 - 3-78 .............................17 5-14 - 5-20 ...............................0 7-105 3-79 - 3-81 ...............................0 5-21 ........................................20 7-106 3-82 ..........................................4 5-22 - 5-23 ...............................0 7-107 - 7-124 3-83 ..........................................0 5-24 Blank...............................0 7-125 3-84 ........................................17 6-1 ............................................0 7-126 Blank 3-85 - 3-86 ...............................0 6-2 ............................................2 7-127 3-87 ........................................17 6-3 - 6-4 ...................................0 7-128 3-88 ..........................................0 6-5 ............................................2 7-129 - 7-131 3-89 ........................................17 6-6 - 6-9 ...................................0 7-132 3-90 ..........................................0 6-10 ..........................................3 7-133 3-91 ........................................17 6-11 ..........................................0 7-134 - 7-136 3-92 - 3-93 ...............................0 6-12 Blank...............................0 7-137 3-94 ........................................17 7-1 ............................................0 7-138 3-95 ..........................................0 7-2 ..........................................24 7-139 3-96 ........................................17 7-3 - 7-7 ...................................0 7-140 - 7-142 3-97 ..........................................0 7-8 - 7-9 .................................17 7-143 3-98 ........................................17 7-10 ..........................................0 7-144 3-99 ..........................................4 7-11 ........................................17 7-144.1 - 7-144.2 3-100 - 3-103 ...........................0 7-12 - 7-13 ...............................0 7-145 - 7-152 3-104 ........................................4 7-14 ........................................24 8-1 3-105 ........................................0 7-15 - 7-16 ...............................0 8-2 - 8-4 3-106 ........................................4 7-17 ........................................10 A-1 - A-3 3-107 ........................................0 7-18 - 7-20 .............................17 A-4 Blank 3-108 ......................................17 7-20.1 Added .........................17 B-1 - B-13 3-109 ........................................0 7-20.2 Blank Added..............17 B-14 Blank 3-110 ......................................17 7-21 - 7-23 ...............................0 Glossary 1 - Glossary 3 3-111 - 3-121 ...........................0 7-24 - 7-25 .............................24 Glossary 4 Blank 3-122 ........................................2 7-26 - 7-31 ...............................0 Index 1 3-123 - 3-126 Deleted .............2 7-32 ........................................17 Index 2 3-127 Blank.............................2 7-32.1 Added .........................17 Index 3 - Index 4 3-128 ........................................2 7-32.2 Blank Added..............17 Index 5 - Index 6 3-129 ........................................0 7-33 ........................................17 Index 7 3-130 ........................................2 7-34 ..........................................0 Index 8 - Index 9 3-131 Blank.............................2 7-35 ........................................17 Index 10 Blank 3-132 ........................................2 7-36 - 7-39 3-133 - 3-152 ...........................0 7-40 4-1 ..........................................17 7-41 - 7-46 4-2 ............................................0 7-47 - 7-48 4-3 ..........................................17 7-49 - 7-50 4-4 ............................................0 7-51 4-5 ..........................................17 7-52 4-6 - 4-8 ...................................0 7-53 - 7-74 4-9 ..........................................17 7-74.1 Added

*Zero in this column indicates an original page

Change 24 B/(C blank)

TABLE OF CONTENTS

Chapter/Para Page Chapter/Para Page

LIST OF ILLUSTRATIONS .................. iii III HIGH-STRENGTH STEEL

COMPONENTS (OVER

LIST OF TABLES .................................. vi 200 KSI) .............................................. 2-63 SAFETY SUMMARY.............................. ix IV WING CONDENSATE

DRAIN HOLE LOCATIONS ............. 2-63INTRODUCTION ................................... xi

CHAPTER 3 - FUSELAGE.......................................... 3-1 CHAPTER 1 - GENERAL PREPARATION ............... 1-1

I CORROSION PRONEI PREPARATION OF SUR-

AREAS................................................... 3-1FACES FOR CORROSION

INSPECTION ....................................... 1-1 II MAGNESIUM COMPO-

NENT LOCATIONS......................... 3-116II CORROSION INSPEC-

TION METHODS ............................... 1-12 III HIGH-STRENGTH

STEEL COMPONENTSIII POST CLEANING

(OVER 200 KSI) ............................... 3-116LUBRICATION................................... 1-13

IV FUSELAGE CONDEN-IV INSPECTING, CLEAN-

SATE DRAIN HOLEING, AND STERILIZING

LOCATIONS ..................................... 3-120FUEL TANKS..................................... 1-13

V DeletedV CORROSION REMOVAL

PROCEDURES FOR IN- VI MODULAR AIRBORNE

TEGRAL FUEL TANKS .................... 1-19 FIRE FIGHTING SYS-

TEM (MAFFS) .................................. 3-128VI SEALING FOR CORRO-

SION PROTECTION IN CHAPTER 4 - EMPENNAGE ..................................... 4-1

INTEGRAL FUEL TANKS................ 1-20

I CORROSION PRONE

VII SEALING FOR CORRO- AREAS................................................... 4-1

SION PROTECTION OF

AIRPLANE STRUCTURE ................. 1-23 II MAGNESIUM COMPO-

NENT LOCATIONS........................... 4-12

VIII CORROSION CONTROL

OF ELECTRICAL III HIGH-STRENGTH STEEL

COMPONENTS .................................. 1-31 COMPONENTS (OVER

200 KSI) .............................................. 4-12

IX C-130 INSPECTION, COR-

ROSION AND REPAIR IV EMPENNAGE CONDEN-

RECORDING (ICARR) SATE DRAIN HOLE

PROGRAM .......................................... 1-34 LOCATIONS ....................................... 4-12

X C-130 EXTERIOR FIN- CHAPTER 5 - ENGINE NACELLES AND

ISH REQUIREMENTS ................... 1-34.1 PYLONS............................................... 5-1

XI PLASTIC MEDIA I CORROSION PRONE

BLASTING.......................................... 1-38 AREAS................................................... 5-1

CHAPTER 2 - WING.................................................... 2-1 II MAGNESIUM COMPO-

NENT LOCATIONS........................... 5-20

I CORROSION PRONE

AREAS................................................... 2-1 III HIGH-STRENGTH STEEL

COMPONENTS (OVER

II MAGNESIUM COMPO- 200 KSI) .............................................. 5-20

NENT LOCATIONS........................... 2-63

IV NACELLE AND PYLON

CONDENSATE DRAIN

HOLE LOCATIONS........................... 5-20

Change 15 i

TABLE OF CONTENTS - Continued

Chapter/Para Page Chapter/Para Page

CHAPTER 6 - LANDING GEAR AND CHAPTER 7 - TABLES ................................................ 7-1

WHEEL ASSEMBLIES ....................... 6-1

CHAPTER 8 - SPECIAL MATERIALS

I CORROSION PRONE LIST....................................................... 8-1

AREAS................................................... 6-1

APPENDIX A........................................A-1

II MAGNESIUM COMPO-

APPENDIX B........................................B-1NENT LOCATIONS............................. 6-8 GLOSSARY ...............................Glossary 1III HIGH-STRENGTH STEEL

COMPONENTS (OVER 200 INDEX............................................Index 1

KSI)........................................................ 6-8

IV SKI ASSEMBLIES ............................. 6-10

ii Change 2

LIST OF ILLUSTRATIONS

Figure Title Page Figure Title Page i-1 Knocked Out by Corrosion.............................. xi 2-10 Lower Exterior Surface of Wing................. 2-24 i-2 Corrosion Prone Area/Item Index ................ xiii 2-11 Wing Panel Risers at ‘‘H’’ Clip 1-1 Typical Washing Facility .............................. 1-2 Attachments..............................................2-27 1-2 Exterior Washing Sequence.......................... 1-5 2-12 Engine Mount Drag Angles, 1-3 Skin Stains From Unauthorized Lower Surface of Wing ............................2-30

Cleaning Compounds .................................1-6 2-13 Wing Leading Edges ................................... 2-33 1-4 Local Interior Cleaning................................. 1-8 2-14 Bleed Air and Anti-Icing Ducts.................. 2-35 1-5 Paint Stripping .............................................. 1-8 2-15 Hinges on Wing Leading and 1-6 Masking of Surfaces for Paint Trailing Edges ..........................................2-37

Stripping .....................................................1-9 2-16 Wing Beam (Spar) Caps ............................. 2-40 1-6.1 Radar Absorbing Material 2-17 IR Shield Attach Fittings

(RAM) Locations....................................1-10.1 (AC-130U Only) ........................................2-42 1-6.2 AN/AAQ-24(V) System Sensor 2-18 HF Probe Antenna Attach Fit-

Locations (Paint Stripping) ..................1-10.2 tings (AC-130U Only) ..............................2-44 1-7 Drain Tool for Condensate 2-19 Beam Webs .................................................. 2-47

Drain Valves .............................................1-11 2-20 Bonded-Beaded Trailing Edge 1-8 Access to Integral Fuel Tanks.................... 1-15 Skins..........................................................2-50 1-9 Integral Fuel Tank Interior........................ 1-17 2-21 Ailerons ........................................................ 2-53 1-10 Corrosion Blisters Under Fuel 2-22 Flaps ............................................................. 2-55

Tank Sealant ............................................1-18 2-23 Flap Tracks and Jackscrews ...................... 2-57 1-11 Polysulfide and Buna-N Coated 2-24 Integral Fuel Tanks .................................... 2-59

Fuel Tank Interior Surfaces....................1-22 2-25 Wing Panel Rib Pads (Centroid 1-12 Polyurethane Coated Fuel Tank Risers) .......................................................2-62

Bottom Surface .........................................1-25 2-26 Magnesium Component 1-13 Panel Shapes Requiring Square Locations ...................................................2-64 and Round Cornering 2-27 High-Strength Steel Techniques ................................................1-28 Components ..............................................2-66

1-14 Trimming Sealant Tape for a 2-28 Wing Condensate Drain Hole Square Corner ..........................................1-28 Locations ...................................................2-67

1-15 Cornering Method for Rounded 3-1 Lower Exterior Skin...................................... 3-3 or Angled Corners ....................................1-28 3-2 Fuselage Skin Under Fuse-

1-15.1 StretchSeal Tape Compression .................. 1-32 lage-to-Wing Fillet Assembly, 1-15.2 Potting Compound Injection....................... 1-32 FS 432 to FS 477 .......................................3-5 1-15.3 Removal of Excess StretchSeal 3-3 Battery Compartment ................................... 3-7

Tape...........................................................1-32 3-4 Forward Chaff/Flare Dispensers 1-15.4 Installation of Self-Fusing Sili- (AC-130U Only) ........................................3-10 cone Tape ...............................................1-32.1 3-5 Waveguide Access Panels 1-15.5 Removal of Self-Fusing Sili- (AC-130U Only) ........................................3-12 cone Tape ...............................................1-32.1 3-6 Combined Altitude Radar Altim- 1-16 Corrosion Prone Areas For Elec- eter (CARA) Antenna Mounts trical Components ....................................1-33 (AC-130U Only) ........................................3-14 2-1 Deleted 3-7 Lower UHF/L-band, 2-2 Outer Wing Upper Skin Panels ................... 2-5 ARC-164/TACAN Antenna 2-3 Outer Wing Attachment at Wing Support Structure (AC-130U Only) ........3-16

Station 220..................................................2-7 3-8 AN/APR-46 Low Band Antenna 2-4 Wing Attach Bolts, C-130 Support Structure (AC-130U

Airplanes.....................................................2-9 Only)..........................................................3-18 2-5 Wing Joint Attachment Fittings ................ 2-12 3-9 Lower AN/APR-46 2-6 Wing Beam Cap (Corner) Fit- Omni-Directional Antenna tings, Wing Station 220...........................2-14 Support Structure (AC-130U Only) ........3-20 2-7 Dry Bay Access Doors on Wing 3-10 AN/AAR-44 IRWR Sensor Sup-

Upper Surface...........................................2-16 port Structure (AC-130U Only)...............3-22 2-8 Dry Bay Access Openings in 3-11 Compass Sail Antenna Support

Wing Upper Surface.................................2-19 Structure (AC-130U Only).......................3-24 2-9 Over-The-Wing Hoist Mounting

Bracket Bolt Holes ...................................2-21

Change 24 iii

LIST OF ILLUSTRATIONS - Continued

Figure Title Page Figure Title Page

3-12 25MM/(On Airplanes Modified 3-37 Underfloor Bulkhead End by TO 1C-130(A)U-640) GUN Fittings......................................................3-90 1 Gunport Structure 3-38 Main Landing Gear Frames, FS (AC-130U Only) ........................................3-27 517 and FS 597, and Center

3-13 Forward Cargo Door.................................... 3-30 Fuselage Dispensers, FS 570 3-14 Chine Caps................................................... 3-32 to FS 617...................................................3-93 3-15 Cargo Floor Panels, FS 245 to 3-39 Fuselage Window Retainers ....................... 3-95

FS 737 .......................................................3-35 3-40 Flight Deck Chine Plates............................ 3-97 3-16 TGMS and ASHS/(On Airplanes 3-41 Cargo Ramp Floor Panels......................... 3-100

Modified by TO 3-41.1 Cargo Ramp Leading Edge 1C-130(A)U-640) TGMS and Assembly .................................................3-101 AFSS Bearing Pads (AC-130U 3-42 Cargo Ramp Seal Retainers ..................... 3-103 Only)..........................................................3-37 3-43 Cargo Ramp Tension Strap ...................... 3-105

3-17 Fuselage Underfloor Structure................... 3-40 3-44 Upper Longeron Fitting, FS 3-18 Interior Surfaces of Lower Fuse- 1041 .........................................................3-107 lage Skin ...................................................3-43 3-45 Floor Support Beams, FS 196, 3-19 105MM Gunport Structure FS 212, FS 228, and WL 146

(AC-130U Only) ........................................3-46 (Airplanes Prior to 3-20 IDS Support Structure AF91-1231 Not Modified by

(AC-130U Only) ........................................3-48 TO 1C-130-1323, TO 3-21 Longeron Fitting Under Para- 1C-130-1465 and TO troop Door Sill ..........................................3-53 1C-130-1466)...........................................3-109 3-22 Lower Longeron Fitting, FS 3-46 Floor Support Beams, FS 196, 1041 ...........................................................3-55 FS 212, FS 228, and WL 146 3-23 Lower Aft Longeron in Area (Airplanes Modified by TO

Under Urinals...........................................3-57 1C-130-1323, TO 3-24 Windshield Retainers and For- 1C-130-1465, TCTO ward Sensor Panel Retainers..................3-59 1C-130-1466 and Airplanes AF91-1231 and 3-25 AN/AAR-47 Sensor Supports Up)...........................................................3-111

(Airplanes Modified by TO 3-47 Static Line Support Beam (‘‘H’’ 1C-130-1323, TO 1C-130-1465, Beam) Web, FS 245, WL 228 ................3-113 TO 1C-130-1466 and Air- 3-48 Autopilot and Radio Junction planes AF91-1231 and Up)......................3-61 Boxes .......................................................3-115

3-26 Electronic Equipment Support 3-49 Magnesium Component Structure ...................................................3-63 Locations .................................................3-117

3-27 Nose Landing Gear Wheel Well................. 3-65 3-50 High-Strength Steel 3-28 Main Landing Gear Wheel Components ............................................3-119

Wells..........................................................3-68 3-51 Fuselage Condensate Drain 3-29 Aerial Refueling Receptacle........................ 3-70 Hole Locations ........................................3-121 3-30 Forward Upper Centerline An- 3-52 Deleted tenna Support Structure 3-53 Deleted (AC-130U Only) ........................................3-72 3-54 Antenna and Dome Boots ......................... 3-132

3-31 Marker Beacon Antenna Sup- 4-1 Horizontal Stabilizer-to-Fuselage port Doubler (AC-130U Only) .................3-74 Fillet Areas .................................................4-2

3-32 40MM/(On Airplanes Modified 4-2 Elevators ........................................................ 4-4 by TO 1C-130(A)U-640) GUN 4-3 Elevator Counterbalance Arm...................... 4-6 2 Gunport Structure 4-4 Vertical Stabilizer Flush (AC-130U Only) ........................................3-76 Antenna.......................................................4-8

3-33 ALLTV LRU Shelf (AC-130U 4-5 Vertical Stabilizer Longeron Only)..........................................................3-80 Fittings......................................................4-10

3-34 Lower Longeron Doubler, FS 4-6 Magnesium Component 737 to FS 770 ...........................................3-83 Locations ...................................................4-11

3-35 Lower Longeron Fitting, FS 737................ 3-85 4-7 Empennage Condensate Drain 3-36 Fuselage-to-Wing Pressure Skin, Hole Locations ..........................................4-13

FS 477 to FS 617 .....................................3-88 iv Change 17

LIST OF ILLUSTRATIONS - Continued

Figure Title Page Figure Title Page

4-8 Empennage Condensate Drain 7-1 Interior Surface Finishes............................ 7-42 Hole Locations (AC-130U Only)..............4-14 7-2 Exterior Surface Finishes for

5-1 Engine Truss Mounts.................................... 5-3 Airplanes without Equipment 5-2 Power Plant Upper Longeron....................... 5-7 Excellence Paint Scheme.........................7-43 5-3 Firewall Frame and Nacelle 7-3 Exterior Surface Finishes for

Structure ...................................................5-12 Airplanes with Equipment 5-4 Nacelle Sealing ............................................ 5-14 Excellence Paint Scheme.........................7-44 5-5 External Fuel Tanks ................................... 5-17 7-4 Metal Removal Limits for Wing 5-6 HF Probe Antenna Assembly Structure ...................................................7-51

Mounting Bracket fittings 7-5 Metal Removal Limits for Fuse- (AC-130U Only) ........................................5-19 lage Structure...........................................7-75

5-7 Nacelle and Pylon Condensate 7-6 Metal Removal Limits for Em- Drain Hole Locations ...............................5-21 pennage Structure..................................7-127

5-8 Nacelle and Pylon Condensate 7-7 Metal Removal Limits for En- Drain Hole Locations gine Nacelle and Pylon Structure.........7-133 (AC-130U Only) ........................................5-22 7-8 Metal Removal Limits and Re-

6-1 Landing Gears ............................................... 6-3 work of Nose Landing Gear 6-2 Wheel Assemblies.......................................... 6-6 Outer Cylinder Steering Col- 6-3 Magnesium Component Locations ............... 6-7 lar Area ...................................................7-150 6-4 High-Strength Steel Components B-1 NVIS Flight Deck Interior Trim

(Over 200 KSI) ...........................................6-9 and Finishes .............................................. B-1

Change 17 v

LIST OF TABLES

Number Title Page Number Title Page

1-1 Damage and Repair Required................. 1-30.4 7-2 Corrosion Removal ...................................... 7-16 1-2 PMB Operation Parameters ....................... 1-39 7-3 Finish System.............................................. 7-23 3-1 Fastener Substitutions For 7-4 Technical Repair

Corroded Hardware ...............................3-133 Center-Repaired Items Finish 5-1 7175-T74 Aluminum Truss System.......................................................7-41

Mounts ........................................................5-2 7-5 Sealant System............................................ 7-45 6-1 Applicable Landing Gear Techni- 8-1 Special Materials List................................... 8-1 cal Manuals ................................................6-2 A-1 Plastic Media Blasting Approved 7-1 Corrosion Inspection ..................................... 7-1 Parts List ................................................... A-1 vi Change 24

SAFETY SUMMARY

GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs and NOTEs included in that task shall be reviewed and understood.

WARNINGS, CAUTIONS AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or mainte-nance procedures, practices, conditions or statements which are considered essential to protection of per-sonnel (WARNING) or equipment (CAUTION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of a heading (WARNING, CAUTION), a statement of the hazard, minimum precautions, and possible result if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions or state-ments which are not essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending upon the information to be highlighted. The headings used and their defini-tions are as follows:

WARNING

Highlights an essential operating or maintenance procedure, practice, condi-tion, statement, etc, which if not strictly observed, could result in injury to, or death of, personnel or long term health hazards.

CAUTION

Highlights an essential operating or maintenance procedure, practice, condi-tion, statement, etc, which if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

CLEANERS/CHEMICALS SPECIAL HANDLING.

Ensure cleaners/chemicals are stored in approved safety containers and in minimum quan-tities. Some cleaners/chemicals may have an adverse effect on skin, eyes, and respiratory tract. Observe manufacturer’s WARNING labels and current safety directives. Use cleaners/chemicals only in authorized areas. Discard soiled cloths into safety cans. Consult the local Bioenvironmental Engineer and/or Mate-rial Safety Data sheets (MSDS) for specific precaution, protective equipment, and ventilation requirements.

PERSONAL PROTECTIVE EQUIPMENT.

Wear protective clothing/equipment (i.e. gloves, apron, eye protection, etc.) approved for materials, procedures and tools being used. If necessary, contact supervisor, Bioenvironmental Engineer or the Base Safety Office for guidance.

SAFETY APPROVED EQUIPMENT.

ix

SAFETY SUMMARY - Continued

Use only approved explosion-proof lights, blowers, and other equipment when cleaners, primers and other coatings are being applied. Ensure that appropriate fire extinguishing equipment is readily available.

LIST OF RELEVANT GENERAL SERIES TECHNICAL

ORDERS AND SYSTEM PECULIAR MANUALS

TO 00-110A-3 Decontamination of Radioactively Contaminated Aircraft Exterior Surfaces

TO 00-110A-5 Decontamination of Radioactive Aircraft Engines and their Parts

TO 00-110A-10 Decontamination of Radioactively Contaminated Aircraft Accessories

TO 00-110N-2 Radioactive Waste Disposal

TO 1-1-3 Preparation, Inspection, and Repair of Aircraft Fuel, Oil and Water-Alcohol Cells and Integral Tanks

TO 1-1-4 Exterior Finishes, Insignia and Markings Applicable to Aircraft and Missiles

TO 1-1-8 Application of Organic Coatings

TO 1-1-17 Storage of Weapons

TO 1-1-689 Prevention and Control of Corrosion and Fungus In Communications, Elec-tronic, Meteorological, and Avionic Equipment

TO 1-1-691 Aircraft Weapons Systems Cleaning and Corrosion Control

TO 1C-130A-36 Nondestructive Inspection Procedures

TO 1C-130(A)U-2-14 Sensors

TO 1C-130(A)U-2-15 Armament

TO 2J-1-18 Corrosion Control of Gas Turbine Engines

TO 2J-T56-101 Corrosion Control Through Field Level Maintenance

TO 12-1-3 Climatic Deterioration Prevention Treatment, Electronic and Communications Equipment

TO 33B-1-1 Nondestructive Inspection Procedures

TO 42A-1-1-1 Evaluation and Service Testing Materials-Cleaning, Painting, Sealing, Protec-tive Treating, Anti-Corrosion, Inspection Materials and Related Items

TO 42C-1-9 Information on Toxicity, Flashpoint and Flammability of Chemicals x

Figure i-1. Knocked Out by Corrosion

INTRODUCTION

PURPOSE OF MANUAL.

This system peculiar corrosion control manual is prepared to acquaint corrosion control personnel with the corrosion susceptible area/items peculiar to all USAF models of the C-130, the protective system utilized to afford corrosion resistance, and appropriate methods for the inspection, removal, treatment and repair of corroded components and surfaces.

SCOPE OF MANUAL.

This manual applies to all USAF models and series of C-130 airplanes. The content of the manual is limited to airplane peculiar items that have been found to be corrosion susceptible in service and that require airplane peculiar corrosion control with respect to location, inspection, corrosion removal, damage evaluation, metal removal, sealing, and finish requirements. Historical information documenting materials, surface treatment, sealant and finish specifications applicable to each airplane model or series is also included. A list of relevant general series technical orders is contained, that are referenced when appropriate, as applicable to the corrosion prevention and control of C-130 airplanes. Implementation of the procedures contained in this manual is intended to be the responsibility of personnel trained as corrosion control specialists.

CORROSION PRONE AREA/ITEM INDEX.

Corrosion prone area/items peculiar to the airplane are illustrated in figure i-2. This index provides a title definition of each area/item that is synonymous with the item number and title used within the chapter of this manual assigned to that peculiar part of the airplane structure.

FINISH SYSTEMS.

Finish materials applied during operation are given for historical information. These materials shall be reapplied only when minor touch-up of an area is required. The repair finish is the current protective finish system for an area which shall be applied when the production finish system is deteriorated or found to be xi nonexistent. The old deteriorated finish shall be completely removed before application of the repair finish.

Sealing of the area shall be accomplished before application of the organic finish. Finish systems shall be applied in accordance with TO 1-1-8. When required by aircraft operations, Color No. 37038 per Fed Std 595 shall be used instead of the interior colors given in this manual.

xii

Figure i-2. Corrosion Prone Area/Item Index (Sheet 1 of 5) xiii

Figure i-2. Corrosion Prone Area/Item Index (Sheet 2) xiv

Figure i-2. Corrosion Prone Area/Item Index (Sheet 3) xv

WING

W-1. Center Wing Upper Skin Panels W-2. Outer Wing Upper Skin Panels W-3. Outer Wing Attachment at Wing Station 220 W-4. Wing Attach Bolts, C-130A/D Airplanes W-5. Wing Joint Attachment Fittings W-6. Wing Beam Cap (Corner) Fittings, Wing Station 220 W-7. Dry Bay Access Doors on Wing Upper Surface W-8. Dry Bay Access Openings in Wing Upper Surface W-9. Over-The-Wing Hoist Mounting Bracket Bolt Holes W-10. Lower Exterior Surface of Wing W-11. Wing Panel Risers at ‘‘H’’ Clip Attachments W-12. Engine Mount Drag Angles, Lower Surface of Wing W-13. Wing Leading Edges W-14. Bleed Air and Anti-Icing Ducts W-15. Hinges on Wing Leading and Trailing Edges W-16. Wing Beam (Spar) Caps W-17. IR Shield Attach Fittings (AC-130U only) W-18. HF Probe Antenna Attach Fittings (AC-130U only) W-19. Beam Webs W-20. Bonded-Beaded Trailing Edge Skins W-21. Ailerons W-22. Flaps W-23. Flap Tracks and Jackscrews W-24. Integral Fuel Tanks W-25. Wing Panel Rib Pads (Centroid Risers)

FUSELAGE

F-1. Lower Exterior Skin F-2. Fuselage Skin Under Fuselage-to-Wing Fillet Assembly, FS 432 to FS 477 F-3. Battery Compartment F-4. Forward Chaff/Flare Dispensers (AC-130U only) F-5. Waveguide Access Panels (AC-130U only) F-6. Combined Altitude Radar Altimeter (CARA) Antenna Mounts (AC-130U only) F-7. Lower UHF/L-band, ARC-164/TACAN Antenna Support Structure (AC-130U only) F-8. AN/APR-46 Low Band Antenna Support Structure (AC-130U only) F-9. Lower AN/APR-46 Omni-Directional Antenna Support Structure (AC-130U only) F-10. AN/AAR-44 IRWR Sensor Support Structure (AC-130U only) F-11. Compass Sail Antenna Support Structure (AC-130U only) F-12. 25MM/(On Airplanes Modified by TO 1C-130(A)U-640) GUN 1 Gunport Structure

(AC-130U only) F-13. Forward Cargo Door F-14. Chine Caps F-15. Cargo Floor Panels, FS 245 to FS 737 F-16. TGMS/ASHS/(On Airplanes Modified by TO 1C-130(A)U-640) TGMS/AFSS Bearing

Pads (AC-130U only) F-17. Fuselage Underfloor Structure F-18. Interior Surfaces of Lower Fuselage Skin F-19. 105MM Gunport Structure (AC-130U only)

Figure i-2. Corrosion Prone Area/Item Index (Sheet 4) xvi Change 17

FUSELAGE

F-20. IDS Support Structure (AC-130U only) F-21. Longeron Fitting, Under Paratroop Door Sill F-22. Lower Longeron Fitting, FS 1041 F-23. Lower Aft Longeron in Area Under Urinals F-24. Windshield Retainers and Forward Sensor Retainers F-25. AN/AAR-47 Sensor Supports (Airplanes AF91-1231 and Up) F-26. Electronic Equipment Support Structure F-27. Nose Landing Gear Wheel Well F-28. Main Landing Gear Wheel Wells F-29. Aerial Refueling Receptacle F-30. Forward Upper Centerline Antenna Support Structure (AC-130U only) F-31. Marker Beacon Antenna Support Doubler (AC-130U only) F-32. 40MM/(On Airplanes Modified by TO 1C-130(A)U-640) GUN 2 Gunport Structure

(AC-130U only) F-33. ALLTV LRU Shelf (AC-130U only) F-34. Lower Longeron Doubler FS 737 to FS 770 F-35. Lower Longeron Fitting FS 737 F-36. Fuselage-to-Wing Pressure Skin, FS 477 to FS 617 F-37. Underfloor Bulkhead End Fittings F-38. Main Landing Gear Frames, FS 517 and FS 597, and Center Fuselage Dispensers, FS 570 to FS 617 F-39. Fuselage Window Retainers F-40. Flight Deck Chine Plates F-41. Cargo Ramp Floor Panels F-42. Cargo Ramp Seal Retainers F-43. Cargo Ramp Skin Tension Strap F-44. Upper Longeron Fitting, FS 1041 F-45. Floor Support Beams, FS 196, FS 212, FS 248 and WL 146 (Airplanes Prior to AF91-

1231 Not Modified by TO 1C-130-1323, TO 1C-130-1465 or TO 1C-130-1466) F-46. Floor Support Beams and Forward Dispensers, FS 196, FS 212, FS 248, and WL 146

(Airplanes Not Modified by TO 1C-130-1344, TO 1C-130-1465, TO 1C-130-1466, and Airplanes AF91-1231 and UP)

F-47. Static Line Support Beam (‘‘H’’ Beam) Web, FS 245, WL, 228 F-48. Autopilot And Radio Junction Boxes

EMPENNAGE

E-1. Horizontal Stabilizer-to-Fuselage Fillet Areas E-2. Elevators E-3. Elevator and Rudder Counterbalance Arms E-4. Vertical Stabilizer Flush Antenna E-5. Vertical Stabilizer Longeron Fitting

ENGINE NACELLES AND PYLONS

NP-1. Engine Truss Mounts NP-2. Power Plant Upper and Lower Longerons NP-3. Firewall Frame and Nacelle Structure NP-4. External Fuel Tanks NP-5. External Fuel Tank Pylon Front and Rear Beam Assemblies NP-6. HF Probe Antenna Assembly Mounting Bracket Fittings (AC-130U only)

Figure i-2. Corrosion Prone Area/Item Index (Sheet 5)

Change 17 xvi.1/(xvi.2 blank)

LANDING GEAR

LG-1. Landing Gears LG-2. Wheel Assemblies

Figure i-2. Corrosion Prone Area/Item Index (Sheet 5.1)

Change 17 xvii

APPROVED ENGINEERING CHANGE PROPOSALS AND TIME COMPLIANCE

TECHNICAL ORDERS INCORPORATED IN THIS MANUAL

TO NUMBER ECP NUMBER TITLE

1C-130-1039 2094 Retrofit Installation of Rede-signed Outer Wing, C-130 Air-craft

1C-130-1323 Installation of AN/ALE-40 and AN/AAR-47 for Air Defense on Selected C-130 Aircraft

1C-130-1340 Special Operations Forces Center Wing Replacement, C-130 Aircraft

1C-130-1465 Retrofit Installation of AN/ALE- 47 Countermeasures Dispenser System (CMDS) and AN/AAR-47 Missile Warning System (MWS) on Selected C-130 Aircraft

1C-130-1466 Replacement of AN/ALE-40 with AN/ALE-47 on C-130 Airplanes Previously Modified by Techni-cal Order 1C-130-1323/1388

1C-130-1818 Installation of AN/AAQ-24(V)13 Large Aircraft Infrared Counter-measures (LAIRCM) System on Select C-130H Aircraft

1C-130-1899 Replacement of Center Wing With Enhanced Service Life Wing on Select C-130 Aircraft

1C-130-1914 Replacement of Center Wing on Select C-130 Aircraft

1C-130(A)H-671 Installation of the AAQ-24A(V) LAIRCM System on AC-130H Aircraft

1C-130(A)U-640 Removal of 25MM and 40MM guns and Installation of 30MM Guns on AC-130U Aircraft

1C-130(M)H-598 Modification of MC-130H Air-craft for Integrated Air Refuel-ing System (IARS)

1C-130(M)H-614 Modification of Select C-130H Aircraft to the MC-130W Configuration xviii Change 24

CHAPTER 1

GENERAL PREPARATION

SECTION I

PREPARATION OF SURFACES FOR CORROSION INSPECTION

1-1 CLEANING THE AIRPLANE. diameter of 1-1/2 inches minimum. The purpose of the large diameter rinse hose isProper and frequent cleaning of the airplane to provide a large volume of water, notserves the dual purpose of removing harmful sur- pressure.face deposits that cause corrosion and exposing the surface of the airplane to the discerning eye of a specialist trained in the detection of irregulari- CAUTION ties that are evidenced by a change in color or a deviation from standard surface smoothness. Con- Rinse pressure shall not be boosted sequently, cleaning the airplane is considered a above that of normal tap pressure.

corrosion preventive measure as well as a require-

b. Use MA-1 spray equipment, barrel pumpsment for inspection. That which has been prop-or foamers, mops, and soft bristle brusheserly cleaned has also been inspected and vice to apply and agitate cleaning solutions.versa. Refer to TO 1-1-691 for general require- Refer to T.A. 480 and TO 1-1-691 forments pertaining to safety, cleaning materials and authorized wash rack equipment andequipment required, and the general procedures to materials.be used by personnel in washing airplanes. Spe-cial instructions for cleaning the Allison T-56 engine under highly corrosive environmental con-ditions is contained in TO 2J-T56-101. (See figure WARNING 1-1.)

1-2 CLEANING EQUIPMENT PECULIAR Do not use steam cleaning ITEMS. equipment.

Observe the following limitations/restrictions when c. Always use hot water in a temperature using general purpose equipment defined in TO 1- range of 100 oF to 150 oF to wash and 1-691. rinse the airplane unless heated water can-not be provided at the wash location.a. To ensure complete and rapid removal of Depot facilities shall always use hot water.cleaning solutions from exterior surfaces, the rinsing hoses shall have an inside

1-1

Figure 1-1. Typical Washing Facility

1-3 AIRPLANE COMPONENT REMOVALS 1-4 MASKING TO PREVENT WATER ENTRY.

REQUIRED. Cleaning solutions and rinse water shall be The following components shall be removed from excluded from sheltered areas of the airplane by the airplane prior to exterior washing: applying waterproof covering and/or waterproof tape per the instructions contained in TO 1-1-691.a. Fending lines on HC-130H and HC-130P Airplane peculiar items are as follows:airplanes shall be removed. The knives shall be wiped clean and masked prior to a. Install weather excluding covers and plugs coiling the fending lines. Coils shall be a provided with the airplane as defined in minimum of 6 feet in diameter to prevent the applicable airplane maintenance tech-over stressing the glass fibers. nical manual.

b. On the crash position indicator system, b. Apply waterproof tape over the seams sep-remove the RBA-6 airfoil and MT-3714A arating the crash position transmitter and mount. Install the cover, and mask to pre- the adjacent surfaces if the transmitter is vent water entry. installed.

c. Deleted.

CAUTION d. Cover static port holes.

e. On airplanes modified by TO 1C-130-949,Masking to prevent water entry could prior to washing the airplane or strippinginvolve the covering, of very sensitive paint, the Universal Aerial Refuelingvents such as those of a fuel tank.

Receptacle/Slipway Assembly must be pro-For this reason it is important to tected. The unit may be masked andremove all such masking immediately sealed off with waterproof tape and barrierafter washing the airplane. In the paper, or it may be removed from the air-event that masking tape was left cov-plane. It is absolutely imperative that noering such vents, the function of the moisture, cleaning solvents or paintvent would be denied, resulting in remover be allowed to enter the unit. Forpossible failure of the tank to supply removal and installation procedures, referfuel to the engines or possible rupture to TO 1C-130B-2-5 or TO 1C-130(M)H-2-5.of the tank structure during refueling.

1-2 Change 18

f. On airplanes modified by TOs 1C-130- readily drain from the surface as required to avoid 1323, 1C-130-1388, 1C-130-1465, 1C-130- skin stains similar to those shown in figure 1-3.

1466, all MC-130P/W airplanes, and air- 1-6 LOCAL INTERIOR CLEANING.planes AF91-1231 and up, apply water-proof tape over seam around defensive sys- Interior areas of the airplane subject to the tem flare and chaff dispensers. accumulation of dirt, debris, and airplane fluids residue should be cleaned as required for the pre-g. On AC-130U Gunship, install covers and vention of corrosion as well as to afford the detec-plugs on 25MM, 40MM and 105MM guns. tion of a breakdown in the corrosion protection(On Airplanes modified by TO 1C-130(A)U- finishes originally applied. See figure 1-4 for typi-640.) On AC-130U Gunship, install covers cal soil accumulation. Areas of the airplane whereand plugs on GUN 1, GUN 2 and 105MM such accumulations may occur are:guns. Install protective covers on ALLTV, IDS, FWD scanner and AFT observer a. The wing-to-fuselage fillets discussed in windows. chapter 3, item No. F-2, form a trap for dirt and debris under the wing leadingh. On AC-130U Gunship, mask ALLTV vent edge-to-fuselage fillet, where no drainagelouvers on left main wheel well fairing. provisions are provided. At the general

i. On aircraft not modified by TO 1C-130(U)- cleaning cycle, remove the forward panel

541. On AC-130U Gunship, mask the tri- assembly on the fuselage under the wing to angular penetrations for the IDS support gain access to the compartment under the tees that pass through the nose wheel well fillet. Access is available through the skin. small hole in the bulkhead frame just for-ward of the removed access panel. Vac-j. On aircraft modified by TO 1C-130(U)-541. uum loose debris from the compartment using a thin tube wand. The task is notk. On AC-130U Gunship, install waterproof easy because of the duct installation a fewcovering using waterproof tape over gun inches aft of the access hole.pressure seals.

l. On aircraft equipped with ALQ-157, cover the ALQ-157 transmitters and place a

WARNINGmasking tape barrier on the connectors behind the air deflector doors.

m. On airplanes modified by TO 1C-130-1818 . Cleaning compound MIL-PRF-87937 or TO 1C-130(A)H-671 and MC-130W air- may affect skin, eyes, and respiratory planes, prior to washing the airplane or tract. Use in a well ventilated area.

stripping paint, the AN/AAQ-24 transmit- Industrial safety goggles or face ters, sensor units, and fairings must be shield, and neoprene gloves shall be protected. The units may be masked and worn. Personal injury could result.

sealed off with plastic bags or locally man- . Amlguard, MIL-C-85054, Type I orufactured covers, or they may be removed

Type II is flammable and toxic tofrom the airplane. It is absolutely impera-eyes, skin, and respiratory tract.tive that no moisture, cleaning solvents or Avoid skin and eye contact. Goodpaint remover be allowed to enter the unit.

general ventilation is normally ade-For removal and installation procedures, quate. Keep away from open flamesrefer to TO 1C-130H-2-99JG-10-6 or TO or other sources of ignition.1C-130(A)H-2-99JG-10-6.

b. Engine dry bays become soiled from carbon1-5 EXTERIOR WASHING SEQUENCE.

residues. During each isochronal inspec-

Ensure that all drain holes are open and operative tion, thoroughly clean interior of all dry and then proceed in accordance with the sequence bays aft of the engines using water. Wash indicated in figure 1-2. The following materials the dry bay interior using clean rags. Dry are approved for full exterior wash, MIL-PRF- the area using clean dry rags. During 87937 and MIL-PRF-85570, Type I and II. See cleaning of dry bays if more aggressive TO 1-1-691 for additional instructions for the use cleaning is required use MIL-PRF-87937, of these materials and for specific area cleaning Type II, as directed by TO 1-1-691. Do instructions. Clean the exterior surface area by not use large volume of water. Dry the area, starting at the lower surface and working area by wiping with clean dry rags.

upward. Squeegee off any water that does not

Change 24 1-3

Ensure that all cleaning solution is (1) Pressure is limited to approximately removed and no residue remains. Apply a 500 psi.

light coat of Amlguard, Specification MIL- (2) Water temperature is limited to 120oF.C-85054, Type II by brushing or spraying with a non-aerosol pump sprayer to areas (3) Water volume shall be limited to where the coating system is cracked, miss- approximately 2 gallons/minute.

ing or…