# HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063


# SERVICE BULLETIN

EXPORT CONTROLLED INFORMATION

WARNING

- This document contains data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq. ) as amended, or the Export Administration Act (Title 50, U.S.C., App 2401 et seq.) as amended. Violations of these export laws

are subject to severe criminal and civil penalties.

© 2013 LOCKHEED MART IN CORPORATION. LOC KHEED MARTIN PROPRIE TARY INFORMATION.

December 16 , 2013 

# 382

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Page 1 of 17 WINGS

- OUTER WING UPPER AND LOWER RAINBOW FITTIN G INSPECTION FOR CRACKS AND REPLACEMENT

NOTE: This Service Bulletin includes Appendix A.

1. PLANNING INFORMATION

A. EFFECTIVITY

This service bulletin is applicable to all Model 382, 382B, 382E, 382F, and 382G series FAA certificated Hercules aircraft having O uter W ing S erial s 4542 or later, or all MEP replacement outer wings except the 14Y Series (Part No. 388021

- 9/

- 10).

B. REASON

(1) Fat igue cracking of the outer wing upper and lower rainbow fittings on the durability test and on in

- service aircraft indicates a requirement to perform inspections of the rainbow fittings. Analysis of in

- service cracking has shown that these fittings are su sceptible to Multiple Site Damage (MSD) and an inspection is required to ensure that cracking does not occur in the skin panel

- to

- fitting fastener holes, resulting in an unacceptable reduction in residual strength. The inspection intervals provided in thi s service bulletin will ensure that the probability of failure remains acceptably low until the rainbow fittings are replaced

. (2) The 14 CFR Part 26, Subpart C Aging Aircraft Safety

- Widespread Fatigue Damage rule became effective on January 14, 2011. In co mpliance with this rule, Lockheed Martin Aeronautics Company established a Limit of Validity (LOV) for 382 series aircraft, published in Section VII of customer specific Service Manual Publication (SMP) 515

- C Inspection Programs. 14 CFR Part 121 or Part 1 29 operators must have incorporated the LOV into their maintenance program by July 14, 2013 to comply with FAR §121.1115 or §129.115. This service bulletin incorporates maintenance actions required for the outer wing rainbow fittings to safeguard the airc raft against widespread fatigue damage up to the LOV.

(3) Lockheed Martin Aeronautics Company recommends that inspections specified herein be accomplished on all commercial aircraft outer wings that have accumulated 30,000 or more flight hours. The initial in spection should be performed at the next convenient maintenance period but not to exceed 365 days or 600 flight hours, whichever occurs first, after receipt of this Service Bulletin. Recurring inspection is recommended at 2,000 flight hours

. (4) Lockheed Mart in Aeronautics Company recommends that both upper and lower rainbow fittings be replaced at 50,000 flight hours. This replacement coincides with center wing replacement per Service Bulletin 382

- 57

- 94. Replacement of the rainbow fittings will reset the fl ight hours to zero with respect to the inspection requirements identified in this Service Bulletin

.
NOTE: For commercial operators of aircraft with outer wings that have had previous military usage,

contact Lockheed Martin for adjusted compliance times

.

# HERCULES Lockheed Martin Aeronautics Company Marietta, Georgia 30063


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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 2 NOTE: The replacement times indicated in this service bulletin do not apply to military operators of

382, 382B, 382E, 382F, and 382G aircraft. Contact Lockheed Martin for an Operational Usage Evaluation/Service Life Assessment to determine an appropriate replacemen t schedule

.
C. DESCRIPTION

(1) This Service Bulletin contains instructions for inspecting outer wing upper and lower rainbow fittings using Eddy Current Surface Scan to detect cracks propagating from fasteners attaching the fittings to skin panels. Perform inspections in accordance wit h P aragraph 2.A

. of this Service Bulletin

. (2) This Service Bulletin contains instructions for replacing upper and lower rainbow fittings on the outer wing. Prior to installation of new rainbow fittings, inspect all open fastener holes in mating structure usi ng Automated Bolt Hole Eddy Current as defined in Appendix A of this Service Bulletin. Make necessary repairs and install new rainbow fittings in accordance with P aragraph 2.B

. of this Service Bulletin

.

D. APPROVAL

(1) The aircraft owner/operator will make an ap propriate entry in the aircraft log records upon compliance with this Service Bulletin.

(2) After the work has been completed on each affected aircraft, please complete and mail or fax (770

- 494

- 5682) a Notice of Service Bulletin Compliance; or notify Lockheed Martin Aeronautics Company of compliance with this Service Bulletin at website address: http://www.lockheedmartin.com/eoc and log into Data Library.

(3) This Service Bulletin has been approved by the FAA as co mplying with applicable Federal Aviation Regulations.

E. MANPOWER

The work prescribed in this Service Bulletin has not been performed at the Lockheed Martin facility. Therefore, the manpower estimates provided have not been validated, and should not be const rued as being acceptable for use in making fixed price quotes for accomplishment of the work. These estimates are provided only as a convenience for customer planning purposes. It is e s ti m ated t h a t manhours

r equired, cr e w siz e , a n d el a p s e d t ime wh i le t he aircraft is out of serv i ce a r e as follo w s:

TA S K MAN H OURS C R E W S I ZE EL A P S ED T I ME Primary ECSS Inspection 24 2 12 hrs

Removal a nd I n s talla t ion of one fitting 515 6 285 hrs Primary BHEC Inspection 24 2 12 hrs

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Page 3 NOTE: This Service Bulletin is based upon the configuration of the aircraft as it was delivered from

Lockheed Martin Aeronautics Company . Previous service bulletins issued by Lockheed Martin Aeronautics Company have been considered in the preparation of this Se rvice Bulletin, but no consideration has been given to peculiar changes made to the aircraft by the owner/operator since its delivery.

F. MATERIAL

- COST AND AVAILABILITY

(1) Parts/Materials listed in section 3 of this service bulletin are to be supplied by the a ircraft owner/operator. Parts listed in section 3 of this service bulletin may also be purchased from Lockheed Martin, if desired. Parts bearing Lockheed Martin Aeronautics Company part numbers are considered proprietary and shall be purchased from Lockh eed Martin Aeronautics Company unless methods of fabrication are shown in this publication. Inquiries concerning current prices, applicability, and availability of kits may be directed to the following:

MAIL: Lockheed Martin Aeronautics Company

C

- 130 Commercial Contracts Department F532 Zone 0 195 86 South Cobb Drive Marietta, GA 30063

- 0 195 , USA

TELEPHONE: (770) 494

- 5165

FAX: ( 817 ) 655

- 9700

(2) Additional bulk materials, not included in the kit, will be supplied by the airc raft owner/operator.

G. TOOLING

- PRICE AND AVAILABILITY

(1) For ECSS Inspections :

Eddy current ins p e c ti o n un i t, Nortec 2000D/D+

, or equival e nt.

Probe, shiel d ed, right ang l e, 1/2

- inch drop, 50

- 500 kHz, Fischer/LEMO Triax Connector, Olympus MTF

- 905

- 60, or e quivalent.

Probe, shiel d ed, straight

, 50

- 500 kHz, Fischer/LEMO Triax Connector, Olympus MTF

- 40, or
e quivalent.

Cab l e, 6 f oot, Fischer

/LEMO Triax to 16

- pin LEMO connector, Olympus P/N 9122244, or
e quivalent.

Cali b ration Standard

, alum i num, VM Products, Inc. P/N VM30889

- C1A or P/N VM30889

- C1A/AF, or equivalent.

(2) For BHEC Inspections defined in App e ndix A:

Eddy current instrument, Nortec 2000D/D+, or equivalent

Scanner , high

- speed, MiniMite, 4

- pin Fischer, Olympus P/N 9744738, or equivalent.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 4 Probe , bolt hole, shielded reflection (100 kHz

– 2 MHz), 3/16

- inch diameter (.156

- .187), 4

- pin

Fischer, Olympus SPO

- 5965, P/N 9230061, or equivalent.

Probe, bolt hole, shielded reflection (100 kHz

– 2 MHz), 1/4

- inch diameter (.218

- .250), 4

- pin Fischer, Olympus SPO

- 5965, P/N 921 9980, or equivalent.

Probe, bolt hole, shielded reflection (100 kHz

– 2 MHz), 5/16

- inch diameter (.281

- .312), 4

- pin Fischer, Olympus SPO

- 5965, P/N 9219982, or equivalent.

Probe, bolt hole, shielded reflection (100 kHz

– 2 MHz), 3/8

- inch diameter (.312

- .375), 4

- pin Fischer, Olympus SPO

- 5965, P/N 9219982, or equivalent.

Cable, scanner , high

- speed, 16

- pin Lemo, Olympus P/N 9122090, or equivalent.

Calibration Standard, aluminum, VM Products, Inc. P/N VM30889

- C1A or P/N VM30889 C1A/AF, or equivalent.

(3) For Removal and Installation of Rainbow Fitting:

3307043

- 1/2

- 16F Fixture to locate the new joint fitting.

3307043

- 1/2

- 18F Fixture to mill the nodes of the new joint fitting.

185R105

- 002A Router, or equivalent, for milling the new joint fitting.

446E101

- 015C Cutter, or eq uivalent, for above router.

730M200

- 004A Depth Micrometer or equivalent.

Jig Transit ( with Optical micrometer) or equivalent.

H. WEIGHT AND BALANCE

None

.

I. REFERENCES

SMP 515

- C

- NDI, No n d e structi v e I n s p e ction ( N D I) P roced u res M an u al S upple m ent

SMP 581, He r c u l es M a i ntena n ce Ma nual

SMP 583, Structural Repair Manual

He r c u l es A ir fr eighter P r o gr essive Ins p ec t ion P roced ur es

Service Bulletin 382

- 57

- 94/ Wing s

- R eplacement of Center Wing

The f ollow i ng Lo c k h e ed M artin draw i n g s may be ne e ded for r efer e n c e:

DWG NO. DES C RIPT I ON OUTER WING EFF E CTIV I TY *

3308150 Outer Wing Assy 45 4 2 thru 4960

3319669 Outer Wing Assy 4992 thru 5320

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Page 5 DWG NO. DES C RIPT I ON OUTER WING EFF E CTIV I TY *
3308152 Box Structure, Out e r Wi n g

A s s y 45 4 2 thru 4960

331967 2 Box Structure, Out e r Wi n g

A s s y 4992 thru 5320

3308153 LWR S urf a ce Instl 45 4 2 thru 4960

3325532 LWR S urf a ce Instl 4992 thru 5320

3308154 UPR Surf a ce As s y 45 4 2 thru 4960

3325535 UPR Surf a ce As s y 4992 thru 5320

3308155 UPR Surf a ce Instl 45 4 2 thru 4960

3325531 UPR Surf a ce Instl 4992 thru 5320

3 308156 LWR S urf a ce As s y 45 4 2 thru 4960

3325536 LWR S urf a ce As s y 4992 thru 5320

370500 Wing J o int Bas i c Dim e n s i on All * Outer wing serial number is indicated on the outer wing identification placard located on the rear beam web near OWS180.

J. OTHER PUBLICATIONS AFFECTED

Hercules Airfreighter Progressive Inspection Procedures

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### THIS PAGE INTENTIONA LLY LEFT BLANK.

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Page 7 2. ACCOMPLISHMENT INSTR UCTIONS

A. INITIAL AND RECURRING INSPECTIONS

This service bulletin defines the initial inspection for cracks in outer wing upper and lower rainbow fittings on commercial aircraft at 30,000 flight hours and a recurring inspection at intervals of 2,000 flight hours. Perform nondestructive inspection of th e outer wing upper and lower rainbow fitting to skin panel attachments, left and right, as shown in Figure 1 and Figure 2. The upper and lower inspection areas are located at OWS 3 to OWS 7 between the forward and aft corner fittings and include 2 inboard chord

- wise fastener rows containing approximately 180 fasteners.

The wing joint rainbow fittings are fabricated from 7075

- T73511 aluminum. The rainbow fitting tangs taper in thickness from approximately 0.35 to 0.10 inches in the inspection areas. The u pper and lower surface skin panels are attached to the rainbow fittings in the inspection areas with steel fasteners. Cyclic loading may cause fatigue cracks to begin in the rainbow fitting at the panel attachment fasteners and propagate in a chord

- wise d irection.

These inspections shall be performed as follows:

NOTE: For support data and locally manufactured items and acceptance/rejection criteria, refer to

the SMP 515

- C

- NDI Nondestructive Inspection Procedures Manual Supplement.

(1) ND I e q uipm e nt: Required equipm ent is listed in Paragraph 1.G.(1)

. (2) Access: Access to the upper and lower wing surfaces may be accomplished using appropriate maintenance stands . Use safety restraint harnesses or other available safety equipment when working on top of the wings.

(3) Preparat ion of parts: Remove sealant, scaling paint, oil, and grease in the inspection areas using the procedures detailed in the SMP 515

- C

- NDI Nondestructive Inspection Procedures Manual Supplement, Section 20

- 00

- 00.

(4) Instrument settings/calibration: Set up and ca librate the eddy current instrument as specified in SMP 515

- C

- NDI Nondestructive Inspection Procedures Manual Supplement, Section 20

- 10

- 04 for eddy current scanning of aluminum. The calibration standard is specified in Paragraph 1.G.(1). See Figure 3 for the expected signal responses after calibration of the surface scanning probes noted in this inspection.

NOTE: The eddy current instrument must be recalibrated when probes are changed.

(5) Inspection

- Upper Surface:

(a) Scan around all fasteners attaching the upper r ainbow fitting to the wing skin panels as illustrated in Figure 1. Use the raised fastener heads as a guide when inspecting around the fasteners in the inspection area. Fatigue cracking is expected to propagate in a chord

- wise (fore

- aft) direction.

(b) An in strument screen presentation, as noted during calibration, will indicate a suspected defect in the part being inspected.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 8 (6) Inspection

- Lower Surface:

(a) Scan around all fasteners attaching the lower rainbow fitting to the wing skin panels as illustrated in Figure 2

. Use the raised fastener heads as a guide when inspecting around the fasteners in the inspection area

. Fatigue cracking is expected to propagate in a chordwise (fore

- aft) direction.

(b) A n instrument screen presentation, as noted during calibration, will indicate a suspected defect in the part being inspected.

(7) M ark and report suspected defects. If defects are suspected, proceed to the Backup NDI Procedure

. If no defects are suspected, complete the Primary NDI Procedure and proceed to System Securing

. (8) BACKUP NDI PROCEDURE

(a) T o confirm suspected defects, remove the fastener and perform an Automated Bolt Hole Eddy Current inspection of the open hole in accordance with Appendix A.

(b) R e p ort any d amage d etec t ed by this inspecti o n pr o cedure to L o ck h eed M a rtin A ero n auti c s Com p any Enterprise Operations Center in accordance with the note at the end of the accomplishment instructions

. Provide the followi n g in f or m ation for all d a mage det e ct e d:

1 Aircraft S erial Numb e r

.

2 Out e r Wi n g Flight Ho ur s ( or A ircraft Fl i ght Ho u rs if ou ter w i ng h o urs are u n k n ow n)

.

3 Part numb e r and d e script i on

.

4 Locat i on ( Wi n g S ta t ion, Fu s el a ge S ta t ion ) and s p e cific faste n er h o le locati o n

.

5 Len g th, d e pth, and ori e nta t ion of crack

.

NOTE: Prior to reporting any detected damage to Lockheed Martin Aeronautics Company, it is

recommended that a borescope inspection (side view lens) of the hole bore be performed to determine if the reported damage is due to fatigue cracking, embedded metal at fa ying surfaces or mechanical damage (gouging, reamer/drill marks, elongation) within the hole bore.

(9) S Y ST E M SE C U RI N G

. Restore f in i s h e s and s e alan t s, rein s tall r e m oved co m po n ents, re m ove equip m ent a n d s u p pli e s from t he ins p e cti o n area, a n d p erform op e ra t ional c h e cko u ts as r equ i red in accor d a n ce with appl i c a ble m ainten a nce i n structio n s.

B. REPLACEMENT OF WING JOINT FITTINGS

(1) This Service Bulletin recommends replacement of the outer wing upper and lower rainbow fittings in accordance with Hercules Maintenance M anual on commercial aircraft outer wings having accumulated more than 50,000 total flight hours.

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Page 9 (2) Preparation for Replacement

(a) Perform Alignment and Symmetry on aircraft in accordance with SMP 583 Structural Repair Manual, Chapter 51

- 100

- 00. Retain this data for future reference.

(b) Remove outer wings using instructions in SMP 581 Fig 57

- 10

- 03 and place wings on cradle. Secure the cradle with mechanical locks to avoid movement during Step 2.B.(2)(c). Shoring is required if cradle cannot be mechanically locked.

(c) Conduct a survey of the OWS 0 outer wing joint plane using a suitable optical transit. Record any disparity in planarity between all nodes. Reference drawings 3308150 and 3319669 . Contact Lockheed Martin if the four corner fittings are not co

- pl anar within drawing requirements.

(d) Remove all components such as plumbing and wiring necessary to facilitate installation of replacement rainbow fittings in area between OWS 0 and OWS 7.

(3) Upper Rainbow Fitting Replacement

CAUTION: REPLACE UPPER OR LOW ER RAINBOW FITTI NGS ONE AT A TIME. UNDER NO

CIRCUMSTANCES SHOULD THE RAINBOW FITTINGS AND SPAR CAP CORNER FITTINGS BE REMOVED AT THE SAME TIME. T HE CORNER FITTINGS A RE USED AS A REFERENCE IN TH E MACHINING OF THE R AINBOW FITTINGS AND SHOULD NOT BE REMOVE D UNTIL THE MACHI NING OF THE RAINBOW FITTINGS HAS BEEN COMPLETED.

CAUTION: EXERCISE CAUTION WHE N INSTALLING OR REMO VING THE NEW RAINBOW

FITTING TO AND FROM THE WING

. AVOID APPLYING UNDUE FORCE DURING THIS PROCESS TO PREV ENT CRACKING THE FIT TING AND OTHER WING COMPONENTS.

(a) Remove up per rainbow fitting by removing attaching fasteners and breaking fay surface sealant. Use caution to avoid damage to wing structure and attach holes.

(b) Clean wing attaching structure such as skin panels, stiffeners, corner fittings, attaching angles, and ri b web of sealant and other particles.

(c) Visually inspect the wing faying structure for possible damage or cracks.

(d) Perform Automated Bolt Hole Eddy Current inspection of all open fastener holes in skins, stiffeners, webs

, and angles while fitting is removed i n accordance with Appendix A of this S ervice B ulletin. If confirmed cracks are found, repair in accordance with Hercules Structural Repair Manual SMP 583 or contact Lockheed Martin Aeronautics Company Enterprise Operations Center in accordance with the no te at the end of the accomplishment instructions

. (e) Place the new rainbow fitting in the wing. Some amount of force may be required to properly align fitting. Reference D rawing 3308154 or 3325535 Upper Surface Assembly.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 10 (f) Install 3307043

- 1/2

- 16F Locating Fix ture and attach it to the four corner fittings. A shim of suitable size and thickness must be placed between the fixture and each of the four corner fittings to allow the rainbow fitting nodes to protrude for final node milling to assure joint planarity. All four shims must be the same thickness. Reference D rawing 330815 2 or 33196 72 for wing joint node thickness requirements. All nodes of the rainbow fitting shall be tight against fixture before proceeding.

(g) Check all fitting

- to

- wing skin panel attaching fastener holes for proper edge distance (1.5 x Final Hole Diameter minimum

. )

(h) Visually check the new rainbow fitting for proper placement/alignment prior to drilling operations.

(i) Transfer all fastener holes from outer wing mating structure to new rainbow fi tting in accordance with SMP 583 Structural Repair Manual, Chapter 51

- 70

. (j) Remove the locating fixture and rainbow fitting from wing. Clean fitting and the surrounding wing area for debris and burrs.

(k) Reposition the new rainbow fitting in the wing, picking up previously drilled holes. Fay surface seal in accordance with SMP 583 Structural Repair Manual.

(l) Wet install oversize fasteners of appropriate type in accordance with SMP 583 Structural Repair Manual, Chapter 51

- 70

.

NOTE: Perform S tep 2.B. ( 4) Lower Rainbow Fitting Replacement before performing S tep

2.B. (5) Fitting Node Milling Procedure.

(4) Lower Rainbow Fitting Replacement

CAUTION: EXERCISE CAUTION WHE N INSTALLING OR REMO VING THE NEW RAINBOW

FITTING TO AND FROM THE WING. AVOID APPLYING UNDUE FORCE DUR ING THIS PROCESS TO PREV ENT CRACKING THE FIT TING AND OTHER WING COMPONENTS.

(a) Remove l o wer rainbow f it t ing by removing at t aching fast e ners and b re a king fay su r f a ce
s e a l an t

. U se c aution a s to not damage w i ng structu r e and at t a c h ho l e s

. (b) Clean wing a t tachi n g str u c t ure s uch as skin p a ne l s, sti ffen er s, corn e r f i t t ing s , at t a c hi n g angles, and rib web of sea l ant and oth e r pa r ticl e s.

(c) Visually inspect the wing faying structure for possible damage or cracks.

(d) Perform Automated Bolt Hole Eddy Current inspection of all open fastener holes in mating structure while fitting is removed in accordance with Appendix A of this service bulletin. If confirmed cracks are found, repair in accordance with Hercules Structural Repair Manual SMP 583 or contact Lockheed Martin Aeronaut ics Company Enterprise Operations Center in accordance with the note at the end of the accomplishment instructions

. (e) Place the new rainbow fitting in the wing. Some amount of force may be required to properly align fitting. Reference D rawing 3308156 or 33 25536 Lower Surface Ass embly for proper fit and installation.

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Page 11 (f) Install P/N 3307043

- 1/2

- 16F locating fixture and attach it to the four corner fittings. A shim of suitable size and thickness must be placed between the fixture and each of the four corner fitt ings to allow the rainbow fitting nodes to protrude for final node milling to assure joint planarity. All four shims must be the same thickness. Reference D rawing 33 0 815 2 or 33196 72 for wing joint node thickness requirements. All nodes of the rainbow fi tting shall be tight against fixture before proceeding.

(g) Check all fitting

- to

- wing skin panel attaching fastener holes for proper edge distance (1.5 x Final Hole Dia meter minimum)

(h) Visually check the new rainbow fitting for proper placement/alignment prior t o drilling operations

. (i) Transfer all fastener holes from outer wing mating structure to new rainbow fitting in accordance with SMP 583 Structural Repair Manual, Chapter 51

- 70

. (j) Remove the locating fixture and rainbow fitting from wing

. Clean components and the surrounding wing area for debris and burrs.

(k) Reposition the new rainbow fitting in the wing, picking up previously drilled holes

. Fay surface seal in accordance with SMP 583 Structural Repair Manual.

(l) Wet

- install oversize fasteners of appropriate type i n accordance with SMP 583 Structural Repair Manual, Chapter 51

- 70

.

NOTE: Continue to S tep 2.B. (5) Fitting Node Milling Procedure only after completing S teps

2.B. (3) and 2.B. (4).

(5) Fitting Node Milling Procedure

(a) This step is required for milling procedures: Suppor t the outer wing using instructions in SMP 581 Fig 57

- 10

- 03. Secure the cradle with mechanical locks to avoid movement during machining

. Shoring is required if cradle cannot be mechanically locked.

(b) Position optical transit as required to adequately read the location of the rainbow fittings

. Adjust the cradle until the four corner fitting node faces are in the same vertical plane

. This step will not be necessary if a suitable transit is used that is equipped with degrees of freedom that permit setting th e transit line of sight in a non

- vertical plane with the four corner fitting nodes

. Verify that the four corner fitting nodes are coplanar and check the amount of rainbow fitting node face protrusion

. Node thickness requirements are defined by engineerin g drawing 3308152 and 33 19672

. (c) Ensure that S teps 2.(5) (a) and 2.(5) (b) are completed before milling.

(d) Position milling fixture 3307043

- 1/2

- 18F Left or Right to the outer wing

. Using a proper router with micro depth adjustment as specified in paragraph 1.G .(3), measure the depth to corner fitting nodes

. Cross check using the transit

. Verify that the milling operation will yield the node thickness requirements as defined by Drawings 3308152 or 3319672. Use router to mill each node.

(e) Continue the same proce dure until all upper and lower rainbow fitting nodes are milled to the same plane as the corner fittings

. Always cross check optically with transit.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 12 (f) Remove milling fixture.

(g) Ream wing mate holes to final size in accordance with D rawing 370500. Chamfer sha rp edges of wing mate holes in accordance with Drawing 3308152 or 3319672.

(h) Touch

- up f inish the milled nodes with Al odine and one coat of AMS

- C

- 27725 Polyurethane, or equivalent in accordance with D rawing s 3308152 or 3319672

. (6) Final Installation

(a) Re

- install any components removed to facilitate replacement of the rainbow fittings.

(b) Re

- install outer wings per SMP 581

, Figure 57

- 10

- 03.

(c) Perform an Alignment and Symmetry Check and compare readings to those taken at the start of procedure.

C. RESTORE AIRCRAFT TO SERVIC E

Perform necessary functional checks of interrupted systems per SMP 581, Figure 57

- 10

- 03, Step 39 and return aircraft to service.

NOTE: If assistance is needed, contact your local Lockheed Martin Aeronautics Company Representative, or

the Enterprise Operations Center

- Technical Support in Marietta, Georgia, USA, as follows:

TELEPHONE: (770) 494

- 9131

FAX: (770) 494

- 9122

E

- MAIL: hercules.support@lmco.com

MAIL: Lockheed Martin Aeronautics Company

86 South Cobb Drive Dept. 3E1M, Zone 0591 Marietta, GA 30063, USA

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Page 13 Eddy Current Surface Scan Inspection of Outer Wing Upper Rainbow Fitting Figure 1

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USE, COPYING, AND/OR DISCLOSURE IS GOVERN ED BY THE RESTRICTIV E LEGEND ON THE TITL E PAGE OF THIS DOCUM ENT. December 16 , 2013 Page 14 Eddy Current Surface Scan Inspection of Outer Wing Lower Rainbow Fitting Figure 2

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Page 15 Calibrated Lift

- Off and EDM Notch Responses for Eddy Current Surface Scan Figure 3

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### THIS PAGE INTENTIONA LLY LEFT BLANK

.

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Page 17 3. MATERIAL INFORMATION

The f ollow i ng parts/mat e ri a ls, requ i red to modify each aircraft listed in par a graph 1. A

., will be prov i ded by t h e aircraft owne r

/operat o r. Parts may be o b tained f rom L ockh e ed M a rtin A ero n auti c s C o m pany in accor d a n ce with para g ra p h 1

. F

.

NEW PART NUMBER QTY. PER

WING KEY WORD OLD P A R T N U MB E R INSTRUCTIONS/

DISPOSITION

3308183

- 9/

- 10 1 each Upper Surface Rainbow Fitting 3308183

- 3/

- 4 Note 1

3308183

- 9/

- 10 1 each Upper Surface Rainbow Fitting 3308183

- 9/

- 10 Note 2

3308182

- 9/

- 10 1 each Lower Surface Rainbow Fitting 3308182

- 3/

- 4 Note 1

3308182

- 9/

- 10 1 each Lower Surface Rainbow Fitting 3308182

- 9/

- 10 Note 2

NOTE: 1. Applies to outer wings originally installed on Serials* 45 4 2 thru 47 6 5

.

2. Applies to outer wings originally installed on Serials* 476 6 thru 5320

. * Outer wing serial number is indicated on the outer wing identification placard located on the rear beam web near OWS180

. _______#______

File: I

- 3 68 4

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 1 of A 7

APPENDIX A AUTOMATED BOLT HOLE EDDY CURRENT INSPECTION PROCEDURE

1. PRIM A RY NDI P ROCE D U R E

- AUTOMAT E D BOLT H O L E EDDY CURR E NT

NOT E : For sup p ort d ata and l o c a l l y manufact u r ed i t ems a n d a c c e pt a nce /r eje c ti o n c r it e r ia, refer t o t he

No n d e structi v e I n s p e ction ( N D I) P roced u res M an u al S upple m ent.

A. N D I Equi p m e nt:

(1) Eddy current instrument, Nortec 2000D/D+, or equivalent.

(2) Scanner , high

- speed, MiniMite, 4

- pin Fischer, Olympus P/N 9744738, or equivalent.

(3) Probe , bolt hole, shielded reflection (100 kHz

– 2 MHz), 3/16

- inch diameter (0.156

- 0.187), 4

- pin Fischer, Olympus SPO

- 5965, P/N 9230061, or equivalent

. (4) Probe , bolt hole, shielded reflection (100 kHz

– 2 MHz), 1/4

- inch diameter (0.218

- 0.250), 4

- pin Fischer, Olympus SPO

- 5965, P/N 9219980, or equivalent.

(5) Probe , bolt hole, shielded reflection (100 kHz

– 2 MHz), 5/16

- inch diameter (0.281

- 0.312), 4

- pin Fischer, O lympus SPO

- 5965, P/N 9219982, or equivalent.

(6) Probe , bolt hole, shielded reflection (100 kHz

– 2 MHz), 3/8

- inch diameter (0.312

- 0.375), 4

- pin Fischer, Olympus SPO

- 5965, P/N 9219982, or equivalent.

(7) Cable , scanner, high

- speed, 16

- pin Lemo, Olympus P/N 9122090, or equivalent.

(8) Cali b ration stand a r d

, alum i num

- VM P r od u cts, Inc. P / N VM308 8 9

- C1A or P/N VM30889

- C1A/AF,

or e qui v alent.

B. Prep a ration o f Part: R emove s e al a nt from t he f a s ten e r hol e s with a n y lon br i stled brush of t h e appro p riate d i ameter and an approved alcohol or solvent. Refer to the procedures detailed in the SMP 515

- C

- NDI Nondestructive Inspection Procedures Manual Supplement, Section 20

- 00

- 00 for cleaning of the holes to allow for a cceptab l e pr o be con t a c t wi t h t he part.

C. Equipm e nt C alibrati o n:

NOTE : Allow the instrument to warm

- up for a period of 10

- 15 minutes prior to performing the

inspection to minimize drifting of the signal.

(1) Connect the scanner, cable and the appropriate diameter probe to t he eddy current i n st r ument. Turn on the instrument and allow it to reach operating temperatures.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 2 (2) Adjust the ini t ial i n str u m ent s e t ti ng s on the equipment to the following :

MAIN MENU Frequency 1 ( FREQ ) 50 0 kHz (see Note #1) Frequency 2 ( FREQ ) Off Horizontal Gain ( H

- GAIN ) 55 dB Vertical Gain ( V

- GAIN ) 55 dB Phase Angle ( ANGLE ) 0°

FILTER MENU Low Pass Filter ( LP FILTER ) See Note #2 High Pass Filter ( HP FILTER ) See Note #2 Continuous Null ( CONT ) OFF

DISPLAY MENU Sweep Grid ( SWEEP ) OFF Vertical Screen Position ( V

- POS ) 50% Horizontal Screen Position ( H

- POS ) 50% P ersistence ( PERSIS ) OFF Display Erase Rate ( DIS ERASE ) 0.2 sec Grid Display ( GRATICLE ) ON Focal Spot Shape ( DOT/BOX ) DOT

SETUP MENU Frequency ( 1 ) SINGLE Probe Drive ( 4 ) HIGH Scanner Rotation Rate ( RPM ) 1300 Sync Angle ( SYNC ANG ) 0

NOTES :
1. The frequency may be adjusted within the 200

- 500 kHz range to maintain an improved signal response. Higher frequencies will result in greater sensitivity to surface defects; whereas, lower frequencies will result in reduce noise levels and better resolution of sub

- surfa ce defects.

2. When required, utilize the noted low pass and high pass filter settings for the following probe diameters:

1/8ʺ

- 7/32ʺ D. (0.156ʺ

- 0.219ʺ D.), LPF of 500 Hz, HPF of 150 Hz 7/32ʺ

- 5/16ʺ D. (0.219ʺ

- 0.312ʺ D.), LPF of 500 Hz, HPF of 200 Hz 5/16ʺ

- 7/16ʺ D. (0.312ʺ

- 0.437ʺ D.), LPF of 700 Hz, HPF of 300 Hz

(3) Turn on the scanner

. With the probe placed in the air, press t he NULL soft key on the instrument and wait for nulling to complete

. The null point on the impedance plane should be located at the screen center at 50% horizontal screen width (HSW) and 50% vertical screen height (VSH).

(4) Place the probe on the calibration standard, normal to the surface and away from any edges, holes

, or EDM notches as illustrated in Figure A1

. Generate an initial lift

- off response and verify the initial lift

- off has a narrow response as illustrated in Figure A1

. If a wide looped lift

- off is noted, press the V

- GAIN soft key and reduce the vertical gain until a flat line response is achieved.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 3 (5) If the lift

- off respon se is not horizontal, press the ANGLE soft key and adjust the phase angle until the lift

- off response is as near horizontal as possible

. See Figure A1 for an illustration of the expected phase adjusted lift

- off response.

(6) Inse r t the probe into t h e appropri ate diameter hole in the c a li b ration standard a dj a c e n t to the 0.030” X 0.030” n otch located at the Layer 1

- 2 interface (on calibration standard VM30889

- C1A or

– C1A/AF) or adjacent to the 0.030ʺx0.030ʺ notch on an equivalent standard.

(7) Maximize the notch res ponse on the impedance plane screen, press the H

- GAIN soft key and adju s t the horizontal notch response to 50% full screen width (FSW). Press the V

- GAIN soft key and adjust the vertical notch response to 50% full screen height (FSH). Confirm the notch

re sponse has a 45 degree angle and orientation from the upper left corner to the lower right corner of the impedance plane screen.

(8) Press the GAIN soft key and adjust the notch response until an 80% FSW and 80% FSH response is achieved. The notch response sh ould have a symmetric "Figure 8" pattern split above and below the lift

- off line/null point located at the 50% VSH location. The lift

- off noise, resulting from probe rotation or "chattering" in the hole should be maintained below 40% FSW. See Figure A2 f or the expected calibrated notch response and the acceptable limits for lift

- off noise.

NOTE : If a symmetric notch response cannot be achieved, slight adjustments (± 100 Hz) may be

made to the low

- pass and hi

- pass filter settings to improve symmetry of the notch response.

(9) The instrument is now properly calibrated for the impedance plane screen. No additional changes should be made to the phase setting from this point forward, unless a new calibration is being performed. Any additional changes to the phase angle will result in a change in lift

- off from the horizontal orientation earlier established.

(10) Press the DISPLAY soft key, then press the SWEEP soft key twice to enter SWEEP EXTRN mode.

NOTE : Instrument adjustment made at this time will only affect the sw eep screen notch response and

will have no effect on the impedance plane screen calibration.

(11) With the probe placed in the air, press the NULL soft key on the instrument, and wait for nulling to complete. The null baseline response on the sweep screen shou ld be located at the center of the instrument screen at the 50% VSH position.

(12) Turn the scanner on and reinsert the probe into the same hole in the calibration standard. Locate the 0.030” x 0.030” EDM notch and maximize the notch response on the sweep scre en.

(13) Press the GAIN soft key and adjust the notch response until an 80% FSH response is achieved

. The notch response should be symmetric above and below the null baseline and the noise level of the baseline should be below 20% FSH

. See Figure A2 for the e xpected calibrated notch response and the acceptable limits for baseline noise.

(14) The instrument is now calibrated for completion of the inspection requirements for the fastener holes within the diameter range of the probe being used.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 4 D. Inspection :

NOTE : The eddy cu r rent ins t rum e nt must be r e c a li b rated when pr o b e s are c h a ng e d.

(1) Ens u re i n strument is c alibra t ed as in a ccorda n ce with P a r a graph 1. C. Perform A BHEC s can o f all open h ol e s through all structural layers.

(2) To conf i rm suspected d a m age, c o nd u ct a red u nd a nt A B HEC b a ckup proc e d u re in accor d a n ce with P ara g ra p h 2.

E. Ma r k and r e p ort susp e cted de f e c t s

. If defects are suspected, proceed to the Backup NDI Procedure

. If no defects are suspected, complete the Primary NDI Procedure.

2. BACKUP NDI PROCEDURE

- REDUNDANT AUTOMAT E D BOLT HOLE EDDY CURR E NT

NOT E : For sup p ort d ata and l o c a l l y manufact u r ed i t ems a n d a c c e pt a nce /r eje c ti o n c r it e r ia, refer t o t he

No n d e structi v e I n s p e ction ( N D I) P roced u res M an u al S upple m ent.

A. ND I e q uipm e nt: Same as P rima r y N DI Proced u re.

B. Preparation o f air p lan e : Same as P ri m ary ND I P r ocedu r e.

C. Preparation o f pa r t: Re

- clean and/or hone the hole bore to remove any edge burrs, embedded metal at faying surfaces or mechanical damage that may have resulted in defect indications noted during the Primary NDI Procedure.

NOT E : The eddy current ins t rum e nt must be r e c a li b rated when pr o b e s are c h a ng e d.

D. Instrument se t tings/cal i brat i on: S et up and re

- cal i brate t he eddy cu r rent instru m ent as s p e cified i n the Primary NDI Procedure.

E. Inspection : R epe a t the Pr i mary N DI Pr o c e d ure

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 5 3

. MARK AND REPORT DAMAGE :

Re p ort any d amage d etec t ed by this inspecti o n pr o cedure to L o ck h eed M a rtin A ero n auti c s Com p any

. Provide the followi n g in f or m ation of all d a mage det e ct e d:

A. Aircraft S erial Numb e r

.

B. Outer Wi n g Flight Ho ur s ( or A ircraft Fl i ght Ho u rs if ou ter w i ng h o urs are u n k n ow n)

.

C. Part numb e r and d e script i on

.

D. Location ( Wi n g S ta t ion, Fu s el a ge S ta t ion ) and s p e cific faste n er h o le locati o n

.

E. Length

, d e pth, and ori e nta t ion of crack

.

NOTE : Prior to reporting any detected damage to Lockheed Martin Aeronautics Company, it is

recommended that a borescope inspection (side view lens) of the hole bores be performed to determine if the reported damage is due to fatigue cracking, embedded metal at faying surfaces

, or mechanical damage (gouging, reamer/drill marks, elongation) within the hole bore.

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 6 Typical Automated Bolt Hole Eddy Current Lift

- Off Signal Responses Figure A1

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USE, COPYING, AND/OR DISCLOSURE IS GOVERNED BY THE RESTRICTIVE LEGEND ON THE TITLE PAGE OF THIS DOCUMENT. Page A 7 Typical Impedance Plane and Sweep Display Signal Responses From 0.030" x 0.030" Notch Figure A2