C130_PWS_UDLM_PDM_App_D_C130J_Aircraft_Mid-Cycle_Paint_Work_Specs_dtd_21Oct19.pdf

PWS Appendix F C-130J Aircraft Mid-Cycle

Paint Work Specifications (WS)

TYPE ACFT: USAF C-130J Aircraft

Distribution Statement C: Distribution authorized to Department of Defense and U.S.

Government Agencies and their Contractors (administrative and/or operational use) (20

December 2011). Other requests for this document shall be referred to AFLCMC/WLN, Robins

AFB, GA, 31098-1622.

REV 3: 26 July 2018 APPENDIX D - Mid-Cycle Paint Work Spec

HEADQUARTERS

WARNER ROBINS AIR LOGISTICS CENTER

ROBINS AIR FORCE BASE GA 31098

DATE: 26 July 2018

1 SECTION I: - GENERAL

1.1 Information:

1.2 Terms Explained:

1.3 Data

1.4 Security: Unclassified

1.5 Quality:

1.6 Condemnation and Repair:

1.7 Nonstructural Accessories, Components, Re-Use, Repair and Replacement:

2 SECTION II - RECEIPT OF AIRCRAFT AT FACILITY:

2.1 Handling:

2.2 Inventory:

2.3 Preservation. Preservation is accomplished only if required by technical orders listed below and only if directed by the PAO:

3 SECTION III - WORK REQUIREMENTS

3.1 General Requirements:

3.2 Specific Requirements:

3.3 Accomplish aircraft Weight and Balance IAW TO 1-1B-50:

3.4 Aircraft close out

4 SECTION IV - FINAL PROCESSING OF AIRCRAFT

4.1 Finishing of Aircraft:

4.2 Servicing:

4.3 Functional Ground Check:

4.4 Preflight:

4.5 Acceptance/Functional Check Flight:

4.6 Forms Preparation:

5 SECTION V - TECHNICAL ORDERS AND OTHER DIRECTIVES

5.1 General:

6 SECTION VI - WARRANTY

REV 3: 26 July 2018 APPENDIX D - Mid-Cycle Paint Work Spec

DOCUMENT OF WORK SPECIFICATIONS

1 SECTION I: - GENERAL

1.1 Information:

1.1.1 This document outlines the requirements for aircraft receipt, evaluation of coating systems and AFTO Form 103 requests. Also defined are requirements for scuff sanding or depainting, as applicable; painting with MIL-PRF-85285, Type IV Class H polyurethane topcoat (as authorized by the C-130 Corrosion Manager); marking and performing weight and balance on C-130 H/J aircraft.

Aircraft to be painted will arrive at the paint facility from the home station. The paint shop shall receive the aircraft, inventory the equipment and process it into the facility.

CAUTION

Aircraft squibs, chaff and flares shall be removed before aircraft arrives.

NOTE

This project is unclassified; however, no data, technical or otherwise concerning this project, shall be released through publication or in any manner except with specific written authorization by AFLCMC/WLNE.

1.1.2 The aircraft shall be returned to the assigned organization in the same configuration as received, with the same type components, accessories, and special equipment installed except as modified, removed, or added by requirements of this Document of Work Specifications. Specifically equipped or instrumented aircraft are subject to be worked under the requirements of this work specification. This paragraph shall also apply to special configured aircraft.

NOTE

(C-130J only) Engines and propellers are managed under the Rolls Royce “Power-by-the–Hour" program and are not the responsibility of the ALC or contractor. The Primary Approval Official (PAO) will contact AFLCMC/WLNCA Propulsion Section and AFLCMC/WLNEA Propulsion Engineering Section if an engine or propeller requires additional maintenance while in possession of the ALC or contractor.

1.1.3 Discrepancies found which do not require correction by this specification shall be recorded in aircraft historical records in accordance with TO 00-20-1.

1.1.4 Only those systems worked by a specific requirement or disturbed by other requirements of this specification shall be made operational unless a safety of flight condition exists or it is an overseas requirement as required by the following.

1.1.5 Life raft(s), one each 20 man minimum with accessory kit, shall be installed and rigged IAW TO 1C-130-2 job guides.

1.1.6 Any deviations from this specification must be approved by the AFLCMC/WLNEB C-130 Corrosion Manager.

1.1.7 For the purpose of this work specification, corrosion treatment is defined as cleaning, removal of corrosion and deteriorated coatings, chemical treatment of metals, repair and finishing in accordance with applicable technical orders. Missing or deteriorated coating systems shall be considered a discrepancy.

1.2 Terms Explained:

NOTE

Items listed below shall not be interpreted to delete or minimize any work requirements of technical orders listed in Section V of this document.

1.2.1 A CHECK: A thorough inspection, consisting primarily of checking certain components, areas and systems of the aircraft due to their function, shall be accomplished upon the accrual of 270 days.

1.2.2 ACCESSIBLE: Applies to areas of equipment that may be inspected or worked without disassembly other than required by this specification.

1.2.3 ACCESSORY: A mechanism or device employed in conjunction with a major item of equipment or installed as part of a system.

1.2.4 AIRCRAFT EXTERIOR: Aircraft outer skins and outer skins of components, such as flaps, ailerons, elevators, rudder, ramp, cargo door, nose landing gear doors, and main landing gear doors.

1.2.5 AIRFRAME: The structural components of an airplane including the framework and skin of such parts as the fuselage, empennage, wings, and engine mounts (does not include landing gear and engine).

1.2.6 B CHECK: A thorough inspection, consisting primarily of checking certain components, areas and systems of the aircraft due to their function, shall be accomplished upon the accrual of 540 days.

1.2.7 BASIC MAINTENANCE INSTRUCTIONS: The appropriate section of the applicable aircraft handbooks and manuals listed in Section V of this document.

1.2.8 BENCH CHECK: Visual inspection, physical test, and functional check using shop facilities, equipment, procedures, and test parameters, as set forth in applicable technical publications to determine the exact condition.

1.2.9 C1 CHECK: A thorough inspection, consisting primarily of checking certain components, areas and systems of the aircraft due to their function, shall be accomplished upon the accrual of 1080 days.

1.2.10 C2 CHECK: A thorough inspection, consisting primarily of checking certain components, areas and systems of the aircraft due to their function, shall be accomplished upon the accrual of 2160 days.

1.2.11 CALIBRATION: A comparison between two instruments, one of which is a standard of known accuracy, to detect and correlate or adjust any variation in accuracy of the instrument being compared.

1.2.12 COMPONENT: A separate identifiable part of an end item which performs a function within the system or subsystem and is necessary for the proper operation of that end item.

1.2.13 CORRECT DISCREPANCIES: The accomplishment of all necessary work and testing to restore the part, component or aircraft to a serviceable condition status.

1.2.14 DATA: All management, scientific engineering, and logistics information, reports and documentation which are required.

1.2.15 DEPOT LEVEL MAINTENANCE FACILITY: An industrial type facility established to perform overhaul functions or modification and maintenance in support of field and using organizations. This includes AFMC assigned installations and commercial contractors who are engaged in performing depot level work on weapon systems or equipment under contracts issued and managed by AFMC.

1.2.16 DETERIORATED FINISH: When the finish no longer provides the protection for which it was intended.

1.2.17 DISASSEMBLY: Teardown of the item or parts sufficient to permit the type and amount of inspection and work required.

1.2.18 DISTURBED SYSTEM: Any system of which the whole or component part has been removed, disassembled, repaired, adjusted, modified, disconnected, or altered.

1.2.19 ECONOMICAL REPAIR: The correction of any discrepancy found, that because of access to that discrepancy during UDLM, or because of availability of tools or spares required to correct the discrepancy, is more economical to accomplish during UDLM.

1.2.20 END ITEM: A recoverable article of equipment listed in a procuring activity supply catalog.

1.2.21 ENGINE: The complete basic engine as specified in applicable technical order (TO) handbooks listed in the work specification.

1.2.22 ENGINE ACCESSORIES: All external items contained in the fuel, ignition, and control systems that are normally removed for rework or replaced without disassembly of the engine.

1.2.23 FUNCTIONAL CHECK: A check or test of the designed function operation of a specified unit using equipment procedures and limits specified in applicable TOs.

1.2.24 IAW: The abbreviation for In Accordance With.

1.2.25 INSPECT OR CHECK: An examination and evaluation of an item to determine identity, condition and proper installation.

1.2.26 ISOCHRONAL/LETTER CHECK INSPECTION: A searching inspection, consisting primarily of checking certain components, areas and systems of the aircraft which due to their function shall be accomplished upon the accrual of a specified number of calendar days or as determined by the owning organization. This inspection shall be accomplished as directed by AFTO Form 103 and approved by WR-ALC C-130 Production Management. This inspection shall be accomplished to determine that no condition exists which, if not corrected, could result in failure of a component or a system malfunction prior to the next scheduled inspection.

1.2.27 LOOSE FASTENER: In the no-load condition, a loose fastener will be physically loose. A black ring around the head of the fastener does not constitute looseness. A black ring may be the result of the wet installation, as indicated by MDS specific TO 1C-130-3.

1.2.28 MAINTENANCE COMPRESSION: A maximum all-out production of selected war mission aircraft and missiles undergoing PDM/PMP, modification, or area support within AFMC maintenance facilities. It entails actions which include suspension of routine PDM/PMP and modification work and reassembly of aircraft and missiles by accomplishment of only essential safety of flight maintenance and minimum acceptable war configuration mods, realignment of work stations, extension of work week and work day, redistribution of existing labor force, and cannibalization of aircraft on hand.

1.2.29 MDS: Mission Design Series.

1.2.30 MODIFICATION: A change in the physical configuration or in the functional characteristics of system or equipment.

1.2.31 N/A: Not Applicable.

1.2.32 NONDESTRUCTIVE INSPECTION (NDI): Methods for investigating the quality, integrity, properties and dimensions of material and components without damaging or impairing their serviceability.

1.2.33 O& I: Organizational and Intermediate Level Maintenance.

1.2.34 OCONUS: Outside Continental United States.

1.2.35 OVERHAUL: The disassembly, cleaning, inspection, repair or replacement of parts or components, reassembly and test of any item or accessory in accordance with applicable TOs, directives, or authorized manufacturer's publications to provide an operationally safe, serviceable and reliable item.

1.2.36 PAO: Project Administration Officer

1.2.37 PARTS: Essential elements, components, or subassemblies of an item.

1.2.38 PREVENTIVE MAINTENANCE: The normal inspection, upkeep and lubrication of equipment required to maintain the serviceability of equipment subjected to usage, wear and deterioration.

1.2.39 PRODUCT AUDIT: An inspection and evaluation of repaired or modified items for the purpose of Government verification that all work directed fully complies with contractual requirements.

1.2.40 PROGRAMMED DEPOT MAINTENANCE (PDM): Depot level maintenance normally applied to aerospace vehicle schedule on a time cycle basis.

1.2.41 PROGRESSIVE MAINTENANCE PROGRAM (PMP): Commercial type inspection and maintenance program derived from Maintenance Steering Group-3 (MSG-3) analysis. For the C-130J, it consists of A, B, C1 and C2 checks, Functional Significant, Structural, Replacement Schedule and Structural Health Monitoring Inspections as outlined and defined in TO 1C-130J-6 (Aircraft Scheduled Inspection and Maintenance Requirements).

1.2.42 RECLAMATION: The process of recovering serviceable or reparable spare parts.

1.2.43 REINSTALL: The reinstallation of a part or component on an aircraft after it has been removed to facilitate inspection, repair, or for military security purposes.

1.2.44 REPAIR: The restoration or replacement of parts or components of an item as necessitated by wear and tear, damage or failure of part in order to maintain the specific item in serviceable condition.

1.2.45 REPAIR FINISH: The coating system which is required to be applied to an area after replacement of components or accomplishment of any work which deteriorates the corrosion protection of the area after inspection shows coatings to be nonexistent or deteriorated.

1.2.46 REPARABLE: An unserviceable item that can be repaired and restored to a serviceable condition.

1.2.47 REPLACE: The replacement of items that are determined by the Government to be beyond economical repair, or as otherwise specifically directed.

1.2.48 RVSM: Reduced Vertical Separation Minimums. Specialized equipment is added to meet compliance. There are additional markings added to the aircraft to identify this.

1.2.49 SAFETY OF FLIGHT: A failure or malfunction that would present a hazardous condition to equipment or personnel during pre-flight, in-flight, or thru-flight operations.

1.2.50 SERVICEABLE: Capable of meeting the requirement and performing the function for which designed or modified, and meets all test requirements established by the work specifications.

1.2.51 SPECIAL INSPECTION: As used herein shall be interpreted to mean those inspections performed as required in accordance with applicable MDS specific TO 1C-130-6.

1.2.52 TECHNICAL ORDERS (TO): A publication that gives specific technical directives and information with respect to the inspection, storage, operation, and maintenance of given items and equipment. Reference to TOs herein will include supplements and latest published changes.

1.2.53 TIME COMPLIANCE TECHNICAL ORDER (TCTO): An authorized directive issued to provide instructions for accomplishing 'one-time' changes, modifications, installation of new equipment, or inspection of equipment.

1.2.54 TOUCH-UP: The repainting of a local area or marking to provide legibility or protection and to meet quality standards.

1.2.55 UNSCHEDULED DEPOT LEVEL MAINTENANCE (UDLM): Any

maintenance action required that was not anticipated prior to the event that requires input to a depot level facility due to the nature or extent of the effort.

1.2.56 VISUAL INSPECTION: Consists of visually inspecting for cracks, distortion, corrosion, fastener security, pulled rivets, and undue wear and damage. When inspecting items for corrosion, particular attention must be given to areas of dissimilar metal-to-metal contact (bushing, fasteners, etc.)

1.2.57 WORKBOOK: A listing of aircraft serial numbers, the equipment or systems to be modified, work to be accomplished and provisions for indicating that the work has been accomplished.

1.3 Data

1.3.1 Maintenance Records, Forms and Publications.

1.3.1.1 The maintenance facility shall maintain the forms and publications listed in subparagraph 1.3.1.2 below. If records are not received or are illegible, the maintenance facility shall obtain them from the using command or initiate new records in accordance with the applicable directive set forth in subparagraph 1.3.1.2 below. Maintain applicable forms listed in Column 1 in accordance with applicable directives listed in Column 3.

1.3.1.2 These forms and publications shall be maintained from the date the aircraft is received until the date the aircraft departs.

COLUMN 1 COLUMN 2 COLUMN 3

Form Numbers Form Title Applicable Directives

DD 365 Series Record of Weight & Balance TO 1-1B-50

AF 2692 Acft/Missile Equip Transfer/Shipping Listing AFI 21-103

AFTO 95 Significant Historical Data TO 00-20-1

AFTO 781 Series Aerospace Vehicle Flight Data Documents TO 00-20-1

1.3.1.2.1 A notation shall be made in the Significant Historical Data Column of AFTO Form 95, indicating the day, month, year and aircraft time and facility that this work was accomplished in accordance with TO 00-20-1. This shall certify that prescribed requirements of this document were accomplished.

1.3.1.3 Applicable MDS specific TO 1C-130-6 special inspections and all TO 1C-130-36 inspections accomplished under requirements of this document shall be recorded on applicable forms of the aircraft historical records.

1.3.2 Reporting Requirements:

1.3.2.1 C-l30 Inspection Tracking Record shall be entered into the Inspection, Corrosion, and Repair Recording (ICARR) software program IAW this document. Following completion of any Aircraft Structural Integrity Program (ASIP) inspections, Nondestructive Inspections (NDI), and/or structural repairs, record compliance (Positive or Negative) in the ICARR system. Enter inspection/repair information by selecting the “NDI” option in ICARR. ICARR data shall be uploaded to the Automated Inspection, Repair, Corrosion and Aircraft tracking (AIRCAT) server daily.

1.3.2.2 Corrosion Tracking Records shall be entered into ICARR IAW this document.

All corrosion or other defects in primary aircraft structure exceeding limits of structural repair manual (TO directed or general observation) shall be entered into ICARR. If corrosion grindout results in a repair installation enter specific repair information into ICARR while entering grindout results. Enter grindout/repair information by selecting the “Damage” option in ICARR.

ICARR data shall be uploaded to AIRCAT server daily.

1.3.2.3 For each aircraft send one copy of completed AFTO Form 95 to C-130 ASIP Manager, AFLCMC/WLNEA, 265 Ocmulgee Ct, Robins AFB GA, 31098-1647.

1.3.2.4 The maintenance facility shall provide documentation of ALL ENGINEERING SERVICES required to support the work requirements of this document.

1.3.2.4.1 This engineering authority is limited and allows maintenance facility engineers to provide on-site engineering to develop solutions that resolve discrepancies discovered on the aircraft during accomplishment of this task when the discrepancies are not addressed by specific repair instructions. All engineering dispositions shall be approved by AFLCMC/WLNEB engineering prior to accomplishment of any work.

1.3.2.4.2 These engineering solutions will be provided to AFLCMC/WLNE through the C- 130 Automated AFMC Form 202 web page. The maintenance facility shall complete Part A of the AFMC Form 202 and Part B through block 26A. When the completed form is approved by the government the form will be returned to the maintenance facility (via the automated system) with block 26E completed, which will indicate AFLCMC/WLNEB engineering approval. The maintenance facility shall complete Part C of the AFMC Form 202 after receipt of AFLCMC/WLNEB engineering approval.

1.3.3 Technical Data:

1.3.3.1 The removal, disassembly, inspection, repair, adjustment, modification, test, assembly, and reinstallation of components and equipment shall conform to the basic maintenance instruction manuals and other applicable TOs listed in Section V of this work specification.

1.3.3.2 Replacement parts and materials used in the repair of the aircraft or any other equipment shall be those authorized in USAF approved publications.

1.3.3.3 Obtain and use approved torque values and safety methods from publications listed below.

1.3.3.3.1 MDS specific TOs 1C-130-2 job guides and 1C-130-3 structural repair manuals.

1.3.3.3.2 If not listed in MDS specific TOs 1C-130-2 job guides or 1C-130-3 structural repair manuals, refer to accessory maintenance manuals.

1.3.3.3.3 If not listed in 1.3.3.3.1 or 1.3.3.3.2 above see TOs 1-1A-1 and 1-1A-8.

1.3.3.4 All fluids, fuel, oils, grease, and compounds used in servicing the aircraft shall be specified in the individual job guides for each MDS specific C-130 aircraft.

1.3.3.5 Nondestructive Inspection (NDI): Requirements for NDI shall be obtained from MDS specific TO 1C-130-36.

1.3.3.6 Nondestructive Inspection (NDI) methods, TOs 33B-1-1, 33B-1-2 and MDS specific 1C-130-36 shall be utilized when:

1.3.3.6.1 Directed by TOs or this document.

1.3.3.6.2 Questionable indications of defects are noted.

1.3.3.6.3 Parts are reworked in any way that could adversely affect the quality of parts such as milling, welding, machining, plating, grinding and heat-treating.

1.3.3.7 Non-Destructive Inspections:

1.3.3.7.1 Magnetic particle inspection shall be accomplished as directed by TOs 33B-1-1, 33B-1-2, MDS specific 1C-130-36 and ASTM E14444. Procedures specified in the General TO and specification shall not supersede those of the overhaul handbook unless so stipulated.

1.3.3.7.2 When the condition of metal parts and material indicates un-serviceability, such parts and material shall be inspected using methods and equipment prescribed in specification MIL-HDBK-6870 or equivalent specification.

1.3.3.7.3 Fluorescent penetrant inspection shall be accomplished in accordance with MDS specific TOs 1C-130-36, 33B-1-1, 33B-1-2, and ASTM E1417 or equivalent specification.

1.3.3.7.4 Radiographic inspection shall be accomplished in accordance with TOs 33B-1-1, 33B-1-2, MDS specific 1C-130-36 and MIL-STD-453 or equivalent standard. Procedures specified in the general TO and specification shall not supersede those of the overhaul handbooks unless so stipulated.

1.3.3.7.5 When inspection techniques not listed in MDS specific TO 1C-130-36 are used, they shall be reported using AFTO Form 242 in accordance with TOs 33B-1-1 and 33B-1-2.

The information reported shall be sufficient to enable maintenance personnel with training in the use of NDI to accomplish the reported inspection.

1.3.3.7.6 Personnel performing the nondestructive inspections required by this Work Specifications document shall have had formal training in the usage of the inspection equipment and shall possess certification of such training. NDI inspectors shall meet the training standards and/or qualifications for Class II inspectors as detailed in NAS 410 and MIL-STD-00453 or equivalent standards.

1.3.3.7.7 NDI inspections shall be performed utilizing NDI equipment authorized for use in accordance with MDS specific TO 1C-130-36.

1.3.3.7.8 It shall be certified that the NDI techniques performed on each structural item have been performed successfully under the conditions and circumstances specified in MDS specific TO 1C-130-36.

1.3.3.8 All deviations from technical and engineering data must be approved in accordance with paragraph 1.3.2.4 and sub-paragraphs.

1.4 Security: Unclassified.

NOTE

In the event an aircraft should arrive at the organic facility with classified equipment immediately notify AFLCMC/WLNA and owning organization.

1.5 Quality:

1.5.1 The maintenance facility shall have a quality management system per ISO 9001:2000 or equivalent.

1.6 Condemnation and Repair:

1.6.1 The maintenance facility shall not repair condemned items without prior approval.

The Maintenance facility shall not repair items where the cost of parts and labor exceeds 75% of the replacement cost of the item unless authorized.

1.7 Nonstructural Accessories, Components, Re-Use, Repair and Replacement:

1.7.1 When determined from inspection, operational test, or bench check that overhaul is required to insure serviceability, items shall be replaced with serviceable accessories or components. In the event serviceable accessories or components cannot be provided by the item manager in sufficient time to avoid work stoppages, the maintenance facility may repair or overhaul reparable accessories or components only to the extent required to preclude work stoppages, and as approved by the PAO.

1.7.2 Cannibalization of parts, components, and accessories required to prevent schedule slippage is authorized, as approved by the PAO.

1.7.3 No item is to be repaired as job routed if serviceable assets are available, and/or if estimated delivery date does not affect production critical path.

2 SECTION II - RECEIPT OF AIRCRAFT AT FACILITY:

2.1 Handling:

2.1.1 Aircraft shall be handled in accordance with instructions in MDS specific TOs 1C-130-2 job guides. Qualification of personnel handling and operating aircraft shall conform to AFI 11-218, AFI 11-205 and AFJI 10-22.

NOTE

When towing C-130J models IAW 1C-130J-2-09JG-10-1 (Equivalent Equipment to the part numbers listed is acceptable) Tow Bars PN 87197-1 or PN 55J22139-4 and Tow Vehicle MB-2 currently used at OC-ALC are equivalent equipment.

2.1.2 Upon receipt of aircraft at the maintenance facility, accomplish a receiving inspection to identify Foreign Object Damage (FOD) on all jet engines as follows: Visually inspect air inlet guide vanes and first stage compression rotor blades for damage. Results of this inspection shall be referred to the PAO for certification and disposition.

2.1.3 Perform a Post Flight Inspection IAW TOs 1C-130H-6WC-13 or 1C-130J-6WC- 10.

2.1.4 Handle and store fuel according to TOs 00-25-172, 42B-1-1, 42B1-1-1, and MIL- STD-1518. All drained fuel shall be credited to the procuring activity. (If aircraft forms are removed before defueling, assure that the fuel to be removed is recorded and usable fuel is placed in proper storage).

2.1.4.1 All fuel cells, tanks, and lines shall be drained and purged or made inert according to TO 1-1-3 and MDS specific TOs 1C-130-2 job guides.

2.1.5 Liquid and gaseous oxygen used for aviator's breathing purposes shall be handled in accordance with MIL-STD-1551.

2.1.6 Removal of fire extinguisher bottles is not required.

2.2 Inventory:

2.2.1 Inventory each aircraft jointly with the aircraft commander or his designated representative against property listed in aircraft property records AF Form 2692. Accomplish this inventory as soon as possible after receipt of the aircraft. Record and process inventory in accordance with AFI 21-103. The same AF Form 2692 equipment removed from an aircraft shall be reinstalled prior to departure.

NOTE

Annotate missing insulation in aircraft records. Maintenance facilities are not required to replace missing insulation.

2.2.2 Aircraft received from OCONUS bases and that are scheduled to return over water shall have survival equipment, life rafts, pyrotechnics pistols, and life vests inventoried.

2.3 Preservation. Preservation is accomplished only if required by technical orders listed below and only if directed by the PAO:

2.3.1 Accomplish engine preservation in accordance with MDS specific TOs 1C-130-2- 4 or 1C-130-23 or 1C-130-2-2 and 1C-130H-2-00GE-00-1 or 1C-130J-2-00GV-00-1 job guides.

2.3.2 Treat the aircraft as directed in TOs 1-1-17 and MDS specific TO 1C-130-17 when storage is anticipated. Drained fluids shall be disposed of or reused as follows:

2.3.2.1 Defuel, and make safe for maintenance IAW MDS specific TO 1C-130-2-12JG- 10-1 job guides and local instructions as required. Serviceable fuel shall be recorded on AFTO Form 781H and credited to the aircraft when re-servicing.

2.3.2.2 Drained hydraulic fluid shall be disposed of as condemned property and need not be accounted for.

2.3.2.3 Drained engine oil shall be disposed of as condemned property and need not be accounted for.

2.3.2.4 Fuel used for flushing the fuel system, detection of fuel leaks, or that may be contaminated from other sources shall be checked in accordance with TOs 42B-1-1 and 42B1-1- 1.

2.3.3 Accomplish required internal preservation and cap off open ports in accordance with TOs 44H3-1-3 and MDS specific TO 1C-130-17 when required. Internal preservation of tanks and systems is not required except when the aircraft is being prepared for extended storage IAW MDS specific TO 1C-130-17. Bladder cells shall be treated with a light coat of oil in accordance with TO 1-1-3.

3 SECTION III - WORK REQUIREMENTS

3.1 General Requirements:

3.1.1 Prepare aircraft for maintenance IAW MDS specific TOs 1C-130-2 job guides, 1C-130-3 and 1C-130-23.

3.1.2 Corrosion control procedures shall be used on installation of all components IAW applicable technical data to include, but not limited to, TOs 1-1-8 and MDS specific 1C-130-23.

3.1.3 Reserved:

3.2 Specific Requirements:

3.2.1 Aircraft Paint Requirements:

3.2.1.1 Determination of Finish Maintenance Requirements: The following criteria shall be used to determine the extent of exterior finish maintenance required on each aircraft. These requirements do not apply to control surfaces which are addressed in MDS specific TO 1C-130- 23.

3.2.1.1.1 The aircraft historical records shall be inspected to verify previously performed work. If the records show that the aircraft has one or more complete scuff sand and overcoats, the aircraft shall be completely depainted and repainted per the requirements of MDS specific

TO 1C-130-23.

3.2.1.1.2 Visually inspect the aircraft exterior. If multiple damaged areas exist, such as paint cracking in the wing milled panel and peeling in numerous locations, pay particular attention to the composite areas and contact AFLCMC/WLNEB C-130 Corrosion Manager for disposition. Typical peeling/blistering areas exist on the leading edges, engines, nose, and windshields. When contacting C-130 Corrosion Manager provide the following information:

1. Damage location by FS, WS, WL, and/or BL.

2. Estimated repair man-hours for each damaged area.

3. Provide photos of damage, if available.

If the estimated number of total man-hours to repair including reseal, scuffing, sectional stripping touch-up paint, and overcoating exceeds 75% the number of man-hours of a complete depaint/repaint, provide this information to C-130 Corrosion Manager to determine whether to depaint and repaint the entire aircraft.

3.2.1.2 Control surfaces (ailerons, elevators, and rudder) shall be removed IAW applicable technical data for complete depaint and repaint. Strip the exterior control surface coating (excluding coves), prepare the surface, and re-apply finish per depaint and repaint requirements in MDS specific TO 1C-130-23. Ensure all fabric or protective tape patches are inspected and replaced as required.

NOTE

Removal of Aft Nose Landing Gear Door is not required

3.2.1.3 Lightly sand flap wells and aileron, elevator, and rudder coves to remove loose, peeling, and deteriorated paint/primer. Inspect and replace worn/unserviceable fabric or protective tape patches as required. Do not abrade the underlying alclad surface. Coat as directed in AF drawings #9144700 (Equipment Excellence), #200917977 (EC-130J) or #201122423 (WC-130J and C-130J long and short) as applicable.

NOTE

When painting the exterior of the aircraft wing trailing edges, slight overspray from painting the exterior of the wing trailing edges is allowed and masking of the flap wells is not required.

3.2.1.4 Solvent wipe or PreKote (preferred), then apply MIL-PRF-23377 Type 1 Class C2 and MIL-PRF 85285 Type IV Class H polyurethane topcoat as authorized by the C-130 Corrosion Manager (color to match paint scheme) to all bare metal and scuff sanded areas, excluding unpainted areas as stated in applicable AF drawing.

NOTE

If titanium panels are painted upon aircraft incoming for mid-cycle paint, depaint panels using procedures and materials approved in TOs 1-1-8, MDS specific 1C-130-23, and applicable AF drawings.

3.2.1.5 Ensure life raft T-handle access panels, fabric or protective tape patches are inspected and replaced as required.

3.2.1.6 Antennas and radomes: Reference applicable paint drawing, for Legacy AF drawing #9144700, for EC-130J AF drawing #200917977 and for WC-130J & C-130J (long and short) AF drawing #201122423.

3.2.1.7 Complete Depaint/Repaint Requirements: The following requirements apply if complete depaint/repaint is necessary. These requirements also apply to sectionalized depaint/repaint.

NOTE

Areas on the lower surface of the wing with boron repairs shall not be depainted if boron patch has been previously installed. Often boron repairs are located under the aft nacelle/heat shields. C- 130Js have considerable amounts of fiberglass and composite components that cannot come in contact with chemical depaint, reference TO 1C-130J-23.

3.2.1.7.1 Masking: Proper masking shall be accomplished per TOs 1-1-8 and MDS specific 1C-130-23 prior to depaint operations.

3.2.1.7.2 Depainting: Completely depaint the exterior coating system using procedures and materials approved in TOs 1-1-8 and MDS specific 1C-130-23. Do not depaint flight control surface wells or coves, landing gear wells, or air deflector door wells. Do not apply depaint material to any composite surfaces; reference MDS specific TOs 1C-130-3 and 1C-130-23 for composite panel identification.

3.2.1.7.3 Following depaint operations a visual inspection shall be performed of all aircraft exterior seam and fillet sealant. All defective, loose or deteriorated sealant shall be removed and replaced using MIL-PRF-81733 Type II, Grade A or B or SAE AMS 3265 sealant per application instructions in TO 1-1-691. Application shall be with a sealant gun only.

3.2.1.7.4 Composite surfaces require mechanical removal of topcoat by 50/50 sanding in lieu of chemical depaint. For 50/50 sanding, sand surfaces until a mixture of 50% primer and 50% topcoat is visible (leaving a leopard skin appearance), reference TOs 1-1-8 and MDS specific 1C-130-23.

NOTE

Composite surfaces are easily damaged. Ensure a thorough inspection of all composite surfaces after sanding is completed in order to allow for repairs prior to continuing paint preparation operations.

3.2.1.7.5 Washing: The aircraft shall be washed per TO 1-1-691 and MDS specific TOs 1C-130-23 and 1C-130-23CL-1 after depaint operations are complete to remove all chemical depaint residue.

NOTE

Paint must be applied to the lower surface of the wing prior to installing aft nacelle and aft lower heat shields.

3.2.1.7.6 Environmental Conditions: All operations shall be accomplished indoors, in an environmentally controlled facility. Aircraft skin and ambient air temperature shall be 60°F - 90°F prior to and during surface pretreatment operations. Lower wing surfaces under pylons and aft engine nacelle may be prepared prior to input to environmentally controlled facility

3.2.1.7.7 Surface Pretreatment: Repair and sealing requirements shall be completed prior to input of aircraft for prepaint cleaning and surface pretreatment operations. Surface pretreatment (including washing and masking) shall be accomplished per TOs 1-1-691, 1-1-8, and MDS specific 1C-130-23.

3.2.1.7.7.1 Water break tests, as defined in TO 1-1-8 shall be performed immediately prior to initiating surface pretreatment operations. Any areas which fail the test shall be cleaned per TO 1-1-691 and retested. Water break not required for PreKote.

3.2.1.7.7.2 A record of the wash and water break test results shall be available to the government inspector upon request (if required).

3.2.1.7.8 Application of Materials: Prepare all bare aluminum exterior surfaces for paint application using procedures and materials (SAE AMS-1640 and MIL-DTL-5541/81706) approved in TOs 1-1-8, 1-1-691, and MDS specific 1C-130-23. PreKote is the preferred pretreatment process and is authorized for use in lieu of SAE AMS-1640 and MIL-DTL- 5541/81706.

3.2.1.7.9 Records: Preparation records shall include date and time that surface preparation operations are initiated and completed for each aircraft. These records shall be available to the government inspector upon request.

3.2.1.7.10 Finish System Application: All pretreatment surface preparations shall be completed prior to initiating finish system application. All aircraft painting operations shall be accomplished per TOs 1-1-8, AF drawing #9144700 (Equipment Excellence), #200917977 (EC- 130J) and #201122423 (WC-130J and C-130J long and short) as applicable.

3.2.1.7.11 All operations shall be accomplished indoors, in an environmentally controlled facility. Atmospheric conditions and aircraft skin temperatures shall meet TO 1-1-8 requirements. Painting operations shall not be initiated or shall be immediately suspended whenever the specified conditions cannot be met.

3.2.1.7.12 The temperature and humidity shall be recorded at the time paint operations are initiated. This record shall be made available to the government inspector upon request.

3.2.1.7.13 Application of Materials: Application of specialty coatings (PR-1432GV/PR- 1436G), primer, topcoat, fuselage walkway, and stabilizer walkway coatings shall be accomplished per procedures and materials approved in TOs 1-1-8, MDS specific 1C-130-23, and the applicable AF drawing.

3.2.1.7.14 The specialty coatings (PR-1432GV/PR-1436G) and primer shall be applied IAW TO 1-1-8 or manufacturer’s recommendations after completion of the surface pretreatment operations in paragraph 3.2.1.7.7. If more than 48 hours lapse, the surface pretreatment operations in paragraph 3.2.1.7.7 shall be repeated.

3.2.1.7.15 If the primer is not topcoated within time specified by manufacturer’s recommendations, reactivate the surface with a solvent wipe. If the primer is not topcoated within 24 hours, the surface shall be scuff sanded and solvent wiped.

3.2.1.7.16 For application of specialty coatings (PR-1432GV/PR-1436G), see applicable AF drawing for locations and required mil thicknesses. Then apply one coat MIL-PRF-23377, Type I, Class C2 epoxy primer, and two coats MIL-PRF-85285, Type IV Class H color as per the applicable drawing and MDS specific TO 1C-130-23. All coatings shall be applied as per chapters 4, 5, and 6 of TO 1-1-8.

NOTE

All aircraft shall be painted using MIL-PRF-85285, Type IV Class H polyurethane topcoat as authorized by C-130 Corrosion Manager.

3.2.1.7.17 Aircraft shall be painted per AF Drawings #9144700 (Equipment Excellence), #200917977 (EC-130J) and #201122423 (WC-130J and C-130J long and short) as applicable or by AFTO Form 103 requests as approved by the AFLCMC/WLNEB C-130 Corrosion Manager.

3.2.1.7.18 After the paint system has cured, cut through the paint which has bridged over the seams of all entry doors, escape hatches, life raft doors, inspection doors, cargo door and cargo ramp with a non-metallic tool prior to opening. Failure to accomplish this procedure will cause peeling of the paint system in these areas or prevent proper function.

3.2.1.7.19 Paint records shall include date and time that specialty coatings (PR-1432GV and PR-1436G), primer, and topcoat operations are initiated and completed for each aircraft.

Temperature and humidity conditions shall also be recorded at the time coating operations are initiated, every 2 hours thereafter, and at completion of coating application. These records shall be available to the government inspector upon request.

NOTE3M 8641 Protective Tape (Belly Tape) must be removed prior to painting and will not be painted over. If belly tape has not been removed, over and above resources will be used to remove belly tape after approved by PCO.

3.2.1.8 Scuff Sand and Overcoat Requirements: The following requirements apply if scuff sand and overcoat is necessary.

3.2.1.8.1 The aircraft shall be washed and masked per TO 1-1-691 and MDS specific TOs 1C-130-23 and 1C-130-23CL-1 prior to initiation of scuff sanding operations.

3.2.1.8.2 Areas of severely deteriorated or contaminated coating shall be thoroughly evaluated and considered for entire aircraft/selective depaint. Submit AFMC Form 202 as required.

NOTE

Areas on the lower surface of the wing with boron repairs shall not be depainted if boron patch has been previously installed. Often boron repairs are located under the aft nacelle/heat shields, see MDS specific TOs 1C-130-3 and 1C-130-23.

3.2.1.8.3 Inspect the area under the aft nacelles and engine heat shields. If the coating system on the skin area under the aft nacelles and engine heat shields is deteriorated; the area shall be completely depainted. If the primer is intact, scuff/sand and apply one coat of MIL- PRF-23377, Type I, Class C2, followed by MIL-PRF-85285, Type IV Class H polyurethane topcoat, FED STD 595 color #16473, gloss gray.

3.2.1.8.4 Scuff sand the entire exterior surface of the aircraft per the procedures in

TO 1-1-8.

3.2.1.8.5 Following scuff sanding operations, a visual inspection shall be performed of all aircraft exterior seam and fillet sealant. All defective, loose, or deteriorated sealant shall be removed.

3.2.1.8.6 Exclude the following areas from scuff sanding operations.

3.2.1.8.6.1 Bare metal areas previously stripped.

3.2.1.8.6.2 Fuselage and horizontal stabilizer walkways (where walkway coatings have been applied).

3.2.1.8.6.3 Wing walkways (if walkway coatings have been applied).

3.2.1.8.6.4 Scuff sanding on and around raised rivet heads shall be accomplished with abrasive mat, A-A-58054, Type I, Grade B (medium grade aluminum oxide).

3.2.1.8.7 Wash the aircraft per TO 1-1-691, and MDS specific TOs 1C-130-23 and 1C-130- 23CL-1 to remove all scuff sanding debris.

3.2.1.8.8 Walkway coatings areas shall be brush cleaned.

3.2.1.8.9 For C-130J aircraft only, if applicable, inspect non-slip coating on wing walkways after scuff sand and wash of aircraft. Brush clean and mist coat only.

NOTE

Omit walkway coating on all access panels and screw heads.

3.2.1.8.10 Repair or replace damaged sealant on all exterior seams with MIL-PRF-81733 Type II, Grade A or B or SAE AMS 3265 sealant per application instruction in TO 1-1-691.

Application shall be with a sealant gun only. Locations that shall be sealed include, but are not limited to the following.

3.2.1.8.10.1 Upper and lower wing panel seams (including leading and trailing edges).

3.2.1.8.10.2 Horizontal and vertical stabilizer (including leading edges).

3.2.1.8.10.3 Flap panel seams.

3.2.1.8.10.4 Antennas.

3.2.1.8.10.5 Anti-collision light.

3.2.1.8.10.6 External Doublers.

3.2.1.8.10.7 Fuselage panel seams.

3.2.1.8.11 Apply PreKote and primer coating per TO 1-1-8 and applicable AF drawing (Overspray of Existing Coating Systems).

3.2.1.8.12 Topcoat shall be applied per the requirements specified in paragraph 3.2.1.7.10.

3.2.1.8.13 After the paint system has cured, cut through the areas where the paint has bridged over seams as directed in paragraph 3.2.1.7.18, and ensure proper function.

3.2.1.8.14 The records and quality requirements specified in paragraphs 3.2.1.7.19 shall apply.

3.2.1.8.15 Access and inspection panels shall be sealed with SAE AMS 3284 or PR-1403G sealant per TOs 1-1-691 and MDS specific 1C-130-23.

3.2.1.9 Markings:

3.2.1.9.1 For C-130J (long and short) aircraft: All exterior marking shall be applied per TO 1-1-8, the applicable AF paint drawings #201122423, AF exterior marking drawing #201122424 (for WC-130J and C-130J long and short) and specific MAJCOM Instruction. For EC-130J aircraft, AF paint drawing #200917977 and AF exterior marking drawing #200917976 and specific MAJCOM Instruction.

3.2.1.9.2 RVSM markings shall be applied per AF drawing #201122423/#201122424 and AF drawing #200917977/#200917976. If RVSM markings conflict with other marking locations, minor adjustments of locations are authorized to de-conflict the markings, so long as the intent is maintained.

3.2.1.9.3 Ensure Paint Facility/Finish Identification Block is applied to aircraft IAW TO 1- 1-8. Paint block will contain depot activity or cage code of location performing the work, date of completion, MIL SPEC and Manufacturer’s Product Part Number for Pretreatment, Primer, and Topcoat.

3.2.1.9.4 Unit specific markings, tail flashes, insignia, nose art, crew names, and other markings not called out as listed in 3.2.1.9.1 and 3.2.1.9.2 above are considered over and above work by the paint facility and are not part of a standard paint package. These are typically applied upon return to unit, unless coordinated and approved in advance via AFTO Form 103.

3.2.2 Command Instructions: In addition to the requirements specified by this Document of Work Specifications, the following MAJCOM guidance applies.

3.2.2.1 ANG:

3.2.2.1.1 ANGI 21-105, Air and Space Equipment Structural Management, provides additional marking instructions.

3.2.2.2 AFRC:

3.2.2.2.1 AFI 20-114 AFRC SUP, Air and Space Equipment Structural Maintenance, provides additional marking instructions

3.2.2.2.2 WC-130J. The dewpoint hygrometer (FS 267, WL 200) shall be marked as follows: 4 inch diameter circle, l/2 inch wide. Stencil below circle "SENSOR PROBE DO NOT PAINT" IN 5/16 inch letters, color number 37038.

3.2.2.3 ACC:

3.2.2.3.1 CAFI 21-105 Fabrication Program provides additional marking instructions.

3.2.2.4 AMC:

3.2.2.4.1 MAFI 21-105 Fabrication Program provides additional marking instructions.

3.2.2.5 PACAF/USAFE:

3.2.2.5.1 See CAFI 21-105 or MAFI 21-105 for additional marking instructions.

3.2.2.6 AETC:

3.2.2.6.1 AETCI 21-106, Corrosion Control, provides additional marking instructions.

3.2.3 Quality Inspection and Acceptance Criteria: The completed finish system shall meet the following criteria. All paint system repairs due to quality deficiencies shall be IAW TO 1-1-8 and this document.

3.2.3.1 Perform an inspection on the completed coating system. The following criteria apply.

3.2.3.1.1 Paint system finish shall not exceed approximately 600 grit coarseness.

3.2.3.1.2 No wrinkling, crazing, blistering, fisheye, lifting or pitting as defined in TO 1-1-8 is allowed.

3.2.3.1.3 No more than 2 minor runs per 50 square feet is allowed (a minor run does not exceed 2 inches in length). All runs over 2 inches shall be repaired.

3.2.3.1.4 Paint system shall meet the gloss and wet tape adhesion test requirements in TO 1-1-8.

3.2.3.1.5 Total dry coating thickness for complete depaint and repaint aircraft shall be measured per TO 1-1-8. Thickness measurement locations are the same as identified in paragraph 10.1.

3.2.3.1.6 Thickness requirements are as follows excluding walkway areas (see drawings for specific locations of coating stack ups):

3.2.3.1.6.1 Areas with primer and topcoat only: 2.2 - 3.2 mils.

3.2.3.1.6.2 Areas with PR-1432GV, primer and topcoat: 5.2 - 8.2 mils

3.2.3.1.6.3 Areas with PR-1432GV, PR-1436-G, primer and topcoat: 8.2 - 13.2 mils.

3.2.3.1.7 Control surface wells and coves shall be inspected at a distance of 5 feet or greater unless a complete refurbishment of the area is specified elsewhere in the PDM/PMP work specification. A refurbishment is complete disassembly of the area for depaint and repaint of components.

3.2.3.2 Personnel performing operations per this document shall be familiar with all the referenced technical data and shall be trained in the use of the required equipment and materials.

3.2.3.3 Make an entry in the aircraft historical records (AFTO Form 95) giving the type of paint system applied. The entry shall state whether the aircraft received scuff sand and overcoat or complete depaint and repaint. Also include pretreatment used, the name of paint scheme applied and the reference used; the name, specification number, and manufacturer of the primer applied; the name, specification number and manufacturer of the topcoat(s) applied; and the date of application.

3.3 Accomplish aircraft Weight and Balance IAW TO 1-1B-50:

3.4 Aircraft close out.

3.4.1 Reinstall removed components IAW applicable technical data.

4 SECTION IV - FINAL PROCESSING OF AIRCRAFT

4.1 Finishing of Aircraft:

4.1.1 Interior and exterior of aircraft shall be thoroughly cleaned after work is completed with special attention to removal of metal filings, chips, loose hardware, tools, and debris and any other potential FOD, so that a clean and safe aircraft is presented at time of delivery.

4.1.1.1 For all systems disturbed during accomplishment of work visually inspect all flight control system cables, pulleys, push rods, and components for proper installation prior to closure of areas. After accomplishment of work but prior to flight, inspect all exposed flight control system cables, pulleys, push rods and components for security inside fuselage.

4.1.2 Ensure reinstallation of all door panels, fairings, fillets, parts, components, and assemblies removed during work required by this document that have not been installed by this document.

4.1.2.1 Except for access doors and plates, ensure all repairs and removed structural members of skin are installed/replaced/reinstalled with all fasteners and faying surfaces wet with MIL-PRF-81733 sealant. For wet installation of fasteners, the sealant may be applied either to the hole or to the fastener. When applying sealant to the hole, wet the entire surface.

4.1.3 Ensure that static and vent port covers and obstructions are removed and/or cleared prior to flight.

4.1.4 Remove shoring and de-jack aircraft in accordance with MDS specific TO 1C- 130-2 job guide.

4.2 Servicing:

4.2.1 Service all aircraft systems in accordance with MDS specific TO 1C-130-2 job guide.

4.2.2 Inspect engine fire extinguisher bottles for condition and proper installation, and re-arm in accordance with MDS specific TOs 1C-130-2 job guide and 13F6-2-23.

4.2.3 Reinstall aircraft storage battery/batteries in accordance with MDS specific TO 1C-130-2 job guides.

4.2.3.1 Reinstall -21/AF Form 2691 equipment received with the aircraft and conduct a joint inventory with the ferry crew.

4.2.4 Refuel aircraft IAW MDS specific TOs 1C-130-2-12JG-10-1 job guide.

4.3 Functional Ground Check:

4.3.1 All fuel system components, lines, hoses, and connections, shall be pressure checked and accessible areas checked for leakage IAW applicable TOs 1-1-3 and MDS specific 1C-130-2 job guide for all systems disturbed during accomplishment of this document and associated tabs.

4.4 Preflight:

4.4.1 Accomplish a preflight inspection in accordance with applicable MDS specific TO 1C-130-6WC-10 as required by TO 00-20-1.

4.5 Acceptance/Functional Check Flight:

4.5.1 Accomplish an Acceptance/Functional Check Flight only if directed to do so by the Section III of this document or if required IAW MDS specific TO 1C-130-6 Section II, Part C. Functional check flights performed after accomplishment of maintenance or modification shall be identified as Acceptance/Functional Check Flights. Requirements listed in MDS specific TO 1C-130-6 inspection manual and the MDS specific TO 1C-130-6CF Acceptance/Functional Check Flight Procedures Manual shall be accomplished by flight crew when Acceptance/Functional Check Flight is accomplished.