Appendix H - DIMPLE Ch 2 19 July 2010.pdf

NA P-3 DIMPLE

P-3 Depot Integrated Maintenance Plan for Logistics and Engineering 31 August 2009 Change 2, 19 July 2010

DEPOT INTEGRATED MAINTENANCE

PLAN FOR LOGISTICS AND ENGINEERING

NAVY MODEL

P-3C

AND DERIVATIVE SERIES AIRCRAFT

This document supersedes NAVAIR P-3 PDM dated 01 September 2002 .

DISTRIBUTION STATEMENT C. Distribution statement “C” will apply to this document and is authorized to U.S. Government agencies and their contractors to protect publications required for official use or for administrative or operational purposes, determined on 1 December 1991. Other requests for this document shall be referred to Department of the Navy, Program Executive Office, PMA-290, Bldg. 2185, Ste. W-30-3150 F3 , 22347 Cedar

Point Road, Code 3.1.2M, Patuxent River, Maryland, 20670-1161.

DESTRUCTION NOTICE. For unclassified, unlimited documents, destroy by any means that will prevent disclosure of contents or reconstruction of the document.

Published by direction of the Commander, Naval Air Systems Command i

Table of Contents 1-1 GENERAL REQUIREMENTS ........................................................................................................1-1

1-1.1 SCOPE..................................................................................................................................................... 1-1 1-1.2 INTRODUCTION....................................................................................................................................... 1-1 1-1.3 DEFINITIONS........................................................................................................................................... 1-1 1-1.4 DEFECT CLASSIFICATION ....................................................................................................................... 1-6 1-1.5 IMP INTERVAL ....................................................................................................................................... 1-7 1-1.6 MAINTENANCE REFERENCES.................................................................................................................. 1-7 1-1.7 ACRONYMS............................................................................................................................................. 1-8 1-1.8 PRODUCT ORIENTED SURVEYS............................................................................................................... 1-9 1-1.9 SPECIFIC EQUIPMENT ............................................................................................................................. 1-9 1-1.10 DIMPLE OPERATIONAL DOCUMENT APPROVAL ................................................................................... 1-9 1-1.11 INTERIOR AND EXTERIOR FINISHES ........................................................................................................ 1-9 1-1.12 DISTURBED SYSTEMS ........................................................................................................................... 1-10 1-1.13 AIRCRAFT FLIGHT SUMMARY REPORT (CDRL A00B)......................................................................... 1-10 1-1.14 COMPONENT PLATING FACILITIES........................................................................................................ 1-10 1-1.15 AIRCRAFT EXPLOSIVES......................................................................................................................... 1-10 1-1.16 ELECTROSTATIC DISCHARGE CONTROL PROGRAM .............................................................................. 1-10 1-1.17 AVIATION MISHAP REPORTING AND INVESTIGATION (CDRL A00F) ................................................... 1-10 1-1.18 OZONE DEPLETING SUBSTANCES (ODS) .............................................................................................. 1-11 1-1.19 AIRCRAFT ENGINE MANAGEMENT SYSTEM REPORT (CDRL A00E) ................................................... 1-11 1-1.20 AIRCRAFT INSPECTIONS (SPECIAL)....................................................................................................... 1-11

2-1 INCOMING REQUIREMENTS ......................................................................................................2-1 2-1.1 INCOMING POST FLIGHT BRIEFING ......................................................................................................... 2-1 2-1.2 AIRCRAFT LOGBOOKS AND RECORDS..................................................................................................... 2-1 2-1.3 AIRCRAFT EQUIPMENT INVENTORY........................................................................................................ 2-2 2-1.4 SURVIVAL AND LOOSE EQUIPMENT........................................................................................................ 2-2 2-1.5 HYDRAULIC SYSTEM CONTAMINATION.................................................................................................. 2-2 2-1.6 FUEL SYSTEM ......................................................................................................................................... 2-3 2-1.7 TURBO SHAFT ENGINES .......................................................................................................................... 2-3 2-1.8 TOWING, JACKING, LEVELING, HOISTING AND MOORING ...................................................................... 2-3 2-1.9 AIRCRAFT FUEL LEAK PROCESSING ....................................................................................................... 2-3 2-1.10 AIRCRAFT PRESERVATION...................................................................................................................... 2-4 2-1.11 MAKE AIRCRAFT HANGAR SAFE ............................................................................................................ 2-4 2-1.12 PROPELLERS ........................................................................................................................................... 2-5

2-1.13 APU COMPARTMENT BLANKETS (ZONE 7.1)………………………………………………………… .. 2-5

3-1 PAINT REMOVAL /SEALANT REMOVAL/CORROSION INSPECTION/CORROSION

INHIBITING APPLICATION/RESEAL/ PAINT .......................................................................................3-1

3-1.1 EXTERIOR AIRCRAFT PAINT REMOVAL .................................................................................................. 3-2 3-1.2 PAINT/SEALANT REMOVAL, EXTERIOR DETAIL ..................................................................................... 3-2 3-1.3 CLEAN AIRCRAFT ................................................................................................................................... 3-2 3-1.4 CHEMICAL CONVERSION COATING......................................................................................................... 3-2 3-1.5 EXTERIOR CORROSION INSPECTION........................................................................................................ 3-2 3-1.6 CHEMICAL CONVERSION COATING......................................................................................................... 3-3 3-1.7 EXTERIOR AIRCRAFT PRIMING ............................................................................................................... 3-3 3-1.8 EXTERIOR AIRCRAFT SEALING/PAINTING .............................................................................................. 3-3 3-1.9 INTERIOR AIRCRAFT REFINISHING.......................................................................................................... 3-4

4-1 ACCESS OPEN/ DISASSEMBLY/REASSEMBLY/CLOSE ............................................................4-1 ii

4-1.1 ENTRANCE LADDER................................................................................................................................ 4-1 4-1.2 ALL INTERIOR SEATS ( PMI II)............................................................................................................... 4-1 4-1.3 AFT PARACHUTE RACK (PMI II), BILLBOARD AIRCRAFT....................................................................... 4-1 4-1.4 ALR-66(V) CENTER RECEIVER AMPLIFIER (PMI II) ............................................................................. 4-1 4-1.5 VHF ANTENNA RADOME (P/N AS3153/ALQ-158(V)) (P-3C) .............................................................. 4-2 4-1.6 APN-227/APN-187 DOPPLER RADOME (P-3C) ..................................................................................... 4-2 4-1.7 ARS-3 ANTENNAS (IF INSTALLED)......................................................................................................... 4-2 4-1.8 ARA-25 COVER ..................................................................................................................................... 4-2 4-1.9 ARR-72 COVER...................................................................................................................................... 4-2 4-1.10 ARA-48 ANTENNA................................................................................................................................. 4-2 4-1.11 AFT RADOME ...................................................................................................................................... 4-2 4-1.12 UPPER CANOE LOWER CANOE AND "BIG LOOK" RADOMES (EP-3E)..................................... 4-2 4-1.13 AIP SPINNING DF RADOME.............................................................................................................. 4-2 4-1.14 ECCOSORB BLANKETS (AFT RADOMES) (IF INSTALLED)........................................................ 4-2 4-1.15 APU INSULATIONS BLANKETS....................................................................................................... 4-2 4-1.16 APU, APU EXHAUST DUCT AND APU DOOR ................................................................................ 4-2 4-1.17 URINAL AND TOILET BUCKET ....................................................................................................... 4-3 4-1.18 WING TIPS ........................................................................................................................................... 4-3 4-1.19 ELEVATORS........................................................................................................................................ 4-3 4-1.20 ELEVATORS, FRONT SPAR ACCESS PANELS................................................................................... 4-3 4-1.21 AILERONS (PMI II).............................................................................................................................. 4-3 4-1.22 AILERON FRONT SPAR ACCESS PANELS (PMI I) ............................................................................ 4-3 4-1.23 RUDDER (PMI II)................................................................................................................................. 4-3 4-1.24 RUDDER SPAR ACCESS PANELS (PMI II) ......................................................................................... 4-3 4-1.25 RUDDER BOOST PACKAGE ................................................................................................................ 4-3 4-1.26 AIRCRAFT BATTERY ........................................................................................................................ 4-3 4-1.27 LTN 72 BATTERY................................................................................................................................ 4-3 4-1.28 VERTICAL STABILIZER CAP (PMI II).............................................................................................. 4-3 4-1.29 EMPENNAGE ACCESS PANELS ....................................................................................................... 4-4 4-1.30 #1 & #4 FIRESHIELD PANELS (PMI II) ............................................................................................. 4-4 4-1.32 ENGINE #2 & #3 HIGH RATE DISCHARGE (HRD) ACCESS PANELS AND UPPER AND LOWER

FIRE SHEILDS ..................................................................................................................................... 4-4 4-1.33 WING ACCESS PANELS..................................................................................................................... 4-4 4-1.34 WING ACCESS PANELS (PMI II) ............................................................................................................. 4-4 4-1.35 WING AIR CONTROL PANEL INSPECTION PLATES...................................................................... 4-4 4-1.36 WING CENTER SECTION ACCESS PANEL....................................................................................... 4-4 4-1.37 WING CENTER SECTION GROUND PLANE ASSEMBLY .................................................................... 4-4 4-1.38 WING CENTER RISER (PMI II) .............................................................................................................. 4-4 4-1.39 FUSELAGE PANELS ........................................................................................................................... 4-4 4-1.40 FUSELAGE PANELS (PMI I)..................................................................................................................... 4-5 4-1.41 FUSELAGE PANELS (PMI II) ................................................................................................................... 4-5 4-1.42 BOMB BAY INTERNAL STRESS PANELS (PMI I) .......................................................................... 4-5 4-1.43 FLIGHT STATINO UPPER AND LOWER ACCESS PANELS (PMI II) ............................................ 4-5 4-1.44 FLIGHT STATION ACCESS PANELS (PMI II) ....................................................................................... 4-5 4-1.45 EMPENNAGE FILLET PANELS......................................................................................................... 4-5 4-1.46 EXTENDIBLE RADOME AFT FAIRING (EP-3E) ............................................................................. 4-5 4-1.47 NACELLE TO WING FILLET PANELS.............................................................................................. 4-5 4-1.48 ENGINE #1 AND #4 TAILPIPES (PMI II) ........................................................................................... 4-5 4-1.49 ENGINE #2 AND #3 TAILPIPES............................................................................................................ 4-5 4-1.50 ENGINE #1 AND #4 EXHAUST STRAIGHTNET (PMI II)................................................................... 4-5 4-1.51 ENGINE #2 AND #3 EXHAUST STRAIGHTENER ........................................................................................ 4-6 4-1.52 ENGINE #1 AND #4 TAILPIPE SHROUDS (PMI II) .............................................................................. 4-6 4-1.55 ENGINE #2 AND #3 TAILPIPE SHROUDS .................................................................................................. 4-6 4-1.56 FUSELAGE TO WING AND CENTER SECTION FILLET PANELS ................................................ 4-6 4-1.57 NOSE RADOME (PMI II)..................................................................................................................... 4-6 4-1.58 AIRCRAFT FLOOR PANELS.............................................................................................................. 4-7 iii

4-1.59 AIRCRAFT FLOOR PANELS ...................................................................................................................... 4-7

5-1 AIRCRAFT INSPECTION REQUIREMENTS ...............................................................................5-1 5-1.1 AIRCRAFT INSPECTION PROCEDURES/REQUIREMENTS ........................................................................... 5-1 5-1.2 NACELLES 1, 2, 3, AND 4 EXTERNAL (ZONES 1.3, 2.3, 3.3, AND 4.3)....................................................... 5-2 5-1.3 NACELLE 1 AND 4 INTERNAL (PMI II) (ZONES 1.4 AND 4.4).................................................................. 5-2 5-1.4 NACELLES 2 AND 3 INTERNAL (ZONES 2.4 AND 3.4) .............................................................................. 5-3 5-1.5 NOSE RADOME EXTERNAL (ZONE 5.1) .................................................................................................. 5-3 5-1.6 NOSE LANDING GEAR WHEEL WELL AND DOORS INTERNAL (ZONE 6.2).............................................. 5-3 5-1.7 APU/AIR-CONDITIONING SERVICE BAY INTERNAL (ZONE 7.1)............................................................. 5-3 5-1.8 BOMB BAY AND DOORS INTERNAL (PMI I) (ZONE 8.1) ........................................................................ 5-4 5-1.9 FUEL COMPARTMENT INTERNAL (ZONE 8.2) ......................................................................................... 5-4 5-1.10 EXTENDIBLE RADOME, AFT FAIRING (EP-3E) (ZONES 8.3 AND 8.4) ..................................................... 5-4 5-1.11 WATER ALCOHOL / SERVICE BAY (PMI I) (ZONE 9.1)........................................................................... 5-4 5-1.12 LEFT WING INTERNAL (ZONE 11.1)........................................................................................................ 5-5 5-1.13 RIGHT WING INTERNAL (ZONE 14.1)...................................................................................................... 5-5 5-1.14 LEFT WING EXTERNAL (ZONE 11.2)....................................................................................................... 5-6 5-1.16 LEFT WING LEADING EDGE INTERNAL (ZONE 11.5).............................................................................. 5-7 5-1.17 RIGHT WING LEADING EDGE INTERNAL (ZONE 14.5)............................................................................ 5-7 5-1.18 LEFT WING TIP INTERNAL (PMI II) (ZONE 11.6) ................................................................................... 5-7 5-1.19 RIGHT WING TIP INTERNAL (PMI II) (ZONE 14.6)................................................................................. 5-7 5-1.20 LEFT WING TRAILING EDGE INTERNAL (ZONE 11.7) ............................................................................. 5-7 5-1.21 RIGHT WING TRAILING EDGE INTERNAL (ZONE 14.7)........................................................................... 5-8 5-1.22 AFT FUSELAGE INTERNAL , INCLUDING BILLBOARD AIRCRAFT (ZONE 15.2) (PMI II) .......................... 5-8 5-1.23 LEFT HORIZONTAL STABILIZER INTERNAL (ZONE 15.3)......................................................................... 5-9 5-1.24 RIGHT HORIZONTAL STABILIZER INTERNAL (ZONE 15.6)...................................................................... 5-9 5-1.25 LEFT HORIZONTAL STABILIZER TRAILING EDGE (PMI I) (ZONE 15.5) .................................................. 5-9 5-1.26 RIGHT HORIZONTAL STABILIZER TRAILING EDGE (PMI I) (ZONE 15.8) ................................................ 5-9 5-1.27 VERTICAL STABILIZER INTERNAL (PMI II) (ZONE 15.9)........................................................................ 5-9 5-1.28 VERTICAL STABILIZER AND TRAILING EDGE (PMI II), BILLBOARD AIRCRAFT (ZONE 15.10) ............. 5-10 5-1.29 VERTICAL STABILIZER INTERNAL AND ANTENNA STRUCTURE, BILLBOARD AIRCRAFT (ZONE 15.9)... 5-10 5-1.30 WING CENTER SECTION EXTERNAL (PMI II) (ZONE 16.1) ................................................................... 5-10 5-1.31 WING CENTER SECTION INTERNAL (PMI II) (ZONE 16.2).................................................................... 5-10 5-1.32 WING FAIRING LEFT INTERNAL (ZONE 16.3) ....................................................................................... 5-11 5-1.33 WING FAIRING RIGHT INTERNAL (ZONE 16.4)..................................................................................... 5-11 5-1.34 FLIGHT STATION FUSELAGE INTERNAL (PMI II) (ZONE 17.2) ............................................................. 5-11 5-1.35 FLIGHT STATION FUSELAGE UNDER FLOOR INTERNAL (PMI II,) (ZONE 17.3)..................................... 5-11 5-1.36 RADIO/TAC/NAV/COM/OBS FUSELAGE INTERNAL (PMI II) (ZONE 18.2) ............................................ 5-11 5-1.37 TACTICAL/SENSOR STATION INTERNAL (PMI II) (ZONE 19.2)............................................................. 5-12 5-1.38 ORDNANCE STATION FUSELAGE INTERNAL (PMI I) (ZONE 20.2) ........................................................ 5-12 5-1.39 UPPER RADOME CANOE (EP-3E) (ZONE 20.4)..................................................................................... 5-12 5-1.40 LOWER RADOME CANOE (EP-3E) (ZONE 20.5) ................................................................................... 5-12 5-1.41 “BIG LOOK” RADOME AND ANTENNA (EP-3E) (ZONE 8.3) ................................................................. 5-12 5-1.42 REST AREA INTERNAL (PMI I) (ZONE 21.2) ........................................................................................ 5-13 5-1.43 DORSAL FIN INTERNAL (PMI II) (ZONE 21.3)...................................................................................... 5-13 5-1.44 UNDER FLOOR AREA INTERNAL (PMI II) (ZONE 22.1) ........................................................................ 5-13 5-1.45 REST AREA INTERNAL, BILLBOARD AIRCRAFT (ZONE 21.2) ................................................................ 5-14

6-1 STRUCTURAL INSPECTION REQUIREMENTS .........................................................................6-1 6-1.1 LEFT HORIZONTAL STABILIZER, UPPER SURFACE PLANKS - SSI-E2 (ZONE 15.4) ................................. 6-1 6-1.2 RIGHT HORIZONTAL STABILIZER UPPER SURFACE PLANKS - SSI-E5 (ZONE 15.7) ................................ 6-1 6-1.3 LEFT HORIZONTAL STABILIZER LOWER SURFACE PLANKS - SSI-E3 (ZONE 15.4)................................. 6-1 6-1.4 RIGHT HORIZONTAL STABILIZER LOWER SURFACE PLANKS - SSI-E6 (ZONE 15.7)............................... 6-1 6-1.5 WING PLANK JOINTS - SSI-F26 (PMI II ) (ZONE 16.3) .......................................................................... 6-2 6-1.6 WING PLANK JOINTS - SSI-F27 (PMI II) (ZONE 16.4) ........................................................................... 6-2 iv

6-1.7 FORWARD MAIN RING FITTING (901721-101)– SSI-F31 (ZONE 16.3) ................................................... 6-2 6-1.8 FORWARD MAIN RING FITTING (901721-102)– SSI-F32 (ZONE 16.4) ................................................... 6-2 6-1.9 CENTER SECTION WING PLANKS - SSI-F25 (PMI II) (ZONE 16.1)......................................................... 6-3 6-1.10 AFT SPAR CAP - SSI-W9 (ZONE 11.7) ................................................................................................... 6-3 6-1.11 AFT SPAR CAP - SSI-W47 (ZONE 14.7) ................................................................................................. 6-3 6-1.12 MAIN LANDING GEAR (MLG) DRAG STRUT FITTINGS - SSI-W21 (PMI I) (ZONE 2.4).......................... 6-4 6-1.13 MAIN LANDING GEAR (MLG) DRAG STRUT FITTINGS - SSI-W59 (PMI I) (ZONE 3.4).......................... 6-4 6-1.14 LEFT MAIN LANDING GEAR RIBS - SSI-W18 (PMI II) (ZONE 11.1) ...................................................... 6-4 6-1.15 LEFT MAIN LANDING GEAR RIB - SSI-W81 (ZONE 11.1) ....................................................................... 6-4 6-1.16 RIGHT MAIN LANDING GEAR RIBS - SSI-W56 (PMI II) (ZONE 14.1) .................................................... 6-4 6-1.17 RIGHT MAIN LANDING GEAR RIB - SSI-W80 (ZONE 14.1)..................................................................... 6-5 6-1.18 WING PLANKS - SSI-W26 (PMI II) (ZONE 11.2).................................................................................... 6-5 6-1.19 WING PLANKS - SSI-W64 (PMI II) (ZONE 14.2).................................................................................... 6-5 6-1.20 WING SPANWISE SPLICES AND RUNOUTS - SSI-W28 (PMI II) (ZONE 11.2)........................................... 6-5 6-1.21 WING SPANWISE SPLICES AND RUNOUTS - SSI-W66 (PMI II) (ZONE 14.2)........................................... 6-6 6-1.22 WING ACCESS PANELS - SSI-W29 (PMI II) (ZONE 11.2)....................................................................... 6-6 6-1.23 WING ACCESS PANELS - SSI-W67 (PMI II) (ZONE 14.2)...................................................................... 6-6 6-1.24 WING PLANKS - SSI-W30 (PMI II) (ZONE 11.2).................................................................................... 6-7 6-1.25 WING PLANKS - SSI-W68 (PMI II) (ZONE 14.2).................................................................................... 6-7 6-1.26 WING ACCESS PANELS - SSI-W33 (PMI II) (ZONE 11.2)....................................................................... 6-7 6-1.27 WING ACCESS PANELS - SSI-W71 (PMI II) (ZONE 14.2)....................................................................... 6-7 6-1.28 WING CENTER SECTION UPPER SURFACE WING PLANKS - SSI-F39 (PMI II) (ZONE 16.1).................... 6-8 6-1.29 WING PLANK DOME NUTS - SSI-F48 (ZONE 16.3) (AFC-626 NOT INCORPORATED)............................. 6-8 6-1.30 WING PLANK DOME NUTS - SSI-F49 (ZONE 16.4) (AFC-626 NOT INCORPORATED)............................. 6-8 6-1.31 OUTER WING FRONT BEAM UPPER INSIDE CORNER FITTING (939191-101/-103) – SSI-W72 (ZONE 11.1) 6- 6-1.32 OUTER WING FRONT BEAM UPPER INSIDE CORNER FITTING (939191-102/104) - SSI - W73 (ZONE 14.1) .. 6-8 6-1.33 OUTER WING FRONT BEAM LOWER INSIDE CORNER FITTING (939192-101/-103) – SSI-W74 (ZONE 11.1) 6- 6-1.34 OUTER WING FRONT BEAM LOWER INSIDE CORNER FITTING (939192-102/-104) – SSI-W75 (ZONE 14.1) 6- 6-1.35 OUTER WING FRONT BEAM LOWER OUTSIDE CORNER FITTING (939193-101/-103) – SSI-W76 (ZONE 11.2) 6-9 6-1.36 OUTER WING FRONT BEAM LOWER OUTSIDE CORNER FITTING (939193-102/-104) – SSI-W77 (ZONE 14.2) 6-9 6-1.37 OUTER WING REAR BEAM UPPER CORNER FITTING (939194-101/-103) – SSI-W78 (ZONE 11.1) ............ 6-9 6-1.38 OUTER WING REAR BEAM UPPER CORNER FITTING (939194-102/-104) – SSI-W79 (ZONE 14.1) ............ 6-9 6-1.39 CENTER WING FRONT BEAM LOWER INSIDE CORNER FITTING (939195-101/-107) – SSI-W88 (ZONE 16.2) 6-9 6-1.40 CENTER WING FRONT BEAM LOWER INSIDE CORNER FITTING (939195-102/-108) – SSI-W89 (ZONE 16.2) 6-9 6-1.41 OUTER WING FRONT BEAM UPPER OUTSIDE CORNER FITTING (939196-101/-103) – SSI-W82 (ZONE 11.2) 6-9 6-1.42 OUTER WING FRONT BEAM UPPER OUTSIDE CORNER FITTING (939196-102/-104) – SSI-W83 (ZONE 14.2) 6-9 6-1.43 CENTER WING REAR BEAM LOWER INSIDE CORNER FITTING (939197-101/-103) – SSI-W84 (ZONE 16.2) 6- 6-1.44 CENTER WING REAR BEAM LOWER INSIDE CORNER FITTING (939197-102/-104) – SSI-W85 (ZONE 16.2) 6- 6-1.45 OUTER WING REAR BEAM LOWER CORNER FITTING (939198-101/-103) – SSI-W86 (ZONE 11.1) ......... 6-10 6-1.46 OUTER WING REAR BEAM LOWER CORNER FITTING (939198-102/-104) – SSI-W87 (ZONE 14.1) ......... 6-10 6-1.47 AFT MAIN RING FITTING (901722-101)– SSI-F35 (ZONE 16.3) ........................................................... 6-10 6-1.48 AFT MAIN RING FITTING (901722-102)– SSI-F36 (ZONE 16.3) ........................................................... 6-10 6-1.49 HORIZONTAL STABILIZER FORWARD UPPER SPAR CAP (P/N 901183-101) – SSI-S22 (ZONE 15.2) ..... 6-10 6-1.50 HORIZONTAL STABILIZER UPPER STRINGER AND DEEP FRAME WEB (P/N 902731-101 AND P/N 905072-

3) – SSI-S23 (ZONE 15.2)..................................................................................................................................... 6-11 v

6-1.51 HORIZONTAL STABILIZER UPPER STRINGER AND DEEP FRAME WEB (P/N 902732-101 AND P/N 904471-

1) SSI-S24 (ZONE 15.2)....................................................................................................................................... 6-11 6-1.52 MLG DRAG STRUT FITTING AND ATTACHMENTS, LEFT WING (P/N 901075 AND 901084) – W-90 (ZONE 2.4) 6-11

6-1.53 MLG DRAG STRUT FITTING AND ATTACHMENTS, RIGHT WING (P/N 901075 AND 901084) –

W-91 (ZONE 3.4) 6-12

7-1 FATIGUE INSPECTIONS REQUIREMENTS…………………………………………………………7-1

7-2 NDI TECHNIQUES …………………………………………………………………….…………..7-5

7-2.1 BOLT HOLE EDDY CURRENT ..………………………………………………………….……..........7-5

7-2.2 EDDY CURRENT SURFACE SCAN .………………………………………………………….…………...7-6

7-2.3 ULTRASONIC THICKNESS MEASUREMENT INSPECTION ..…………………………….…………...7-7

7-2.4 SHEAR WAVE ULTRASONIC INSPECTION …………………...………………………………….……...7-8

7-3.1 PANEL #3 LWS 202/RWS179 AT ELECTRICAL FITTING ...……………………………………….7-10

7-3.2 OUTER WING LOWER PANELS 1-3 AT INBD NACELLE LOWER FILLET FAIRING DOME NUT HOLES ..….7-11

7-3.3 OUTER WING LOWER SURFACE PLANKS AT MAIN LANDING GEAR TRUSS ……………………...7-13

7-3.4 OUTER WING LOWER PANELS #1-3 AT MLG DRAG BRACE FITTING...……..…………………………7-17

7-3.5 FORWARD SPAR WEB, W.S. 149-237 …………………………………………………………………...7-19

7-3.6 OUTER WING LOWER PANEL #1 AT 801987-1/2 FITTING …...…………... …………………………...7-22

7-3.7 OUTER WING LOWER PANEL #1, W.S. 149-237 ………….. ……………………………………..…....7-24

7-3.8 FORWARD SPAR WEB, B.L. 65- W.S 148, W.S. 238 - W.S. 414 ……………………………………...7-26

7-3.9 OUTER WING LOWER PANEL #1, W. S. 238 - W.S. 414 ..……………………………………..... 7-30

7-3.10 LOWER WING PANELS #1 - 6 AT INBD NACELLE LOWER SKATE ANGLES .……………………..7-33 7-3.11 OUTER WING LOWER PANELS 1 &4 AT LOWER INBOARD NACELLE ATTACHMENT INSPECTION……...7-35 7-3.12 HORIZONTAL STABILIZER F.S. 1221 AFT UPPER SPAR CAP RADIUS .…. …………………………...7-38 7-3.13 OUTER WING, LOWER PANEL 5,6,7,8 &9 AT PANEL RUNOUT SPLICE .……………………….……... 7-41

7-3.14 B.L. 49 AND BL 56 CENTER WING WEEP HOLES ……………………………………………………..7-42

7-3.15 OUTER WING W.S 170 & W.S. 214 WEEP HOLES …………………...……………………….……...7-44

7-3.16 CENTER WING FORWARD LOWER SPAR CAP, WEB AND PANEL B.L. 32-65 …………………………..7-45 7-3.17 OUTER WING, LOWER PANEL #7, RISER #3, AT MLG ACTUATING FITTING ………………………...…7-48 7-3.18 OUTER WING LOWER PANEL 1-3 AT OB LOWER NACELLE FILLET FAIRING DOME NUT HOLES …...7-50

7-3.19 LOWER WING PANELS AT OTBD NACELLE LOWER ATTACH ANGLES ………………………………...7-52

7-3.20 OUTER WING, LOWER PANEL #6 AT INBOARD NACELLE CLOSEOUT ANGLE ...………….………...7-54

7-3.21 OUTER WING, AFT SPAR WEB, WS 155-275 ...……..……………………………………….....7-55

7-3.22 OUTER WING LOWER PANELS #5 & 6 AT W.S. 275 TEE CLIP ATTACHMENT ……………….……..7-58

7-3.23 OUTER WING, AFT SPAR CAP, WS 167-209 …………………………………………………………..7-58

7-3.24 OUTER WING, LOWER PANELS #6 & #7 AT MLG ACTUATING FITTING .……………………..7-60

7-3.25 B.L. 0 LOWER SURFACE ACCESS PANEL CUTOUT ……………………………………………………..7-61

7-3.26 NLG RETRACT ACTUATOR SUPPORT LUG .……………………………………………...…...7-63

7-3.27 OUTER WING UPPER PANELS 1-3 AT NACELLE 1 &4 ATTACH ANGLES ...………………..…………...7-64 7-3.28 OUTER WING UPPER PANELS #1-8 AT MLG TRUSS RIB ..………………………………………….......7-65 7-3.29 OUTER WING UPPER PANELS #3-5 AT CUTOUTS, WS 209-237 ………………………………… ….....7-67 7-3.30 OUTER WING UPPER PANEL #1 AT SPAR CAP ATTACHMENT W.S. 155-275..………………………….7-68 7-3.31 OUTER WING UPPER PANELS #1-3 AT NACELLES 2&3 FILLET FAIRING DOME NUTS .……………7-70 7-3.32 OUTER WING UPPER PANELS #1-2 AT NACELLES 1 &4 FILLET FAIRING DOME NUTS ..………...…7-71 7-3.33 OUTER WING UPPER PANELS 1-3 AT NACELLE 2 & 3 ATTACH ANGLES .……………………..7-73

7-3.34 EMPENNAGE HS AND VS DRAG ANGLES ..………………………………………………………...…7-74

7-3.35 UNDER FLOOR BEAMS, B.L. 40, FS 252-283 .………………………………………………….7-75

7-3.36 UNDER FLOOR BEAMS, TANK 5A, FS 496-534 …………………………………………………...7-76

7-4 FATIGUE INSPECTION HOLE NUMBERING DIAGRAM S ...……………………………………….7-78

7-4.1 PANEL #3 LWS 202/RWS 179 AT ELECTRICAL FITTING ..………………………………………..7-79

7-4.2 OUTER WING LOWER PANELS 1-3 INBD NACELLE LOWER FILLET FAIRING DOME NUT HOLES …...7-79

7-4.3 OUTER WING LOWER SURFACE PANELS AT MAIN LANDING GEAR TRUSS ...……………………7-80

7-4.4 OUTER WING LOWER PANELS #1 -3 AT MLG DRAG BRACE FITTING ..……………………………...7-81

7-4.5 FORWARD SPAR WEB, W.S. 149-237 ……………………………………………………………7-82

vi

7-4.6 OUTER WING LOWER PANEL #1 AT 801987-1/2 ..…………………………………………………7-86

7-4.7 OUTER WING LOWER PLANK #1, B.L. 65-414 ..…………………………………………………7-86

7-4.8 LOWER WING PANELS #1 - 6 AT INBD NACELLES LOWER SKATE ANGLES ...………………………….7-90 7-4.9 OUTER WING LOWER PANELS 1 & 4 AT LOWER INBOARD NACELLE ATTACHMENT INSPECTION .….7-91

7-4.10 B.L. 49 AND B.L. 56 CENTER WING WEEP HOLES .………………………………………………….7-92

7-4.11 CENTER WING FORWARD LOWER SPAR CAP, WEB, AND PANEL, BL 32-65 .……………………..7-93 7-4.12 CENTER WING FORWARD LOWER SPAR CAP, WEB AND PANEL B.L. 32-65 ………………….…..7-94 7-4.13 OUTER WING LOWER PANEL #7, RISER #3 AT MLG ACTUATOR FITTING .……………………..7-95 7-4.14 OUTER WING LOWER PANELS 1-3 AT OB NACELLE LOWER FILLET FAIRING DOME NUT HOLES ......7-96

7-4.15 OUTER WING, AFT LOWER SPAR WEB, WS 155-275 ...…………………………………..…...7-97

7-4.16 OUTER WING, AFT SPAR CAP, WS 167-209 …………………………………………………7-101

7-4.17 LOWER WING PANELS AT OUTBOARD NACELLE LOWER ATTACH ANGLES …………………….7-102

7-4.18 OUTER WING, LOWER PANELS #6 & #7 AT MLG ACTUATING CYLINDER …………………….7-103

7-4.19 OUTER WING LOWER PANELS #5 &6 AT WS 275 TEE CLIP ATTACHMENT ...…………………..7-104 7-4.20 OUTER WING LOWER PANEL #6 AT INBOARD NACELLE CLOSEOUT ANGLE .……………………7-105

7-4.21 OUTER WING LOWER PANELS 5,6,7,8 & 9 AT PANEL RUNOUT SPLICE .……………………7-106

7-4.22 OUTER WING W.S. 170 WEEP HOLES .………………...………………………………………...7-108

7-4.23 OUTER WING W.S. 214 WEEP HOLES .………………...………………………………………...7-109

7-4.24 B.L. 0 LOWER SURFACE ACCESS PANEL ...…………………………………………………………7-110

7-4.25 UPPER PANEL #1 AT CAP ATTACHMENT, WS 155-275 .……………………………………….7-110

7-4.26 UPPER PANELS #1-3 AT INBOARD NACELLE FILLET FAIRING DOME NUTS ...…………………..7-111 7-4.27 UPPER PANELS #1-3 AT INBOARD NACELLE SKATE ANGLE ATTACHMENT ...…………………..7-112 7-4.28 UPPER PANELS #1-2 AT OUTBOARD NACELLE FILLET FAIRING DOME NUTS ..................………...7-113 7-4.29 UPPER PANELS #1-2 AT OUTBOARD NACELLE SKATE ANGLE ATTACHMENT ...…………………..7-114

7-4.30 UPPER PANELS # 1-8 AT MLG TRUSS RIB ATTACHMENT ………………………………………..7-115

7-4.31 OUTER WING UPPER PANELS 3-5 AT CUTOUTS, WS 209-237 ..……………………………..7-116

8-1 SYSTEM AND COMPONENT INSPECTION REQUIREMENTS ..................................................8-1 8-1.1 AILERON CONTROL DIFFERENTIAL BELLCRANK ASSEMBLY TORQUE TUBE (PMI I)............................. 8-1 8-1.2 AILERON ASSEMBLY (PMI I).................................................................................................................. 8-1 8-1.3 ELEVATOR ASSEMBLY............................................................................................................................ 8-1 8-1.4 ELEVATOR TORQUE TUBE AND BEARINGS ............................................................................................. 8-1 8-1.5 RUDDER BELLCRANK/TORQUE TUBE (PMI II) ....................................................................................... 8-1 8-1.6 RUDDER ASSEMBLY (PMI II) ................................................................................................................ 8-2 8-1.7 FUEL TANK 1, 2, 3, 4 SURGE BOX AND BOOST FUEL PUMP SYSTEM (PMI II)......................................... 8-2 8-1.8 ELEVATOR DOWN SPRING CARTRIDGE (PMI I) ......................................................................................... 8-3 8-1.9 FORCE LINK TAB MECHANICAL SPRING CARTRIDGE (PMI I).................................................................... 8-3 8-1.10 FORCE LINK TAB MECHANICAL ROLL OFF CARTRIDGE (PMI I) ............................................................. 8-3 8-1.11 CABIN HEAT EXCHANGERS (ZONE 17.1) .................................................................................................. 8-3

9-1 DIMPLE REPORTS ........................................................................................................................9-1 9-1.1 DIMPLE REPORTS (CDRL A001 – A006)............................................................................................. 9-1 9-1.2 NBNC REPORT (CDRL A001) ............................................................................................................... 9-1 9-1.3 STRUCTURAL SAMPLING REPORT (CDRL A002) ................................................................................... 9-1 9-1.4 QUALITY DEFICIENCY REPORTS (QDR)(CDRL A003) .......................................................................... 9-1 9-1.5 STRUCTURAL ALTERATION REPORT (CDRL A004) ............................................................................... 9-1 9-1.6 MAINTENANCE HISTORY SUMMARY AND CORROSION INSPECTION (MHS&CI) REPORT (CDRL A005) 9-2 9-1.7 FATIGUE INSPECTION FINDINGS REPORT (CDRL A006) ........................................................................ 9-5

10-1 FINAL PROCESSING ...............................................................................................................10-1 10-1.1 DEPRESERVATION ................................................................................................................................ 10-1 10-1.2 DISTURBED SYSTEMS ........................................................................................................................... 10-1 10-1.3 AIRCRAFT SPECIAL INSPECTIONS ......................................................................................................... 10-1 vii

10-1.4 TURBOSHAFT ENGINES ......................................................................................................................... 10-1 10-1.5 FUEL LEAK CHECK............................................................................................................................... 10-1 10-1.6 WEIGHT AND BALANCE........................................................................................................................ 10-2 10-1.7 LOGS AND RECORDS............................................................................................................................. 10-2 10-1.8 HYDRAULIC SYSTEM CONTAMINATION................................................................................................ 10-3 10-1.9 MAKE AIRCRAFT READY FOR FLIGHT .................................................................................................. 10-3 10-1.10 FUNCTIONAL/ACCEPTANCE FLIGHTS................................................................................................ 10-3

11-1 MAINTENANCE REFERENCES ..............................................................................................11-1 11-1.1 MAINTENANCE REFERENCES................................................................................................................ 11-1

12-1 GOVERNMENT FURNISHED PROPERTY .............................................................................12-1

13-1 STRUCTURALLY SIGNIFICANT ITEMS (SSI) CARDS .........................................................13-1

15-1 OVER AND ABOVE REQUIREMENTS ...................................................................................15-1 15-1.1 GENERAL REQUIREMENTS.................................................................................................................... 15-1 15-1.2 UNSCHEDULED ACCESSORY AND COMPONENT REPAIR........................................................................ 15-1 15-1.3 CONCURRENT REPAIR OF REPAIRABLE COMPONENTS.......................................................................... 15-1 15-1.4 STANDARD REPAIRS ............................................................................................................................. 15-1 15-1.5 NON-STANDARD REPAIRS .................................................................................................................... 15-1 15-1.6 PREVIOUS REPAIRS INCORPORATED IN FATIGUE CRITICAL AREAS ...................................................... 15-1 15-1.7 WELDING.............................................................................................................................................. 15-2 15-1.8 EXTERIOR AIRCRAFT PAINT REMOVAL ................................................................................................ 15-3 15-1.9 FILLER TYPE REPAIRS .......................................................................................................................... 15-3

16-1 SERVICEABILITY REQUIREMENTS .....................................................................................16-1 16-1.1 ACCEPTABLE CONDITIONS.................................................................................................................... 16-1 16-1.2 INSPECTION SERVICEABILITY LIMITS ................................................................................................... 16-1 16-1.3 CROSS-REFERENCE INDEX.................................................................................................................... 16-1 16-1.4 CORROSION DEFINITIONS ..................................................................................................................... 16-1

1-1

Section 1 General Requirements

1-1 General requirements

1-1.1 Scope

This document provides instructions and responsibilities for P-3 aircraft Depot Integrated Maintenance Plan for Logistics and Engineering (DIMPLE) work and its associated support to the U.S. Navy. The goal of this maintenance program is to ensure safe, reliable, and available operation of the aircraft throughout its service period in order to meet U.S. Navy mission requirements. This Depot Integrated Maintenance Plan (IMP) establishes the Depot Level Maintenance (DLM) requirements for the P-3 series aircraft (i.e., P-3C, EP-3E, NP-3C, and NP-3D).

The depot activity shall provide all services, support equipment, equipment, tools, tooling, facilities necessary, and any other items necessary to perform the requirements of this document.

1-1.2 Introduction

This document contains general and specific DIMPLE maintenance requirements, standards, guidelines, instructions, inspections, tests, and other DIMPLE requirements to be accomplished and complied with by the depot activity. Each requirement shall be complied with as an item of scheduled maintenance at the specified DIMPLE interval or time limitation. Upon completion of DIMPLE, the aircraft and its accessories/components shall be completely reassembled, applicable systems rigged, aligned and/or tested (in accordance with the specified requirements) and the aircraft prepared for the Functional Check Flight process. The aircraft will be flight checked by the Government. The scheduled DIMPLE maintenance requirements prescribed in this document are the requirements necessary to ensure the timely discovery and correction for actual and/or anticipated defects based on the aircraft intended use. The DIMPLE requirements described herein provide for airframe, systems, and component inspection. These requirements correspond with flight safety considerations. Additionally, technical support for evaluation of aircraft condition is provided throughout the aircraft service life.

1-1.3 Definitions

The following definitions are provided to establish the terminology, as applied to the maintenance and DIMPLE requirements of this DOCUMENT. Terminology not defined in these paragraphs and used by this DOCUMENT shall be understood under the definitions of COMNAVAIRFORINST 4790.2 series, and interpreted within the context of the requirements of this DOCUMENT.

• Accessible Areas exposed by the removal of access doors, panels, fairing, etc., and such other disassembly required by the maintenance requirements and not involving destructive disassembly unless specified.

• Accessory See Airframe Accessories and Engine Accessories.

• Aircraft Wiring All electrical wiring considered part of the standard configuration of the aircraft that is permanently installed, and not an integral part of any accessory, component, or "black box".

• Airframe The structural components, including the framework and skin of such parts as the fuselage, empennage, wings, control surfaces, landing gear (minus tires), and engine mounts.

• Airframe Accessories The items of equipment that are required for operation of the aircraft and not be considered an integral part of the airframe or engine, such as wheels, brakes, hydraulic equipment, fuel system, deicing equipment, anti-icing equipment, and other items regardless of whether attached to the engine or airframe.

• Calibrate To determine and make required corrections in calibration standards or Precision Measuring Equipment (PME). It consists of the comparison of two instruments, one of which is a certified calibration standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the other instrument or PME being compared with the certified calibration standard.

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• Caution Indicates danger to the weapon system and/or personnel. The word “caution” precedes the item to which it refers.

• Chafing The wearing away of the applicable material by rubbing or scraping.

• Check To perform a thorough examination to ascertain the existence of unacceptable deviations from the intended state or condition as established by the applicable document.

• Check Flight Airborne operational tests performed to determine whether the airframe, power plant, accessories, and other items of equipment are functioning in accordance with predetermined standards while subjected to the intended operating environment.

• Checkout A sequence of functional, operational, and calibration tests to determine the condition and status of a weapon system and/or its components .

• Cleanliness The state of being free from impurities, impediments, and foreign matter not specified to be applied to the surface in question.

• Component A part or subassembly, or any combination thereof, joined to perform a specific function.

• Conditional Inspection See Inspections, Aircraft/Engine.

• Continental United States (CONUS) The states on the North American mainland bound by borders with Canada on the north, and Mexico on the south. The United States with the exception of the states of Alaska and Hawaii.

• Corrosion An action or process, which destroys metal by chemical or electrochemical action and converts it into an oxide, hydroxide, or sulfate compound.

• Damage Reduced resistance to failure.

• Defect Any nonconformance of the unit or product with specified requirements. Defects will normally be grouped into one or more of the following classes but may be grouped into other classes or subclasses within these classes:

• Critical Defect A defect that constitutes a hazardous or unsafe condition, or as determined by experience and judgment could conceivably become so, thus making the aircraft unsafe for flight or endangering operating personnel.

• Major Defect A defect, other than critical, that could result in failure or materially reduce the usability of the unit or part for its intended purpose.

• Minor Defect A defect that does not materially reduce the usability of the unit or part for its intended purpose, or is a departure from standards, which has no significant bearing on the effective use or operation of the unit or part.

• Insignificant Defect A minor defect with no bearing on the effective use or operation of the unit or part.

This defect normally affects cosmetic appearance of the cabin of the aircraft or crew convenience. This type of defect does not require correction or warrant inclusion in the Noted But Not Corrected (NBNC) list.

See No Work (NW) Defects in Section 16 of this DOCUMENT.

• Defective The state of possessing a deviation from specified requirements.

• Delamination A physical break of the bond between the binder material and any two or more plies of laminated panels fabricated of plastic, metal, or other materials or combinations thereof.

• Depot Activity The industrial establishment, either Government or Commercial, designated by the Naval Air Systems Command as having Depot level maintenance capability for DIMPLE for a particular model aircraft.

• Deterioration The breakup, eating away, or decomposition of a substance by the action of weather, corrosive material, or other environmental condition.

• Discrepancy See “Defect.”

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• Distortion Any disfigurement or change in form or shape from the intended design configuration resulting from a twisting or torsional action.

• Disturbed System A system whose installed integrity has been interrupted, broken, or interfered with to the extent that system installation and operation cannot be assured without certification by a functional/operational test.

• Electric/Electronic Wiring Circuits Verification (General) A test of system wiring and wiring components to verify ability of aircraft wiring to perform its intended function when mated to a set of operational black boxes.

May be accomplished by either of the following procedures:

• Functional or operational test of the system using existing aircraft black boxes, if operable, or "Slave" units if available. Tests shall be limited to the depth required to demonstrate adequacy of system wiring

• Any suitable method of continuity checks.

• Group A collection of units, assemblies, or subassemblies which is a subdivision of a set or system, but which is not capable of performing a complete operational function (See SYSTEM).

• Inspect To perform a critical investigation of an item, unit, component, or airframe through the visual, auditory, olfactory, and tactile senses, utilizing simple manipulation, gauging, and measurements, as required, for the specific intent of determining its conformance to the assigned specification within the tolerances permitted. The process may require partial disassembly of such items.

• Erosion The act of wearing away by corrosion, friction, scraping, or rubbing.

• Evidence Factual data, which establishes the possibility of an existing, or impending unsatisfactory condition.

• Evaluation An investigation to determine condition, i.e., the existence of defects and damage.

• Exterior Surface That part of the airframe exposed to the elements when in a "clean" flight configuration including wing and stabilizer control(s). Does not include landing gear structure, wheel wells, etc., or areas exposed by extension of landing gear.

• Failure The event, or inoperable state, in which any item or part of an item does not, or would not perform…