MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 1 OF 11

NDI OF CENTER WING FRONT BEAM WEB AND LOWER CAP BETWEEN CWS 77 AND CWS 81. LEFT AND RIGHT WARNING: COMPLY WITH SFAR 88 CDCCL REQUIREMENTS, REFER TO SP-322 AND SP-323

1. Perform nondestructive inspection of the center wing front beam web and lower cap between approximately CWS 77 2.

3.

4.

and CWS 81, left and right. In particular look for cracks emanating from the fastener holes attaching web, cap, and stiffener. (See Figure 1.) DESCRIPTION. The front beam lower cap and web are fabricated from 7075-T6fT73 aluminum and finished with epoxy primer. The beam cap is approximately 0.25 inch thick at the attach location of the beam cap, web, and stiffener. The cap is approximately 1.0 inch thick below the attachments of the cap, web and stiffener. The upper fastener attaching the cap, web, and stiffener is located 0.38 inch belowthe top edge of the vertical flange of the cap. The lower fastener attaching the vertical flange of the cap and the web stiffener is located 0.56 inch downward from the upper fastener and on the same CWS. The thicker portion of the vertical flange of the lower cap begins approximately 1.6 inches below the top edge of the cap vertical flange. DEFECTS. Cyclic loading may cause fatigue cracks to begin in the upper fastener location in the cap, progress to the upper edge of the vertical flange of the cap, next proceed downward to the lower fastener location, and then proceed downward into the lower horizontal leg of the cap. The cracks in the web will approximate the direction of those in the cap through the fasteners, and will then likely propagate vertically upward and in an inboard direction. PRIMARY NDE PROCEDURE NO. 1 - EDDY CURRENT. NOTE: For support data and locally manufactured items and acceptance/ rejection criteria, refer to SMP 515-C, Work Card SP-76, Appendix A. A. NDE equipment: (1) Crack Detector, Magnaflux, P/N ED-520, or equivalent. (2) Probe, Shielded, Pencil, High Sensitivity, VM Products P/N VM 200, or equivalent.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 2 OF 11

(3) Calibration Standard, Aluminum, as furnished with the Magnaflux Instrument, or Lockheed-Georgia Co. P/N PDL 457A. B. Preparation of airplane: WARNING: ENSURE THAT POWER IS ISOLATED FROM ALL SYSTEMS IN THE INSPECTION AREA PRIOR TO APPROACHING THE INSPECTION AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY TO PERSONNEL. (1) Isolate power from all systems in the inspection area in accordance with applicable maintenance manuals. WARNING: ENSURE THAT ALL APPLICABLE SAFETY PRECAUTIONS PERTAINING TO WORK IN FUEL/FUME AREAS SPECIFIED IN THE APPLICABLE MAINTENANCE MANUAL ARE STRICTLY OBSERVED WHILE WORKING IN THE FUEL TANKS AND DRY BAY AREAS. PERSONNEL SHALL WEAR NON-SPARKING PROTECTIVE CLOTHING SUCH AS 100 PERCENT COTTON. ENTRY INTO THE FUEL TANKS AND DRY BAY AREAS FOR DEPUDDLING MUST NOT BE MADE UNTIL THE AREAS HAVE BEEN PURGED TO THE FIRE-SAFE 20 PERCENT LOWER EXPLOSIVE LIMIT (LEL), AS DETERMINED USING FUEL VAPOR DETECTION AND MEASURING EQUIPMENT. FULL FACEPIECE RESPIRATOR MUST BE WORN UNTIL EACH AREA HAS BEEN PURGED TO 5 PERCENT LEL. A CARTRIDGE TYPE RESPIRATOR MAY BE WORN BETWEEN 5 PERCENT LEL AND 1.5 PERCENT LEL. NO RESPIRATOR IS REQUIRED WHEN THE HEALTH-SAFE 0.0 TO 1.5 PERCENT LEL AND 19.5 PERCENT OXYGEN CONTENT HAVE BEEN ATTAINED. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY OR DEATH TO PERSONNEL AND DAMAGE TO THE AIRCRAFT. (2) Defuel the applicable auxiliary fuel tank bladder cells and remove residual fuel in accordance with SMP 515C, Work Card SP-12.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 3 OF 11

(3) Remove the Auxiliary Tank Access door, (332/460), and (333/461), on the lower surface of the center wing and internal bulkhead door to the inboard auxiliary tank as necessary. (4) Purge the applicable fuel cell and cavity in accordance with the applicable maintenance manual to within 0.0 and 1.5 percent of the lower explosive limit (LEL). (5) Remove bladder cells and liners from L/R inboard auxiliary tanks as required in accordance with applicable maintenance manuals. C. Access: Access to the center wing lower surface is from beneath each wing with the use of appropriate maintenance stands. Access to the inboard auxiliary fuel tank is through the Auxiliary Tank Access door into the center auxiliary fuel tank, and then through the access opening from the center to the inboard auxiliary tank. WARNING: METHYL ETHYL KETONE (MEK) IS FLAMMABLE AND TOXIC TO EYES, SKIN AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. KEEP AWAY FROM OPEN FLAMES OR OTHER SOURCES OF IGNITION. D. Preparation of part: After the auxiliary tank and liner have been removed or pulled back to provide access to the inspection area, remove the sealing compound from the lower beam cap vertical and horizontal flanges using phenolic scrapers and methyl-ethyl-ketone (MEK), or commercial equivalent. Continuous ventilation must be provided during cleaning and inspection process; it is recommended that full face mask and respirators be provided for cleaning and inspection personnel. E.

Instrument settings/calibration: Set up and calibrate instrument as specified in SMP 515-C, Work Card SP-76, Appendix A, for surface scanning.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 4 OF 11

NOTE: The eddy current instrument must be recalibrated when inspection probes are changed. Inspection: (1) Scan around the fourteen fasteners in the cap as illustrated. Scan in both clockwise and counterclockwise directions. (2) A sharp meter deflection, as noted during calibration, will indicate a suspect defect in the beam cap. G. Mark and report suspected defects. H. To confirm suspected defects proceed to Backup NDE Procedure No. 1. If no defects are suspected proceed to Primary NDE Procedure No. 2. PRIMARY NDE PROCEDURE NO. 2 - VISUAL. A. NDE equipment: (1) Magnifying glass, pocket, 1OX-power, commercial. (2) Mirror, inspection, Battery Machinery P/N 730N002-022A, or equivalent. (3) Flashlight, inspection, Ziegler Tools P/N 255FO05-002A, or equivalent. (4) Batteries, Eveready, D-cells, 4 required, Union Carbide, or equivalent. B. Preparation of airplane: WARNING: ENSURE THAT POWER IS ISOLATED FROM ALL SYSTEMS IN THE INSPECTION AREA PRIOR TO APPROACHING THE INSPECTION AREA. FAILURE TO COMPLY MAY RESULT IN SERIOUS INJURY TO PERSONNEL. (1) Isolate power from all systems in the inspection area in accordance with applicable maintenance manuals. (2) Remove the upper left and right Controls and Electrical Access Panels. See Access for additional potential removals. C. Access: Use appropriate maintenance stands for access to the front beam area on the upper surface of the wing. When the access panel is removed, F.

5.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 5 OF 11

access to the inspection area is by reaching down from the top surface of the wing while laying on the wing with the arm extended between electrical wire bundles and the front beam web and behind the insulated bleed air duct located just forward of the forward lower beam cap. If the arm will not pass between wire bundles and front beam web, remove/loosen wire bundle clamps to provide more arm room or remove the section of leading edge bleed air duct in the inspection area. An alternate method would be to remove the Landing Gear Hydraulic System Access Door, and gain access to the inspection area from the lower wing at the leading edge with the use of appropriate maintenance stands. WARNING:

FEDERAL SPECIFICATION 0-T-620, TYPE I, TRICHLOROETHANE IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL VENTILATION IS NORMALLY ADEQUATE. FAILURE TO COMPLY COULD RESULT IN INJURY TO PERSONNEL.

D. Preparation of part: Clean the inspection areas using clean cloths wet with Federal Specification 0-T-620, Type I, Trichloroethane (or equivalent). E. Instrument settings/calibration: None F. Inspection: (1) Perform detail visual inspection of the center wing forward beam web between approximately CWS 77CWS 81, lower edge of web upwards approximately 2.0 inches, left and right sides of the aircraft. In particular, look for cracks emanating from the six fastener holes attaching web, cap, and stiffener. (2) On those aircraft modified from 382E to 382G or other aircraft modified with Mod Kit Installation drawing 3304350, and specifically

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

6.

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 6 OF 11

modified with Web Replacement-Front Beam, Center Wing, drawing 3304483, the front beam stiffener at CWS 79 has been replaced with a bulb angle "T" stiffener and a tabed out flat splice plate located on the forward side of the front beam web and centered at CWS 80. The lower end of the splice plate is tabed out to a total width spanning between existing stiffener inboard and outboard of original stiffener at CWS 79. See Figure 1. When this modification has been performed the web at the six fasteners shown in Figure 1 will be covered by the new splice plate. Inspect the web around the lower perimeter of the splice plate in accessible areas for cracks coming from web-to-splice plate attach holes and propagating vertically upward and inboard. G. Mark and report suspected defects. H. To confirm suspected defects, proceed to Backup NDE Procedure No. 2. If no defect is suspected proceed to System Securing. BACKUP NDE PROCEDURE NO. 1 - EDDY CURRENT. NOTE: For support data and locally manufactured items and acceptance/ rejection criteria, refer to SMP 515-C, Work Card No. SP-76, Appendix A. A. NDE equipment: (1) Crack detector, Magnaflux, P/N ED-520, or equivalent. (2) Probe, bolt hole, Ideal Specialty Co., P/N 6200-3/16-BH-BNC, or equivalent. (3) Calibration standard, aluminum, as furnished with the Magnaflux instrument, or Lockheed-Georgia Co. P/N PDL 457A. B. Preparation of airplane: Same as Primary NDE Procedures No. 1 and No. 2. C. Access: Same as Primary NDE Procedures No. 1 and No. 2. WARNING: FEDERAL SPECIFICATION 0-T-620, TYPE I, TRICHLOROETHANE IS TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED OR PROLONGED CONTACT. GOOD GENERAL

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 7 OF 11

VENTILATION IS NORMALLY ADEQUATE. FAILURE TO COMPLY COULD RESULT IN INJURY TO PERSONNEL. D. Preparation of part: Remove fasteners from suspected defective fastener holes per Hercules Structural Repair Manual. The holes will be cleaned with a stiff nylon (not metal) bristle brush wet with Federal Specification 0-T620, Type I, Trichloroethane, or commercial equivalent. E. Instrument settings/calibration: Set up and calibrate instrument as specified in SMP 515-C, Work Card SP-76, Appendix A, for bolt hole scanning. NOTE: The eddy current instrument must be recalibrated when inspection probes are changed. F.

7.

Inspection: Perform bolt hole inspection of the defective fastener hole. Care should be taken by the operator to locate each layer of material in the suspect hole to ensure that the correct part is being inspected; reference SMP 515-C, Work Card SP-76, Appendix A, for bolt hole scanning techniques. G. Mark and report indicated defects. If no defects are indicated, proceed to Primary NDE Procedure No. 2. If defects are noted, take appropriate corrective action. BACKUP NDE PROCEDURE NO. 2 - EDDY CURRENT. NOTE: For support data and locally manufactured items and acceptance/ rejection criteria, refer to SMP 515-C, Work Card SP-76. A. NDE equipment: (1) Crack Detector, Magnaflux, P/N ED-520, or equivalent. (2) Probe, Shielded, Pencil, High Sensitivity, VM Products P/N VM200 or equivalent. (3) Calibration Standard, aluminum, as furnished with the Magnaflux instrument, or Lockheed-Georgia Co. P/N PDL 457A.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 8 OF 11

B. C. D. E.

8.

Preparation of airplane: Same as Primary NDE Procedure No. 2. Access: Same as Primary NDE Procedure No. 2. Preparation of part: Same as Primary NDE Procedure No. 2. Instrument settings/calibration: Set up and calibrate instrument as specified in SMP 515-C, Work Card SP-76, Appendix A, for surface scanning. NOTE: The eddy current instrument must be recalibrated when inspection probes are changed. F. Inspection: Inspect only the suspected defective area. Refer to surface scanning technique in SMP 515-C, Work Card SP-76. A sharp meter deflection, as noted during calibration, will indicate a probable crack in the part. G. Mark and report indicated defects. If no defects are indicated, proceed to System Securing. If defects are noted, take appropriate corrective action. 8. SYSTEM SECURING. Restore finishes and sealants, reinstall removed components, remove equipment and supplies from the inspection area, and perform operational checkouts as required in accordance with applicable maintenance instructions.

THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 9 OF 11

Figure 1. Front Beam Web and Lower Cap, CWS 77 to CWS 81. (Sheet 1 of 3) THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 10 OF 11

Figure 1. Front Beam Web and Lower Cap, CWS 77 to CWS 81. (Sheet 2 of 3) THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.

MODEL L-382/C-130

SMP 515 C INSPECTION PROCEDURES

SYSTEM WINGS CHAPTER 57

ZONE

REV DATE

500/600

14 DEC 08

CARD NO. SP-169 11 OF 11

Figure 1. Front Beam Web and Lower Cap, CWS 77 to CWS 81. (Sheet 3 of 3) THIS MATERIAL CONTAINS PROPRIETARY INFORMATION OF LOCKHEED MARTIN AERONAUTICAL SYSTEMS. USE COPYING AND/OR DISCLOSURE WITHOUTH WRITTEN AUTHORIZATION IS PROHIBITED.