# 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.

© 201 3 LOCKHEED MARTIN CORP ORATION. LOCKHEED M ARTIN PROPRIETARY IN FORMATION. 

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* REVISION NOTICE *

WINGS

- CENTER WING UPPER AN D LOWER RAINBOW FITT ING INSPECTION FOR CRACKS AND REPLACEMENT

Attached is Revision 6 , dat ed July 11, 2013

, to S ervice Bulletin 82

- 771 /382

- 57

- 82 . Information added or changed in this issue is indicated by a vertical revision bar in the outside margin of affected pages, or pointing hand for illustrations.

The 14 CFR Part 26, Subpart C Aging Aircraft Safety

- Widespread Fatigue Damage rul e became effective on January 14, 2011. In compliance 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 I nspection Programs. 14 CFR Part 121 or Part 129 operators must incorporate the LOV into their maintenance program by July 14, 2013 to comply with FAR §121.1115 or §129.115. This revision incorporates maintenance actions required for the center wing rainb ow fittings to safeguard the aircraft against widespread fatigue damage up to the LOV, which include updates to the initial and recurring inspection schedule.

This revision is a complete reissue and replaces Revision 5 of this S ervice Bulletin dat ed August 12 , 20 10

. Retain this notice with your copy of this Service Bulletin.

List of Previous Revisions and/or Reissues

Basic December 7, 200 4

Revision 1 ( R eissue) February 24, 2005

Revision 2 ( R eissue) February 15, 2007

Revision 3 ( R eissue) April 25, 2008
Revision 4 ( R eissue) May 20, 2009
Revision 5 (Reissue) August 12, 2010

___________#__________

File: I

- 2996R 6

# 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.

© 201 3 LOCKHEED MARTIN CORP ORATION. LOCKHEED M ARTIN PROPRIETARY IN FORMATION. 

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D ecember 7, 2004 

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- CENTER WING UPPER AN D LOWER RAINBOW FITTING INSPECTION FOR CRACKS AND REPLACEMENT

NOTE: T his Se rvice Bulletin contains Appendices A, B , and C

.

1. PLANNING INFORMATION

A. EFFECTIVITY

(1) 382

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- 82 , FAA Certificated Aircraft: This Service Bulletin is applicable to all model 382, 382B, 382E, 382F, and 382G series FAA Certificated Hercules aircraft (excluding 382 J series aircraft)

. (2) 82

- 771 , Foreign Direct Sales Aircraft: This Service Bulletin is applicable to all model 282, 382, 382C, and 382T series Hercules aircraft (ex cluding 382U and 382V series aircraft)

. (3) 82

- 771 , MAP/FMS/SAP Aircraft: This Service Bulletin is applicable to all model C

- 130 series Hercules aircraft (excluding C

- 130J Hercules aircraft).

B. REASON

(1) Fatigue cracking of the wing upper and lower rainbow fittin gs o n the durability test and on in

service aircraft indicates a requirement to perform inspections prior to the current published Hercules Airfreighter Series Progressive Inspection Procedures and Hercules Airfreighter Progressive Inspection Procedures in tervals. Analysis of in

- service cracking has shown that these fittings are susceptible to Multiple Site Damage (MSD) and a more frequent inspection is required to ensure that multiple adjacent node cracking does not occur resulting in an unacceptable redu ction in residual strength. Th is Service Bulletin identifies revised inspection intervals in order to reduce the probability of failure to an acceptably low level until such time as the wing joint fitting s are replaced consistent with the recommendations identified herein.

NOTE: The inspection intervals provided are subject to in dividual operator usage severity.

The intervals provided in this Service Bulletin are based on the Lockheed Martin Baseline Military and/or Commercial mission profiles and utilization rates. Operators who have completed a Lockheed Martin usage evaluation analysis may adjust the intervals provided in the S ervice B ulletin by the severity factors developed for their inspection programs.

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

- Widespread Fatigue Damage rule became effective on Ja nuary 14, 2011. In compliance 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 129 operators must incorporate the LOV into their maintenance program by July 14, 2013 to comply with FAR §121.1115 or §129.115. Revision 6 incorporates maintenance actions required for the center wing rainbow fittings to safeguard th e aircraft against widespread fatigue damage up to the LOV, which include updates to the initial and recurring inspection intervals.

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(3) Lockheed Martin Aeronautics Company recommends that the inspection specified herein be accomplished on all military aircraf t center wing s that have accumulated more than 1 0 ,000 Equivalent Baseline H ours (EBH) as determined from Service Bulletin 82

- 788 Paragraph 2.A. or from Lockheed Martin Aeronautics Company Operational Usage Evaluation in accordance with Service Bulletin 82

- 788, paragraph 2.B.(2). The initial inspection should be performed at the next convenient maintenance period but not to exceed 365 days or 6 00 flight hours, whichever occurs first, after receipt of this Service B ulletin. For center wings that have accumu lated 1 5,000 or more total EBH , Lockheed Martin Aeronautics Company recommends restricting the aircraft in accordance with Service Bulletin 82

- 788 Paragraph 2.B.(4) until the inspection is accomplished. For center wings that have accumulated 20,000 or more total E BH , Lockheed Martin Aeronautics Company recommends grounding the aircraft until the inspection is accomplished. Accomplishment of this inspection in accordance with the basic or R evision 1 of this Service Bulletin meets the intent of the i nitial inspection. Recurring inspection is recommended at 2,500 EBH for center wings with less than 25,000 total EBH and at 1 ,000 EBH for center wing that have

accu mulated 25,000 or more total EBH

. (4) For commercial operators, Lock h eed M a rtin A ero n aut i cs Co m p any recom me n d s inspections be completed as follows:

(a) The upper surface rainbow fitting inspection specified in Appendix A should be accomplished for commercial center wings that have accumulated 10,000 or more flight hours. The initial inspection 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. For center wings that have accumulated 20,000 or more flight hours, Lockheed Martin Aero nautics Company recommends grounding the aircraft until the inspection is accomplished. Accomplishment of this inspection in accordance with the basic or earlier revisions of this Service Bulletin meets the intent of the initial inspection. Recurring ins pection is recommended at 2,500 flight hours.

(b) The lower surface rainbow fitting insp e ction s p e cifi e d in Appendix B should be accompl i shed for commercial c e nter wings that ha v e a c c u mu l ated 1 5 ,000 or mo re fl i ght hours. The i n it i al inspecti o n should be p erfor m ed at the next con v enie n t maint e na n ce p e riod but not to exceed 36 5 days or 6 00 f light hou r s, wh i c h ev e r occurs f i r st, af t er r e c e ipt of this S erv i ce B ulletin. For cen te r w i ngs that ha v e accumulat e d 20,000 or m ore fl i ght ho ur s, Lo c kheed Martin A ero n auti c s Com p any re c omme n ds g roundi n g t he ai r c r aft un t il the ins p e c ti o n is accompl i she d

. A c c ompl i s h ment of this ins p e c t ion in acc o rdan c e with the bas i c or earlier revisions of t his Service B ulle t in mee t s the i ntent of the initial insp e ction. Recurri n g in s p e ction is rec o mmen d ed at 3,600 f light h ours.

(5) Lockheed Martin Aeronautics Company recommends that both upper and lower joint fittings be replaced on military aircraft at 25,0 00 EBH and on commercial aircraft at 30 ,000 flight hours. This will reset the EBH or flight hours to zero w i th respect to the inspection re quirements identified in this Service Bulletin

.

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Inspect center wing upper and lower rainbow fitting for cracks in accordance with Appendi c es A and B of this Service Bulletin. H ercules Airfreighter Progressive Inspection Procedures and Hercules Airfreighter Series Progressive Inspection Procedures work cards SP

- 176 ( upper fitting ) and SP

- 257 (lower fitting) meet the intent of this Service Bulletin

.

Rem ove installed upper and lower rainbow fitting . Prior to installation of a new rainbow fitting, an Automated Bolt Hole Eddy Current Inspection should be competed in accordance with Appendix C

. After all necessary repairs have been completed , install new rainbow fitting.

D. APPROVAL

(1) The aircraft owner/operator shall make an appropriate 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: www.lockheedmartin.com/eoc an d log into Data Li brary

.

E. MANPOWER

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 prepar ation of this Service Bulletin, but no consideration has been given to peculiar changes made to the aircraft by the owner/operator since its delivery.

The work prescribed in this Service Bulletin has not been performed at the Lockheed Martin facility exactly as described herein. The manpower estimates provided have not been validated and should not be construed as being acceptable for use in making fixed price quotes for accomplishment of the work. These estimates are provided only as a convenience f or aircraft owner/operator planning purposes. It is estimated that manhours required, crew size, and elapsed time while the aircraft is out of service are as follows:

TASK MANHOURS CREW SIZE ELAPSED TIME
Inspection Appendix A & B 24 2 12

Removal and Ins tallation of fitting 740 6 4 10
Inspection Appendix C 2 4 2 12

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USE, COPYING AND/OR DISCLOSURE IS GOVERNED BY THE STATEMENT ON THE TITLE PAGE OF THIS DOCUMENT. December 7, 2004 Page 4 Revision 6

, July 11, 2013 F. MATERIAL

- COST AND AVAILABILITY

Parts/Materials listed in paragraph 3 are to be supplied by the aircraft owner/operator.

Parts listed in paragraph 3 may also be purchased from Lockheed Martin, as noted, if desired. Direct inquiries concerning prices and availability to the following:

MAIL: Lockheed Martin Aeronautics Company

C

- 130 Commercial Contracts Depart ment F532 Zone 0195 86 South Cobb Drive Marietta, GA 30063

- 0195, USA

TELEPHONE: (770) 494

- 5165

FAX: (770) 494

- 7657

G. TOOLING

- PRICE AND AVAILABILITY

(1) For Appendix A :

 Eddy current inspection unit, Nortec 19e, or equivalent.

 Probe, shiel ded, right angle, 1/2

- inch drop, VM Products P/N VM202RA

- 1/2, or equivalent.

 Probe, pencil, surface, 1/8

- inch diameter

, Mu Metal shielded, stainless steel body , VM Products P/N VM200

- 3, or equivalent.

 Cable, 6 foot, Microdot connector, VM Products P/N VM99 BM, or equivalent.

 Calibration s tandard, aluminum, Lockheed Martin Aeronautics Company P/N PDL 457A as illustrated in Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 40

- 00 or equivalent.

(2) For Appendix B:

 Eddy Current Flaw Detector, Zetec P/N MIZ

- 20A, or equivalent.

 Probe, surface , right angle, 1/4

- inch drop, VM Products P/N VM202RA

- 1/4, or equivalent.

 Probe, pencil, surface, 1/8

- inch diameter, Mu Metal shielded, stainless steel body, VM Products P/N VM200

- 3, or equivalent.

 Cable, 6

- f oot Microdot connector, VM Products P/N VM99BM, or equivalent.

 Calibration standard, aluminum, Lockheed Martin Aeronautics Company P/N PDL 457A as illustrated in Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 40

- 00 or equivalent.

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(3) F or Removal and Installation of R ainbow F itting :

 3302624

- 16F Fixture to locate the New Joint Fitting.

 3302624

- L/R

- 18F Fixture to Mill the nodes of the new Joint Fitting.

 185R105

- 002A Router for milling the new Joint Fitting.

 446E101

- 015C Cutter for above router.

 730M200

- 004A Depth Micrometer.

 Jig Transit (with Optical micrometer)

(4) For Appendix C :

 Eddy current instrument

- Zetec MIZ

- 21A or equivalent

 Mini probe drive

- GE Inspection Technologies P/N 33A100 or equivalent

 Cable, MIZ

- 21 to mini probe drive

- Ze tec P/N 2100

- 03

- 04 or equivalent

 Probe, rotating hole, reflection type, 200 kHz to 2 MHz, 3/16”, 1/4”, and 5/16” diameter

- GE Inspection Technologies P/N 620

- 546

- 156 or equivalent

 Calibration standard, aluminum

- VM Products, Inc. P/N VM30889

- C1A or equiv alent (see F igure C1)

H. WEIGHT AND BALANCE

None.

I. REFERENCES

Nondestructive Inspection (NDI) Procedures Manual Supplement

(1) 382

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- 82 , F AA Certificated Aircraft :

Hercules Maintenance Manual Hercules Airfreighter Progressive Inspection Procedures

Service Bulletin 382

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- 84/ Wing

- Operational Usage Evaluation and Service Life Assessment

(2) 82

- 771, Fore ign Military Aircraft :

Hercules Maintenance Instructions Manual Hercules Airfreighter Series Progressive Inspection Procedures

Service Bulletin 82

- 788 / Wing

- Operational Usage Evaluation a nd Service Life Assessment

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(3) The following Lockheed Martin drawings may be needed for reference

DWG NO. DESCRIPTION A/C EFFECTIVITY

LM 398801 LWR Surface Instl 4314

- 5214

LM 398802 LWR Surface Assy 4314

- 5214 & MEP 12Y,4R,7W

LM 3333915 LWR Surface Instl 5215 & Subsequent

LM 3333917 LWR Surface Assy 5215 & Subsequent

LM 398803 UPR Surface Instl 4314

– 5305

LM 398804 UPR Surface Assy 4314

– 5214 & MEP 12Y,4R,7W

LM 3337184 UPR Surface Instl 5306 & Subsequent

LM 3333918 UPR Surface Assy 5215 & Subsequent

LM 398800 Center Wing Assy 4299

– 5509

LM 3356018 Center Wing Assy 5510 & Subsequent

LM 370500 Wing Joint Basic Dimension

J. OTHER PUBLICATIONS AFFECTED

Hercules Airfreighter Progressive Inspection Procedures Hercules Airfreighter Series P rogressive Inspection Procedure

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Revision 6, July 11, 2013 Page 7 2. ACCOMPLISHMENT INSTR UCTIONS

A. INITIAL INSPECTION

(1) This Service Bulletin changes the initial inspection in the Hercules Airfreighter Series Progressive Inspection Procedures to 10,000 Equivalent Baseline Hours (EBH) on military aircraft for cracks in center wing upper and lower rainbow fitting ( s ee Appendix A and Appendix B)

. (2) This Service Bulletin changes the initial inspection in the Hercules Airfreighter Progressive Inspection Procedu res for commercial aircraft to 10,000 flight hours for cracks in center wing upper rainbow fitting (see Appendix A) and 15,000 flight hours for cracks in center wing lower rainbow fitting (see Appendix B)

.

B. RECURRING INSPECTION

(1) This Service Bulletin changes the recurring inspection in the Hercules Airfreighter Series Progressive Inspection Procedures to 2,500 EBH on military aircraft with less than 25, 0 00 total EBH accumulated on the center wing and 1,000 EBH o n military ai rcraft that have accumulated 25,000 or more EBH total on the center wing

. (2) This Service Bulletin changes the recurring inspection in the Hercules Airfreighter Progressive Inspecti on Proc edures on commercial aircraft to 2,500 flight hours for the center wing upper rainbow fitting and 3,600 flight hours for the lower center wing rainbow fitting

.

C. REPLACEMENT OF WING JOINT FITTINGS

(1) This Service Bulletin recommends replacement of the upper and lower wing joint fittings in accordance with Hercules Maintenance Instructions Manual on military aircraft with more than 25,000 total EBH accumulated on the center wing

. (2) This Service Bulletin recommends replacement of the upper and lower wi ng joint fittings in accordance with Hercules Maintenance Manual on commercial aircraft with more than 30 ,000 total flight hours accumulated on the center wing.

(3) Preparation for Replacement

(a) Perform Alignment and Symmetry on Aircraft in accordance with SMP58 3 Structural Repair Manual, Chapter 51

- 100

- 00

. Retain this data for future reference.

(b) Remove Outer Wings using instructions in SMP581 Fig 57

- 10

- 03 or TM382C

- 2

- 1 Fig 7

- 4 and place wings on Cradle.

(c) Remove No. 2 and 3 E ngines including lower nacelles

. (d) Conduct a survey of the WS 220 center wing joint plane using a suitable optical transit

. Record any disparity in planarity between all nodes

. Ref drawings 398800 and 3356018. Conta ct L ockheed Martin Aeronautics Company if the four corner fittings are no t co

- planar within drawings requirements.

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(e) Removal of all components such as plumbing and wiring necessary to facilitate installation of joint fittings will be accomplished in area between WS 178 and WS 220.

(f) Remove as necessary or disconnect one end of the CWS 213 truss mount diagonal brace. Ref. Drawing (339166).

(g) Remove clips , four per side, common to the corner fittings, wing joint fittings, and skin. See F igure 1 depicting the removed upper rainbow fitting and connections.

(4) Upper Fitting Replacement

WARNING: REPLACE UPPER OR LOWER FITTI NGS ONE AT A TIME. RIGHT AND LEFT

SIDE MAY BE DONE SIMULTANEOUSLY.

(a) Remove upper fitting by removing attaching fasteners and breaking fay surface sealant. Use caution as to not damage wing structure and attach holes. See Figure 2 for illustrative view of uninstalled Rainbow fittings.

WARNING: EXERCISE CAUTION WHEN INSTALLING OR R EMOVING THE NEW FITTING

TO AND FROM THE WING

. AVOID APPLYING UNDUE FORCE DURING THIS PROCESS TO PREVENT C RACKING THE FITTING AND OTHER WI NG COMPONENTS

. (b) Clean wing attaching structure such as skin panels, stringers, corner fittings, attaching angles, and straps

, of sealant and other particles.

(c) Visually inspect the wing faying structure for possible damage or cracks and perform Automated Bolt Ho le Eddy Current inspection of all opened fitting attachment fastener holes in skins, stringers, straps, and angles while fitting is removed in accordance with Appendix C of this Service Bulletin

. (d) Place the new fitting in the wing

. Some amount of force may be required to properly align fitting. Reference D rawing 398804 or 3333918 Upper Surface Assy.

(e) Install P/N 3302624

- 16F ( Fig ure 3 ) locating fixture and attach it to the four corner fittings

. A shim of suitable size and thickness must be placed between th e fixture and each of the four corner fittings to allow the joint fitting nodes to protrude for final node milling to assure joint planarity

. All four shims must be the same thickness. Reference E ngineering D rawing 398800 or 3356018 for wing joint node thickness requirements

. All nodes of the rainbow fitting shall be tight against fixture before proceeding.

(f) Check all fitting to wing attaching fastener holes for proper edge distance (2 X Hole Dia meter nominal & 1 1/2 X Hole Dia meter min imum)

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

(h) Transfer all fastener holes from center wing mating structure to new joint fitting.

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(i) Remove the locating fixture and joint fitting from wing. Clean fitting and the su rrounding wing area for debris and burrs.

(j) Reposition the new joint fitting in the wing, picking up previously drilled holes

. Fay surface seal in accordance with SMP583 SRM.

(k) Wet install oversize fasteners of appropriate type per engineering drawing and SMP583 SRM.

(l) Install clips common to the corner fitting, wing joint fitting, and skin as shown on engineering drawing.

(5) Lower Fitting Replacement

(a) Remove lower fitting by removing attaching fasteners and breaking fay surface sealant

. Remove straps and angles common to the fitting, skin, and stringers

. Use caution as to not damage wing structure and attach holes.

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

WARNING: EXERCISE CAUTION WHE N INST ALLING OR REMOVING T HE NEW FITTING

TO AND FROM THE WING

. AVOID APPLYING UNDUE FORCE DURING THIS PROCESS TO PREVENT C RACKING THE FITTING AND OTHER WING COMPONENTS.

WARNING: VISUALLY INSPECT THE WING FAYING STRU CTURE FOR POSSIBLE

DAMAGE OR CRACKS AND PERFORM AUTOMAT ED BOLT HOLE EDDY CURRENT INSPECTION O F ALL OPENED FITTING ATTACHMENT FASTENER HOLES IN SK INS, STRINGERS, STRA PS, AND ANGLES WHILE FITTING IS REMOVED IN ACCORDANCE WITH A PPENDIX C OF THIS SERVICE BULLETIN.

(c) P lace the new fitting in the wing

. Some amount of force may be required to properly align fitting. Reference D rawing 398802 or 3333917 Lower Surface Assy for proper fit and installation.

(d) Install 3302624

- 16F ( Figure 3 ) 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 fittings to allow the joint fitting nodes to protrude for final node milling to assure joint planarity

. All four shims must be the same thickness. Reference engineering drawing 398800 or 3356018 for wing joint node thickness requirements

. All nodes of fitting shall be tight against fixture before proceeding.

(e) Check all fitting to wing attaching fastener holes for proper edge distance

. (2 X Hole Dia meter nominal & 1 1/2 X Hole Dia meter minimum)

(f) Visua lly check the new joint fitting for proper placement/alignment prior to drilling operations.

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(g) Transfer all remaining fastener holes from center wing mating structure to new joint fitting

(h) Remove the locating fixture, joint fitting, str aps, and angles from wing

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

(i) Reposition the new joint fitting, straps, and angles in the wing, picking up previously drilled holes. Fay surface seal in accordance with SMP583 SRM

. (j) Wet install oversize fasteners of appropriate type per engineering drawing and SMP583 SRM.

(k) Install clips common to the corner fitting, wing joint fitting, and skin

. (l) C ontinue to Fitting Node Procedures.

(6) Fitting Node Milling Procedure

(a) This step is required for m illing and optical procedures: Support the aircraft using nose and main landing gear jacks

. Mechanically lock jacks to avoid movement during machining

. Do not utilize wing jacks

. Shoring is required if jacks cannot be mechanically locked.

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

. Adjust the jacks 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 equipp ed with degrees of freedom that permit setting the 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 joint fitting node face protrusion

. Node thickness requirements are defined by E ngineering D rawing 398800 or 3356018.

(c) En sure that Ste p s 2.C.(6) (a) and 2.C.(6) (b) are accomplished before mil ling.

(d) Position M illing F ixture 3302624

- 18F Left or Right (Figure 4 ) to wing

. Using a proper router with micro depth adjustment (Ref: 185R105

- 002A), 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 398800 or 3356018 E ngineering D rawing

. Use router to mill each node.

(e) When replacing both joint fittings, continue the same procedure until all upper and lower nodes are m illed to the same plane as the corner f ittings

. Always cross check optically with transit.

(f) Remove milling fixture.

(g) Ream wing ma te holes to fina l size in accordance with E ngineering D rawing 3 70500.

(h) Touch up finish the milled nodes with MIL

- DTL

- 81706 per specification MIL

- C

- 5541 in accordance with E ngineering D rawing 398800 or 3356018.

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(7) Final Installation steps

(a) Re

- install lower nacelle, engines, outer wings, and any components removed to facilitate replacement of the wing joint fittings.

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

(c) Perform necessary fun ctional checks of d isturbed systems and return aircraft to service.

D. RESTORE AIRCRAFT TO SERVICE

NOTE: If assistance pertaining to this Service Bulletin or information regarding your Hercules aircraft

is needed, contact your local Lockheed Martin Aeronautics Company representative or the Enterprise Operations Center

- Technical Support in Marie tta, 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 Department 3E1M, Zone 0591 Marietta, GA 300 63

- 0591, USA

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Figure 1

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- 16F Attached To Center Wing Figure 3

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Milling Fixture For Replacement Of Upper And Lower Rainbow Fitting Figure 4

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.

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Revision 6

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The following parts/materials, required to modify each aircraft listed in paragraph 1.A., will be provided by the aircraft owner/operator. Parts may be obtained from Lockheed Martin Aeronautics Company in accordance with paragraph 1.F.

NEW PART NUMBER QUANTITY KEY WORD OLD PART NUMBER INSTRUCTIONS/

DISPOSITION

370517

- 11 /

- 12 1 each Upper Surface Wing Joint Fitting (1 )

398335

- 1 /

- 2 1 each Upper Surface Wing Joint Fitting (2 )

398335

- 3 /

- 4 1 each Upper Surface Wing Joint Fitting (3 )

370518

- 3/

- 4 1 each Lower Surface Wing Joint Fitting (1 )

398827

- 1 /

- 2 1 each Lower Surface Wing Joint Fitting (4 )

398827

- 3 /

- 4 1 each Lower Surface Wing Joint Fitting (5 )

NOTE: 1. Lockheed Martin S erial N umbers 4299, 4300, 4302, 4303, 4314 through 4322, and 4324.

2. Lockheed Martin S erial N umbers 4323, 4325 through 4937, and C enter W ing R eplacement MEPs 04R, 07R, 07W, and 12Y.

3. Lockheed Martin S erial N umbers 4301, 4938 and up.

4. Lockheed Martin S erial N umbers 4325 through 4637, and C enter W ing R eplacement MEPs 04R, 07R , 07W, and 12Y

5. Lockheed Martin S erial N umbers 4301, 4638 and up.

_______#____

_ __

File: I

- 2996R 6

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NDI CENTER WING UPPER RAINBOW FITTING ACCESS CUTOUTS, CWS 21 6 TO 219

1. Perform nondestructive inspection of the center wing upper surface wing joint (rainbow) fitting, left, and right, in access cutouts for wing attachment bolts at CWS 21 6 to CWS 219

. (See Figure A 1.)

NOTE: Both Primary and Back

- up Procedures are to be performed.

2. DESCRIPTION

. The upper surface wing joint (rainbow) fitting is fabricated from 7075

- T6 aluminum and f inished with a sulfuric acid anodize followed with a coating of integral fuel tank polyurethane

. The upper surface skin panels are attached to the rainbow fitting in the general inspection area with steel fasteners

. The thickness of the rainbow fitting t ang tapers from approximately 0.25 to 0.37 inches in the inspection area

. The inspection area is located at approximately CWS 21 6 to CWS 219 on the fore and aft sides of each

access cutout for the eleven (11) center wing attach bolts, right, and left wings.

3. DEFECTS

. Cyclic loading may cause fatigue cracks to begin in the attach bolt hole coun terbore and spot face area or along the edges of the outboard tapered portion of the bolt access cutout in the panel attachment tang and propagate in a chordwise direction.

4. PRIMARY NDI PROCEDURE

- EDDY CURRENT

.

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

Nondestructive Inspection (NDI) Procedures Manual Supplement.

A. NDI equipment:

(1) Eddy current inspection unit, Nortec 19e, or equivalent.

(2) Probe, s hielded

, right angle, 1/2

- inch drop, VM Products P/N VM202RA

- 1/2 , or equivalent.

(3) Probe, pencil , surface, 1/8

- inch diameter , Mu Metal shielded, stainless steel body , VM Products P/N VM200

- 3, or equivalent.

(4) Cable, 6 foot, Microdot connector, VM Products P/N VM99BM, or equivalent.

(5) Calibration Standard , aluminum

, Lockheed Martin Aeronautics Company P/N PDL 457A as illustrated in Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 40

- 00 or eq uivalent.

B. Preparation of airplane : Remove center wing upper surface Wing Joint Access cover on left and right wings in accordance with applicable maintenance instructions.

C. Access : Access to the upper wing surfaces may be accomplished using the Top Forward Emergency Exit or with appropriate maintenance stands

. Use safety restraint harnesses or other available safety equipment when working on top of the wings.

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USE, COPYING AND/OR DISCLOSURE IS GOVERNED BY THE STATEMENT ON THE TITLE PAGE OF THIS DOCUMENT. December 7, 2004 Page A 2 Revision 6, July 11, 2013 (Reissue) D. Preparation of part: Remove sealant, scaling paints, oil, and grease in th e inspection area using the procedures detailed in the Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 00

- 00.

E. Instrument settings/calibration: Set up and calibrate the eddy current i nstrument as specified in Nondestructive Insp ection (NDI) Procedures Manual Supplement, Section 20

- 10

- 04 for surface scan of Aluminum.

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

F. Inspection:

(1) Inspect the upper wing joint fittings at each attach bolt cutout along the compl ete accessible edge of the cutout from the aft radius area to the forward radius area as illustrated in Figure 1

. Use the surface probe to inspect along the accessible upper surface of the fitting tang along the edge of the cutout, starting at the edge of the wing panel overlap, proceeding outboard around the nose of the cutout, then inboard to the opposite wing panel overlap

. Use the right angle probe to inspect the interior edge at the fore and aft cutout radius areas

. Inspect eleven (11) cutouts on th e upper surface rainbow fitting on each left and right wings

. Use care when inspecting near steel fasteners in the inspection areas.

(2) A change in the CRT presentation as noted during calibration will indicate a probable crack in the part being inspected.

G. M ark and report suspected defects : P roceed to Backup NDI Procedure

.

5. BACKUP NDI PROCEDURE

- EDDY CURRENT

.

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

Nondestructive Inspection (NDI) Procedures Manual Supplement.

A. NDI equipment : Same as Primary NDI Procedure.

B. Preparation of airplane : Same as Primary NDI Procedure.

C. Access : Same as Primary NDI Procedure.

D. Preparation of part : Same as Primary NDI Procedure.

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Revision 6, July 11, 2013 (Reissue) Page A3 NOTE: The eddy current instrument must be recalibrated when probes are changed.

NOTE: A fluorescent penetrant inspection of the suspect area may be performed, but should not be

interpreted so as to rule out the possibility of a defect existing if no penetrant indication is visible

. Penetrant inspection should therefore be considered for this application only as a possible aid in locating and measuring the defect.

E. Instrument settings/calibration: Set up and calibrate the eddy current instrument as specified in Nondestructive Inspection (NDI) Procedures Manual Supplement, Section 20

- 10

- 04 for surface scan of aluminum.

WARNING: PENETRANT INSPECTION MATERIALS CAN INTROD UCE POTENTIAL FIRE A ND

HEALTH HAZARDS

. REFER TO SMP 515

- C

- NDI PROCEDURES MANUA L SUPPLEMENT SECTION 2 0

- 20

- 00 FOR SAFETY PRECAUTIONS.

F. Inspection : R ep eat the Primary NDI Procedure (eddy current scans)

. Use one of the methods outlined below.

(1) Preferred Method: Different inspector using a different instrument calibrated in accordance with Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 10

- 04.

(2) Alternate Method No.1: Different inspector using the same instrument re

- calibrated in accordance with Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 1 0

- 04.

(3) Alternate Method No.2: The same inspector , after a one hour delay, using the same instrument

re

- calibrated in accordance with Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 10

- 04.

G. Mark and report indicated defects

. If defec ts are indicated, take appropriate corrective action

. If no defects are indicated, proceed to System Securing.

6. SYSTEM SECURING

. Restore finishes and sealants, reinstall removed components, remove equipment and supplies from the inspection area, and perfo rm operational checkouts as required in accordance with applicable maintenance instructions.

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USE, COPYING AND/OR DISCLOSURE IS GOVERNED BY THE STATEMENT ON THE TITLE PAGE OF THIS DOCUMENT. December 7, 2004 Page A 4 Revision 6, July 11, 2013 Fig ure A 1. Upper Surface Wing Joint (Rainbow) Fitting, Attachment Bolt Access Cutouts ( Sheet 1 of 2)

Fig ure A 1. Upper Surface Wing Joint (Rainbow) Fitting, Attachment Bolt Access Cutouts ( Sheet 2 )

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- 257.

NDI OF CENTER WING LOWER SURFACE RAINBOW FITTING ACCESS CUTOUT , WS 2 16 TO 2 19

1. Perform nondestructive inspection of all nodes of the center wing lower surface rainbow fitting, both left and right side

. Fatigue cracks may initiate in the rainbow fitting at the lower surface panel and stringer attachment fastener hole s or i n the attac hment bolt counterbore and spot face areas

. Cracks will propagate in the fitting in a fore

- aft (chordwise) and/or vertical direction

. (See Figure B 1.) The most common location of cracking is from the outboard part of the bolt access cutout extending acr oss the horizontal face of the node then up the vertical scalloped area between nodes.

The material within the inspection area is 7075

- T6 aluminum.

NOTE: Both Primary and Back

- up Procedures are to be performed.

CAUTION: THE SAFETY NOTES AND PRECAUTIONS OF THE H ERCULES MAINTENANCE MANUAL A ND

NONDESTRUCTIVE INSPE CTION (NDI) PROCEDUR ES MANUAL SUPPLEMENT MUST BE COMPLIED WITH THROUG HOUT THE WORK DETAIL ED IN THIS WORK CARD

.

2. PRIMARY NDI PROCEDURE

- EDDY CURRENT

.

A. NDI equipment:

(1) Eddy Current Flaw Detector, Zetec P/N MIZ

- 20A

, or equivalent.

(2) Probe, surface, right angle, 1/4

- inch drop, VM Products P/N VM202RA

- 1/4, or equivalent.

(3) Probe

, pencil, surface, 1/8

- inch diameter , Mu Metal shielded, stainless steel body , VM Products P/N VM200

- 3, or equivalent.

(4) Cable , 6

- foot

, Microdot connector, VM Products P/N VM99BM, or equivalent.

(5) Calibration standard, aluminum, L ockheed Martin Aeronautics Company P/N PDL 457A as illustrated in Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 40

- 00 or equivalent.

CAUTION: ENSURE POWER IS ISOL ATED FROM ALL SYSTEM S IN THE INSPECTION AR EA

.

FAILURE TO ISOLATE P OWER MAY CAUSE PERSO NNEL INJURY AND AIRP LANE DAMAGE.

B. Preparation of airplane:

(1) Isolate power from all systems in the inspection area.

(2) Remove the lower surface wing joint access strip.

C. Access : Access to the center wing upper and lower surface is obtained with use of the appropriate maintenance stands.

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, July 11, 2013 D. Preparation of part: Remove sealant, scaling paints, oil, and grease in the inspection area using the procedures detailed in the Nondestructive Inspection (NDI) Procedures Manual Supplement Section 20

- 00

- 00.

E. Instrument settings/calibration : Set up and calibrate the eddy current instrument as specified in Nondestructive Inspection (NDI) Procedures manual Supplement, Section 2 0

- 10

- 04 for eddy current surface scanning of aluminum.

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

F. Inspection :
(1) Scan the entire exposed exterior surface of the rainbow fitting including the exposed radius area in the wing join t between nodes

. Scan in both an up and down direction as well as a forward and aft direction. (See Figu re B 1, V iew B.)

(2) Scan along the exposed edge of the rainbow fitting tang under the lower surface skin panel

. Scan in both an inboard and outboard dir ection as well as a forward and aft direction

. (See Figure B 1, V iew C.)

(3) Lockheed Martin Aeronautics Company recommend s two inspectors for this procedure: one to perform the surface scan and the other to monitor the display. Any signal, as noted when scanning notches during calibration, will indicate a probable crack in the part being inspected.

G. Mark and report suspected defects

. Proceed to Backup NDI Procedure

.

3. BACKUP NDI PROCEDURE

- EDDY CURRENT

.

A. NDI equipment : Same as the Primary NDI Procedure.

B. Preparation of airplane : Same as the Primary NDI Procedure.

C. Access : Same as the Primary NDI Procedure.

D. Preparation of part : Same as the Primary NDI Procedure.

E. Instrument settings/calibration : Same as the Primary NDI Procedure.

F. Inspection : In order to verify suspect defects repeat the Primary NDI Procedure using one of the methods outlined below.

(1) Preferred Method : Different inspector using different eddy current equipment.

NOTE: The eddy current instrument must be recali brated before reinspection

. (2) Alternate Method No. 1 : Different inspector using the same eddy current equipment.

(3) Alternate Method No. 2 : The same inspector using the same eddy current equipm ent after a

one

- hour delay.

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Revision 6, July 11, 2013 Page B 3 G. Mark and report confirmed defects : Co mplete the Primary NDI Procedure and then go to System Securing.

4. SYSTEM SECURING

. Restore finishes and sealants; remove equipment and supplies from the inspection area; reinstall removed components; and perform operational checkouts as required.

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Figu re B 1. Inspection of Center Wing Lower Surface Rainbow Fitting ( Sh eet 1 of 2 )

Figure B 1. Inspection of Center Wing Lower Surface Rainbow Fitting ( Sheet 2 )

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Revision 6

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SPLICE ANGLES WITH RAINBOW FITTING REMOVED

1. The purpose of this inspection is to verify the fastener holes in the upper and lower surface skin panel, stringers, splice straps a nd splice angles that are common to the rainbow fittings are free of defects/damage prior to installing the new

. After removal of the rainbow fitting and prior to installing the new rainbow fitting, perform the Primary Inspection procedure.

2. PRIMARY PROCEDURE

. AUTOMATED BOLT HOLE EDDY CURRENT

A. NDI Equipment:

(1) Eddy current instrument

- Zetec MIZ

- 21A or equivalent

(2) Mini probe drive

- GE Inspection Technologies P/N 33A100 or equivalent

(3) Cable, MIZ

- 21 to mini probe drive

- Zetec P/N 2100

- 03

- 04 or equivalent

(4) Probe, rotating hole, reflection type, 200 kHz to 2 MHz, 3/16”, 1/4”, and 5/16” diameter

- GE Inspection Technologies P/N 620

- 546

- 156 or equivalent

(5) Calibration standard , aluminum

- VM Products, Inc. P/N VM30889

- C1A or equivalent (see F igure C1)

B. Preparation of Part: R emove sealant from the fastener hole(s) with a nylon bristled brush of the appropriate diameter as necessary for acceptable probe contact with the part.

C. Access : Use appropriate maintenance stands to gain access to the inspection area.

D. Equipment Calibration:

(1) Turn the instrument on.

(2) Connect the cable to the instrument.

(3) Connect the mini probe drive to the cable.

(4) Insert the appropriate diameter probe into the mini probe drive.

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(5) Use t he following initial instrument settings:

FREQ 500K

PRB REFL HI

PRB GAIN 85

MODE X

- Y

V SCALE 0.2

H SCALE 0.4

FILTER DIFF 01

SCREEN SET AUTOCLEAR 0

(6) Press the BAL button to null the instrument.

(7) Using the rocker switch on the probe controller, turn the rotating probe gun to the ON position at the slower of the two available speeds.

(8) Insert the probe coil into the calibration standard ( P/N VM30889

- C1A ) adjacent to the 0.030” X 0.030” notch at the to p of the appropriate diameter fastener hole. Adjust the PRB GAIN and PHASE to obtain a signal as shown in F igure C2.

(9) Change MODE to TRG SWP and press the BAL button to null the instrument.

NOTE: It may be necessary to rotate the position of the probe controller to obtain a similar signal

position as shown in F igure C3.

(10) With the rotati ng probe coil still held adjacent to the 0.030” X 0.030” notch at the top of the appropriate diameter fastener hole , adjust PRB GAIN

, V SCALE

, H SCALE, and PHASE to obtain a signal height of approximately 98% as shown in F igure C3.

E. I nspection :

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

(1) Ensure instrument is calibrated as in accordance wit h P aragraph D. Perform ABHEC scan of all open holes in the upper and lower skin panels, stringers, attach angles and straps.

(2) To confirm suspected damage, conduct a redundant ABHEC backup procedure in accordance with P aragraph F.

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Revision 6, July 11, 2013 Page C 3 F. Redundant Inspection (for confirmation only):

(1) Inspector Verification

(a) Wrong alignment

1 Reset and recalibrate the same equipment. The same inspector repeats the inspection. If crack is confirmed, complete the verification outlined below.

(b) Verification

1 Preferred Metho d

– Different inspector repeats the inspection using the same equipment, after resetting and recalibrating the equipment.

2 Alternate Method No. 1

– Inspector re

- inspects the area with an appropriate alternate method.

G. Mark and Report Damage:

(1) Report any damage detected by this inspection procedure to Lockheed Martin Aeronautics Company. Provide the following information of all damage detected:

(a) Aircraft Serial Number

(b) Center Wing Flight Hours (or Aircraft Flight Hours if center wing hours is unknown)

(c) Cente r Wing Equivalent Baseline Hours (EBH) calculated in accordance with Service Bulletin 82

- 788.

(d) Part number and description

(e) Location (Wing Station, Fuselage Station), and specific fastener hole location

(f) Length , depth and orientation of crack

(2) Refer to the Hercules Structural Repair Manual SMP 583 for repair instructions. Contact Lockheed Martin Aeronautics Company if the damage exceeds the repair limits defined in the Structural Repair Manual :

Telephone: (770) 494

- 9131

Fax: (770) 494

- 9122

E

- Mail: hercules.support@lmco.com

Mail: Lockheed Martin Aeronautics Company 86 South Cobb Drive Department 3E1M, Zone 0591 Marietta, GA 30063

- 0591, USA

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Figure C1

- General Purpose Eddy Current Calibration Standard 7075

- T6 Aluminum

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Revision 6, July 11, 2013 Page C 5

Figure C2

- Typical X

- Y Signal Response from 0.030” X 0.030” Notch

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Figure C3

- Typical Time

- based Signal Response from 0.030” X 0.030” Notch

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Revision 6, July 11, 2013 Page C 7 Figure C4

- Lift

- off and Notch Signals