TO 1-1-691

TO 1-1-691TECHNICAL MANUAL

CLEANING AND CORROSION PREVENTIONAND CONTROL,

AEROSPACE AND NON-AEROSPACE EQUIPMENT

F42620-00-D-0038FA8501-07-F-A080

This manual incorporates Interim Operational Supplement, TO 1-1-691 S-3, dated 29 October 2020.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number PA04-11-96. Other requests for thisdocument shall be referred to 406 SCMS/GUEE. Questions concerning technical content shall be referred to AFLCMC/EZPT-CPCO.

Published Under Authority of the Secretary of the Air Force

2 NOVEMBER 2009 CHANGE 18 - 22 FEBRUARY 2021

BASIC AND ALL UPDATES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . .2 November 2009Change . . . . . . . . 1. . . . . . .12 April 2010Change . . . . . . . . 2 . . . . . . . 11 May 2011Change . . . . . . . . 3. . . . .15 January 2013Change . . . . . . . . 4. . . . . .14 March 2013Change . . . . . . . . 5 . . . . . . 5 August 2013Change . . . . . . . . 6 . . . . 17 February 2014Change . . . . . . . . 7 . . . . . . . 29 May 2014Change . . . . . . . . 8 . . . . . . . 11 July 2014Change . . . . . . . . 9 . . . . 4 December 2014

Change . . . . . . . 10. . . . .14 January 2015Change . . . . . . . 11 . . . . . . . . 2 July 2015Change . . . . . . . 12. . . . . .1 January 2016Change . . . . . . . 13 . . . . 20 February 2016Change . . . . . . . 14 . . . . . . . 13 July 2017Change . . . . . . . 15 . . . . . . . 30 June 2018Change . . . . . . . 16 . . .29 September 2018Change . . . . . . . 17. . . .8 November 2019Change . . . . . . . 18 . . . . 22 February 2021

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 402, CONSISTING OF THE FOLLOWING:

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Title . . . . . . . . . . . . . . . . . . . . . 18A - B. . . . . . . . . . . . . . . . . . . . 18C Blank. . . . . . . . . . . . . . . . . . . .6i . . . . . . . . . . . . . . . . . . . . . . . . 17ii. . . . . . . . . . . . . . . . . . . . . . . .11iii - viii. . . . . . . . . . . . . . . . . . .16ix . . . . . . . . . . . . . . . . . . . . . . . 11x Blank . . . . . . . . . . . . . . . . . . . 11xi - xii . . . . . . . . . . . . . . . . . . . 17xiii - xiv . . . . . . . . . . . . . . . . . . 11xv. . . . . . . . . . . . . . . . . . . . . . .18xvi . . . . . . . . . . . . . . . . . . . . . . 17xvii Deleted . . . . . . . . . . . . . . . . 11xviii Deleted. . . . . . . . . . . . . . . .151-1 . . . . . . . . . . . . . . . . . . . . . . . 31-2 . . . . . . . . . . . . . . . . . . . . . . 142-1 - 2-7. . . . . . . . . . . . . . . . . . .02-8 . . . . . . . . . . . . . . . . . . . . . . . 22-9 - 2-11. . . . . . . . . . . . . . . . . .02-12 . . . . . . . . . . . . . . . . . . . . . 172-12.1 Added . . . . . . . . . . . . . . . 172-12.2 Blank. . . . . . . . . . . . . . . .172-13 - 2-20 . . . . . . . . . . . . . . . . . 03-1 . . . . . . . . . . . . . . . . . . . . . . . 33-2 . . . . . . . . . . . . . . . . . . . . . . 143-2.1 - 3-2.2 Deleted. . . . . . . . . .143-3 - 3-6. . . . . . . . . . . . . . . . . .143-7 - 3-8. . . . . . . . . . . . . . . . . .153-9 - 3-11. . . . . . . . . . . . . . . . . .53-12 . . . . . . . . . . . . . . . . . . . . . 183-13 . . . . . . . . . . . . . . . . . . . . . . 53-14 . . . . . . . . . . . . . . . . . . . . . . 03-15 . . . . . . . . . . . . . . . . . . . . . . 13-16 . . . . . . . . . . . . . . . . . . . . . . 03-17 - 3-19 . . . . . . . . . . . . . . . . . 53-20 . . . . . . . . . . . . . . . . . . . . . . 23-21 - 3-24 . . . . . . . . . . . . . . . . . 5

3-25 - 3-28 . . . . . . . . . . . . . . . . . 03-29 . . . . . . . . . . . . . . . . . . . . . 103-30 - 3-36 . . . . . . . . . . . . . . . . . 03-37 . . . . . . . . . . . . . . . . . . . . . . 53-38 . . . . . . . . . . . . . . . . . . . . . . 63-39 . . . . . . . . . . . . . . . . . . . . . 153-40 . . . . . . . . . . . . . . . . . . . . . . 53-41 . . . . . . . . . . . . . . . . . . . . . . 03-42 - 3-43 . . . . . . . . . . . . . . . . . 53-44 - 3-45 . . . . . . . . . . . . . . . . . 03-46 - 3-48 . . . . . . . . . . . . . . . . 133-48.1 - 3-48.2 Added. . . . . . . . . .23-49 . . . . . . . . . . . . . . . . . . . . . . 63-50 . . . . . . . . . . . . . . . . . . . . . . 03-51 . . . . . . . . . . . . . . . . . . . . . . 53-52 - 3-53 . . . . . . . . . . . . . . . . . 03-54 - 3-55 . . . . . . . . . . . . . . . . . 53-56 - 3-57 . . . . . . . . . . . . . . . . . 03-58 - 3-59 . . . . . . . . . . . . . . . . 103-60 - 3-63 . . . . . . . . . . . . . . . . . 53-64 . . . . . . . . . . . . . . . . . . . . . . 04-1 . . . . . . . . . . . . . . . . . . . . . . . 34-2 . . . . . . . . . . . . . . . . . . . . . . . 04-3 - 4-4. . . . . . . . . . . . . . . . . . .74-4.1 Added . . . . . . . . . . . . . . . . .74-4.2 Blank . . . . . . . . . . . . . . . . . 74-5 - 4-14. . . . . . . . . . . . . . . . . .04-15 . . . . . . . . . . . . . . . . . . . . . 104-16 - 4-18 . . . . . . . . . . . . . . . . . 05-1 - 5-11. . . . . . . . . . . . . . . . . .05-12 . . . . . . . . . . . . . . . . . . . . . . 55-13 - 5-15 . . . . . . . . . . . . . . . . . 05-16 . . . . . . . . . . . . . . . . . . . . . 135-17 - 5-26 . . . . . . . . . . . . . . . . . 05-27 . . . . . . . . . . . . . . . . . . . . . . 55-28 . . . . . . . . . . . . . . . . . . . . . . 35-29 . . . . . . . . . . . . . . . . . . . . . . 0

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TO 1-1-691

LIST OF EFFECTIVE PAGESINSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins ofthe page. Changes to illustrations are indicated by shaded or screened areas, or by miniaturepointing hands.

* Zero in this column indicates an original page.

A Change 18 USAF

8-12 - 8-13 . . . . . . . . . . . . . . . . . 38-14 . . . . . . . . . . . . . . . . . . . . . . 58-14.1 Added . . . . . . . . . . . . . . . . 38-14.2 Blank . . . . . . . . . . . . . . . . 38-15 . . . . . . . . . . . . . . . . . . . . . . 18-16 . . . . . . . . . . . . . . . . . . . . . . 58-16.1 Added . . . . . . . . . . . . . . . . 18-16.2 Blank . . . . . . . . . . . . . . . . 18-17 . . . . . . . . . . . . . . . . . . . . . . 08-18 Blank. . . . . . . . . . . . . . . . . .09-1 - 9-3. . . . . . . . . . . . . . . . . .149-4 Blank . . . . . . . . . . . . . . . . . . 010-1 Added . . . . . . . . . . . . . . . . . 410-2 . . . . . . . . . . . . . . . . . . . . . . 510-3 Added . . . . . . . . . . . . . . . . . 410-4 Blank. . . . . . . . . . . . . . . . . .4A-1. . . . . . . . . . . . . . . . . . . . . .15A-2 - A-9. . . . . . . . . . . . . . . . . .0A-10. . . . . . . . . . . . . . . . . . . . . .5A-11 - A-12 . . . . . . . . . . . . . . . . 0A-13 - A-14 . . . . . . . . . . . . . . . 18A-14.1 Added. . . . . . . . . . . . . . .18A-14.2 Blank . . . . . . . . . . . . . . . 18A-15 . . . . . . . . . . . . . . . . . . . . . 14A-16 - A-19 . . . . . . . . . . . . . . . . 0A-20 - A-21 . . . . . . . . . . . . . . . 10A-22 - A-54 . . . . . . . . . . . . . . . . 0A-55 - A-57 . . . . . . . . . . . . . . . . 5A-58 Blank . . . . . . . . . . . . . . . . . 0B-1 . . . . . . . . . . . . . . . . . . . . . . 15B-2 - B-18 . . . . . . . . . . . . . . . . . 0B-19 . . . . . . . . . . . . . . . . . . . . . . 2B-20 . . . . . . . . . . . . . . . . . . . . . 18B-20.1. . . . . . . . . . . . . . . . . . . .18B-20.2 Blank . . . . . . . . . . . . . . . . 2B-21 - B-27 . . . . . . . . . . . . . . . . 0B-28 - B-30 . . . . . . . . . . . . . . . . 8B-30.1 - B-30.3 Added . . . . . . . . . 8B-30.4 Blank . . . . . . . . . . . . . . . . 8B-31 - B-41 . . . . . . . . . . . . . . . . 0B-42 . . . . . . . . . . . . . . . . . . . . . . 2B-43 . . . . . . . . . . . . . . . . . . . . . 15B-44 - B-45 . . . . . . . . . . . . . . . . 0B-46 Blank . . . . . . . . . . . . . . . . . 0Glossary 1 - Glossary 4 . . . . . . . . 0Index 1 . . . . . . . . . . . . . . . . . . . 18Index 2 - Index 4. . . . . . . . . . . .17Index 4.1 Added . . . . . . . . . . . . . . 9Index 4.2 Blank . . . . . . . . . . . . . . 9Index 5 - Index 7. . . . . . . . . . . .17Index 8 . . . . . . . . . . . . . . . . . . . 18Index 8.1 - Index 8.2 Deleted . . . . 5Index 9 . . . . . . . . . . . . . . . . . . . 17

Index 10 Blank. . . . . . . . . . . . . .17Index 11 - Index 14 Deleted . . . . . 5

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TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . vii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . viii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . xi

SAFETY SUMMARY . . . . . . . . . . . . . . . . . 0

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1

1.1 CORROSION CONTROLPROGRAM. . . . . . . . . . . . . . . 1-1

1.1.1 Training . . . . . . . . . . . . . . . . . . . 1-11.1.2 Maintenance . . . . . . . . . . . . . . . . 1-11.1.3 Facilities . . . . . . . . . . . . . . . . . . . 1-11.2 SAFETY. . . . . . . . . . . . . . . . . . . 1-11.2.1 Responsibility of Supervisors . . . . . 1-11.2.2 Materials Handling . . . . . . . . . . . . 1-11.3 MATERIALS . . . . . . . . . . . . . . . 1-2

2 CORROSION THEORY . . . . . . . . . . . . . . . 2-1

2.1 INTRODUCTION TO CORRO-SION THEORY . . . . . . . . . . . . 2-1

2.2 DEFINITION OFCORROSION . . . . . . . . . . . . . 2-1

2.3 CHEMICAL DEFINITIONS . . . . . 2-12.3.1 Atom . . . . . . . . . . . . . . . . . . . . . 2-12.3.2 Electron . . . . . . . . . . . . . . . . . . . 2-12.3.3 Ions . . . . . . . . . . . . . . . . . . . . . . 2-12.3.4 Electrolyte. . . . . . . . . . . . . . . . . . 2-12.4 THEORY OF CORROSION . . . . . 2-12.4.1 Anode . . . . . . . . . . . . . . . . . . . . 2-12.4.2 Cathode . . . . . . . . . . . . . . . . . . . 2-12.4.3 Electrolyte. . . . . . . . . . . . . . . . . . 2-12.4.4 Electrical Contact . . . . . . . . . . . . . 2-12.5 DEVELOPMENT OF

CORROSION . . . . . . . . . . . . . 2-22.5.1 Corrosion Under Painted

Surfaces . . . . . . . . . . . . . . . . . 2-22.6 FACTORS INFLUENCE

CORROSION . . . . . . . . . . . . . 2-22.6.1 Type of Metal . . . . . . . . . . . . . . . 2-22.6.2 Dissimilar Metal Coupling (Galvanic

Corrosion). . . . . . . . . . . . . . . . 2-22.6.3 Anode and Cathode Surface

Area. . . . . . . . . . . . . . . . . . . . 2-32.6.4 Temperature . . . . . . . . . . . . . . . . 2-42.6.5 Heat Treatment and Grain

Direction. . . . . . . . . . . . . . . . . 2-42.6.6 Electrolytes . . . . . . . . . . . . . . . . . 2-42.6.7 Oxygen. . . . . . . . . . . . . . . . . . . . 2-52.6.8 Electrolyte Concentration. . . . . . . . 2-5

Chapter Page

2.6.9 Biological Organisms . . . . . . . . . . 2-52.6.10 Mechanical Stress. . . . . . . . . . . . . 2-52.6.11 Time . . . . . . . . . . . . . . . . . . . . . 2-52.7 TYPES OF CORROSION . . . . . . . 2-52.7.1 Uniform Surface Corrosion . . . . . . 2-52.7.2 Galvanic Corrosion. . . . . . . . . . . . 2-52.7.3 Pitting Corrosion . . . . . . . . . . . . . 2-62.7.4 Intergranular Corrosion . . . . . . . . . 2-62.7.5 Exfoliation Corrosion . . . . . . . . . . 2-62.7.6 Crevice/Concentration Cell

Corrosion . . . . . . . . . . . . . . . . 2-62.7.7 Corrosion Fatigue. . . . . . . . . . . . . 2-82.7.8 Filiform Corrosion . . . . . . . . . . . . 2-82.7.9 Fretting Corrosion . . . . . . . . . . . . 2-102.7.10 High Temperature Oxidation (Hot

Corrosion). . . . . . . . . . . . . . . . 2-112.8 METALS AFFECTED BY

CORROSION . . . . . . . . . . . . . 2-112.8.1 Magnesium . . . . . . . . . . . . . . . . . 2-112.8.2 Steel. . . . . . . . . . . . . . . . . . . . . . 2-122.8.3 Aluminum. . . . . . . . . . . . . . . . . . 2-122.8.4 Anodized Aluminum. . . . . . . . . . . 2-122.8.5 Titanium . . . . . . . . . . . . . . . . . . . 2-122.8.6 Copper and Copper Alloys. . . . . . . 2-132.8.7 Cadmium . . . . . . . . . . . . . . . . . . 2-162.8.8 CRES/Stainless Steel . . . . . . . . . . 2-162.8.9 Nickel and Chromium. . . . . . . . . . 2-162.8.10 Silver, Platinum, and Gold. . . . . . . 2-162.8.11 Graphite/Carbon Fiber

Composites . . . . . . . . . . . . . . . 2-162.9 CORROSIVE

ENVIRONMENTS. . . . . . . . . . 2-162.9.1 Moisture . . . . . . . . . . . . . . . . . . . 2-162.9.2 Temperature . . . . . . . . . . . . . . . . 2-172.9.3 Salt Atmospheres . . . . . . . . . . . . . 2-172.9.4 Ozone . . . . . . . . . . . . . . . . . . . . 2-172.9.5 Other Industrial Pollutants . . . . . . . 2-172.9.6 Sand, Dust, and Volcanic Ash. . . . . 2-182.9.7 Solar Radiation . . . . . . . . . . . . . . 2-182.9.8 Climate. . . . . . . . . . . . . . . . . . . . 2-182.9.9 Factors of Influence in Tropical

Environments . . . . . . . . . . . . . 2-182.9.10 Manufacturing . . . . . . . . . . . . . . . 2-192.9.11 Storage . . . . . . . . . . . . . . . . . . . . 2-192.9.12 Shipment . . . . . . . . . . . . . . . . . . 2-192.9.13 Industrial and Ship Emitted Air

Pollutants . . . . . . . . . . . . . . . . 2-192.9.14 Animal Damage . . . . . . . . . . . . . . 2-192.9.15 Microorganisms . . . . . . . . . . . . . . 2-192.10 DEGRADATION OF

NON-METALS . . . . . . . . . . . . 2-202.11 PREVENTIVE

MAINTENANCE. . . . . . . . . . . 2-20

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Chapter Page

3 PREVENTIVE MAINTENANCE . . . . . . . . . 3-1

SECTION I INTRODUCTION. . . . . . . . . . . 3-1

3.1 PREVENTIVE MAINTENANCEPROGRAM. . . . . . . . . . . . . . . 3-1

3.1.1 Preventive Maintenance. . . . . . . . . 3-1

SECTION II CLEANING . . . . . . . . . . . . . . 3-6

3.2 INTRODUCTION . . . . . . . . . . . . 3-63.2.1 Reasons for Cleaning . . . . . . . . . . 3-63.2.2 When to Accomplish Work . . . . . . 3-73.2.3 Aircraft Clear Water Rinse (CWR)

Requirements. . . . . . . . . . . . . . 3-73.2.4 Immediate Cleaning . . . . . . . . . . . 3-83.2.5 Deployed Aircraft Wash

Requirements. . . . . . . . . . . . . . 3-83.3 CLEANING COMPOUNDS . . . . . 3-93.3.1 Alkaline Cleaners . . . . . . . . . . . . . 3-93.3.2 Solvent Emulsion and Aqueous

Cleaners for Turbine Engine GasPath and General AreaCleaning . . . . . . . . . . . . . . . . . 3-10

3.3.3 Aqueous Parts Washer CleaningSolutions. . . . . . . . . . . . . . . . . 3-10

3.3.4 Solvents . . . . . . . . . . . . . . . . . . . 3-113.3.5 Miscellaneous Cleaning Agents . . . 3-113.3.6 Steam Cleaning . . . . . . . . . . . . . . 3-123.3.7 Dilution . . . . . . . . . . . . . . . . . . . 3-123.4 CLEANING EQUIPMENT . . . . . . 3-293.4.1 High Pressure/Hot Water Wash

Equipment. . . . . . . . . . . . . . . . 3-293.4.2 Portable, 15 Gallon, Foam Generat-

ing, Cleaning Unit . . . . . . . . . . 3-293.4.3 Portable, 45 Gallon, Foam Generat-

ing Cleaning Unit. . . . . . . . . . . 3-323.4.4 Turbine Engine Compressor Clean-

ing Equipment . . . . . . . . . . . . . 3-333.4.5 Miscellaneous Large Cleaning

Equipment. . . . . . . . . . . . . . . . 3-333.4.6 Spray Cleaning Guns for

Solvents . . . . . . . . . . . . . . . . . 3-333.4.7 Pneumatic Vacuum Cleaner . . . . . . 3-333.4.8 Universal Wash Unit . . . . . . . . . . . 3-333.4.9 Aqueous Parts Washers . . . . . . . . . 3-343.4.10 Miscellaneous Equipment . . . . . . . 3-353.5 CLEANING PROCEDURES . . . . . 3-363.5.1 Warnings and Cautions . . . . . . . . . 3-363.5.2 Cleaning Methods . . . . . . . . . . . . 3-393.5.3 Clear Water Rinsing of Aircraft . . . 3-463.5.4 Post Cleaning Procedures . . . . . . . 3-463.5.5 Treatment and Disposal of Wash

Rack Waste . . . . . . . . . . . . . . . 3-473.5.6 Fungus Growth Removal . . . . . . . . 3-47

Chapter Page

3.5.7 Soil Barriers . . . . . . . . . . . . . . . . 3-48.23.5.8 Bird Strike Cleaning . . . . . . . . . . . 3-493.5.9 Bodily Fluids Contamination

Cleanup . . . . . . . . . . . . . . . . . 3-51

SECTION III LUBRICATION . . . . . . . . . . . 3-53

3.6 INTRODUCTION . . . . . . . . . . . . 3-533.6.1 Conventional Lubricants . . . . . . . . 3-533.6.2 Solid Film Lubricants . . . . . . . . . . 3-543.6.3 Application of Conventional

Lubricants . . . . . . . . . . . . . . . . 3-54

SECTION IV PRESERVATION . . . . . . . . . . 3-56

3.7 INTRODUCTION . . . . . . . . . . . . 3-563.7.1 Operational Preservation . . . . . . . . 3-563.7.2 Non-Operational Preservation. . . . . 3-563.7.3 Types of CPC’s . . . . . . . . . . . . . . 3-563.7.4 Time Limitations of CPC’s . . . . . . 3-573.7.5 Description of CPC’s . . . . . . . . . . 3-573.7.6 Preservation of Specific Areas . . . . 3-643.7.7 Preservation Application

Methods . . . . . . . . . . . . . . . . . 3-643.8 APPLICATION OF POLISH AND

WAX . . . . . . . . . . . . . . . . . . . 3-64

4 INSPECTION AND CORROSION PRONEAREAS. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SECTION I INSPECTION . . . . . . . . . . . . . 4-1

4.1 Purpose . . . . . . . . . . . . . . . . . . . 4-14.1.1 Responsibility . . . . . . . . . . . . . . . 4-14.1.2 Frequency of Inspections . . . . . . . . 4-14.1.3 General Inspections . . . . . . . . . . . 4-14.1.4 Detailed Inspections . . . . . . . . . . . 4-14.2 INSPECTION METHODS. . . . . . . 4-14.2.1 Visual inspection . . . . . . . . . . . . . 4-14.2.2 Depth Gauge . . . . . . . . . . . . . . . . 4-24.2.3 Visual Inspection with a

Borescope/Videoscope. . . . . . . . 4-34.2.4 Optical Depth Micrometers . . . . . . 4-34.2.5 Fluorescent Penetrant

Inspection . . . . . . . . . . . . . . . . 4-54.2.6 Eddy Current Inspection . . . . . . . . 4-64.2.7 Ultrasonic Inspection . . . . . . . . . . 4-64.2.8 Radiographic Inspection . . . . . . . . 4-64.3 EVALUATION OF CORROSION

DAMAGE. . . . . . . . . . . . . . . . 4-64.4 DEGREES OF CORROSION . . . . 4-64.4.1 Light Corrosion . . . . . . . . . . . . . . 4-94.4.2 Moderate Corrosion . . . . . . . . . . . 4-94.4.3 Severe Corrosion . . . . . . . . . . . . . 4-9

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

ii Change 11

Chapter Page

SECTION II CORROSION PRONE AREAS . 4-9

4.5 COMMON AREAS . . . . . . . . . . . 4-94.5.1 Fasteners. . . . . . . . . . . . . . . . . . . 4-94.5.2 Faying Surfaces and Crevices. . . . . 4-94.5.3 Spot Welded Assemblies . . . . . . . . 4-94.5.4 Engine Exhaust and Gun Gas Im-

pingement Areas . . . . . . . . . . . 4-104.5.5 Wheel Wells and Landing Gear . . . 4-104.5.6 Flap and Slat Recesses . . . . . . . . . 4-114.5.7 Engine Frontal Areas and Air Inlet

Ducts . . . . . . . . . . . . . . . . . . . 4-114.5.8 Wing/Fin-Fold Joints and Wing and

Control Surface LeadingEdges . . . . . . . . . . . . . . . . . . . 4-14

4.5.9 Hinges . . . . . . . . . . . . . . . . . . . . 4-144.5.10 Control Cables. . . . . . . . . . . . . . . 4-144.5.11 Relief Tube Outlets. . . . . . . . . . . . 4-144.5.12 Water Entrapment Areas . . . . . . . . 4-144.5.13 Bilge Areas . . . . . . . . . . . . . . . . . 4-144.5.14 Battery Compartments and Battery

Vent Openings . . . . . . . . . . . . . 4-144.5.15 Magnesium Parts . . . . . . . . . . . . . 4-154.5.16 Electrical Connectors and Other

Components . . . . . . . . . . . . . . 4-15

4 CORROSION REMOVAL AND SURFACETREATMENT . . . . . . . . . . . . . . . . . . . . 4-0

SECTION I CORROSION REMOVAL . . . . . 5-1

5.1 PURPOSE. . . . . . . . . . . . . . . . . . 5-15.2 RESPONSIBILITY. . . . . . . . . . . . 5-15.3 CORRECTIVE ACTIONS. . . . . . . 5-15.4 PAINT REMOVAL. . . . . . . . . . . . 5-15.5 CORROSION REMOVAL. . . . . . . 5-15.5.1 Mechanical Methods . . . . . . . . . . . 5-25.5.2 Non-Powered Tools and

Materials. . . . . . . . . . . . . . . . . 5-25.5.3 Power Tools and Materials. . . . . . . 5-45.5.4 Abrasive Blasting . . . . . . . . . . . . . 5-75.6 SURFACE FINISH. . . . . . . . . . . . 5-115.7 PITTING ON CRITICAL

STRUCTURE . . . . . . . . . . . . . 5-115.8 CORROSION REMOVAL

PROCEDURES-MECHANICAL 5-115.8.1 Warnings and Cautions . . . . . . . . . 5-115.8.2 Non-Powered Mechanical Corrosion

Removal . . . . . . . . . . . . . . . . . 5-145.8.3 Powered Mechanical Corrosion

Removal . . . . . . . . . . . . . . . . . 5-155.8.4 Abrasive Blasting Corrosion

Removal . . . . . . . . . . . . . . . . . 5-155.9 CORROSION

REMOVAL-CHEMICAL. . . . . . 5-17

Chapter Page

5.9.1 Aluminum Alloys . . . . . . . . . . . . . 5-175.9.2 Magnesium Alloys . . . . . . . . . . . . 5-205.9.3 Ferrous Metal (Steel) Alloys Other

Than Stainless Steels(CRES). . . . . . . . . . . . . . . . . . 5-21

5.9.4 Stainless Steel (CRES) and NickelBased Alloys . . . . . . . . . . . . . . 5-26

5.9.5 Copper and Copper BasedAlloys . . . . . . . . . . . . . . . . . . 5-30

5.9.6 Titanium and Titanium BasedAlloys . . . . . . . . . . . . . . . . . . 5-32

5.9.7 Plated and Phosphated Surfaces . . . 5-33

SECTION II SURFACE TREATMENT . . . . . 5-36

5.10 PURPOSE. . . . . . . . . . . . . . . . . . 5-365.10.1 Chemical Prepaint Treatments . . . . 5-365.10.2 Surface Preparation. . . . . . . . . . . . 5-385.10.3 Precautions . . . . . . . . . . . . . . . . . 5-385.10.4 Application of Surface

Treatments . . . . . . . . . . . . . . . 5-395.10.5 Notes on Conversion Coating/Sur-

face Treatment . . . . . . . . . . . . . 5-405.10.6 Post Treatment. . . . . . . . . . . . . . . 5-405.10.7 Temporary Preservation. . . . . . . . . 5-41

SECTION III SHOT PEENING . . . . . . . . . . 5-42

5.11 REQUIREMENTS FOR SHOTPEENING. . . . . . . . . . . . . . . . 5-42

5.12 SHOT PEENING OF METALSURFACES. . . . . . . . . . . . . . . 5-42

5.12.1 Types of Peening . . . . . . . . . . . . . 5-425.12.2 Shot Peening Application. . . . . . . . 5-43

SECTION IV ROTO-PEENING. . . . . . . . . . 5-43

5.13 ROTO-PEENING (ROTARY FLAPPEENING) . . . . . . . . . . . . . . . 5-43

5.13.1 Roto-Peening Procedures . . . . . . . . 5-445.13.2 Determining Peening/Intensity . . . . 5-455.13.3 Peening Process Preparation. . . . . . 5-465.13.4 Post Peening Surface Finish . . . . . . 5-46

6 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 PURPOSE. . . . . . . . . . . . . . . . . . 6-16.2 APPLICATIONS . . . . . . . . . . . . . 6-16.3 SEALING COMPOUNDS. . . . . . . 6-16.3.1 Sealant Packaging . . . . . . . . . . . . 6-16.3.2 Polysulfide, Polyurethane, and Poly-

thioether SealingCompounds . . . . . . . . . . . . . . . 6-1

6.3.3 Silicone Sealing Compounds . . . . . 6-2

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Change 16 iii

Chapter Page

6.3.4 Adhesion Promoters . . . . . . . . . . . 6-26.3.5 SAE AMS 3255 Oil and Water Re-

sistant, Expanded Polytetrafluoro-ethylene Sealing Tape (EPTFE)Skyflex . . . . . . . . . . . . . . . . . . 6-2

6.3.6 Av-Dec® Polyurethane SealantTapes and Two ComponentSealants . . . . . . . . . . . . . . . . . 6-2

6.4 EQUIPMENT . . . . . . . . . . . . . . . 6-26.4.1 Sealant Gun. . . . . . . . . . . . . . . . . 6-26.4.2 Application Nozzles . . . . . . . . . . . 6-36.4.3 Injection Gun . . . . . . . . . . . . . . . 6-36.4.4 Sealant Kits (Semkits®) . . . . . . . . 6-36.4.5 Sealant Removal and Application

Tools . . . . . . . . . . . . . . . . . . . 6-36.5 SEALANT MIXING. . . . . . . . . . . 6-36.5.1 Application Life. . . . . . . . . . . . . . 6-36.5.2 Storage Instructions . . . . . . . . . . . 6-46.5.3 Mixing MIL-PRF-81733, Type III

Sprayable Sealant Coating . . . . . 6-56.6 SEALANT APPLICATION

PROCEDURES . . . . . . . . . . . . 6-226.6.1 Cleaning . . . . . . . . . . . . . . . . . . . 6-226.6.2 Masking . . . . . . . . . . . . . . . . . . . 6-226.6.3 Adhesion Promoters . . . . . . . . . . . 6-256.6.4 Brush Spatula or Caulking Gun

Application . . . . . . . . . . . . . . . 6-256.6.5 Spray Gun Application . . . . . . . . . 6-266.6.6 Peel and Stick Application; SAE

AMS 3255 EPTFE Skyflex® andAv-Dec® HT3935-7 and HT3000Sealing Tapes . . . . . . . . . . . . . 6-26

6.7 SEALING OF SPECIFICAREAS . . . . . . . . . . . . . . . . . 6-27

6.7.1 Faying Surface Sealing . . . . . . . . . 6-276.7.2 Fillet Sealing . . . . . . . . . . . . . . . . 6-286.7.3 Injection Sealing . . . . . . . . . . . . . 6-286.7.4 Fastener Sealing. . . . . . . . . . . . . . 6-296.7.5 Integral Fuel Cells/Tanks and Re-

movable Fuel Tanks . . . . . . . . . 6-296.7.6 Form-In-Place (FIP) Gasket Sealant

Repair . . . . . . . . . . . . . . . . . . 6-296.7.7 SAE AMS 3255 EPTFE (Skyflex®)

and Av-Dec® HT3000 andHT3935-7 Sealing Tape GasketRepair . . . . . . . . . . . . . . . . . . 6-30

6.7.8 External Aircraft Structure . . . . . . . 6-316.7.9 Depressions . . . . . . . . . . . . . . . . . 6-316.7.10 Damaged Sealant . . . . . . . . . . . . . 6-316.7.11 Extensive Repair . . . . . . . . . . . . . 6-326.7.12 High Temperature Areas . . . . . . . . 6-326.7.13 Low Temperature Curing. . . . . . . . 6-326.8 STORAGE/SHELF LIFE CON-

TROL OF SEALANTS . . . . . . . 6-32

Chapter Page

7 TREATMENT OF SPECIFIC AREAS . . . . . . 7-1

7.1 INTRODUCTION . . . . . . . . . . . . 7-17.2 BATTERY COMPARTMENTS,

BOXES, AND ADJACENTAREAS . . . . . . . . . . . . . . . . . 7-1

7.2.1 Preparation of Solutions for Clean-ing and Neutralizing BatteryElectrolytes . . . . . . . . . . . . . . . 7-1

7.2.2 Cleaning and NeutralizingProcedures . . . . . . . . . . . . . . . 7-2

7.2.3 Paint Systems . . . . . . . . . . . . . . . 7-27.3 RELIEF TUBE AREAS . . . . . . . . 7-27.4 CORROSION TREATMENT FOR

STEEL CABLES . . . . . . . . . . . 7-37.5 PIANO TYPE HINGES . . . . . . . . 7-37.6 INTEGRAL AND EXTERNAL

FUEL TANKS AND DROPTANKS . . . . . . . . . . . . . . . . . 7-3

7.6.1 Corrosion Removal and Rework ofPitted Areas of Integral FuelTanks . . . . . . . . . . . . . . . . . . . 7-3

7.6.2 Removal of Corrosion and Reworkof Aluminum External FuelTanks/Drop Tanks. . . . . . . . . . . 7-4

7.7 FAYING SURFACES AND AT-TACHMENT POINTS . . . . . . . 7-5

7.7.1 Faying Surfaces, Joints, andSeams . . . . . . . . . . . . . . . . . . 7-5

7.7.2 Attaching Parts and Hardware . . . . 7-57.7.3 Severely Corroded (Rusted)

Hardware . . . . . . . . . . . . . . . . 7-67.8 NATURAL AND SYNTHETIC

RUBBER PARTS. . . . . . . . . . . 7-77.9 POTABLE WATER TANKS . . . . . 7-77.10 SURFACES AND COMPONENTS

EXPOSED TO EXHAUSTGASES, GUN GASES, ANDROCKET BLAST . . . . . . . . . . 7-7

7.11 ELECTRICAL AND ELECTRONICEQUIPMENT . . . . . . . . . . . . . 7-7

7.11.1 Grounding and BondingConnections. . . . . . . . . . . . . . . 7-7

7.11.2 Conduit and Junction Boxes. . . . . . 7-77.11.3 Wires and Cables . . . . . . . . . . . . . 7-77.11.4 Deleted. . . . . . . . . . . . . . . . . . . . 7-77.11.5 Moisture and Fungus Proofing of

Electrical and ElectronicEquipment. . . . . . . . . . . . . . . . 7-7

7.11.6 Antennas. . . . . . . . . . . . . . . . . . . 7-77.12 STRUCTURAL TUBING MEM-

BERS AND ASSEMBLIES . . . . 7-8

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iv Change 16

Chapter Page

7.12.1 Structural Aluminum AlloyTubing . . . . . . . . . . . . . . . . . . 7-8

7.12.2 Structural Magnesium AlloyTubing . . . . . . . . . . . . . . . . . . 7-8

7.12.3 Structural Copper Alloys, StainlessSteel (CRES) Alloys, and HeatResistant Alloy Tubing . . . . . . . 7-8

7.12.4 Structural Carbon Steel Tubing. . . . 7-87.13 NON-STRUCTURAL TUBING

MEMBERS ANDASSEMBLIES. . . . . . . . . . . . . 7-8

7.13.1 Aluminum Alloy Tubing . . . . . . . . 7-87.13.2 Stainless Steel (CRES) Tubing . . . . 7-97.13.3 Cadmium Plated Steel Tubing . . . . 7-107.13.4 Special Instructions for Tubing Fit-

tings and Sleeves . . . . . . . . . . . 7-107.13.5 Removable Installations. . . . . . . . . 7-107.14 CORROSION REMOVAL FROM

THIN METAL (0.0625 INCHTHICKNESS AND LESS). . . . . 7-11

7.15 AIR INTAKE DUCTS FOR JETAIRCRAFT. . . . . . . . . . . . . . . 7-11

7.16 CLOSELY COILED SPRINGS . . . 7-117.17 CORROSION PREVENTION ON

ASSEMBLIES AND PARTS RE-MOVED FROM AIRCRAFTDURING MAINTENANCE, 30DAY SHORT TERM STORAGE,AND OVER 30 DAY LONGTERM STORAGEREQUIREMENTS . . . . . . . . . . 7-11

7.17.1 Short Term Storage. . . . . . . . . . . . 7-117.17.2 Long Term Storage. . . . . . . . . . . . 7-127.18 DEPLETED URANIUM

COUNTERWEIGHTS. . . . . . . . 7-127.18.1 Corrosion and Finish Damage Treat-

ment Procedures. . . . . . . . . . . . 7-137.19 MONEL RIVETS. . . . . . . . . . . . . 7-147.20 BERYLLIUM-COPPER ALLOYS,

BERYLLIUM-ALUMINUM AL-LOYS, AND BERYLLIUMOXIDE. . . . . . . . . . . . . . . . . . 7-14

7.20.1 Corrosion Removal andTreatment . . . . . . . . . . . . . . . . 7-14

7.20.2 Depot Maintenance. . . . . . . . . . . . 7-147.21 EMI SEALS AND GASKETS . . . . 7-157.21.1 Treatment of EMI Seals and

Gaskets. . . . . . . . . . . . . . . . . . 7-15

8 EMERGENCY PROCEDURES . . . . . . . . . . 8-1

8.1 PURPOSE. . . . . . . . . . . . . . . . . . 8-18.2 RESPONSIBILITY. . . . . . . . . . . . 8-18.3 EMERGENCY

PREPARATIONS . . . . . . . . . . . 8-1

Chapter Page

8.3.1 Priority Removal List of Equipmentand/or Components. . . . . . . . . . 8-1

8.3.2 Emergency Reclamation Team . . . . 8-28.3.3 Emergency Reclamation

Equipment. . . . . . . . . . . . . . . . 8-28.3.4 Production Planning . . . . . . . . . . . 8-28.4 GENERAL PROCEDURES . . . . . . 8-2.18.4.1 Removal of Contaminated Installed

Equipment. . . . . . . . . . . . . . . . 8-88.4.2 Disassembly/Removal of

Components . . . . . . . . . . . . . . 8-88.4.3 Clean . . . . . . . . . . . . . . . . . . . . . 8-88.4.4 Tagging . . . . . . . . . . . . . . . . . . . 8-88.5 GENERAL CLEANING

PROCEDURES . . . . . . . . . . . . 8-88.5.1 Primary Method . . . . . . . . . . . . . . 8-98.5.2 Alternate Methods . . . . . . . . . . . . 8-98.5.3 Removing Fire Extinguishing Pow-

der (O-D-1407 Potassium Bicar-bonate [Purple K{PKP}], SodiumBicarbonate, Ammonium Phos-phate Monobasic) and/or OtherDry Chemical Agents . . . . . . . . 8-10

8.5.4 Removing MIL-F-24385 AqueousFilm Forming Foam (AFFF) FireExtinguishing Agent and OtherSynthetic Based Foaming AgentsIncluding High-Expansion (Hi-Ex) Foams . . . . . . . . . . . . . . . 8-10

8.5.5 Removal of Carbon Dioxide (CO2),HFC-125, Halon and 3MNOVEC 1230 Fire ExtinguishingAgents . . . . . . . . . . . . . . . . . . 8-11

8.5.6 Removal of Protein Type Foam andSoda-Acid Fire ExtinguishingAgents . . . . . . . . . . . . . . . . . . 8-11

8.5.7 Treatment After Landing on aFoamed Runway . . . . . . . . . . . 8-11

8.5.8 Treatment After Exposure to Volca-nic Ash. . . . . . . . . . . . . . . . . . 8-11

8.6 SPECIFIC INTERNALAREAS . . . . . . . . . . . . . . . . . 8-12

8.6.1 Aircraft Cockpit Area . . . . . . . . . . 8-128.6.2 Aircraft Ejection Seats . . . . . . . . . 8-128.6.3 Avionic, Electronic, and Electrical

Equipment. . . . . . . . . . . . . . . . 8-138.6.4 Photographic Equipment . . . . . . . . 8-138.6.5 Graphite or Carbon Fiber/Epoxy,

Boron Fiber/Epoxy, and TungstenFiber/Epoxy CompositeMaterials. . . . . . . . . . . . . . . . . 8-13

8.7 SPECIFIC EXTERNAL AREAS OFAIRCRAFT. . . . . . . . . . . . . . . 8-14

8.7.1 Airframes . . . . . . . . . . . . . . . . . . 8-148.7.2 Antennas. . . . . . . . . . . . . . . . . . . 8-14

TO 1-1-691


Change 16 v

Chapter Page

8.7.3 Reciprocating Engines. . . . . . . . . . 8-148.7.4 Turbine Engines . . . . . . . . . . . . . . 8-158.7.5 Treatment for Engines Which Have

Ingested Fire Extinguishing Pow-der (Potassium Bicarbonate[Purple K{PKP}], Sodium Bicar-bonate, Ammonium PhosphateMonobasic) and/or SyntheticFoaming Agents (AFFF, Hi-Ex,AR) . . . . . . . . . . . . . . . . . . . . 8-15

8.7.6 Helicopter Transmission, RotorHead, and Rotor Hub . . . . . . . . 8-16

8.7.7 Helicopter Main and Tail RotorBlades . . . . . . . . . . . . . . . . . . 8-16

8.7.8 Armament . . . . . . . . . . . . . . . . . . 8-168.7.9 Aircraft Fuel Systems . . . . . . . . . . 8-17

9 SOUTHWEST ASIA ENVIRONMENTS . . . . 9-1

9.1 INTRODUCTION . . . . . . . . . . . . 9-19.1.1 Climatic Conditions . . . . . . . . . . . 9-19.1.2 Aircraft Wash . . . . . . . . . . . . . . . 9-19.1.3 Aircraft Clear Water Rinse

(CWR) . . . . . . . . . . . . . . . . . . 9-19.1.4 Effects of Desert Environment . . . . 9-19.2 PRE-DEPLOYMENT

RECOMMENDATIONS . . . . . . 9-19.3 RECOMMENDED ACTIONS

WHILE DEPLOYED . . . . . . . . 9-29.3.1 High Efficiency Particulate Air

(HEPA) Filtration . . . . . . . . . . . 9-29.3.2 Areas to be Checked and

Cleaned . . . . . . . . . . . . . . . . . 9-29.4 POST DEPLOYMENT . . . . . . . . . 9-39.5 CORROSION PREVENTIVE

COMPOUNDS (CPC’s) . . . . . . 9-39.5.1 Recommended CPC’s . . . . . . . . . . 9-3

10 REMOTELY PILOTED AIRCRAFT CORRO-SION PREVENTION . . . . . . . . . . . . . . . 10-1

10.1 REMOTELY PILOTED AIRCRAFT(RPA). . . . . . . . . . . . . . . . . . . 10-1

10.1.1 Definition . . . . . . . . . . . . . . . . . . 10-1

Chapter Page

10.2 CORROSION CONTROLPROGRAM. . . . . . . . . . . . . . . 10-1

10.3 CARBON FIBER COMPOSITESAND CORROSION . . . . . . . . . 10-1

10.3.1 Corrosion Concerns . . . . . . . . . . . 10-110.3.2 Moisture Absorption . . . . . . . . . . . 10-210.4 CORROSIVE

ENVIRONMENTS. . . . . . . . . . 10-210.5 APPROVED CLEANING

COMPOUNDS . . . . . . . . . . . . 10-210.5.1 MIL-PRF-87937, Type IV and MIL-

PRF-85570, Type II . . . . . . . . . 10-210.5.2 MIL-PRF-87937, Type III and MIL-

PRF-85570, Type V . . . . . . . . . 10-210.5.3 A-A-59921 (Formerly MIL-C-

43616), Class 1A EmulsionCleaner. . . . . . . . . . . . . . . . . . 10-2

10.6 AIRCRAFT CLEANING. . . . . . . . 10-210.6.1 Frequency of Cleaning . . . . . . . . . 10-310.6.2 Wipe Down or Spot Cleaning. . . . . 10-3

APPENDIX A CONSUMABLEMATERIALS. . . . . . . . . . . . . . . . . . . . . . A-1

A.1 INTRODUCTION . . . . . . . . . . . . A-1A.1.1 Shelf Life . . . . . . . . . . . . . . . . . . A-1A.1.2 Consumable Materials

Containers. . . . . . . . . . . . . . . . A-1A.1.3 Local Purchase . . . . . . . . . . . . . . A-1A.1.4 Local Environmental Laws and

Regulations . . . . . . . . . . . . . . . A-1A.1.5 Unit of Issue Codes . . . . . . . . . . . A-1

APPENDIX B EQUIPMENT FOR CLEAN-ING AND CORROSION PREVENTIONAND CONTROL . . . . . . . . . . . . . . . . . . . B-1

B.1 INTRODUCTION . . . . . . . . . . . . B-1B.1.1 Unit of Issue Codes . . . . . . . . . . . B-1

GLOSSARY . . . . . . . . . . . . . . . . . . . . . Glossary 1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

TO 1-1-691


vi Change 16

LIST OF ILLUSTRATIONS

Number PageTitle

2-1 Simplified Corrosion Cell . . . . . . . . . . . 2-22-2 Elimination of Corrosion by Application

of an Organic Film to a MetalSurface . . . . . . . . . . . . . . . . . . . . . . 2-3

2-3 Effect of Sea Water on GalvanicCorrosion . . . . . . . . . . . . . . . . . . . . 2-3

2-4 Galvanic Corrosion in a FlashlightBattery . . . . . . . . . . . . . . . . . . . . . . 2-4

2-5 Effect of Area Relationship in DissimilarMetal Contacts . . . . . . . . . . . . . . . . . 2-4

2-6 Galvanic Corrosion of Magnesium Adja-cent to a Steel Fastener . . . . . . . . . . . 2-5

2-7 Pitting of an Aluminum WingAssembly . . . . . . . . . . . . . . . . . . . . 2-6

2-8 Cross-Section of Corrosion Pits . . . . . . . 2-62-9 Cross-Section of 7075-T6 Aluminum

Alloy . . . . . . . . . . . . . . . . . . . . . . . 2-72-10 Grain Structure of a Corroding Aluminum

Surface . . . . . . . . . . . . . . . . . . . . . . 2-72-11 Intergranular Corrosion of 7075-T6 Alumi-

num Adjacent to Steel Fastener. . . . . . 2-72-12 Example of Exfoliation . . . . . . . . . . . . . 2-72-13 Another Example of Exfoliation . . . . . . . 2-72-14 Concentration Cell Corrosion . . . . . . . . . 2-92-15 Stress Corrosion Cracking . . . . . . . . . . . 2-92-16 Galvanic Series of Metals and Alloys in

Sea Water . . . . . . . . . . . . . . . . . . . . 2-102-17 Filiform Corrosion Found Under Paint

Coating on a Magnesium Panel. . . . . . 2-112-18 Schematic of the Development of Filiform

Corrosion on an Aluminum Alloy . . . . 2-112-19 Magnesium Corrosion Products. . . . . . . . 2-122-20 Steel Corrosion Products (Rust) . . . . . . . 2-132-21 Aluminum Surface Corrosion

Products . . . . . . . . . . . . . . . . . . . . . 2-142-22 Cadmium Plated Surface Conditions . . . . 2-152-23 Failed Chromium Plating . . . . . . . . . . . . 2-173-1 Foam Generating Cleaning Unit (15

Gallons) . . . . . . . . . . . . . . . . . . . . . 3-303-2 Foam Generating Cleaning Unit (45

Gallons) . . . . . . . . . . . . . . . . . . . . . 3-313-3 Universal Wash Unit . . . . . . . . . . . . . . . 3-323-4 Top Loading Type . . . . . . . . . . . . . . . . 3-363-5 Front Loading Type . . . . . . . . . . . . . . . 3-363-6 Use of Aircraft Washing Applicator . . . . . 3-403-7 Aircraft Cleaning Procedure . . . . . . . . . . 3-413-8 Automatic Water Spray Nozzle . . . . . . . . 3-444-1 Depth Dimension of Corrosion Pits . . . . . 4-44-2 Fiber Optic Borescope. . . . . . . . . . . . . . 4-44-3 Optical Depth Micrometer (Analog Me-

chanical Read Out Type) . . . . . . . . . . 4-74-4 Optical Depth Micrometer (Digital Read

Out Type) . . . . . . . . . . . . . . . . . . . . 4-8

Number PageTitle

4-5 Typical Use of a Straight Edge to Deter-mine if Suspect Areas Have Been Pre-viously Reworked . . . . . . . . . . . . . . . 4-9

4-6 Corrosion Around Fasteners . . . . . . . . . . 4-104-7 Galvanic Corrosion of Aluminum Adjacent

to Steel Fasteners . . . . . . . . . . . . . . . 4-104-8 Spot Weld Corrosion . . . . . . . . . . . . . . . 4-114-9 Spot Welded Skin Corrosion

Mechanism . . . . . . . . . . . . . . . . . . . 4-114-10 Gun Blast Area Corrosion Points. . . . . . . 4-124-11 Exhaust Trail Area Corrosion Points . . . . 4-124-12 F-15 Nose Landing Gear Wheel Well . . . 4-124-13 Flaps Lowered to Expose Recess

Areas . . . . . . . . . . . . . . . . . . . . . . . 4-124-14 Reciprocating Engine Frontal Area Corro-

sion Points. . . . . . . . . . . . . . . . . . . . 4-134-15 Jet Engine Frontal Area Corrosion

Points . . . . . . . . . . . . . . . . . . . . . . . 4-134-16 Corrosion Prone Point of Air Inlet. . . . . . 4-134-17 Corrosion in Air Intake Duct . . . . . . . . . 4-144-18 Wing Fold Joint . . . . . . . . . . . . . . . . . . 4-154-19 Hinge Corrosion Points . . . . . . . . . . . . . 4-164-20 Piano Hinge Lugs . . . . . . . . . . . . . . . . . 4-164-21 Control Cables . . . . . . . . . . . . . . . . . . . 4-164-22 Personnel Relief Tube Vent . . . . . . . . . . 4-164-23 Common Water Entrapment Areas. . . . . . 4-174-24 Bilge Areas . . . . . . . . . . . . . . . . . . . . . 4-174-25 Battery Compartment . . . . . . . . . . . . . . 4-185-1 3M Co. Scotch-BriteTM Flap Brush and

Mandrel . . . . . . . . . . . . . . . . . . . . . 5-45-2 Abrasive Flap Wheels with Spindle

Mount. . . . . . . . . . . . . . . . . . . . . . . 5-45-3 3M Co. Radial Bristle Disc . . . . . . . . . . 5-55-4 3M Co. Roloc Discs . . . . . . . . . . . . . . . 5-65-5 3M Co. Inline Bristle Disc . . . . . . . . . . . 5-75-6 Abrasive Blasting Equipment . . . . . . . . . 5-105-7 Shaping Reworked Areas . . . . . . . . . . . . 5-135-8 Acceptable Clean-Up of Pitting Corrosion

on Critical Structure . . . . . . . . . . . . . 5-135-9 Limited Clearance. . . . . . . . . . . . . . . . . 5-145-10 A Water-Break Free Surface Compared

with One with Breaks . . . . . . . . . . . . 5-405-11 Magnetic Almen Strip Holder . . . . . . . . . 5-46.15-12 “A” Test Strip Magnetic to SAE J442 Stri-

pholder Arc Height ConversionGraph . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-13 “A” Test Strip Arc Height Magnetic toSAE J442 Stripholder ConversionChart, 0.001 Inch . . . . . . . . . . . . . . . 5-48

TO 1-1-691

Change 16 vii

Number PageTitle

5-14 “N” Arc Height Magnetic to SAE J442Stripholder Conversion Graph. . . . . . . 5-49

5-15 “N” Arc Height Magnetic to SAE J442Stripholder Conversion Chart, 0.001Inch . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-16 Arc Height Plotting Chart . . . . . . . . . . . 5-515-17 Example of Coverage . . . . . . . . . . . . . . 5-525-18 Flap Deflection Ranges . . . . . . . . . . . . . 5-536-1 Pneumatic Sealant Gun . . . . . . . . . . . . . 6-66-2 Sealant Application Nozzles . . . . . . . . . . 6-76-3 Countersink Application Nozzles. . . . . . . 6-86-4 Rivet Application Nozzles . . . . . . . . . . . 6-96-5 Sealant and Adhesive Smoothing

Tools . . . . . . . . . . . . . . . . . . . . . . . 6-106-6 Sealant Injection Guns. . . . . . . . . . . . . . 6-116-7 Injection Style Semkit®. . . . . . . . . . . . . 6-126-8 Non-Metallic Spatula . . . . . . . . . . . . . . 6-266-9 Faying Surface Sealing . . . . . . . . . . . . . 6-286-10 Typical Fillet Seal. . . . . . . . . . . . . . . . . 6-296-11 Typical Injection Seal . . . . . . . . . . . . . . 6-306-12 Typical Methods of Sealing Fasteners . . . 6-31

Number PageTitle

6-13 Typical Lap Skin Sealing . . . . . . . . . . . . 6-336-14 Sealing Procedures for Typical Aircraft

Fitting. . . . . . . . . . . . . . . . . . . . . . . 6-346-15 Typical Spar Cap Sealing. . . . . . . . . . . . 6-356-16 Sealing of Access Doors . . . . . . . . . . . . 6-367-1 Beryllium-Copper Spiral Contact with En-

vironmental Fluorosilicone Seal . . . . . 7-167-2 Dorsal Longeron EMI Seal . . . . . . . . . . 7-177-3 Stainless Steel (CRES) EMI Screen. . . . . 7-177-4 Bonding Cable from Airframe to Graphite/

Epoxy Avionics Bay Door . . . . . . . . . 7-187-5 EMI Bonding Washers in an Avionics

Bay . . . . . . . . . . . . . . . . . . . . . . . . 7-199-1 Soil Makeup in the SWA Area . . . . . . . . 9-29-2 Global Dust Producing Regions . . . . . . . 9-29-3 Open Circuit Board. . . . . . . . . . . . . . . . 9-3B-1 Back Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . . . B-43B-2 Front Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . . . B-44B-3 Hooded Air Respirator System . . . . . . . . B-45

LIST OF TABLES

Number PageTitle

2-1 Corrosion of Metals - Type of Attack andAppearance of Corrosion Products . . . 2-15

3-1 Aircraft Wash Intervals . . . . . . . . . . . . . 3-23-2 Cleaning of Specific Areas and

Components. . . . . . . . . . . . . . . . . . . 3-123-3 Deicing/Anti-Icing Fluid Residue Inspec-

tion and Cleaning Procedures . . . . . . . 3-283-4 Recommended Dilution of Low Tempera-

ture Cleaner . . . . . . . . . . . . . . . . . . . 3-453-4.1 Fungus Growth Removal from Organic

Materials . . . . . . . . . . . . . . . . . . . . . 3-473-5 Common Military Greases and Their

Uses . . . . . . . . . . . . . . . . . . . . . . . . 3-553-6 Time Limitations for CPC’s . . . . . . . . . . 3-573-7 Corrosion Preventive Compounds . . . . . . 3-573-8 Preservation of Specific Areas and

Components. . . . . . . . . . . . . . . . . . . 3-604-1 NDI Inspection Tools for Various Types of

Corrosion . . . . . . . . . . . . . . . . . . . . 4-25-1 Grades of Abrasive Mats . . . . . . . . . . . . 5-35-2 Grades of Steel Wool . . . . . . . . . . . . . . 5-35-3 Recommended Powered Abrasives for

Corrosion Removal . . . . . . . . . . . . . . 5-85-4 Recommended Non-Powered Abrasives for

Corrosion Removal . . . . . . . . . . . . . . 5-105-5 Typical Chemical Corrosion Removal Pro-

cedures for Aluminum Alloy Parts andAssemblies . . . . . . . . . . . . . . . . . . . 5-18

Number PageTitle

5-6 Typical Chemical Corrosion Removal Pro-cedures for Magnesium Alloys . . . . . . 5-22

5-7 Typical Chemical Corrosion Removal Pro-cedures for Ferrous Metals Other ThanStainless Steel (CRES) . . . . . . . . . . . 5-26

5-8 Typical Chemical Corrosion Removal Pro-cedures for Stainless Steel (CRES) andNickel Based Alloys . . . . . . . . . . . . . 5-28

5-9 Control of Corrosion Removal/PicklingAction of Nitric-Acid-HydrofluoricSolutions . . . . . . . . . . . . . . . . . . . . . 5-30

5-10 Typical Chemical Corrosion Removal Pro-cedures for Copper and CopperAlloys. . . . . . . . . . . . . . . . . . . . . . . 5-32

5-11 Typical Chemical Corrosion Removal ofTitanium and Titanium BaseAlloys. . . . . . . . . . . . . . . . . . . . . . . 5-34

5-12 Typical Chemical Corrosion Removal Pro-cedures for Plated and PhosphatedSurfaces . . . . . . . . . . . . . . . . . . . . . 5-36

5-13 Prepaint Treatments for MetalSurfaces . . . . . . . . . . . . . . . . . . . . . 5-41

5-14 Tool Speed Operation Requirements . . . . 5-445-15 Standard Peening Intensity (Isp) for Com-

plete Coverage Arc-Height (All Num-bers in Inches) . . . . . . . . . . . . . . . . . 5-45

6-1 Sealing Compounds . . . . . . . . . . . . . . . 6-13

TO 1-1-691

LIST OF ILLUSTRATIONS - CONTINUED

viii Change 16

Number PageTitle

6-2 Time Requirements for Sealants WhenUsed at 75° F (24° C) and 50%RH. . . . . . . . . . . . . . . . . . . . . . . . . 6-22

8-1 Priority Guide for Emergency Treatmentof Aircraft, Missiles, andEquipment . . . . . . . . . . . . . . . . . . . . 8-3

8-2 Suggested List of Emergency ReclamationItems . . . . . . . . . . . . . . . . . . . . . . . 8-3

Number PageTitle

10-1 Air Force RPA Tiers . . . . . . . . . . . . . . . 10-1A-1 Unit of Issue Codes . . . . . . . . . . . . . . . A-1A-2 Consumable Materials . . . . . . . . . . . . . . A-2B-1 Unit of Issue Codes . . . . . . . . . . . . . . . B-1B-2 Equipment for Cleaning and Corrosion

Prevention and Control . . . . . . . . . . . B-2

TO 1-1-691

LIST OF TABLES - CONTINUED

Change 11 ix/(x blank)

INTRODUCTION

1 PURPOSE.

The purpose of this manual is to provide information onmaterials and procedures for the prevention and repair ofcorrosion damage to aircraft and missile weapon systems andrelated equipment. Supervisory and maintenance personnelshall use this manual as a guide for all corrosion control andmaintenance efforts. Contractors who maintain and repaircorrosion of aircraft, missiles, and related equipment shallalso use this manual. Use this manual in conjunction withand in support of the appropriate systems specific aircraft,missile, or equipment technical orders (TO’s). In the case ofa conflict between this manual and a systems specific air-craft, missile, or equipment manual, the system specificmanual shall take precedence over this manual. Paragraph 6lists related technical publications used by personnel in-volved in cleaning and corrosion control.

2 SCOPE.

The material in this manual provides basic cleaning, corro-sion prevention and control, and corrective maintenance in-formation to be used at organizational, intermediate, and de-pot levels. This manual is divided into eight chapters, twoappendices, a glossary, and an alphabetical index. Chapter 1explains the appropriate usage of this manual. Chapter 2 ex-plains what corrosion is, why it occurs, the various forms itcan take, and how to recognize it. Chapter 3 outlines ac-cepted procedures, methods, and materials to be used inmaintenance cleaning in Section I, lubrication in Section II,and preservation in Section III of aircraft, missiles, and re-lated equipment. Chapter 4 describes inspection techniquesfor detecting corrosion in Section I and discusses corrosionprone areas in Section II. Chapter 5 outlines the approvedmethods for the removal of corrosion damage in Section Iand the application of surface treatments in Section II. Chap-ter 6 covers recommended materials and procedures for theapplication of sealing compounds to aircraft, missile, andrelated equipment structures. Chapter 7 describes the recom-mended procedures for treating and protecting against corro-sion in specific areas. Chapter 8 outlines emergency proce-dures to be followed after exposure of aircraft to salt water,fire extinguishing chemicals, etc., Appendix A lists the rec-ommended materials for cleaning, corrosion prevention, sur-face treatment, and preservation of aircraft, missiles, and re-lated equipment. Appendix B lists equipment used forcleaning, corrosion removal, conversion coating, and sealingof aircraft, as well as associated safety equipment includingpersonal protective equipment (PPE) for these operations.

3 LIST OF ABBREVIATIONS AND ACRONYMS.

All abbreviations used in this manual are in accordance withASME Y14.38.

AFCPCO Air Force Corrosion Prevention and Con-trol Office

AFFF Aqueous Film Forming FoamAFPHIS Animal and Plant Health Inspection Ser-

vicesAISI American Iron and Steel InstituteAOR Area of ResponsibilityBOD Biological Oxygen DemandCaCO3 Calcium CarbonateCaSO4.2H2O Anhydrous Calcium SulfateCBR Chemical, Biological, RadiologicalCBRNE Chemical, Biological, Radiological,

Nuclear, and High-Yield ExplosiveCC Cubic CentimetersCFM Cubic Feet Per MinuteCPC Corrosion Preventive CompoundsCRES Corrosion Resistant SteelsCrO3 Chromic AcidCWR Clear Water Rinse°C Degrees Celsius°F Degrees FahrenheitDFT Dry Film ThicknessDI DeionizedDTIC Defense Technical Information CenterEA EachEPA Environmental Protection AgencyEPTFE Expanded Polytetrafluoroethyleneft Foot/FeetFIP Form-In-PlaceHAP Hazardous Air PollutantsHCFC HydrochlorofluorocarbonHEPA High Efficiency Particulate AirID Inside Diameterin InchIVD Ion Vapor DepositedKSI Kilograms per Square InchLG Landing GearLOX Liquid OxygenMEK Methyl Ethyl Ketonemg/L Milligrams per Litermm Hg Millimeters of MercuryMOS Maximum Operating SpeedNDI Non-Destructive InspectionNRA Nuclear Regulatory AgencyNSN National Stock NumberOD Outside DiameterODC Ozone Depleting Compounds

TO 1-1-691

Change 17 xi

ODS Ozone Depleting SubstancesPDM Program Depot MaintenancepH Potential of HydrogenPMB Plastic Media BlastPMF Pre-Mixed and FrozenPN Part NumberPPE Personal Protective Equipmentppm Parts Per MillionPSI Pounds Per Square InchQPD Qualified Products DatabaseQPL Qualified Products ListRH Relative HumidityRPM Rotations Per MinuteRTU Ready-To-UseSDS Safety Data SheetsSE Support EquipmentSLED Shelf Life Extension DocumentSPD System Program DirectorSPM System Program ManagerSWA Southwest AsiaTDS Total Dissolved SolidsTNP Touch-N-PrepTM

TO Technical OrderTPH Total Petroleum HydrocarbonTSS Total Suspended SolidsVOC Volatile Organic Compound

4 RELATED PUBLICATIONS.

NOTE

When searching Technical Order (TO) numbers inthe Enhanced Technical Information ManagementSystem (ETIMS) catalog, please use the wildcard(*) after typing in the TO number. Many TOs arenot available in paper format, (i.e., digital (WA-1)or Compact Disk (CD-1)). This ensures TOs in allmedia formats will populate the search.

The following publications contain information in support ofthis technical manual.

List of Related Publications

Number TitleAFI 20-114 Air and Space Equipment

Structural ManagementAFI 32-1067 Water SystemsAFI 32-7001 Environmental Management

List of Related Publications - Continued

Number TitleAFI 40-201 Managing Radioactive Mate-

rials in the U.S. Air ForceAFI 23-101 AF Material ManagementAFMAN 10-2503 Operations in a Chemical,

Biological, Radiological,Nuclear, and High-Yield Ex-plosive (CBRNE) Environ-ment

AFMAN 24-204-IP Preparing Hazardous Materi-als for Military Air Ship-ments

AFMAN 91-223 Aviation Safety Investiga-tions and Reports

AF-PAM 91-212 Bird/Wildlife Aircraft StrikeHazard (BASH) Manage-ment Techniques

AFI 91-203 Air Force Consolidated Oc-cupational Safety Instruction

ASME Y14.38 Abbreviations and Acronymsfor Use on Drawings andRelated Documents

DOD 4140.27-M Shelf Life ManagementManual

DOD 6050.5LR Hazardous Material Controland Management (HMC&M)

MIL-HDBK-729 Corrosion and CorrosionPrevention-Metals

TO 00-5-1 AF Technical Order SystemTO 00-20-1 Aerospace Equipment Main-

tenance Inspection, Docu-mentation, Policy and Proce-dures

TO 00-20-2 Maintenance Data Documen-tation

TO 00-25-107 Maintenance AssistanceTO 00-25-172 Ground Servicing of Aircraft

and Static Grounding/Bond-ing

TO 00-25-234 General Shop Practice Re-quirements for the Repair,Maintenance, and Test ofElectronic Equipment

TO 00-25-235 Safety Procedures andEquipment for ConfinedSpace Entry (Including Mis-sile Propellant Tanks)

TO 1-1-691

xii Change 17


Number TitleTO 00-35D-54 USAF Material Deficiency

Reporting and InvestigatingSystem

TO 00-85A-03-1 Preservation, Packaging andPacking - External AircraftFuel Tanks, Fuel Cells

TO 00-110A-1 Guidelines for Identificationand Handling of Aircraft andMaterial Contaminated withRadioactive Debris (Fallout)

TO 1-1-3 Inspection and Repair ofAircraft Integral Tanks andFuel Cells

TO 1-1-8 Application and Removal ofOrganic Coatings, Aerospaceand Non-Aerospace Equip-ment

TO 1-1-17 Storage of Aircraft and Mis-siles Systems

TO 1-1-24 Maintenance Repair andElectrical Requirements forFiberglass Airborne Ra-domes

TO 1-1-689-1 Cleaning and CorrosionControl, Volume I, CorrosionProgram and CorrosionTheory

TO 1-1-689-3 Cleaning and CorrosionControl, Volume III, Avion-ics and Electronics

TO 1-1-689-5 Cleaning and CorrosionControl, Volume V, Consum-able Materials and Equip-ment for Avionics

TO 1-1-690 General Advanced Compos-ite Repair Processes

TO 1-1A-1 Engineering H/B Series forAircraft Repair - GeneralManual for Structural Repair

TO 1-1A-8 Engineering Manual Seriesfor Aircraft and MissilesRepair Structural Hardware

TO 1-1A-9 Engineering Series for Air-craft Repair Aerospace MetalGeneral Data and UsageFactors

TO 1-1A-12 Fabrication, Maintenanceand Repair of TransparentPlastic

TO 1-1A-14 Installation Practices for Air-craft Electric and ElectronicWiring


Number TitleTO 1-1A-15 General Maintenance In-

structions for Support Equip-ment (SE)

TO 2-1-111 Standard Maintenance Prac-tices, Navy, USAF andArmy, P&W Aircraft En-gines

TO 2J-1-13 Cleaning of Gas TurbineAircraft Engines and Parts

TO 2J-1-18 Preparation for Shipmentand Storage of Gas TurbineEngines

TO 2J-1-32 Standard Maintenance Prac-tice Instructions - GE Air-craft Engines, Model TF-34-GE-100, A, -400, A, B,TF58-GE-3, -5, -8B, -10,-16, -100 (USCG), -400B,-402, T64-GE-6B, -7, A,100, -413, -415, -416,-416A, F404-GE-400,YF404-GE-400, F110-GE-400, YT700-GE-401, T700-GE-401, 4

TO 4B-1-32 Maintenance and O/H In-structions - All Type AircraftBrakes

TO 4S-1-182 General O/H & MaintenanceInstr. All FSC 1620 LandingGear & Components

TO 4W-1-61 Operation, Service, andMaintenance Instructions-AllAircraft Wheels

TO 10-1-179 Corrosion Control Manualfor Photographic Equipment

TO 13A1-1-1 Repair, Cleaning, Inspectionand Testing Aircraft SafetyBelts, Shoulder Harness, andMiscellaneous PersonnelRestraint Equipment

TO 31-1-221 Field Instructions for Paint-ing and Preserving Electron-ics Command Equipment

TO 33B-1-1 Nondestructive InspectionMethods

TO 34-1-3 Inspection and Maintenanceof Machinery and ShopEquipment

TO 35-1-3 Corrosion Prevention, Paint-ing, and Marking of USAFSupport Equipment (SE)

TO 1-1-691

Change 11 xiii


Number TitleTO 35-1-4 Processing and Inspection of

Support Equipment for Stor-age and Shipment

TO 36-1-191 Technical and ManagerialReference for Motor VehicleMaintenance

TO 42A1-1-1 Evaluation and Service Test-ing of Materials - Cleaning,Painting, Sealing, ProtectiveTreating, Anti-Corrosion,Inspection Materials, andRelated Items

TO 42A3-1-2 General Use of Cements,Sealants, and Coatings


Number TitleTO 42B-1-6 Corrosion Preventive Lubri-

cants and Anti-Seize Com-pounds

TO 42C-1-2 Anti-Icing, Deicing, and De-frosting of Parked Aircraft

TO 42C-1-12 Quality Control of Chemi-cals

TO 42C2-1-7 Electro Deposition of Metalsand Metal Surface Treat-ments to Meet Air ForceMaintenance Requirements

TO 1-1-691

xiv Change 11

1 RECORD OF APPLICABLE TIME COMPLIANCETECHNICAL ORDERS (TCTOS).

List of Time Compliance Technical Orders

TCTONumber

TCTOTitle

TCTODate

None

2 HARDNESS CRITICAL ITEMS (HCI).

The HCI symbol ( ) establishes special require-ments limiting changes and substitutions and thatthe specific parts listed must be used to ensurehardness is not degraded.

If included, items with nuclear survivability requirements aremarked with the HCI symbol ( ). All changes to, or pro-posed substitutions of, HCIs must be approved by the ac-quiring activity.

3 ELECTROSTATIC DISCHARGE SENSITIVE(ESDS) ITEMS.

All ESDS parts shall be handled in accordancewith the ESDS device handling procedures in TO00-25-234.

If included, items containing ESDS parts are marked withthe ESDS symbol ( ).

4 RESPONSIBILITY FOR CHANGES TO THISMANUAL.

This manual is maintained for technical content by the AirForce Corrosion Prevention and Control Office (AFCPCO),AFLCMC/EZPT-CPCO, 325 Richard Ray Blvd., RobinsAFB, GA 31098-1639, Tel: (478) 926-3284 (DSN 468-3284),Fax: (478) 926-6619 (DSN 468-6619), email:[email protected]; and for TO administration by WRALC/LESGI, 460 Richard Ray Blvd., Robins AFB, GA 31098-1640, Tel: (478) 926-7046 x122 (DSN 468-7046 x122),email: [email protected].

5 IMPROVEMENT REPORTS.

Recommended changes to this manual shall be submitted inaccordance with TO 00-5-1.

6 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processeswhich may cause injury or death to personnel, or damage toequipment if not properly followed. This safety summaryincludes general safety precautions and instructions that mustbe understood and applied during operation and maintenanceto ensure personnel safety and protection of equipment. Priorto performing any task, the WARNINGs, CAUTIONs andNOTEs included in that task shall be reviewed and under-stood.

7 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual tohighlight operating or maintenance procedures, practices,conditions or statements which are considered essential toprotection of personnel (WARNING) or equipment (CAU-TION). NOTEs are used in this manual to highlight operat-ing or maintenance procedures, practices, conditions or state-ments which are not essential to protection of personnel orequipment. The headings used and their definitions are asfollows:

Highlights an essential operating or maintenanceprocedure, practice, condition, statement, etc.,which if not strictly observed, could result in in-jury to, or death of, personnel or long term healthhazards.

TO 1-1-691

Change 18 xvAll data on page xviii deleted

Highlights an essential operating or maintenanceprocedure, practice, condition, statement, etc.,which if not strictly observed, could result in dam-age to, or destruction of, equipment or loss of mis-sion effectiveness.

NOTE

Highlights an essential operating or maintenanceprocedure, condition or statement.

8 SAFETY PRECAUTIONS.

The following safety precautions shall be observed whileperforming procedures in this manual.

• Some cleaning materials specified herein are flam-mable and/or toxic. Keep away from open flame orother ignition sources. Do not use synthetic wipingcloths with flammable solvents. Open all circuitbreakers associated with battery power prior to ap-plication of any flammable solvent. Provide ad-equate ventilation and avoid skin/eye contact. WearPersonal Protective Equipment (PPE). Consult theSafety Data Sheets (SDS) for specific informationon hazards, effects, and protective equipment re-quirements.

• Some cleaning processes described herein use ma-terials and generate effluent that may be hazardousto personnel and the environment. Contact the localBioenvironmental Engineer and safety office forguidance on PPE and other health and safety pre-cautions, and waste disposal.

• Some cleaning operations described herein utilizepower tool operations and abrasive blasting opera-tions which often generate toxic/hazardous airborneparticles. Always wear proper PPE.

• Ensure that all electrical power is disconnected andall systems in aircraft, missiles, or equipment aredeactivated before starting cleaning operations onavionics, electronics, or electrical equipment to pre-vent electrical shock.

• Remove jewelry and remove/cover loose fittingclothing before operating power equipment to pre-vent entanglement and injury.

• Cleaning with compressed air can create airborneparticles that may enter eyes or penetrate skin. Pres-sure shall not exceed 30 PSIG. Wear goggles. Donot direct compressed air against skin.

• Depleted uranium is extremely toxic and shall beworked only under a license from the Nuclear Regu-latory Agency (NRA). Machining or other work,such as surface sanding, may be done only by thelicensee. No drilling, sanding, abrasive blasting, orother mechanical work is permitted on depleteduranium by any field level (organizational or inter-mediate) maintenance activity. If the protective fin-ish (plating) which covers the depleted uranium ischipped, peeled, or otherwise removed so the darkgray or black uranium oxide is visible, the part mustbe returned to the licensee for rework or disposal.Packaging and shipping procedures shall conformto AFI 40-201 and any other related current regula-tions for handling radioactive materials.

TO 1-1-691

xvi Change 17 All data on page xviii deleted

CHAPTER 1INTRODUCTION

1.1 CORROSION CONTROL PROGRAM.

All activities responsible for maintenance of aircraft, mis-siles, and related equipment shall establish corrosion preven-tion and control programs as required by AFI 20-114. Thetype of program depends upon the environment to which theaircraft, missile, or equipment may be exposed. Aircraft,missiles, and equipment may be exposed to industrial gases,salts, rain, mud, and mists containing sea salts if located nearsalt water. A comprehensive corrosion prevention and con-trol program shall provide a Structural Maintenance WorkCenter with personnel trained in the prevention, early detec-tion, reporting, and repair of corrosion damage. In addition,such a program requires a dedicated effort by all mainte-nance personnel to prevent corrosion from occurring and/orto detect it in its initial stages so it can be treated early thusminimizing costly repairs and improving the operationalreadiness of aircraft, missiles, and equipment.

1.1.1 Training. All personnel performing maintenance onaircraft, missiles, and related equipment shall be trained inbasic corrosion prevention and control skills and must befully aware of the reasons for the corrosion prevention andcontrol program. Without such training and understanding,more severe damage and additional problems will result.

1.1.2 Maintenance. An effective corrosion prevention andcontrol program shall include thorough cleaning, inspection,preservation, and lubrication, at specified intervals, in accor-dance with Chapter 3 and Chapter 4. Check for corrosiondamage and integrity of protective finishes during all sched-uled and unscheduled maintenance. Early detection and re-pair of corrosion will limit further damage. When corrosionis discovered, treat corrosion as prescribed in Chapter 5 andChapter 7 as soon as possible using only approved materials,equipment, and techniques. Only affected areas shall be re-paired. Seal in accordance with Chapter 6 and paint, as re-quired, in accordance with TO 1-1-8 and the systems spe-cific TO. All maintenance personnel shall report corrosionpromptly in accordance with established Air Force directives.

1.1.3 Facilities. In accordance with Paragraph 7.10.5 ofAFH 32-1084 titled “FACILITY REQUIREMENTS”, baseswith a large number of aircraft (40 or more large or mediumassigned aircraft) or located in a severe environment are au-thorized, with proper justification, a Corrosion Control Han-gar and aircraft wash hangar.

1.2 SAFETY.

Safety is everyone’s business and concern.

1.2.1 Responsibility of Supervisors. Work center super-visors shall receive the following training in accordance withestablished Air Force directives:

• The recognition and elimination of hazards.

• Occupational safety and health.

• The safety of the individual.

• Accident investigation and reporting.

• The inspection and maintenance of personal protec-tive equipment (PPE).

a. Supervisors shall ensure that all corrosion control per-sonnel are informed of current safety procedures.

• Characteristics of materials to which they willbe exposed.

• Required protective clothing and personal pro-tective equipment (PPE) to ensure safety ofpersonnel.

b. In addition, supervisors shall ensure that an adequatesupply of safety equipment is in a ready-for-issue con-dition, and that personnel under their control are given,and use, appropriate protective equipment to preventaccidents, injuries, and occupational illness. Mainte-nance personnel shall use the appropriate equipmentwhile exposed to hazardous conditions, and shall re-port any protective equipment that is broken, damaged,defective, or inadequate to the supervisor. No one shalluse protective equipment that is not in a satisfactoryand serviceable condition. Personnel shall comply withoccupational safety and health requirements, includingmedical examinations, respirator training and fit test-ing, and protection for eyes, ears, head, skin, and feet.

1.2.2 Materials Handling. Many of the materials and pro-cedures outlined in this manual are potentially hazardous topersonnel and potentially damaging to aircraft, missiles, andequipment, especially when improperly used. When usingany chemicals, such as paint removers, detergents, conver-sion coatings, and solvents, follow the correct proceduresand use appropriate protective gear to prevent personnel in-jury and structural damage. Read the appropriate warningsand cautions in this manual prior to use of any hazardousmaterials. Misuse of certain materials can damage parts orcause corrosion which may lead to catastrophic failure. Re-

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fer to DOD 6050.5LR, Hazardous Materials InformationSystem, and the appropriate Air Force directives for the han-dling, storage, and disposal of hazardous materials. Refer tolocal directives and policies pertaining to hazardous wastemanagement. When in doubt, contact the base safety office,and/or Bioenvironmental Engineer for assistance.

1.3 MATERIALS.

Consumable materials listed in Appendix A and accessorieslisted in Appendix B shall be used for corrosion preventionand control. The materials and equipment listed have beenapproved only after extensive testing to prove their ability toperform properly and effectively without damage to any ofthe metallic or nonmetallic materials used in aircraft, mis-

siles, and related equipment. Only those materials listed inthis manual shall be used for cleaning and corrosion preven-tion and control of aircraft, missile, and equipment compo-nents. Materials listed in other manuals shall be used onlywhen required procedures are not covered by this manual.Materials or processes considered to be an improvement overexisting ones shall be forwarded to the Aircraft System Pro-gram Director (SPD) or the Missile or Equipment SystemProgram Manager (SPM) and the Air Force Corrosion Pre-vention and Control Office (AFCPCO), AFLCMC/EZPT-CPCO, for further evaluation. When approved materials arenot available, substitutions shall only be made after approvalby the appropriate SPD/SPM in conjunction with the AF-CPCO. When several methods or materials are listed, thepreferred one is listed first, with alternates following.

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CHAPTER 2CORROSION THEORY

2.1 INTRODUCTION TO CORROSION THEORY.

This chapter is an introduction to corrosion theory, the causesof corrosion, and the factors which influence its develop-ment. The various forms of corrosion and the effect of cor-rosive environments on aircraft and metals are described.The purpose of this discussion is to provide maintenancepersonnel with the background knowledge necessary to un-derstand the causes of corrosion and to minimize corrosiondamage.

2.2 DEFINITION OF CORROSION.

Corrosion is the electrochemical deterioration of a metal be-cause of its chemical reaction with the surrounding environ-ment. This reaction occurs due to the tendency of metals toreturn to their naturally occurring states, usually oxide orsulfide ores. For example, iron in the presence of moistureand air will return to its natural state, iron oxide or rust.Aluminum and magnesium form corrosion products that arewhite oxides or hydroxides. When a water solution contain-ing soluble salts is present, corrosion of many alloys canoccur easily at ambient (room) temperatures. This type ofcorrosion can be effectively treated by maintenance person-nel as discussed in this manual. Corrosion can also occur inthe absence of water, but only at high temperatures such asthose found in gas turbine engines. However, the most com-mon type of corrosion (and the one that can be most effec-tively treated by maintenance personnel) is electrochemicalcorrosion.

2.3 CHEMICAL DEFINITIONS.

2.3.1 Atom. The smallest unit of an element. There areover 100 elements, including metals such as aluminum,magnesium, gold, platinum, iron, nickel, titanium, cadmium,chromium, copper, silver, lead, uranium, beryllium, zinc andcarbon and non-metals such as hydrogen, oxygen, nitrogen,sulfur, chlorine, helium and boron.

2.3.2 Electron. A negatively charged particle muchsmaller than an atom. An electric current occurs when elec-trons are forced to move through metal conductors. Elec-trons flow through water solutions only in the presence ofions.

2.3.3 Ions. Atoms or groups of atoms bound togetherwhich are either positively or negatively charged. An electriccurrent occurs when ions are forced to move through watersolutions. Ions cannot move through metal conductors.

2.3.4 Electrolyte. A liquid (usually water) solution con-taining ions. Salt water is an electrolyte: an aqueous (mean-ing, water) solution of sodium ions and chloride ions. Elec-trochemistry is the branch of chemistry concerned withchemical reactions at surfaces in contact with electrolytes.

2.4 THEORY OF CORROSION.

All structural metals will corrode to some extent in a naturalenvironment. When a metal corrodes, the metal atoms loseelectrons and become positively charged metal ions in theelectrolyte. In solution, the positively charged metal ions cancombine with negatively charged ions to form corrosionproducts, such as metallic chlorides, oxides, hydroxides, sul-fides, etc. Four conditions must exist before this type of cor-rosion can occur.

2.4.1 Anode. A metal which has a tendency to corrodemust be present (the corroding metal is known as the anode).

2.4.2 Cathode. A dissimilar conductive material (the cath-ode) which has less tendency to corrode than the anode mustbe present (such as a different metal, a protected part of thesame metal, or conductive plastics).

2.4.3 Electrolyte. A conductive liquid (electrolyte) mustconnect the anode and cathode (so that ions can carry elec-tric current between them).

2.4.4 Electrical Contact. Electrical contact between theanode and cathode (usually in the form of metal-to-metalcontact) must exist (so that electrons can move from theanode, where they are released, to the cathode).

2.4.4.1 Elimination of Anode, Cathode, Electrolyte, orElectrical Contact. The elimination of any one of the fourconditions, illustrated in Figure 2-1, will stop corrosion. Forexample, a paint film on a metal surface will prevent theconducting liquid (electrolyte) from connecting the anodeand cathode, thereby, stopping the electric current. (Refer toFigure 2-2). Another example: two connected dissimilarmetal parts placed in distilled water corrode very slowly dueto a lack of ions in solution to conduct the electric current; insea water the corrosion reaction is accelerated by a factor of1,000 or more. (Refer to Figure 2-3).

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2.5 DEVELOPMENT OF CORROSION.

All corrosive attack begins on the surface of metals. If al-lowed to progress, corrosion can penetrate in the metal. Ifcorrosion begins on an inside surface of a component (forexample, the inner wall of metal tube), it may go undetecteduntil perforation occurs. When corrosion products form, theyoften deposit on the corroding surface as a powdery deposit.This film of corrosion products may reduce the rate of cor-rosion, if the film acts as a barrier to electrolytes. Some met-als (such as stainless steel and titanium), under the right con-ditions, produce corrosion products that are so tightly boundto the corroding metal that they form an invisible oxide film(called a passive film), which prevents further corrosion.However, when the film of corrosion products is loose andporous (such as those of carbon steel, aluminum and magne-sium), an electrolyte can easily penetrate and continue thecorrosion process, producing more extensive damage thansurface appearance shows.

2.5.1 Corrosion Under Painted Surfaces. Paint coatingscan mask the initial stages of corrosion. Since corrosionproducts occupy more volume than the original metal, paintsurfaces should be inspected often for irregularities such asblisters, flakes, chips, lumps, and worm like tracks.

2.6 FACTORS INFLUENCE CORROSION.

Some factors which influence metal corrosion and the rate ofcorrosion are:

• Type of metal.

• Presence of a dissimilar, less corrodible metal (gal-vanic corrosion).

• Anode and cathode surface areas (in galvanic cor-rosion).

• Temperature.

• Heat treatment and grain direction.

• Presence of electrolytes (hard water, salt water, bat-tery fluids, etc.).

• Availability of oxygen.

• Presence of different concentrations of the sameelectrolytes.

• Presence of biological organisms.

• Mechanical stress on the corroding metal.

• Time of exposure to a corrosive environment.

2.6.1 Type of Metal. Most pure metals are not suitable foraircraft construction and are used only in combination withother metals, and sometimes non-metals, to form alloys.Most alloys are made up entirely of small crystalline re-gions, called grains. Corrosion can occur on surfaces of thoseregions, which are less resistant, and also at boundaries be-tween regions, resulting in the formation of pits and inter-granular corrosion. The metals most commonly used in air-craft construction are aluminum, steel, titanium, andmagnesium. Cadmium, zinc, nickel, chromium, and silverare sometimes used as protective platings. Metals have awide range of corrosion resistance. The most active metals(those which tend to lose electrons easily), such as magne-sium and aluminum, corrode easily and are listed at the topor anodic end of Figure 2-16. The most noble metals (thosewhich do not lose electrons easily), such as gold and silver,do not corrode easily and are listed at the bottom or cathodicend of Figure 2-16.

2.6.2 Dissimilar Metal Coupling (Galvanic Corrosion).When two dissimilar metals make electrical contact in thepresence of an electrolyte, the rate at which corrosion occursdepends on the difference in their activities, that is, theirpositions in Figure 2-16. The greater the difference in activ-ity, the faster corrosion occurs. For example, magnesiumwould corrode very quickly when coupled with gold in ahumid atmosphere. But aluminum would corrode veryslowly, if at all, in contact with cadmium. A flashlight bat-tery (or dry cell) is an example of galvanic corrosion put topractical use. In Figure 2-4, the zinc battery casing steadilycorrodes supplying a steady flow of electrons, but only whenthe switch is closed. When the switch is open, there is nocorrosion because electrons are not able to leave the zincanode.

Figure 2-1. Simplified Corrosion Cell

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2.6.3 Anode and Cathode Surface Area. The rate ofgalvanic corrosion also depends on the size of the parts incontact. If the surface area of the corroding metal (the an-ode) is smaller than the surface area of the less active metal(the cathode), corrosion will be rapid and severe. But, when

the corroding metal is larger than the less active metal, cor-rosion will be slow and superficial. For example, an alumi-num fastener in contact with a relatively inert Monel struc-

Figure 2-2. Elimination of Corrosion by Application of an Organic Film to a Metal Surface

Figure 2-3. Effect of Sea Water on Galvanic Corrosion

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ture may corrode severely, while a Monel bracket secured toa large aluminum member would result in a relatively super-ficial attack on the aluminum sheet. (Refer to Figure 2-5).

2.6.4 Temperature. Higher temperature environmentstend to produce more rapid corrosion due to acceleratedchemical reactions and, in humid environments, higher con-centration of water vapor in the air. In addition, nightly dropsin temperature can cause greater amounts of condensation,leading to increased corrosion rates.

2.6.5 Heat Treatment and Grain Direction. When heat-treated, heavy sections of metals do not cool uniformly and,as a result, tend to vary in chemical composition from onepart of the metal to another. This can cause galvanic corro-sion if one area is more active than another. Alloys, whichare fabricated by rolling, extruding, forging, or pressing, haveproperties which depend highly on direction (grain length vs.cross grain). For example, exposed end grains corrode muchmore easily than flattened elongated surfaces in sheet stock.This explains why exfoliation occurs at the edge of aircraftskin sections or next to countersunk fasteners.

2.6.6 Electrolytes. Electrically conducting solutions areeasily formed on metallic surfaces when condensation, saltspray, rain, or rinse water accumulate. Dirt, salt, acidic stackgases, and engine exhaust gases can dissolve on wet sur-faces, increasing the electrical conductivity of the electro-lyte, thereby increasing the rate of corrosion.

Figure 2-4. Galvanic Corrosion in a Flashlight Battery

Figure 2-5. Effect of Area Relationship in DissimilarMetal Contacts

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2.6.7 Oxygen. When some of the electrolyte on a metalsurface is partially confined (such as between faying sur-faces or in a deep crevice) metal in this confined area cor-rodes more rapidly than other metal surfaces of the samepart outside this area. This type of corrosion is called anoxygen concentration cell or differential aeration cell. Corro-sion occurs more rapidly than would be expected becausethe reduced oxygen content of the confined electrolyte causesthe adjacent metal to become anodic to other metal surfaceareas on the same part immersed in electrolyte exposed tothe air.

2.6.8 Electrolyte Concentration. In the same way thatmetals can corrode when exposed to different concentrationsof oxygen in an electrolyte, corrosion will also occur if theconcentration of the electrolyte on the surface varies fromone location to another. This corrosive situation is known asa concentration cell.

2.6.9 Biological Organisms. Slimes, molds, fungi, andother living organisms (some microscopic) can grow ondamp surfaces. Once they are well established, the area tendsto remain damp, increasing the possibility of corrosion. Theirpresence can cause the areas they occupy to have differentoxygen and electrolyte concentrations. In addition, corrosivewastes are secreted, which cause corrosion.

2.6.10 Mechanical Stress. Almost all alloys used in air-craft construction are sensitive to a form of corrosion knownas stress corrosion cracking. Manufacturing processes suchas machining, forming, welding, or heat treatment can leavestresses in aircraft parts. This residual stress and/or stressapplied to a part causes corrosion to proceed more rapidly instructurally important regions of the part until failure occurs.

2.6.11 Time. As time goes on, metals naturally tend tocorrode. In some cases, the corrosion process occurs at thesame rate, no matter how long the metal has been exposed to

the environment. In other cases, corrosion can decrease withtime, due to the barrier formed by corrosion products, orincrease with time if a barrier to corrosion is being brokendown.

2.7 TYPES OF CORROSION.

Corrosion is catalogued and typed in many ways. Occasion-ally, different names are used for the same type of corrosion.The common types of corrosion are described below.

2.7.1 Uniform Surface Corrosion. Uniform surface cor-rosion or etching results from a direct chemical attack on ametal surface and involves only the metal surface. On a pol-ished surface, this type of corrosion is first seen as a generaldulling or etching of the surface and, if the attack is allowedto continue, the surface becomes rough and possibly frostedin appearance. This type of corrosion appears uniform be-cause the anodes and cathodes are very small and constantlyshift from one area of the surface to another. An example isthe etching of metals by acids. The discoloration or generaldulling of metal created by exposure to elevated tempera-tures is not considered to be uniform surface corrosion.

2.7.2 Galvanic Corrosion. Galvanic corrosion occurswhen different metals are in contact with each other and anelectrolyte, such as salt water. It is usually recognizable bythe presence of a buildup of corrosion at the joint betweenthe metals. For example, aluminum skin panels and stainlesssteel doublers, riveted together in an aircraft wing, form agalvanic couple if moisture and contamination are present.Figure 2-6 shows galvanic corrosion of magnesium adjacentto steel fasteners. When metals which are known to be inelectrical contact are well separated from each other in Fig-ure 2-16, galvanic corrosion is probably occurring.

Figure 2-6. Galvanic Corrosion of Magnesium Adjacent to a Steel Fastener

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2.7.3 Pitting Corrosion. The most common corrosion onaluminum and magnesium alloys is called pitting. (Refer toFigure 2-7). It is first noticeable as a white or gray powderydeposit, similar to dust, which blotches the surface. Whenthe deposit is cleaned away, tiny pits or holes can be seen inthe surface. (Refer to Figure 2-8). Pitting corrosion can alsooccur in other types of alloys. The combination of smallactive anodes to large passive cathodes causes severe pitting.

2.7.4 Intergranular Corrosion. Intergranular corrosion isan attack on the grain boundaries of the metal. A highlymagnified cross section of any commercial alloy (refer toFigure 2-9 and Figure 2-10), shows the granular structure ofthe metal. It consists of quantities of individual grains, each

having a clearly defined boundary, which chemically differsfrom the metal within the grain. Frequently, the grain bound-aries are anodic (tend to corrode more easily) to the metalwithin the grain. When in contact with an electrolyte, rapidcorrosion occurs at the grain boundaries. Figure 2-11 showsintergranular corrosion of 7075-T6 aluminum alloy adjacentto steel fasteners. In this example, the grain boundaries areanodic to both the metal grain and the steel fastener.

2.7.5 Exfoliation Corrosion. Exfoliation (refer to Figure2-12 and Figure 2-13), is an advanced form of intergranularcorrosion where the surface grains of a metal are lifted up bythe force of expanding corrosion products occurring at thegrain boundaries. The lifting up or swelling is visible evi-dence of exfoliation corrosion. Exfoliation occurs on ex-truded, rolled, wrought and forged high strength aluminumand magnesium parts.

2.7.6 Crevice/Concentration Cell Corrosion. Crevicecorrosion occurs when the electrolyte has a different concen-tration from one area to another. Electrolyte inside the crev-ice contains less oxygen and more metal ions than electro-lyte just outside the crevice. As a result, the metal surfaces,even though they may be part of the same metal, have dif-ferent activities and corrosion occurs inside the crevice. Thiskind of corrosion also occurs when a surface is covered by aforeign material. There are three general types of crevice/concentration cell corrosion, (1) metal ion concentration cells(2) oxygen concentration cells, and (3) active-passive cells.(Refer to Figure 2-14).

Figure 2-7. Pitting of an Aluminum Wing Assembly

Figure 2-8. Cross-Section of Corrosion Pits

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2.7.6.1 Metal Ion Concentration Cells. Stagnant electro-lytes under faying surfaces will normally have a high con-centration of metal ions, while a low concentration of metalions will exist adjacent to the crevice created by the fayingsurface. The area of the metal in contact with the higherconcentration of metal ions will be cathodic and not showsigns of corrosion, but the area in contact with the lowermetal ion concentration will be anodic and suffer corrosion.Figure 2-14, View A, illustrates metal ion concentration cellcorrosion.

2.7.6.2 Oxygen Concentration Cells. Electrolyte in con-tact with metal surfaces will normally contain dissolved oxy-gen. An oxygen cell can develop at any point where theoxygen in the air is not allowed to diffuse into the solution,thereby creating a difference in oxygen concentration be-tween two points. Typical locations of oxygen concentrationcells are under either metallic or non-metallic deposits (dirt)on the metal surface and under faying surfaces such as riv-eted lap joints. Oxygen cells can also develop under gaskets,wood, rubber, plastic tape, and other materials in contact

Figure 2-9. Cross-Section of 7075-T6 Aluminum Alloy

Figure 2-10. Grain Structure of a CorrodingAluminum Surface

Figure 2-11. Intergranular Corrosion of 7075-T6Aluminum Adjacent to Steel Fastener

Figure 2-12. Example of Exfoliation

Figure 2-13. Another Example of Exfoliation

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with the metal surface. Corrosion will occur in the area oflow oxygen concentration (anode) as illustrated in Figure2-14, View B. Alloys, such as stainless steel, which owetheir corrosion resistance to surface passivity, are particu-larly susceptible to this type of crevice/concentration cellcorrosion.

2.7.6.3 Active/Passive Cells. Metals which depend on atightly adhering passive film, such as the oxide film on cor-rosion resistant steel, are prone to rapid corrosive attack byactive/passive cells. The corrosive action usually starts witha deposit of dirt or salt, which creates an oxygen concentra-tion cell. The passive film is then broken in the area of thesalt deposit and the more active metal beneath the passivefilm will be prone to corrosive attack. This small anodic areawill corrode rapidly due to the much larger area of the sur-rounding cathode (passive film). The result is rapid pitting ofthe surface, as illustrated in Figure 2-14, View C.

2.7.6.4 Stress Corrosion Cracking. Stress corrosioncracking (refer to Figure 2-15), is the intergranular or trans-granular cracking of a metal caused by the combined effectsof constant tensile stress (internal or applied) and corrosion.Internal or residual stresses are produced by cold working,forming, and heat treatment operations during manufactureof a part and remain concealed in the part unless stress reliefoperations are used. Other hidden stresses are induced inparts when press or shrink fits are used and when slightlymismatched parts are clamped together with rivets and bolts.All these stresses add to those caused by applying normalloads to parts in operation. Metals have threshold stressesbelow which stress corrosion cracking will not occur. Thisthreshold stress varies from metal to metal, is different fordifferent tempers of the same metal, and is different for eachof the three grain directions in which stress can be applied.

2.7.6.5 Associated Hazards. Stress corrosion cracking isan extremely dangerous type of failure because it can occurat stress levels far below the rated strength of a metal, start-ing from what is thought to be a very minor corrosion pit.Parts can completely sever in a split second or they can crackslowly, and the rate of cracking is very unpredictable in op-erating service. As an example, 7075-T6 aluminum alloy canfail by stress corrosion cracking when a stress which is only10% of its rated strength is present across the thickness of itsmetal grains or the short transverse grain direction.

2.7.6.6 Causes. Specific environments have been identi-fied which cause stress corrosion cracking of certain alloys.Salt solutions, seawater, and moist salt laden air may causestress corrosion cracking of heat treatable aluminum alloys,high strength steels, stainless steels, and some titanium al-loys. Magnesium alloys may stress corrode in moist air.Stress corrosion can be prevented by placing an insulating

barrier between the metal and the corrosive environment suchas protective coatings and water displacing corrosion pre-ventive compounds. Stress relief operations during fabrica-tion of parts will help because it lowers the residual stresslevel in the parts. Shot peening a metal increases resistanceto stress corrosion cracking by creating compressive stresseson the surface which must be overcome by an applied tensilestress before the surface sees any tension load.

2.7.7 Corrosion Fatigue. Corrosion fatigue is the crack-ing of metals caused by the combined effects of cyclic stressand corrosion and is very similar to stress corrosion crack-ing. No metal is immune to a reduction of its resistance tocyclic stressing if it is in a corrosive environment. Damagefrom corrosion fatigue is greater than the sum of the damagefrom both cyclic stresses and corrosion. Corrosion fatiguefailure occurs in two stages. During the first stage, the com-bined action of corrosion and cyclic stress damages the metalby pitting and crack formation in the pitted area. The secondstage is the continuation of crack propagation by a straightfatigue mode, in which the rate of cracking is controlled bythe stress concentration in the main cross section and thephysical properties of the metal. Fracture of a metal part dueto corrosion fatigue occurs at a stress far below the fatiguelimit even though the amount of corrosion may be very small.For this reason, protection of all parts subject to alternatingstress is particularly important, even in environments that areonly mildly corrosive. Preventive measures are the same asthose given above for stress corrosion cracking.

2.7.8 Filiform Corrosion. Filiform corrosion (refer to Fig-ure 2-17), is a special form of oxygen concentration cellcorrosion or crevice corrosion which occurs on metal sur-faces having an organic coating system. It is recognized byits characteristic wormlike trace of corrosion products be-neath the paint film. Filiform occurs when the relative hu-midity of the air is between 78 and 90%, and when the sur-face is slightly acidic. It starts at breaks in the coating system,such as scratches and cracks around fasteners and seams,and proceeds underneath the coating, due to the diffusion ofwater vapor and oxygen from the air through the coating.(Refer to Figure 2-18). Filiform corrosion can attack steel,magnesium, and aluminum surfaces, and may lead to moreserious corrosion in some locations. Filiform corrosion canbe prevented by storing equipment and aircraft in an envi-ronment with a relative humidity below 70%, by using coat-ing systems having a low rate of diffusion for oxygen andwater vapors, by maintaining coatings in good condition, andby washing equipment and aircraft to remove acidic con-taminants from the surface (such as those created by pollut-ants in the air). Maintain coatings in good condition (prompttouch-up around fasteners) and apply corrosion preventivecompounds (CPC’s) when paint is damaged.

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Figure 2-14. Concentration Cell Corrosion

Figure 2-15. Stress Corrosion Cracking

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2.7.9 Fretting Corrosion. This is a special form of con-centration cell corrosion which occurs in combination withsurface wear. The corrosion products increase the wear ofthe surface and the wear exposes more bare metal surface tobe corroded. The overall effect is greater than the single ef-fects of corrosion and wear added together. It has the generalappearance of galling, in which chunks of metal are tornfrom the surface with corrosion at the torn areas or raggedpits. This type of corrosion occurs on faying surfaces of closetolerance and on parts under high pressure in a corrosive

environment when there is slight relative movement of theparts such as that caused by vibration. Fretting corrosion isnormally encountered in heavily loaded static joints whichare subject to vibration and are not and/or cannot be sealedto prevent moisture entry, such as landing gear componentattachment areas having lug holes with slight press fits orslip fit bushings with very close tolerance bolts passingthrough the bushings. Another area is wing root access pan-els or wing-to-body fairings, which are generally not tightlysecured and cannot be sealed in faying surfaces.

Figure 2-16. Galvanic Series of Metals and Alloys in Sea Water

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2.7.10 High Temperature Oxidation (Hot Corrosion).Corrosion in the absence of water can occur at high tempera-tures, such as those found in turbine engine compressors andhot sections. When hot enough, metals can react directly withthe surrounding gases producing oxide scale (by-products ofoxidation). Contaminants, such as chlorides and sulfates (by-products of sulfidation), can accelerate the hot corrosion re-action by reducing the melting point of the metallic oxideand promoting its vaporization. High temperature ceramiccoatings can reduce this type of corrosion but are usuallyapplied only by the manufacturer due to highly specializedequipment required for application.

2.8 METALS AFFECTED BY CORROSION.

Characteristics of corrosion on metals are summarized inTable 2-1. The following is a discussion of corrosion char-acteristics of metals commonly used on aircraft, missiles,and related equipment.

2.8.1 Magnesium. Magnesium alloys are the lighteststructural metals used for aircraft and missile airframes.These alloys are highly susceptible to corrosion, which ap-pears as white, powdery mounds or spots when the metal

Figure 2-17. Filiform Corrosion Found Under Paint Coating on a Magnesium Panel

Figure 2-18. Schematic of the Development of Filiform Corrosion on an Aluminum Alloy

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surface is exposed to the environment without a protectivefinish. (Refer to Figure 2-19). The normal oxide-carbonatefilm formed on magnesium alloys does not provide sufficientcorrosion protection even in the mildest environment. Thecorrosion rate of a magnesium alloy increases when the al-loy is immersed in water, periodically subjected to moisture,coupled to a dissimilar metal, or exposed to water in whichconductive contaminants are dissolved. Corrosion of magne-sium alloys can be greatly diminished by the use of theproper protective finish. Some magnesium parts in currentaircraft and missiles have been originally protected by anod-izing processes, such as the ASTM D 1732, Class II, TypeIII (MIL-M-45202, Type I, Class A) HAE and the ASTM D1732, Class II, Type II (MIL-M-45202, Type I, Class C)DOW 17 coatings. The HAE process can be identified by thebrown to mottled gray appearance of the unpainted surface.DOW 17 coatings have a green to grayish-green color. Coat-ings of this type are thicker than those applied by immersionor brushing. Anodized finishes cannot be restored in the field.Care should be taken to minimize removal of these coatings.

2.8.2 Steel. Ferrous (iron) alloys are used to manufacturemany aircraft and missile components, and massive struc-tural assemblies in aircraft and missile ground support equip-ment, such as missile gantries, silo crib structures, framesand bodies of trailers and vans, and lesser structural partssuch as brackets, racks, and panels. If unprotected, ferrousalloy surfaces (with the exception of Corrosion ResistantSteels (CRES) or stainless steels) easily corrode or rust inthe presence of moisture. Ferrous alloy surfaces of structuresor assemblies are normally painted or plated and painted toprevent corrosion. Corrosion of steel is easily recognized be-cause the corrosion product is red rust. (Refer to Figure2-20). When ferrous alloys corrode, a dark corrosion productusually forms first, and when moisture is present, it convertsto red rust. Further attack is promoted by the rust absorbingmoisture from the air. Effective sacrificial coatings that pre-vent corrosion on ferrous alloys are cadmium plating or lowhydrogen embrittling zinc nickel (LHE Zn-Ni) plating perdrawing 201027456 (for all steels including high strengthsteels) or 201427084 (for low strength steel fasteners). LHE

Zn-Ni is an environmentally friendly alternative to cadmiumthat provides equivalent corrosion protection for ferrous al-loys including high strength steels. When switching fromcadmium to LHE Zn-Ni, the LHE Zn-Ni should be specifiedwith the same Type and Class (thickness) as the originalcadmium coating. Paint is often applied over cadmium orLHE Zn-Ni plated surfaces to provide additional protection.Testing has shown good performance when painting LHEZn-Ni coatings with epoxy primers per MIL-PRF-85582Type I, Class C2 or N or MIL-PRF-23377 Type I, Class C2or N.

2.8.3 Aluminum. Aluminum and its alloys are the mostwidely used materials for aircraft and missile construction.Aluminum is highly anodic as evidenced by its position inthe galvanic series. (Refer to Figure 2-16). However, the for-mation of a tightly adhering oxide film offers increased re-sistance under mild corrosive conditions. The corrosion prod-ucts of aluminum (refer to Figure 2-21), are white to graypowdery materials (aluminum oxide or hydroxide), whichcan be removed by mechanical polishing or brushing withabrasive. It is anodic to most other metals and, when in con-tact with them, galvanic corrosion of the aluminum will oc-cur. Aluminum alloys are subject to pitting, intergranularcorrosion, intergranular stress corrosion cracking, and corro-sion fatigue cracking. In some cases, the corrosion productsof the metal in contact with aluminum are corrosive to alu-minum. Therefore, it is necessary to clean and protect alumi-num and its alloys to prevent corrosion. Since pure alumi-num is more corrosion resistant as well as being more anodicthan most alloys, aluminum alloy sheet stock is often cov-ered with a thin layer of nearly pure aluminum called alclad.While fully intact, the alclad layer is very resistant to corro-sion because a very adherent oxide film rapidly forms on itssurface to protect it. Alclad is easily removed by harsh treat-ment with abrasives and tooling, exposing the more corro-sion susceptible aluminum alloy base metal surface. If thebreak in the alclad layer is small, the alclad will sacrificiallycorrode and protect the exposed base metal alloy because itis more anodic than the alloy. In such areas, chemical con-version coatings, paints, and corrosion preventive compoundsare especially important. In a marine environment, all alumi-num surfaces require protection.

2.8.4 Anodized Aluminum. Some aluminum parts areprotected with an electrochemically applied oxide coating(i.e., anodize). An aluminum oxide film on aluminum is anaturally occurring protective film, and anodizing merely in-creases the thickness and density of the oxide film. Whenthis coating is damaged in service, it can be only partiallyrestored by chemical conversion coating treatment of thedamaged area. (Refer to Chapter 5, Section II). Avoid dam-age (e.g., nicks and scratches) to the anodized surface duringprocessing of anodized aluminum alloy parts.

2.8.5 Titanium. Titanium and titanium alloys have manyuses in aircraft and missiles at temperatures up to 1,000° F(540° C). Above 1000° F, titanium readily absorbs gases fromthe surrounding air becoming very brittle. Titanium and its

Figure 2-19. Magnesium Corrosion Products

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alloys are highly corrosion resistant because an extremelyadherent oxide film forms on their surfaces almost immedi-ately upon contact with air and thus provides a protectivebarrier. This is identical to the way aluminum forms a pro-tective oxide film on its surface. Even at temperatures ap-proaching 1,000° F, titanium retains its strength and corro-sion resistance. When titanium is heated, different oxideshaving different colors form on the surface. A blue oxide

coating will form at 700° to 800° F (370° to 425° C), apurple oxide will form at 800° to 950° F (425° to 510° C),and a gray or black oxide will form at 1,000° F (540° C) orhigher. These are protective discolorations and should not beremoved. Titanium is the less active member (cathodic) ofmost dissimilar metal couples, and could possibly greatlyaccelerate corrosion of a dissimilar metal coupled to it.However, electrical insulation between titanium and other

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metals is provided by the rapidly formed, very adherent,non-conductive oxide film, which prevents galvanic corro-sion of the other metal. Frequent inspection of such areas isrequired to ensure that the oxide film has not failed and al-lowed corrosion to begin. Under certain conditions, chlo-rides and some chlorinated solvents may induce stress corro-sion cracking of certain titanium alloys.

2.8.6 Copper and Copper Alloys. Copper and copper al-loys are quite corrosion resistant and corrosion is usuallylimited to staining and tarnish. Generally, such changes insurface conditions are not dangerous and should ordinarilyhave no effect on the part. Copper corrosion is evidenced bythe accumulation of blue or blue-green corrosion productson the corroded part. Protective paint coatings are seldom

required because of the inherent resistance of the metal.However, paint finishes may be applied for decorative pur-poses or if the normal tarnish or green patina on the copperis objectionable. The green patina is merely a thin coatingconsisting mainly of basic copper sulfate and perhaps hy-drated copper carbonate. The patina in the thin, firmly adher-ing state actually offers increased corrosion protection to thebase metal, but the patina in a rough or frosted state shouldbe removed. When coupled with most metals used in aircraftconstruction, copper is the less active metal and greatly ac-celerates corrosion of the other metals. This is especiallytrue in copper/aluminum couples. Examples are usuallyfound in electrical components and in areas where copperbonding strips or wires are fastened to an aluminum chassisor structural components.

Figure 2-20. Steel Corrosion Products (Rust)

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Figure 2-21. Aluminum Surface Corrosion Products

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Table 2-1. Corrosion of Metals - Type of Attack and Appearance of Corrosion Products

Alloys Type of Attack to Which Alloy is Susceptible Appearance of Corrosion ProductMagnesium Alloy Highly susceptible to pitting. White, powdery, snow-like mounds, and

white spots on the surface.Low Alloy Steel (4000-

8000 Series)Surface oxidation and pitting; surface and inter-

granular corrosion.Reddish-brown oxide (rust).

Aluminum Alloy Surface pitting, intergranular, exfoliation, stresscorrosion and corrosion fatigue cracking, andfretting.

White to gray powder.

Titanium Alloy Highly corrosion resistant; extended or repeatedcontact with chlorinated solvents may result indegradation of the metal’s structural proper-ties.

No visible corrosion products at low tempera-ture. Various colored surface oxides de-velop above 700° F (360° C). Color depen-dant on temperature.

Cadmium (used as aprotective plating forsteel)

Uniform surface corrosion; used as sacrificialplating to protect steel.

From white powdery deposit to brown orblack mottling of the surface.

Stainless Steels (300-400 Series)

Crevice/concentration cell corrosion; some pit-ting in marine environments; corrosion crack-ing; intergranular corrosion (300 Series); sur-face corrosion (400 Series).

Rough surface; sometimes a red, brown, orblack stain.

Nickel-base Alloy (Inc-onel, Monel)

Generally has excellent corrosion resistancequalities; susceptible to pitting in sea water.

Green powdery deposit.

Copper-base Alloy,Brass, Bronze

Surface and intergranular corrosion. Blue or blue-green powdery deposit (patina).

Chromium (plate) Pitting (promotes rusting of steel where pits oc-cur in plate).

No visible corrosion products; blistering ofplating due to rusting of the base metal andlifting of plating.

Figure 2-22. Cadmium Plated Surface Conditions

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2.8.7 Cadmium. Metal parts are plated either to increasethe corrosion resistance of the parts or to develop certainphysical properties on the surface of the parts, such as abra-sion (wear) resistance and high temperature oxidation resis-tance. Parts may also be plated to create a compatible dis-similar metal contact, to provide a satisfactory surface forsoldering, or to provide a sacrificial metal layer. Cadmium isused as a coating to protect metal parts and to provide acompatible surface when a part is in contact with other ma-terials. Attack on cadmium is evidenced by brown to blackmottling of the surface or as white powdery corrosion prod-ucts. When cadmium shows mottling and isolated voids orcracks in the coating, the plating is still performing its pro-tective function. The cadmium plate on iron or steel contin-ues to protect until such time as actual iron rust appears.(Refer to Figure 2-22). Even then, any mechanical removalof corrosion products should be limited to metal surfacesfrom which the cadmium has been depleted.

2.8.8 CRES/Stainless Steel. Basically, stainless steels,or corrosion resistant steels (CRES), as they are more prop-erly described, are alloys of iron with chromium and nickel.Many other elements, such as sulfur, molybdenum, vana-dium, cobalt, columbium, titanium, and aluminum are addedin various amounts and combinations to develop specialcharacteristics. Stainless/CRES steels are much more resis-tant to common rusting, chemical action, and high tempera-ture oxidation than ordinary steels, due to the formation ofan invisible oxide film or passive layer on the surface ofthese alloys. Corrosion and heat resistance are the major fac-tors in selecting stainless/CRES steels for a specific applica-tion. However, it should be well understood that stainless/CRES steels are not the cure-all for all corrosion problems,due to service conditions which can destroy the oxide filmon their surfaces. Stainless/CRES steels are highly suscep-tible to crevice/concentration cell corrosion and stress corro-sion cracking in moist, salt laden environments and can causegalvanic corrosion of almost any other metal with whichthey are in contact if proper techniques of sealing and pro-tective coating are ignored. Stainless/CRES steels may bemagnetic or non-magnetic. The magnetic steels are identifiedby numbers in the American Iron and Steel Institute (AISI)400-Series, such as 410, 430, etc. These steels are not ascorrosion resistant as the non-magnetic steels which areidentified by numbers in the AISI 300-Series, such as 304,316, etc. The AISI 300-Series steels have nickel contentsranging from 6% to 22%, while the 400-Series steels havenickel contents of only 2%.

2.8.9 Nickel and Chromium. Nickel and chromium areused as protective platings. Chromium plating is also used toprovide a smooth, wear-resistant surface and to reclaim wornparts. Where corrosion resistance in a marine environment isrequired, a nickel undercoat is used. The degree of protec-tion is dependent upon plating thickness. Both of these met-als form continuous oxide coatings that can be polished to a

high luster and still protect not only themselves but also anyunderlying metal. Chromium platings contain micro-cracks,and corrosion/rust originates on the base metal below theseseparations and peels the plating from the surface. Figure2-22 shows the results of a failed chromium plate.

2.8.10 Silver, Platinum, and Gold. These metals do notcorrode in the ordinary sense, although silver tarnishes in thepresence of sulfur. The tarnish is a brown-to-black film. Goldtarnish is not really corrosion but is a very thin layer of soilsor contaminants that shows up as a darkening of the reflect-ing surfaces. All these metals are highly cathodic to almostall other metals and can cause severe galvanic corrosion ofalmost any metal with which they are in contact in the pres-ence of moisture if joint areas are not sealed or otherwiseinsulated.

2.8.11 Graphite/Carbon Fiber Composites. Graphite orcarbon fiber composites are materials which consist of rein-forcing fibers in a matrix, made of organic resin, usuallyepoxy. They are an important class of aviation materials be-cause of their high strength-to-weight ratios and high stiff-ness. Since carbon is the least active metal in the galvanicseries, it will accelerate the corrosion of any aircraft metal towhich it is coupled. Insulation between graphite or carbonepoxy composites and other metals is necessary to preventdissimilar metal attack on the attached part.

2.9 CORROSIVE ENVIRONMENTS.

Corrosion of aircraft, missiles, and equipment is caused byboth natural and man-made environments. Natural condi-tions, which affect the corrosion process, are moisture, tem-perature, salt atmospheres, ozone, sand, dust, solar radiation,insects and birds, and microorganisms. Man-made condi-tions, which also affect the corrosion process, are industrialpollution, manufacturing operations, storage conditions, andshipment. By understanding these conditions, maintenancepersonnel will be better able to prevent aircraft damage.

2.9.1 Moisture. Moisture is present in air as a gas (watervapor) or as finely divided droplets of liquid (mist or fog)and often contains contaminants such as chlorides, sulfates,and nitrates, which increase its corrosive effects. Moistureenters all areas of an aircraft or missile that air can enter. Allenclosed areas, which are not sealed, allow air to enter andleave as the difference in pressure between inside and out-side changes. These pressure differences occur when the air-craft changes altitude, when atmospheric pressure changes,and when the temperature of air inside an enclosed areachanges. Moisture will condense out of air when the air be-comes too cool to hold all of the moisture in it. The dewfound on aircraft and missile exteriors and many times ontheir interior surfaces after a cool night is the result of con-densation.

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2.9.1.1 Condensed Moisture. Condensed moisture willusually evaporate as surrounding air warms, but will leaveits contaminants (residues), including salts, behind. This canresult in the buildup of soils and salt contamination. Con-densed moisture and its contaminants can also be trapped inclose fitting wettable joints, such as faying surfaces. Somegasket and packing materials will absorb several times theirweight in water and, when heated, can transmit this retainedmoisture into the sealed area. Moisture can accumulate insuch areas through successive cycles of warming and cool-ing leaving pools of moisture and a relative humidity ap-proaching 100%. This is known as the desert still effect. Inaddition, moisture can be drawn into poor bond lines bycapillary action (wicking). Conditions of temperature andhumidity can vary widely in separate sections of aircraft de-pending on the success of environmental sealing condensa-tion and location near heat-generating equipment.

2.9.1.2 Effect of Moisture. Electrolyte formation resultsfrom condensation and/or collection of moisture. All non-metals absorb some moisture, which may cause changes indimensional stability, dielectric strengths, ignition voltages,and volume insulation resistances. In general, organic matrixcomposites are adversely affected by moisture and may suf-fer a loss of strength and stiffness from exposure. Hermeticsealing (liquid and vapor proof at normal temperatures andpressures) is recommended for moisture-critical items suchas capacitors and quartz crystals. Refer to TO 1-1-689 seriesfor additional information related to electronics equipment.

2.9.2 Temperature. Temperatures at the high end of therange for which equipment is designed may result in eitherimprovement or degradation of equipment, depending on

conditions. Some electronic equipment may not functionproperly at high temperatures. Generally, corrosion and otherharmful processes (such as the degradation of non-metallicmaterials) increase as temperatures rise, but in some in-stances, moderate increases in temperature may serve to re-duce corrosion by preventing condensation. Growth of moldsand bacteria is also inhibited by temperatures above 104° F(40° C). Temperatures at the low end of the design rangegenerally reduce the rate of corrosion.

2.9.3 Salt Atmospheres. When dissolved in water, saltparticles form strong electrolytes. The ocean, which carriesfrom 3.5 to 3.9% salt, is the world’s primary source of salt.Normal sea winds carry from 10 to 100 pounds of sea saltper cubic mile of air. Since dissolved salts are strong elec-trolytes, it is easy to understand why shipboard and coastalenvironments are highly corrosive.

2.9.4 Ozone. Ozone is a particularly active form of oxy-gen, which is formed naturally during thunderstorms, by arc-ing in electrical devices, and by photochemical reactions insmog. When ozone is absorbed by electrolyte solutions incontact with metals, it increases the rate of corrosion. It alsooxidizes many non-metallic materials, being particularlyharmful to natural and certain types of synthetic rubber.Rubber seals stored near welding equipment have experi-enced complete degradation.

2.9.5 Other Industrial Pollutants. Carbon (from internalcombustion engine exhaust), nitrates (from agricultural fer-tilizers), ozone (from electrical motors and welding opera-tions), sulfur dioxide (from engine exhaust and industrial and

Figure 2-23. Failed Chromium Plating

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ship smoke stacks), and sulfates (from automobile exhaust)are important airborne pollutants. The combination of thesepollutants contributes to the deterioration of non-metallicmaterials and severe corrosion of metals.

2.9.6 Sand, Dust, and Volcanic Ash. Sand, dust, andvolcanic ash are present in many areas. In industrial areas,they often contain a number of tar products, ashes, and soot.Dust is also found in the tropic zones during times of little orno rainfall. Sand and dust are extreme problems in the des-erts, since dry, powdery sand and dust are carried by wind.During sandstorms, they can penetrate sealed equipment aswell as many internal areas of airframes, and small sandparticles are often blown as high as 10,000 feet by the siroc-cos hot, dust laden winds). Sand, dust, and volcanic ash arehygroscopic and, when present on internal or external sur-faces of aircraft or electronic parts, can absorb and holdmoisture. The presence of sand, dust, and volcanic ash mayalso effect the operation of electrical contacts, prevent properaction of rotating motor-drive devices, and cause malfunc-tions of indicating instruments. Dust from volcanic areascontains chlorides and sulfates, which are extremely corro-sive in the presence of moisture. Although small amounts ofsand or dust may be unnoticed by operating personnel, theymay be sufficient to promote corrosion and wear.

2.9.7 Solar Radiation. The two ranges of solar radiationmost damaging to materials are ultraviolet, the range thatcauses sunburn, and infrared, the range that makes sunlightfeel warm. On earth, maximum solar radiation occurs in thetropics and equatorial regions, but considerable damage oc-curs in the temperate zones as a result of solar heating, pho-tochemical effects, and combinations of these two phenom-ena. Non-metals, especially organic and synthetic materials,are strongly affected by sunlight. Both natural and syntheticrubber deteriorates rapidly in sunlight. After extended expo-sure, plastics darken, paints lose their protective characteris-tics, polymers undergo marked decreases in strength andtoughness, and colors fade. This can lead to removal of es-sential color-coding on tubing and electronic components.Most electronic equipment is housed in enclosed structuresand is protected from solar radiation. Extra care must betaken in the selection and surface treatment of parts, such ascables and harnesses that are to be exposed to exterior envi-ronments.

2.9.8 Climate. Warm, moist air, normally found in tropi-cal climates, tends to accelerate corrosion while cold, dry air,normally found in arctic climates, tends to reduce corrosionrates. Corrosion does not occur in very dry conditions. Forthis reason, desiccants are used in shipping containers toproduce very dry local environments. The operational cli-mate extremes have always been considered in aircraft de-sign. However, certain areas within an aircraft, such as thecockpit and air-conditioned equipment bays, may be sub-jected to climatic conditions very different from external ar-eas of the aircraft. Relatively warm, dry air that has beencooled by air conditioners, thus increasing its relative hu-midity, and ducted into interior areas of the aircraft withoutdrying or passing it through an expansion valve can release

sufficient moisture to accelerate corrosion. It is imperative toconsider not only the exterior operational environment butalso the environments in which the equipment will be fabri-cated, transported, reworked, repaired, and mounted insidethe aircraft or missile.

2.9.8.1 Desert. Hot, wind-swept deserts create a severemaintenance problem because powdery dust can penetrateeven supposedly sealed components. High daytime tempera-tures, high humidities (in areas such as the Persian Gulf),ultraviolet radiation, and fine dust are the four most serious,destructive elements of the desert climate. Non-metallic ma-terials suffer the most damage from the hot desert climateswhere air temperature during the day may reach 124° F (51°C). Temperatures inside closed containers may be 100° F(38° C) higher than external air temperatures.

2.9.8.2 Temperate Zones. The temperate or intermediateclimate zone encompasses most of the North American andEuropean continents. These areas at various times of the yearmay approximate the extremes of polar, desert, or tropicaltemperatures and humidity. The temperate zone temperaturesrange from -25° to +59° F (-32° to +15° C) in the winter andfrom +59° to +125° F (+15° to +52° C) in the summer. Therelative humidity (RH) also fluctuates between 5 and 100.The most critical areas are coastal locations during the warmperiods of the year in which the RH approaches 100% atnight and the air has high concentrations of salt. Moisturefrom this salt-laden air can condense on equipment duringearly evening and morning hours, thereby causing seriouscorrosion. Because of its relatively mild temperatures, thetemperate zone is also the most heavily populated. Conse-quently, the smoke, smog, ozone, and corrosive fumes asso-ciated with heavy industry are also found there.

2.9.8.3 Tropics. The greatest challenge to the aircraft andmissile industries is to the design equipment that is protectedfrom corrosion and deterioration in the heat and humidity oftropical climates. Even though they encompass only a smallportion of the earth’s land area, the tropics demand thegreatest amount of consideration from the standpoint of cor-rosion treatment and control. Relative humidities of up to100% at ambient (room) air temperatures of 85° F (29° C)and above create a formidable threat of corrosion. When highhumidity and temperature conditions are combined with salt-laden air, the corrosive environment becomes extremely se-vere. The critical combination of high temperatures, conden-sation, high relative humidity, and contaminants such as saltand sand, may cause catastrophic failure of equipment. De-terioration of the materials used in electronic equipment mayalso be accelerated.

2.9.9 Factors of Influence in Tropical Environments.Tropical environments are noted for long periods of heavyrainfall during which 100 inches or more of rain may fall.Extended periods of high heat and humidity contribute torapid corrosion of metals, cracking and flaking of rubber andplastic materials, and deterioration of seals. Equipment,whether stored or in use, requires special protective contain-

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ers/measures and frequent preventive maintenance. microor-ganisms multiply excessively in tropical environments andattack many non-metallic materials. Many items becomecovered with fungi in a matter of hours. Electronic equip-ment requires special efforts for effective operation in thetropics. Intensive preventive maintenance and the best pos-sible protective techniques are necessary for aircraft, mis-siles, and their components in tropical environments.

2.9.10 Manufacturing. During the manufacture, assembly,or repair of aircraft, missiles, and their subsystems, manyfactors that might lead to corrosion may be introduced. Theuse of unsuitable materials and improper materials process-ing can cause corrosion. The shearing or hole-punching op-erations on some metal alloys, especially high strength alu-minum, may introduce stresses that eventually lead to stresscorrosion cracking. Assembly of parts in areas contaminatedby fumes or vapors from adjacent operations may result inentrapment of the fumes or vapors in the equipment whichmay cause future corrosion. Spaces that are air conditionedwithout humidity control may be sources of condensed mois-ture.

2.9.11 Storage. Even traces of corrosive vapors in pack-ages containing aircraft or missile parts may result in seriouscorrosion. Moreover, the natural breathing of packages mayintroduce moisture into the parts and equipment. Some pack-ing materials have been known to decompose and emit cor-rosive vapors during periods of prolonged storage. Refer toTO 1-1-17 and the system specific (-17) manual for addi-tional storage information.

2.9.12 Shipment. During shipment, materials such asplastics and lubricants are often exposed to environmentsthat were not considered during the design stage. Materialsshipped by air are subjected to changes in atmospheric pres-sure and can lose volatile components by out-gassing. Thevibration and mechanical shocks associated with shipmentby truck can damage protective coatings or platings. Ship-ment by ocean vessel may expose the equipment to corro-sive marine environments, vibrations and shock from enginesor sea conditions, and residual corrosive vapors from previ-ous shipments. Although packaging equipment in accordancewith MIL-STD-2073-1 will protect the equipment from cor-rosive environments, packaging may be damaged duringhandling and thus become ineffective.

2.9.13 Industrial and Ship Emitted Air Pollutants.Smog, smoke, soot, and other airborne contaminants are ex-tremely corrosive to exposed aircraft, missiles, and equip-ment. Many of the fumes and vapors emitted by ships andfrom factories can greatly accelerate metal corrosion. Indus-trial atmospheres may exist over large areas, since wind maycarry these corrodents many miles from their source. Gener-ally, air pollutants, when combined with water, create elec-trolytic solutions and accelerate corrosion.

2.9.14 Animal Damage. Damage to aircraft, missiles, andtheir subsystems may be caused by insects, birds, and vari-ous small animals, especially in tropical environments.

Equipment in storage is most susceptible to this type of at-tack, since animals may enter through vent holes or tears inpackaging and sometimes build nests. Moisture absorbed bynests plus excretions from animals may cause corrosion anddeterioration that goes unnoticed until equipment is put intouse and fails. Another type of damage may occur when or-ganic materials, such as upholstery, are shredded for nests orconsumed as food.

2.9.15 Microorganisms. Microbial attack includes the ac-tion of bacteria, fungi, or molds. Microorganisms are nearlyeverywhere and outnumber all other types of living organ-isms. Organisms that cause the greatest corrosion problemsare bacteria and fungi. Damage resulting from microbialgrowth can result from (1) the tendency of the growth tohold moisture which then causes corrosion, (2) digestion ofthe substrate as food for the microorganism, or (3) corrosionof the surface beneath the growth by secreted corrosive flu-ids

2.9.15.1 Bacteria. Bacteria may be either aerobic or an-aerobic. Aerobic bacteria require oxygen to live. They canaccelerate corrosion by oxidizing sulfur to produce sulfuricacid or ammonia to produce nitric acid. Bacteria living on oradjacent to metals may promote corrosion either by deplet-ing the oxygen supply or by releasing metabolic products.Anaerobic bacteria, on the other hand, can survive only whenfree oxygen is not present. The metabolism of these bacteriarequires them to obtain food sources by oxidizing inorganiccompounds such as iron, sulfur, hydrogen, and carbon mon-oxide. The resultant chemical reactions cause corrosion.

2.9.15.2 Microbial Growth Requirements. Fungi makeup one class of microorganisms that feed on organic matter.Low humidity levels inhibit the growth of most species offungi and bacteria. Ideal growth conditions for most fungiand bacteria are temperatures of +68° to +104° F (+20° to+40° C) and relative humidities of 85 to 100%. It was for-merly believed that microbial attack could be prevented byapplying moisture-proof coatings to nutrient materials or bydrying the interiors of compartments with desiccants. How-ever, some moisture-proof coatings are attacked by microor-ganisms, especially if the surface to which they are appliedis contaminated. Some microorganisms can survive in sporeform for long periods while dry and can become active whenmoisture is available. When desiccants become saturated,they form what is known as a “desiccant pump” whichpumps their absorbed moisture into the affected area byevaporation and allows microorganisms to begin to grow.Dirt, dust, and other airborne contaminants are the least rec-ognized contributors to microbial attack. Unnoticed, smallamounts of airborne debris may be sufficient to promote fun-gal growth by absorbing moisture.

2.9.15.3 Microbial Nutrients. Since fungi, bacteria, andother microorganisms are classified as living, it was previ-ously thought that only materials derived from living organ-isms could provide them with food. Thus wool, cotton,feathers, leather, etc., were known to be microbial nutrients.To a large extent, this rule of thumb is still valid but the

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increasing complexity of synthetic materials makes it diffi-cult, if not impossible, to determine from the name alonewhether a material will support growth of microorganisms.Many otherwise resistant synthetic materials are renderedsusceptible to microbial attack by the addition of chemicalswhich change the properties of the material. In addition, dif-ferent species of microorganisms have different growth re-quirements. The service life, size, shape, surface smooth-ness, cleanliness, environment, and species of microorganisminvolved all determine the degree of microbial attack on theaffected item.

2.10 DEGRADATION OF NON-METALS.

Non-metallic materials (plastics, elastomers, paints, and ad-hesives) are not subject to electrochemical corrosion, sinceions are not easily formed from non-metallic materials andtheir electrical conductivity is extremely low. The degrada-tion of non-metals depends on the chemical makeup of thematerial and the nature of the environment. In general, non-metallic materials on aircraft, missiles, and related equip-ment are selected for their obvious performance properties(flexibility, transparency, strength, electrical resistance, etc.,)as well as their resistance to heat, impact, abrasion, ultravio-let radiation, moisture, ozone and other detrimental gases,and operational fluids such as hydraulic fluid, lube oil, clean-

ers, deicing fluids, etc. However, the use of unauthorizedmaintenance chemicals and procedures can accelerate degra-dation and ultimately lead to material failure resulting inleakage, corrosion, electrical shorts, crazing, and/or mechani-cal failure.

2.11 PREVENTIVE MAINTENANCE.

The two most important factors in preventing corrosion, andthe only ones which can be controlled by field personnel, arethe removal of the electrolyte and the application of protec-tive coatings. Since the extent of corrosion depends on thelength of time electrolytes are in contact with metals, corro-sion can be minimized by frequent washing. If noncorrosivecleaners are used, the more frequently a surface is cleaned ina corrosive environment the less the possibility of corrosiveattack. In addition, by maintaining chemical treatments, paintfinishes, lubricants, and corrosion preventive compounds(CPC’s) in good condition, corrosion can be minimized. Thedegradation of non-metallic materials can be minimized byavoiding the use of unauthorized maintenance chemicals andprocedures. In addition, when repair or replacement of non-metallic materials is required, use only approved materials.Dedication to proper preventive maintenance practices maxi-mizes equipment reliability.

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CHAPTER 3PREVENTIVE MAINTENANCE

SECTION I INTRODUCTION

3.1 PREVENTIVE MAINTENANCE PROGRAM.

As directed by AFI 20-114, the prevention and control ofcorrosion on aircraft missiles and related equipment is acommand responsibility. Each command must place specialemphasis on the importance of the corrosion control pro-gram and lend its full support to ensure that corrosion pre-vention and control receives sufficient priority to be accom-plished along with other required maintenance.

3.1.1 Preventive Maintenance. Aluminum and magne-sium alloys found in aviation equipment will corrode if saltdeposits, other corrosive soils, or electrolytes are allowed toremain on their surfaces. To prevent corrosion, a constantcycle of cleaning, inspection, operational preservation, andlubrication must be followed. Prompt detection and removalof corrosion will limit the extent of damage to aircraft com-ponents. An effective preventive maintenance program re-quires all of the procedures specified in this chapter, but alsoincludes corrosion removal, paint removal, surface treatment,sealing, and painting. A disciplined preventive maintenanceprogram includes the following:

a. Regularly scheduled aircraft washing as specified inTable 3-1.

b. Regularly scheduled cleaning or wipe down of all ex-posed unpainted surfaces, such as landing gear strutsand actuating rods of hydraulic cylinders with a com-patible fluid or lubricant as specified by system spe-cific technical orders.

c. Keeping low-point drains open.

d. Inspection, removal, and reapplication of corrosionpreventive compounds (CPC’s) on a scheduled basis.

e. Earliest detection and repair of damaged protectivecoatings.

f. Use clean/fresh potable water for all aircraft, missile,and equipment washing and rinsing operations.

g. If using closed-loop water recycling systems for wash-ing aircraft, water shall meet the following require-ments and be tested every 30 days to detect anybuild-up of corrosive salts and/or other contaminants.Any abnormal readings should be reported to theAFCPCO for waiver consideration.

(1) Chloride content shall be 400 mg/L maximum(somewhat higher than EPA potable drinking wa-ter standard of 250 mg/L).

(2) pH shall be between 6.5 and 8.5.

(3) Total dissolved solids (TDS) content shall be 500mg/L maximum.

(4) Total suspended solids (TSS) content shall be 5mg/L maximum.

(5) The Langlier Saturation Index shall be slightlyabove 0.

(6) The biological oxygen demand (BOD) concentra-tion shall be 5 mg/L maximum.

(7) Adequate disinfection of the water shall be pro-vided to control the growth of microorganisms inthe water.

(8) The water hardness shall be between 75 and 150mg/L as CaCO3.

(9) The total petroleum hydrocarbon (TPH) contentshall be 10 mg/L maximum.

h. Use padded panel racks to store panels/parts for air-craft and equipment during maintenance; use protec-tive measures to prevent abrasions/scratches resultingfrom placement of parts, tools, tool boxes, etc., onwings, fuselage or other aircraft surfaces.

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Change 3 3-1

Table 3-1. Aircraft Wash Intervals

Air Base Name and Location Wash Interval by Severity* Asterisks before Air base Name and Location designatesenvironments considered as SWA and fall under Chapter 9.

Severe (30Days)

Moderate (90Days)

Mild (180Day)

*Afghanistan (All Locations) X*Aj Taif, SA X*Al Dhafra UAE X*Al Jouf, SA X*Al Udeid AB QATAR X*Ali Al Salem Kuwait XAllen C. Thompson Fld.; Jackson, MS XAltus AFB, OK XAnderson AFB, GU XAnchorage IAP, AK XAndrews AFB, MD (Washington DC) X*As Sulayyil, SA XAtlantic City, NJ XAviano AB, IT X*Bahrain X*Balad, Iraq XBangor IAP, ME XBarksdale AFB; Shreveport, LA XBarnes M. Apt.; Westfield, MA XBattle Creek, MI XBeale AFB; Marysville, CA XBirmingham Apt.; AL XBoise Air Term., ID (ANG) XBradley IAP; Windsor Locks, CT XBrindisi/Casale AB, IT XBuckley ANGB; Denver, CO XBurlligton IAP, VT XByrd Fld.; Richmond,VA X*Camp Lemonnier, Djibouti XCannon AFB; Clovis, NM XCapital Mun. Apt.; Springfield, IL XChannel Island; Port Hueneme NAS, CA XCharleston AFB, SC XCharleston Apt.; WV XCheyenne Apt.; WY XColumbus AFB, MS XCreech AFB, NV XCuracao Netherlands Antilles X*Cyprus International Airport XDanelly Fld.; Montgomery, AL XDavis-Monthan AFB; Tucson, AZ XDes Moines IAP, IA X*Dhahran, SA XDiego Garcia XDobbins ARB; Marietta, GA XDouglas IAP; Charlotte, NC XDover AFB, DE X

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3-2 Change 14 All data on pages 3-2.1 through 3-2.2 deleted

Table 3-1. Aircraft Wash Intervals - Continued


Severe (30Days)

Moderate (90Days)

Mild (180Day)

Duluth IAP, MN XDyess AFB; Abilene, TX XEareckson (Shemya) AFB, Aleutian Is., AK XEast. WV Reg. Apt.; Martinsburg, WV XEdwards AFB; Rosamond, CA XEglin AFB; Valparaiso, FL XEglin AFB (Aux Fld.; #3), FL XEielson AFB, AK XEllington Fld.; Houston, TX XEllsworth AFB; Rapid City, SD XElmendorf AFB; Anchorage, AK XFairchild AFB; Spokane, WA XFairford, UK XFalcon AFB, CO XForbes Fld.; KS XFort Kutaka Army Base, AZ XFort Rucker, Enterprise, AL XFort Smith Mun. Apt.; AR XFort Wayne Apt.; IN XFrancis E. Warren AFB; Cheyenne, WY XFresno Air Term., CA XGeilenkhirchen, GE XGen. Mitchell IAP; Milwaukee, WI XGrand Forks AFB; Emarado, ND XGreat Falls IAP, MT XGreater Peoria Apt.; IL XGriffiss AFB; Rome, NY XGrissom ARB; Peru, IN XHancock IAP; Syracuse, NY XHanscomb AFB; Bedford, MA XHarrisburg IAP, PA XHector IAP; Fargo, ND XHickam AFB; Honolulu, HI XHill AFB; Ogden, UT XHolloman AFB; Alamogordo, NM XHomestead ARB, FL XHoward AB; Panama XHulman Reg. Apt.; IN XHurlburt Fld.; Fort Walton Beach, FL X*Incirlick AB, Turkey XIstres AB, France XJacksonville IAP, FL X*Jeddah, SA XJoe Foss Fld.; Sioux Falls, SD XKadena AB, Japan XKeesler AFB; Biloxi, MS XKey Fld.; Meridian, MS X

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Change 14 3-3



Severe (30Days)

Moderate (90Days)

Mild (180Day)

*Khamis Mushay, SA X*Khandahar Afghanistan X*Kiruk Iraq X*King Khalid, SA XKingsley Fld.; Klamoth Falls IAP, OR XKirtland AFB, NM; Albuquerque, NM XKulis ANGB, Anchorage, AK XKunsan AB; S. Korea XLackland AFB, TX XLajes Fld.; Azores, Portugal XLambert Fld.; St. Louis IAP, MO XLangley AFB; Hampton, VA X*Larnaka International Apt.; Cyprus XLaughlin AFB; Del Rio, TX XLincoln Mun. Apt.; NE XLittle Rock AFB, AR XLuke AFB; Glendale, AZ XMacDill AFB; Tampa, FL XMalmstrom AFB; Great Falls, MT XManas Kyrgystan XMansfield Lahm Apt.; OH XMantas Ecuador XMarch ARB; Riverside, CA XMartin St. Apt.; Baltimore, MD XMaxwell AFB; Montgomery, AL XMcChord AFB; Tacoma, WA XMcConnell AFB, Wichita, KS XMcEntire ANGB; Columbia, SC XMcGhee Tyson Apt.; Alcoa, TN XMcGuire AFB; Wrightstown, NJ XMcMurdo Station Antarctica XMemphis IAP, TN XMinot AFB, ND XMinn.-St. Paul IAP, MN XMisawa AB, Japan XMoffett Fld.; CA XMoody AFB; Valdosta, GA XMoron AB, Spain XMountain Home AFB; Boise, ID XNAS Fort Worth, TX XNAS Keflavik, Iceland XNAS New Orleans, LA XNAS Pensacola, FL XNAS Sigonella; Sicily, Italy XNashville Met. Apt.; TN XNellis AFB; Las Vegas, NV XNewburgh Apt.; NY X

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3-4 Change 14



Severe (30Days)

Moderate (90Days)

Mild (180Day)

New Castle Co. Apt.; Wilmington, DE XNiagra Falls IAP, NY XOffutt AFB; Omaha, NE XO’Hare IAP; Chicago, IL XOsan AB; S. Korea XOtis ANGB; Falmouth, MA XPatrick AFB; Cocoa Beach, FL XPease ANGB; Portsmouth, NH XPeterson AFB; Colorado Springs, CO XPittsburgh IAP, PA XPope AFB; Fayetteville, NC XPortland IAP, OR X*Prince Sultan AB, Al Kharj, SA XPuerto Rico IAP/Muniz ANGB; San Juan, PR XQuonset St. Apt.; Providence, RI X*RAF Akrotiri, Cyprus XRAF Lakenheath, UK XRAF Mildenhall, UK XRAF Waddington, UK XRamstein AB, GE X XRandolph AFB; San Antonio, TX XReno/Tahoe IAP, NV XRhein-Main, GE XRickenbacker IAP; Columbus, OH X*Riyadh, SA XRobins AFB; Warner Robins, GA XRosecrans Mem. Apt.; St. Joseph, MO XSalt Lake City IAP, UT XSchenectady Co. Apt.; NY XScott AFB; Belleville, IL XSelfridge ANGB; Mount Clemens, MI XSeymour Johnson AFB; Goldsboro, NC XShaw AFB; Sumter, SC XSheppard AFB; Wichita Falls, TX XSioux Gateway Apt.; Sioux City, IA XSouda Bay, Crete XSky Harbor Apt.; Phoenix, AZ XSpangdalhem AB, GE XSpringfield-Bleckley Mun. Apt.; OH XStandiford Fld./Lvle. IAP; Louisville, KY XSuffolk Co. Apt.; NY X*Tabuk, SA XTaegu, S. Korea X*Talil Iraq XTinker AFB; Oklahoma City, OK X*Thumrait Oman XToledo Exp. Apt.; Swanton, OH X

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Change 14 3-5



Severe (30Days)

Moderate (90Days)

Mild (180Day)

Travis AFB; Fairfield, CA XTravis Fld.; Savannah, GA XTruax Fld./Dane City Reg. Apt.; Madison, WI XTucson IAP, AZ XTulsa IAP, OK XTyndall AFB; Panama City, FL XUSAF Academy, CO XVance AFB; Enid, OK XVandenburg AFB; Lompoc, CA XWestover AFB; Chicopee, MA XWhiteman AFB; Knobnoster, MO XWillow Grove ARS; Philadelphia, PA XWill Rogers IAP; Oklahoma City, OK XWright-Patterson AFB; Dayton, OH XYokota AB, Japan XYoungstown-Warren Reg. Apt.; ARS, OH X

SECTION II CLEANING

3.2 INTRODUCTION.

• Authorized cleaning agents and equipment arelisted in this chapter, Appendix A, and Appen-dix B. Order materials and equipment by NSNfrom the lists in these appendices through regu-lar supply channels, or local purchase fromvenders listed on the most current QPL/QPD ofa specification or by vender part number listedin these appendices for an authorized non-specification material.

• Specification QPL/QPD’s are the responsibilityof the authority for the specification. For infor-mation access, many cleaning and corrosionprevention and control process related specifi-cations having a QPL/QPD are available, withtheir most current revision, from the AF Portal.Search “AFCPCO”, or the Defense TechnicalInformation Center (DTIC) Scientific and Tech-nical Information Network web site: http://sti-net.dtic.mil.

• Do not use unauthorized cleaners. Althoughother commercial cleaners may appear to per-form as well as, or better than, approved prod-ucts, these materials may be corrosive to metalalloys used in aircraft, missiles, and relatedequipment. They can also accelerate degrada-

tion of non-metallic materials causing materialfailures which may result in fluid leakage, cor-rosion of surrounding metals, electrical shorts,crazing, and/or mechanical failure.

NOTE

Ozone depleting substances (ODS) are solventssuch as, but not limited to, 1,1,1 trichloroethane(MIL-T-81533) and trichlorotrifluoroethane (MIL-C-81302). These solvents, as well as productscontaining them, are still used in some aircraftmaintenance processes, including oxygen systemscleaning and some avionics cleaning. Alternatematerials continue to be identified. Wherever pos-sible, specifications are being changed to elimi-nate their use automatically. Some products thathave been reformulated are now flammable. Payclose attention to all CAUTION/WARNING labelson solvents and solvent-based products.

3.2.1 Reasons for Cleaning. Aircraft cleaning is the firststep in preventing aircraft corrosion. Cleaning requires aknowledge of the materials and methods needed to removecorrosive contaminants and fluids which tend to retain con-taminants. Clean aircraft, missiles, and related equipmentregularly in order to:

a. Prevent corrosion by removing salt deposits, other cor-rosive soils, and electrolytes.

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3-6 Change 14

b. Maintain visibility through canopies and windows.

c. Allow a thorough inspection for corrosion damage;aircraft washing before Isochronal (ISO)/Phase inspec-tions is strongly recommended to facilitate corrosioninspections.

d. Maintain turbine engine efficiency.

e. Reduce fire hazards by the removal of accumulationsof leaking fluids.

f. Improve overall appearance.

g. Ensure aerodynamic efficiency of the aircraft.

h. Maintain paint scheme characteristics.

3.2.2 When to Accomplish Work. Accomplish cleaningand related treatments at the frequency prescribed in thisSection, or more frequently if inspection indicates the need.Inspect areas of missiles not protected from the elements(e.g. rain, dust, snow, etc.,) daily. The Aircraft System Pro-gram Director (SPD) in conjunction with the Using Com-mand and the Air Force Corrosion Prevention and ControlOffice (AFCPCO) shall establish aircraft wash cycle require-ments. The unit Commander shall establish a definite sched-ule for inspection, cleaning, and corrosion treatment of theunit’s assigned aircraft, missiles, and equipment, and may athis/her discretion direct a wash cycle that is more frequent(not less frequent) than the established aircraft wash cycle toensure optimum corrosion protection and to promote theprofessional appearance of assigned aircraft, missiles, andequipment.

3.2.2.1 Cleaning Frequency. Base locations not listed inTable 3-1 will use the requirements of the nearest base loca-tion unless within 1.25 miles of salt water. All locationswithin 1.25 miles of salt water are considered severe andrequire 30 day wash. Contact AFCPCO for further guidanceif needed. The frequency of inspection, cleaning, and relatedcorrosion treatment depends on the type of systems assigneddeployments to corrosive environments well as the existinglocal environmental and other conditions. Table 3-1 specifiesthe required aircraft/weapon system wash interval by base orlocation as dictated by existing, recorded environmental andpollution data at each base and/or location unless a differentinterval is specified in a system specific technical order. Un-der certain local conditions, depending on aircraft type andusage, the established wash cycle may be insufficient. Sometypes of aircraft, missiles, and related equipment may re-quire more frequent cleaning of affected areas.

NOTE

When unique operational requirements, contingen-cies, droughts, or facility limitations severely im-pact a unit’s ability to wash as prescribed in Table

3-1. The requirement may be temporarily waivedtwo wash cycles not to exceed one year and ap-proved by the Aircraft System Program Director(SPD). The MAJCOM Corrosion Program Man-ager and AFCPCO shall be notified of all approvedwaivers to monitor for trends.

a. Excessive exhaust or gun blast soil and exhaust gasesaccumulate within impingement areas.

b. Paint is peeling, flaking, or softening.

c. Fluid leakage (coolant, hydraulic fluid, oil, etc.,) oc-curs.

d. Exposure to salt spray, salt water, or other corrosivematerials occurs.

e. Treated with deicing/anti-icing fluids. Deicing residueshould be removed at the first wash following the win-ter season. Refer to Table 3-3 for inspection and clean-ing instructions.

f. Deployments to corrosive environments with no or in-adequate wash capability.

3.2.3 Aircraft Clear Water Rinse (CWR) Require-ments.

Clear water rinsing shall not be accomplished out-side when the temperature is at 40° F (4° C) orbelow. Spraying flight control areas outside withwater when the temperature is below freezing canresult in ice that could impair flight controls.

Aircraft exposed to a salt water environment require clearwater rinse (CWR). Specific rinse requirements are as man-dated by aircraft station location, aircraft runway approach,and mission requirements.

3.2.3.1 Aircraft Stationed Within 1.25 Miles of SaltWater. All aircraft stationed within 1.25 miles (2 km) of saltwater require a CWR at least once every 15 days unlesswashed first.

3.2.3.1.1 Deployed Aircraft to Stations Within 1.25Miles (2KM) of Salt Water. All aircraft deployed to stationswithin 1.25 miles (2 km) of salt water for 10 days or moremust follow the CWR requirements of the deployment loca-tion. Deployment locations where mission requirementsand/or facilities limitations prevent accomplishment of CWR,the aircraft forms will be documented to require a CWR beperformed within 3 days of return to home station. Aircraftdeployed for 30 days or more to a location where a CWR

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Change 15 3-7

cannot be accomplished shall require a complete aircraftwashed within 5 days of returning to home station.

NOTE

When extremely unique requirements or facilitylimitations severely impact a unit’s ability to CWRdaily, this requirement may be temporarily waivedby the MAJCOM Corrosion Program Manager inconjunction with the Aircraft System Program Di-rector (SPD) who has the final approval authority.The MAJCOM Corrosion Program Manager mustforward a copy of the waiver to the Air Force Cor-rosion Prevention and Control Office (AFCPCO).

3.2.3.2 Low Level (Below 3,000 Feet) Salt Water Run-way Approach. Aircraft making two or more take-offs andor/landings, including touch-and-go landings, when the run-way approach is under 3,000 feet and over salt water requirea CWR after the aircraft completes the last flight of the day.

3.2.3.2.1 Single Take-Off and/or Landing. Any aircraft(primarily transient aircraft) performing only a single take-off and/or landing requiring low-level flight (below 3,000feet) over salt water in a single day are excluded from CWRunless there are ten or more occurrences within a 30 dayperiod. After the tenth occurrence, an entry shall be made inthe aircraft forms to require a CWR within 5 days after re-turning to home station.

3.2.3.3 Search, Rescue, and Recovery Missions andLow-Level Flight Operations Under 3,000 Feet. Search,rescue, and recovery missions or any other low-level flightoperations that require aircraft to operate over salt water ataltitudes under 3,000 feet require a CWR after the aircraftcompletes the last flight of the day.

NOTE

• Optimum use of taxi-through rinse facilities isrecommended for removal of salt contamina-tion.

• CWR does not satisfy aircraft washing require-ments as a CWR only removes readily water-soluble matter from aircraft exterior surfaces.

3.2.4 Immediate Cleaning. These affected areas and soilsmust be cleaned immediately.

a. Spilled electrolyte and corrosive deposits found aroundbattery terminals and battery area shall be cleaned,

neutralized, and treated. Close attention and regularcleaning is required for battery areas of aircraft, mis-siles, and equipment.

b. Areas of aircraft, missiles, and equipment exposed tocorrosive fire extinguishing materials shall be cleanedwithin 4 hours after application if at all possible. If anaircraft, missile, or piece of equipment is impoundedby an Accident Investigation Board, the board shallconsider the corrosive effect of fire fighting materialsand direct their removal as soon as possible consistentwith the accident investigation. Prompt removal ofthese materials saves considerable labor hours and ma-terials when salvaging and restoring equipment to aserviceable status. (Refer to Chapter 8 for instructions).

c. Salt deposits, relief tube waste, or other contaminants.

d. Aircraft, missiles, or equipment exposed to significantamounts of salt water. If shipped or transported viaship over salt water, they shall be cleaned and givenany necessary treatment after receipt, particularly if thepreservation and/or packaging are damaged.

e. Fungus growth.

f. Chemical, Biological, and/or Radiological Contami-nated Assets. Any asset that has been contaminated orpotentially contaminated must be identified, markedand decontaminated in accordance with AFMAN 10-2503, Operations in a Chemical, Biological, Radiologi-cal, Nuclear, and High-Yield Explosive (CBRNE) En-vironment and TO 00-110A-1.

g. Spills of corrosive chemicals. An entry in the aircraftAFTO 781A Form shall be made for all corrosivechemical spills and the chemicals shall be neutralizedin accordance with procedures in AFMAN 24-204-IP.

3.2.5 Deployed Aircraft Wash Requirements. All air-craft deployed to a location for more than 20 days shall fol-low the wash intervals from Table 3-1 of the deployed baselocation. Aircraft deploying from a location with a shorterwash interval than the deployed location must be washedimmediately prior to deploying, then will fall into the washintervals of the deployed location. If an aircraft cannot bewashed prior to deploying, the aircraft would remain on it’shome station wash cycle until after the first wash. After thefirst wash at the deployed location, the aircraft would followthe wash interval of the deployed location.

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3-8 Change 15

3.3 CLEANING COMPOUNDS.

Cleaning compounds work by dissolving soluble soils, emul-sifying oily soils, and suspending solid soils. There are sev-eral types of cleaning compounds, each of which cleans asurface using one or more of these mechanisms.

3.3.1 Alkaline Cleaners.

When high strength steels (typically 180 KSI andabove), some high strength aluminum, and somestainless steels are exposed to acid paint removers,plating solutions, other acidic materials (cleaners,etc.,) and even some alkaline materials, a cathodicreaction on the metal surface produces hydrogen.The hydrogen diffuses into the bulk metal, accu-mulating at grain boundaries and weakens thestructure. If the part is under load or contains re-sidual manufacturing stresses, sudden catastrophicfailure known as hydrogen embrittlement occurswhen the part can no longer sustain the internaland/or applied stresses. Hydrogen embrittlementhas been known to occur in parts stressed to only15% of the nominal tensile strength of the metal.

Many alkaline cleaners are not authorized for cleaning of AirForce aircraft, missiles, and related equipment because theyare incompatible with the polyimide insulation on the elec-trical wiring used on many aircraft, missiles, and relatedequipment. Cleaning compounds conforming to MIL-PRF-87937 and MIL-PRF-85570 and that are listed on the QPL/QPD for each specification have been tested and provencompatible with polyimide insulation. Types I and IV ofMIL-PRF-87937 and Types I and II of MIL-PRF-85570 allcontain detergents and foaming agents and work the sameway as any detergent solution. Type I cleaners of both speci-fications contain solvents and are more effective for removalof heavy oils and greases such as wire rope lubricant, butthey cannot be used in poorly ventilated areas due to theirsolvent content. Type IV of MIL-PRF-87937 and Type II ofMIL-PRF-85570 are all good general cleaners for removalof dirt, grime, light oils, and hydraulic fluid, and they areusable in confined areas such as cockpits, cabins, bilges, andequipment bays as they contain no solvents.

3.3.1.1 MIL-PRF-87937, Type I and MIL-PRF-85570,Type I. MIL-PRF-87937, Type I (terpene solvent based) andMIL-PRF-85570, Type I (aromatic solvent based) cleanersare water dilutable and biodegradable materials and are verygood general cleaners for washing aircraft, missiles, compo-nents, and support equipment. However, since they containsolvents, environmental and waste disposal factors need tobe considered prior to use. Since MIL-PRF-87937, Type Imaterials contain terpenes which are potentially corrosive ifentrapped and not completely removed, their use may berestricted on some weapon systems in specific applications.Always consult weapon system specific -23 TO’s for precau-

tions and/or restrictions on use of this class of materials.These cleaners may be used as alternates for MIL-PRF-87937, Type IV and MIL-PRF-85570, Type II materials.MIL-PRF-87937, Type I cleaners are approved for use onsupport equipment (SE) per TO 35-1-3 and aircraft wheelsper TO 4W-1-61.

3.3.1.2 MIL-PRF-87937, Type IV and MIL-PRF-85570,Type II. MIL-PRF-87937, Type IV and MIL-PRF-85570,Type II cleaners are water dilutable and biodegradable mate-rials and are the primary cleaners for washing the exterior ofaircraft, missiles, engines, and support equipment (SE). Theyare excellent materials for removing light to medium soils(greases, oils, grime, etc.,) from almost all surfaces. Sincethey contain no solvents, their use is not limited, except thatapproval by the aircraft SPD is required prior to use ontransparent plastic aircraft canopies, windows, and wind-shields/windscreens. Depending on the type of soils involved,these cleaners may be used in various dilutions as substitutesfor solvents in hand wipe cleaning of greasy and oily areas.Apply them from a pump spray bottle followed by dryingwith a clean, lint free cloth. When applied from a pumpspray bottle at the most dilute mixture recommended, theseare excellent cleaners for lightly soiled surfaces in aircraftcabins and cockpits such as non-transparent plastic parts andinstrument glass covers.

3.3.1.3 MIL-PRF-87937, Type III and MIL-PRF-85570,Type V. MIL-PRF-87937, Type III and MIL-PRF-85570,Type V are gel type cleaners intended for full strength appli-cation with no dilution in areas requiring special cleaning,such as aircraft wheel wells, control surface wells, and wingbutts. They contain small amounts of solvents, detergents,and thickening agents, which make them cling very well tovertical and overhead surfaces. These cleaners are very ef-fective in emulsifying and/or cleaning heavy deposits of hy-draulic fluids, oils, greases, and carbon. In areas where com-plete rinsing with water can be tolerated, they may be usedas direct replacements for solvent cleaners such as MIL-PRF-680, MIL-PRF-32295, Type II, and A-A-59601. To be mosteffective, these materials are applied full strength with nopre-rinsing of the surface, allowed to dwell 5 to 15 minutes,agitated with a non-metallic bristle brush, and then rinsedthoroughly with tap water. These cleaners are not intendedfor and shall not be used on transparent plastic aircraft cano-pies, windows, and windshields/windscreens.

3.3.1.4 MIL-PRF-87937, Type IV. MIL-PRF-87937,Type IV is also an excellent heavy duty, water dilutable,solventless cleaner intended for removal of light to heavydeposits of greases, oils, hydraulic fluids, and carbon fromaircraft, missile, and other equipment surfaces. It is not in-tended for and shall not be used on transparent plastic air-craft canopies and windows.

3.3.1.5 MIL-PRF-85570, Type IV. MIL-PRF-85570,Type IV is a cleaner that contains solvents, detergents, andsuspended rubber particles and is intended for removal ofexhaust gas and gun gas residues, smudges, boot marks, andother embedded soils from aircraft, missiles, and other equip-

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Change 5 3-9

ment with flat (low gloss)/camouflage coating systems. Whenrubbed across a soiled surface, the rubber particles in thecleaner mechanically entrap the soils like tiny erasers with-out polishing the surface of the coating system and increas-ing its gloss.

NOTE

Solvents used in MIL-PRF-85570, Type IV clean-ers may be hazardous air pollutants (HAP’s). Con-sult with Bioenvironmental Engineering before us-ing this cleaner. MIL-PRF-87937, Types III andIV or MIL-PRF-85570, Type V may be used asalternates.

3.3.1.6 MIL-PRF-85570, Type III. MIL-PRF-85570, TypeIII is a cleaner that contains detergents and fine abrasiveparticles and is intended for removal of exhaust gas and gunblast residues from aircraft with a high gloss coating system.When rubbed across a soiled surface, the abrasive particlesmechanically remove the soils which are then suspended inthe detergent while producing only a very minimal dulling ofthe high gloss coating system.

3.3.2 Solvent Emulsion and Aqueous Cleaners for Tur-bine Engine Gas Path and General Area Cleaning. MIL-PRF-85704, Types I, II, and III materials are solvent emul-sion (Types I and II) and aqueous (Type III) cleaners intendedfor cleaning the internal areas or gas path of aircraft turbineengines. A-A-59921 (formerly MIL-C-43616), Class 1A ma-terials are solvent emulsion cleaners intended for generalcleaning of heavily soiled exterior areas of aircraft, missiles,and other equipment. Use only those materials listed on theQPL/QPD’s for MIL-PRF-85704 and A-A-59921 (formerlyMIL-C-43616).

3.3.2.1 MIL-PRF-85704, Type I. MIL-PRF-85704, TypeI (solvent emulsion with aromatic hydrocarbons) and Type II(aqueous with some non-aromatic hydrocarbons) are materi-als intended for cleaning the interior of an aircraft engine byspraying the cleaner into the intake while the starter is mo-toring the engine. There is a Type II, RTU (ready-to-use)material that requires no dilution before use, but the bulkform of Type II and Type I must be diluted with water hav-ing a maximum conductivity of 10 micro-mho/centimeterand a pH in the 5.0 to 8.0 range before use. Type III (bulk,same water dilution requirements) and Type III RTU (ready-to-use with no dilution) are aqueous materials with no hy-drocarbon solvents intended for cleaning the interior of anaircraft engine by spraying the cleaner into the intake whilethe engine is on line or running per specific engine mainte-nance instructions. These cleaners work very well for re-moval of accumulated salts, dirt, and oily soils from thecompressor section and other areas of the gas path of aircraftengines, and their use is followed by spraying fresh tap wa-ter through the engine to rinse away the contaminants.

3.3.2.2 A-A-59921, (Formerly MIL-C-43616), Class1A. A-A-59921 (formerly MIL-C-43616), Class 1A aerosolmaterial is a solvent emulsion cleaner and is very effective

for removal of oily and greasy soils from general exteriorpainted (polyurethane only) and unpainted areas of aircraft,missiles, and other equipment.

NOTE

• MIL-PRF-85704 materials are specially formu-lated to minimize corrosion of aircraft turbineengines. Other types of cleaners shall not beused to clean engine interior areas without spe-cific approval by the engine SPM and/or as re-quired by the system specific engine mainte-nance TO. The system specific enginemaintenance TO shall be consulted for interiorcleaning procedures and the requirement/autho-rization to use MIL-PRF-85704 cleaners.

• A-A-59921 (formerly MIL-C-43616) solventemulsion cleaners shall not be used on non-polyurethane paint systems and markings astheir high solvent content can cause them tofade and/or streak. These cleaners also leave avery thin oil and/or solvent film on the surface,so they are not suitable for use as a final cleanerprior to painting, sealing, or adhesive bonding.

• Large scale use of bulk solvent emulsion clean-ers may cause problems for waste water treat-ment facilities. Local air pollution regulationsmay restrict the amount and application meth-ods of solvent emulsion cleaners. If so, useMIL-PRF-85704, Type II, RTU in lieu of theType I and the appropriate type of MIL-PRF-87937 or MIL-PRF-85570 in lieu of A-A-59921(formerly MIL-C-43616), Class 1A.

3.3.3 Aqueous Parts Washer Cleaning Solutions. Ma-terials conforming to and listed on the QPL/QPD for MIL-PRF-29602, Type I (liquid concentrate) and Type II (pow-der) Cleaning Compounds for Parts Washers and SprayCabinets, either diluted with water (Type I) or dissolved inwater (Type II) in accordance with manufacturer’s instruc-tions are the cleaning agents to be used in high pressurecabinet style parts washers for removing oils and greasesfrom disassembled components. They are not to be used forbearings unless authorized by system specific technical data.Due to their maximum allowable pH of 13.5, MIL-PRF-29602 cleaning solutions can attack/corrode aluminum al-loys. Aircraft SPD and/or equipment SPM engineering au-thority approval is required before cleaning aluminum alloyparts. In addition, many heated MIL-PRF-29602 solutionscan attack the IVD (Ion Vapor Deposited) aluminum coatingused on many high strength steel components and generatehydrogen, which can enter into the steel and cause a cata-strophic failure by hydrogen embrittlement. This is of par-ticular concern for IVD aluminum coated high strength steelaircraft landing gear (LG) components. These LG compo-nents shall be cleaned in aqueous parts washers using onlythose materials listed on the most current revision of theapplicable landing gear technical orders.

TO 1-1-691

3-10 Change 5

3.3.4 Solvents. Cleaning solvents dissolve oily and greasysoils so that they can be easily wiped away or absorbed on acloth. However, solvents differ significantly in their cleaningability, toxicity, evaporation rate, effect on paint, and flam-mability. A-A-59601, and/or MIL-PRF-680, are the mostcommon cleaning solvents used on aircraft due to their lowtoxicity, minimal effect on paint, and relative safety. MIL-PRF-32295, Type II cleaning solvents provides the cleaningperformance of MIL-PRF-680 and also with low toxicity,minimal effect on paint, and relative safety. Other solventssuch as alcohols, ketones, chlorinated solvents, and naphtha,are specialized materials restricted for use as recommendedin Table 3-2.

NOTE

• Solvent cleaning operations are becoming moreand more limited due to environmental regula-tions. Determine local requirements regardinglimitations on type and volume used and dis-posal from your work center supervisor, safetyofficer, and/or Bioenvironmental Engineer.

• MIL-PRF-32295 was developed as a low-VOCand HAP-free replacement for P-D-680, A-A-59601, and MIL-PRF-680.

• A-A-59601 Dry Cleaning and Degreasing Sol-vent P-D-680 and MIL-PRF-680 DegreasingSolvent, replace P-D-680 Dry Cleaning andDegreasing Solvent. MIL-PRF-680 has beenreformulated to reduce Hazardous Air Pollut-ants by reducing the aromatic content of thesolvent, while A-A-59601 is identical to P-D-680.

3.3.4.1 MIL-PRF-680 Degreasing Solvent and A-A-59601 Dry Cleaning and Degreasing Solvent, P-D-680.These solvents are used as cleaners and degreasers for paintedand unpainted metal parts and to remove corrosion preven-tive compounds. The solvents are available in several types.Although the degreasing effectiveness is approximately thesame, the flash points differ as follows: Type I, both specifi-cations, 100° F (38° C) minimum; Type II, both specifica-tions, 140° F (60° C) minimum; Type III, both specifica-tions, 200° F (93° C) minimum, Type IV (D-limoneneadditive), and MIL-PRF-680 only, 140° F (60° C) minimum.Though the flash points differ, all types will burn intenselyonce ignited. Type I, both specifications, is not authorized asa general cleaner due to its flammability, but may be used inparts washers designed for such solvents. Type II, bothspecifications, is the most common cleaning solvent used onaircraft, missiles, and equipment because of its higher flashpoint. If necessary, ASTM D 235, Type II, Class C, MineralSpirits may be used as a substitute for MIL-PRF-680 orA-A-59601, Type II. Type III, both specifications, is intendedfor use in confined spaces and in locations with environmen-tal constraints where a solvent with a very low vapor pres-sure (evaporation rate) and a very high flash point is re-quired. MIL-PRF-680, Type IV (D-limonene additive), maybe used where a higher flash point and strong solvency is

desired if approved by the aircraft SPD or the missile orequipment SPM. The dwell time for all types should be heldto a minimum (less than 15 minutes), to avoid damage topaint.

3.3.4.1.1 MIL-PRF-32295, Type II. These solvents areused as cleaners and degreasers for painted and unpaintedmetal parts and to remove corrosion preventive compounds.NAVSOLVE® is currently the only solvent meeting theMIL-PRF-32295 specification. NAVSOLVE® is a combus-tible solvent with a flash point of 142 °F (61.1 °C). NAV-SOLVE® has a solvent vapor pressure of 2.8 mm Hg (Con-forms to Type I limit of <7mm Hg @ 20 °C, and Type IIlimit of < 45 mm Hg @ 20 °C).

3.3.4.2 TT-I-735 Isopropyl Alcohol. Isopropyl alcohol isa flammable solvent used primarily as a disinfectant forcleaning fungus and mold. It is a poor degreaser.

3.3.4.3 ASTM D 740 Methyl Ethyl Ketone (MEK). Thisis a highly flammable solvent used primarily for cleaningprior to painting and bonding. It may also be used for clean-ing if surfaces become contaminated with leaking oils and/orhydraulic fluids after surface treatment. Most locations can-not use MEK due to environmental restrictions on use ofsolvents with vapor pressures greater than 44 millimeters ofmercury (mm Hg). MIL-PRF-87937, Type IV or MIL-PRF-85570, Type II (either-diluted one part cleaner to nine partswater), may be used as an alternate followed by rinsing thor-oughly with fresh water and air drying or surfaces may becleaned by solvent wiping with SAE AMS 3166, solvents,cleaning, Cleaning Prior to Application of Sealing Com-pounds.

3.3.4.4 Aliphatic Naphtha. Aliphatic naphtha is a highlyflammable solvent used primarily for cleaning oily or greasydeposits from acrylic canopy materials. Other solvents causecrazing of acrylics. It can also be used to remove masking orpreservation tape residue.

3.3.4.5 MIL-T-81772, Type I (Polyurethane) and TypeII (Epoxy) Thinner. Both of these thinners are highly flam-mable solvents that can be used for prepaint solvent cleaningwhen necessary at locations requiring a solvent vapor pres-sure less than 45 mm Hg.

3.3.5 Miscellaneous Cleaning Agents. Some othercleaning materials used on aircraft, missiles, and equipmentare listed here. P-P-560 plastic polish containing a mildabrasive is used to polish out scratches in acrylic canopy andwindow materials. Some alkaline chemicals used to neutral-ize specific acidic soils are: A-A-59370 ammonium hydrox-ide for urine and ASTM D 928 sodium bicarbonate for elec-trolyte spills from sulfuric acid batteries. Some acidicchemicals used to neutralize specific alkaline soils are: ANSI/AWWA B504 monobasic sodium phosphate and A-A-59282boric acid for electrolyte spills from nickel-cadmium batter-ies. MIL-F-24385 AFFF fire extinguishing agent containingwetting and foaming agents can be used to wash out residuesfrom fire extinguishing solutions made with salt water. A-A-

TO 1-1-691

Change 5 3-11

59199 optical glass lens cleaner is used for cleaning opticallenses on aircraft, missiles, and equipment. Solutions ofO-D-1435 and A-A-1439 disinfectants are used to sanitizeand deodorize relief tube areas; latrine areas including toiletbowls, urinals, and latrine buckets, garbage receptacles,sinks, galley areas, and other interior areas of aircraft andequipment requiring disinfection.

3.3.5.1 General Disinfectants. Calla® 1452 is a concen-trated disinfectant and AeroDis® 7127 is a ready-to-use dis-infectant that can be used as general cleaners for aircraft andequipment interior surfaces requiring disinfection. All mate-rials listed in this paragraph are to be mixed and/or appliedper manufacturer’s instructions unless otherwise specified bythe cognizant engineering authority and/or System ProgramOffices (SPO).

3.3.6 Steam Cleaning. Steam cleaning shall not be usedon aircraft and missiles at all levels (Organizational/Unit,Intermediate, or Depot) of maintenance. In addition, steam

cleaning shall not be used on the following items on equip-ment and components removed from aircraft and missiles:honeycomb bonded structure, sealant, fiberglass composites,acrylic windows and canopies, or electrical wiring. Steamcleaning erodes paint, crazes plastics, disbonds adhesives,damages electrical insulation, and drives lubrication out ofbearings.

3.3.7 Dilution. More concentrated solutions than those rec-ommended do not clean any better and are wasteful; MOREIS NOT ALWAYS BETTER. In fact, if too much cleaner isused, the solution merely becomes slippery film, preventingthe washing pad from loosening the soil and making rinsingmore difficult. Do not exceed the cleaner dilution ratios rec-ommended in Table 3-2.

Table 3-2. Cleaning of Specific Areas and Components

Area or Component Type of Soil Cleaning Agent orCompound

Mixing Directionsand Nomenclature

Cleaning Procedures

NOTE

• Cleaning procedures are listed in this table. Ordering information for approved materials can be found in Ap-pendix A. Ordering information for approved equipment can be found in Appendix B.

• Use of hot water (120° to 140° F/49° to 60° C) for rinsing during aircraft washing operations is strongly rec-ommended as it provides much more efficient rinsing and is known to reduce man-hours for aircraft washingoperations by approximately 20%.

• A-A-59601 dry cleaning and degreasing solvent, P-D-680, MIL-PRF-32295 and MIL-PRF-680 degreasing sol-vent are combustible. Keep away from open flames. Use in a well ventilated area. Wear rubber gloves andchemical or splash proof goggles. Avoid skin contact. Consult the local safety office regarding respiratoryprotection.

• Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operationsusing MIL-PRF-87937 and MIL-PRF-85570 cleaning compounds. If cleaner is splashed in eyes, rinse thor-oughly with fresh water for 15 minutes and report to medical facility. Remove clothing saturated with cleaningsolution immediately and flush exposed skin areas with fresh water.

EXTERIOR SUR-FACES, PAINTED

Light Soils (dirt,dust, mud, salt,loose soot)

MIL-PRF-87937,Type IV or MIL-PRF-85570, Type IIor

1 part cleaner in 9parts water

Apply cleaner solution withfoam generator, spray, sponge,soft brush, or cloth. Scrub andthen rinse with fresh waterand dry. MIL-PRF-87937,Type I materials contain ter-penes. Aircraft SPD and/ormissile or equipment SPMrestrictions may apply. Con-sult system specific mainte-nance manuals.

MIL-PRF-87937 orMIL-PRF-85570,Type I

1 part cleaner in16 parts water

TO 1-1-691

3-12 Change 18

Table 3-2. Cleaning of Specific Areas and Components - Continued



Cleaning Procedures

Moderate Soils(hydraulic flu-ids, lube soils,light preserva-tives) HeavySoils (carbon-ized oil, agedpreservatives,grease, gunblast, and ex-haust deposits)

MIL-PRF-87937,Type IV or MIL-PRF-85570, TypeII or


Apply cleaner solution withfoam generator spray,sponge, soft brush, or cloth.Rub gently with a circularmotion for up to 1 minute.Rinse with fresh water anddry. Use of MIL-PRF-87937, Type I is subject torestrictions noted above.



MIL-PRF-87937,Type III or MIL-PRF-85570, TypeV or

Undiluted Spray or brush on cleaner.After 5 to 15 minutes,brush and rinse thoroughly.

A-A-59601 or MIL-PRF-680

Degreasing SolventUndiluted

Pre-clean by wiping or brush-ing with A-A-59601, MIL-PRF-32295, Type II orMIL-PRF-680, Type II orIII solvent, then applycleaner solution with foamgenerator, spray, sponge, orcloth. Allow the cleaner todwell for up to 1 minutewithout scrubbing, thenscrub for up to a minute.Rinse thoroughly, then dry.Do not allow cleaning solu-tion to dry on surfaces orstreaking will occur. Use ofMIL-PRF-87937, Type I issubject to restrictions notedabove in Exterior PaintedSurfaces.

CCC-C-440, Type IIor III, Class 1 orA-A-2522, GradeA or SAE AMS3819, Class 1,Grade A and

Cotton Cheesecloth(Unbleached)White CottonCloth WhiteCleaning Cloth

MIL-PRF-87937 orMIL-PRF-85570,Type I or


MIL-PRF-87937,Type IV or MIL-PRF-85570, TypeII


Stubborn Soil onGloss PaintedAircraft (scuffmarks, ex-haust, etc.)

MIL-PRF-87937,Type IV


Apply cleaner with a dampcloth. Rub with a circularmotion. Rinse thoroughly,then dry. Do not allow thecleaner to dry on surfacesor rinsing may be difficult.

MIL-PRF-85570,Type III, IV, or V

Undiluted

Stubborn Soil onLow Gloss/Flatand/or Camou-flage PaintScheme Air-craft (scuffmarks, ex-haust, etc.)

MIL-PRF-85570,Type IV

Undiluted Apply cleaner with a non-abrasive cleaning pad. Al-low 1 to 3 minutes dwelltime. Rub with a circularmotion. Rinse thoroughly,then dry. Do not allow thecleaner to dry on surfacesor rinsing may be difficult.

TO 1-1-691

Change 5 3-13




Cleaning Procedures

Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operations usingMIL-PRF-87937 or MIL-PRF-85570 cleaning compounds. If cleaner is splashed in eyes, rinse thoroughly withfresh water for 15 minutes and report to medical facility. Remove clothing saturated with cleaning solution imme-diately and flush exposed skin with fresh water.

Do not allow MIL-PRF-87937 or MIL-PRF-85570, Type I cleaning solutions to contact canopy, window, or wind-shield/windscreen transparent plastic panels as they may cause crazing.

EXTERIOR SUR-FACES, UN-PAINTED

Gunblast resi-dues, carbon-ized exhaustresidues



Wet surface with fresh water.Apply cleaning solution andscrub briskly with A-A-58054, Type I, Grade A orB abrasive mat. Rinse withfresh water and dry. Use ofMIL-PRF-87937, Type I issubject to restrictions notedabove in Exterior PaintedSurfaces.

MIL-PRF-87937,Type III or MIL-PRF-85570, TypeIV or V

Undiluted

• Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operationsusing MIL-PRF-87937 or MIL-PRF-85570 cleaning compounds. If cleaner is splashed in eyes, rinse thor-oughly with fresh water for 15 minutes and report to medical facility. Remove clothing saturated with cleaningsolution immediately and flush exposed skin with fresh water.

• When using Ammonium Hydroxide (Ammonia), do not breathe vapors and avoid skin contact. Wash immedi-ately, if spilled on skin.

• When using Ammonium Hydroxide (Ammonia), do not allow any solutions to contact aircraft wiring. Flushimmediately with fresh water if spillage occurs.

• Avoid use of compressed air to clean electronic equipment. Do not use abrasives in radome compartments.

INTERIOR AREASLavatories

Urine residue A-A-59370 Ammonium Hy-droxide (Ammo-nia) 1 part in 20parts water

Sponge with a solution ofammonium hydroxide (am-monia). Flush with freshwater or wet surface withsodium bicarbonate solu-tion, allow to dry, and rinsewith fresh water. Dry with aclean cloth.

ASTM D 928 Sodium Bicarbon-ate, 6 OZ to 1GL of fresh wa-ter

TO 1-1-691

3-14




Cleaning Procedures

USDA Reg 100-12-1 Germicidal Tablets Use germicidal tables as toiletand urinal deodorants.

All types of soilson lavatorysurfaces

O-D-1435, A-A-1439, or AMS1476

Mix per manufac-turer’s instruc-tions

Pour solution into toilets, uri-nals, and latrine buckets.Scrub with a brush andrinse with fresh water.Sponge all other surfaceswith the solution, spongearea with fresh water, andwipe dry.

Floor and Deck Dirt, debris MIL-PRF-87937,Type IV or MIL-PRF-85570, TypeII (Preferred) or


Remove loose dirt withvacuum cleaner. Wipe withcleaning compound andrinse with fresh water. Useof MIL-PRF-87937, Type Iis subject to restrictionsnoted above in ExteriorPainted Surfaces.

MIL-PRF-87937, orMIL-PRF-85570,Type I (Alternate)


Radome and Equip-ment Compart-ment (Interior)

Dust, dirt, oil,and debris

MIL-PRF-87937,Type IV or MIL-PRF-85570, TypeII and


Remove loose dirt with avacuum cleaner. Wipe fiber-glass and other surfaceswith a cloth wet with clean-ing solution and rinse withcloth wet with fresh water.Dry with a clean cloth.

CCC-C-440, Type Ior II, Class 1 orA-A-59323, TypeII or SAE AMS3819, Class 1,Grade A or B

Cotton Cheesecloth(Unbleached)Cleaning Cloth,Low lint WhiteCleaning Cloth

Cockpit Interior Dust, dirt, mud,and light de-bris



Loosen any accumulations ofmud on control pedals,floors, or other cockpitequipment with brush andremove with vacuumcleaner. Wipe with clothwet with cleaning solutionand follow with a cloth wetwith fresh water. Dry with aclean cloth.

A-A-50129 Cloth, Flannel

Environmental Con-trol Ducting

Light debris,dust, andgrime



Refer to applicable mainte-nance manuals.

NOTE

Refer to aircraft system specific manual to determine acrylic plastic parts.

ACRYLIC PLAS-TIC PARTS (EX-CEPT CANO-PIES ANDWINDOWS)

Light soil andsmudges



Wipe with cloth wet withcleaning solution and followwith a cloth wet with freshwater. Dry with a cleancloth.A-A-50129 Cloth, Flannel

TO 1-1-691

Change 1 3-15




Cleaning Procedures

INTERIOR PLAS-TIC ANDGLASS PANELS

A-A-50129 Cloth, Flannel Vacuum and then dust withsoft, clean, damp cloth.Keep cloth free of grit byrinsing frequently in waterand wringing out.

ELASTOMERICSEALS

Dust, dirt, oil,and grime



Wipe with cloth wet withcleaning solution and rinsewith a cloth wet with freshwater. Dry with a cleancloth.CCC-C-440, Type I

or II, Class 1 orCotton Cheesecloth

(Unbleached)Cleaning Cloth

(Low lint) WhiteA-A-59323, Type II

or SAE AMS3819, Class 1,Grade A or B

Cleaning Cloth

Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operations usingMIL-PRF-87937 and MIL-PRF-85570 cleaning compounds. If cleaner is splashed in eyes, rinse thoroughly withfresh water for 15 minutes and report to medical facility. Remove clothing saturated with cleaning solution imme-diately and flush exposed skin with fresh water.

FABRIC PARTS,SOUND-PROOF-ING AND UP-HOLSTERY

Light soil and oilspots



Remove loose dirt withvacuum cleaner. Apply soapsolution with sponge andscrub briskly. Rinse withclean, dampened rag orsponge using clean, freshwater. Allow area to dry.Raise nap by brushing.

Do not use synthetic wiping cloths with flammable solvents, such as TT-N-95 aliphatic naphtha.

Refer to aircraft system specific manual to determine cleaning procedures for aircraft canopies. In addition, referto TO 1-1A-12. Remove rings, watches, or other hard objects from hands and wrists before washing transparentplastics. Personnel must also take precautions to prevent buttons, badges, or other hard objects from scratchingsurfaces. Do not use hard, dirty, or gritty cloths in cleaning and polishing transparent plastics. Wiping with suchcloths can mar and scratch plastic surfaces. Do not use any chemical compounds unless specifically authorized forcleaning plastics. Do not rub dry plastic panels with dry cloth, which might scratch surface or create electrostaticcharge that attracts dust.

TO 1-1-691

3-16




Cleaning Procedures

CANOPY EXTE-RIOR, PLASTICAND GLASSWINDOW ANDWINDSHIELD/WINDSCREENPANELS

Dust, dirt, grime,salt, and spray

P-P-560 Plastic PolishCompound

Rub gently with bare hands orclean cloth while flushingwith fresh water to removeloose dirt. Apply polishingcompound with a soft, cleancloth and rub using a circu-lar motion until clean. Pol-ish with another soft, cleancloth.


Oil, grease TT-N-95 and Aliphatic Naphtha Apply naphtha with soft,clean cloth. Blot gently,solvent will evaporate andnot leave a film.

P-P-560 and Plastic PolishCompound

Apply polishing compound.Rub, using a circular mo-tion until clean and polishwith another soft, cleancloth.


• Open all circuit breakers associated with battery power (refer to applicable system specific maintenance manu-als), prior to application of MIL-PRF-680 degreasing solvent, MIL-PRF-32295, Type II or A-A-59601 drycleaning and degreasing solvent, P-D-680.

• All of these solvents are combustible. Keep away from open flames. Use in a well ventilated area. Wear rubbergloves and chemical or splash proof goggles. Avoid skin contact. Consult the local safety office regarding re-spiratory protection.

Do not use excessive cleaning solvent on control cables. Solvent will remove internal lubricant.

CONTROLCABLES

Dust, dirt oil,and grease


Degreasing Solvent Wipe with clean cloth damp-ened with solvent. ApplyMIL-PRF-81309, Type IIwater displacing CPC tocables and re-coat cableswith MIL-PRF-16173,Grade 4 CPC.

MIL-PRF-81309,Type II and

Water Displacing,CPC

MIL-PRF-16173,Grade 4

CPC

Wipe away from seal areas to preclude collection of soil at seal junction areas. Make sure piston surface is cleanand completely lubricated but not dripping. If piston is dry, telescoping action of strut will force gritty particlesinto cylinder causing leaks and eventual failure. Do not use aerosol type cleaning fluids on hydraulic systems.

TO 1-1-691

Change 5 3-17




Cleaning Procedures

LANDING GEAREXPOSED PIS-TON SURFACES

Sand, dirt, saltdeposits, andother foreignparticles

MIL-PRF-83282 Hydraulic Fluid Clean exposed surfaces withclean cloth dampened withhydraulic fluid. Take carenot to scratch the surface.Wipe away from seals, nottoward them.

CCC-C-440, Type Ior II, Class 1 orA-A-59323, TypeII or SAE AMS3819, Class 1,Grade A or B

Cotton Cheesecloth(Unbleached)Cleaning Cloth(Low lint)Cleaning Cloth



Do not use MIL-PRF-16173, Grade 4 or MIL-DTL-85054 on micro-switches or exposed piston rod surfaces.

DOORS, LINK-AGES, CYLIN-DERS

Dust, dirt, oil,and grease


Degreasing Solvent Brush surfaces, as necessary,with solvent. Cover rodends and springs with MIL-PRF-16173, Grade 4 CPC.Where lubrication is notrequired, MIL-DTL-85054CPC may be applied.

MIL-PRF-16173,Grade 4 or

CPC

MIL-DTL-85054 CPC

WHEELS ANDBRAKES

Oil, grease, dirt,sand, and otherforeign matter

For cleaning wheels andbrakes, reference TO 4W-1-61 and TO 4B-1-32.

Applicable LandingGear TechnicalOrder specifiedmaterials

Dilute and/or mixper manufactur-er’s instructions

Use only those cleaners listedin the most current revisionof the applicable landinggear technical order. Placeoff aircraft parts in theaqueous parts washer andrun through the completewash, rinse, and dry cycle.

TO 1-1-691

3-18 Change 5




Cleaning Procedures


• All of these solvents are combustible. Use in a well ventilated area. Keep it away from open flames. Avoidcontact with skin.


Protect tires from contact with degreasing solvents or cleaning solutions.

LANDING GEAR(OTHER THANEXPOSED PIS-TON AREA)AND WHEELWELLS

Dirt, grease, hy-draulic fluid,etc.

MIL-PRF-87937,Type III or MIL-PRF-85570, TypeV or

Undiluted Apply thixotropic gel, TypeIII or Type V cleaner withspray or brush and allow a5 to 15 minute dwell.Brush, if necessary, andrinse thoroughly with freshwater. Repeat rinsing withbrushing to remove cleanerresidues.


Undiluted Degreas-ing Solvent

Alternate procedure: Brush onsolvent to loosen stubbornsoil.

MIL-PRF-85570,Type I


Apply MIL-PRF-85570, TypeI, or MIL-PRF-87937, TypeI cleaning solution, brush,and rinse. Omit solvent pre-soak, if desired. Use ofMIL-PRF-87937, Type Imay be restricted as notedabove in Exterior PaintedSurfaces.

Before cleaning electrical and avionic equipment, make sure electrical power is disconnected. Injury and deathmay otherwise result.

TO 1-1-691

Change 5 3-19




Cleaning Procedures

Avoid use of compressed air in electronic compartments because air can force dust, dirt, and other foreign materi-als into components or equipment and cause damage.

ELECTRICALCONNECTORSAND AVIONICCOMPONENTS

Dust, dirt, lint,and other looseforeign matter,grease, oilsmudges, lighttarnish, corro-sion, or fungi

Refer to TO 1-1-689-1, TO1-1-689-3, and TO 1-1-689-5.

OXYGEN LINES(EXTERIORSURFACES)

Oil, grease Refer to system specific maintenance manuals.


RELIEF TUBES(EXTERIOR)

Human waste(urine)



Wash thoroughly with solu-tion using a soft, bristlebrush, then rinse thoroughlywith fresh water and wipedry.

TO 1-1-691

3-20 Change 2




Cleaning Procedures


Do not use strong alkaline cleaners or highly abrasive compounds when cleaning rotor tip cap areas. Refer to sys-tems specific technical orders for specific cleaning instructions.

HELICOPTERAND PROPEL-LER BLADES

Grime, oil,grease, exhauststains



Apply cleaning solution witha cleaning pad or brush andagitate. Rinse with freshwater and wipe dry.

A-A-3100 Cleaning PadHELICOPTER

CARGO ANDRESCUE HOISTCABLE, ANDEND FITTINGS

Salt and salt wa-ter

MIL-PRF-16173,Grade 3 or MIL-PRF-81309, TypeII or MIL-L-87177,Type I, Grade B

Water DisplacingCorrosion Pre-ventive Com-pound

Flush thoroughly with freshwater. Blow dry with clean,compressed air or thor-oughly dry with a cottoncloth. Spray with MIL-PRF-16173, Grade 3, MIL-PRF-81309, Type II, or MIL-L-87177, Type I, Grade Bcompound as it is beingrewound. Remove excesswith clean dry cloth.


Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operations usingMIL-PRF-87937, or MIL-PRF-85570 cleaning compounds. If cleaner is splashed in eyes, rinse thoroughly withfresh water for 15 minutes and report to medical facility. Remove clothing saturated with cleaning solution imme-diately and flush exposed skin with fresh water.

HELICOPTERCARGO ANDRESCUE HOISTDRUM




Rinse with fresh water. Applycleaning solution and scrubwith a clean cloth orsponge. Rinse with cleanwater. Blow dry with clean,compressed air or dry witha clean, dry cloth. Use ofMIL-PRF-87937, Type Imay be restricted as notedabove in Exterior PaintedSurfaces.

TO 1-1-691

Change 5 3-21




Cleaning Procedures


HELICOPTERRESCUE SLING




Rinse with fresh water. Applycleaning solution withsponge or clean cloth. Rinsethoroughly with fresh water.Blow dry with clean, com-pressed air or suspend andallow to dry. If suspendedto dry, ensure water willdrain away from the buckle.



ENGINES, RECIP-ROCATING

Oxidized oil,dust, carbon,salt deposits

A-A-59601 or MIL-PRF-680 and

Degreasing Solvent Apply solvent with cleaningcloth or brush. Repeat ap-plication and dry. Collectsolvent runoff and disposein accordance with localregulations.

CCC-C-440, Type Ior II, Class 1 or

Cotton Cheesecloth(Unbleached)

A-A-59323, Type IIor SAE AMS3819, Class 1,Grade A or B

Cleaning ClothLow Lint Clean-ing Cloth

Wear rubber gloves, chemical or splash proof goggles, protective wet weather clothing where necessary, and waterresistant boots during cleaning operations using cleaning compound MIL-PRF-85704, Types II or II RTU. Ifcleaner is splashed in eyes, rinse thoroughly with fresh water for 15 minutes and report to medical facility. Re-move clothing saturated with cleaning solution immediately and flush exposed areas with fresh water.

TO 1-1-691

3-22 Change 5




Cleaning Procedures

• Use only MIL-PRF-85704 cleaning compound for cleaning turbine engine gas paths. Prepare aircraft in accor-dance with applicable system specific maintenance manuals and/or maintenance work cards. In case of conflict,the manuals and/or work cards take precedence over the following instructions.

• MIL-PRF-85704, Type I gas path cleaners typically contain 30 to 60% solvent. When diluted (1 part cleaner to4 parts water), some products are above the 10% solvent limit and most contain enough naphthalene to causewash rack runoff to exceed the discharge permit limits. The current substitute is MIL-PRF-85704, Type II, awater-base product that contains less than 10% solvent in the concentrate. This material shall be used at thesame dilution ratio while using the same starter cranked engine wash procedures, which are currently approvedin aircraft engine manuals. MIL-PRF-85704, Type II RTU is ready-to-use (does not require dilution, but re-quired 5 times the storage space since it is already diluted with water).

GAS TURBINEENGINE INTE-RIOR (GASPATH)


MIL-PRF-85704,Type II or


Use in accordance with appli-cable engine maintenancemanual instructions. Dis-pose of waste cleaner inaccordance with local regu-lations.

MIL-PRF-85704,Type II RTU

Do not dilute, thisis a ready mixform

Wear rubber gloves, chemical or splash proof goggles, and water resistant boots during cleaning operations usingMIL-PRF-87937, MIL-PRF-85570, or MIL-PRF-85704, Types I or II cleaning compounds. If cleaner is splashedin eyes, rinse thoroughly with fresh water for 15 minutes and report to medical facility. Remove clothing saturatedwith cleaning solution immediately and flush exposed skin with fresh water.

Prepare aircraft in accordance with applicable system specific maintenance manuals and/or maintenance workcards. In case of conflict, the manuals and/or work cards take precedence over the following instructions.

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Change 5 3-23




Cleaning Procedures

GAS TURBINEENGINE EXTE-RIOR, ENGINEBAY AND EN-GINE BAYDOORS


MIL-PRF-85704,Type I or II or


Apply mixed cleaning solu-tions (MIL-C-43616, Class1, MIL-PRF-85704, Type Ior II, MIL-PRF-87937,Type IV, or MIL-PRF-85570, Type II) or the pre-mixed cleaners (MIL-C-43616, Class 1A or MIL-PRF-85704, Type II RTU)with a brush. Scrub, thenrinse with fresh water.When using the MIL-PRF-87937, Type III or MIL-PRF-85570, Type V, applythe undiluted concentratewith a brush, allow cleanerto remain on surface for 5minutes, then brush andrinse thoroughly. Dispose ofwaste cleaners in accor-dance with local directives.

A-A-59921 (formerlyMIL-C-43616),Class 1A or

Aerosol Can

MIL-PRF-85704,Type II RTU or

Do not dilute, thisis a ready mixform



MIL-PRF-87937,Type III or MIL-PRF-85704, TypeV

Undiluted concen-trate

Never use a wire brush to clean a battery or a battery area. Wear rubber gloves, a rubber apron, and protectivegoggles when handling batteries.

• Nickel-cadmium batteries must not be exposed to acid or acid vapors. Battery electrolytes are extremely corro-sive. Spilled electrolyte shall be removed immediately. Refer to applicable system specific aircraft, missile, orequipment manuals for battery type.

• Fumes from overheated electrolyte will spread to adjacent areas causing rapid corrosion on unprotectedsurfaces.

NOTE

Refer to Chapter 7 for additional instructions.

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3-24 Change 5




Cleaning Procedures

Battery Compart-ments

Nickel-cadmiumbattery electro-lyte deposits(potassiumhydroxide so-lution)

A-A-59282 or Boric Acid Remove spilled electrolyteimmediately by flushingwith fresh water. Spray thecontaminated area with Bro-mothymol Blue solution.(Refer to Chapter 7). Neu-tralize the area by spongingor spraying generously withboric acid or sodium phos-phate solution. Brush with afiber bristle brush and flushwith fresh water. Reapplythe Bromothymol Blue so-lution to determine if all theelectrolyte has been neutral-ized. Retreat area, as re-quired, and rinse. Dry withclean wiping cloths. Keepthe cell vents open but donot allow any solutions toenter the cells. Preservecompartment with MIL-PRF-81309, Type II, Class1 or 2 or MIL-L-87177,Type I or II, Grade B CPC.Do not paint or preservebatteries.

ANSI/AWWA B504 Monobasic sodiumphosphate

Mix either material6 OZ in 1 GLwater

MIL-PRF-81309,Type II, Class 1 or2 or MIL-L-87177,Type I or II, GradeB

Water DisplacingCPC

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Cleaning Procedures

Lead-acid batteryelectrolyte de-posits (sulfuricacid solution)

ASTM D 928 Sodium bicarbon-ate, 6 OZ in 1GL water

Remove spilled electrolyteimmediately by flushingwith fresh water. Spray thecontaminated area with Lit-mus solution. (Refer toChapter 7). Neutralize thearea by sponging or spray-ing with sodium bicarbonatesolution. Apply generouslyuntil bubbling stops and theLitmus solution turns blue.Let it stay on the surfacefor 5 minutes but do notallow to dry. Brush with afiber bristle brush, thenflush with fresh water. Re-apply the Litmus solution todetermine if all the electro-lyte has been neutralized.Retreat the area, as re-quired, and rinse. Dry withclean wiping cloths. Keepthe cell vents open but donot allow any solutions toenter the cells. Preservecompartment with MIL-PRF-81309, Type II, Class1 or 2 or MIL-L-87177,Type I or II, Grade B CPC.Do not paint or preservebatteries.

MIL-PRF-81309,Type II, Class 1 or2 or MIL-L-87177,Type I or II, GradeB

Water DisplacingCPC


• A-A-59601, Type III dry cleaning and degreasing solvent, P-D-680 and MIL-PRF-680, Type III degreasingsolvent are non-combustible, but can still burn if exposed to flames. Use in a confined area is allowed, but thisarea should still be well ventilated. Keep away from open flames. Avoid contact with skin.

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Cleaning Procedures

BILGE AREAS Hydraulic fluid,water, dirt,metallic debris



Vacuum clean liquids and de-bris. Wipe area with asponge dampened in clean-ing solution. Rinse bysponging with fresh water.Wipe dry with a cleancloth.



Use of MIL-PRF-87937, TypeI may be restricted as notedabove in Exterior PaintedSurfaces.

A-A-59601 or MIL-PRF-680, Type III

Degreasing Solvent Wipe with cloth dampenedwith solvent. Wipe dry witha clean cloth.

Algae contami-nation



Mix cleaner and water in apump spray bottle. Spraymixture on contaminatedarea and allow it to dwell atleast 2 minutes. Wipe offwith a sponge and dry witha clean cloth. Use of MIL-PRF-87937, Type I may berestricted as noted above inExterior Painted Surfaces.



MIL-PRF-87937,Type III or MIL-PRF-85570, TypeV

Undiluted concen-trate

OPTICAL GLASS Dust, grease, andoil

A-A-59199 and Optical cleaner Spray cleaner onto flannel andcarefully wipe the lens orother optical surface. Wipedry with clean flannel cloth.


EJECTION SEATS

• Application of corrosion preventive compounds (CPC’s) or paints to certain areas of ejection seats could pre-vent or restrict seat operation. Specific ejection seat instructions must be followed carefully.

• See system specific ejection seat maintenance manuals and SPM instructions for corrosion prevention and con-trol and lubrication of ejection seats.

REMOVABLEMETAL FUELTANKS

Fuel residues,grease, andexhaust depos-its

MIL-PRF-85570 Use MIL-PRF-85570 deter-gent in accordance withprocedures in systems spe-cific fuel tank manuals.

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Table 3-3. Deicing/Anti-Icing Fluid Residue Inspection and Cleaning Procedures

Area Components VisuallyInspect for

Characteristics Cleaning Procedures Lubrication

Wing RearSpar Area,Includingthe Actua-tion Com-ponents

Spoilers, aile-rons, flaper-ons (if appli-cable),control sur-face hingesand balancebays

The presenceof dry orrehydrateddeicing/anti-icing fluidresidue

Dry residue is hardto see, has a thinfilm and is par-tially covered withdirt or grease

Spray areas with finemist of warm waterto rehydrate any resi-due present. Rehy-drate process may beslow, especially ifresidue has accumu-lated over a longperiod of time. If norehydrated residue isvisible, repeat theabove procedurethree more timesincluding the 15minute wait periodto allow rehydrationto occur.

After wash, per-form lubrica-tion/CPC re-quirements perapplicable TO.

Wing Lead-ing Edge

Devices includ-ing actuatingcomponents

Rehydrated residuewill be a gel-likesubstance, morevisible thickness

HorizontalStabilizerRear Spar

Actuating com-ponents forelevators,elevator tabs(if appli-cable), con-trol surfacehinges andbalance bays

Do not spray flightcontrol areas withwater when thetemperature is be-low freezing un-less the aircraft isin a heated hangar/shelter. Doing socan result in icethat impairs theflight controls.

Vertical Sta-bilizer

Actuating com-ponents forthe rudder,control sur-face hinges

Remove identified resi-due using warm wa-ter with rags and softbristle brushes. Alow pressure air (10to 15 PSI) is usefulto rinse away theresidue. Deicing fluid(SAE AMS 1425,Type I) or a mixtureof water and Type Ideicing fluid workswell to remove resi-due.

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3.4 CLEANING EQUIPMENT.

• Do not use high pressure spray nozzles to ap-ply cleaning compounds. Cleaning compoundsshall only be applied using a low pressure soapnozzle. High pressure can cause cleaning com-pounds to become entrapped in enclosed areacausing corrosion.

• High pressure wash equipment shall never beused on aircraft landing gear and components,wheels, and brakes as they can force lubricantsout of bearings and attach points and cause cor-rosion and wear problems.

NOTE

• Use only cleaning materials and equipment au-thorized and described in this manual. Experi-mentation with unauthorized cleaners maydamage aircraft, missiles, and equipment thusreducing reliability and increasing maintenancecosts.

• Cleaning equipment specific to one type of air-craft, missile, or piece of equipment is not cov-ered by this manual. Approved equipment forgeneral cleaning is discussed in this manual andordering information is presented in AppendixB of this manual. General operating instructionsare in Paragraph 3.4.1 through Paragraph 3.4.9.See specific equipment operating manuals fordetailed equipment operating instructions.

3.4.1 High Pressure/Hot Water Wash Equipment. Ifapproved by the aircraft SPD and/or the equipment SPM,high pressure/hot water wash equipment can be used forgeneral purpose cleaning of aircraft, support equipment, andvehicles. These machines can deliver four gallons per minuteof water and/or cleaning solution at a temperature of 210° Fand a pressure of 3000 PSI at the attach points on the ma-chine for each output hose. These machines shall be oper-ated per these instructions and the directions in the specificequipment operating manual.

a. Fill the cleaner reservoir with only approved cleaningcompounds.

b. Set the water cleaning compound mixture ratio to fiftyparts water to one part cleaner.

c. Use only 40° flat fan spray nozzles.

d. Ensure that the nozzle stand-off distance to the surfaceis always at least 12 inches and never less.

NOTE

• Pressure and temperature at the nozzles will beless than at the hose attach points on the ma-chine due to losses in the hoses.

• This equipment may remove any loose sealantand/or paint.

3.4.2 Portable, 15 Gallon, Foam Generating, CleaningUnit. This cleaning unit is compact, portable, light, and idealfor cleaning hard to reach areas. It consists of a 54 inchapplicator wand, 50 feet of hose, and a 15 gallon tankmounted on a frame with rubber tire wheels. (Refer to Fig-ure 3-1). The control system allows the operator to adjust thefoam wetness to fit any job. The cleaning unit provides afoam capable of clinging to vertical surfaces to soften anddislodge soils. These machines shall be operated per theseinstructions and the directions in the specific equipment op-erating manual.

Do not service the portable 15 gallon foam gener-ating cleaning unit without releasing the tank pres-sure.

When the cleaning task is completed, drain andflush the tank with fresh water to prevent formingan extremely concentrated solution by pouring ad-ditional cleaner into the solution remaining in thetank which could damage the equipment beingcleaned.

a. Release the tank pressure prior to servicing and re-move the tank fill cap. Fill the tank with an authorized,pre-diluted cleaning solution while leaving an adequateair space at the top of the tank. Replace the tank fillcap.

b. Connect the air supply hose to the air inlet valve onthe air regulator.

NOTE

Refer to Table 3-2 for the proper cleaner to watermix ratio.

c. Open the cleaning compound metering valve and theair inlet valve to the full, open position and set the airregulator to a pressure within the range of 30 to 70PSI.

d. Open the foam discharge valve while directing thenozzle at the surface to be cleaned.

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Change 10 3-29

Figure 3-1. Foam Generating Cleaning Unit (15 Gallons)

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Figure 3-2. Foam Generating Cleaning Unit (45 Gallons)

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e. If the foam is too wet, close the cleaning compoundmetering valve slightly. If the foam is too dry, open thecleaning compound metering valve slightly and/orlower the air pressure slightly by adjusting the airregulator. Dry foams have a longer dwell time and pro-long the cleaning operation but wet foams clean better.

f. Apply the foam to the surface and allow it to dwell fora minimum of 1 minute, but not long enough to dry onthe surface, and then scrub with a cleaning kit, brush,or cloth and rinse. Refer to Table 3-2 for additionalinstructions.

3.4.3 Portable, 45 Gallon, Foam Generating CleaningUnit. This cleaning unit is a simplified, portable pressureoperated, foam-dispensing system. (Refer to Table 3-2). Ituses available air supply for its power source without usingpumps. Air is metered directly into the pressurized solutionchamber which forces cleaning solution into the hose to cre-ate foam. These machines shall be operated per these in-structions and the directions in the specific equipment oper-ating manual.

Figure 3-3. Universal Wash Unit

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3-32

Do not service the portable 45 gallon foam gener-ating cleaning unit without releasing the tank pres-sure.

When the cleaning task is completed, drain thetank and flush with fresh water to prevent formingan extremely concentrated solution by pouring ad-ditional cleaner into the solution remaining in thetank which could damage the equipment beingcleaned.

a. Release the tank pressure prior to servicing. Close thecleaning compound metering valve and the air valveand open the air dump valve to bleed off retained airpressure.

b. Open the tank by removing the cover retaining boltsand lifting off the cover. Fill the tank with an autho-rized, pre-diluted cleaning solution while leaving anadequate air space at the top of the tank. Replace thecover and bolt it firmly in place.

NOTE

Refer to Table 3-2 for the proper cleaner to watermix ratio.

c. Make sure the cleaning compound metering valve andthe air valve are closed. Attach an air line to the airinlet/dump valve on the side of the unit and fill thevoid in the tank with air until the pressure is within therange of 30 to 70 PSI as indicated at the air regulator.

d. Open the air valve and then open the cleaning com-pound metering valve slowly while pointing the nozzleat the surface to be cleaned. Adjust the cleaner com-pound metering valve until the desired foam consis-tency is reached.

e. If the foam is too wet, close the cleaning compoundmetering valve slightly and/or open the air valveslightly. If the foam is too dry, open the cleaning com-pound metering valve slightly and/or close the air valveslightly.

f. Apply the foam to the surface and allow it to dwell fora minimum of 1 minute, but not long enough to dry onthe surface, and then scrub with a cleaning kit, brush,or cloth and rinse. Refer to Table 3-2 for additionalinstructions.

3.4.4 Turbine Engine Compressor Cleaning Equip-ment. Equipment used for cleaning aircraft turbine enginesis contained in specific system specific engine TO’s.

3.4.5 Miscellaneous Large Cleaning Equipment. Otherequipment such as truck, trailer, or wash rack/hangermounted spray or foam equipment may be available at manylocations.

3.4.6 Spray Cleaning Guns for Solvents. These solventspray guns have an extended nozzle/tube and require ap-proximately 14 CFM of air at 50 PSI to siphon solvent orcleaner from container and deliver it to a surface in a non-atomized spray.

3.4.7 Pneumatic Vacuum Cleaner. This unit is a small,portable, wet/dry, air-operated vacuum cleaner for removingdebris and water from aircraft. (Refer to Appendix B).

3.4.8 Universal Wash Unit. Universal wash units are usedfor general purpose cleaning. (Refer to Figure 3-3). Theyapply cleaning solutions to aircraft and/or equipment sur-faces in a non-foam state at the approximate rate of 2.5 gal/min at a pressure of 30 PSI. These machines shall be oper-ated per these instructions and the directions in the specificequipment operating manual.

Use the universal wash unit in the horizontal po-sition only.

a. Connect the strainer unit to the intake hose and insertit into the container of water or cleaning compoundsolution.

b. Connect the wand and the spray nozzle assembly tothe output/discharge hose or connect the dischargequick disconnect to the aircraft wash manifold quickdisconnect.

c. Press the start switch on the unit or the remote startswitch and observe the pressure gauge on the unit. Itshould indicate an increase of pressure immediately.When the pressure reaches approximately 10 PSI, re-lease the start switch and the unit will continue to run.

d. Point the nozzle at the aircraft or equipment surface tobe cleaned and spray the surface with the cleaning so-lution.

e. Press the stop switch on the unit or the remote stopswitch to stop the unit.

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f. Allow the cleaning compound solution to dwell forseveral minutes, but not long enough to dry on thesurface, and then scrub with a cleaning kit, brush, orcloth and rinse. Refer to Table 3-2 for additional in-structions.

3.4.9 Aqueous Parts Washers. These units are automaticindustrial power washers comprised of an enclosed cabinetequipped with a system of spray impingement nozzles, acycle timer, a cleaning solution reservoir with a heater unit,a fluid pump, and an effluent reservoir with a skimmer unitfor removal of oil, grease, and residues. (Refer to Figure 3-4and Figure 3-5). These automatic washers can effectivelyclean aircraft, missile, and equipment components by usingaqueous cleaning solutions applied at varying combinationsof high temperatures and pressures for the removal of soils,oils/greases, corrosion preventive compounds, and other con-taminants when authorized by the aircraft SPD and/or themissile or equipment SPM. These machines shall be oper-ated per these instructions and the directions in the specificequipment operating manual.

3.4.9.1 Effectiveness of Cleaning in Aqueous PartsWashers.

Materials used in and effluent generated by thiscleaning process may be hazardous to personneland the environment. Contact the local Bioenvi-ronmental Engineer and safety office for guidanceon personal protective equipment (PPE) and otherhealth and safety precautions and waste disposal.Parts may be very hot and retain hot water and/orcleaning solution in part cavities at the end of thecleaning cycle. Handle parts with water proof andheat resistant protective gloves and drain entrappedfluids back into the parts washer.

• Aqueous parts washers shall not be used toclean bearings unless authorized by system spe-cific technical data.

• Due to the maximum allowable pH of 13.5 forthe MIL-PRF-29602 cleaning compounds usedin these parts washers, they can attack alumi-num alloy and IVD aluminum coated parts.Aircraft SPD and/or missile or equipment SPMapproval is required prior to cleaning thesetypes of parts in aqueous parts washers.

• Due to the possibility for hydrogen embrittle-ment and other damage, only those cleaners

which have been tested, approved, and listed inthe most current revision of the applicable land-ing gear technical order shall be used in aque-ous parts washers for cleaning LG componentsincluding wheels and brakes.

• Depending on the type of equipment used, wa-ter/cleaning solution spray pressures in aque-ous parts washers can range from 40 to 100PSI. Suitable fixtures and/or baskets must beused to secure components during the cleaningcycle to prevent damage caused by impinge-ment of the high pressure spray.

The effectiveness of cleaning in aqueous parts washers isinfluenced by several factors that should be considered whenusing this cleaning method.

3.4.9.1.1 Spray Nozzles. There are two basic nozzle de-signs, fan and cone spray. The distance of the parts in thecabinet from the spray nozzles determines how effective theforce of the spray from the nozzles will be and the area ofcoverage. Placing parts too close to the spray nozzles re-duces the surface coverage of the nozzles and too far fromthe spray nozzles reduces the force of the spray. Understand-ing this and racking parts properly in aqueous parts washerswill improve the cleaning effectiveness of the machine.

3.4.9.1.2 Bath Quality. Maintaining the condition of thecleaning bath affects its ability to remove soils. There aretwo types of detergents used in aqueous cleaning, emulsify-ing and non-emulsifying. Emulsifying cleaners break downthe oils and greases and hold them in suspension in the bath.With these cleaning materials, their cleaning ability becomesdegraded by excessive amounts of oil and greases being heldin the bath. It is important to monitor and change the bathsolution routinely to maintain effective cleaning. The non-emulsifying cleaners break down the oils and greases but donot hold the materials in the bath solution, they rise to thetop of the bath. It is important to have an effective skimmeron machines using non-emulsifying cleaners to remove theoil and greases. The proper concentration of cleaner in thebath also affects the bath performance. The heated cleaningsolutions cause evaporation and proper make up of both wa-ter and cleaner should be added. This should be monitoredregularly and adjustments made per the manufacturer’s in-structions.

3.4.9.1.3 Skimmers and Filtration. Several types of bothskimmers and filtration systems are available for use withaqueous parts washers. These have a major impact on main-taining bath quality. It is recommended that both the filtersand skimmers be used and that they be maintained properlyper manufacturer’s instructions to ensure bath quality andthe cleaning effectiveness of the machine.

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3.4.9.2 Determination of Capacity of the AqueousParts Washer. Determine the capacity of the aqueous partswasher cleaning compound reservoir and fill it with MIL-PRF-29602 or the applicable landing gear technical orderapproved cleaning compound solution mixed/diluted per themanufacturer’s directions.

NOTE

Agitation prior to reaching the required operatingtemperature may cause the cleaning solution tofoam excessively. Do not use the washer until thecleaning solution has stabilized at the proper tem-perature.

a. Allow the cleaning solution to stabilize at the tempera-ture recommended by the manufacturer within therange of 140° to 180° F.

• When cleaning components which can entrapfluids, load the components in the basket so thatas many cavities as possible that can entrap flu-ids are face down to prevent corrosion causedby fluid retention.

• Due to evaporation of the heated cleaning baths,the bath level must be monitored. This is nec-essary to ensure levels do not go down and ex-pose the heating elements of the machine asthis will cause them to burn out.

b. Place components to be cleaned in the aqueous partswasher and either secure them to the turntable or se-cure the basket in which they are placed on the turn-table.

Do not leave parts unattended in the washer cabi-net as the very hot and humid environment insidethe unit can cause the parts to corrode rapidly. Re-move the cleaned components from the washer assoon as possible after the cycle is complete.

c. Set the wash cycle timer for 3 to 30 minutes depend-ing on the type of soil to be removed, the quantity ofsoils on the parts, and the number of parts involvedand based on the manufacturer’s recommendations inthe equipment operating manual. Light degreasing mayrequire only 3 minutes while heavy soils and baked on

grease may require a full 30 minute cycle. Always runthe aqueous parts washer for the entire programmedtime cycle and then allow the cleaned components tocool for a short time before removing and handlingthem.

d. If the cleaned components are to be subjected to animmediate in line process such as fluorescent penetrantinspection, surface treatment and/or painting, or fol-low-on precision cleaning, rinse the part with fresh tapwater and dry them thoroughly.

e. Apply a film of MIL-PRF-81309, Type II, MIL-L-87177, Type I, Grade B, or MIL-PRF-16173, Grade 3,followed by a film of MIL-PRF-16173, Grade 4 onbare steel parts that have been cleaned and rinsed andwill be left unprotected from the environment withoutfurther processing for a period of time.

3.4.10 Miscellaneous Equipment. Accessories and con-sumable materials for manual cleaning operations are listedin Appendix A and Appendix B, and include the followingimportant items.

a. The 3M Co., PN 251 aircraft washing kit (refer to Fig-ure 3-6), is a conformable plastic device/head with asurface for attaching non-abrasive cleaning pads andsponges. It attaches to a mop handle for cleaning air-craft surface areas.

b. A-A-3100, non-metallic cleaning and scouring pads arecrimped polyester fiber pads for use with detergentsand solvents for cleaning aircraft, missile, and equip-ment surfaces. These pads can also be attached to a3M Co., PN 251 aircraft washing kit.

c. MIL-B-23958, non-metallic bristle brushes are used toagitate MIL-PRF-87937 and MIL-PRF-85570 deter-gent cleaners on aircraft, missile, and equipment sur-faces during cleaning operations.

d. CCC-C-440, Type I or II, Class 1 or 2 cheesecloth,CCC-C-46, Type I, Class 7 non-woven wiping cloths,A-A-59323, Type I or II low lint cleaning cloths, andSAE AMS 3819, Class 1 or 2, Grade A or B cleaningcloths are used for cleaning critical areas where anexceptionally clean cloth is required, such as solventcleaning prior to painting, adhesive bonding, or seal-ing.

e. A-A-2806, or equal, plastic pump-spray bottles areused for applying diluted MIL-PRF-87937, Type I or

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IV and MIL-PRF-85570, Type I or II, or concentratedMIL-PRF-87937, Type III and MIL-PRF-85570, TypeV cleaning solutions to small, localized areas beingcleaned.

3.5 CLEANING PROCEDURES.

Where high outdoor temperatures are encountered (80° F/27° C and above) and an indoor wash rack is not available,cleaning operations should be scheduled for early morning,late afternoon, or night. Wet aircraft exteriors with fresh wa-ter before applying cleaners to cool surfaces and help pre-vent fast evaporation and drying of cleaners during hotweather. For cold weather procedures, refer to Paragraph3.5.2.6.

NOTE

Only water meeting the requirements in Paragraph3.1.1, step g shall be used in cleaning operations(washing and rinsing) on aircraft, missiles, andequipment.

3.5.1 Warnings and Cautions. The following warningsand cautions shall be observed during aircraft cleaning op-erations:

3.5.1.1 Electrical.

• Aircraft and/or other equipment shall not bewashed, cleaned, or inspected on an outdoorwashrack when an electrical storm is in the im-mediate area.

• Open all circuit breakers associated with bat-tery power (refer to applicable aircraft manu-als), prior to application of flammable solventcleaners.

• In order to guard against the danger of staticelectricity, aircraft shall be electricallygrounded during all cleaning operations andwhen moored and parked.

• Before cleaning electrical and avionic equip-ment, make sure electrical power is discon-nected. Injury or death may otherwise result.

Figure 3-4. Top Loading Type

Figure 3-5. Front Loading Type

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3.5.1.2 Personal Protection.

• Wear rubber gloves, chemical or splash proofgoggles, and water resistant boots during clean-ing operations using MIL-PRF-87937, MIL-PRF-85570, or MIL-PRF-85704 cleaning com-pounds. If cleaner is splashed in eyes, rinsethoroughly with fresh water for 15 minutes andreport to medical facility. Remove clothingsaturated with cleaning solution immediatelyand flush exposed skin areas with fresh water.

• Cleaning solutions are slippery. Use mainte-nance stands where practical. A safety harnessand safety lines shall be used when standing onupper surfaces of aircraft during cleaningoperations.

Consult the local safety office and Bioenvironmental Engi-neer for personal protective equipment (PPE) requirements.

3.5.1.3 Use of Solvents.

• Do not use synthetic wiping cloths with flam-mable solvents such as TT-N-95 aliphatic naph-tha.

• Solvents shall not be applied with atomizingspray equipment. This is not only hazardous,but violates environmental regulations in mostareas.

• Keep all solvents away from open flames andany live electrical circuit or sources of electri-cal arcing. Ensure that residual solvent is re-moved from aircraft, engine bays, and equip-ment.

• Use solvents only in well ventilated areas. Wearchemical resistant rubber gloves and chemicalor splash proof goggles when using solvents.Avoid skin contact. Consult the local safety of-fice and Bioenvironmental Engineer regardingrespiratory protection.

• Do not mix cleaning compounds with any sol-vent, MIL-PRF-32295, such as A-A-59601 andMIL-PRF-680. The added solvents create a firehazard, a serious disposal problem, and candamage non-metallic materials.

3.5.1.4 Use of Cleaners.

• Steam shall not be used for cleaning aircraft,missiles, or their components. Steam can dam-age and/or deteriorate sealants, paint coatings,and elastomers.

• Do not apply MIL-PRF-87937 (except Type IV)or MIL-PRF-85570 (except Type II), A-A-59921 (formerly MIL-C-43616), or MIL-PRF-85704, Type I cleaning solutions or any unau-thorized solvents to electrical wiring or plasticaircraft canopies as they may cause damage toinsulation or crazing of transparent surfaces.

• Do not use cleaning compounds at higher con-centrations than those recommended. Do notallow cleaning solutions to dry on aircraft sur-faces. Such practices cause streaking and candamage aircraft finishes and components.

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Change 5 3-37

3.5.1.5 Water Intrusion.

• To prevent entrapment of water, solvents, andother cleaning solutions inside of aircraft, mis-sile, and equipment parts and structural areas,all drain holes, flapper valves, etc., shall beopened before washing to ensure that properdrainage occurs.

• Do not wash or rinse aircraft, missiles, or equip-ment with a solid stream of water. Use a softspray pattern to avoid damaging fragile sectionsor causing water intrusion.

• Do not direct water streams at pitot tubes, staticports, vents, etc. These areas shall be adequatelyprotected by masking prior to starting a clean-ing operation.

• Relubricate all fittings and other lube points inareas where cleaning compounds have been ap-plied, such as wheel wells, flap wells, flightcontrol wells, etc. Ensure that these areas areadequately drained and check the system spe-cific aircraft manual to determine lubricationrequirements.

3.5.1.6 Oxygen Systems.

Observe warnings and cautions in system specificoxygen system manuals.

3.5.1.7 Special Precautions.

Use extreme care when cleaning around radomes,access doors to integral fuel tank cells, light fix-tures, electrical components, antennas, etc. Theseareas may be damaged by cleaning solutions andequipment.

3.5.1.8 Preparation for Cleaning.

Open all circuit breakers associated with batterypower (refer to applicable system specific aircraftmanuals), prior to application of any flammablesolvent.

Cover acrylic or polycarbonate canopies and win-dows on aircraft during washing operations to pre-vent accidental scratching or crazing by cleaningcompounds and equipment. Cover canopies and/orwindows with A-A-50129 flannel cloth. Cover theflannel cloth on the canopies and/or the windowswith MIL-PRF-131, Class 1 barrier material (plas-tic side toward aircraft) and tape it to the canopyand/or window frames, or the painted surface nearthem using AMS-T-21595, Type III masking tapeor AMS-T-22085, Type II preservation tape orequivalent. Do not apply the tape directly to thetransparent surfaces.

3.5.1.9 Pre-Wash Lubrication Point Protection. To pro-tect against cleaning solution entrapment, inspect all lubrica-tion points having exposed lubrication fittings. Prior to mask-ing any components or parts, remove all foreign matter fromjoints, fittings, and bearing surfaces, using a CCC-C-46,non-woven cleaning cloth or an SAE AMS 3819, Class 1,Grade B cleaning cloth. Wipe up all spilled or excess oil andgrease. Mask all fittings which will be exposed to wash so-lutions with MIL-PRF-131, Class 1, barrier material andAMS-T-21595, Type III masking tape or equivalent, asneeded. See the applicable system specific maintenancemanuals and card, and Paragraph 3.6 for location of lubrica-tion points.

NOTE

Consult the system specific aircraft (-23) corro-sion manual for cleaning operation masking re-quirements for specific aircraft in addition to thosein this manual.

3.5.1.10 Water/Cleaning Compound Intrusion. Take thefollowing steps to prevent water/cleaning compound intru-sion during cleaning operations:

a. Close all doors, removable panels, and emergencyopenings, and seal and/or mask their edges, if required,to prevent leakage into interior areas. Mask all areaswhere cleaning solutions and water can become en-trapped and cause corrosion and other damage to air-craft and missile components and structure, such aspod doors, areas around thrust rings, radomes, opticalglass, nirdomes, etc. Use prefabricated covers and/orMIL-PRF-131, Class 1 barrier material and AMS-T-21595, Type III masking tape or AMS-T-22085, TypeII preservation tape or equivalent for masking.

b. Check drain holes. Make sure that all drain holes areclean by inserting a probe, such as a pipe cleaner, into

TO 1-1-691

3-38 Change 6

them except for pressurized flapper valves. Refer tosystem specific aircraft maintenance manuals or (-23)corrosion manuals for location of drain holes.

Make sure that pitot static tubes and static vents/openings/ports are not fouled by tape adhesivetransfer. Cover them as directed in step c below.

c. Cover all static vents, openings, and ports with circularcut pieces of MIL-PRF-131, Class 1 barrier material(plastic side toward the aircraft surface) and hold inplace with AMS-T-21595, Type III masking tape orAMS-T-22085, Type II preservation tape or equivalent.Refer to system specific aircraft and missile mainte-nance manuals and (-23) corrosion manuals for loca-tions of static vents, openings, and ports to be masked.Place covers on pitot static tubes. If covers are notavailable, a piece of MIL-PRF-131, Class 1 barriermaterial may be cut and taped in place on the pitotstatic tube with AMS-T-21595, Type III masking tapeor AMS-T-22085, Type II preservation tape or equiva-lent. Covers and masking must be removed prior torelease of aircraft for flight. Particular care shall betaken to ensure that static vents, openings, and portsand pitot static tubes are not fouled by tape adhesivetransfer. In the event of significant adhesive transfer,clean with TT-N-95 aliphatic naphtha.

Do not use a direct spray of water or cleaningcompound on carbon brakes, wheels, or wheelhubs. If wheel bearings are suspected of contami-nation, corrosion, or loss of lubricant, removewheel bearings and relubricate in accordance withapplicable system specific maintenance instruc-tions and TO 4W-1-61. If carbon brakes are sus-pected of contamination, decontaminate per appli-cable system specific maintenance instructions andTO 4B-1-32.

d. Cover wheels with covers designed and manufacturedfor the specific aircraft or locally fabricated covers toprevent water/cleaning compound contamination ofwheel bearings and carbon brakes. Carbon brakes havetemporarily reduced performance when subjected towater, deicers, degreasers, and oil. Protect brakes fromdirect impingement of fluids as much as practical dur-ing maintenance and aircraft cleaning operations. Weakor spongy brakes (and in some cases, smoke), mayresult until the contaminants are burned off (normallyone flight/take off and landing).

3.5.2 Cleaning Methods.

• Wear rubber gloves, chemical or splash proofgoggles, and water resistant boots during clean-ing operations using MIL-PRF-87937, MIL-PRF-85570, or MIL-PRF-85704 cleaning com-pounds. If cleaner is splashed in eyes, rinsethoroughly with fresh water for 15 minutes andreport to medical facility. Remove clothingsaturated with cleaning solution immediatelyand flush exposed skin areas with fresh water.

• Open all circuit breakers associated with bat-tery power (refer to applicable system specificaircraft manuals), prior to application of flam-mable solvents.

• There are potential health risks associated withcleaning compounds if proper handling, mix-ing, and usage instructions are not followed.Consult the specific cleaning compound SafetyData Sheets (SDS) and the local safety officeand Bioenvironmental Engineer for specificinformation.

The methods for cleaning aircraft, missiles, and equipmentmay vary depending upon the type of aircraft, missile, orequipment involved. Use the following methods for cleaningaircraft, missile, and equipment exterior surfaces. Refer toTable 3-2 for instructions on specific areas and componentsand Table 3-3 for deicing/anit-icing fluid residue inspectionand removal.

3.5.2.1 Alkaline Detergent and/or Solvent EmulsionCleaning, Painted and Unpainted Surfaces; Fresh Wa-ter Readily Available.

Do not use A-A-58054 abrasive mats for cleaningoperations on painted or unpainted surfaces.

Accomplish cleaning operations in planned steps startingwith the lowest and most inboard surfaces to be cleaned andwork upward and outward. Dilute and/or mix cleaning com-pounds as recommended in Table 3-2.

TO 1-1-691

Change 15 3-39

a. Flush aircraft, missile, or equipment surfaces with freshwater when necessary to reduce skin temperature.Streaking will occur if cleaning solutions run down onand/or dry on hot painted or unpainted surfaces.

• A-A-59921 (formerly MIL-C-43616) solventemulsion cleaner and A-A-59601 and/or MIL-PRF-680 solvents shall not be used on non-polyurethane paint systems and markings as thesolvent materials will cause them to fade.

• Consult the base Bioenvironmental Engineerbefore using these solvent materials as they cancreate waste disposal problems.

b. Apply properly mixed/diluted MIL-PRF-87937, Type Ior IV, or MIL-PRF-85570, Type I or II cleaning com-pound solution from a bucket, spraying equipment (in-cluding the high pressure type if approved by the air-craft SPD and/or the missile or equipment SPM), orfoaming equipment. Scrub surfaces with a 3M Co., PN251 aircraft washing kit (Appendix B, Item No. 1) fit-ted with a cleaning pad (Appendix A, Item No. 37,refer to Figure 3-6), one of the 3M Co., improved washpads fitted to its appropriate holder and handle (Ap-pendix A, Item No. 38), or with a cleaning brush. Al-low the solution to dwell on the surface for 5 to 10minutes. Start at the lower and inboard edges of thesurfaces being cleaned working upward and outward.(Refer to Figure 3-7).

NOTE

MIL-PRF-87937, Type I materials contain ter-penes. Aircraft SPD and/or missile or equipmentSPM restrictions may apply. Consult system spe-cific maintenance manuals.

c. Rinse away the loosened soil and cleaner with fresh,heated, tap water at a temperature of 120° F/49° Cminimum to 140° F/60° C maximum. Use a rubberpadded shutoff spray nozzle (refer to Figure 3-8), torinse the cleaner and loosened soil from aircraft, mis-sile, or equipment surface. Adjust the nozzle to pro-vide a light to coarse fan spray directed at an anglebetween 15° and 30° from the surface. Start at theoutboard and upper edges of the area being rinsed

working inward and downward. Continue rinsing untilall evidence of cleaner and soils have been removedfrom aircraft, missile, or equipment. Small areas maybe rinsed with water applied with cloths or spongeswhich are rinsed out frequently, and then dried with aclean cloth or sponge, or allowed to air dry.

NOTE

If hot water is unavailable, regular tap water maybe used for rinsing but it takes a great deal longer,requires much more water, and is not as efficientin removal of residue from the surface. Hot waterrinsing is known to reduce man-hours required forrinsing by approximately 20%.

d. For aircraft or equipment painted with a low gloss/flatand/or camouflage paint scheme, ground-in soils (bootmarks, smudges, etc.,) can be cleaned with MIL-PRF-85570, Type IV spot cleaner. Apply with a cleaningpad or sponge and after several minutes dwell time,scrub these areas with the pad or sponge and rinsethoroughly. When the rubber particles in this cleanerare rubbed with the pad, removable soils are erasedfrom the low areas or depressions in the surface of thepaint

Figure 3-6. Use of Aircraft Washing Applicator

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3-40 Change 5

Figure 3-7. Aircraft Cleaning Procedure

TO 1-1-691

3-41

e. Clean wheel, flap, aileron, elevator, rudder wells, andother heavily soiled areas which can tolerate waterrinsing with MIL-PRF-87937, Type III or MIL-PRF-85570, Type V gel cleaner. These cleaning compoundsmay be sprayed on using a hand operated pump spray.Allow to dwell for 5 to 15 minutes and then rinsethoroughly with a rubber padded shutoff fan spraynozzle adjusted to provide a light to coarse fan spray.(Refer to Figure 3-8).

f. Clean painted and unpainted surfaces on aircraft, mis-siles, and/or equipment that are protected/treated withCPC’s with A-A-59921 (formerly MIL-C-43616),Class 1A solvent emulsion cleaner applied by spray orA-A-59601, Type II or III, MIL-PRF-32295, Type II,or MIL-PRF-680, degreasing solvents applied with abrush, cloth, sponge, or non-atomizing spray. Rinse thearea thoroughly with fresh tap water (preferably hotwater), and then wash by alkaline detergent cleaningper step b and step c above.

NOTE

MIL-PRF-87937, Type III or MIL-PRF-85570,Type V gel cleaning compounds may be used asalternates to clean CPC coated areas per proce-dure in step e above.

g. If surfaces are not clean at this point, repeat the clean-ing process.

3.5.2.2 Waterless Wipe Down. Waterless wipe downprocedures for spot cleaning will be used only when water isnot available for rinsing or when cold weather prevents theuse of water. The waterless wipe down method for removalof soils and corrosive salt residues is as follows:

a. Using a plastic spray bottle, apply MIL-PRF-87937,Type I or IV or MIL-PRF-85570, Type I or II, (mixedone part cleaner to nine parts water) to the exteriorsurfaces of the aircraft (several square feet at a time).

NOTE


b. After 30 seconds, scrub, then wipe cleaner and soilfrom the surface with a clean CCC-C-46, Type I, Class7 or SAE AMS 3819, Class 1, Grade B cloth.

c. Rinse the cleaned surface with fresh water when it be-comes available and/or weather permits.

3.5.2.3 Alkaline Detergent Cleaning with Only LimitedFresh Water Available. Use the following procedure onlywhen sufficient rinse water is not available.

a. Mix either of the following in a bucket depending onthe type of soil to be removed.

(1) One part MIL-PRF-87937, Type I or IV or MIL-PRF-85570, Type I or II cleaning compound andsixteen parts water for removal of light to moder-ate soils.

(2) One part MIL-PRF-87937, Type I or IV or MIL-PRF-85570, Type I or II cleaning compound andfour parts water for removal of heavy soils.

NOTE


b. Apply the cleaner with a cleaning pad, sponge, cloth,or cleaning brush one small area at a time (10 to 20SQFT).

c. Scrub the area with the applicator from step b, andthen wipe clean with a CCC-C-46, Type I, Class 7 orSAE AMS 3819, Class 1, Grade B cloth.

d. For very stubborn soils, clean with A-A-59601, MIL-PRF-32295,Type I or II, or MIL-PRF-680, degreasingsolvent, and then scrub with one of the above solutionsin step (1).

3.5.2.4 Solvent Cleaning. The use of MIL-PRF-87937,Type III or MIL-PRF-85570, Type V cleaning compoundsfor cleaning very stubborn or exceptionally oily areas onexhaust tracks, landing gears, wheel wells, control surfacewells, and engine nacelles will normally be sufficient. Whenthese materials do not completely clean these areas, A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, can beused in small quantities. The quantity used shall be limitedto the minimum necessary to accomplish the required clean-ing. Remember that solvents will burn intensely once ig-nited, so limit the amount of solvent available at the aircraft,missile, or piece of equipment to a maximum of three gal-lons under the use and/or control of each authorized personinvolved in the solvent cleaning operation. Each authorizedperson shall be thoroughly familiar with applicable safetyprecautions and disposal requirements/information. The sol-vent dwell time on painted surfaces shall be held to a mini-mum of 10 to a maximum of 15 minutes to prevent softeningof the paint. Any dirty solvent draining off the surface duringthe cleaning operation shall be controlled to prevent unau-thorized entry into the sewer. All solvent spillage shall becleaned up per local regulations/directions. In no instanceshall solvents be allowed to drain into or enter a public seweror otherwise be allowed to contaminate streams or lakes.These guidelines shall be followed when using A-A-59601,MIL-PRF-32295, Type II or MIL-PRF-680, solvents.

a. Use only in areas approved by the local safety office.

TO 1-1-691

3-42 Change 5

b. Ensure that the area within 50 feet of the solventcleaning operation is clean and remains clear of allpotential ignition sources.

c. Use only explosion-proof electrical devices and powerequipment. Power units used in servicing shall beplaced upwind and beyond the 50 feet clearance. En-sure that the aircraft, missile, or equipment is properlygrounded.

d. No smoking shall be allowed in the solvent cleaningarea.

e. Mixing of solvents with other chemicals, cleaningcompounds, water, etc., is strictly prohibited except asspecified by this manual.

f. Suitable fire extinguishing equipment shall be avail-able to the solvent cleaning area.

g. Wear ANSI Z87.1, Type II goggles, protective wetweather clothing, solvent resistant gloves, boots, andhead covering. Use a respirator fitted with organic va-por cartridges when working in an enclosed area. En-sure that good ventilation is maintained. Consult thelocal safety office and Bioenvironmental Engineer forPPE requirements.

h. Apply A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, solvents using a pad, cloth, or brush. Cleanup solvent spills as they occur.

i. Ensure that no solvent is trapped or has entered theequipment interior. Remove by wiping with clean cot-ton wiping cloths or by blowing dry, using clean, lowpressure air (10-15 PSI).

j. Collect waste solvents and solvent wetted wiping ragsand dispose of them per local regulations/directions.

k. After cleaning with A-A-59601, MIL-PRF-32295, TypeII, or MIL-PRF-680 solvents, reclean the area usingprocedures in Paragraph 3.5.2.1 to remove residue leftby the solvents.

3.5.2.5 Interior Cleaning (Vacuum). Remove dirt, dust,small loose objects, paper, etc., from an area with an indus-trial or domestic type vacuum cleaner. A soft bristle brush onthe end of the inlet tube/hose of the vacuum cleaner will aidin removal of soils.

a. Inspect aircraft floor boards and bilge area underneaththe floor boards during depot level maintenance and as

may otherwise be required during field level mainte-nance for conditions that would necessitate cleaning orcorrosion removal and treatment. Particular attentionshall be given to urinal and latrine areas.

Accidental spills shall be investigated immediatelyafter occurrence to determine if the spilled mate-rials are corrosive. Spills determined to be corro-sive shall be neutralized as soon as possible perdirections in AFMAN 24-204-IP followed bycleaning per procedures in Table 3-2. Failure tocomply can result in extensive corrosion damageand possible unsafe conditions for operation of theaircraft, missile, or equipment.

b. When it is determined that harmful contamination, (i.e.,dirt, spillage, foreign material, etc.,) is present in anaircraft bilge area, remove the floor boards as neces-sary to allow proper cleaning of the bilge area.

c. Clean the aircraft bilge area by vacuuming up all looseforeign material, dirt, etc., The vacuum removal of dirtor soil may be aided by agitating with the brush. Becareful not to sweep or wipe the dirt, etc., into oily orwet areas.

Ensure there is adequate ventilation when usingA-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, solvents and be sure the bilge and/orother areas are properly ventilated (blown out) be-fore floor boards are reinstalled or closed. Warn-ing signs shall be conspicuously placed at all air-craft entrances to indicate that combustiblematerials are being used. The guidelines cited inParagraph 3.5.2.4 for solvent cleaning proceduresapply.

d. Clean oily areas and/or spots by wiping them with aclean cloth dampened with A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, solvent followed im-mediately by drying with a clean dry cloth. Do notoversaturate the cloth used for applying the solventbecause this may result in the solvent puddling or en-tering recessed areas and creating a fire hazard. Pre-cautions shall be taken when using these solventsaround electrical equipment to prevent entry.

TO 1-1-691

Change 5 3-43

Before starting the following cleaning operation,be sure that the spray or other method of applica-tion will not result in moisture damaging anycomponents, especially electrical components. Be-fore using a spray method, ensure all drain holesare open, that the fluid materials will drain, andthat the cleaning solution will not be forced intoinaccessible areas. Do not apply the solution toany moisture absorbing material such as insula-tion, sponge rubber (open cell), felt, etc.

e. If further cleaning is required, use a solution of onepart MIL-PRF-87937, Type IV or MIL-PRF-85570,Type II mixed with nine parts fresh water applied byspray, mop, sponge, or brush. Use this solution only ifit can be adequately rinsed and/or removed from thesurface.

f. After applying the cleaning solution, allow dwell timeof approximately 10 minutes, agitate the solution onthe surface with a non-metallic bristle brush, and flushor rinse with clean water. Check drain holes to ensurethat they are open and that the cleaning solution andwater are draining properly. Remove any remainingwater using clean cloths. The surface shall then bethoroughly dried by blowing warm air over the surfaceor wiping with clean, dry cloths.

g. In those areas where the above procedures cannot beused due to lack of drainage, possible damage to com-ponents, etc., hand cleaning procedures will have to beused. Apply a solution of one part MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II mixed with nineparts water to the surface with a rag or sponge wettedwith the solution and then agitate it with the applicator.Immediately following agitation of the solution, rinsethe area by wiping it with a rag wetted with clean

Figure 3-8. Automatic Water Spray Nozzle

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3-44

water and then wipe it dry with a clean, dry rag. Thisprocedure may have to be repeated several times onextremely soiled areas.

h. If corrosion is encountered and/or paint is removed,treat the corrosion per this manual and the applicablesystem specific maintenance manual, and touch-up thepaint system per TO 1-1-8 and the applicable systemspecific maintenance manual before the floor boardsare replaced or area is closed.

3.5.2.6 Low Temperature Cleaning. Do not perform rou-tine scheduled cleaning when the temperature is 40° F (4° C)and below. Instead, aircraft, missiles, or equipment shall becleaned in an indoor, heated wash rack. However, if the tem-perature is between 40° F (4° C) and 32° F (0° C) and sucha facility is not available, exterior areas/surfaces on aircraft,missiles, or equipment contaminated with corrosive materi-als, such as runway deicing agents and salt water shall havethese areas/surfaces cleaned outdoors using the waterlesswipe down method in Paragraph 3.5.2.2. Normal cleaningsolutions cannot be used in freezing weather of 32° F (0° C)and below, so under these conditions, the following proce-dures shall be used for cleaning:

Table 3-4. Recommended Dilution of Low Tem-perature Cleaner

Ambient (Room)Temperature

Dilution Ratio (PartsMixture: Parts Water)

+30° F and above 1:4+10° F to +30° F 1:2+10° F and below 1:1

SAE AMS 1424, Type I aircraft deicing/anti-icingfluid is mildly toxic. Contact with skin and eyesshall be avoided. Do not inhale deicing fluid mist.Spray equipment operators and personnel usingbrush applicators should stay on the windward side

of the aircraft and/or equipment to be cleaned dur-ing cleaning solution application. Chemical, splashproof goggles and wet weather gear, includingboots and gloves, shall be worn by all mainte-nance personnel involved in low temperaturecleaning operations.

TT-I-735 isopropyl alcohol or any other alcoholshall not be used for deicing acrylic plastic cano-pies. Use Type SAE AMS 1424, Type I aircraftdeicing/anti-icing fluid for these applications.

a. If necessary, deice the aircraft, missile, or equipmentper procedures in TO 42C-1-2 and/or the applicablesystem specific maintenance manual.

b. Solvent clean heavily soiled areas of aircraft by wipingor brushing with A-A-59601, Type II or III or MIL-PRF-680, Type II or III degreasing solvent using pro-cedures in Paragraph 3.5.2.2.

c. To make a low temperature cleaner, mix ½ pint ofconcentrated/undiluted MIL-PRF-87937, Type IV orMIL-PRF-85570, Type II cleaning compound into onegallon of the ready-to-use (RTU) SAE AMS 1424,Type I aircraft deicing/anti-icing fluid or into one gal-lon of a solution of the concentrated form of the SAEAMS 1424, Type I aircraft deicing/anti-icing fluid di-luted 1 to 1 with water. If necessary, warm either ofthese cleaning compound materials until they can beeasily poured into the deicing/anti-icing fluid. Mixthoroughly.

d. Dilute this mixture, as required, by the ambient (room)temperature involved per Table 3-4 and mix thoroughly.

e. Scrub the aircraft, missile, or equipment using a brush,cloth, or aircraft washing kit.

TO 1-1-691

3-45

f. Rinse by deicing as in step a. Heated deicing/anti-icingfluid mixtures will speed up the rinsing process.

3.5.3 Clear Water Rinsing of Aircraft.

• Do not rinse aircraft with a solid stream of wa-ter. Use a soft, spray pattern to avoid damagingfragile sections or causing water intrusion. Wa-ter must not be directed at pitot tubes, staticports, vents, etc. Critical areas shall be ad-equately protected with ground plugs, covers,etc.

• Clear water rinsing shall not be accomplishedoutside when the temperature is at 40° F (4° C)or below. Spraying flight control areas outsidewith water when the temperature is belowfreezing can result in ice that could impair flightcontrols.

• Application of water in wheel wells, flap wells,flight control wells, etc., may necessitate therelubrication of some components/areas. Ensurethat these areas are adequately drained andcheck the system specific aircraft maintenancemanuals to determine lubrication requirements.

NOTE

• Clear water rinsing does not satisfy aircraftwashing requirements.

• Only water meeting the requirements in Para-graph 3.1.1, step g shall be used for clear waterrinse operations.

3.5.3.1 Requirements. As directed by the requirementsin Paragraph 3.2.3, aircraft shall be clear water rinsed toremove salt contamination from aircraft surfaces caused byoperations near salt water. Most salt deposits are readily dis-solved and/or dislodged and flushed away by rinsing. Rins-ing can be done in a taxi-through facility or by direct manualspraying.

3.5.3.2 Taxi-Through Rinsing. Deluge rinse facilities(bird baths) are automatic installations located in a taxiwayarea for use by aircraft after flight through salt air. Theseinstallations provide multiple jet sprays of fresh water tocover the entire aircraft exterior surface to rinse off salt andwater soluble contaminants. Such facilities should be used asfrequently as possible per the requirements in Paragraph3.2.3.

3.5.3.3 Manual Application. Fresh water can be appliedfrom a hand held hose or piece of spraying equipment. Theforce or pressure used to apply the water is not as critical as

the amount of water. Satisfactory results are achieved withan amount of water that will create a full flowing action overthe surface. This requires a minimum of eight gallons perminute (GPM) of water at a nozzle pressure of 25 PSI mini-mum to 175 PSI maximum.

3.5.3.4 Rinsing Procedures. Clear water rinsing shall beaccomplished as follows:

a. Direct water at an angle of 15° to 30° from the surface.Ensure that sufficient water flow is achieved on all sur-faces.

b. Begin rinsing on lower surfaces and work upwardstarting with the lower wing surfaces, then the lowerfuselage, and the lower horizontal stabilizer surfaces.Then rinse from the top down, starting with the upperand lower surfaces of the horizontal stabilizer on T-tailaircraft, the vertical stabilizer surfaces, then the upperfuselage, upper wing surfaces, and upper horizontalstabilizer surfaces. (Refer to Figure 3-7).

3.5.4 Post Cleaning Procedures.

Do not use synthetic wiping cloths with flammablesolvents as these solvents can dissolve them.

3.5.4.1 Post Cleaning Task Sequence. Strict compli-ance with the following post cleaning procedures is essentialand they shall be done in the following order.

a. Remove covers and masking from all static vents, pitotstatic tubes, air ducts, heater ducts, etc.

b. Remove tape from all other openings sealed with mask-ing tape.

c. Remove all tape adhesive residues with TT-N-95 ali-phatic naphtha or TT-I-735 isopropyl alcohol.

d. Ensure all drain holes are open by inserting a probe,such as a pipe cleaner.

e. Ensure that all areas that accumulate water have beendrained and/or otherwise dried. Whenever this is a re-curring problem, specialized procedures shall be de-veloped and implemented to remove entrapped waterand other fluids to prevent their accumulation.

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3-46 Change 13

An effective corrosion prevention and control pro-gram requires that prescribed preservation and lu-brication procedures be accomplished as soon aspossible after a cleaning operation to prevent/mini-mize the occurrence of corrosion.

f. Upon completion of all cleaning operations, lubricateall exposed static joints and inject lubricant into alllube fittings in the areas cleaned in accordance withParagraph 3.6 and applicable system specific mainte-nance manuals to displace any entrapped water orcleaning materials that could cause corrosion and fail-ure of lubricated parts if they remained.

g. Apply preservatives/corrosion preventive compounds(CPC’s) to components in the area cleaned in accor-dance with Paragraph 3.7 and applicable system spe-cific maintenance manuals, as necessary. Cleaningcompounds tend to remove preservatives, making pre-viously protected surfaces vulnerable to corrosion.

3.5.5 Treatment and Disposal of Wash Rack Waste.

NOTE

Cleaning solutions which remove greases, oils, andsurface contamination from aircraft, missiles,equipment, and components may exceed dischargeconcentration limits for oil and grease (especiallywhere oil/water separators are not installed or notoperating properly), naphthalene (from cleanerscontaining aromatic hydrocarbons), chromium,cadmium, nickel, or other heavy metals (fromcleaning operations involving engines or platedparts). If your wash rack is a source of hazardous

waste, consult the base safety office and/or Bioen-vironmental Engineer to determine corrective ac-tion. Take precautionary measures to prevent washrack waste from contaminating lakes, streams, orother natural environments. Some chemicals usedfor cleaning require treatment or other specialcontrols prior to disposal.

The disposal of materials shall be accomplished in accor-dance with applicable directives and in a manner that willnot result in the violation of local, state, or federal pollutiondirectives.

a. To reduce the problems associated with disposal andthe actual cleaning process, all work shall be accom-plished on an approved wash rack. The only exceptionto this requirement shall be for those facilities whichare temporarily established to support combat opera-tions or special missions.

b. Aircraft wash rack cleaning waste shall receive theequivalent of secondary sewage treatment. When MIL-PRF-85704, Type I solvent emulsion cleaning solutionsare used, waste shall be released so that the total efflu-ent entering the waste treatment plant does not containmore than the amount limited by local environmentalregulations or 100 parts per million (PPM) of cleaningcompound.

3.5.6 Fungus Growth Removal. Fungus growth (mildewand mold) occurs on the surface of organic materials (plas-tics, paper, organic coatings/paints, etc.,) and inorganic ma-terials (metals, concrete, etc.,) particularly in warm, damp/humid climates. Fungus growths must be removed to preventcorrosion of metals and deterioration of other materialscaused by fungus by-products. Refer to Table 3-4.1 for spe-cific cleaning instructions.

Table 3-4.1. Fungus Growth Removal from Organic Materials

Organic Material Type of Soil Cleaning Agent orCompound

Mixing Directions andNomenclature

Cleaning Procedures

A 50-50 by volume mixture of isopropyl alcohol and water is flammable with a flash point of 60 °F. Use only withadequate ventilation and comply with guidelines for solvent cleaning in this chapter. Open all circuit breakersassociated with battery power (refer to applicable system specific maintenance manuals), prior to application ofTT-I-735 isopropyl alcohol. Do not use synthetic wiping cloths with flammable solvents such as TT-I-735 isopropylalcohol. Failure to strictly observe could result in injury to, or death of personnel or long term health hazards.

TO 1-1-691

Change 13 3-47

Table 3-4.1. Fungus Growth Removal from Organic Materials - Continued



Cleaning Procedures

Do not use isopropyl alcohol on transparent acrylic or polycarbonate plastics used for aircraft canopies andwindows or methacrylate plastic (Plexiglass) components as it can cause them to craze. If not strictly observe couldresult in damage to or destruction of, equipment or loss of mission effectiveness.

Plastics,PlasticElectricalInsulation

Fungi, Mold,Mildew

TT-I-735, Grade A orB (IsopropylAlcohol)

50-50 by volume solutionof TT-I-735, Grade AOr S, and fresh tapwater with two (2) fluidounces of P-D-410,Type II detergent pergallon of solution.

Scrub the contaminated areawith a lint free cloth orsponge wet with 50-50TT-1-735 solution. Wipe offthe residue with a lint freecloth wet with fresh tapwater and wipe dry with aclean, dry cloth.CCC-C-440, Type I or

II, Class 1 orA-A-59323, Type IIor SAE AMS 3819,Class 1, Grade A orB.

Cotton CheeseclothCleaning Cloth LowLint Cleaning Cloth

Navclean Mildew Mix per manufacturer’sdirections.

Apply and clean contaminatedarea using lint free cloth,soft bristle brush or spongewet with Navclean. Allowformula to remain on thesurface for 5-15 minutes.Thoroughly rinse treatedsurfaces with fresh tap waterto ensure no residueremains. Reapply Navcleanas necessary followed bythorough rinsing. Inspecttreated surfaces for detergentresidue. If any indication ofresidue remains, rinse treatedsurfaces again with freshwater and re-inspect. Repeatprocess as necessary toremove residue.

Remover Kit NSN6850-01-581-2150(Single Kit) or NSN6850-01-581-2172(Five Single Kits)

TT-N-95 Aliphatic Naphtha is flammable and toxic to the skin, eyes, and respiratory tract. Keep away from allsources of ignition. Avoid skin and eye contact. Good general ventilation is adequate. Failure to strictly observecould result in injury to, or death of personnel or long term health hazards.

TT-N-97 Aromatic Naphtha shall not be used to clean transparent plastics as it can attack and damage them. If notstrictly observed could result in damage to or destruction of equipment or loss of mission effectiveness.

TO 1-1-691

3-48 Change 13




Cleaning Procedures

Acrylic,PolycarbonateandMethacrylate(Plexiglass)TransparentPlasticComponents

Fungi, Mold,Mildew

TT-N-95 (AliphaticNaphtha

Aliphatic Naphtha Scrub contaminated area withlint free cloth or sponge wetwith TT-N-95 and then wipewith a clean, dry cloth. Ifpolishing is required, rubarea with SS-P-821, Grade For finer pumice abrasive.Consult TO 1-1A-12 fordetails on polishingtransparent plastics.

CCC-C-440, Type I orII, Class 1 orA-A-S9323, Type IIor SAE AMS 3819,Class 1, Grade A orB.


SS-P-821 or FinerPumice GroundAbrasive

Pumice Ground Abrasive

Metal Surfacesother thanelectricalconnectors

Fungi, Mold,Mildew

IT-I-735, Grade A or B(Isopropyl Alcohol)

Isopropyl Alcohol Wipe the contaminated surfaceother than electricalconnectors with TT-I-735,Grade A or B followed bycleaning per the standardmethods in Table 3-2 for thetype of area involved.

CCC-C-440, Type I orII, Class 1 orA-A-S9323, Type IIor SAE AMS 3819,Class 1, Grade A orB.


Navclean MildewRemover Kit NSN6850-01-581-2150(Single Kit) or NSN6850-01-581-2172(Five Single Kits)

Mix per manufacturer’sdirections.

Apply and clean contaminatedarea using lint free cloth,soft bristle brush or spongewet with Navclean. Allowformula to remain on thesurface for 5-15 minutes.Thoroughly rinse treatedsurfaces with fresh tap waterto ensure no residueremains. Reapply Navcleanas necessary followed bythorough rinsing. Inspecttreated surfaces for detergentresidue. If any indication ofresidue remains, rinse treatedsurfaces again with freshwater and reinspect. Repeatprocess as necessary toremove residue.

Exterior Surfacesof ElectricalConnectors andMalePins/Contacts

Fungi, Mold,Mildew


Isopropyl Alcohol Wipe contaminated exteriorsurface with a lint free clothor brushing withnon-metallic bristle brushwet with TT-I-735, Grade Aor B followed by rinsingwith a stream of the alcoholfrom a plastic wash bottleand then drying with clean,dry, oil free compressed air(15 PSI max).

CCC-C·440, Type I orII, Class 1 orA-A-S9323, Type IIor SAE AMS 3819,Class 1, Grade A orB.


Non-metallic BristleBrush (tooth brush)

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Change 2 3-48.1




Cleaning Procedures

NOTE

Consult TO 1-1-689 series for additional information on cleaning of electrical connectors.

FemalePins/Contacts

Fungi, Mold,Mildew


Isopropyl Alcohol Scrub pins/contacts with pipecleaner or toothpicksaturated with TT-I-735,Grade A or B followed byrinsing with a stream ofalcohol with a plastic washbottle and drying with clean,dry, oil free compressed air(15 PSI max).

Pipe Cleaner orToothpick

Fuel Systems Fungi, Mold,Mildew

Contact the appropriate aircraftSPD and/or missile orequipment SPM.

3.5.7 Soil Barriers.

Do not apply soil barrier materials to any areaother than engine exhaust and gun gas residue ar-eas on aircraft having a camouflage or a flat paintscheme. These materials increase the speculargloss and IR reflectance of paint systems therebycompromising the effectiveness of the camouflageand flat paint schemes.

Soil barriers are transparent materials that are very effective

in preventing damage to both painted and unpainted engineexhaust track areas and areas exposed to gun gas residue onaircraft and/or other equipment. Soil barrier materials shallbe applied to these areas on aircraft immediately after curingof a new or overcoat paint system prior to engine run andexisting paint systems after each aircraft wash as a part ofthe aircraft wash. Soil, soot, and/or gun gas residue gradu-ally accumulate on or in the soil barrier film instead of thepaint system protected by the film. When the protected areadoesn’t meet acceptable aircraft or equipment appearancestandards or an aircraft undergoes a routine wash, removethe soil barrier film per Paragraph 3.5.7.3 and reapply perParagraph 3.5.7.2 using materials specified in Paragraph3.5.7.1.

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3-48.2 Change 2

3.5.7.1 Materials. McGean-Rocho, Inc., PN Cee-Bee A-6is the soil barrier material approved for use on Air Forceaircraft and equipment.

NOTE

• Rain or water do not deteriorate soil barriermaterials but solvents, alkaline cleaners, andsolvent emulsion cleaners tend to degradeand/or remove them.

• If the temperature of the surfaces to be treatedwith soil barriers reaches or exceeds 100° F(38° C), cool the surfaces with a light spray offresh water before applying soil barrier materi-als.

• No prior cleaning and/or rinsing of an area isrequired if soil barriers are being applied on anew or overcoat paint system.

3.5.7.2 Application. If an old soil barrier film is presenton the surface, remove it per Paragraph 3.5.7.3.

a. Thoroughly clean surface with MIL-PRF-87937, TypeIV or MIL-PRF-85570, Type II cleaning compound perTable 3-2 and Paragraph 3.5.2.1.

b. Rinse surface thoroughly with fresh water to removeall grease, oil, dirt, and cleaning compound residue andallow the water to drain off.

c. When most of the rinse water has drained off, apply auniform film of either soil barrier material listed inParagraph 3.5.7.1 with a non-atomizing type sprayer(garden sprayer), brush, or roller, and allow the film todry for 1 hour before releasing the aircraft or equip-ment.

d. Flush the sprayer and/or rinse the brush or roller withfresh water immediately after completing the applica-tion operation. If soil barrier materials dry on/in appli-cation equipment, remove it with A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, degreasingsolvent or soak the equipment in a solution of one part

MIL-PRF-87937, Type IV or MIL-PRF-85570, Type IIcleaning compound and four parts water for a mini-mum of 4 hours.

3.5.7.3 Removal.

a. Apply McGean-Roncho, Inc., PN Cee-Bee A-276LV(NSN 6850-01-529-2002) soil barrier remover or A-A-59601, or MIL-PRF-680, degreasing solvent to thesurface from which the soil barrier film is to be re-moved with a non-atomizing sprayer, mop, brush, orcloth.

NOTE

• Soil barrier removers may be used as receivedor diluted 1 to 1 with water, but undiluted worksbest.

• Soil barrier removers are to be used only forremoval of soil barrier films. They shall not beused for any other type of aircraft or equipmentcleaning

b. Allow the soil barrier remover or solvent to dwell onthe surface until it penetrates the soil barrier film (usu-ally about 20 to 60 minutes).

c. Scrub the area thoroughly with a brush or 3M Co., PN251 aircraft washing kit fitted with a non-abrasivecleaning pad or sponge, and then flush the area withfresh water.

d. Reapply soil barrier material per Paragraph 3.5.7.2.

3.5.8 Bird Strike Cleaning. Aircraft occasionally collidewith birds in the air during take-off or landing resulting inresidue that must be cleaned from the exterior and/or interiorof the aircraft after landing. In areas where avian influenza A(H5N1) outbreaks are ongoing among bird populations (SeeEmbargo of Birds from Specified Countries: http://www.cd-c.gov/flu/avian/outbreaks/embargo.htm), special precautionsand cleaning procedures must be followed. Collisions with

TO 1-1-691

Change 6 3-49

infected birds pose a risk of contaminating the exterior and/orinterior surface of the aircraft with infectious blood, feces,feathers, or other materials.

3.5.8.1 Bird Strike Cleanup.

• Any potential risk of human exposure to infec-tious material from bird strikes may be reducedby observing the following cleaning recommen-dations.

• Use non-sterile vinyl or nitrile gloves that coverpart of the arm.

• If the cleaning method may create splashing,safety goggles or glasses and an N-95 Dispos-able Respirator (Appendix B, Table B-2, ItemNo. 70), or equivalent, surgical mask may beworn to protect mucous membranes.

• Under the advisement of the Base Safety Officeand Bioenvironmental, flexibility in modifyingpersonal protective equipment requirementsmay be necessary as determined on the basis ofthe task and circumstances of the cleaning ac-tivity.

• Wear disposable coveralls to protect clothingand skin while cleaning.

• Avoid touching the mouth or face area withsoiled hands or gloves. Wash hands thoroughlywith soap and water after cleaning or beforeeating or smoking. Clean hands with an alco-hol-based hand gel (at least 60% alcohol) whennot visibly soiled or when soap and water arenot available.

The following procedures describe a normal bird strikecleanup.

a. Place bird carcasses and/or parts in a double plasticbag and contact the installation safety office in accor-dance with AFMAN 91-223 Aviation Safety Investiga-tions and Reports.

b. If the bird strike occurred in a suspected H5N1 area,use one of the four approved treatment methods andinclude necessary documentation when shipping re-mains to the Smithsonian Institution, Division of BirdsNHB, E610, MRC 116, 10th and Constitution Ave.,NW, Washington, DC 20560. The USDA approvedmethods include:

(1) Immerse in 70% alcohol and allow to dry.

(2) Heat to 130º F for at least 30 minutes.

(3) Immerse in phenol and allow to dry.

(4) Immerse in 10% formalin and allow to dry.

(5) Required documentation includes:

(a) Certificate of Origin.

(b) Certificate of Treatment.

(c) Copy of Smithsonian U.S. Dept. of Agricul-ture Animal and Plant Health Inspection Ser-vice (APHIS) permit. All documents can beaccessed at http://afsafety.af.mil/SEF/Bash/SEFW_new.shtml or contact the Bird/Wild-life Aircraft Strike Hazard (BASH) Team at(505) 846-1440/5673/5679. Reference AF-PAM 91-212 for more information on theBASH Team.

• Do not wash contaminated surfaces with highpressurized water or cleaner, which could aero-solize H5N1 viral particles that could be in-haled.

• Consult the installation’s Civil Engineering En-vironmental Flight and Bioenvironmental Engi-neering Flight for proper containment, decon-tamination and/or disposal of contaminatedwastewater.

c. Clean the exterior and interior surfaces of the aircraft,removing blood, feces, feathers, or other material thor-oughly using hand-cleaning method only as outlined inParagraph 3.5.2.5, step g of this TO. Apply a solutionof MIL-PRF-87937 or MIL-PRF-85570 mixed perParagraph 3.3 of this TO. Apply the cleaning solutionto the surface with an aircraft wash pad and agitate.

d. Rinse the area using low pressure water. In areas wherewater could damage components or create drainageproblems, rinse area with rag wetted with clean water.

e. Wipe the area with a clean, dry rag.

f. Repeat the above procedure, as necessary, for ex-tremely soiled/contaminated areas.

TO 1-1-691

3-50

Consult the Base Bioenvironmental Office forproper disposal and handling of contaminatedcleaning tools and materials.

NOTE

Consult the weapons system specific, (-23, orequivalent), manual for cleaning requirements inaddition to those in this manual.

g. Place all scrapers, brushes, rags and other cleaningtools in a designated receptacle for proper cleaningand/or disposal.

3.5.8.2 Internal/Enclosed (Water Sensitive) AreaCleanup. Use the following procedures in internal/enclosedareas where use of copious amounts of water could damagecomponents, create drainage problems, etc.

a. Follow Paragraph 3.5.8.1, step a through step g, exceptat step c, use one of the prepackaged ready-to-use(RTU) cleaners MIL-PRF-87937 (NSN 6850-01-461-0065) or A-A-59921, Class 1A (NSN 6850-00-005-5305).

Ethyl alcohol is flammable and moderately toxicto skin, eyes, and respiratory tract. Eye and skinprotection is required. Good general ventilation isrequired.

Consult system specific manuals to identify sys-tem de-energizing requirements prior to usingflammable materials in aircraft interior areas.

b. Wipe the area with clean cloth saturated in 70% ethylalcohol (O-E-760, NSN 6550-01-315-5333). The alco-hol must remain on the surface approximately 10 min-utes to ensure the H5N1 virus is killed. More than oneapplication may be required to achieve this dwell-time.

Consult the Base Bioenvironmental Office forproper disposal and handling of contaminatedcleaning tools and materials.

c. Place all scrapers, brushes, rags and other cleaningtools in a designated receptacle for proper cleaningand/or disposal.

3.5.9 Bodily Fluids Contamination Cleanup. Aircraftoccasionally are dispatched to transport enemy prisoners,wounded/medically ill personnel, or human remains. The in-terior of the aircraft can become contaminated with differenttypes of human bodily fluids during these operations. It isrecommended that prior to transporting, which could resultin bodily fluid contamination, some type of barrier materialbe applied to the cargo areas such as plastic, canvas, or bar-rier paper. This will help contain the contaminants and re-duce the cleanup efforts required upon arriving at the finaldestination. The aircraft should be considered contaminatedif bodily fluids come in contact with aircraft surfaces, equip-ment, or personnel. This paragraph will address the cleanupof bodily fluids in regards to corrosion damage potential toaircraft and equipment such as cargo, pallet, etc. For infor-mation regarding personnel protection, contact your localbioenvironmental office.

3.5.9.1 Bodily Fluid Containment During Flight.


• Wear safety goggles or glasses and an N-95Disposable Respirator (Appendix B, Table B-2,Item No. 70), or equivalent, surgical mask toprotect the mucous membranes and inhalationof blood borne pathogens that may exist.


• Avoid touching the mouth or face area withsoiled hands or gloves. Wash hands thoroughlywith soap and water after cleaning or beforeeating or smoking. Clean hands with an alcoholbased hand gel (at least 60% alcohol), whennot visibly soiled or when soap and water arenot available.

The following procedures are general guidelines for the con-tainment of bodily fluids during flight.

a. If possible, cordon off the contaminated area to keepunauthorized personnel away from the area and track-ing the fluids throughout the aircraft.

b. Apply paper towels or other absorbent material to thefluid to absorb the fluids and minimize the spill area.

3.5.9.2 Bodily Fluid Cleanup. To reduce any potentialdamage to the aircraft/equipment during the cleanup, person-nel shall adhere to the following cleaning procedures.

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Change 5 3-51




• Wear disposable coveralls (Appendix B, TableB-2, Item No. 94) to protect clothing and skinwhile cleaning.


• Consult the Installation BioenvironmentalFlight for proper disposal of contaminatedwaste materials.

• In the event of contract fleet service or aircraftwash contract personnel performing this opera-tion, ensure all personnel are thoroughly briefedon cleanup and disinfectant procedures.

Chlorine bleach and other disinfectants are harm-ful to the aircraft structure. Personnel must strictlyadhere to the following procedures to limit poten-tially harmful effects.

NOTE

The use of non-approved Industrial/Janitorial typecleaners can be corrosive to equipment and shallnot be used.

a. Clean the cargo floor or other contaminated areas ofthe aircraft by absorbing all liquid spills with papertowels, or equivalent, absorbent material.

b. Clean the contaminated spill area thoroughly using asolution of MIL-PRF-87937 or MIL-PRF-85570 in ac-cordance with Table 3-2.

3.5.9.3 Disinfection of Contaminated Areas.




• Protective footwear covers (Appendix B, TableB-2, Item No. 103) should be worn if walkingin the contaminated area is unavoidable.


• Consult the Installation BioenvironmentalFlight for proper disposal of contaminatedwaste materials.

• Aircraft power must be turned off prior to startof disinfection process. Isopropyl alcohol ishighly flammable.

• Open aircraft doors/hatches to ventilate the air-craft interior for a minimum of 10 minutes dur-ing and prior to reapplying power to the air-craft.

• Use a non-synthetic wiping cloth with TT-I-735isopropyl alcohol.

• Do not use isopropyl alcohol on transparentacrylic or polycarbonate plastics used for air-craft canopies and windows or methacrylate(plexiglas).

Following cleanup of contaminated area, the areas must bedisinfected. Undiluted isopropyl rubbing alcohol or a dilutedsolution of isopropyl alcohol, TT-I-735, mixed in a 70%concentration should be used.

TO 1-1-691

3-52

NOTE

Iso-Tech Kits(tm) (NSN 6515-01-524-9755) areavailable through medical supply channels. Thesekits contain all the items needed to complete thedisinfection process.

a. Use a paper towel, rag, or equivalent, dampened withundiluted isopropyl rubbing alcohol (NSN 6505-00-655-8366) to wipe the affected area. If using isopropylalcohol, TT-I-735, use a diluted 70% solution mixture.To obtain a 70% solution of isopropyl alcohol, TT-I-735, fill a one pint container to 70% by volume of100% isopropyl alcohol, TT-I-735, and 30% by vol-ume distilled water (if distilled water is unavailable,tap water can be used). Do not pour the disinfectantsolution onto the aircraft surface.

b. Reapply, as necessary, to allow the solution to dwellon the surface for 10 minutes.

c. Rinse the area with clean paper towels, or equivalent,material dampened with clean water.

d. Dry the area with clean paper towels, or equivalent,material.

Use caution when removing PPE after disinfectantoperations as to avoid personal contamination.

e. Remove PPE.

f. Place contaminated materials, such as paper towels andPPE in biohazard bag, or equivalent. Securely closewith twist tie.

g. Dispose of contaminated materials as directed by thelocal bioenvironmental office.

SECTION III LUBRICATION

3.6 INTRODUCTION.

Lubrication performs a dual purpose, to prevent wear be-tween moving parts and also to fill air spaces, displace wa-ter, and provide a barrier against corrosive elements. Thelubrication requirements contained in system specific main-tenance manuals and/or cards are usually adequate to pre-vent corrosion of most lubricated surfaces under normal op-erating conditions. Aircraft lubrication shall be accomplishedonly by personnel qualified in lubrication procedures. In theevent that the specified lubricant is not available, requestsubstitutions from the aircraft SPD and/or the missile orequipment SPM.

NOTE

Comply with relubrication time frame require-ments outlined in the system specific maintenancemanual.

3.6.1 Conventional Lubricants. Table 3-5 contains thetitle, specification, intended use, and temperature range ofthe most frequently used conventional lubricating materials.

TO 1-1-691

3-53

3.6.2 Solid Film Lubricants.

• Not all lubricating materials are compatiblewith each other and/or metals used in Air Forceaircraft, missiles, or equipment. Some areknown to promote galvanic corrosion or causepaint or acrylic plastics to deteriorate. Usingthe correct lubricating material is critical. Donot use greases or oils with solid film lubri-cants. Use only lubricants specified by appro-priate system specific manuals and/or cards.

• Do not lubricate Teflon bearings or bushings.Clean teflon bearings and bushings with A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, degreasing solvent.

• Lubricants containing graphite, either alone orin mixture with any other lubricants, shall notbe used since graphite is cathodic to most met-als and will cause galvanic corrosion in thepresence of electrolytes.

• Do not use solid film lubricants in areas subjectto rotational speeds above 100 RPM underheavy loads or on roller bearing elements be-cause they will not provide adequate lubrica-tion in these situations.

• Do not use solid film lubricants in conjunctionwith oils or greases as they are not compatible.

Solid film lubricants are used where conventional lubricantsare difficult to apply or retain, or where other lubricants maybe contaminated with dust, wear products, or moisture andto reduce fretting corrosion on close tolerance fittings thatsee primarily static loads with only very small relative move-ment caused by vibration. Typical applications of solid filmlubricants are sliding motion components such as flap tracks,hinges, turnbuckles and cargo latches.

3.6.2.1 Surface Preparation for Solid Film Lubricants.As with paints, surface preparation prior to application isextremely important to the service wear life of solid filmlubricants. In reality, solid film lubricants are nothing morethan paints with solid (powder) type lubricants used as thepigment. They are usually applied over surfaces pre-coatedwith other films, such as anodize (aluminum and magnesiumbase material), phosphate (steel base material), and some-times over organic coatings such as epoxy primers.

3.6.2.2 SAE AS5272 (MIL-PRF-46010). SAE AS5272(MIL-PRF-46010), lubricant, solid film, heat cured, corro-sion inhibiting is a heat cured, corrosion inhibiting, solidfilm lubricant that provides extended wear life. It can beused on aluminum, copper, steel, stainless steel, and titanium

in areas of infrequent operation and in areas requiring longterm protection under static conditions to prevent galling,corrosion, and metal seizure. Because SAE AS5272 (MIL-PRF-46010), Type I must be cured at 400° F (205° C) for 1hour and Type II must be cured at 300° F (149° C) for 2hours, they are not suitable for all applications as metallur-gical damage may occur at these temperatures.

3.6.2.3 MIL-PRF-46147 and/or MIL-L-23398. MIL-PRF-46147 and/or MIL-L-23398, lubricant, solid film, aircured, corrosion inhibiting are air cured, corrosion inhibit-ing, solid film lubricants that can be used on aluminum, steeland titanium in areas of infrequent operation and areas re-quiring long term protection under static conditions to pre-vent galling, corrosion, and metal seizure. They providemoderate wear life and corrosion protection in these areaswhen it is not feasible to use a solid film lubricant that re-quires curing at elevated temperatures, and can be used torepair damaged SAE AS5272 (MIL-PRF-46010) heat cured,solid film lubricants. MIL-L-23398, Type I (bulk) and TypeII (aerosol) both require a 6 hour cure at a temperature of77° ±3° F (25° ±2° C). MIL-PRF-46147, Form 1 (bulk) andForm 2 (aerosol); Type I (standard solvents) require a 18hour cure and Type II (low VOC content), both forms, re-quire a 24 hour cure at these same temperatures. Curing ofboth MIL-L-23398 and MIL-PRF-46147 solid film lubricantsmay be accelerated by allowing air drying at room tempera-ture for 30 minutes to flash off solvents and then heating to125° ±5° F (52° ±3° C) for 1 to 1 ½ hours.

3.6.3 Application of Conventional Lubricants.

When lubricating hinges and pinned joints, applya generous quantity of either MIL-PRF-63460(preferably), MIL-PRF-81309, Type II, or MIL-PRF-32033 water displacing, Corrosion preventivecompound (CPC) before applying the specified lu-bricant. Actuate hinges several times to make surethat the CPC’s and lubricants penetrate all crev-ices thoroughly, and then wipe off excess from ex-terior surfaces.

Apply lubricants as sparingly as possible to prevent accumu-lation of dust, dirt, and other foreign matter, but always ap-ply enough to provide adequate lubrication. Wipe away anyexcess lubricant. Using the proper method of application asspecified in the appropriate system specific maintenancemanual is important. Apply lubricants by one of the follow-ing methods:

• Grease guns, lever or pressure type.

• Oil, squirt, and aerosol spray cans.

• Hand or brush.

TO 1-1-691

3-54 Change 5

3.6.3.1 Grease Gun Application. When applying greasetype lubricants in pressure type grease fittings (Zerk fittings)with a grease gun, clean grease fitting with A-A-59601,MIL-PRF-32295, Type II, or MIL-PRF-680, degreasing sol-vent and clean cloth before applying lubricant. Make surethe lubricant has emerged around the bushing. If no greaseappears, check the fitting and grease gun for proper opera-tion. Be certain the grease gun is properly attached to the

fitting prior to applying pressure. When applying grease to aflush type (high pressure) fitting, make sure that the greasegun is fitted with a flush type adapter and held perpendicularto the surface of the fitting before applying pressure. If thefitting does not accept lubrication, replace the fitting and lu-bricate. Wipe excess grease from the fitting and the surround-ing surfaces with a clean, dry cloth.

Table 3-5. Common Military Greases and Their Uses

Specification and Nomenclature Intended Use Recommend Temperature RangeAMS-G-4343 Grease, Pneu-

matic System (NATO CodeG-392)

Lubrication between rubber and metal parts ofpneumatic systems; pressurized cabin bulk-head grommets and other mechanisms requir-ing rubber to metal lubrication.

-65° to 200° F (-54° to 93° C)

AMS-G-6032 Grease, Plug,Valve, Gasoline and Oil Re-sistant (NATO Code G-363)

Tapered plug valves; gasket lubricant or seal;general plug valve and fitting use where gaso-line, oil, alcohol, or water resistance is re-quired.

-32° to 200° F (0° to 93° C)

MIL-G-21164 Grease, Molyb-denum Disulfide, for Lowand High Temperatures(NATO Code G-353)

Heavily loaded steel sliding surfaces, accessorysplines, or anti-friction bearings carrying highloads and operating through wide temperatureranges where molybdenum disulfide will pre-vent or delay seizure in the event of inad-equate lubrication. This grease is not intendedfor use in wheel bearings.

-100° to 250° F (-73° to 121° C)

MIL-PRF-23827 Grease, Air-craft and Instrument, Gearand Actuator Screw (NATOCode G-354)

Lubrication of ball, roller, and needle bearings,gears, and sliding and rolling surfaces ofequipment such as instruments, cameras, elec-tronic gear and aircraft control systems thatare subject to extreme marine and low tem-perature conditions; rolling and sliding sur-faces of equipment with low motivating power(low torque equipment); general use on air-craft gears, actuator screws, and other equip-ment with high load carrying capacity. Its ex-tremely low volatility makes it useful onaircraft optical equipment since it will not pro-duce oil fogging.

-100° to 250° F (-73° to 121° C)

MIL-G-25013 Grease, Aircraft,Ball and Roller Bearing(NATO Code G-372)

Lubrication of ball and roller anti-friction bear-ings that operate at extreme high or low tem-peratures, especially in applications wheresoap-type petroleum or synthetic oil greasesand oils cannot be used. Can be used on air-craft actuators, gearboxes, and similar equip-ment.

-100° to 450° F (-73° to 232° C)

MIL-G-25537 Grease, Aircraft,Helicopter, Oscillating Bear-ing (NATO Code G-366)

Lubrication of aircraft bearings having oscillat-ing motion of small amplitude.

-65° to 160° F (-54° to 71° C)

MIL-PRF-27617 Grease, Air-craft and Instrument, Fueland Oxidizer Resistant

Lubrication of taper plug valves, gaskets, andbearings in aircraft and ground support equip-ment fuel systems; lubrication of valves,threads, and bearings of liquid oxygen (LOX)systems of aircraft, aerospace vehicles, andsupport equipment. Do not use on aluminumor magnesium dynamic bearings due to pos-sible ignition hazard.

TO 1-1-691

Change 5 3-55

Table 3-5. Common Military Greases and Their Uses - Continued

Specification and Nomenclature Intended Use Recommend Temperature RangeType I (NATO Code G-397) -65° to +300° F (-54° to +149°

C)Type II (NATO Code G-398) -40° to +400° F (-40° to +204°

C)Type III (NATO Code G-399) -30° to +400° F (-34° to +204°

C)Type IV (NATO Code G-1350) -100° to +400° F (-73° to +204°

C)Type V -100° to +450° F (-73° to +232°

C)MIL-PRF-81322 Grease, Air-

craft, General Purpose, WideTemperature Range (NATOCode G-395)

NLGI, Grade 1: arresting gear sheave spacersand other equipment that operates under highcontact loads and high sliding speeds.

-65° to +350° F (-54° to +177°C)

NLGI, Grade 2: aircraft wheel bearings and in-ternal brake wheel assemblies, anti-frictionbearings, gearboxes, and plain bearings. Bothwill withstand high speed operations and op-erations on equipment subject to extreme ma-rine environments.

SECTION IV PRESERVATION

3.7 INTRODUCTION.

Corrosion preventive compounds (CPC’s), or preservatives,are used to protect metal aircraft, missile, and equipmentparts and components by preventing corrosive materials fromcontacting and corroding bare metal surfaces. Many of thesecompounds are also able to displace water, including seawater, and other contaminants from these surfaces, and someprovide lubrication, as well as corrosion protection. Gener-ally, CPC’s are mixtures of special additives in petroleumderivative bases (special oils or greases). CPC’s range inappearance and consistency from the thick, black types, suchas MIL-PRF-16173, Grade 1, to light oils, such as MIL-PRF-32033. The thicker CPC’s provide the best corrosionprotection, are longer lasting, and are more difficult to re-move. The thinner materials provide some lubrication and donot crack, chip, or peel but they must be removed and re-placed regularly to provide continuing protection.

3.7.1 Operational Preservation. The day to day applica-tion of CPC’s to prevent corrosion on operational aircraft isknown as operational preservation. Areas which are corro-sion prone or where paint has been damaged should be rou-tinely protected by CPC’s until more permanent treatment,such as paint touch-up or sealant, can be applied.

3.7.2 Non-Operational Preservation. Preservation of air-craft or components during periods of prolonged inactivity,storage, or shipment is known as non-operational preserva-tion.

3.7.3 Types of CPC’s. CPC’s can be separated into twomajor categories, water displacing and non-water displacingcompounds.

3.7.3.1 Water Displacing Compounds. Water displacingCPC’s can be used to remove water, including sea water, orother electrolytes from metal surfaces. MIL-PRF-81309,MIL-PRF-63460, MIL-PRF-16173, Grade 3, and MIL-PRF-32033 are water displacing CPC’s that are able to penetrateinto cracks, crevices, voids at faying surface edges, aroundfastener heads, and into hinges. They usually provide verythin coatings, one mil (0.001 inch) or less in thickness, thatare clear or translucent and remain soft and oily after appli-cation, so they cannot provide long term protection outdoorsor in areas which are frequently handled. Another type,MIL-DTL-85054, differs from the other water displacingcompounds as it doesn’t penetrate into joints very well, butforms a relatively hard, dry film on exterior surfaces, andtherefore, it can be used for protection outdoors and in areasof frequent handling.

3.7.3.2 Non-Water Displacing Compounds. Non-waterdisplacing CPC’s may be used on dried surfaces or on sur-faces which have been first treated with a water displacingCPC. MIL-PRF-16173, Grades 1, 2, and 4 are non-waterdisplacing CPC’s. They are heavier bodied, waxy typegreases which provide long term corrosion protection byforming a barrier film on metal surfaces. These CPC’s pro-vide thicker coatings and are light brown to very dark brown

TO 1-1-691

3-56

in color, with a waxy greasy appearance. They provide goodcorrosion protection in areas where large amounts of watercollect on or run off of structures.

3.7.4 Time Limitations of CPC’s. Because of their tem-porary nature, CPC’s must be regularly removed and re-placed to provide continuing corrosion protection. Table 3-6provides the recommended time intervals for indoor and out-door CPC use.

3.7.5 Description of CPC’s. A list of CPC’s and theirintended uses is summarized in Table 3-7.

Table 3-6. Time Limitations for CPC’s

CPC Outdoor1 Indoor2 Indoor Covered3

Soft, Thin FilmsMIL-PRF-81309, Type II 14 Days 30 Days 180 DaysMIL-PRF-81309, Type III 5 Days 14 Days 90 DaysMIL-L-87177, Grade B 5 Days 14 Days 90 DaysMIL-PRF-16173, Grade 3 14 Days 30 Days 180 Days

Lubrication and ProtectionMIL-PRF-32033 5 Days 30 Days 180 DaysMIL-PRF-63460 5 Days 30 Days 180 Days

Hard, Thick FilmsMIL-DTL-85054 90 Days 210 Days 365 DaysMIL-PRF-16173, Grade 4 90 Days 210 Days 365 DaysMIL-PRF-16173, Grade 2 90 Days 210 Days 365 DaysMIL-PRF-16173, Grade 1 210 Days 365 Days 365 Days

1 Outdoor: Without cover; exposed to elements in a mild climate; absence of Outdoor: Without cover; exposed to ele-ments in a mild climate; absence of Outdoor: Without cover; exposed to elements in a mild climate; absence of rainand other washing forces; free from air and water borne pollutants.

2 Indoor: Hangars, shop areas, storage or parts accumulation areas, warehouses.3 Indoor covered: Items are wrapped or sealed in a water-resistant material and stored indoors in a hangar, warehouse, or

shop area. Soft, thin film CPC’s were designed for indoor use and ease of removal.

Table 3-7. Corrosion Preventive Compounds

Specification and Nomenclature Intended Use Type of CoatingWATER-DISPLACING CPC’s

MIL-PRF-32033 Lubricating Oil, Gen-eral Purpose, Preservative, (WaterDisplacing, Low Temperature); Mili-tary Symbol PL-S; NATO CodeO-190

Lubrication and corrosion protection ofhinges, other moving parts, small arms andautomatic weapons, and wherever a lowtemperature, water displacing lubricant isrequired; requires frequent reapplications.

Soft, oily coating and lubricant.

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Table 3-7. Corrosion Preventive Compounds - Continued

Specification and Nomenclature Intended Use Type of CoatingMIL-PRF-63460 Lubricant, Cleaner,

and Preservative for Weapons andWeapons Systems; Military SymbolCLP; NATO Code S-758

Lubrication and short term preservation ofhinges, and small and large caliber weap-ons in all climatic conditions within a tem-perature range of -65° to +150° F (-54° to+66° C); facilitates the effective removalof firing residues, gums, and other con-taminants from weapons components whileproviding adequate lubrication and shortterm preservation. Of all water displacingCPC’s, this material is the best lubricant.Excellent water displacing characteristicsand penetration into tight joints.

Thin corrosion preventive lubricantfilm.

MIL-PRF-16173 Corrosion PreventiveCompound, Solvent Cutback, ColdApplication, Grade 3

Displacement of water; short term corrosionprotection of metal surfaces during ship-ment, storage, and in-service use; can beused on moving parts where minor lubrica-tion is required, such as on hinges, bombracks, and sliding parts.

Soft, oily, thin film (1.0 mil), lightamber color.

MIL-PRF-81309 Corrosion PreventiveCompounds, Water Displacing, Ultra-thin Film, Type II

Displacement of water; short term corrosionprotection of metal surfaces during ship-ment, storage, and in-service use; corrosionprotection of moving parts where very mi-nor lubrication is required, such as hingeareas, bomb racks, and sliding parts. Can-not be used on interior of electrical orelectronic equipment and connectors.

Soft, oily, very thin film (0.5 mil)translucent, light amber color.

Type III Displacement of water; corrosion protectionof electrical, avionics, and other electronicequipment, electrical connector plugs andcontact pins.

Soft, oily, ultra thin film (0.2 mil),translucent, light amber color.

MIL-L-87177 Lubricants, CorrosionPreventive, Water Displacing, Syn-thetic, Grade B

Displacement of water, corrosion protection,and some lubrication on in-service lightlyloaded moving parts.

Soft, oily, thin film (0.5 mil), trans-lucent, light amber color.

MIL-DTL-85054 Corrosion PreventiveCompound, Water Displacing, Clear

Corrosion protection and water displacementfor non-moving parts, such as skin seams,installed fastener heads where paint hascracked, access panel edges, and areaswith damaged paint. Cannot be used oninterior areas of electrical or electronicsequipment and connectors or in joint areasof moving parts as it dries to a hard film.

Dry, thin film (1.0 mil), transparent,colorless to slight blue tint.

NON-WATER DISPLACING CPC’sMIL-PRF-16173 Corrosion Preventive

Compound, Solvent Cutback, ColdApplication, Grade 1

Protection of metal surfaces against corrosionwhen exposed with or without coveringindoors or outdoors. Cannot be used iftemperatures will fall below 0° F (-18° C)as the film will crack and can peel fromthe surface leaving it unprotected.

Hard, tack-free, thick film (4.0mils), dark brown or black color.

Grade 2 Protection of metal surfaces against corrosionduring rework or storage; film remainstacky.

Soft, non-drying, thick (2.0 mils),light brown color.

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3-58 Change 10

Table 3-7. Corrosion Preventive Compounds - Continued

Specification and Nomenclature Intended Use Type of CoatingGrade 4 Protection of metal surfaces against corrosion

during indoor storage when a transparentcoating is required; coating of aircraft andequipment interior, metal wire controlcables.

Soft, tack-free, thick (2.0 mils),light brown color.

3.7.5.1 MIL-PRF-81309, Corrosion Preventive Com-pound, Water Displacing, Ultra Thin Film and MIL-L-87177, Lubricants, Corrosion Preventive, Water Dis-placing, Synthetic.

MIL-DTL-85054, MIL-PRF-63460, and MIL-PRF-81309 have been revised to eliminate ODC’s.Some reformulated products now contain flam-mable solvents and/or propellants. Pay close atten-tion to all CAUTION/WARNING labels on theproduct containers.

MIL-PRF-81309 and MIL-L-87177 materials are generalpurpose corrosion preventive compounds for use when a thin,water displacing CPC is needed. MIL-PRF-81309 and MIL-L-87177 are for indoor protection and short term protectionwhere surfaces can be re-coated when required. These mate-rials are excellent water displacing compounds which pro-vide an ultra thin, soft film (0.5 mil or less). The MIL-PRF-81309 specification covers two types of materials and theMIL-L-87177 specification covers one grade of material thatare useful for Air Force purposes to provide temporary pro-tection from corrosion while still being easily removable witha solvent. They should not be used around LOX fittings. Allof these CPC’s may be applied by either dipping, brushing,or spraying with a pump or aerosol sprayer.

3.7.5.1.1 MIL-PRF-81309, Type II and MIL-L-87177,Grade B. These CPC’s form a soft, thin film for general useon moving or sliding parts where some lubrication is needed,such as on hinges or bomb rack components. These materi-als can be easily washed away by rain or wash procedures,so frequent reapplication may be required. They are useful inthe protection of areas which cannot be properly drained orcontain recesses that are particularly difficult to reach due totheir excellent water displacing abilities.

3.7.5.1.2 MIL-PRF-81309, Type III and MIL-L-87177,Grade B. These CPC’s form an ultra thin, soft film thatprovides excellent water displacement and corrosion protec-tion.

3.7.5.2 MIL-DTL-85054, Corrosion Preventive Com-pound, Clear. MIL-DTL-85054 is a water displacing CPCwhich forms a clear, hard/dry, semi-flexible film. It is in-tended for use as a protective coating on bare metal areaswhere the paint system has been damaged or failed untiltouch-up and/or repainting is practical. Because of its paint-like characteristics, it provides no lubrication and blockselectrical conductivity.

3.7.5.2.1 Application of MIL-DTL-85054.

Ensure that all areas where MIL-DTL-85054 isapplied are fully dried before sealing an area. Al-though MIL-DTL-85054 is a corrosion preventivecompound, its solvent vapors may cause corrosionif not allowed to dissipate.

MIL-DTL-85054 can be applied by either dipping, brushing,or spraying with a paint spray gun or an aerosol can, but it isprimarily applied by spraying from aerosol cans. Invert theaerosol can after each use and spray to clear the spray tip(nozzle) of entrapped material. If an aerosol can does notspray, invert and depress the spray tip several times to clearthe delivery tube and spray tip (nozzle). If the can still doesnot spray, remove and clean the plastic spray tip (nozzle),and then reinstall the spray tip (nozzle), and spray again toclear the delivery tube. Dip application provides only a verythin coating and therefore much less corrosion protection.

3.7.5.2.2 Removal of MIL-DTL-85054. Remove MIL-DTL-85054 if it is damaged due to abrasion, there are cracksin the coating, or if there is evidence of corrosion under thecoating. Since excessive MIL-DTL-85054 buildup is diffi-cult to remove, especially after prolonged exposure to directsunlight, remove previously applied coatings before reappli-cation. If the solvents recommended in Table 3-8 do not re-

TO 1-1-691

Change 10 3-59

move old films of MIL-DTL-85054, spraying on fresh MIL-DTL-85054 to soften the film and wiping or rubbing whilewet is often effective.

3.7.5.3 MIL-PRF-16173, Corrosion Preventive Com-pound, Solvent Cutback, Cold Application. MIL-PRF-16173 covers five different grades of CPC’s which can beapplied by brushing or dipping. Grades 1, 2, and 4 do notdisplace water and must be applied to dried surfaces or tosurfaces which have been treated with MIL-PRF-81309,Type II or III, MIL-L-87177, Grade B, or MIL-PRF-16173,Grade 3.

3.7.5.3.1 Grade 1. A thick, hard, black CPC which canbe removed with difficulty using mineral spirits or degreas-ing solvents. It offers the most corrosion protection of all theCPC’s indoors and outdoors, and may be used at tempera-tures down to 0° F (-18° C). If used at temperatures below0° F (-18° C), the CPC film can crack and fall off leaving thesurface unprotected.

Table 3-8. Preservation of Specific Areas and Components

Area or Component CPC Application Instructions Removal Instructions

NOTE

Prior to the application of preservatives (CPC’s), ensure removal of old preservative CPC coatings.

EXTERIOR SURFACES NOTREQUIRING LUBRICA-TION

Unpainted areas and areas withdamaged paint which do notrequire lubrication (fastenerheads; faying surface, accesspanel, door, and frame edges;attachment points; non-mov-ing attachment hardware;wheel well areas; ram airducts; and flap/slat cavities)

MIL-DTL-85054 Wipe off dirt and excessmoisture. Apply thincoating of MIL-DTL-85054. Allow to dry ½hour. Apply a secondcoat.

Use a non-synthetic wipingcloth wet with A-A-59601, MIL-PRF-32295,Type II, or MIL-PRF-680, degreasing solvent.For stubborn MIL-DTL-85054, refer to Para-graph 3.7.5.2.2.

MIL-PRF-81309, Type II,MIL-L-87177, Grade B,and MIL-PRF-16173,Grade 4

Wipe off dirt and excessmoisture. Apply a coat-ing of MIL-PRF-81309,Type II or MIL-L-87177,Grade B followed by acoating of MIL-PRF-16173, Grade 4.

EXTERIOR SURFACES NOTREQUIRING HIGH PER-FORMANCE LUBRICANTOR HYDRAULIC FLUID

Sliding or moving parts requir-ing only minor lubrication(bomb rack components,hinges, door locks)

MIL-PRF-63460 Apply a continuous wetcoat of MIL-PRF-63460.

Use a non-synthetic wipingcloth wet with A-A-59601, MIL-PRF-32295,Type II, or MIL-PRF-680, degreasing solvent.

MIL-PRF-81309, Type II,MIL-L-87177, Grade B,and MIL-PRF-32033

Apply a coating of MIL-PRF-81309, Type II orMIL-L-87177, Grade Bfollowed by a coating ofMIL-PRF-32033. Ifhandled, reapply as nec-essary.

THREADED SURFACES

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3-60 Change 5

Table 3-8. Preservation of Specific Areas and Components - Continued

Area or Component CPC Application Instructions Removal InstructionsScrews, various fasteners MIL-PRF-63460, MIL-PRF-

81309, Type II, MIL-L-87177, Grade B, or MIL-PRF-16173, Grade 4

Dip screws or fasteners inCPC and install. Whendisassembly is frequent,use MIL-PRF-63460,preferably, or use MIL-PRF-81309, Type II orMIL-L-87177, Grade Bas alternates. When dis-assembly is infrequent,use MIL-PRF-16173,Grade 4 for long termprotection.

Immerse screws or fasten-ers in A-A-59601, MIL-PRF-32295, Type II, orMIL-PRF-680, degreas-ing solvent and blot orblow dry.

HYDRAULIC PISTON SUR-FACES

System hydraulic fluid Wipe exposed surface witha cloth dampened withthe hydraulic fluid usedin the system. Alwayswipe away from seals.Take care not to scratchsurfaces.

Do not remove. Reapply asnecessary.

ELECTRICAL CONNECTORSHELLS (EXTERIOR SUR-FACES)

NOTE

For additional information, refer to TO 1-1-689-3.

Connector shells located in con-trol surface wells, wheelwells, bilge areas, and otherinterior areas of aircraft andmissiles, and all areas ofother equipment

MIL-DTL-85054 Wipe off dirt and excessmoisture. Apply thincoating of MIL-DTL-85054. Do not allowCPC to contact internalsurfaces. Allow to dry ½hour and then apply asecond coat.


For stubborn MIL-DTL-85054, refer to Para-graph 3.7.5.2.2.

MIL-C-81309, Type II or III,MIL-L-87177, Grade B,and MIL-PRF-16173,Grade 4

Wipe off dirt and excessmoisture. Apply coatingof MIL-PRF-81309, TypeII or III or MIL-L-87177,Grade B followed by acoating of MIL-PRF-16173, Grade 4.

ELECTRICAL CONNECTORSHELLS (INTERIOR SUR-FACES)

NOTE

For additional information, refer to TO 1-1-689-3.

Do not use any other type of CPC than those listedhere on the interior of electrical connector shells asall other types will interfere with electricalconductivity.

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Change 5 3-61


Area or Component CPC Application Instructions Removal InstructionsConnector shells located in all

the same areas noted for exte-rior surfaces of connectors

MIL-PRF-81309, Type III orMIL-L-87177, Grade B

Wipe off dirt and excessmoisture. Apply a thin,uniform coating of CPC.

Use a non-synthetic wipingcloth wet with TT-I-735isopropyl alcohol.

ELECTRICAL CONNECTORPINS (ALL)

Do not use any othertype of CPC than thoselisted here on electricalconnector pins andsockets as they willinterfere with electricalconductivity.

Connector pins and sockets MIL-PRF-81309, Type III orMIL-L-87177, Grade B

Apply a continuous thin,wet coat of CPC. Ifhandled or exposed towater, reapply.

Use an acid brush withnon-synthetic bristles toapply TT-I-735 isopropylalcohol to pins and sock-ets. Lightly dab all pinsand sockets, and thenblot dry.

ELECTRICAL AND ELEC-TRONIC EQUIPMENT

Refer to TO 1-1-689-3.

CONTROL CABLES (ALL)(INTERIOR AND EXTE-RIOR)

MIL-PRF-81309, Type II orMIL-L-87177, Grade B

Apply a continuous film ofMIL-PRF-81309, TypeII, MIL-L-87177, GradeB, or MIL-PRF-16173,Grade 3 water displacingCPC by aerosol can orby wiping with cloth wetwith the CPC.


MIL-PRF-16173, Grade 3and MIL-PRF-16173,Grade 4

Follow with a coating ofMIL-PRF-16173, Grade4 applied with a non-synthetic cloth or a non-metallic bristle brush.

HELICOPTER CARGO HOISTDRUM

MIL-PRF-81309, Type II orMIL-L-87177, Grade B,MIL-PRF-16173, Grade 3

Apply a continuous film ofMIL-PRF-81309, TypeII, MIL-L-87177, GradeB, or MIL-PRF-16173,Grade 3 water displacingCPC to the drum sur-faces by aerosol can orby wiping with a non-synthetic cloth wet withthe CPC. Wipe with aclean cloth to removeexcess.


MIL-DTL-85054 Spray a continuous film ofMIL-DTL-85054 on thedrum surfaces by aerosolcan. Allow to dry ½ hourand then apply a secondcoat.

For stubborn MIL-DTL-85054, refer to Para-graph 3.7.5.2.2.

ARMAMENTS Refer to the system specific equipment maintenance and/or instruction manual.

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3-62 Change 5


Area or Component CPC Application Instructions Removal InstructionsEJECTION SEATS Refer to the system specific ejection seat maintenance manuals and SPM instructions.

3.7.5.3.2 Grade 2. A thick, soft, grease-like, brown CPCthat remains tacky and can be removed with mineral spiritsor degreasing solvents. It protects under relatively severeconditions and given adequate maintenance touch-up as nec-essary, can be used for most maximum protection require-ments. It may be used at temperatures down to -40° F (-40°C). It is not a good choice for parts that are handled fre-quently since it remains tacky.

3.7.5.3.3 Grade 3. A thin, soft, oily film, water displac-ing CPC. This CPC doesn’t penetrate into tight joints as wellas MIL-PRF-81309, Type II or MIL-L-87177, Grade B, soone of them should be used as a substitute for this type ofapplication.

NOTE

Remove the MIL-PRF-16173, Grade 3 film withA-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, degreasing solvent prior to inspectingan area when the coating is dark and prevents vi-sual inspection of the underlying surface for cracksand hydraulic leaks.

3.7.5.3.4 Grade 4. A thick, soft, waxy type CPC that driesto a tack-free, semi-transparent film through which identifi-cation can be read. It provides good protection under rela-tively severe conditions when touched-up as necessary. It isexcellent for use on in-service equipment over MIL-PRF-81309, Type II, MIL-L-87177, Grade B, or MIL-PRF-16173,Grade 3 water displacing CPC since it dries to a tack-freefilm. It can be used at temperatures down to -40° F (-40° C).

3.7.5.4 MIL-PRF-63460, Lubricant, Cleaner, and Pre-servative for Weapons and Weapon Systems.

• If MIL-PRF-63460 is used in an area whichwill later be sealed or totally enclosed with no

ventilation, allow at least 4 hours for the sol-vent to evaporate prior to sealing or closing offthe area. Although MIL-PRF-63460 is a corro-sion preventive compound, its solvent vaporsmay cause corrosion if not allowed to dissipate.

• Do not use MIL-PRF-63460 on rubber or otherelastomeric parts. MIL-PRF-63460 containssolvents which attack rubber O-rings and otherelastomeric parts. Do not use as a direct substi-tute for MIL-PRF-32033.

MIL-PRF-63460 is a thin, water displacing, protective, pen-etrating lubricant used for cleaning, lubrication, and preser-vation of aircraft, missile, and equipment hinges and fittingjoints that experience only minor and infrequent relative mo-tion, and on parts and areas of small or large caliber weap-ons. This material has good lubricating properties between-65° and +150° F (-54° and +65° C), and it is the best lubri-cant of all water displacing CPC’s. It may be applied bybrushing, dipping, or spraying by aerosol can or a pumpsprayer.

3.7.5.5 MIL-PRF-32033, Lubricating Oil, General Pur-pose, Preservative, Water Displacing.

MIL-PRF-32033 material suffers a loss of viscos-ity or starts to gel at very low temperatures, there-fore, it shall not be used when temperatures candrop below -40° F (-40° C).

MIL-PRF-32033 is a general purpose, water displacing, lu-bricating oil with preservative properties intended for thelubrication and preservation of aircraft, missile, and equip-ment components. It may be applied by brushing, dipping, orspraying by aerosol can or a pump sprayer.

TO 1-1-691

Change 5 3-63

3.7.6 Preservation of Specific Areas.

• Do not use corrosion preventive compounds onthe interior of fuel tanks or fuel cells, engines,or engine fuel systems as fouling of fuel sys-tems may occur.

• Do not use corrosion preventive compounds onengine parts or accessories which exceed 800°F (427° C). Corrosive reactions may occur withCPC’s at high temperatures.

• CPC’s are not compatible with LOX and shouldnot be used on oxygen equipment, lines, fit-tings, or storage bottles. Fire may result.

NOTE

Use only corrosion preventive compounds (CPC’s)authorized by and described in this manual and/ora system specific equipment manual.

Table 3-8 provides procedures for the preservation of spe-cific areas and components where the use of a CPC on ex-posed metal surfaces is generally recommended for reducingcorrosion. This list does not constitute authority to use CPC’son specific equipment. The use of some or all types of CPC’sin certain areas or on equipment may be detrimental. There-fore, consult the appropriate system specific aircraft, missile,or equipment corrosion and/or maintenance manuals beforeapplying a CPC in a new area to determine which, if any,compounds should be used in that area.

3.7.7 Preservation Application Methods.

• CPC’s and solvents can produce toxic vapors.Use only in well ventilated areas. Avoid con-tact with skin. Consult the local safety officeand Bioenvironmental Engineer for PersonalProtective Equipment (PPE) requirements.

• Do not use synthetic wiping rags or cloths withthese materials as they will dissolve the syn-thetic cloth/rag.

• Keep CPC’s and solvents away from openflames, heat, or sparks as they are flammable.

CPC’s can be applied by brushing, dipping, or spraying. Thearea of application, viscosity of the material, and conditionsunder which they need to be applied are factors that influ-ence the decision of which application method should beused. Low viscosity materials are best applied by spraying,whereas high viscosity materials are more suited for brush-ing or dipping. Dipping can be used for all types of materialsbut the thickness of the coating obtained with low viscositymaterials may be too thin to provide adequate corrosion pro-tection. Prior to application of preservatives, remove old pre-servative coatings and then apply a fresh coating using oneof the following methods:

3.7.7.1 Brushing. Brushing may be accomplished usingan ordinary paint brush. This method is most appropriate forapplying thick materials on small areas or in areas where itis necessary to prevent material from getting on surroundingareas or nearby equipment.

3.7.7.2 Dipping. Dipping may be accomplished using anysuitable container for the CPC. It is most suitable for smaller,disassembled parts. It cannot be used for assemblies whichcontain any part or area adversely affected by the CPC.

3.7.7.3 Spraying.

For spray application, do not thin or dilute bulkpreservative CPC unless absolutely necessary. Donot use synthetic wiping cloths. Mask off adjacentareas to prevent overspray.

Spraying may be accomplished using paint spraying equip-ment, various types of pump sprayers, or aerosol cans. Thismethod is very effective for application to large areas whereconfined areas are not involved. The viscosity of the materialwill determine which type of spraying apparatus to use.

3.8 APPLICATION OF POLISH AND WAX.

Polishing and waxing of aircraft exterior surfaces is prohib-ited.

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3-64

CHAPTER 4INSPECTION AND CORROSION PRONE AREAS

SECTION I INSPECTION

4.1 PURPOSE.

Frequent corrosion inspections are essential for an effectiveoverall corrosion control program. Early detection, identifi-cation, and treatment minimizes the costs resulting from cor-rosion damage. Without regular systematic inspections, cor-rosion will seriously damage aircraft, missiles, andequipment. This chapter describes the basic visual and Non-Destructive (NDI) inspection procedures for detecting corro-sion as well as some of the signs of corrosion damage.

4.1.1 Responsibility. Corrosion detection is everyone’sresponsibility. Since corrosion can occur almost anywhereon aircraft, missiles, and equipment, all maintenance person-nel must be able to identify and report corrosion problems.Personnel performing any scheduled inspections shall bequalified in corrosion detection and shall have attended ap-propriate corrosion prevention and control courses estab-lished by AETC and the MAJCOM, and required by AFI20-114.

4.1.2 Frequency of Inspections. The frequency and ex-tent of inspections are established by the aircraft SystemProgram Director (SPD) and/or the missile or equipmentSystem Program Manager (SPM). However, during sched-uled or unscheduled maintenance actions on aircraft, mis-siles, or equipment and their components, the area involvedas well as those within 36 inches (18 inches on each side) ofthe repair or treatment area shall be visually inspected forcorrosion. Additional inspections of areas particularly proneto corrode, such as magnesium gear boxes, wheel and con-trol surface wells, bilge areas, etc. may be necessary. Corro-sion prone areas are discussed in Paragraph 4.5.

4.1.3 General Inspections. A general inspection of air-craft, missiles, and equipment is performed as follows:

a. Clean area thoroughly per instructions in Paragraph3.5.

Prior to removing any access covers or panelscoated with TT-P-2760 flexible polyurethaneprimer either with or without a MIL-PRF-85285polyurethane topcoat, score the coating system at

the edges of the cover/panel with a sharp plastictool to prevent fraying or peeling of the paint fin-ish system when the panel is removed for the firsttime after the finish system is applied.

b. If corrosion is suspected, examine the area with a 10Xmagnifying glass and flashlight. Pay particular atten-tion to edges of skin panels, rivet heads, and othercorrosion prone areas. If blisters, bubbles, or othercoating irregularities are present, attempt to dislodgethe paint by scraping with a sharp plastic tool. If paintdoes not dislodge easily, the irregularity is probably asag or run which is confined to the paint film itself andno further action is necessary. When corrosion is sus-pected but no irregularities are present, clean and drythe area per Paragraph 3.5 and apply a strip of 3M Co.,PN 250 (preferred) or A-A-883, Type II, flat-backmasking tape over the area leaving a two inch lengthfree at one end. Hand rub the tape for several strokesin order to assure good adhesion. Grip the free end ofthe tape and remove the tape with an abrupt liftingmotion. Where paint is removed, inspect and deter-mine the extent/degree of corrosion as described byParagraph 4.4.

c. Remove corrosion, clean, and treat the surface per pro-cedures in Chapter 5 and touch-up the paint per TO1-1-8.

4.1.4 Detailed Inspections. A detailed inspection of air-craft, missiles, and equipment shall be performed if the cor-rosion damage found during a general inspection is suspectedto be extensive or severe and/or as specified in appropriatesystem specific aircraft, missile, or equipment maintenancemanuals. Aircraft, missiles, and equipment shall be carefullyinspected for corrosion using the NDI tools and procedureslisted in Table 4-1. Refer to Paragraph 4.5 for information oncommon corrosion prone areas.

4.2 INSPECTION METHODS.

4.2.1 Visual inspection. Visual inspection is the mostwidely used method for the detection and evaluation of cor-rosion. It is very effective for detecting most types of corro-sion if done carefully with a knowledge of where and forwhat to look. Read Chapter 2 (Corrosion Theory) before per-forming corrosion inspection paying particular attention to

TO 1-1-691

Change 3 4-1

Table 2-1 (Appearance of Corrosion Products). The follow-ing tools can be used to find and evaluate the extent of cor-rosion damage:

• Flashlight.

• 10X Magnifying Glass.

• Plastic Scraper.

• Depth Gauge, pin micrometer type.

• Borescope.

• Optical Micrometer.

4.2.1.1 Evidence of Corrosion. Aluminum corrosionproducts are either white, gray, or black and may appear as apaste when wet or as either a hard, adherent film or easilycrumbled deposits when dry. Magnesium corrosion productsare white and powdery and form in large amounts with sig-nificant losses to the base metal. Steel corrosion products(rust) are red, brown, or black deposits either in the form ofa powder or when severe, as flakes that peel off easily. Cop-per corrosion products (patina) are blue or blue-green depos-its that adhere tightly to the surface. Titanium and stainlesssteels do not produce significant amounts of visible corro-sion products on their surfaces but they can exhibit crackingdue to stress corrosion cracking. When corrosion occurs be-neath a paint system, the surface of the paint appears blis-tered, bubbled, or distorted.

4.2.2 Depth Gauge. Depth gauges are tools used to mea-sure the depth of corrosion pits and areas reworked for pit-ting, exfoliation, and other types of corrosion to determinethe extent of corrosion damage and the amount of metalremoved during rework. If the pit and/or rework area depthare within allowable tolerances specified in a system specific

aircraft, missile, or equipment manual as directed by Para-graph 5.6, the pits can be acceptably reworked, and areasreworked for corrosion damage of any type are acceptable.Reapplication of a protective coating system to reworkedareas per TO 1-1-8 and the applicable system specific air-craft, missile, or equipment manual is required. If the depthof pits or a reworked area are not within allowable toler-ances, the part must be replaced or repaired, if allowed, or arequest for engineering assistance must be submitted to theaircraft SPD and/or the missile or equipment SPM.

NOTE

On thin sheet material, waviness in the materialmay result in false depth readings. Several read-ings may be necessary or it may be necessary toimprovise another method for determining thedepth of the corrosion damage. The depth gauge isnot suitable for determining the depth of a stresscorrosion or corrosion fatigue crack due to therelatively large size of the indicator pin.

4.2.2.1 Use of Depth Gauges. Take several depth read-ings in the affected area and select the deepest reading as thecorrosion damage depth. Where there are several damagedareas in the same skin panel or component part, plot or sketcha diagram of the depth and location of each damaged areafor comparison with damage limits specified in the appli-cable system specific aircraft, missile, or equipment manualsor for forwarding to the aircraft SPD and/or the missile orequipment SPM engineer when requesting engineering assis-tance. Place the depth gauge base flat against the undamagedsurface on each side of the corrosion damage area. Whentaking measurements on concave or convex surfaces, placethe base perpendicular to the surface. (Refer to Figure 4-1).Also, on the interior or exterior of an aircraft fuselage or amissile body, it is best to align the length of the depth gaugebase with the fuselage or body length.

Table 4-1. NDI Inspection Tools for Various Types of Corrosion

EquipmentType of Corrosion Detected orEvaluated (See Type Below)

Borescope 1, 2, 3, 4, 5, 10, 11, 12Depth Gauge 4, 5Optical Micrometer 1, 2, 4, 5, 6, 7, 8, 10, 11Fluorescent Penetrant 3, 4, 8, 9Eddy Current 1, 3, 4, 6, 8, 9Ultrasonic 3, 4, 6, 8, 9,Radiography 6, 8, 9,Type 1 Uniform surface corrosion

2 Galvanic or dissimilar metal corrosion3 Intergranular attack (general)4 Intergranular attack (exfoliation)5 Pitting6 Crevice/concentration cell corrosion

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Table 4-1. NDI Inspection Tools for Various Types of Corrosion - Continued

EquipmentType of Corrosion Detected orEvaluated (See Type Below)

7 Fretting corrosion8 Stress corrosion cracking9 Corrosion fatigue10 Filiform corrosion11 Microbiologically induced corrosion12 High temperature oxidation

4.2.3 Visual Inspection with a Borescope/Videoscope.The borescope has a small, high intensity light that can beused to aid in the inspection of interior surfaces which arenot accessible by any other method. Insert the head assemblyinto any cavity having a large enough opening. With thecavity illuminated, visually inspect it’s interior for defects,such as damage to the paint system and corrosion. (Refer toFigure 4-2).

NOTE

Wearing eyeglasses makes it difficult to place theeye at the ideal distance from the eyepiece and theview is distorted by external glare and reflection.Rubber eye shields on optical instruments (e.g.borescope, optical micrometer) are designed toshut out external light, but are not as effectivewhen glasses are worn. For these reasons, it isdesirable that the inspector be able to adjust theinstrument without wearing glasses to compensatefor variations in visual acuity.

4.2.3.1 The videoscope is essentially an advanced versionof a borescope. It utilizes a miniaturized camera and lightsource to transmit a very clear image to a hand-held videomonitor. The clarity of the image makes minor corrosion andpaint damage much easier to identify than is possible when aconventional borescope is used. Also, since the image ap-pears on a video monitor instead of inside a small borescopeinstrument tube, the problems commonly associated withwearing eyeglasses when using a borescope are avoided.Some videoscopes have additional corrosion mitigation ca-pabilities, such as the ability to extract entrapped water, re-move minor corrosion through dry ice abrasion, and applycorrosion prevention compounds (CPCs). These additionalcapabilities expand the usefulness of these types of video-scopes far beyond corrosion inspection and identification.Refer to the applicable weapons system technical order andequipment operating manual for information on the properapplication and use of videoscopes.

4.2.4 Optical Depth Micrometers.

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4.2.4.1 Analog Mechanical Read-Out Type. This in-spection tool is an alternate for the digital read-out opticaldepth micrometer and is used to measure the depth ofscratches, cracks, pits, and reworked areas and/or the height

of spurs and other protrusions. (Refer to Figure 4-3). Theoptical depth micrometer is first focused on the highest sur-face in the area of interest and a reading is taken. A secondreading is taken when the lowest surface is in focus. The

Figure 4-1. Depth Dimension of Corrosion Pits

Figure 4-2. Fiber Optic Borescope

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difference between the readings is the distance between thetwo surfaces. Optical micrometers are available with 100 and200 power magnification, reticle eyepieces, and accessorylighting. Use the procedures outlined below to determine thedepth of corrosion pits and/or areas reworked due to corro-sion damage on any surface with the optical depth microm-eter.

a. Select the appropriate base surface (e.g., flat, curved,round, or inside/outside angle surfaces) in the areawhere the measurement is to be made that will providea stable location for the micrometer feet.

b. Position the micrometer solidly over the base surfaceA of Figure 4-3 (undamaged surface close to surface Bof Figure 4-3) to make an initial measurement. Whilethe micrometer is set over the surface, a pin point oflight will cover the area being measured.

c. Look through the eyepiece of the micrometer and ro-tate the micrometer thimble clockwise or counterclock-wise starting with the hundred thousandth scale, thenthe ten thousandth scale, and finally the thousandthscale until surface A of Figure 4-3 comes into sharpfocus using extreme care when focusing to reduce in-accuracy in the measured values.

d. Obtain and record the reading for surface A of Figure4-3 located on the vernier scale. Since the vernier scaleis not one that can be simply read, an experiencedtechnician with the proper training is required to readthe scale accurately.

e. Position the micrometer over surface B of Figure 4-3(corrosion pit or area reworked due to corrosion dam-age) to measure the pit or rework depression depth.When measuring the depth of corrosion pits or re-worked areas, ensure that the surface being measuredhas a large enough area to focus on for an accuratereading.

f. Repeat procedures in step c and step d on surface B ofFigure 4-3. Take several readings from the corrosiongrind-out area and/or the corrosion pit and use thedeepest reading for the depth calculation.

g. Subtract the surface A of Figure 4-3 reading from thesurface B of Figure 4-3 reading to obtain the depth ofa corrosion grind-out or a corrosion pit or: Pit/DamageDepth = B Reading - A Reading.

4.2.4.2 Digital Read-Out Type. This digital read-out op-tical depth micrometer is the preferred inspection tool formeasuring the depth of scratches, cracks, pits, and reworkedareas and/or the height of spurs and other protrusions. (Referto Figure 4-4). The optical depth micrometer is first focusedon the highest surface in the area of interest (usually an un-damaged surface next to a scratch, pit, or grind out area),and the digital display is set to zero (0). The micrometer isthen focused on the lowest surface of the area being inspected

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(the bottom of the scratch, pit, or grind out area). The read-ing shown in the digital display when the lowest surface isbrought into focus is the actual depth of the area or the dif-ference between the undamaged surface and the bottom ofthe damaged area. This type of optical micrometer comeswith extra lenses capable of 40, 80, 100, and 200 powermagnification. The depth of narrow features such as stresscorrosion and corrosion fatigue cracks can be observed andmeasured with the higher power lenses while using the reticleeyepiece to measure the width of such features. The digitalmicrometer kit also includes interchangeable bases, acces-sory lighting, and a sample scratch plate for demonstrationand practice. Use the procedures outlined below to deter-mine the depth of corrosion pits and/or areas reworked dueto corrosion damage on any surface with the optical depthmicrometer.

a. Select the appropriate base to use on the type of sur-face (e.g. flat, curved, round, or inside/outside angle)on which the measurement will be made.

b. Turn on the digital display and check to see if it readsin inches and not millimeters. Change it to inches withthe in/mm button, if necessary.

NOTE

The “origin” button is not needed or used in thisapplication.

c. Shine a flashlight down through the eyepiece to spotthe target and position the micrometer. Look throughthe eyepiece and focus up and down to assure thatboth the high and low surfaces are within the field ofview. Rotating the focus thimble counterclockwisemoves the lens up and clockwise moves the lens down.The 10X objective lens will focus when it is approxi-mately ¼ in above the surface.

d. Focus on surface A and carefully press the “zero” but-ton on the display without moving the micrometer.

e. Focus on surface B and read the depth on the digitaldisplay while observing the following points:

(1) Do not move the micrometer base when refocus-ing between surface A at the 0.000 inch digitalread-out and surface B.

(2) To get accurate readings, take extreme care in fo-cusing. Be sure to focus well past the surface B(clockwise rotation) you picked in case evenlower areas might be found.

(3) If both surfaces A and B are not within the fieldof view, use the 4X lens to get a wider field ofview.

f. Take several readings from the corrosion damaged/grind out area and select the deepest reading as theactual depth.

4.2.5 Fluorescent Penetrant Inspection.

The apparent simplicity of the penetrant inspec-tion is deceptive. Very slight variations in the in-spection process can invalidate the inspection byfailing to indicate serious flaws. It is essential thatpersonnel performing penetrant inspection betrained and experienced in the penetrant process.

NOTE

The following inspection methods shall be accom-plished only by qualified and certified NDI techni-cians. Refer to TO 33B-1-1 and the specific sys-tem specific NDI manual for more detailedinspection procedures.

Fluorescent penetrant inspections require components to becleaned and then treated with a fluorescent penetrating liquidwhich is capable of entering surface cracks and/or flaws.After removing the penetrant from the surface, a developer(powder or liquid suspension of powder) is applied to absorbpenetrant trapped in the cracks or flaws. Under ultravioletlight, the absorbed penetrant is visible directly above thecracks or flaws from which it was drawn out. The penetrantinspection method is used to detect stress corrosion cracking,corrosion fatigue and plain fatigue cracks, intergranular cor-rosion, and residual corrosion following corrosion removalby grinding or sanding. Intergranular corrosion attack at me-tallic grain boundaries and the network of very fine cracks itforms are visible in the early stages only under a 10X orgreater magnification, and developer is not used when evalu-ating a penetrant indication with a magnifying glass. In ad-dition, if penetrant inspection is used to monitor a surfacefor adequacy of corrosion removal by grinding or sanding,caution must be exercised because mechanical removal meth-ods can cause smearing which may obscure indications ofremaining corrosion. When monitoring corrosion grind outareas with penetrant, a developer is not used following re-moval of excess surface penetrant because the area must alsobe examined with a 10X magnifying glass after a minimum5 minute dwell time. When corrosion is no longer detectedin a corrosion grind-out area, the inspection process shall berepeated using non-aqueous developer to determine if anycracks are present.

4.2.5.1 Limitations of Penetrant Inspection.

4.2.5.1.1 Flaw Location. Penetrant inspection is appli-cable to all solid, non-porous materials provided the flaw

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being inspected for is open to the surface of the part. Todetect subsurface flaws, another inspection method must beused.

4.2.5.1.2 Restricted Flaw Openings. The penetrant in-spection process depends upon the ability of the penetrant toenter and exit the flaw opening. Any factor that interfereswith the entry or exit reduces its effectiveness. Organic coat-ings, such as paint, oil, grease, or resin, are examples of thisinterference. Any coating that covers or bridges the flawopening prevents penetrant entry, and even if it does notcover the opening, material at the edge of the opening affectsthe mechanism of penetrant entry and exit, and greatly re-duces the reliability of the inspection. Coatings at the edgeof the flaw may also retain penetrant causing backgroundfluorescence. An inspection method other than penetrant mustbe used if the organic coating cannot be stripped or removedfrom the surface in the area to be inspected.

4.2.5.1.3 Smeared Metal. Mechanical operations, such asshot peening, machine honing, abrasive blasting, buffing,wire brushing, grinding, or sanding can smear or peen thesurface of metals. This mechanical working closes or re-duces the surface opening of any existing discontinuities orflaws. Mechanical working (smearing or peening) also oc-curs during service when parts contact or rub against eachother. Penetrant inspection will not reliably indicate discon-tinuities or flaws when it is performed after a mechanicaloperation or service that smears or peens the surface. Chemi-cal etching per procedures in TO 33B-1-1 and/or the systemspecific aircraft, missile, or equipment NDI manual is rec-ommended prior to penetrant operations to improve test sen-sitivity when smeared metal is present.

4.2.5.1.4 Porous Surfaces. Penetrant inspection is im-practical on porous materials with interconnected subsurfaceporosity. The penetrant rapidly enters the pores and migratesthrough the network. This results in an overall fluorescenceor color that masks any potential discontinuity or flaw indi-cations. In addition, removal of the penetrant after the in-spection may be impossible.

4.2.6 Eddy Current Inspection. The eddy current inspec-tion method may be used to detect or evaluate accessible andinaccessible surfaces for corrosion. This method can detectand evaluate pitting, intergranular, exfoliation, stress corro-sion cracking, and corrosion fatigue cracking. Detection ofcorrosion with eddy current techniques is used on aircraft,missile, and equipment skins where corrosion may occur oninaccessible interior surfaces. Corrosion usually occurs in ar-eas where moisture is entrapped in faying surface areas. Ifrelatively uniform thinning is expected, corrosion detectionmay be simply a matter of thickness measurement. In mostinstances, corrosion is confined to smaller localized areas ofrelatively small diameter. As skin thicknesses increase, sen-sitivity to small areas and shallow depths of corrosion isreduced. Corrosion on either member of faying surfaces maybe detected. Refer to TO 33B-1-1 and/or the system specific

NDI manuals for more detailed inspection procedures. Eddycurrent can also be used for corrosion removal inspectionsbut is less sensitive than penetrant.

4.2.7 Ultrasonic Inspection. The ultrasonic inspectionmethod may be used to detect exfoliation, intergranular, pit-ting, corrosion, and stress corrosion and corrosion fatiguecracking. Ultrasonic thickness gauging is included in thismethod. Ultrasonic inspection for far-side pitting and inter-nal exfoliation corrosion may be accomplished using shear(“S”) wave and longitudinal (“L”) wave techniques. The useof a delay line transducer is recommended for “L” waveinspection to improve resolution of both near and far surfacecorrosion. Technique development is required for each spe-cific application. Refer to TO 33B-1-1 and/or system specificNDI manuals for more detailed inspection procedures.

4.2.8 Radiographic Inspection. Although the radio-graphic inspection method is available for detection andevaluation of corrosion, it is generally used only when noother method can accomplish the inspection. The labor hourrequirements are high for on-aircraft/missile/equipment radi-ography as well as requiring restricted access for other main-tenance personnel during the inspection. Radiographic in-spection is used in combination with ultrasonics to determinethe condition of aluminum honeycomb. Refer to TO 33B-1-1and/or system specific NDI manuals for more detailed in-spection procedures.

4.3 EVALUATION OF CORROSION DAMAGE.

Visually determine if the corrosion is present in an areawhich has previously been reworked. If the corrosion dam-age is in a previously reworked area, measure the damage toinclude the material which has previously been removed. Astraight edge and a 10X magnifying glass may be used toassist in determining if an area has previously been reworked.Place the straight edge across the area being examined atvarious angles and check for irregularities, low spots, or de-pressions. (Refer to Figure 4-5). If any irregularities, lowspots, or depressions are found and a visual determinationcannot verify previous rework, closely examine the suspectedarea and the surrounding area using the 10X magnifyingglass. After determining that the area has been previouslyreworked, evaluate the depth of the previous rework (grind-out) to determine if further metal removal will exceed grind-out limits specified in the applicable aircraft, missile, orequipment system specific manuals or as specified in Para-graph 5.6. Depth measurements can also be made using thedepth gauges as described in Paragraph 4.2.2 and Paragraph4.2.4.

4.4 DEGREES OF CORROSION.

Corrosion must be evaluated after the initial inspection andcleaning to determine the nature and extent of repair or re-work needed. It is difficult to draw a distinct and specificdividing line among the degrees of corrosion, so reliableevaluation requires sound maintenance judgment. Use thefollowing categories in reporting degrees of corrosion.

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Figure 4-3. Optical Depth Micrometer (Analog Mechanical Read Out Type)

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Figure 4-4. Optical Depth Micrometer (Digital Read Out Type)

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4.4.1 Light Corrosion. This degree of corrosion is indi-cated by the protective coating being scraped, gouged, orchipped to bare metal, or showing the tracks of filiform cor-rosion in the film and the bare metal showing is character-ized by discoloration of surface corrosion and/or pitting to adepth of approximately one mil (0.001 inch) maximum. Thistype of damage can normally be removed by light handsanding.

4.4.2 Moderate Corrosion. This degree of corrosion lookssomewhat like light corrosion except some blisters or evi-dence of scaling and flaking of the coating or paint system is

present and the pitting depths may be as deep as 10 mils(0.010 inch). This type of damage is normally removed byextensive hand sanding or light mechanical sanding.

4.4.3 Severe Corrosion. The general appearance of thisdegree of corrosion is similar to moderate corrosion in theappearance of the coating system but with severe intergranu-lar corrosion cracks and blistering exfoliation with scaling orflaking of the metal surface. The pitting depths are deeperthan 10 mils (0.010 inch). This damage must be removed byextensive mechanical sanding or grinding and may require apatch type repair or component replacement.

SECTION II CORROSION PRONE AREAS

4.5 COMMON AREAS.

There are certain corrosion prone areas common to all air-craft, missiles, and equipment. (Refer to Figure 4-6 throughFigure 4-25). Corrosion prone areas should be cleaned, in-spected, and treated more frequently than less corrosionprone areas. The following paragraphs describe the areas andcontain illustrations to aid in inspections. However, the list isnot complete and should be expanded by referring to thesystem specific maintenance manuals and cards for each spe-cific aircraft, missile, or piece of equipment which showother possible trouble spots.

4.5.1 Fasteners. There are hundreds to thousands of fas-teners on aircraft, missile and equipment exterior surfaces,and areas around these fasteners are trouble spots. (Refer toFigure 4-6 and Figure 4-7). These areas are subject to highoperational loads and/or moisture intrusion which makes theskin material highly susceptible to corrosion at fastener lo-cations. High strains cause paint to crack around the fasten-

ers which provides a path for corrosive materials to enter thejoint between fastener heads and skin panels. Any paint thatis not highly flexible will crack to some degree around fas-teners.

4.5.2 Faying Surfaces and Crevices. Similar to corro-sion around fasteners, corrosion in faying surfaces, seams,and joints is caused by the intrusion of salt water and/orother corrosive fluids or agents. Entry of fluids by capillaryaction causes corrosive liquids to flow into the tightest ofjoints. The effect of corrosion resulting from fluid intrusioninto joint areas is usually detectable as bulging of the skinsurface.

4.5.3 Spot Welded Assemblies. Spot welded assembliesare particularly corrosion prone due to entrapment of corro-sive agents between the parts of the assemblies. (Refer toFigure 4-8 and Figure 4-9). Corrosive attack causes skinbuckling or spot weld bulging (refer to Figure 4-9), andeventual spot weld fracture. Skin and spot weld bulging may

Figure 4-5. Typical Use of a Straight Edge to Determine if Suspect Areas Have Been Previously Reworked

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be detected in their early stages by sighting or feeling alongspot welded seams. This condition is prevented by keepingpotential moisture entry points such as gaps, seams, and holescreated by broken spot welds filled with a sealant or a suit-able preservative or CPC.

4.5.4 Engine Exhaust and Gun Gas Impingement Ar-eas. Exhaust and gun gas impingement areas include areason an aircraft, missile, or piece of equipment exposed toengine, rocket, missile, and equipment exhaust, gun blast orany other surface exposed to them on installed equipment.These gases cover the organic finish on the surface with de-posits (i.e. corrosive ash and residual solids) that damage thefinish. Surfaces located in the path of rocket and gun blasts,including gun compartment systems and spent ammunitioncollection chutes, are particularly susceptible to deteriorationand corrosion. (Refer to Figure 4-10). In addition to the cor-

rosive effect of the gases and exhaust deposits, the protectivefinish is often blistered by the heat, blasted away by the highvelocity gases, or abraded by spent shell casings or solidparticles from engine, gun, and rocket exhausts/gases. (Referto Figure 4-11). These areas require more attention duringinspections.

4.5.5 Wheel Wells and Landing Gear. Wheel well areasprobably receive more abuse than any other area on an air-craft. They are exposed to water spray, mud, salt and otherrunway deicing agents, gravel, and other flying debris fromrunways during taxiing, takeoff, and landing. They are alsoexposed to salt air and spray when aircraft are parked atlocations near salt water. Because of the many complicatedshapes, assemblies, and fittings in the area, complete cover-age with protective coatings is difficult to maintain. (Refer toFigure 4-12).

Figure 4-6. Corrosion Around Fasteners

Figure 4-7. Galvanic Corrosion of Aluminum Adjacent to Steel Fasteners

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4.5.6 Flap and Slat Recesses. Flap and slat recesses/wells (refer to Figure 4-13), and equipment installed in themare normally hidden from view since flaps and slats are usu-ally maintained in the retracted/closed position when an air-craft is on the ground and they may experience corrosionthat goes unnoticed unless special inspections are performed.

4.5.7 Engine Frontal Areas and Air Inlet Ducts. Sincethese areas are constantly abraded by dirt, dust, and gravel,and eroded by rain, special attention shall be given to thefollowing:

a. Engine frontal areas (refer to Figure 4-14 and Figure4-15), for general surface corrosion, pitting, intergranu-lar corrosion, and erosion.

b. Leading edges of air inlet ducts, including hardwareinside ducts (refer to Figure 4-16 and Figure 4-17), fordamaged/deteriorated protective coating/paint system,galvanic corrosion at fastener locations, general sur-face corrosion, exfoliation corrosion, and erosion.

Figure 4-8. Spot Weld Corrosion

Figure 4-9. Spot Welded Skin Corrosion Mechanism

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Figure 4-10. Gun Blast Area Corrosion Points

Figure 4-11. Exhaust Trail Area Corrosion Points

Figure 4-12. F-15 Nose Landing Gear Wheel Well

Figure 4-13. Flaps Lowered to Expose Recess Areas

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Figure 4-14. Reciprocating Engine Frontal AreaCorrosion Points

Figure 4-15. Jet Engine Frontal Area Corrosion Points

Figure 4-16. Corrosion Prone Point of Air Inlet

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c. Due to heat dissipation requirements, oil cooler coresand reciprocating engine cylinder fins are not usuallypainted. Engine accessory mounting bases may havesmall, unpainted areas on the machined mounting sur-faces. With moist, salt-laden air flowing over thesesurfaces, they are vulnerable to general surface corro-sion/rusting and pitting.

4.5.8 Wing/Fin-Fold Joints and Wing and Control Sur-face Leading Edges.

a. Wing and fin-fold areas are vulnerable to corrosive at-tack when the wings or fins are folded so they requirespecial attention. (Refer to Figure 4-18).

b. Both wing and control surface leading edges on air-craft are constantly exposed to salt laden air and winderosion which make them vulnerable to corrosion sothey both require special attention.

4.5.9 Hinges. Hinges (refer to Figure 4-19 and Figure4-20), are highly susceptible to corrosion because of dissimi-lar metal contact that results from wear and damage to pro-tective metallic coatings. They are natural traps for dirt, salt,and moisture. Piano type hinges which are used extensivelyon aircraft hatches and control surfaces are especially vul-nerable to attack.

4.5.10 Control Cables. Control cables present a corro-sion problem whether they are made of carbon steel or stain-less steel. As shown in Figure 4-21, the presence of barespots in the plastic cladding on clad cables or missing orgaps in the protective CPC coating are the main contributingfactors to the corrosion of cables. Dirt, grime, and rust thatcollect between cable strands lead to more severe corrosionand wear that eventually cause cable failure.

4.5.11 Relief Tube Outlets. Urine products are very cor-rosive. (Refer to Figure 4-22). Relief tube areas should becleaned frequently and the paint finish kept in good condi-

tion. The relief tubes are usually made of plastic and do notpresent a corrosion problem, but the surrounding metallicaircraft fuselage structure can be severely corroded by urineproducts.

4.5.12 Water Entrapment Areas. Figure 4-23 showscommon water entrapment areas. Design specifications re-quire that aircraft have drains installed in all areas wherewater may collect, but in many cases these drains are inef-fective either because of improper location or because theyare plugged by sealants, fasteners, dirt, grease, and/or otherdebris. The plugging of a single drain hole or the altering ofthe attitude of the aircraft can cause serious structural defectif salt water or other corrosives remain for any appreciableamount of time in one of these entrapment areas. Daily in-spection and cleaning, if necessary, of low point drains is astandard requirement. These areas may accumulate waterfollowing washing or rinsing of aircraft. Where this is a re-curring problem, field units shall request the aircraft SPD todevelop procedures to prevent water accumulation. Drainholes shall not be drilled by field units unless specificallyauthorized by the aircraft SPD.

4.5.13 Bilge Areas. Aircraft bilge areas are natural col-lection points (i.e., low points/areas in an aircraft fuselage)for water, salt water, dirt, loose fasteners, drill shavings, andother debris. (Refer to Figure 4-24). Keeping bilge areas freeof debris and fluids, maintaining the protective finish systemin good condition, and application of CPC’s, as required, inaircraft system specific maintenance manuals are the bestprotection against corrosion in bilge areas.

4.5.14 Battery Compartments and Battery Vent Open-ings. In spite of protective paint systems, corrosion preven-tive compounds, and venting provisions, battery compart-ments are high corrosion problem areas. (Refer to Figure4-25). Fumes from overheated battery electrolyte will spreadto adjacent internal cavities causing rapid corrosion of un-protected surfaces. If the battery installation has an external

Figure 4-17. Corrosion in Air Intake Duct

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vent opening on the aircraft, missile, or equipment skin, in-clude this area in battery compartment inspection and main-tenance procedures. Frequent cleaning and neutralization ofdeposits will minimize corrosion. Leakage of electrolytes ofeither sulfuric acid from lead-acid batteries or potassium hy-droxide from nickel-cadmium batteries will cause corrosion.Consult the applicable system specific maintenance manualsof the particular aircraft, missile, or piece of equipment todetermine which type of battery is used. Refer to Chapter 3,Chapter 8, and system specific maintenance manuals for in-structions on neutralizing battery electrolytes.

4.5.15 Magnesium Parts. Magnesium parts are extremelycorrosion prone. Special attention must be given to propercorrosion preventive surface pretreatment of their surfaces,insulation from contact with other metal surfaces, and main-tenance of protective paint coatings.

4.5.16 Electrical Connectors and Other Components.Some electrical connectors are potted with a sealant com-pound to prevent the entrance of water into the backsideareas of connectors where wires are attached to pins. RubberO-rings are also used to seal moisture out of the front side orpin mating areas of connectors when two connector halvesare mated together. If moisture gets into electrical plugs, itwill cause corrosion and electrical failure. Electrical plugsmust be disconnected periodically for inspection and corro-sion treatment. The use of improper and unauthorized seal-ants, potting compounds, and corrosion preventive com-pounds can cause severe corrosion damage and/or electricalfailure of electrical connectors or components.

Figure 4-18. Wing Fold Joint

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Figure 4-19. Hinge Corrosion Points

Figure 4-20. Piano Hinge Lugs

Figure 4-21. Control Cables

Figure 4-22. Personnel Relief Tube Vent

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Figure 4-23. Common Water Entrapment Areas

Figure 4-24. Bilge Areas

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Figure 4-25. Battery Compartment

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CHAPTER 5CORROSION REMOVAL AND SURFACE TREATMENT

SECTION I CORROSION REMOVAL

5.1 PURPOSE.

This chapter covers procedures for corrosion removal andsurface treatment. When corrosion is detected, a specific andimmediate corrective action is required. Each type of corro-sion has its own specifics and requires special treatment.Complete treatment involves a thorough inspection of allcorroded areas, evaluation of the corrosion damage (refer toChapter 4), paint removal per TO 1-1-8, corrosion removalper this chapter, application of chemical surface treatmentsper this chapter, sealing (refer to Chapter 6), and application/touch-up of protective paint finishes per TO 1-1-8.

5.2 RESPONSIBILITY.

Propellers and helicopter blades have critical bal-ance requirements. Refer to the appropriate sys-tem specific propeller or blade manual for evalua-tion and repair limits for corrosion, erosion, andabrasion damage.

Personnel assigned to perform corrosion removal correctivemaintenance tasks shall be specially trained in the use ofchemical paint removers, abrasive materials, powered andhand tools, depth and area measurement of metal removed,and determination of damage limits from the applicable sys-tem specific maintenance manuals. Inadequate training willlead to further damage of equipment and poses a safety haz-ard to the individual.

5.3 CORRECTIVE ACTIONS.

Corrective maintenance depends on the type of surface in-volved (metallic or composite), the area of the damaged sur-face (small corrosion spot or large heavily corroded area),and the degree of corrosion, as determined in Chapter 4.Composite materials, such as fiberglass or graphite-rein-forced structures, shall not be exposed to chemical paint re-mover, but shall only be scuff sanded to the primer coat.Since composite materials do not corrode, corrosion removaltechniques are not applicable and shall not be used. Corro-sion shall always be removed by the mildest effective tech-

nique. For mechanical procedures specific to the variousmetal alloys, refer to Table 5-3 and Table 5-4.

5.4 PAINT REMOVAL.

Refer to TO 1-1-8 for proper paint removal procedures.Choose the most effective method that produces the leastamount of hazardous waste and danger to personnel for thejob to be accomplished.

5.5 CORROSION REMOVAL.

Corrosion can be removed by either mechanical or chemicalmethods. Certain factors must be considered prior to startingany corrosion removal operation. The most important factoris that corrosion products must be removed completely with-out causing additional damage to the structure during theprocess. This can be accomplished by first removing all cor-rosion visible through a 10X magnifying glass, then remov-ing an additional two mils (0.0020 inch) to ensure that alldeposits have been eliminated. Failure to remove all corro-sion allows the corrosion to continue even after affected sur-faces are refinished. Additional factors to consider are asfollows:

a. Before attempting to remove corrosion products, stripthe paint and clean contaminants from the surface.Surface contaminants and paint interfere with corro-sion removal procedures and make the operation moredifficult.

b. Protect adjacent components and parts from corrosionresidue and possible damage that could be caused bythe removal operation. Corrosion residue can cause ad-ditional corrosion and damage the surface finish of thesurrounding area. An accidental slip of a corrosion re-moval tool can quickly result in additional damage.

c. Prior to corrosion removal, determine the allowablelimits from the system specific aircraft, missile, and/orequipment manuals and/or technical orders. When re-moving corrosion from critical aircraft, missile, orequipment structure, take the following steps:

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(1) If allowable metal removal or damage limits willnot be exceeded, remove corrosion completely.Metal loss due to corrosion damage is cumula-tive. Metal loss from prior corrosion removal op-erations and corrosion removal from areas on theopposite side of a part must be considered whenassessing the degree of corrosion damage.

(2) If allowable damage limits will be exceeded, re-pair the damaged area or replace parts per proce-dures in system specific aircraft, missile, or equip-ment repair manuals/technical orders. Coordinateany repair or part replacement not covered inthese manuals/technical orders with the aircraftSPD or the missile or equipment SPM.

5.5.1 Mechanical Methods. There are various mechani-cal methods for removing corrosion from metal surfaces. Themethod used and the types of tools and equipment selectedfor the removal operation depend on the type of metal in-volved, the location and accessibility of the corroded area,the degree of damage, and the type of corrosion involved. Itis important that the removal method, tools, and equipmentselected be compatible with the metal surface. Compatibilityinvolves two considerations: the mechanical effect of theequipment and tools on the surface and the compatibility ofmetallic particles worn off the removal equipment and toolswhich might become embedded in the metal surface.

5.5.1.1 Mechanical Compatibility.

Corrosion removal accessories/tools, such as flapbrushes or rotary files, shall be used on one typeof metal only. For example, a flap brush used toremove corrosion from aluminum alloys shall notbe used to remove corrosion from magnesium al-loys or steel also.

Mechanical compatibility refers to the selection of the righttools and equipment to prevent additional damage caused bythe removal process. Often, it is necessary to select a seriesof removal techniques involving the use of different gradesor classes of equipment and material to effectively removethe corrosion products. The initial use of a rapid and coarseremoval method followed by a slower and finer removalmethod produces a smooth metal surface finish (e.g. using avacuum blaster first followed by using a fine abrasive clothor paper to finish the job).

5.5.1.2 Material Compatibility. Material compatibility re-fers to using a medium for brushing, abrading, blasting, etc.,that will not cause additional corrosion. Material compat-ibilities are assured by using like metals during corrosionremoval operations (e.g. regular carbon steel wool shall neverbe used to remove corrosion from aluminum alloys as it willembed in the aluminum alloy surface and cause galvaniccorrosion).

5.5.2 Non-Powered Tools and Materials.

5.5.2.1 Abrasive Mats. Abrasive mats are made from anylon mesh material impregnated with various grades of alu-minum oxide. Abrasive mats are available in 9 x 11 inchsheets under A-A-58054, Type I, Class 1, Grade A - VeryFine (280-400 grit), Grade B - Fine (180 grit), and Grade C- Medium (100-150 grit). These mats are used by hand toremove small areas of corrosion and/or paint where the useof powered tools would be impractical or prevented by theshape or accessibility of the area. Table 5-1 is a guide forrelating abrasive mat materials to coated abrasive paperand/or cloth grit particle sizes.

5.5.2.2 Abrasive Cloth. Abrasive cloths with bonded alu-minum oxide grit per A-A-1048 and silicon carbide grit perA-A-1200 are used for dry sanding of light to moderate cor-rosion products. They are available in 9 x 11 inch sheets and2 or 3 inch wide x 150 foot long rolls in 240 grit (Fine) and320 grit (Very Fine) grades.

5.5.2.3 Abrasive Paper. Heavy paper with silicon car-bide grit bonded to it per A-A-1047 is used for either wet ordry sanding to remove light to moderate corrosion. It isavailable in 9 x 11 inch sheets in 240 grit (Fine) and 320 grit(Very Fine) grades. Silicon carbide is usually more effectivethan aluminum oxide on harder metals such as low carbonand corrosion resistant steel alloys. Other abrasive paper andcloth with bonded emery or flint are available but they sufferfrom poor efficiency and short working life.

5.5.2.4 Metallic Wools. Metallic wools are abrasive ma-terials used for removing corrosion that is not tightly bondedto a metal surface. The four major types of metallic woolsare aluminum, copper, stainless (CRES) steel, and carbonsteel. Metallic wools are available in five grades, rangingfrom very fine to extra coarse. Table 5-2 is a guide to helpselect the correct grade of metallic wool.

5.5.2.4.1 Use of Metallic Wool on Corroded Metals.The type of corroded metal must be known before usingmetallic wool. Carbon steel wool is used on low carbon steelalloys, aluminum wool is used on aluminum and magnesiumalloys, copper wool is used on copper, bronze, and brassalloys, and stainless steel wool is used on stainless (CRES)steel alloys. The use of metallic wools which are not gal-vanically compatible with the metal surface being treated isnot authorized. These metallic wool materials are very goodfor removing corrosion from tubing or extruded parts. Re-move all metallic wool residue from the metal surface beingtreated and the surrounding area with a vacuum cleaner. Me-tallic wool particles can create galvanic cells if left on themetal surface.

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Table 5-1. Grades of Abrasive Mats

Grade Coated Abrasive (CA) EquivalentMedium (C) 100 - 150

Fine (B) 180 - 240Very Fine (A) 240 - 320

Super Fine (AA) 500 & finerUltra Fine (AAA) 10 microns & finer

Table 5-2. Grades of Steel Wool

Type Grade UseVery Fine Final smoothing

II Fine Most commonly usedIII Medium General purposeIV Coarse Rough workV Extra coarse Restoration work

5.5.2.5 Wire Brushes. Wire brushes are available withcarbon steel, stainless (CRES) steel, aluminum, and brassbristles and are used to remove heavy corrosion deposits andflaking paint that are not tightly bonded to the metal surface.Densely set, short, stiff bristles are most effective for rapidcorrosion removal. The metallic bristles must be compatiblewith the metal surface being treated to prevent galvanic cor-rosion with stainless (CRES) steel being considered neutraland usable on all metals. Do not use brushes with a bristlewire gauge or diameter above 0.010 inch, as severe gougingof the surface leading to stress risers and fatigue crackingmay occur. Remove the corrosion with a linear motion, donot cross-hatch as this will unnecessarily damage the sur-rounding surface area. After wire brushing, the surface areasmust be polished with fine abrasive paper to remove and/orsmooth out gouges and scratches.

5.5.2.6 Pumice Powder. Pumice powder is a very fineand soft abrasive used to remove stains or to remove surfacecorrosion on thin metal surfaces where minimum metal re-moval is allowed. It is mixed with water and then rubbedover the area with a soft cloth to polish the surface. After thecorrosion is removed, the powder is wiped off the surfacewith a clean cloth wet with fresh water.

5.5.2.7 Scrapers. Scrapers are used primarily for the ini-tial removal of heavy corrosion deposits such as flaking rustand exfoliation blisters, and are particularly effective in cor-ners and crevices that cannot be reached with other equip-ment. Scrapers may be locally manufactured from phenolicplastic, fiberglass, aluminum alloys, plain carbon steel orcarbide-tipped carbon steel, or stainless (CRES) steel. Plasticand fiberglass scrapers may be used on any type of metalsurface but are of limited value due to their softness relativeto a metal surface, stainless (CRES) steel and carbide-tippedcarbon steel scrapers may be used on any type of metal sur-face, aluminum alloy scrapers may be used only on alumi-num or magnesium alloy surfaces, and plain carbon steelscrapers may be used only on carbon steel surfaces. Scrapersmade from copper or brass alloys shall never be used on anystructural metal surface as galvanic corrosion will result.Failure to use the correct metal scraper can also lead to gal-vanic corrosion after the part is returned to service. Surfaceareas must receive further finishing after corrosion removalwith scrapers due to the gouging action of scrapers and thedifficulty in determining complete corrosion removal aftertheir use.

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5-3

5.5.3 Power Tools and Materials.

• Power tool operations can often generate toxicairborne particles containing heavy metals, suchas chromium (in the form of chromates), tita-nium, nickel, and beryllium, depending on thesurface being treated. Eye protection, ventila-tion, and an adequate respirator for dust controlare required.

• Do not use hands to probe for air leaks in powertools and their hoses as injury may result.

• Before using any powered equipment, removeany clothing such as ties and shirts with longloose sleeves as well as all rings and other jew

elry which might become entangled in theequipment. Always wear proper personal safetyequipment (PPE), such as goggles, face-shields,respirators, etc. Ensure that all electrical equip-ment is grounded.

• Corrosion removal with power tools is a veryaggressive method which shall only be usedwhen and where the extent of corrosion makesnon-powered corrosion removal impractical.The indiscriminate use of power tools for cor-rosion removal can result in damage to protec-tive surface finishes.

Power tools are used to remove heavy corrosion from local-ized areas on metal surfaces or mild to severe corrosion overlarge surface areas. Their use results in saving time andmoney, but care must be exercised when using power tools.Application of excessive pressure can easily damage metal

Figure 5-1. 3M Co. Scotch-BriteTM Flap Brush and Mandrel

Figure 5-2. Abrasive Flap Wheels with Spindle Mount

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surfaces and cause internal metallurgical changes in the metaldue to excessive heat buildup.

5.5.3.1 Pneumatic Drill Motors. Pneumatic drill motorsare the preferred power tools for removing heavy corrosionor reworking large surface areas. The drill motor is normallyused with wire brush wheels, rotary files, flap brushes, sand-ing pads, abrasive wheels, or buffing wheels. These drills areavailable in many shapes and sizes to satisfy almost anyrequirement. Check all pneumatic equipment air hoses forbreaks or bulges in the coverings.

a. Maximum chuck capacity of portable powered drills isusually ¼ inch. Insert the tool shank into the drill andtighten chuck securely with the chuck key prior to use.When it is difficult or impossible to reach the workarea with a straight drill, use a flexible shaft or angleadapter. The flexible shaft permits working around ob-structions with a minimum of effort.

b. To prevent the rotary file, abrasive wheel, flap brush,or sanding disc from digging into the metal, keep thetool off the metal when initially starting the drill mo-tor. When the abrading stroke is finished, lift the toolfrom the metal before releasing the power to the mo-tor.

c. Holding the drill motor with both hands, apply moder-ate pressure while holding the rotary file, sanding disc,flap brush, or abrasive wheel against the work surface.

When using the pneumatic tool as a sander, be sure tocheck the size and type of the abrasive disc. Ensurethat the type of disc is compatible with the metal. Keepthe sanding disc tilted to approximately a 10 degreeangle so that only one side of the disc is in contactwith the metal surface. If the entire disc surface is incontact with the surface, a “bucking” effect will occur.Excessive pressure will cause a “chattering” effect.Move the tool over the surface with slightly overlap-ping strokes. Do not grind, sand, or file in one area forany extended length of time without stopping and al-lowing the metal to cool. Excessive heating of themetal will alter its metallurgical structure.

5.5.3.2 Pneumatic Sanders. The proper technique forusing pneumatic sanders with oscillating heads shall includethe following:

a. To prevent the sander from digging into the metal, startthe sander before it touches the metal. When the sand-ing stroke is finished, lift the sander from the metalbefore pressing the stop switch. Do not lay the unitdown with the motor running.

b. For best results, apply moderate pressure while hold-ing the sander against the work. Move the sander overthe surface with parallel and slightly overlappingstrokes. Move it as slowly as possible without causingoverheating of the metal. Generally, the coverage rateshould be about two square feet per minute.

Figure 5-3. 3M Co. Radial Bristle Disc

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5.5.3.3 3M Co. Scotch-BriteTM Finishing Flap Brushes.

Do not use flap brushes (refer to Figure 5-1), downto within 2 inches of core. Continued use beyondthis limit may cause gouging due to loss of flex-ibility of fiber. When using flap brushes, applyminimal pressure to remove a minimum amountof metal. Excessive pressure on flap brushes willcause paint at the edge of the area being workedto melt, gum up, and streak onto the work area.Do not use on non-metallic surfaces.

Flap brushes are made of non-woven, nylon webbing im-pregnated with aluminum oxide grit. The brushes are veryeffective for removing mild surface corrosion and preppingsurfaces. It can also be used for mechanical removal andfeathering of paint systems. The brushes are comprised of aseries of flaps bonded to a cardboard core and attached to amandrel. Each flap impacts the surface as the brush spins.When used correctly, the brushes will lead to minimal metalremoval. The flap brush and mandrel (refer to Figure 5-1),shall be assembled so that the arrow, painted on the brush, isfacing the operator and points in the direction of rotation(clockwise). To achieve maximum effectiveness, use at thespecified RPM and do not exceed the maximum RPM ratingspecified on the brush to prevent disintegration during useand either damage to equipment or injury to personnel.

5.5.3.4 Abrasive Flap Wheels. Abrasive flap wheelscome in various types. One type is made of paper flaps im-pregnated with aluminum oxide abrasive and mounted on aspindle. (Refer to Figure 5-2). Another type is made from aresin reinforced nylon mesh impregnated with aluminum ox-ide abrasive in a convoluted flap form per A-A-59292, Class1 or a unitized, rigid, laminated form per A-A-59292, Class2, both of which are mounted on arbors. Depending on gritsize, these wheels can be used to remove medium to severecorrosion from thick materials, but caution must be used tominimize the amount of metal removal. For the most effec-tive use of this equipment, use at the specified RPM andnever exceed the maximum RPM rating specified on thewheel to prevent disintegration of the wheel during use andeither damage to equipment or injury to personnel.

5.5.3.5 Abrasive Cloth and Paper. Aluminum oxide andsilicon carbide cloth and paper can be used with sanders anddrill motors by cutting suitable pieces from stock or usingprecut discs mounted on pad type holders.

5.5.3.6 Powered Wire Brushes. Powered wire brushesare available with various types of wire (straight, twisted, orcrimped), various lengths of wire (short, medium, or long),and various wire densities (light, medium, or heavy). Differ-ent actions can be obtained by varying wire type, trim length,and density.

Figure 5-4. 3M Co. Roloc Discs

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5.5.3.7 Rotary Files.

Unless authorized and directed by the cognizantaircraft SPD or missile or equipment SPM, rotarywire brushes are not authorized for corrosion re-moval on any metals except low strength carbonsteels. They can severely damage softer metal al-loys such as aluminum and magnesium by leavingdeep gouges in them and cause fatigue problemsin high strength steel and aluminum alloys due tothe stress risers created by the deep scratches/gouges they leave on the surface.

Since they provide one of the fastest ways to remove corro-sion and underlying metal, rotary files should only be handledby an experienced structural repair technician. This tool is atungsten carbide cylinder or cone into which cutting edgeshave been machined. When installed in the chuck of a pneu-matic drill, rapid metal removal can be achieved.

5.5.3.8 3M Co. RolocTM Disc and Radial Disc Abra-sives.

Improper use of rotary files can rapidly damagealuminum structures by creating thin spots thatexceed established damage limits. Their use is au-thorized only for removal of severe intergranular

or exfoliation corrosion by qualified structural re-pair technicians. Do not use rotary files to removecorrosion from installed fasteners.

These tools are available in various grits and diameters tocover all corrosion removal requirements from initial grindout to final finishing/smoothing of the grind-out area. TheRolocTM discs consist of a spindle that screws into a discpad that receives a screw on type paper coated abrasive disc,a Scotch-BriteTM nylon mesh abrasive disc, or a plasticBristle DiscTM abrasive. These disc assemblies are mountedto either a straight or right angle type pneumatic drill toremove corrosion from all types of readily accessible metalsurfaces. The radial type plastic Bristle DiscTM is similar toa flap wheel and is mounted to an arbor either by itself or inmultiples with the assembly being installed in a straight typepneumatic drill to remove corrosion from all types of metalsurfaces, particularly in bores and recessed areas. To achievemaximum effectiveness with these discs, use at the specifiedRPM and never exceed the maximum RPM rating specifiedon the disc to prevent disintegration of the disc during useand either damage to equipment or injury to personnel.

5.5.4 Abrasive Blasting.

Abrasive blasting operations create airborne par-ticles which may be hazardous to the skin andeyes. A hood, gloves with gauntlets, and adequateventilation are required.

Figure 5-5. 3M Co. Inline Bristle Disc

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In abrasive blasting, abrasive media is propelled toward thework piece either with air pressure (conventional or vacuumblasting) or with water (wet blasting).

5.5.4.1 Conventional Equipment. Two types of equip-ment are used to propel dry abrasives, direct pressure feedand suction/venturi feed. In direct pressure equipment: theabrasive holding tank is a pressure vessel from which abra-sive media is forced, through a metering device, into thepressurized blast line to the blast nozzle. In suction/venturifeed equipment, the abrasive holding tank is unpressurizedand provides media, through a metering device, into a pass-ing air stream which then propels it through the blast hose tothe blast nozzle. Small blast cabinets known as glove boxes(refer to Figure 5-6, A), are built to accommodate small partsand have a recycle system which removes dust and lightparticle contaminants such as paint chips or corrosion prod-ucts. Blasting rooms, designed for large components, use arecycling and ventilating system. The operator works withinthe room, using a blast gun.

NOTE

Suction/venturi feed equipment requires highernozzle pressure than direct pressure equipment toobtain the required abrasive action. Pressures givenin Table 5-3 are for direct pressure equipment. Asa general rule, increase the nozzle pressure by 50%when using suction/venturi feed equipment.

5.5.4.1.1 Blast Media. A wide variety of materials invarious sizes (measured by mesh or grit size) are availablefor blasting applications. Only aluminum oxide per A-A-59316, Type I, Grades A or B and glass beads per AMS2431/6, Designation Nos. 15, 12, 9, and 6 (sizes 10-13) abra-sives are approved for use on aircraft, missiles, and theircomponents. Other media may be used on steel componentsof support equipment as designated in TO 35-1-3 and/or theequipment system specific maintenance manual.

5.5.4.1.2 Air Hoses. The nozzle pressure of a blast streamis affected by the length and inside diameter (ID) of the airhoses. It is best to use the shortest hose possible to preventexcessive pressure drop due to friction. If it is necessary tocouple lengths of hose, use quick disconnect external cou-plers.

5.5.4.1.3 Blast Nozzles. In general, larger nozzle sizesare preferable to smaller ones because more area can becleaned per hour with the same amount of labor. High effi-ciency, wear resistant nozzles (e.g. tungsten carbide) shouldbe used since they have a longer service life and direct theblasting particles more efficiently. Inspect nozzles periodi-cally for wear and discard them when the orifice is worn to adiameter which is 50% greater than the diameter when new.A worn nozzle, just as a larger nozzle, will require a largervolume of air flow from the compressor to sustain the neededpressure at the nozzle.

Table 5-3. Recommended Powered Abrasives for Corrosion Removal

Abrasive Blasting Parameters

AlloyFlap Brush, Abra-

sive Wheels1Abrasive Cloth/

Paper2 Media3 Pressure (PSI) Other ToolsAluminum

Alloys(Clad)

Aluminum oxideor silicon car-bide


Glass beads (Sizes10-13) or (AGB-15, 12, 9, or 6)

30-404 None

AluminumAlloys(Non-clad)




40-454 Rotary files(fine fluted)

MagnesiumAlloys




10-354 Rotary files(fine fluted)

Ferrous Met-als (otherthan Stain-less Steel)



Aluminum oxide(Type I, Grade A orB); Glass beads(Sizes 10-13) or(AGB-15, 12, 9, or6)

40-504 40-504 Rotary files,Wirewheels(steel orstainlesssteel)

Stainless Steeland Nickelalloys



5 Glass beads (Sizes10-13) or (AGB-15, 12, 9, or 6)

40-504 Wire wheels(stainlesssteel) Ro-tary files(fine fluted)

Copper Alloys DO NOT USE POWERED ABRASIVE METHODS DUE TO TOXICITY OF RESIDUE/PAR-TICLES GIVEN OFF - IN PARTICULAR FROM BERYLLIUM-COPPER ALLOYS.

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5-8

Table 5-3. Recommended Powered Abrasives for Corrosion Removal - Continued

Abrasive Blasting Parameters

AlloyFlap Brush, Abra-

sive Wheels1Abrasive Cloth/

Paper2 Media3 Pressure (PSI) Other Tools

Powered abrasive operations on titanium alloys can generate severe sparking. Keep area clear of all ignitable sub-stances when performing powered abrasive operations on titanium alloys.

Titanium Al-loys



Glass beads (Sizes10-13) or (AGB-15, 12, 9, or 6);Aluminum oxide(Type I, Grade A orB)

40-504 40-504 None

Plated andPhosphatedSurfaces

DO NOT USE POWERED ABRASIVE METHODS DUE TO TOXICITY OF RESIDUE/PAR-TICLES GIVEN OFF FROM MANY TYPES OF PLATING AND PROBABLE SEVEREDAMAGE TO VERY THIN PLATING FILMS.

1 This includes RolocTM type discs and in-line radial type Bristle DiscsTM.2 This includes RolocTM type discs.3 Media specifications: Glass beads - AMS 2431/6 aluminum oxide - A-A-59316.4 Indicated pressure is for direct pressure equipment. For suction/venturi equipment, use 50% higher pressure.5 Use only on heavily corroded parts prior to acid pickling and/or passivation.

5.5.4.1.4 Air Supply. Frictional losses in the hoses reducethe pressure at the nozzle and nozzle wear increases the vol-ume of air needed to maintain the desired nozzle pressure.To allow for nozzle wear, it is generally good practice to usea compressor with the capability of delivering at least 1 ½times the cubic feet per minute (CFM) of air required for anew nozzle to permit adjustments as the nozzle wears. Mois-ture and oil in the air stream gradually accumulates in theabrasive during blasting operations and will eventually causethe abrasive to clog the blaster. A water and oil separatormust be used in the compressed air supply line to preventthis problem.

5.5.4.2 Portable Vacuum Abrasive Blast Equipment.Also known as vacu-blasters or dry honing machines, thesedevices are portable machines designed to recover the abra-sive as it rebounds from the work piece. Vacu-blasters havean abrasive hopper, a reclaimer, a dust collector, a vacuumpump, and a blast gun which contains both a blast nozzleand a vacuum duct surrounding the nozzle for recovery ofthe media. (Refer to Figure 5-6, B). This equipment is usefulonly on flat or slightly curved surfaces so that the rebound-ing media can be collected by the vacuum duct surroundingthe blast nozzle. Refer to TO 35-1-3, the equipment opera-

tors manual, and systems specific maintenance manuals forthe aircraft, missile, or equipment being repaired for furtherinformation on the authorization and use of these machines.

5.5.4.3 Wet Abrasive Blasting Equipment. Wet abrasiveblasters use high pressure water as the medium for the deliv-ery of abrasives. This method is not as harmful to the basemetal as dry abrasive blasting due to the cushioning effect ofthe water medium. Unfortunately, this effect inhibits thespeed with which corrosion products are removed and thewater can be driven into joint areas and cause corrosion it-self. For these reasons, this method should not be used onaircraft or missiles. Wet abrasive blasters are useful for re-moving rust from steel surfaces of support equipment. Theabrasive material is normally not recoverable in wet blastingoperations, and only sand per A-A-59316, Types II or VI,Grades B or C, aluminum oxide per A-A-59316, Type I,Grades A or B, or glass beads per AMS 2431/6, DesignationNo. AGB-6 (Size 13) shall be used. A corrosion inhibitormust be added to the water or a temporary protective filmsuch as a Corrosion Preventive Compound (CPC) must beapplied to the blasted surface immediately after blasting toprevent rusting of the steel surface until the part can bepainted.

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Table 5-4. Recommended Non-Powered Abrasives for Corrosion Removal

AlloyNon-Woven

AbrasiveAbrasive Cloth/

Paper Metallic Wool Brushes OthersAluminum

AlloysAbrasive Mat Aluminum oxide,

Silicon carbideAluminum wool Stainless steel,

AluminumPumice paste, Carbide-

tipped scrapersMagnesium

AlloysAbrasive Mat Aluminum oxide,

Silicon carbideNone Stainless steel,

AluminumPumice paste, Carbide-

tipped scrapers

Figure 5-6. Abrasive Blasting Equipment

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Table 5-4. Recommended Non-Powered Abrasives for Corrosion Removal - Continued

AlloyNon-Woven

AbrasiveAbrasive Cloth/

Paper Metallic Wool Brushes OthersFerrous Met-

als (otherthan Stain-less Steel)

Abrasive Mat Aluminum oxide,Silicon carbide

Steel wool Carbon steel,Stainless steel

Carbide-tipped scrapers

StainlessSteel andNickel Al-loys

None Aluminum oxide,Silicon carbide

Stainless steelwool

Stainless steel,Aluminum

None

Copper Al-loys

None Aluminum oxide(400 grit), Sili-con carbide (400grit)

Copper wool Brass None

Titanium Al-loys


Stainless steelwool

Stainless steel,Aluminum

Pumice paste, Carbide-tipped scrapers

Cadmium orZinc Platedsurfaces


None None None

Chromium,Nickel, Tin,or CopperPlated Sur-faces


None Stainless steel,Aluminum

None

PhosphatedSurfaces

USE METHOD RECOMMENDED FOR BASE METAL

5.6 SURFACE FINISH.

All depressions resulting from corrosion removal shall beblended smoothly and evenly with the surrounding originalsurfaces. In critical and highly stressed areas, all pits remain-ing after removal of corrosion products, by any method, shallbe blended out to prevent stress risers which may becomestarting points for stress corrosion cracking and/or metal fa-tigue. On non-critical structures, it is not necessary to blendout pits remaining after removal of corrosion products sincethis can result in unnecessary metal removal. Always checkthe system specific aircraft, missile, or equipment mainte-nance/repair manuals for maximum allowable depth of de-pressions due to pitting or corrosion removal. The generalguidelines for shaping and blending corrosion grind outs areshown in Figure 5-7 through Figure 5-9. For additional in-formation on blend out procedures, refer to the system spe-cific aircraft, missile, or equipment maintenance manualsand/or contact the aircraft SPD or the missile or equipmentSPM.

5.7 PITTING ON CRITICAL STRUCTURE.

On critical structures having a large number of closely spacedpits, intervening material may be removed to minimize sur-face irregularity or waviness. The resulting depression shall

have no sharp corners and shall be saucer-shaped, whereverclearance permits, with its major axis running spanwise onwings and horizontal stabilizers, longitudinally on fuselages,and vertically on vertical stabilizers. (Refer to Figure 5-7).In areas where a true saucer shaped depression cannot beformed due to inadequate clearance, blend out a depressionas nearly as possible to that shape so that there are no abruptor sharp edges.

5.8 CORROSION REMOVAL PROCEDURES-ME-CHANICAL.

5.8.1 Warnings and Cautions. The following warningsand cautions shall be observed during corrosion removal op-erations.

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5-11


• Many materials such as copper alloys (espe-cially beryllium-copper, refer to Paragraph7.20), cadmium plate, chromate conversioncoatings, paints containing chromates, lead,barium, and strontium, and chemicals used forcorrosion removal are toxic. Use approved res-pirators, eye protection, and skin protection.Take proper safety precautions to avoid inhala-tion or ingestion of chemical fumes or liquidsand dust from corrosion products during corro-sion removal. Wash hands thoroughly beforeeating or smoking.

• All powered mechanical corrosion removal pro-cedures create airborne particles. Respiratorsand eye protection and adequate ventilation arerequired.

• It is essential that all blasting media and otherresidue be completely removed after abrasiveblasting operations. The blasting media can bevery slippery and can cause dangerous falls.

• Operators shall be adequately protected withcomplete face and head covering equipment,and provided with pure breathing air per re-quirements of AFI 91-203 and AFOSH Stan-dards 48-137 for all abrasive blasting opera-tions.

• Wear leather gloves when using metallic woolsto prevent hand injuries.

• Do not use abrasive flap brushes, wheels, discs,or wire brushes above their authorized RPMrating. These tools can fly apart causing seriousinjury.

• Abrasive blasting operations create extensiveairborne particles which may be hazardous tothe eyes, lungs, skin, etc. A hood, gloves withgauntlets, and respirator are required.

• Exercise caution when using sharp or pointedtools to prevent injury.

• Depleted uranium is extremely toxic and shallbe worked only under a license from theNuclear Regulatory Agency (NRA). Machiningor other work, such as surface sanding, may bedone only by the licensee. No drilling, sanding,abrasive blasting, or other mechanical work ispermitted on depleted uranium by any fieldlevel (organizational or intermediate) mainte-nance activity. If the protective finish (plating)which covers the depleted uranium is chipped,peeled, or otherwise removed so the dark grayor black uranium oxide is visible, the part mustbe returned to the licensee for rework or dis-posal. Packaging and shipping procedures shallconform to AFI 40-201 and any other relatedcurrent regulations for handling radioactivematerials.

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Figure 5-7. Shaping Reworked Areas

Figure 5-8. Acceptable Clean-Up of Pitting Corrosion on Critical Structure

TO 1-1-691

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5.8.1.2 Mechanical Damage.

• Use extreme care to ensure that blast mediadoes not contaminate hydraulic, fuel, oil, cool-ant, or oxygen systems. Blockages in flightcritical components caused by abrasive mediaparticles can result in loss of life and aircraft.

• Finely divided dried particles of many materi-als (metallic, organic, and inorganic) can formexplosive mixtures with air resulting in dustexplosion hazards. Use extreme care when dryabrasive blasting magnesium and titanium al-loys and provide adequate ventilation to pre-vent formation of explosive dust mixtures dur-ing all abrasive blasting operations.

• Abrasive blasting operations of these surfacesshall not be subjected to severe abrasive action.Do not use rotary files to remove corrosionfrom installed fasteners.

• Use only non-powered abrasive paper, cloth, ormat, powered flap brushes or wheels, or abra-sive blasting to remove corrosion from highsteels. Other power tools can cause local over-heating and/or formation of notches which cangenerate fatigue or stress corrosion crackingfailures. Refer to TO 4S-1-182 for additionalprocedures/restrictions to be used on aircraftlanding gear components.

• Dry abrasive blasting of titanium alloys andhigh strength steel crates sparking. Ensure thatthe abrasive blasting area is free of all flam-mable vapors and liquids.

• Do not use flap brushes down to within twoinches from the center of the hub. Continueduse beyond this limit may cause gouging due toloss of flexibility of the fiber. Follow directionof rotation as indicated by arrow imprinted onside surface of the core.

• Excessive pressure on flap brushes will causepolyurethane paint to melt, gum up, and streakaround the area being worked

• Protect areas adjacent to corrosion removal op-erations from chips, dust, and other debriswhich could produce dissimilar metal corrosionon previously uncorroded surfaces.

• Use only those materials recommended in Table5-3 and Table 5-4 to prevent dissimilar metalparticles from becoming embedded in surfacesand generating rapid galvanic corrosion.

• Be careful when removing corrosion from softplated surfaces (zinc, cadmium, etc.). Soft plat-ing is easily damaged or removed by mechani-cal methods.

5.8.2 Non-Powered Mechanical Corrosion Removal.This method is accomplished by abrading the corroded sur-face with hand held tools or abrasives to remove the corro-sion. It is normally used to remove surface corrosion andother forms of mild to moderate corrosion by scraping orwearing away the corrosion products along with a minoramount of base metal. The basic steps in this procedure areas follows:

Figure 5-9. Limited Clearance

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a. Determine whether all the corrosion can be removedwithout exceeding the allowable damage limits beforestarting the removal operation. If damage limits willbe exceeded, repair or replace the part per directions inthe applicable system specific aircraft, missile, orequipment maintenance manual or request dispositionfrom the aircraft SPD or the missile or equipment SPMif repair or replacement is not covered in the manuals.

b. Protect adjacent components and/or areas from scale,chips, corrosion products, and chemical agents. Masklap joints, hinges, faying surfaces, access doors, airscoops, and other openings which would allow chips,dust, or other debris to enter interior areas. Use barriermaterial/paper and masking tape.

(1) Clean the affected area to remove grease, oil, andsoils. (Refer to Chapter 3).

(2) Using materials in Table 5-4, remove all corro-sion using the mildest effective method. Deter-mine whether corrosion has been completely re-moved by inspecting with a 10X magnifier. (Referto Appendix B). If necessary, a more sensitiveevaluation can be made by using fluorescent pen-etrant in conjunction with the magnifier.

(3) When complete removal has been attained, blendor fair out the edges of the damaged areas usingfine abrasive paper or cloth. After all corrosionhas been removed, recheck to ensure that allow-able damage limits have not been exceeded

(4) Treat the surface in accordance with Section II ofthis chapter and apply protective coatings in ac-cordance with TO 1-1-8 and the applicable sys-tem specific maintenance manual.

5.8.3 Powered Mechanical Corrosion Removal. Pow-ered corrosion removal is generally done using pneumaticdrills with flap brush, rotary file, sanding pad, or abrasivewheel attachments. This method is normally used to removeheavy corrosion by wearing away the corrosion products.Part of the base metal is abraded away with the corrosionproducts using this procedure. The basic steps in corrosionremoval are as follows:

a. Determine whether all the corrosion can be removedwithout exceeding the allowable damage limits before

starting the removal operation. If damage limits willbe exceeded, repair or replace the part per directions inthe applicable system specific aircraft, missile, orequipment maintenance manual or request dispositionfrom the aircraft SPD or the missile or equipment SPMif repair or replacement is not covered in the manuals.

b. Protect adjacent components and/or areas from scale,chips, corrosion products, and chemical agents. Masklap joints, hinges, faying surfaces, access doors, airscoops, and other openings which would allow chips,dust, or other debris to enter interior areas. Use barriermaterial/paper and masking tape.

(1) Clean the affected area to remove grease, oil, andsoils. (Refer to Chapter 3).

(2) Using materials in Table 5-3, remove all corro-sion using the mildest effective method. Deter-mine whether corrosion has been completely re-moved by inspecting with a 10X magnifier. (Referto Appendix B). If necessary, a more sensitiveevaluation can be made by using fluorescent pen-etrant in conjunction with the magnifier.

(3) When complete removal has been attained, blendor fair out the edges of the damaged areas usingfine abrasive paper or cloth.

(4) After all corrosion has been removed, recheck toensure allowable damage limits have not been ex-ceeded.

(5) Treat the surface in accordance with Section II ofthis chapter and apply protective coatings in ac-cordance with TO 1-1-8 and the applicable sys-tem specific maintenance manual.

5.8.4 Abrasive Blasting Corrosion Removal. Before be-ginning abrasive blasting operations, ensure that all safetyprecautions listed in the warnings and cautions in Paragraph3.5.1.2 and Paragraph 5.8.1.2 are fully observed. Failure tocomply with these precautions may result in harm to person-nel and equipment.

5.8.4.1 Abrasive Blasting Procedures. The blasting op-eration should be accomplished in the following steps.

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PMB used for blasting ferrous metals shall not beused to blast non-ferrous metals (i.e. aluminum,magnesium, etc.). Abrasives used for cleaning fer-rous metals will retain many ferrous metal par-ticles which will contaminate any non-ferrousmetal and promote corrosion. It is recommendedthat separate PMB booths or cabinets be obtainedand labeled as “For Ferrous Only” and “Non-Fer-rous Only”.

NOTE

A log should be maintained for each PMB unit totrack media usage hours. Blast media used on air-craft and aircraft components shall be tested forcontamination or purged every 80 hours of equip-ment operation or after each aircraft or large pieceof aerospace equipment is blasted (whichever islonger). Blast media used on non-aerospace equip-ment such as SE shall be tested or purged every800 hours of equipment operation. Follow TO1-1-8, Paragraph 2.11.12 for contamination testingprocedures.

a. Inspect corroded areas and surfaces and decide whichones can be abrasively blasted and what techniqueswill be used. Clean any oil, grease, or other soils fromsurfaces with MIL-PRF-87937, Type IV, MIL-PRF-85570, Type II, or an approved cleaning solvent suchas A-A-59601, MIL-PRF-32295, Type II and/or MIL-PRF-680, per instructions in Chapter 3 of this manual.

(1) Blasting shall not be used in areas or under con-ditions that would allow any escaped abrasiveparticles to contaminate any system, engine, orother component.

(2) Examine all corroded areas for corrosion blisters.If intergranular and/or exfoliation corrosion ispresent, use other recommended mechanical re-moval methods. Abrasive blasting will not removethese types of corrosion effectively.

(3) Blasting shall not be performed on surfaces wherethere is a danger of warping or distorting the basematerial. Sheet metal, 0.0625 inch (16 gauge, U.S.Standard) or thinner, shall not be blasted. Consultthe applicable system specific aircraft, missile, orequipment manuals to determine metal type,thickness, and allowable metal removal limits forthe particular part.

b. Determine what areas need protection from the mediablast stream and entrapment of the media and mask orseal these areas. Composite surfaces and those requir-ing a very smooth surface finish (63 RMS or better),must be effectively protected from the media blast

stream. Use form fitting metal or wood shields, as re-quired, and an impact resistant tape such as 3M Co.,PN 510 or YR-500.

c. Statically ground the abrasive blast equipment and theaircraft, missile, or equipment to be blasted.

d. Blast corroded areas using the pressures and materialsgiven in Table 5-3. Do not attempt to use pressureshigher than those specified since higher air pressurestend to cause significant damage to components byrapidly removing too much surrounding metal alongwith the corrosion products. When cleaning non-fer-rous metal alloys (i.e. aluminum, magnesium, etc.,)never use media which has been used for cleaning fer-rous metals. Abrasives used for cleaning ferrous met-als will retain many ferrous metal particles which willcontaminate any non-ferrous metal being blasted. Re-fer to the applicable abrasive blasting equipment op-erator’s manual for specific operating instructions.

(1) Direct the blast stream at the surface from whichcorrosion is being removed to sweep across thesurface at an angle of 30° to 40° from the blastnozzle to the surface. Several short passes overthe corroded area with the blast nozzle are muchmore effective and less damaging to the surround-ing metal than dwelling on an area for an ex-tended period of time. Passes should start a fewinches before and end a few inches beyond thecorroded area being worked.

(2) Maintain the nozzle distance from the surface be-ing cleaned wherever the best cleaning is obtainedwithin the range of 2 inches minimum to 6 inchesmaximum.

(3) Continue blasting with short passes over the cor-roded area until a near-white metal surface is ob-tained. A near-white metal surface is a surfacefrom which all mill scale, rust, oxides, any othertypes of corrosion products, paint, and/or anyother foreign matter have been removed.

(4) On critical high strength aluminum and steel parts,it is necessary to fair out and smooth edges ofpits to reduce stress concentrations that generatemetal fatigue and/or stress corrosion crackingproblems. The most effective manner is to rotatethe blast nozzle around the outer edge of the pitkeeping the nozzle at a constant rate using sev-eral short passes over the corroded area.

e. Upon completion of blasting, inspect for the presenceof corrosion in the blasted area. It may be necessary touse fluorescent penetrant inspection in conjunction witha 10X magnifier. Pay particular attention to areas whereit is suspected that pitting has progressed into inter-granular attack because abrasive blasting has a ten-

TO 1-1-691

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dency to close up streaks of intergranular corrosionrather than remove them if the operator uses an im-proper impingement angle. If corrosion has not beenremoved in a total blasting time of 60 seconds on anyone specific area, other mechanical methods of removalshould be utilized.

NOTE

• Refer to the individual system specific aircraft,missile, or equipment maintenance manuals forlimits on metal removal. Do not exceed theselimits without engineering approval from theaircraft SPD or the missile or equipment SPM.

• Abrasive blasting will not remove intergranularand/or exfoliation corrosion from aluminum al-loys.

• Abrasive blasting shall be used on stainlesssteel (CRES) and nickel alloy parts only to re-move severe/heavy corrosion and prior to acidpickling and/or passivation.

f. Completely clean all residue from the surface and ex-posed areas using either a pneumatic or an electricwet/dry vacuum cleaner. The vacuum cleaner nozzleshall be plastic or covered with masking tape to pro-tect surfaces from mechanical damage. Clean the sur-face using materials and procedures in Chapter 3. Treatand protect all blasted areas as soon as possible afterblasting in accordance with the procedures in SectionII of this chapter.

5.9 CORROSION REMOVAL-CHEMICAL.

The following paragraphs discuss chemical removal proce-dures for use on aircraft, missile, and other equipment parts/components and assemblies. Each type of metal alloy re-quires specific chemicals for removal of the different typesof corrosion that are encountered on the metal alloy. Theauthorized chemical corrosion removal materials and proce-dures for their usage for each of the various metal alloysused on Air Force aircraft, missiles, and equipment is dis-cussed separately for each metal alloy.

5.9.1 Aluminum Alloys. These paragraphs outline chemi-cal corrosion removal procedures for aluminum alloy partsand assemblies of aircraft, missiles, and other equipment.Table 5-5 provides procedures for removal of specific typesof corrosion.

5.9.1.1 Preparation. Before starting chemical removal ofcorrosion products, perform the following procedures:

a. Clean all dirt, grease, oil, and other contamination fromsurfaces to be worked in accordance with Chapter 3.

b. Inspect the equipment to determine which area(s) areand should be treated with a chemical corrosion re-moval compound. If an aircraft is being prepared forcomplete painting or repainting, all cleaned bare alu-minum surfaces shall be treated.

• Protect all magnesium surfaces from contactwith SAE AMS-1640 (MIL-C-38334) corrosionremoval compound and treat later, as prescribedin this manual. Steel and cadmium plated partsshould also be protected from this compound,but protection of all steel and cadmium platedsteel fastener heads in large structures is im-practical and need not be done.

• Do not allow these chemical corrosion remov-ers to contact high strength steel. Hydrogenembrittlement may occur and cause a cata-strophic failure.

c. Mask all lap joints, hinges, faying surfaces, accessdoors, air scoops, and other openings that would allowthe corrosion removal compound to enter interior areasor crevices, or contact unprotected magnesium, steel,and cadmium plated parts. Mask with MIL-PRF-131,Class 1 water and vapor proof barrier material (plasticside toward the surface) and SAE AMS-T-23397, TypeII (MIL-T-23397, Type II) masking tape. 3M Co., PN425 tape is the most effective tape for extensive opera-tions, such as chemical corrosion removal and surfacepreparation on large structures such as aircraft exteri-ors during depot repaint operations.

5.9.1.2 Chemical Corrosion Removal Materials forAluminum Alloys. SAE AMS-1640 (MIL-C-38334, Type I)Corrosion Removal Compound for Aircraft Surfaces is theauthorized general chemical remover for removing corrosionproducts from aluminum alloys, in particular on larger areas.Limited area corrosion removal can also be accomplished byusing MIL-DTL-81706, Class 1A chemical conversion coat-

TO 1-1-691

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ing solution or Semco® PN Pasa-Jell 102 gel-type alumi-num corrosion remover in conjunction with A-A-58054, TypeI, Grade B or C abrasive mats.

5.9.1.2.1 SAE AMS-1640 (MIL-C-38334, Type I) Cor-rosion Removing Compound for Aircraft Surfaces.

SAE AMS-1640 (MIL-C-38334, Type I) andSemco® PN Pasa-Jell 102 are moderately toxicand MIL-DTL-81706, Class 1A is highly toxic toskin, eyes, and respiratory tract. Chemical orsplash proof goggles and/or face shields, andchemical resistant rubber gloves, and aprons arerequired. Good general ventilation is normallyadequate.

This material is a liquid concentrate material which shall bemixed with an equal volume of tap water before use; furtherdilution renders it ineffective. This material has a shelf lifeof one year from the date of manufacture, discard any of thematerial which has reached or exceeded its shelf life. SAEAMS-1640 (MIL-C-38334, Type I) is used as a generalchemical corrosion remover to remove surface and pittingcorrosion products from aluminum alloy surfaces. It is notLiquid Oxygen (LOX) compatible.

5.9.1.2.1.1 Application and Use. The procedure for ap-plication and use of SAE AMS-1640 (MIL-C-38334, Type I)materials is as follows:

a. After mixing properly, apply the solution by eitherflowing, mopping, sponging, brushing, wiping, orspraying with a non-atomizing sprayer onto the surfacebeing worked. For large areas, begin the application at

the lowest point and work upward while using a circu-lar motion to apply the solution to ensure proper cov-erage and to disturb the oxide film on the surface.

b. Allow the solution to dwell on the surface for 11 to 12minutes while vigorously agitating it on the surface atleast every 2 minutes with a non-metallic, acid resis-tant, bristle brush or an A-A-58054, Type I, Grade Bor C abrasive mat. Then rinse the surface thoroughlywith fresh water heated to a temperature of +120° to+140° F (+49° to +60° C). The solution is much moreeffective if it is also heated to a temperature of +120°to +140° F (+49° to +60° C) and applied while warm.For severe pitting, removal may be aided by lightlyagitating the pits by hand with a stainless steel (CRES)wire bristle brush with wire bristles having a maxi-mum diameter between 0.005 and 0.006 inch (5-6mils). Areas with moderate to heavy surface or pittingcorrosion may require additional applications.

c. After each solution application and rinse, examine thearea being worked, aided with a 10X magnifier forpitting, to determine if all corrosion products have beenremoved. If not, repeat this process a maximum ofthree more times. If corrosion products remain afterthe fourth application of this chemical remover, use anappropriate mechanical method described in this chap-ter to remove the remaining corrosion products.

NOTE

MIL-DTL-81706/MIL-DTL-5541, Class 1Achemical chromate conversion coating shall be ap-plied immediately after the final rinse when corro-sion removal is the last process of a rework opera-tion, or when the item or area will be painted.

Table 5-5. Typical Chemical Corrosion Removal Procedures for Aluminum Alloy Parts and Assemblies

Type of CorrosionStep 1

Corrosion Removal

Step 2Surface Treatment(When Applicable)

Step 3Final Protective Paint Finish

(When Applicable)Light or heavy pit-

ting or etching ofaluminum alloys(clad)

Remove corrosion withSAE AMS-1640 (MIL-C-38334, Type I) perParagraph 5.9.1.2.1.

MIL-DTL-81706/MIL-DTL-5541, Class 1A per Sec-tion II of this chapter.

See TO 1-1-8 and aircraft, mis-sile, or equipment systemspecific maintenance manu-als for paint system.

Light or heavy pit-ting or etching ofaluminum alloys(non-clad)

Remove corrosion withSAE AMS-1640 (MIL-C-38334, Type I) perParagraph 5.9.1.2.1 fol-lowed by appropriatemechanical methods inthis chapter, if neces-sary.

As above As above

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Table 5-5. Typical Chemical Corrosion Removal Procedures for Aluminum Alloy Parts and Assemblies- Continued


Corrosion Removal

Step 2Surface Treatment(When Applicable)

Step 3Final Protective Paint Finish

(When Applicable)Intergranular or exfo-

liation corrosion ofaluminum alloys

Not applicable. Removecorrosion by appropriatemechanical methods inthis chapter.

As above As above

Light or heavy pit-ting or etching onsmall aluminumalloy parts whichcan be removedfor treatment

Remove corrosion and/oroxide film by immersionin a SAE AMS-1640(MIL-C-38334, Type I)prepared per Paragraph5.9.1.2.1.

Immersion in MIL-DTL-81706, Class 1A solutionper Section II of thischapter.

As above

Stress corrosioncracking of alumi-num

Not applicable. Replace/repair, as required, inthe structural handbook

See step 1 See step 1

5.9.1.2.2 Semco® PN Pasa-Jell 102. This material is agel type chemical corrosion remover for use on aluminumalloys in limited areas, in particular where LOX compatibil-ity is required, to remove pitting and surface corrosion oretching/oxidation. Pasa-Jell 102 is a relatively strong acidmixture that can be detrimental to equipment or componentsif improperly used. Therefore, it shall be used only in smallareas and primarily where LOX compatibility is an essentialrequirement. Personnel must be properly trained and quali-fied to use this material for corrosion removal.

5.9.1.2.2.1 Application and Use.

Do not use aluminum or any type of steel wool toapply or agitate Semco® PN Pasa-Jell 102 or firewill result.

Excessive use of abrasive materials and Semco®PN Pasa-Jell 102 can cause removal of protectivecladding (Alclad) and/or excessive metal removal.

The procedure for application and use of Semco® PN Pasa-Jell 102 material is as follows:

a. Apply Pasa-Jell 102 with an acid brush. Agitate areasof deep pitting with an acid brush that has the bristlesshortened by cutting off half their length or an A-A-58054, Type I, Grade A or B abrasive mat until corro-sion products are removed. A thin, evenly dispersedfilm gives the best results. Keep the dwell time to theminimum necessary to effectively remove the corro-

sion products (5 to 12 minutes). Usually, dwell timecan be controlled by closely observing the reaction ofthe Pasa-Jell 102 mixture with the aluminum surfaceto which it is applied to determine when all corrosionproducts have been lifted from the surface.

b. After all the corrosion products have been freed fromthe surface or the maximum 12 minutes dwell time isreached, whichever is first, wipe off the Pasa-Jell 102and other residue with a clean, moist cloth followed byrinsing with a stream of fresh tap water applied with awash bottle or continue to wipe with a clean, moistcloth, frequently rinsed in fresh tap water.

c. Inspect the area being worked to determine if all cor-rosion has been removed giving particular attention topitted areas. Use a 10X magnifier to aid in examina-tion of questionable areas. Remaining corrosion willappear as a powdery crust, slightly different in colorthan the uncorroded base metal. One application ofPasa-Jell 102 is usually sufficient in most cases. How-ever, in severe cases, the preceding steps may have tobe repeated.

5.9.1.2.3 MIL-DTL-81706, Class 1A Chemical Chro-mate Conversion Coating Solutions. Limited area corro-sion removal from aluminum alloy surfaces while simultane-ously applying a chemical chromate conversion coating canbe accomplished by using a MIL-DTL-81706, Class 1A so-lution in conjunction with an A-A-58054, Type I, Grade Cabrasive mat. This material helps to clean an area by oxidiz-ing all organic soils on the aluminum alloy surface, whilethe abrasive mat acts to remove the corrosion products, andthen the solution forms a chemical chromate conversioncoating film on the aluminum alloy surface. If organic soilsare present, they will turn green upon application of the so-lution. The green residue and the solution contaminated with

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the residue should be wiped from the surface and discarded.Mix the MIL-DTL-81706, Class 1A solution in accordancewith the manufacturer’s instructions and Section II of thischapter. It is recommended that the technician practice onsome condemned components or parts prior to using thismaterial on serviceable aircraft, missile, or equipment alumi-num alloy parts.

5.9.1.2.3.1 Application of MIL-DTL-81706, Class 1ASolutions for Corrosion Removal.

MIL-DTL-81706, Class 1A chemical chromateconversion coating solutions are moderately toxicto the skin, eyes, and respiratory tract. Chemicalor splash proof goggles and chemical resistantrubber gloves are required. Good general ventila-tion is normally adequate.

MIL-DTL-81706, Class 1A solutions shall not beused on high strength steels (180 KSI or higher),due to the potential of hydrogen embrittlement.Also, they shall not be used on magnesium, tita-nium, or cadmium or zinc plated parts/surfaces asthey will damage and/or corrode these metals.

The procedures for application of these materials for corro-sion removal are the same as those cited in Section II of thischapter for the standard chemical chromate conversion coat-ing solutions, except as follows:

a. The small area requiring corrosion removal and sur-face treatment can be cleaned with the chemical chro-mate conversion coating solution instead of cleaning,rinsing, and drying per Chapter 3 before application ofthe solution.

b. Thoroughly wet or flood the area being worked withthe solution and keep it wet with solution until allphases of the process are completed and the final filmis formed to prevent streaking and/or powdering on thesurface.

c. Lightly abrade the surface while wet with the solutionusing a A-A-58054, Type I, Grade C abrasive mat.

d. If the solution turns green, continue to abrade the en-tire area until it is completely cleaned and then wipeall dirty solution from the surface with a sponge, whichshould leave a bright, shiny surface. If dark spots orlines are seen in the area which indicates the presenceof residual spots of moderate to severe corrosion, re-apply the solution and vigorously agitate the wettedarea with an abrasive mat as before. If the corrosion is

not completely removed after this second applicationof solution, remove the remaining corrosion using anappropriate mechanical method in this chapter. Aftercorrosion removal is complete and the dirty solution isremoved, reapply MIL-DTL-81706, Class 1A to forma MIL-DTL-5541, Class 1A film on the surface andallow the film to form in accordance with proceduresin Section II of this chapter for application of chemicalchromate conversion coatings to aluminum alloy sur-faces.

5.9.1.3 Application of Organic Coatings. Reapply theorganic coating system specified in the appropriate systemspecific maintenance manual and/or engineering drawing forthe aircraft, missile, or piece of equipment and TO 35-1-3for support equipment (SE) using TO 1-1-8 for applicationprocedures. Apply a MIL-DTL-5541, Class 1A chemicalchromate conversion coating using materials conforming toMIL-DTL-81706, Class 1A, if not already done, per SectionII of this chapter and paint within 48 hours after applicationof the conversion coating. Reapply the conversion coating inaccordance with Section II of this chapter if more than 48hours have elapsed since application of a conversion coating.

5.9.2 Magnesium Alloys. These paragraphs outlinechemical corrosion removal procedures for the removal ofcorrosion from magnesium alloy parts and assemblies of air-craft, missiles, or other equipment. Table 5-6 provides pro-cedures for the removal of specific types of corrosion. Re-movable parts can be treated more effectively by applyingone of the electrodeposition conversion coatings, such asType IV or VII, of SAE AMS-M-3171 (MIL-M-3171) aftercorrosion removal instead of the brush on Type VI coatingspecified for coating repair after corrosion removal fromsmall areas discussed here.

5.9.2.1 Preparation. Before starting chemical removal ofcorrosion products, remove paint from the area per TO 1-1-8and clean all grease, oil, and other contamination from sur-faces to be worked in accordance with Chapter 3 if immer-sion, spray, or vapor blast cleaning is not practical. If prac-tical, use one of the procedures for cleaning magnesiumalloys by immersion, spray, or vapor blast included in SAEAMS-M-3171 (MIL-M-3171).

5.9.2.2 Chemical Corrosion Removal Materials forMagnesium Alloys. Chromic acid pickle solution which is amixture of A-A-55827 chromic acid in water may be used toremove surface oxidation and light corrosion from magne-sium alloy surfaces. It is not adequate for removal of deeppitting, heavy corrosion, sand or other blast media residue,or the effects of blasting which will require use of one of themechanical methods described in this chapter. If properlyused, this chemical method removes much less metal caus-ing much less reduction of sectional thickness than mechani-cal methods, but it shall not be used on parts containingcopper or steel inserts unless they are completely maskedoff. Do not allow excessive amounts of anions such as chlo-rides, sulfates, or fluorides to build up in the solution, they

TO 1-1-691

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tend to coat or etch the metal surface rather than removingcorrosion products. Do not reuse old solutions, prepare freshsolutions for each separate removal operation.

5.9.2.2.1 Application and Use.

• Do not allow rags, brushes, abrasive mats, orany other item soaked with A-A-55827 chro-mic acid or the chromic acid pickle solutionprepared with it to come in contact with anyorganic solvent (MEK, acetone, paint thinner,A-A-59601/MIL-PRF-680 dry cleaning solvent,etc.,) or fire will result.

• A-A-55827 chromic acid and the chromic acidpickle solution prepared with it are highly toxicto the skin, eyes, and respiratory tract. Chemi-cal splash proof goggles and/or face shield,chemical resistant rubber gloves and apron arerequired. Good general ventilation is usuallyadequate. In case of eye or skin contact, flushwith water immediately and report to the basemedical facility.

The procedure for application and use of chrome pickle so-lution, a mixture of A-A-55827 chromic acid in water, is asfollows:

a. Mix 24 ounces of A-A-55827 chromium trioxide inenough water to make one gallon for each gallon ofsolution being prepared in a container fabricated fromlead lined steel (any alloy), stainless steel (any CRESalloy), or 1100 aluminum alloy. For depot level opera-tions only, a removable part that is being treated canbe completely immersed in the solution with an im-mersion time ranging from 1 to 15 minutes at an oper-ating temperature ranging from 190° to 202° F (88° to94° C). For hand application with the solution at roomtemperature, the dwell time for the solution on the sur-face is 15 minutes minimum to 30 minutes maximum.Step b through step d are for hand application. Step ethrough step g apply to both the immersion and handapplication methods.

b. Mask off the surrounding areas, in particular to includeall nearby operating mechanisms, joints, crevices, cop-per and/or steel inserts, and plated steel to keep thesolution from attacking them.

c. Apply the chromic acid pickle solution carefully to thecorroded area with an A-A-289 acid brush.

d. Allow the solution to remain on the surface for ap-proximately 15 minutes for a solution at room tem-perature. Agitate the area with an A-A-289 acid brushhaving half the bristle length cut off or an A-A-58054,Type I, Grade B or C abrasive mat.

e. Thoroughly rinse the solution from the surface withplenty of fresh tap water.

f. Repeat the preceding sequence, as necessary, until allcorrosion products have been removed and the metal isa bright metallic color.

g. Apply a SAE AMS-M-3171 (MIL-M-3171), Type VIchromic acid brush-on pretreatment coating to the areafrom which corrosion was removed in accordance withprocedures in Section II of this chapter for applicationof a brush-on chromic acid pretreatment coating tomagnesium alloy surfaces. If desired, parts that weretreated by complete immersion may receive one of theother coatings listed in SAE AMS-M-3171 (MIL-M-3171) for depot level operations.

5.9.2.3 Application of Organic Coatings. Reapply theorganic coating system specified in the appropriate systemspecific maintenance manual and/or engineering drawing forthe aircraft, missile, or piece of equipment and TO 35-1-3for support equipment (SE) using TO 1-1-8 for applicationprocedures. Apply the paint within 48 hours after applicationof the pretreatment coating. Reapply the pretreatment coat-ing in accordance with Section II of this chapter if more than48 hours have elapsed since application of the pretreatmentcoating.

5.9.3 Ferrous Metal (Steel) Alloys Other Than Stain-less Steels (CRES). These paragraphs outline chemicalcorrosion removal procedures for treating ferrous metal alloyparts and assemblies of aircraft, missiles, and other equip-ment. Use of chemical corrosion removers on steels is rec-ommended only for areas where there is no danger of entrap-ping the chemicals in crevices and/or recesses. Table 5-7provides procedures for the removal of specific types of cor-rosion.

5.9.3.1 Preparation. Before starting chemical removal ofcorrosion products, remove paint from the area per TO 1-1-8and clean all heavy deposits of grease, oil, and other con-taminants from the surfaces to be worked in accordance withChapter 3.

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Table 5-6. Typical Chemical Corrosion Removal Procedures for Magnesium Alloys

Type of Corrosion Step 1Corrosion Removal

Step 2Surface Treatment

Step 3Protective Finish

Light pitting or sur-face oxidation/etching

Remove corrosion withchromic acid pickle solu-tion per Paragraph5.9.2.2.

SAE AMS-M-3171 (MIL-M-3171),Type VI per Section II of thischapter

Approved paint systemper Paragraph 5.9.2.3

Heavy pitting oretching

Not applicable. Removecorrosion by an appropri-ate mechanical method inthis chapter.

As above As above

Intergranular orexfoliation

Not applicable. Removecorrosion by an appropri-ate mechanical method inthis chapter.

As above As above

Light or heavy cor-rosion on smallparts which canbe removed fortreatment

Remove corrosion in accor-dance with SAE AMS-M-3171 (MIL-M-3171).

As above As above

Stress corrosioncracking

Not applicable. Replace orrepair, as required, in thesystem specific structuralhandbook.

Not applicable Not applicable

5.9.3.2 Chemical Corrosion Removing Materials forFerrous Metal Alloys Other Than Stainless Steels(CRES). Chemical corrosion/rust removers for steels are oftwo types; the MIL-C-10578 acid type and the A-A-59260(MIL-C-14460) alkaline type.

5.9.3.2.1 MIL-C-10578 Corrosion Removing and MetalConditioning Compound (Phosphoric Acid Base). MIL-C-10578 covers six separate types of phosphoric acid basedcorrosion/rust removing compounds used to remove corro-sion/rust from ferrous metal surfaces. The following typesare available:

5.9.3.2.1.1 Type I (Wash-Off) and II (Wipe-Off). Type Iand II materials are suitable as rust removers for ferrousalloy metal parts. They may also be used as metal condition-ers for ferrous and nonferrous (zinc galvanized, cadmium,brass, and relatively pure aluminum or alclad) metals priorto the primer and paint application and/or as a corrosionpreventive to provide minor corrosion protection to thesemetals in an unpainted condition. Remove very heavy rustincrustations using an appropriate mechanical method listedin this chapter and heavy grease, oil, and other contamina-tion per Chapter 3 as directed by Paragraph 5.9.3.1 beforeapplication of these materials. Type I is a little more efficientin removing rust and grease than Type II. Type I materialsare applied by either spray, dip, flow-on, brush, rag, orsponge and are always rinsed off with water, preferably hot.Type II materials are applied by either brush, rag, or sponge

and do not have to be rinsed off with water, but are wiped offwith clean, damp rags followed by wiping with clean, dryrags prior to painting. Type II materials leave a light, gray-white coating/film on the surface that acts as a pretreatmentfor painting.

5.9.3.2.1.2 Type III (Inhibited). Type III materials are in-tended for corrosion/rust removal from chromium plated fer-rous alloy surfaces and those bare ferrous alloy surfaces re-quiring very close dimensional tolerances. Remove veryheavy rust incrustations by an appropriate mechanical methodin this chapter and heavy grease, oil, and contamination perChapter 3 as directed by Paragraph 5.9.3.1 or by vapordegreasing before application of these materials. Type IIImaterials are applied by either spray, dip, flow-on, brush orby full immersion in a tank containing the material. Parts areleft in the solution tank or the solution is left on the surfaceof the part until the rust is dissolved or loosened sufficientlyto permit easy removal, and then the residue is rinsed off thesurface with fresh, tap water, preferably hot, and the part isdried. It is then ready for application of the required corro-sion preventive treatment or paint system application.

5.9.3.2.1.3 Type IV (Non-Foaming). Type IV materialsare very similar to Type I, except that non-foaming deter-gents are included in the mixture. It is intended for use inpressurized spray systems at temperatures up to 150° F (66°C) maximum, after which it is rinsed off with fresh, tap wa-ter.

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5.9.3.2.1.4 Type V (Immersion Tank). Type V materialsare also very similar to Type I, except no grease removingsolvents are used in these materials, so they are only suitablefor use on surfaces from which all grease, oil, and contami-nation have been completely removed by cleaning per Chap-ter 3 as directed by Paragraph 5.9.3.1. It is intended for usein immersion tanks either at ambient (room) temperatures orat temperatures up to 140° F (60° C) maximum.

5.9.3.2.1.5 Type VI (Brush, Spray, or Dip). Type VI ma-terials are surface pretreatments and/or rust converters forapplication on either newly sand blasted or corroded/rustysteel surfaces by spray, brush, or dipping. All old grease, oil,and dirt must be removed as well as all loose and scaly rustbefore applying these materials. After application, they areallowed to dwell on the surface for a minimum of 6 hours toform a pretreatment coating on uncorroded ferrous alloys orto convert the rust on a corroded ferrous surface to a protec-tive, pretreatment film. After a dwell time of 6 hours, theexcess materials are rinsed off, the surface is allowed to airdry, and then the surface can be primed and painted or treatedwith a CPC.

5.9.3.2.2 Application and Use of MIL-C-10578 Corro-sion Removing Compounds.

• Phosphoric acid corrosion removal compoundsare toxic to the skin, eyes, and respiratory tract.Chemical splash proof goggles and rubbergloves and aprons are required. Use only in awell ventilated area. In case of eye or skin con-tact, flush immediately with water and report tothe Base Medical Facility.

• When mixing, always add the phosphoric acidcorrosion remover to the water. Do not add thewater to the acid, since this causes excessiveheat to be generated.

• High strength steel parts, those heat-treatedabove Rockwell C40 (180,000 PSI) tensilestrength, are subject to hydrogen embrittlementwhen exposed to acids, therefore, use of acidrust/corrosion removers on these parts is pro-hibited.

• Do not use acidic rust/corrosion removers ifthere is a danger of entrapping the materials increvices or recesses, as they can cause corro-sion in these areas.

5.9.3.2.2.1 Application and Use of Type I (Wash-Off).The directions for application and use of these materials areas follows:

a. Add one part of the concentrated material as receivedto three parts of water by volume. Use either a stain-less steel, aluminum, vinyl, polyethylene, or rubbermixing container.

b. Remove heavy grease, oil, and contamination perChapter 3 and heavy rust using an appropriate me-chanical method in this chapter before applying thechemical removal compound.

c. Protect adjacent components by masking to preventdamage by scale, chips, corrosion products, or chemi-cals.

d. Apply the solution to the surfaces to be treated by ei-ther non-atomized spray, dip, flow-on, or brush. Allowthe material to remain only long enough to wet thesurface and cause etching. On rusted surfaces, allowthe solution to dwell on the surface long enough toloosen the rust (2 to 10 minutes, depending on thedegree of rusting) while agitating the surface with anA-A-58054, Type I, Grade C abrasive mat or a handheld stainless steel (CRES) brush.

e. Rinse the surface with fresh tap water, preferably hot(120° -140° F/49° -60° C). Allow the surface to drythoroughly prior to application of a rust/CPC or a re-quired paint system.

5.9.3.2.2.2 Application and Use of Type II (Wipe-Off).The directions for application and use of these materials areas follows:

a. Add one part of the concentrated material as receivedto three parts of water by volume. Use the same typeof mixing containers specified in Paragraph 5.9.2.2.1,step a.

b. Remove heavy grease, oil, and contamination perChapter 3 and heavy rust using an appropriate me-chanical method in this chapter before applying thechemical removal compound.

c. Protect adjacent components by masking to preventdamage by scale, chips, corrosion products, or chemi-cals.

d. Apply the solution to the surfaces to be treated by ei-ther brush, rag, or sponge. Allow the compound todwell on the surface for about 30 seconds.

e. Wipe off residue first with damp rags followed withdry rags leaving no more than a light gray-white coat-ing film on the surface. Allow the surface to dry thor-oughly prior to applying the required paint system.

5.9.3.2.2.3 Application and Use of Type III (Inhibited).The directions for application and use of these materials areas follows:

TO 1-1-691

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a. Follow these procedures for non-atomized spray, flow-on, and brush applied operations with Type III materi-als.

(1) Add one part of the concentrated material, as re-ceived, to one part of water by volume. Use thesame type of mixing containers specified in Para-graph 5.9.2.2.1, step a.

(2) Remove grease, oil, and contamination per Chap-ter 3 and heavy rust using an appropriate me-chanical method in this chapter prior to applyingthe chemical removal compound.

(3) Protect adjacent components by masking to pre-vent damage by scale, chips, corrosion products,or chemicals.

(4) Apply the solution to the surfaces to be treated bynon-atomized spray, flow-on, or brush. Allow theconditioner to dwell on the surfaces long enoughto loosen and/or dissolve the rust, and then rinseoff all residue with fresh, hot, tap water (120°-140° F/49° -60° C).

(5) Allow the surface to thoroughly dry, and then ei-ther apply a CPC or a required paint system, orplace the part directly into service, whichever isdirected by the system specific maintenance tech-nical data for the equipment involved.

Heated dip tanks shall be properly ventilated andventilation shall be evaluated by the Bioenviron-mental Engineer prior to initial use.

b. Follow these procedures for dip tank operations withType III materials.

(1) Stainless steel (CRES) tanks are preferred for usewith this method. Mix the material, as specified,for non-atomized spray, flow-on, and brush appli-cations, but mix it in the stainless steel (CRES)dip tank.

(2) Immerse the part in the solution only long enoughto loosen the rust. For heavy rust removal, thesolution can be heated to 140° F (60° C) maxi-mum.

(3) Agitate the part in the solution to increase therust removal rate. Rinse in a continuously over-flowing fresh, cold, tap water rinse tank, if avail-able, or spray with fresh, hot, tap water (120°

-140° F/49° -60° C). Thoroughly dry the partsand immediately apply the required paint systemor CPC or place the part directly into service,whichever is directed by the system specific main-tenance technical data for the equipment involved.

5.9.3.2.2.4 Application and Use of Type IV (Non-Foaming). The directions for application and use of thesematerials are as follows:

a. Add one part of the concentrated material as receivedto three parts of water by volume. Use the same typeof mixing containers as specified in Paragraph5.9.3.2.2.1, step a.

b. Remove all heavy grease, oil, and contamination perChapter 3 and heavy rust using an appropriate me-chanical method in this chapter prior to applying thechemical removal compound.

c. Apply the solution to the surface being treated by non-atomized, pressurized spray. To increase the rust re-moval rate, the solution may be heated up to a tem-perature of 150° F (66° C).

d. Rinse with fresh, tap water, preferably hot (120° -140°F/49° -60° C).

e. Allow the part to thoroughly dry prior to application ofa rust/CPC or a required paint system.

5.9.3.2.2.5 Application and Use of Type V (ImmersionTank). The directions for application and use of these mate-rials are as follows:

a. Add one part of the concentrated material as receivedto three parts of water by volume. Use the same typeof mixing containers as specified in Paragraph5.9.3.2.2.1, step a and pour the solution into a stainlesssteel (CRES) immersion tank or mix the solution di-rectly in the immersion tank.

b. This material contains no solvents to assist in cleaning,so all heavy grease, oil, and contamination must bethoroughly removed per Chapter 3 or immersion in analkali bath prior to immersing a part in the corrosionremoval solution. Remove heavy rust with an appro-priate mechanical method in this chapter also prior toimmersion of the part in the chemical removal com-pound.

c. Submerge the part being treated in the chemical re-moval compound just long enough to loosen the rust.For heavy rust removal, the solution can be heated to atemperature of 140° F (60° C).

TO 1-1-691

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d. After immersion, rinse all metal surfaces thoroughlywith fresh, tap water, or immerse the part in an alkalisolution followed by rinsing with fresh, tap water.

e. Allow the part to thoroughly dry prior to applying aCPC or a required paint system.

5.9.3.2.2.6 Application and Use of Type VI (Brush,Spray, or Dip). The directions for application and use ofthese materials are as follows:

a. Add one part of the concentrated material as receivedto three parts of water by volume. Use the same typeof mixing containers specified in Paragraph 5.9.2.2.1,step a. This material is also available mixed in a pentype applicator for direct application to the surface.

b. Remove all heavy grease, oil, and contamination perChapter 3 and heavy rust using an appropriate me-chanical method in this chapter prior to applying thechemical removal compound.

c. Apply the solution to the surface being treated bybrush, any sprayer that will accommodate acid solu-tions, dipping the part in the solution, or with the penapplicator.

d. Allow the material to dwell on the surface and reactwith the metal and convert the rust to a protective filmfor 6-24 hours for brush and spray applications. Fordip applications, allow the part to remain in the solu-tion for 1-5 hours, and then remove it from the solu-tion, and allow the material to dwell on the part sur-faces for an additional 6-24 hours.

e. After the dwell time is completed, rinse all excess/unreacted material off all part surfaces with fresh, run-ning, tap water for at least 30 seconds.

f. Allow the part to thoroughly dry prior to applying aCPC or a required paint system.

5.9.3.2.3 A-A-59260 (MIL-C-14460, Type I) CorrosionRemoving Compound, Sodium Hydroxide Base; forElectrolytic or Immersion Application. This is a highly al-kaline chemical corrosion/rust removing compound suitablefor rust removal by immersion of the parts in the solution. Itdoesn’t cause dimensional change of critical or machinedsurfaces and it is safe to use on high strength steels as it will

not cause hydrogen embrittlement. It can be used on smallparts with or without paint, grease, or other surface coatings.

5.9.3.2.4 Application and Use of A-A-59260 (MIL-C-14460, Type I) Corrosion Removing Compounds. Thedirections for application and use of these materials are asfollows:

• A-A-59260 (MIL-C-14460, Type 1) corrosion/rust removing compound is a sodium hydrox-ide solution and therefore, highly alkaline. It istoxic to the skin, eyes, and respiratory tract.Chemical splash proof goggles and/or faceshields and chemical resistant rubber glovesand aprons are required. Heated dip tanks shallbe properly ventilated and ventilation shall beevaluated by the Bioenvironmental Engineerprior to their initial use.

• When preparing/mixing this highly alkaline so-lution, never pour water onto the sodium hy-droxide granules or flakes, this will generate anexcessive amount of heat. Always pour the so-dium hydroxide granules/flakes into the water.

a. Prepare/mix this alkaline corrosion/rust remover solu-tion per the manufacturer’s instructions printed on thecontainer to obtain a solution concentration of fivepounds of sodium hydroxide granules or flakes pergallon of water. Use either carbon steel or stainlesssteel (CRES) tanks to contain the solution.

b. Immerse the parts in the corrosion/rust remover solu-tion. Rust removal time varies with the extent of therust. At room temperature, rust removal is very slow,and a long soak time is required. This solution is mosteffective if the temperatures of the solution is broughtup to the point of a rolling boil which increases therate of the corrosion/rust removal significantly.

c. Rinse the parts thoroughly in fresh, tap water (prefer-ably hot -120° -140° F/49° -60° C).

d. Dry the parts thoroughly and immediately apply a CPCor a required paint system.

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Table 5-7. Typical Chemical Corrosion Removal Procedures for Ferrous Metals Other Than Stain-less Steel (CRES)

Type of Corrosion Corrosion RemovalLight or heavy rust on installed parts where

chemical rust removal is practical.Remove very heavy corrosion by wire brushing, sanding, or

other appropriate mechanical method in this chapter fol-lowed by phosphoric acid etch with MIL-C-10578, Type I,II, IV, or VI materials. (Refer to Paragraph 5.9.3.2.2.1, Para-graph 5.9.3.2.2.2, Paragraph 5.9.3.2.2.4, and Paragraph5.9.3.2.2.6). Do not use phosphoric acid etch on highstrength steel.

Light or heavy rust on small parts where vattreatment is practical.

Acid Method: Remove corrosion by immersing parts in MIL-C-10578, Type III, V, or VI phosphoric acid solution. (Referto Paragraph 5.9.3.2.2.3, Paragraph 5.9.3.2.2.5, and Para-graph 5.9.3.2.2.6). Do not use phosphoric acid on highstrength steel.

Alkaline Method: (Recommended for critical or mechanicalsurfaces). Remove corrosion by immersing parts in A-A-59260 (MIL-C-14460, Type I) alkaline solution. (Refer toParagraph 5.9.3.2.4).

5.9.3.3 Application of Organic Coatings. Reapply theorganic coating system specified in the appropriate systemspecific maintenance manual and/or engineering drawing forthe aircraft, missile, or piece of equipment and TO 35-1-3for support equipment (SE) using TO 1-1-8 for applicationprocedures. Apply the paint system, when required, within 4hours after completion of the corrosion removal procedure toprevent surface rusting from occurring. As a minimum, aprimer should be applied within this time frame.

5.9.4 Stainless Steel (CRES) and Nickel Based Alloys.These paragraphs outline chemical corrosion removal proce-dures for stainless steel (CRES) and nickel based alloy partsand assemblies. Table 5-8 provides procedures for removingspecific types of corrosion. Chemical corrosion removal isrecommended for severely corroded areas only when there isno danger of entrapping chemicals in recesses, cavities, or

joint areas or damaging surrounding metals and plating. Usethese chemical procedures on installed components whichare not readily removable. When internal corrosion is evi-dent, affected components shall be removed and processedthrough an overhaul facility in accordance with system spe-cific maintenance manuals for the specific aircraft, missile,or piece of equipment.

5.9.4.1 Preparation. If the corroded area is contaminatedwith grease, oil, dirt, or any other foreign material, clean thearea per Chapter 3.

a. Protect adjacent unaffected areas not being treated bymasking to prevent damaging them with the chemicalsused.

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• A-A-59601, MIL-PRF-32295, Type II andMIL-PRF-680, dry cleaning and degreasing sol-vents are toxic to the skin, eyes, and respiratorytract. Skin and eye protection are required.Avoid repeated or prolonged skin contact or in-halation. Good general ventilation is normallyadequate.

• When using metallic wools, wear leather glovesand exercise care to prevent injury to hands andfingers.

• Take care to prevent solvents from splashing orrunning because they can damage paints andelastomers (e.g., rubbers, plastics).

• Take care to protect surrounding unaffected ar-eas next to the area being treated by preventingleakage of chemicals into recesses or inacces-sible areas in the structure which can cause ad-ditional damage from corrosion attack.

b. Remove all loose corrosion by abrading the surfacewith either A-A-1043, Type IV, Class 1 stainless steelwool, 240 grit ANSI B74.18 (A-A-1047) silicon car-bide abrasive paper or ANSI B74.18 (A-A-1200) sili-con carbide abrasive cloth, 240 grit ANSI B74.18 (A-A-1048) aluminum oxide abrasive paper or cloth, orA-A-58054, Type I, Grade C abrasive mat. Remove allloose particles by wiping the surface with a clean clothdampened with A-A-59601, MIL-PRF-32295, Type IIor MIL-PRF-680, dry cleaning and degreasing solvent.

5.9.4.2 Chemical Corrosion Removing Materials forStainless Steel (CRES) and Nickel Based Alloys. Thereare three types of chemicals used for corrosion removal fromstainless steels (CRES) and nickel based alloys, Semco® PNPasa-Jell 101 mineral acid, gel type material, MIL-C-10578,Type III inhibited phosphoric acid based solution, and acidpickling solutions consisting of a mixture of A-A-59105 (O-N-350) nitric acid, MIL-A-24641 hydrofluoric acid, and wa-ter.

5.9.4.2.1 Semco® PN Pasa-Jell 101. This is a mineralacid, gel type material used for chemical corrosion removalfrom assembled aircraft, missile, and equipment structures inareas involving LOX storage and gaseous oxygen transfersystems and other areas where a gel type material is neces-sary and/or preferred.

5.9.4.2.1.1 Application and Use of Semco® PN Pasa-Jell 101.

• Do not use aluminum or steel wool to agitateSemco® PN Pasa-Jell 101, as a combustiblereaction will occur.

• Semco® PN Pasa-Jell 101 contains strong ac-ids and is toxic to the skin, eyes, and respira-tory tract. Chemical splash proof goggles and/orface shield and chemical resistant rubber glovesand aprons are required. Avoid inhaling fumesand use only in a well ventilated area.

The directions for the application and use of this material areas follows:

a. Prepare the area per the procedures outlined in Para-graph 5.9.4.1.

b. Apply the Semco® PN Pasa-Jell 101 material to thearea being worked with an acid brush and in accor-dance with the manufacturer’s instructions.

c. To remove light to medium corrosion, agitate the areawith an acid brush having half the bristle length cutoff, if necessary. To remove heavy corrosion where pit-ting is present, agitate the area with an A-A-58054,Type I, Grade C abrasive mat until all corrosion em-bedded in pits and on the surface is removed. Allowthe material to dwell on the surface only long enoughto loosen and/or dislodge all the corrosion products.

d. Remove the Semco® PN Pasa-Jell 101 material andcorrosion products from the surface with a clean, lintfree cloth frequently rinsed in fresh tap water.

e. For a final wipe, use a clean, lint free dry cloth. Afterdrying, either apply a CPC or a required paint system,or place the part directly into service, whatever is di-rected by the system specific maintenance technicaldata for the equipment involved. Usually, stainless steel(CRES) and nickel based alloy parts do not requirepainting.

5.9.4.2.2 MIL-C-10578, Type III Corrosion Removingand Metal Conditioning Compound (Phosphoric AcidBase)/Inhibited. This is a phosphoric acid based materialthat can be used to remove corrosion from assembled air-craft, missile, and equipment structures in areas that do notcontain oxygen systems and where a liquid material is ac-ceptable.

5.9.4.2.2.1 Application and Use of MIL-C-10578, TypeIII. The directions for the application and use of this materialare as follows:

TO 1-1-691

Change 5 5-27


b. Protect adjacent components by masking to preventdamage by scale, chips, corrosion products, or chemi-cals.

c. Add one part of the concentrated material, as received,to one part of water by volume. Use either a stainlesssteel, aluminum, vinyl, polyethylene, or rubber mixingcontainer.

d. Apply the solution to the surfaces to be treated by non-atomized spray, flow-on, or brush. Allow the condi-tioner to dwell on the surfaces long enough to loosenand/or dissolve the corrosion/rust, and then rinse off allresidue with fresh, hot tap water (120° -140° F/49°-60° C).

e. Allow the surface to thoroughly dry and then eitherapply a CPC or a required paint system, or place thepart directly into service, whatever is directed by thesystem specific maintenance technical data for theequipment involved. Usually, stainless steel (CRES)and nickel based alloy parts do not require painting.

5.9.4.2.3 Acid Pickling for Corrosion Removal. (FORDEPOT AND OTHER AUTHORIZED FACILITY USEONLY). Acid pickling solutions consisting of a mixture ofA-A-59105 (O-N-350) nitric acid, MIL-A-24641 hydroflu-oric acid, and water are used to remove corrosion/rust fromremoved stainless steel (CRES) and nickel based alloy partsthat can be immersed in the solution.

Table 5-8. Typical Chemical Corrosion Removal Procedures for Stainless Steel (CRES) and Nickel Based Al-loys


Corrosion RemovalStep 2

Surface TreatmentStep 3

Protective FinishLight to heavy corro-

sion/rust to includepitting on installedparts where liquidchemical corrosion/rust removal isimpractical becauseof location involv-ing LOX storageor gaseous oxygentransfer equipment,complexity of thestructure, or rins-ing difficulties.

Remove very heavy corrosion/rust first with stainless steelwool or wire brush, rotary file,or other mechanical means inthis chapter followed by appli-cation of Semco® PN Pasa-Jell101. (Refer to Paragraph5.9.4.2.1.1).

None Normally not required (referto Paragraph 5.9.4.3), fordiscussion of paint systems.

As above, when liq-uid chemical corro-sion/rust removalis practical.

Remove very heavy corrosion/rust as above first, followed byapplication of MIL-C-10578,Type III solution. (Refer toParagraph 5.9.4.2.2.1).

None As Above

Light to heavy corro-sion to includepitting on partswhich can be re-moved for process-ing.

Remove very heavy corrosion/rust as above first followed byimmersion in the nitric-hydro-fluoric-acid pickling solution.(Refer to Paragraph5.9.4.2.3.1).

Passivate in accor-dance withAMS2700, Type II,VI, VII, or VIII asapplicable to thetype of stainlesssteel (CRES) alloybeing treated.

As Above

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5-28 Change 3

5.9.4.2.3.1 Pickling Solution Concentration.

Scale loosening, pickling, and passivating solu-tions are all strong acids which are toxic to theskin, eyes, and respiratory tract. Chemical splashproof goggles and/or face shield and chemical re-sistant rubber gloves and aprons are required. Incase of eye or skin contact, flush immediately withwater and report to the Base Medical Facility.Avoid inhaling fumes and provide adequate venti-lation. Solution tanks shall be properly ventilatedwith a lateral exhaust type ventilation system. Theventilation system and procedure shall be properlyevaluated by the Bioenvironmental Engineer priorto initial use.

• Heat-treatable stainless steel alloys, such asAISI types 403, 410, 420, and others, are sus-ceptible to cracking when placed in picklingsolutions. Use only mechanical methods to re-move corrosion from these alloys.

• When preparing pickling solutions, never pourwater into the acids as excessive heat will begenerated. Always pour the acids into the wa-ter.

• Rubber lined or Koroseal tanks shall be used tohold these solutions because they are so highlyacidic.

Pickling solutions are prepared by mixing various amountsof A-A-59105 (O-N-350) nitric acid and MIL-A-24641 hy-drofluoric acid in water with the correct content of the twoacids for a given corrosion removal job being determined bythe testing procedure outlined below. The nitric acid contentmay vary from 5 to 50% by volume, while the hydrofluoricacid content may vary from 0.5 to 5% by volume. A solutionof 12 to 15% nitric acid by volume and 1% hydrofluoric acidby volume in water is normally used to remove light scaleand/or corrosion/rust. Increase the percentage of hydroflu-oric acid within the range specified above to remove heavierscale and/or corrosion/rust. As the amount of nitric acid in-creases with respect to the amount of hydrofluoric acid in thesolution, the rate of corrosion/rust and/or scale removal de-creases, because nitric acid inhibits the action of hydroflu-oric acid.

5.9.4.2.3.2 Pickling Solution Temperature. The tem-perature of the pickling solution may be adjusted from am-bient (room) temperature up to a maximum of 140º F (60ºC). Higher temperatures shall be avoided to reduce evapora-

tion loss of hydrofluoric acid. Use temperatures below 120ºF (49º C) if intergranular attack is experienced in localizedareas, such as weld zones.

NOTE

AISI 300-Series stainless steel (CRES) alloy tub-ing may be used to manufacture steam coils toheat the solution. The heating coils should be in-stalled so that they are easily replaced, since theywill be corroded by the solution over time.

5.9.4.2.3.3 Testing for Optimum Pickling Conditions.Optimum pickling conditions (temperature, time, and acidconcentration), shall be determined by exposing test panelsto various combinations of these parameters and processingthem through the entire cleaning and corrosion removal/pickling cycle. Excessive etching and/or intergranular attackof the base metal indicates conditions are too aggressive andslow removal rates indicate conditions are not aggressiveenough.

a. Make four inch square test panels from the same ma-terial from which the parts that will be treated aremade. Process these test panels through the completecleaning and corrosion removal/pickling cycle.

b. If etching or intergranular attack is excessive (i.e.,would cause the component to be condemned), or ifcorrosion removal is not complete, adjust the acid con-centration, immersion time, and/or solution tempera-ture until the desired result is obtained. Table 5-9 showsthe effect that varying the parameters of acid concen-tration, immersion time, and/or solution temperaturehas on the corrosion removal/pickling action of the so-lution.

5.9.4.2.3.4 Application and Use of Acid Pickling Solu-tions for Corrosion Removal. The directions for the appli-cation and use of nitric-acid-hydrofluoric acid solutions forcorrosion removal are as follows:

a. Clean parts to be treated per procedures in Chapter 3.

b. If severe scale is present, remove it by one of the fol-lowing methods:

(1) Remove scale using an appropriate mechanicalmethod in this chapter.

(2) Remove scale using this chemical method.

(a) Immerse parts in a solution of 8 to 10% byweight A-A-55828 (O-S-809) sulfuric acidand water at a temperature of 150° to 160° F(66° to 71° C) for about 5 minutes. If re-quired, scrub the surface of the parts with a

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stainless steel (CRES) wire brush to removeany sludge formed in the area having severescale.

(b) Repeat the above process, if required, andthen quickly rinse the parts thoroughly infresh, hot tap water at a temperature of 120°to 130° F (49° to 54° C).

c. Prepare the pickling solution by mixing the properproportions of A-A-59105 (O-N-350) nitric acid andMIL-A-24641 hydrofluoric acid in fresh tap water. Asa starting point, a typical pickling solution consists of15% nitric acid by volume and 2 to 3% hydrofluoricacid by volume in water. Make adjustments as deter-mined by results of the testing in Paragraph 5.9.4.2.3.3.

d. Immerse parts in the typical pickling solution at a tem-perature of 60° to 140° F (16° to 60° C) for a period of5 to 15 minutes. Make adjustments to the solution tem-perature and immersion time as determined by the re-sults of the testing in Paragraph 5.9.4.2.3.3. If required,scrub the surface of the parts with a stainless steel(CRES) wire brush to loosen and remove all corrosionproducts.

NOTE

• Ensure that the parts are completely immersedin these solutions to prevent corrosive attack ofthe part at the liquid level line.

• New welds should be mechanically vibrated oragitated during the pickling operation.

e. Immediately after removing the parts from the picklingsolution, thoroughly rinse the parts with fresh, hot tapwater at a temperature of 120° to 130° F (49° to 54°C).

5.9.4.3 Passivation of Stainless Steel (CRES) AlloyParts. After corrosion removal is completed on removedstainless steel (CRES) parts, passivate the surfaces of theseparts as follows:

a. Prepare a passivating solution in accordance withAMS2700 either Type II, VI, VII, or VIII as applicableto the stainless steel (CRES) alloy of the part to bepassivated.

Table 5-9. Control of Corrosion Removal/Pickling Action of Nitric-Acid-Hydrofluoric Solutions

Action is More Aggressive Action is Less Aggressive1. When the nitric acid content is decreased and/or the

hydrofluoric acid content is increased.1. When the nitric acid content is increased and/or the hydroflu-

oric acid content is decreased.2. When the temperature is increased. 2. When the temperature is decreased.3. When immersion time is increased. 3. When immersion time is decreased.

b. Immerse the part in the passivating solution held withinthe temperature range and for the time interval speci-fied in AMS2700.

c. Remove the parts from the passivating solution andthoroughly rinse with fresh, hot tap water at a tempera-ture of 120° to 130° F (49° to 54° C). As required byAMS2700, immerse all ferritic and/or martensitic stain-less steel (CRES) alloy parts in a 4 to 6% by weightsolution of A-A-59123 (O-S-595) sodium dichromatein water at a temperature of 140° to 160° F (60° to 71°C) for 30 minutes.

d. Remove the parts from the sodium dichromate solu-tion. Rinse thoroughly with fresh tap water and dry.Place the parts directly in service or in the supply sys-tem unless painting is required by system specifictechnical data.

5.9.4.4 Application of Organic Coatings. Stainless steels(CRES) and nickel based alloys are normally not painted.However, where extreme corrosive conditions are encoun-tered, where organic finishes are required for decorative pur-poses, or where the stainless steel (CRES) or nickel based

alloy is in contact with a dissimilar anodic metal, paintingmay be required. Reapply the organic coating system speci-fied in the appropriate system specific maintenance manualand/or engineering drawing for the aircraft, missile, or pieceof equipment and TO 35-1-3 for support equipment (SE)using TO 1-1-8 for application procedures.

5.9.5 Copper and Copper Based Alloys. These para-graphs outline chemical corrosion removal procedures forcopper and copper based alloy parts and assemblies of air-craft, missiles, and equipment. Table 5-10 provides proce-dures for removing specific types of corrosion.

5.9.5.1 Preparation. If the corroded area is contaminatedwith grease, oil, dirt, or other foreign materials, clean thearea per Chapter 3. Protect adjacent components and areasnot being treated by masking to prevent damaging them withthe chemicals used.

5.9.5.2 Chemical Corrosion Removing Materials forCopper and Copper Based Alloys. There are two types ofchemical solutions used for corrosion removal from copperand copper based alloys provided there is no danger ofchemical entrapment in crevices and/or recesses: MIL-C-

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10578, Type III Corrosion Removing and Metal Condition-ing Compound (Phosphoric Acid Base)/Inhibited solutionand A-A-55828 (O-S-809) Sulfuric Acid solution.

5.9.5.2.1 MIL-C-10578, Type III Corrosion Removingand Metal Conditioning Compound (Phosphoric AcidBase)/Inhibited. This is a phosphoric acid based materialused to remove corrosion from assembled copper and/orcopper alloy aircraft, missile, and equipment structures inareas that do not contain oxygen systems and where a liquidmaterial is acceptable.

5.9.5.2.1.1 Application and Use of MIL-C-10578, TypeIII Solutions. The directions for the application and use ofthis material are as follows:


b. Add one part of the concentrated material, as received,to one part of water by volume. Use either a stainlesssteel, aluminum, vinyl, polyethylene, or rubber mixingcontainer.

c. Apply the solution to the surfaces to be treated by non-atomized spray, flow-on, or brush. Allow the condi-tioner to dwell on the surfaces long enough to loosenand/or dissolve the corrosion and then rinse off allresidue with fresh, hot tap water (120° -140° F/49°-60° C).

d. Allow the surface to thoroughly dry, and then eitherapply a CPC or a required paint system, or place thepart directly into service, whatever is directed by thesystem specific maintenance technical data for theequipment involved.

5.9.5.2.2 A-A-55828 (O-S-809) Sulfuric Acid Solu-tions. Sulfuric acid solutions may be used to remove corro-sion from copper and/or copper alloy components which canbe disassembled and treated in immersion tanks. The tanksmust be either manufactured from or lined with either stain-less steel (CRES), lead, ceramic, glass, or acid resistant rub-ber and they must be provided with an adequate lateral ex-haust ventilation system. Part holding racks must bemanufactured from either stainless steel (CRES) or Monel.The proper conditions (i.e., time, temperature, and acid con-centration) for the process shall be determined by the sametest procedure outlined in Paragraph 5.9.4.2.3.3, using testpanels made from the same material being treated.

5.9.5.2.2.1 Application and Use of A-A-55828 (O-S-809) Sulfuric Acid Solutions.

Sulfuric acid solutions are toxic to the skin, eyes,and respiratory tract. Chemical, splash proofgoggles and/or face shields and chemical resistantrubber gloves and aprons are required. In case ofeye or skin contact, flush immediately with freshwater and report to the Base Medical Facility.

The directions for the application and use of this material areas follows:

a. Disassemble the components from which corrosionwill be removed to the piece part level, as necessary.

b. Prepare parts per the procedures outlined in Paragraph5.9.5.1.

When preparing sulfuric acid solutions, never pourwater into the acid, as excessive heat will be gen-erated. Always pour the acid into the water.

c. Prepare a 5 to 10% by volume solution of A-A-55828(O-S-809) sulfuric acid in water and maintain the so-lution temperature within a range of 60° to 120° F (16°to 49° C). As required by Paragraph 5.9.5.2.2, deter-mine the actual operating solution concentration andtemperature within the ranges listed above and estab-lish the required part immersion time by testing perParagraph 5.9.4.2.3.3.

Do not process components having assembled dis-similar metal parts or separate parts made fromdifferent metals in a sulfuric acid solution, as cor-rosion problems can result.

d. Immerse parts in the sulfuric acid solution preparedand maintained at the solution concentration and tem-perature per step c, for the immersion time establishedin step c.

e. Remove the parts from the acid solution and immedi-ately rinse them thoroughly with fresh tap water.

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NOTE

Thorough rinsing is important since any residualacid will cause staining of the metal surface.

f. If a red stain appears on the parts following the abovetreatment, remove the stain by immersion of the partsin a solution of 4 to 10% by volume A-A-55828 (O-S-809) sulfuric acid and 4 to 8 ounces per gallon of so-lution of A-A-59123 (O-S-595) sodium dichromate inwater maintained within a temperature range of 60° to120° F (16° to 49° C).

Compressed air used for drying purposes can causeairborne particles that may enter the eyes. Eyeprotection is required. Air pressure shall not ex-ceed 30 PSI.

g. Dry rapidly, preferably with hot air, to prevent waterstains on the surface, and then either apply a CPC or arequired paint system, or place the part directly intoservice, whatever is directed by the system specificmaintenance technical data for the equipment involved.

5.9.5.3 Application of Organic Coatings. Normally cop-per and copper based alloys are not painted. If required, re-apply the organic coating system specified in the system spe-

cific maintenance manual and/or engineering drawing for theaircraft, missile, or piece of equipment and TO 35-1-3 forsupport equipment (SE) using TO 1-1-8 for application pro-cedures.

5.9.6 Titanium and Titanium Based Alloys. These para-graphs outline chemical corrosion removal procedures fortitanium and titanium alloy parts and assemblies. Table 5-11provides procedures for removing specific types of corro-sion.

5.9.6.1 Preparation. If the corroded area is contaminatedwith grease, oil, dirt, or other foreign materials, clean thearea per Chapter 3.

a. Protect adjacent unaffected areas not being treated bymasking to prevent damage from scale, chips, corro-sion products, or chemicals.

b. If present, remove gray or black oxides by an appro-priate mechanical method in this chapter.

5.9.6.2 Chemical Corrosion Removal Materials for Ti-tanium and Titanium Based Alloys. There are two types ofchemical solutions used for corrosion removal from titaniumand titanium based alloys: an acid pickling solution of A-A-59105 (O-N-350), nitric acid and MIL-A-24641, hydroflu-oric acid in water, and an SAE AMS-1640 (MIL-C-38334)corrosion removing compound solution.

Table 5-10. Typical Chemical Corrosion Removal Procedures for Copper and Copper Alloys

Type of Corrosion Step 1Corrosion Removal

Step 2Surface Treatment

Step 3Protective Finish

Tarnish or coloredcorrosion products(patina) on in-stalled compo-nents wheneverchemical corro-sion removal ispractical.

Remove corrosion withMIL-C-10578, Type IIIcorrosion removing com-pound (phosphoric acidbase)/inhibited. (Refer toParagraph 5.9.5.2.1.1).

Not required Refer to Paragraph5.9.5.2.1.1 for specificinstructions.

Corrosion on partswhich can be dis-assembled forimmersion treat-ment.

Remove corrosion by im-mersion in A-A-55828(O-S-809) sulfuric acidsolution. (Refer to Para-graph 5.9.5.2.1.1, step athrough step d).

If required, remove stain byimmersion in A-A-55828(O-S-809) sulfuric acid solu-tion and A-A-59123 (O-S-595) sodium dichromate so-lution. (Refer to Paragraph5.9.5.2.2.1, step f throughstep h).

As above

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5.9.6.2.1 Acid Pickling Solutions.

• Nitric-acid-hydrofluoric acid pickling solutionsare toxic to the skin, eyes, and respiratory tract.Chemical, splash proof goggles and/or faceshields and chemical resistant rubber glovesand aprons are required. In case of eye or skincontact, flush immediately with water and re-port to the Base Medical Facility. Use only in awell ventilated area.

• When preparing sulfuric acid solutions, neverpour water into the acid, as excessive heat willbe generated. Always pour the acid into thewater.

Titanium is susceptible to hydrogen embrittlementin acid solutions. Therefore, acid pickling shall beused only when other corrosion methods are notadequate. Competent operators must be assignedto monitor the process.

An acid pickling solution for removing corrosion from re-moved titanium and titanium alloy parts consists of a mix-ture of 20% by volume, A-A-59105 (O-N-350), nitric acidand 3% by volume, MIL-A-24641, hydrofluoric acid in wa-ter. This solution will remove most oxide coatings from tita-nium, provided the scale was formed at temperatures below1000° F (538° C) by immersing them in the solution. Asnoted in Paragraph 5.9.6.1, step b, gray or black oxides whichform at temperatures above 1000° F (538° C) should be re-moved by an appropriate mechanical method in this chapter,such as abrasive blasting, prior to the acid pickling to pre-vent pitting of the titanium.

5.9.6.2.1.1 Application and Use of Acid Pickling Solu-tions. The directions for the application and use of thesematerials are as follows:

a. Remove the components to be treated and disassemblethem to the piece part level.

b. Prepare the parts per Paragraph 5.9.6.1.

c. Immerse the parts in the nitric-acid-hydrofluoric acidpickling solution specified in Paragraph 5.9.6.2.1 whilemaintaining the solution at room temperature. Allowthe parts to remain in the solution only long enough toloosen and remove the oxide film from the surface.Intermittent scrubbing of the part surfaces with an acidbrush or wiping them with a cloth during this opera-tion will facilitate oxide film removal and minimizeany pitting of the part surfaces.

NOTE

This process may be optimized by adjusting theacid concentration and immersion time as deter-mined by testing per Paragraph 5.9.4.2.3.3 prior tostarting the pickling operation

d. Remove the parts from the solution and immediatelyrinse them thoroughly in fresh, running tap water. Ei-ther air dry them at room temperature or dry them in acirculating air oven at a temperature of 180° to 240° F(82° to 116° C).

e. If required by system specific technical data, apply anorganic coating system per Paragraph 5.9.6.3.

5.9.6.2.2 SAE AMS-1640 (MIL-C-38334) CorrosionRemoval Compound for Aircraft Surfaces. This is thesame material used to remove corrosion from aluminum al-loy surfaces, and it may also be used to remove corrosionfrom titanium and titanium alloy assemblies and/or on equip-ment surfaces. (Refer to Paragraph 5.9.1.2.1).

5.9.6.2.2.1 Application and Use of SAE AMS-1640(MIL-C-38334). The procedure for application and use ofthis corrosion removal compound to remove corrosion prod-ucts/oxides from titanium and titanium alloy surfaces is thesame as it is for aluminum alloy surfaces. (Refer to Para-graph 5.9.1.2.1.1).

5.9.6.3 Application of Organic Coatings. Titanium andtitanium alloys do not normally require a paint system forcorrosion protection. Where organic finishes are required fordecorative purposes, for continuity with the finish system onsurrounding surfaces, or to provide a barrier to prevent con-tact with a dissimilar anodic material, prepare the titanium ortitanium alloy surface for painting by applying a thixotropicMIL-DTL-81706/MIL-DTL-5541, Class 1A chemical chro-mate conversion coating solution per Section II of this chap-ter. Apply the organic finish system specified in the appli-cable system specific aircraft, missile, or equipmentmaintenance manual and/or engineering drawing and TO 35-1-3 for support equipment using TO 1-1-8 for applicationprocedures.

5.9.7 Plated and Phosphated Surfaces. These para-graphs outline chemical corrosion removal procedures forremoving corrosion from plated and phosphated surfaces.Table 5-12 provides guidelines for touch-up of corroded ar-eas, but where an organic finish on the plated part is speci-fied and/or required for engineering or other reasons, thetable can be used as a guide for treating the entire surface ofthe plated or phosphated parts. Chemical corrosion removalusing acid type chemical corrosion/rust removers is recom-mended for use where there is no danger of the chemicalsbecoming entrapped in crevices or recesses. They are in-tended for brush application following removal of heavycorrosion by an appropriate mechanical means in this chap-

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ter to remove the remaining red rust and other types of cor-rosion from the base metal and to condition the metal sur-face for better paint adhesion.

5.9.7.1 Preparation.

Many platings and their corrosion products, suchas copper, cadmium, and chromium are toxic. Takeproper safety precautions to avoid inhalation oringestion of residue created during corrosion re-moval operations. Wash hands thoroughly beforeeating, drinking, or smoking after removing corro-sion from plated surfaces.

If the corroded area is contaminated by grease, oil, dirt, orother foreign materials, clean the area per Chapter 3. Protectadjacent components and areas by masking to prevent dam-age from scale, chips, corrosion products, and the chemicalsused.

5.9.7.2 Treatment of Corroded Areas on Cadmium orZinc Plated Surfaces. Cadmium and zinc platings provideanodic protection to underlying steel/ferrous (sometimes cop-per) base metal. If the plating surface is broken during nor-mal usage, the cadmium or zinc plate being anodic to thebase metal will corrode preferentially and sacrificially pro-tect the base metal. The removal of corrosion from cadmiumor zinc plated surfaces shall be limited to the removal of theplating and the base metal corrosion products from the local-ized area of the underlying base metal.

5.9.7.2.1 Application and Use of Chemical CorrosionRemovers on Cadmium and Zinc Plated Surfaces. Thedirections for the application and use of chemical removerson these plated surfaces are as follows:

a. Prepare the area per Paragraph 5.9.7.1.

b. As stated in Paragraph 5.9.7, remove heavy cadmiumor zinc and base metal corrosion products from part

surfaces using an appropriate hand type mechanicalmethod in this chapter such as ANSI B74.18 (GGG-C-520, Type II, Class 1) 240 grit abrasive paper, ANSIB74.18 (A-A-1047) 240 grit abrasive cloth, or A-A-58054, Type I, Grade B abrasive mat. Avoid removingundamaged cadmium or zinc plating adjacent to thecorroded area and limit corrosion removal to the im-mediate area of the corrosion on the base metal andthe plating surrounding it.

c. Remove any remaining corrosion and condition thesurface of the plating and base metal with MIL-C-10578, Type I, wash-off, phosphoric acid base, corro-sion removing and conditioning compound. Refer toParagraph 5.9.3.2.2.1 for additional instructions for ap-plication and use of this material. Allow the acid tocontact the surface only long enough to remove thecorrosion and then rinse the area thoroughly with freshtap water.

d. Allow the area to dry and immediately apply an or-ganic coating system or CPC as directed by systemspecific technical data. (Refer to Paragraph 5.9.7.5).

NOTE

These procedures are intended only for field leveltreatment of localized corroded areas on cadmiumor zinc plated surfaces and reapplication of a pro-tective coating after corrosion removal. When theuse of organic finishes or the thickness of the or-ganic finish will impair the normal operation of apart, severely corroded parts must be removed andreplaced. Where facilities are available, parts withseverely corroded cadmium or zinc plating maybe stripped and replated in accordance with proce-dures in TO 42C2-1-7. When high strength steelsare being replated, use only those specialized pro-cedures authorized for high strength steels as manyplating solutions can cause hydrogen embrittle-ment of these materials.

Table 5-11. Typical Chemical Corrosion Removal of Titanium and Titanium Base Alloys

Type of Corrosion Corrosion Removal Protective FinishLight to heavy oxide on

parts where acid picklingis practical on removedparts.

(1) Remove gray or black oxide by an ap-propriate mechanical method in thischapter.

When required, refer to Paragraph5.9.6.3.

(2) Remove remaining oxide by immersionin nitric-acid-hydrofluoric acid solution.(Refer to Paragraph 5.9.6.2.1.1.

Light to heavy oxide onassembled parts and/or onequipment surfaces.

(1) As in (1) above. As above

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Table 5-11. Typical Chemical Corrosion Removal of Titanium and Titanium Base Alloys - Continued

Type of Corrosion Corrosion Removal Protective Finish(2) Remove remaining oxide by treating

with SAE AMS-1640 (MIL-C-38334)solution. (Refer to Paragraph 5.9.6.2.2.1and Paragraph 5.9.1.2.1.1).

5.9.7.3 Treatment of Corroded Areas on Plated Sur-faces Except Cadmium or Zinc Plating. When a breakoccurs in the surface of either chromium, nickel, tin, or cop-per platings, corrosion of the steel/ferrous base metal andundercutting of the plating will rapidly follow. The corrosionwill occur at a highly accelerated rate due to the galvanicaction of these platings which are highly cathodic to thesteel/ferrous base metals.

5.9.7.3.1 Application and Use of Chemical CorrosionRemovers on Plated Surfaces Except Cadmium or ZincPlating. Directions for the application and use of chemicalremovers on plated surfaces except cadmium and zinc plat-ings are as follows:

a. Prepare the area per Paragraph 5.9.7.1.

b. Remove heavy corrosion by an appropriate hand typemechanical method in this chapter, such as a wire brushor abrasive paper, cloth, or mat.

c. Remove any remaining corrosion and condition thesurface of the plating and base metal with MIL-C-10578, Type I, wash-off, phosphoric acid base, corro-sion removing and conditioning compound. Refer toParagraph 5.9.3.2.2.1 for additional instructions for ap-plication and use of this material. Allow the acid tocontact the surface only long enough to remove thecorrosion and then rinse the area thoroughly with freshtap water.

d. Allow the area to dry and immediately apply an or-ganic coating system or CPC or place the part directlyinto service, whichever is directed by system specifictechnical data. (Refer to Paragraph 5.9.7.5).

NOTE

These procedures are intended only for field leveltreatment of localized corroded areas on chro-mium, nickel, tin, and copper plated surfaces.

Where service temperatures preclude the use oforganic finishes and/or the film thickness of theorganic finish will impair normal operation of thepart, severely corroded parts must be removed andreplaced. Where facilities are available, severelycorroded parts with chromium, nickel, tin, or cop-per plating may be stripped and replated in accor-dance with procedures in TO 42C2-1-7. Whenhigh strength steels are being replated, use onlythose specialized procedures authorized for highstrength steels as many plating solutions can causehydrogen embrittlement of these materials.

5.9.7.4 Treatment of Corroded Areas on PhosphatedSurfaces. Cadmium and zinc plated surfaces as well asmany bare steel surfaces are treated with a phosphate coat-ing at the time of manufacture to improve paint adhesionand corrosion resistance of the surfaces or as a base for theapplication of grease, oil, or CPC’s. When phosphated sur-faces corrode, corrosion should be removed by the methodrecommended for the base material.

5.9.7.5 Application of Organic Coatings. Organic coat-ings may be applied to phosphated surfaces and some platedsurfaces to provide corrosion protection to the plating and/orto increase the corrosion protection the plating or phosphatecoating provides to the base metal. They should not be usedwhen the part operates at temperatures which preclude theiruse or when the finish will prevent the part from performingits intended function. Organic coatings shall not be used onbearing or wearing surfaces of gears, cams, slides, etc., andon surfaces requiring electrical conductivity. Apply the or-ganic finish system specified in the applicable system spe-cific aircraft, missile, or equipment maintenance manualand/or engineering drawing and TO 35-1-3 for support equip-ment using TO 1-1-8 for application procedures.

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Table 5-12. Typical Chemical Corrosion Removal Procedures for Plated and Phosphated Surfaces

Type of Corrosion Corrosion Removal Protective Finish1

Light corrosion of plating andbase metal under and atbreaks in cadmium or zincplatings.

Remove corrosion from platingand base metal with an abrasivepaper, cloth, or mat. Completecorrosion removal and conditionmetal with MIL-C-10578, TypeI, wash-off, phosphoric acidbase corrosion removing andconditioning compound. (Referto Paragraph 5.9.7.2.1 and Para-graph 5.9.3.2.2.1).

Refer to Paragraph 5.9.7.5 for discussionof organic coating systems.

Light corrosion of base metalunder and at breaks in tin,chromium, nickel, or copperplatings.

Remove corrosion from the basemetal using an appropriate handmechanical method in thischapter followed by metal con-ditioning with MIL-C-10578,Type I, wash-off, phosphoricacid base corrosion removingand conditioning compound.(Refer to Paragraph 5.9.7.3.1and Paragraph 5.9.3.2.2.1).

As above

Heavy corrosion of base metalunder and at breaks in cad-mium, zinc, chromium,nickel, or copper platings.

As above As above

Light to heavy corrosion ofbase metal under and atbreaks in phosphate coatings.

Remove corrosion by methodused for corrosion removal onthe base metal.

As above

1 Protective finish should be applied only when the service temperature of the part does not preclude use of an organiccoating and/or where the film thickness of the coating will not impair the operation of the part.

SECTION II SURFACE TREATMENT

5.10 PURPOSE.

Surface treatment of the metal with a prescribed chemical toform a protective film is an important step in the corrosionprevention process. Properly applied chemical treatmentsimpart considerable corrosion resistance to the metal andgreatly improve the adhesion of subsequently applied paints.Epoxy primers, for example, which do not adhere well tobare aluminum alloy surfaces, adhere very well to them whenthey are treated with chemical conversion coatings.

5.10.1 Chemical Prepaint Treatments. Also known aschemical conversion coatings, chromate conversion coatings,chemical films, or surface pretreatments, these treatments areaqueous acid solutions of active inorganic compounds whichcombine with aluminum or magnesium surfaces to form acorrosion resistant film. In addition, these films improve theadhesion of paint coatings.

5.10.1.1 MIL-DTL-81706 Chemical Conversion Mate-rials for Coating Aluminum and Aluminum Alloys. MIL-DTL-81706 covers six different forms (I, II, III, IV, V, andVI) of two different classes (1A and 3) of chromate prepainttreatment materials (with various fluoride activators) withfour separate application methods (A-spray, B-brush, C-im-mersion, and D-pen application) for treating bare and cladaluminum surfaces, including touch-up of damaged anodizedaluminum and titanium alloys. Application of these materialsand the performance of the coatings developed by them arecovered by MIL-DTL-5541. MIL-DTL-81706, Class 1Acoatings provide maximum protection against corrosion whenleft unpainted and superior adhesion when paint systems areapplied. Class 3 coatings are intended for use as a corrosionpreventative film for electrical and electronic applicationswhere low contact resistance is required. Class 1A is avail-able in the following forms:

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5.10.1.1.1 Form I (Concentrated Liquid).

• Form II (powder) and Form V (premeasuredthixotropic powder) contain chromic acid dustand the other forms contain liquid chromic acidall of which can cause burns of the skin, eyes,and mucous membranes, including irritationand ulcers of the nasal septum. Use chemicalresistant, rubber gloves and aprons, chemical,splash proof goggles and/or face shield, and adust filter mask when mixing the powder andhandling the solutions.

• Chromic acid is a strong oxidizer and may ig-nite on contact with organic materials and re-ducing agents.

NOTE

Mix the Form I concentrated liquid, the Form IIpowder, and the Form V premeasured thixotropicpowder in accordance with the manufacturer’sinstructions.

When the concentrated liquid is mixed with water, prefer-ably deionized (DI) water, per the manufacturer’s instruc-tions, it forms a solution equivalent to a Form III solutionand is ready for use in touch-up by brush, spray, and immer-sion (Methods A, B, and C) applications. The unused por-tions of the mixed solution may be stored in a container andused, as required. The shelf life of the concentrated liquidand the mixed solution is around six months if they are notcontaminated.

5.10.1.1.2 Form II (Powder). When the powder is mixedwith water, DI water, per the manufacturer’s instructions, asolution equivalent to a Form III solution is formed that canbe used for brush, spray, and immersion (Methods A, B, andC) applications. The powder has an indefinite shelf life untilmixed with water. The unused portions of the mixed solutionmay be stored in a closed container and used as required.Once mixed, the shelf life of the solution is around sixmonths if the solution is not contaminated.

5.10.1.1.3 Form III (Pre-Mixed Liquid). This material isready for use, as received, for brush, spray, and immersion(Methods A, B, and C) applications. The Form III pre-mixedliquid is the most convenient form of MIL-DTL-81706 foruse at field level since it requires no mixing but is moreexpensive than the Form II powder. The shelf life of thisliquid is about six months from the date of manufacture.

5.10.1.1.4 Form IV (Pre-Mixed, Thixotropic Liquid).This material is a thickened, pre-mixed liquid which isready-to-use, as received, for brush (Method B) application.It is ideal for use on small areas, particularly vertical sur-faces, since it will remain in place without running. It is alsointended for use as a surface pretreatment on titanium alloysprior to painting. The shelf life of this liquid is about sixmonths from the date of manufacture.

5.10.1.1.5 Form V (Premeasured, Thixotropic Pow-der). This material is a premeasured powder that will form athixotropic solution equivalent to Form IV when mixed withwater, preferably DI water, per the manufacturer’s instruc-tions. Its use and application are the same as Form IV. Thepowder has an indefinite shelf life until mixed with water.The unused portions of the mixed solution may be stored ina closed container and used as required. Once mixed, theshelf life of the solution is about six months if the solution isnot contaminated.

5.10.1.1.6 Form VI (Pre-Mixed Liquid in a Self-Con-tained Applicator Device). This material is a pre-mixed,ready-to-use liquid contained in its own applicator device/pen for application by (pen application) (Method D). It isintended to touch-up small damaged areas of MIL-DTL-5541chemical chromate conversion coatings and anodized coat-ings, and to apply a pretreatment coating on corrosion grindout areas on aluminum alloys. The shelf life of the solutionsin the applicators is about six months from the date of manu-facture.

5.10.1.2 SAE AMS-M-3171 (MIL-M-3171), Type VIMagnesium Alloy, Processes for Pretreatment and Pre-vention of Corrosion on; Chromic Acid Brush-On Treat-ment.

The newly formed conversion coating is soft andcan be easily removed. Do not disturb the coatedsurface until coating is completely dry. Maintainthe drying temperature below 140° F (60° C) toavoid compromising integrity of the film. Theminimum drying time is 2 hours.

Also known as the Henkel Process, this is a corrosion pre-ventive and prepaint surface treatment/conversion coating forapplication on all magnesium alloys after corrosion removalby either brush-on or immersion methods. Either obtain thepre-mixed SAE AMS-M-3171 (MIL-M-3171), Type VI solu-tion through supply channels or mix the solution per theseinstructions.

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• SAE AMS-M-3171 (MIL-M-3171), Type VI,contains chromic acid which can cause burnsof the skin, eyes, and mucous membranes, in-cluding irritation and ulcers of the nasal sep-tum. Use chemical resistant rubber gloves andaprons, chemical, splash proof goggles and/orface shield, and dust filter mask when mixingor handling these chemicals and/or solutions.

• Chromic acid is a strong oxidizer and may ig-nite on contact with organic materials such assolvents, thinners, and reducing agents.

• MIL-DTL-81706/MIL-DTL-5541 aluminumconversion coating is not authorized for treat-ing magnesium alloy surfaces as it can causecorrosion of these surfaces as well as poor paintadhesion to magnesium alloys.

a. Obtain a one gallon stainless steel, aluminum, vinyl,polyethylene or rubber container.

b. Add ½ gallon of water, preferably DI water, to thecontainer.

c. Add 1-1/3 ounces (37.8 grams) of A-A-55827 (O-C-303) Chromic Acid (CrO3) and 1 OZ (28.3 grams) ofO-D-210 Anhydrous Calcium Sulfate (CaSO4.2H2O)to the water. (Refer to Appendix A for ordering infor-mation of chemicals).

d. Top off with enough water to make one gallon of so-lution and mix thoroughly until calcium sulfate hascompletely dissolved into the solution.

5.10.2 Surface Preparation. After completing corrosionremoval, proceed as follows:

a. Feather the edges of the paint around areas that havebeen chemically or mechanically stripped for removaland treatment of corrosion prior to pretreatment/con-version coating and repainting to ensure a smooth,overlapping transition between the old and new paintsurfaces. Feathering shall be accomplished using 240or 320 grit ANSI B74.18 (A-A-1048) aluminum oxideabrasive cloth or paper, A-A-58054, Type I, Grade Bor C (fine or medium) aluminum oxide abrasive mat,or a fine or very fine aluminum oxide finishing flapbrush.

b. Clean the surface of the parts and/or areas being treatedper procedures in Chapter 3 to remove all grease, oil,and dirt, and then rinse with fresh water. For watersensitive areas, use an approved cleaning solvent perprocedures in Chapter 3.

c. Abrade the area from which corrosion was removedwith an A-A-58054, Type I, Grade A or B (Very Fineor Fine) aluminum oxide abrasive mat to remove theoxide layer/coating. This is the most effective meansfor cleaning the surface so that it will accept a prepainttreatment/chemical conversion coating.

NOTE

For aluminum alloy surfaces, the oxide layer maybe removed from the area being treated with SAEAMS-1640 (MIL-C-38334) corrosion removingcompound per procedures in TO 1-1-8 and/orParagraph 5.9.1.2.1 of this manual followed byrinsing with fresh water.

d. After abrading and/or deoxidizing the area, rinse thesurface thoroughly by flushing with fresh water, pay-ing particular attention to fasteners and other areaswhere residues may become entrapped. At this stage ofthe cleaning process, the surface should be water-breakfree. (Refer to Figure 5-10). A surface showing water-breaks (water beading or incomplete wetting) is in-dicative of contamination, which will later interferewith conversion coating, sealing, and painting.

e. If the surface is not free of water-breaks, repeat step b,step c, and step d.

NOTE

Areas of aircraft, missiles, or equipment that havebeen waxed, particularly with a silicone material,or that have been treated with a silicone grease oroil require special cleaning to obtain a surface freeof water breaks. When silicone wax, grease, or oilare suspected, solvent clean using an approvedcleaning solvent per procedures in Chapter 3, andthen perform step b, step c, and step d.

5.10.3 Precautions. Observe the following precautionswhen applying chemical prepaint treatments on aluminum,titanium, or magnesium.

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5.10.4 Application of Surface Treatments.

• Chemical prepaint treatments are toxic to theskin, eyes, and respiratory tract. Use chemicalresistant rubber gloves and aprons, and chemi-cal, splash proof goggles and/or face shieldduring mixing or application. If the material(which is an acid) accidentally contacts the skinor eyes, flush immediately with plenty of freshwater and report to the Base Medical Facility ifeyes are affected or the skin is burned.

• Mixing and application should be done in anadequately ventilated area. Avoid prolongedbreathing of vapors.

• Chemical conversion coating/prepaint treatmentmaterials are strong oxidizers and are a firehazard in contact with flammable, combustible,and readily oxidizable materials. They must bestored separately from flammable, combustible,and oxidizable materials and never mixed incontainers previously containing flammable,combustible, and oxidizable products. Ragscontaminated with chemical conversion coatingmaterials should be thoroughly rinsed and dis-posed of as soon as it is practicable.

• Do not use chemical prepaint treatments onhigh strength steel parts. Catastrophic failuremay occur due to hydrogen embrittlement.

• Do not use steel, lead, copper, or glass contain-ers for holding/storing chemical prepaint treat-ments. Use only plastic, rubber, or stainlesssteel. Brushes with tin plated steel handles orferrules may be used but contact with the treat-ment solution should be minimized.

NOTE

Acrylic tip of TNP pen can be modified or alteredto form any shape to allow touching up hard toreach areas.

Refer to Table 5-13 for recommended materials and proce-dures for specific alloys. Immediately after cleaning to a wa-ter break-free surface and rinsing thoroughly, apply chemicalconversion coating material by brush, sponge stick moist-ener, immersion, or non-atomizing spray. The type of appli-

cation method used depends on the type of conversion ma-terial being applied, the area to be covered, and whetherapplication is on a removed part or on an assembly or onequipment area. The sponge stick moisteners and the Touch-N-PrepTM (TNP) pens are particularly useful for small areas.The sponge stick moisteners may be used to apply all typesof conversion coatings for aluminum, magnesium, and tita-nium alloys and when used, they should be rinsed with freshwater and discarded at the end of each work shift. The TNPpens are used to apply MIL-DTL-81706, Class 1A, Form VI,Method D (Alodine 1132) conversion coatings on aluminumalloys.

5.10.4.1 Conversion Coating Using TNP Pens. The re-pair of damaged chemical conversion coatings on aluminumalloys can be accomplished by applying Alodine 1132 usingthe TNP pens conforming to MIL-DTL-81706, Class 1A,Form VI, Method D. The TNP pen applicators are ideal fortouching-up small surface areas such as nicked, scratched,and chipped areas in a protective coating system. The solu-tion applied with TNP pens doesn’t require rinsing or wipingoff following application, thus minimizing hazardous wastegeneration. Empty pens can be returned to manufacturer fordisposal. To use the TNP pen, remove the cap and charge thetip by pressing the tip against a flat surface for 10 to 15seconds. The conversion coating solution will saturate thetip. Do not oversaturate the tip. Refresh solution often dur-ing use in a similar fashion. Use of TNP pens is restricted to1 sq ft.

a. Prepare and clean the damaged area to be repaired inaccordance with Paragraph 5.10.2 prior to using theTNP pen.

b. Immediately following cleaning, use the TNP pen toapply a chemical conversion coating solution in over-lapping parallel strokes. Do not over apply the solutionwhich would allow puddles, drips, or runs to form.

c. Apply one coat of solution and allow coating to dryfor 5 to 10 minutes before next application.

d. Apply a second coat perpendicular to the first coat andallow it to dry. The treated surface does not requirerinsing or wiping off and it can be air dried at ambient(room) temperature or force air dried with hot air. Oncecompletely dried, the coating is ready for primingand/or painting.

e. After processing, if bare surface areas still exist, repeatstep b through step d. Also, if the treated surface doesnot turn to an iridescent yellow color shortly followingapplication, reclean the surface and reapply per step athrough step d.

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5.10.5 Notes on Conversion Coating/Surface Treat-ment. Prepaint treatments shall be applied immediately aftercorrosion removal procedures. Failure to obtain a good con-version coating may be attributed to the following:

a. Allowing too long a period of contact prior to rinsingcan result in a powdery coated surface. Chemical con-version coating/prepaint treatments for aluminum al-loys shall be rinsed immediately when the surface hasan iridescent yellow to gold appearance. This usuallyoccurs in 1 to 5 minutes. A brownish color indicatestoo long a dwell time and produces a powdery coating.This will not provide a good surface to which thepaint/coating system can adhere. If a powdery coatingis formed, remove it with an A-A-58054, Type I, GradeB abrasive mat and reapply the material. The normaldwell time for magnesium conversion coating/paintpretreatments is 1 to 3 minutes to form a brown-greenfilm, but longer contact times for magnesium pretreat-ments do not usually cause problems. Titanium alloysrequire a dwell time of 45 minutes using a thixotropicMIL-DTL-81706, Form IV or V solution. ConsultChapter 3 of TO 1-1-8 and the material manufacturer’sinstructions for additional instructions for mixing andapplication of conversion coating solutions.

b. Allowing pretreatment solutions to contact lead, steel,copper, glass, or other incompatible materials can re-duce the effectiveness of the solutions and may pre-vent adequate pretreatment.

c. Insufficiently cleaned metal surfaces will prevent theconversion coating from forming on the metal surface.Cleaning must provide a water break-free surface. Re-fer to Paragraph 5.10.2, step d.

d. Insufficient dwell time doesn’t allow the conversioncoating to form on the metal surface. As the solutionapproaches its shelf life, or at temperatures below 50°F (10° C), more time may be required to form goodfilms.

e. Test a solution or material that is beyond its shelf lifedate using a small sample of scrap of the aluminum ormagnesium alloy metal that is to be treated. If a irides-cent yellow to gold coating is produced within 5 min-utes on an aluminum alloy or a brown-green coating isformed within 3 minutes on a magnesium alloy at 77°F (25° C), the material may be used.

5.10.6 Post Treatment. Chemical conversion coated sur-faces should be allowed to dry in accordance with thechemical manufacturer’s recommended instructions beforethey are subsequently painted or adhesion failures may oc-cur. More time may be required at low temperatures or highhumidity. The coating is soft until completely dried. Do notwipe the area with a cloth or brush when coating is still wet,since this will remove the coating. To avoid contaminationof the treated surface and to provide a surface that is recep-tive to organic coatings, prime the treated area per proce-dures in TO 1-1-8 with the primer specified in the systemspecific maintenance manual for the aircraft, missile, orequipment involved within 48 hours after application of theconversion coating/prepaint treatment. If this is not possible,perform temporary preservation procedures (refer to Para-graph 5.10.7), as soon as possible. If the surface is allowedto become dirty, scratched, or more than 48 hours haveelapsed since its application, it must be cleaned with a wetA-A-58054, Type I, Grade A or B abrasive mat and retreatedbefore any organic coatings/paint systems or sealants are ap-plied.

Figure 5-10. A Water-Break Free Surface Compared with One with Breaks

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5.10.7 Temporary Preservation. Under adverse condi-tions or when the pressure of operations will not permit theapplication and curing of an organic coating/paint system,

apply an appropriate CPC in accordance with Chapter 3.

Table 5-13. Prepaint Treatments for Metal Surfaces

Alloy Surface Treatment ProcedureAluminum Al-loys

MIL-DTL-81706, Class 1A, Form I(Concentrated Liquid), Form II(Powder), Form III (Pre-mixed Liq-uid), Method A, B, or C

Prepare a proper solution with either Form I or II ma-terials per the manufacturer’s instructions and TO1-1-8 or use a Form III solution, as received. Spraythe solution with a non-atomizing sprayer (Method A)or brush the solution with a sponge stick applicator orbrush (Method B) on the part or area being treated orimmerse a removed part in solution (Method C). Keepthe part/area wet with or the part immersed in the so-lution for 1 to 5 minutes, until an iridescent yellow/gold color is obtained. Immediately rinse part thor-oughly. Allow to dry in accordance with chemicalmanufacturer’s recommended instruction prior topainting but not to exceed 48 hours. 1

MIL-DTL-81706, Class 1A, FormVI, Method D; TNP Pen

Brush the surface using the acrylic tip of the pen toapply a MIL-DTL-81706, Form VI conversion coatingper Method D. (Refer to Paragraph 5.9.4.1). Thetreated surface does not require rinsing.

Magnesium Al-loys

SAE AMS-M-3171 (MIL-M-3171),Type VI (Chromic Acid Brush-onTreatment)

Obtain a pre-mixed solution or mix a solution per in-structions in Paragraph 5.10.1.2. Apply the solution tothe area being treated with a sponge stick applicator orbrush and keep the area wet with solution for 1 to 3minutes until a brown-green, brassy, or brown-yellowcolor is obtained. Immediately rinse part thoroughly.Allow part to dry in accordance with chemical manu-facturer’s recommended instruction. 1

Ferrous Metal(other thanStainless Steel)

None Treatment prior to painting is limited to corrosion re-moval, cleaning, and application of MIL-PRF-26915organic zinc rich primer or MIL-C-8514 or DOD-P-15328 wash primer per instructions in TO 1-1-8. Someof the MIL-C-10578 treatments will leave a film ad-equate to paint over. (Refer to Paragraph 5.9.3.2.2).

Stainless Steeland Nickel Al-loys

None Under engineering guidance, surfaces may be pickled.(Refer to Paragraph 5.9.4.2.3).

Cooper Alloys None 2

Titanium Alloys MIL-DTL-81706, Class 1A, FormIV (Pre-mixed Thixotropic Liquid)or Form V (Pre-mixed Thixotropicpowder)

Obtain the Form IV pre-mixed thixotropic liquid ormix the Form V pre-mixed thixotropic powder withwater per the manufacturer’s instructions and apply thesolution to the surface being treated with a spongestick applicator or a brush. Allow the solution to dwellon the surface for 45 minutes and then rinse thor-oughly with fresh water. Allow to dry in accordancewith chemical manufacturer’s recommended instruc-tion prior to painting but not to exceed 48 hours. 1

Plated and Phos-phated Cadmium

None 2

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Change 15 5-41

1 Drying time may be accelerated by blowing with filtered warm air (140° F/60° C maximum). If the air contains oil(from a compressor) or other impurities, the paint system which is applied over the conversion coating will not pass wettape adhesion tests and will probably peel leading to additional corrosion. Drying air temperatures higher than 140° F(60° C) will degrade the conversion coating and cause it to lose its effectiveness.2 Treatment is limited to corrosion removal and cleaning. These surfaces are not normally painted, but may require paint-ing for decorative purposes, or in instances where the surface will be in contact with a dissimilar anodic metal. (CPC’s)may be applied as recommended in Chapter 3.

SECTION III SHOT PEENING

5.11 REQUIREMENTS FOR SHOT PEENING.

Prior to completing any shot peening operations ensure youhave been trained, have consulted Program Office Engineer-ing, and purchased the following AMS and SAE Standards:

• AMS 2431 - General Shot Peening Requirements

• AMS 2430 - Shot Peening, Automatic

• SAE J442 - Test Strip, Holder, and Gage for ShotPeening

• SAE J2277 - Shot Peening Coverage Determination

5.12 SHOT PEENING OF METAL SURFACES.

Shot peening is a cold working process which produces acompressive stress on the metal surface to alter the mechani-cal properties of the metal. This process utilizes peening me-dia, (i.e. steel shot, glass beads, etc.) in order to slightlydistort the metal surface. This compressive stress on the sur-face increases the resistance of the metal to fatigue and stresscorrosion cracking because both begin on the surface of themetal when it is subjected to tensile stresses. The closure ofexposed end grains and grain boundaries increases the resis-tance of the metal to intergranular corrosion; in particular, itincreases the resistance of high strength aluminum alloys toexfoliation corrosion. Because it increases resistance to cor-rosion and fatigue, peening is specified for protection of nu-merous new, high strength steel and aluminum alloy parts aswell as being required as a final procedure during rework/grind-out of corrosion damaged areas at both field and depotlevels of maintenance on many aircraft, missile, and otherequipment components fabricated from these metals. Shotpeening will not restore the strength lost in a metal structurecaused by metal removal due to corrosion damage, but itincreases corrosion and fatigue resistance of the remainingmetal. Shot peening requires the use of larger sized abrasiveparticles than used in abrasive blasting operations, special-ized blasting procedures for accomplishment, and specialtechniques and equipment for measuring the intensity andsaturation or surface coverage of a peening operation.

5.12.1 Types of Peening.

Peening operations can cause injury to personnelas high speed airborne abrasive particles can strikeunprotected areas of the body, enter into the respi-ratory tract, and cause slippage due abrasive resi-due buildup on the floor. Personal protectivegoggles and/or a faceshield, dusk filter mask,gloves, and coveralls are required for personnelengaged in peening operations. The work areasshall be kept clean of abrasive residue buildup,and adequate ventilation shall be provided.

• Peening is a specialized process requiring spe-cialized training in peening techniques used.Personnel who have not been specificallytrained for peening operations and/or who arenot thoroughly familiar with the specificationswhich cover these operations AMS 2430,AMS2431 and its subordinate slash numbers (/1through /8), AMS2590, SAE J442, SAE J443and SAE J2277 shall not be allowed to performpeening operations. Damage to structure, injuryto personnel, ineffective peening, and a falsesense of security about the condition of peenedaircraft, missile, or piece of equipment struc-ture will result if untrained and inexperiencedpersonnel are allowed to perform peening op-erations.

• Damage to equipment can also result from abra-sive particles which enter working mechanisms.Masking and shielding materials shall be usedto prevent penetration of abrasive particles inareas adjacent to the area being peened and tocontain abrasive overspray to prevent damageto the structure.

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There are two basic types of peening used on Air Forceequipment: shot peening using metallic, glass or ceramicshots per AMS 2430, covered in Section III and roto-peeningper SAE AMS 2590, covered in Section IV.

• Metallic Shot using data from SAE AMS 2431

• Glass Shot using data from SAE AMS 2431

• Ceramic Shot using data from SAE AMS 2431

5.12.1.1 Metallic, Glass, or Ceramic Shot Peening.

Do not use peening media (i.e. steel shot, glassbeads, etc.,) previously used for peening one typeof metal to peen a different type of metal, as con-tamination of the metal surface and subsequentgalvanic corrosion will result. Do not use any steelwire or shot for peening aluminum alloy surfaces,as steel particles will become embedded and causegalvanic corrosion. Use only AMS 2431/6 glassbead shot or AMS 2431/7 ceramic bead shot perparameters outlined in AMS2430 for peening alu-minum alloys.

Metallic, glass, and ceramic shot peening, per AMS2430, isthe peening of a meal surface by directing an air drivenstream of abrasive particles onto the metal surface, using thesame type of equipment employed for abrasive blasting toremove corrosion. The materials used are, stainless steel

(CRES) cut wire shot per AMS2431/4, cast steel shot perAMS2431/1 and /2, conditioned carbon steel wire shot perAMS2431/3 and /8, ceramic bead shot per AMS2431/7, andglass bead shot per AMS2431/6. Consult AMS2430 for allparameters that concern peening, such as intensity, saturationpoints, angle of blasting, nozzle distance, dwell times, pres-sures, and cast shot, cut wire shot, and glass or ceramic beadshot sizes. Shot peening by blasting will not be discussedfurther in this manual as this is normally a depot level op-eration requiring a specific step by step work procedure foreach job and is not used very often in every day corrosionremoval work.

5.12.2 Shot Peening Application. Shot peening is typi-cally used to induce surface residual compressive stresses inmetal parts to increase fatigue strength and resistance tostress-corrosion cracking for parts such as axles, springs (he-lical, torsional and leaf), gears, shafting, aircraft landing gear,structural parts, and similar items, but usage is not limited tosuch applications. Ceramic and glass shot peening, eitherwet or dry, may be used when iron contamination of stain-less steel or non-ferrous parts is a consideration.

5.12.2.1 Related peening processes, such as tumble peen-ing, manual peening, peen forming and straightening, peen-ing for prevention of intergranular corrosion, and peening toproduce a surface texture, are beyond the scope of this speci-fication.

5.12.2.2 Shot peening in accordance with AMS 2432meets or exceeds the requirements of AMS 2430. Part certi-fication in accordance with AMS 2432 is acceptable in addi-tion to AMS 2430.

SECTION IV ROTO-PEENING

5.13 ROTO-PEENING (ROTARY FLAP PEENING).

Rotary flaps containing cast steel shot conformingto AMS2431/1 and /2 shall not be used to peenaluminum alloy surfaces since they can becomeembedded in the surface and cause galvanic cor-rosion.

Roto-peening or rotary flap peening per AMS 2590 is a pro-cess that uses fiber type flaps with tungsten carbide shot em-bedded and bonded to the ends. The flap is mounted in amandrel and rotated in an electric or pneumatic powered tool,properly speed controlled to peen a metal surface. Roto-peening equipment shall conform to AMS 2592. Consult thespecification covering roto-peening of metal parts, AMS2590. This method of peening is convenient for small sur-

face areas where corrosion rework has been accomplished inplace on an aircraft, missile, or piece of equipment since itdoes not produce the contamination and abrasive residue as-sociated with the airblast methods and doesn’t require re-moval/disassembly of a part for placement in a blast booth.Roto-peening is the primary peening process used on air-craft, missile, and equipment components after corrosion re-moval, so it is the only peening process discussed in detail inthis manual. These procedures are limited in scope for useonly for peening or repeening metal surfaces after corrosionremoval and no other purpose. Peening that may be accom-plished is limited as follows:

a. The area peened shall not be larger than 3 x 4 inches.

b. When more than one area on a component requirespeening, the cumulative size of these areas shall notexceed 3 x 4 inches.

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Change 16 5-43

c. This procedure is not authorized for peening to accom-plish fatigue or stress relief on previously unpeenedareas where corrosion removal is not involved.

d. Any roto-peening operation which exceeds these pa-rameters shall be accomplished in accordance with allrequirements in AMS2590 and MIL-R-81841 in addi-tion to these procedures.

e. Roto-peening shall be used on a weapon system com-ponent only when required in a specific system, spe-cific technical order, or the component is identified ashaving been previously peened.

5.13.1 Roto-Peening Procedures.

Roto-peening operations create airborne particles.Eye protection in the form of safety goggles/glasses and/or face shield is required.

5.13.1.1 Equipment. The tools required for roto-peeningare a rotary tool, a flap wheel assembly, Almen test stripsand gage and a magnetic test strip holder.

NOTE

A Flapspeed Kit containing all required Roto-Peening Equipment can be purchased using NSN5280-20-010-9597.

5.13.1.1.1 Rotary Tools. The rotary tool shall be capableof operating within ±100 rpm the speed shown in Table 5-14,while operating a flap in contact with the work piece. Theequipment shall be capable of reproducing consistently therequired peening intensities. Either pneumatic or electricallypowered tools properly speed-controlled are acceptable.

5.13.1.1.2 Flap Assembly. The flap wheel assemblies in-cluding mandrels and flaps shall conform to AMS 2592. Thetool flaps are rotated rapidly and manually forced against thesubstrate being peened. A portion of the flat face of each flapembedded with shot strikes the metal surface causing peen-ing.

5.13.1.1.3 Almen Test Strips and Gage. Almen teststrips and gage shall conform to SAE J442. Test specimensshall be A, C, or N type as specified by the cognizant engi-neering organization.

5.13.1.1.4 Magnetic Test Strip Holder. The magnetictest strip holder conforming to Figure 5-11 shall be used. Itshall consist of a nonmagnetic material block with three per-manent magnets loosely recessed into the top side for thepurpose of positioning a test strip. The bottom surface of theholder shall be faced with non-skid material. A strip of metalconforming to the requirements of the test strip shall be per-manently bonded to the top surface to provide a level ap-proach surface to the test strip. This will prevent the shot onthe flaps from hitting the exposed end of the test strip whichmay dislodge them from the flap. The magnets shall hold thetest strip to the top of the block and against the bonded teststrip.

Table 5-14. Tool Speed Operation Requirements

Flap Assembly Description (Inches) Rotary Tool Operation Speed (RPM)Mandrel with 1 x 2 flaps 1500 to 5000Mandrel with 9/16 x 1 1/4 flaps 1500 to 8000Mandrel with 9/16 x 1 flaps 1500 to 8000

5.13.1.1.5 10x to 30x Magnifying Glass. Used for ob-servation of the surface to determine surface coverage.

5.13.1.2 Surface Preparation Procedure. Prepare therequired surface for peening as follows:

5.13.1.2.1 Dimensions and Part Conditions. Surfaceareas required for roto-peening shall meet the dimensionaland surface finish requirements before peening. Unless oth-erwise directed, all heat treatments required to develop speci-fied mechanical properties, and all machining, grinding, andrequired polishing operations shall be completed beforepeening. Prior to roto-peening, all fillets shall be properlyformed, all burrs shall be removed, and all sharp edges andcorners to be peened shall be machined or sanded to providethem with a sufficient radius to result in complete coveragewithout any distortion.

5.13.1.2.2 Cleaning and Coating/Paint Removal. Un-less otherwise specified, all surface areas requiring roto-peening shall be cleaned in accordance with Chapter 3 ofthis manual and coatings/paints shall be removed from theareas per procedures in TO 1-1-8.

5.13.1.2.3 Masking. Any areas of the part which havecritical surface finishes that must be free from peening shallbe suitably masked or otherwise handled to protect themfrom damage caused by the rotary flap action. Masking ofareas not requiring peening and whose surface finishes arenot critical is optional.

5.13.1.2.4 RPM and Peening Time Determination. Therequired peening intensity “Arc Height” for peening needs tobe converted to Roto-Peening Intensity. First use Table 5-15to find the “Material Thickness” and “Material Type” for the

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5-44 Change 16

aircraft part that requires rotary peening. Once the shot peen-ing “Arc Height” is found using Table 5-15, the followingfigures are used to convert “Arc Height” for Roto-Peeningintensity and time requirements.

NOTE

For Almen Strip “A” use Figure 12 and Figure 13.For Almen Strip “N” use Figure 14 and Figure 15.For Almen Strip “C” Contact Cognizant Engineer.

Table 5-15. Standard Peening Intensity (Isp) for Complete Coverage Arc-Height (All Numbers in Inches)

Material Thickness(Inches)

Steel: Under Steel: Over Titanium and Aluminum and200,000 PSI 200,000 PSI Titanium Alloys Aluminum Alloy

0.090 or less 0.003-0.006A 0.003-0.006A 0.00-0.006A0.090- 0.375 0.006-0.012A 0.006-0.010A 0.006-0.010A 0.006-0.010A0.375 or more 0.012-0.016A 0.006-0.010A 0.060-0.010A 0.010-0.014A

NOTE

• Base on test strip holder as specified in AMS-S-2430.

• The suffix letter A indicates that the values have been determined by using an A type Almen test strip. An Atype Almen test strip is used for arc-heights up to 0.024A.

• For greater intensities, Almen test strip C should be used. Any conversions for C test strips shall be provided bythe cognizant engineering prior to use.

• Almen test strip N is used if the intensity is less than 0.004A

5.13.2 Determining Peening/Intensity. The peening in-tensity is determined from a saturation curve in accordancewith Paragraph 5.13.2.1.1. The saturation curve intensity islimited to each individual operator and equipment type used.Intensity verification is the peening of one test strip for theintensity time “T” from the saturation curve of initial proce-dure qualification. Intensity verification is acceptable if theconverted test strip arc height is within ± 0.0015 inch (±0.038mm) of the original arc height and within the required inten-sity range. The peening intensity required after corrosion re-moval is that which is specified in a system specific mainte-nance technical order for the specific weapon system or itmay be determined from Table 5-15.

T = TsA/As

T = Total peening time, in minutes.Ts = Saturation peening time, as de-

termined from Figure 5-14and/or Figure 5-15, in minutes.

A = Area of part to be peened insquare inches.

As = The 2.25 in2 area of the teststrip when a flap with a widthof 3/4 inch or less is used; ifthe flap width is greater than3/4 inch, multiply effectivewidth of the flap by 3 inches toobtain As.

Isp = Standard peening intensity mea-sured with an AMS-S-13165Almen test strip holder. Theintensity range required forsaturation peening for variousmetal alloys at various thick-nesses is specified in Table5-15.

A = 3 x 4 inch = 12 inch2

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Change 16 5-45

As = 1 x 3 inch = 3 inch2. This is thecase since a Type II, Class 1flap is 1 in (wider than 3/4 in).

Isp = 0.010A (10 mils). This is themaximum allowed intensity foraluminum alloys with a thick-ness within the 0.090 inch to0.375 inch range as determinedwith a AMS-S-13165 (MIL-S-13165) Almen strip holder andspecified in Table 5-18.

Irp = 13.2 mils (0.013A). This is therequired roto-peening intensitymeasured with a MIL-W-81940Almen strip holder. It is deter-mined by entering Figure 5-12on the horizontal (X) axis withthe Isp of 10 mils, moving up tothe line in the graph, and read-ing across to the vertical (Y)axis to find an Irp of 13.2 mils.

T = (3.25) 12/3 = 13.00 min = 13min and 0 sec at a flap speed of2500 RPM.

5.13.2.1 Arc Height Conversion. Strip arc height mea-surements obtained using the magnetic strip holder shall beconverted to the values equivalent to those that are obtainedusing the SAE J442 strip holder using Figure 5-11 throughFigure 5-16. Only the converted arc heights will be used fordata points on saturation curves.

5.13.2.1.1 Intensity Determination Methods. Intensityshall be determined by either of the two methods below. TheSAE J443 10% rule method is preferred but the coveragemethod is permitted.

5.13.2.1.1.1 SAE J443 10% Rule Method. Intensity isdetermined from a saturation curve with the converted archeight at the first point whose time when doubled producesan arc height increase of 10% or less per SAE J443.

5.13.2.1.1.2 Almen Test Strip Coverage Method. Forthis method a saturation curve is developed by plotting con-verted arc heights and strip coverage versus time. Intensity isdetermined as the converted arc height of the saturation curvetest strip at the time when it reaches full coverage as deter-mined by the methods in SAE J2277. Peening of the extremeends of Almen strips is not necessary. However, uniformcoverage of at least the central 2 inches of length is essentialto ensure accurate arc height measurements across the Al-men gage 1.25 inch support ball distance.

5.13.3 Peening Process Preparation.

5.13.3.1 Rotary Tool Speed. To achieve the requiredpeening intensity on an A test strip, the speed necessary forthe flap equipment may be estimated by referring to Table5-14. This is a first estimate that must be adjusted by gen-eration of a saturation curve.

5.13.3.2 Flap Operation. The flap assembly shall bemoved over the surface being peened with longitudinalsweeps and transverse oscillation; i.e., circular motion toprovide uniform surface coverage. Flap standoff distanceshall be determined by the operator so as to be comfortable,sustainable, and effective.

NOTE

The flaps used for this procedure are expensiveand tear apart easily when over the edge of a partduring the peening operation. The use of a hardrubber material clamped in place at the edges ofthe part being peened will prevent the flaps fromdropping over the edge of the part during thepeening operation, thus increasing the useful lifeof each flap.

5.13.3.3 Coverage. Areas of parts specified shall bepeened to complete visual coverage as specified in SAEJ2277 except parts being reshaped or straightened. Deter-mine coverage by visually inspecting surfaces using 10x to30x magnification. Every portion of the critical surface shallshow visible evidence of plastic flow to demonstrate com-plete coverage and saturation which is indicated by the com-plete obliteration of the original surface finish and overlap-ping peening impressions. If visual coverage with 10x to 30xmagnification is not clear refer to SAE J2277 for alternatemethods.

5.13.3.4 Part Peening Time. The area to be peened shallbe peened in increments of time and visually inspected forcoverage until full coverage (98%) is achieved (Figure 5-17).Coverage time is a function of part material hardness. Softparts will receive larger peening dimples and will cover fasterthan harder parts. For coverage requirements greater than100% the time to reach 100% shall be determined first priorto further coverage peening. Higher coverages require timemultiples of the 100% coverage time for the peened area

5.13.4 Post Peening Surface Finish. Conversion coat orpassivate the peened area in accordance with Section II orother applicable paragraphs of this chapter. Apply protectivecoatings, as specified, in the system specific maintenancemanual for the aircraft, missile, or equipment involved usingapplication procedures in TO 1-1-8.

TO 1-1-691

5-46 Change 16

Figure 5-11. Magnetic Almen Strip Holder

TO 1-1-691

Change 5 5-46.1/(5-46.2 blank)

Figure 5-12. “A” Test Strip Magnetic to SAE J442 Stripholder Arc Height Conversion Graph

TO 1-1-691

Change 3 5-47

Figure 5-13. “A” Test Strip Arc Height Magnetic to SAE J442 Stripholder Conversion Chart, 0.001 Inch

TO 1-1-691

5-48 Change 3

Figure 5-14. “N” Arc Height Magnetic to SAE J442 Stripholder Conversion Graph

TO 1-1-691

Change 3 5-49

Figure 5-15. “N” Arc Height Magnetic to SAE J442 Stripholder Conversion Chart, 0.001 Inch

TO 1-1-691

5-50 Change 3

Figure 5-16. Arc Height Plotting Chart

TO 1-1-691

Change 16 5-51

Figure 5-17. Example of Coverage

TO 1-1-691

5-52 Change 3

Figure 5-18. Flap Deflection Ranges

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Change 16 5-53/(5-54 blank)

CHAPTER 6SEALANTS

6.1 PURPOSE.

This chapter covers sealing compounds and procedures fortheir application to aircraft, missile, and equipment struc-tures. When properly applied, sealants prevent the intrusionof moisture from condensation, rain, and salt water as wellas dust, dirt, and aircraft fluids into joint areas where theycan cause extensive corrosion. Sealants are one of the mostimportant tools for corrosion prevention and control. To beeffective, it is critical that the correct sealant be chosen for aspecific area/situation and that it be applied correctly. Onlyqualified personnel thoroughly familiar with sealants andtheir application shall be permitted to handle and apply them.

6.2 APPLICATIONS.

Sealants are used for the following reasons:

a. Fuel sealing (fuel tanks and delivery components).

b. Pressure area sealing (aircraft cabin areas).

c. Weather and fluid sealing (aircraft, missile, and equip-ment exterior and interior skin and structural joints andsurfaces).

d. Firewall sealing (engine and ordnance areas).

e. Electrical sealing (bulkhead wiring, electrical connec-tors, and components).

f. Acid-resistant sealing (aircraft, missile, and equipmentbattery compartments, and aircraft relief tubes andwaste collection tanks).

g. Window sealing (aircraft and equipment windows).

h. High temperature sealing (engine areas, anti-icingducts, and some electronics).

i. Aerodynamic sealing/smoothing (aircraft and missileexterior skin surfaces).

6.3 SEALING COMPOUNDS.

Table 6-1 lists approved sealing compounds and their avail-able types, properties, and intended use. Refer to the appli-cable aircraft, missile, or equipment system specific mainte-nance manual and Paragraph 6.7 for specific informationconcerning selection of the proper sealing compound and its

application. Observe the warnings and cautions in Paragraph6.6 when using any sealing compound.

6.3.1 Sealant Packaging. Sealants are generally pack-aged and available as three different types of packaging orunits of issue (U/I).

6.3.1.1 Two-Part Kit (KT). The package consists of twoseparate containers, usually metal cans. One contains thecatalyst (Part A) and the other contains the base compound(Part B), each in premeasured amounts for mixing together.

6.3.1.2 Cartridge (CA). Cartridges come in two differenttypes. One for single component sealants and one for twocomponent sealants.

6.3.1.2.1 Single Component Sealants. Single compo-nent sealants are contained in a plastic cartridge or tube in aready-to-use condition requiring no mixing. If some of asingle component sealant remains after a job, it can be storedand used at a future time as long as the cartridge/tube istightly capped at the nozzle opening to prevent contact withair.

6.3.1.2.2 Two Component Sealants. Two componentsealants are packaged in Semkits® which are complete plas-tic cartridge assemblies that store both sealant components(each in separate chambers). Mixing of sealant materials isaccomplished within the assembly, which is then used forapplication. Semkits® are convenient because they eliminatethe need to measure and handle the materials for mixing andgenerate less waste as they contain small quantities for smallarea applications.

6.3.1.3 Pre-Mixed and Frozen (PMF). Two componentsealants can be pre-measured, mixed, and frozen at tempera-tures of -40° F (-40° C) and stored at temperatures of -20° F(-29° C) or lower with the unit of issue being in ounces. ThePMF material in plastic tubes is a convenient package con-figuration for low and intermittent usage applications, par-ticularly in depot level operations. Simply thaw the materialand use.

6.3.2 Polysulfide, Polyurethane, and PolythioetherSealing Compounds. All these materials are two compo-nent with the Part B base containing the prepolymer and thePart A catalyst containing the curing agent packaged in sepa-rate containers supplied together as a kit. When thoroughlymixed, the catalyst cures the prepolymer to a rubbery solid.Rates of cure depend on the type of prepolymer and catalyst,

TO 1-1-691

6-1

as well as the temperature and humidity. Full cure of thesematerials may require as long as 7 days. Refer to Table 6-1for a general description of these materials.

6.3.3 Silicone Sealing Compounds.

Room Temperature Vulcanizing (RTV) siliconesconforming to MIL-A-46106 produce acetic acid(vinegar smell) which is corrosive. Therefore, as arule of thumb, if the RTV silicone material smellslike vinegar, don’t use it.

These materials are generally one component materials whichcure by reacting with moisture in the air. If silicones areapplied too thick or in such a way that moisture is preventedfrom entering the material, they may not cure at all. In addi-tion, many unauthorized silicone sealing compounds produceacetic acid, indicated by a vinegar smell, while curing whichcan lead to severe corrosion problems. There are two sili-cone sealant specifications, MIL-A-46146 and MIL-A-46106.Only MIL-A-46146 materials are noncorrosive. MIL-A-46106 materials give off acetic acid while curing and shallnot be used on Air Force equipment.

6.3.4 Adhesion Promoters.

Solvent based adhesion promoters are hygroscopic(absorb moisture) and must be kept away frommoisture. Discard material if it becomes cloudy ora precipitate is formed.

Some sealing compounds may require the application of aspecial primer or adhesion promoter prior to sealant applica-tion in order to develop a good adhesive bond with the sur-face. Use only those primers or adhesion promoters recom-mended by the manufacturer for their product. Thesematerials are especially important for MIL-S-85420, SAE-AMS3277 (supersedes MIL-S-29574), and some siliconebased sealants. Refer to Appendix A for a listing and de-scription of adhesion promoters.

6.3.5 SAE AMS 3255 Oil and Water Resistant, Ex-panded Polytetrafluoroethylene Sealing Tape (EPTFE)Skyflex. The sealant tape consists of an extruded gasket(most of the time with several protruding ribs) with a pres-sure sensitive adhesive backing. No mixing is required andthere are no application life constraints or cure times in-

volved. The sealing tape does not require removal and re-placement unless damaged. The adhesive backing is onlyrequired to hold the sealing tape in place until an accesspanel, floor panel, or component is reinstalled. Tapes may bespecial ordered without adhesive backing for use in areaswhere fluid exposure (e.g. hydraulic fluid or fuel) is expectedand applied with a fluid resistant rubber cement. Refer toTable 6-1 for a general description of these tapes.

NOTE

Use of the EPTFE (Skyflex) sealing tape requiresauthorization from the aircraft SPD or the missileor equipment SPM engineering authority.

6.3.6 Av-Dec® Polyurethane Sealant Tapes and TwoComponent Sealants. Av-Dec® sealing tapes are precuredpolyurethane gasket tapes with the HT3935-7 series having atacky adhesive on both sides and the HT3000 series having atacky adhesive on one side and a permanent Teflon filmbacking on the other side. These tapes require no mixing,have unlimited application life, and require no cure time.The HT3995-7 series tapes are particularly useful for sealinghigh moisture areas such as aircraft floor panels. The HT3000series are useful for sealing frequently removed inspectionand access panels, since once applied they are totally reus-able unless damaged; damaged areas only may be removedand replaced. The HT3326-5 SelfLeveling Green liquid andTF2219 thick orange, TG8498-50, and TG20101-50 thixo-flex grey paste materials are two component curable sealantsthat are particularly useful in filling voids and cavities toprevent moisture and fluid accumulation and subsequent cor-rosion damage in areas where ease of removal for inspectionand/or operational requirements is necessary.

6.4 EQUIPMENT.

The following equipment is available.

NOTE

Avoid air bubbles as much as possible during thefilleting operation. Allow the sealant to cure to, atleast, the tack-free stage before moving the assem-bly.

6.4.1 Sealant Gun. The Semco® Model 250-A or itsequivalent (refer to Figure 6-1), fitted with one of the nozzlesfrom Figure 6-2 is used for the application of fillet seals.When using this gun, the nozzle tip must be pointed into theseam and maintained at a 45 degree angle to the line oftravel, forcing the bead of sealing to precede the gun tip to

TO 1-1-691

6-2 Change 5

minimize entrapment of air. Use fairing/smoothing tools (i.e.,spatulas and spreaders) shown in Figure 6-5 to work sealantsand adhesives into seams.

6.4.2 Application Nozzles.

Care should be taken when using rivet nozzles toprevent sealant material from filling fastener holes.

In addition to the standard, fillet, and ribbon nozzles in Fig-ure 6-2, the countersink and rivet nozzles in Figure 6-3 andFigure 6-4, respectively, can also be used with sealant guns.Countersink nozzles can be used to apply sealants into thecountersink of fastener holes prior to fastener installation.Rivet nozzles are suitable for use to apply sealants intocountersink and through hole prior to fastening part(s) withrivets. The rivet nozzles have a spring-loaded tip. It serves asa check valve and allows for dispensing the precise amountof sealant material.

6.4.3 Injection Gun. Figure 6-6 illustrates two types ofinjection guns used for injecting sealant into confined holes,slots, structural voids, joggles, etc. Follow the proceduresoutlined in the applicable aircraft, missile, or equipment sys-tem specific maintenance manual and the injection gunmanufacturer’s operation instructions for the proper prepara-tion and use of these guns. For hard to reach areas, attach anextension nozzle to the injection tip.

6.4.4 Sealant Kits (Semkits®).

Before using sealant materials, refer to the sealantSafety Data Sheets (SDS) for information on han-dling precautions.

Certain types of sealants, such as SAE AMS-S-8802 (MIL-S-8802) and MIL-PRF-81733, are available as ready-to-usekits (Semkits®). These kits are compact, two-part mixingapplication units designed for convenient storage, easy mix-ing, and proper application of the sealant in small quantities.The base component of the sealant is packed in standard 2 ½OZ and 6 OZ cartridges which are placed in a filleting gunor injection gun for application after mixing with the accel-erator/catalyst. There are two styles: the Barrier Style, whichholds proportioned amounts of the two components sepa-rated by an aluminum barrier disc and the Injection Style,which stores the accelerator/catalyst material within the in-jection rod to separate it from the base compound prior touse. (Refer to Figure 6-7). When using Semkits®, note thatthe handle or the injection/dasher rod contains a pre-mea-sured amount of accelerator/catalyst and should be retaineduntil the ramrod has been operated to break the seal at thebottom of the injection/dasher rod releasing the accelerator/catalyst into the base component and mixing is completed.

All of the materials contained inside these two-componentSemkit® packages are mixed within the cartridges. Followthe manufacturer’s recommended storage instructions forthese Semkits®.

6.4.5 Sealant Removal and Application Tools.

• Sealant removal must be accomplished usingnon-metallic scrapers. The use of metallicscrapers (i.e. steel, aluminum, tin, brass, exactoknives, and pocket knives) to remove sealant isprohibited.

• Metallic scrapers scratch the aircraft surfacepotentially causing cracking and corrosion.

The most commonly used tools for removing or fairing outsealants are shown in Figure 6-5. Other tools may be manu-factured as needed to fit a specific situation. Only plasticshall be used to manufacture these sealant removal and ap-plication tools. The Pneumatic Vibro Gun Sealant Removalkit or Rapid Desealing System (RDS) listed in Table B-2may also be used.

6.5 SEALANT MIXING.

The proper weighing and mixing of components is essentialto assure proper curing and adhesion of sealants. Use anappropriate weight scale (refer to Appendix B), to accuratelymeasure the materials before blending. Accomplish all mix-ing in one designated central area in each organization. Poly-sulfide and polythioether sealants consist of two separatelypackaged components, a base compound (usually Part B)and an accelerator/catalyst (usually Part A) in ½ pint (6 OZ),pint (12 OZ), and quart (24 OZ) kits. The base-to-accelera-tor/catalyst ratio varies with different manufacturer’s of thesame type of sealant. It is important, therefore, to mix thematerial according to the manufacturer’s instructions recom-mendations. Add accelerator/catalyst into the base in the cor-rect ratio and mix until a uniform color is obtained. Difficul-ties with curing and/or adhesion of polysulfide andpolythioether sealants are frequently caused by incompletemixing. Two component sealants are chemically cured anddo not depend on solvent evaporation for curing. Slow handmixing is recommended for two-component can type kits. Ahigh speed mechanical mixer should not be used as internalheat will be generated thus reducing application life and in-troducing air into the mixture. Refer to Figure 6-7 for injec-tion style Semkit® mixing instructions.

6.5.1 Application Life. Application life and cure times aredependant on environmental considerations. The applicationlife of a sealant is the length of time that a mixed sealingcompound remains usable at 77° F (25° C) and 50% relativehumidity (RH). This time (in hours), known as a dash num-ber, is denoted as the last number in a sealant designation(e.g. MIL-PRF-81733, Type II-2 has an application life of 2

TO 1-1-691

Change 15 6-3

hours). Table 6-2 indicates application times, tack-free times,and full cure times for each sealant type and dash number at77° F (25° C) and 50% RH. For each 18°F (10°C) increasein the temperature above 77° F (25° C), the application,tack-free, and cure times are shortened by approximatelyone-half, while for each 18°sF (10°sC) decrease in the tem-perature below 77° F (25° C), the application, tack-free, andcure times are lengthened by approximately one-half. Foreach 15% increase in RH above 50%, the application, tack-free, and cure times are shortened by approximately one-half, while for each 15% decrease in RH below 50%, theapplication, tack-free, and cure times are lengthened by ap-proximately one-half. Maintenance personnel should beaware of the effects of temperature and humidity on the ap-plication life of a sealant. Mix only the amount of materialthat can be applied during the rated work life of the sealant.

6.5.1.1 Enhancement of Sealant Curing. There are sev-eral corrective measures that can be used to prevent and/orlessen sealant curing problems caused by various environ-mental conditions.

a. At a relative humidity of 30% RH or lower (some-times even 40% RH causes a problem), it is very dif-ficult to properly cure sealants. When these conditionsare experienced, adding water vapor to the air to in-crease the humidity by either wetting down the floor ofthe facility, covering the area being sealed with a wetcloth without it touching the sealant surface and keep-ing the cloth wet during the cure cycle, or some otherconvenient method will eliminate the problem.

Do not apply heat to sealants until 30 minutesminimum have elapsed at ambient (room) tem-perature after application to allow the containedsolvents to flash off. Most solvents are flammableand could catch fire if the sealants are exposed tohigher temperatures before the solvents flash off.

NOTE

If sealants are heated to a temperature of 110° F(43° C) or greater as noted in step b below, noadjustment to the humidity is required.

b. Except for MIL-S-85420 and SAE-AMS3277 (MIL-S-29574) sealants that are designed to cure properly withgood adhesion at low temperatures, sealant curing isextremely slow when applied at ambient (room) airtemperatures of 50° F (10° C) and below and adherevery poorly to metal structure having a surface tem-perature of 60° F (16° C) and below due to poor sur-face wetting properties at the time of application. Theseproblems can be eliminated by preheating the metalsurfaces to which a sealant will be applied to a tem-perature of 60° F (16° C) or higher and/or heating thesealant to a temperature of 130° F ±10° F (54° C ±6°

C) after application with hot air, infrared lamps, orsome other approved method after allowing the sealantto stand for minimum of 30 minutes at ambient (room)temperature after it is applied to flash off its containedsolvents.

c. If sealants are applied to metal surfaces having a sur-face temperature of 100° F (37° C) or at ambient(room) air temperatures of 95° F (35° C) or greater,will very likely have bubbles in the cured sealant film,commonly called “solvent pop” due to too rapid evapo-ration of the solvents contained in the sealant. Cool themetal surface down to a temperature of 90° F (32° C)or lower by wetting it down with water and then wip-ing the surface dry or by some other approved methodand/or relocate the equipment to which sealant is to beapplied to an area having an ambient (room) tempera-ture of 90° F (32° C) or lower prior to applying thesealant and keep the equipment in this cooler conditionfor a minimum of 30 minutes to allow the containedsolvents to flash off before relocating the equipment ina hotter area or applying heat to the sealant.

d. Sometimes sealant must be applied in areas whereother maintenance is being accomplished which leadsto sealant smears in the area caused by walking onand/or dragging tools through sealant that is not com-pletely cured. To minimize this problem, apply a poly-ethylene film over the uncured sealant after allowing aminimum of 30 minutes at ambient (room) tempera-ture after it is applied to flash off its contained solventsand permit the film to remain in place until the sealanthas completely cured.

e. The Rapid Curing Device (RCD) (Refer to AppendixB) can be used with SPD/SPO approval for acceleratedcuring of sealants. The RCD consist of the main con-trol module, the thermorcactor (infra-red emitter), 30feet of hosin, temperature sensors and other associatedcomponents. Propane used with the RCD must be pur-chased and stored separately. The RCD is effective onlywhen the energy it generates hits the entire area beingcured. Use on blocked, unreachable, or multiple repairareas will not reduce curing time.

6.5.2 Storage Instructions. When large quantities of seal-ants are used, such as for depot level maintenance opera-tions, it may be advantageous to pre-mix and freeze sealantsto provide a ready supply of mixed sealants when they areneeded. Store two-part kits and Semkit® package sealantsaccording to instructions on the container. Store polysulfidesealants in a pre-mixed and frozen (PMF) form in a freezerat -40° F (-40° C) or below for retention of optimal applica-tion properties and shelf life. Polythioether sealants requireextremely low temperature refrigeration at -80° F (-62° C) orbelow for optimal retention of application properties andshelf life. Thawing of PMF sealants can be accomplished intwo ways. For ambient (room) temperature thaw, place thePMF cartridge in a vertical position. Let stand at +70° to+80° F (+21° to +27° C) approximately 30 minutes. Dry any

TO 1-1-691

6-4 Change 2

condensation from the exterior of the cartridge prior to use.For water bath thaw, place the PMF cartridge upright in a+120° F (49° C) water bath for approximately 4 to 6 min-utes. Upon removal from the bath, carefully dry the exteriorof the cartridge before using.

6.5.3 Mixing MIL-PRF-81733, Type III Sprayable Seal-ant Coating. The base component (Part B) of MIL-PRF-81733, Type III has a tendency to settle out during storage,so it requires thorough mixing with a standard paint shakerto obtain a uniform consistency before the addition of theaccelerator component (Part A). The accelerator component(Part A) requires hand shaking or stirring with a wood stirpaddle/stick in its container to obtain a uniform consistencybefore adding it to the base component (Part B). After bothcomponents, base and accelerator, have been stirred/mixed

separately, add the proper amount of the accelerator to thebase in its container and mix the combined materials, pref-erably with a paint shaker for 3 minutes in an upright posi-tion followed by 3 minutes in an inverted position for kits upto 1 gallon, and for 5 to 10 minutes with an air driven agi-tator in a pressure pot for kits greater than 1 gallon. Forproper application life and cure, the base and acceleratormust be combined in the proper ratio and mixed prior to theaddition of any thinner (solvents). After mixing, the sealantmay be thinned for spraying to a viscosity of 20 to 25 sec-onds in a No. 2 Zahn cup (refer to TO 1-1-8), with a 20 to30% by volume addition of a 50% by volume mixture ofMEK conforming to ASTM D 740 and Toluene conformingto A-A-59107, and stirring for 2 minutes with an air drivenagitator at 70 RPM.

TO 1-1-691

Change 2 6-5

Figure 6-1. Pneumatic Sealant Gun

TO 1-1-691

6-6

Figure 6-2. Sealant Application Nozzles

TO 1-1-691

6-7

Figure 6-3. Countersink Application Nozzles

TO 1-1-691

6-8

Figure 6-4. Rivet Application Nozzles

TO 1-1-691

6-9

Figure 6-5. Sealant and Adhesive Smoothing Tools

TO 1-1-691

6-10

Figure 6-6. Sealant Injection Guns

TO 1-1-691

6-11

Figure 6-7. Injection Style Semkit®

TO 1-1-691

6-12

Tabl

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alin

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Spec

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TO 1-1-691

6-13

Tabl

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seSA

EA

MS

3276

(sup

erse

des

MIL

-S-8

3430

),Se

alin

gC

om-

poun

d,In

tegr

alFu

elTa

nks

and

Gen

eral

Purp

ose

(Pol

ysul

fide)

Cla

ssA

(thi

n)-

for

brus

hap

-pl

icat

ion

Two

com

pone

nts

Cla

ssB

(thi

ck)

-fo

rse

alan

tgu

nor

spat

ula

appl

icat

ion

Roo

mte

mpe

ratu

recu

re

Cla

ssC

(thi

ck)

-fo

rus

ew

here

exte

nded

asse

mbl

ytim

esar

ere

quir

ed

Serv

ice

tem

p:-6

5°to

+25

0°F

(-54

°to

+12

1°C

)su

stai

ned,

inte

rmitt

ent

(abo

ut6

hour

sm

ax)

expo

sure

to36

0°F

(182

°C

)

For

high

erte

mpe

ratu

reap

pli-

catio

ns.

Use

dfo

rfu

elta

nkse

alin

g,ca

bin

pres

sure

seal

-in

g,ho

lean

dvo

idfil

ling,

and

aero

dyna

mic

smoo

thin

g;fo

rfa

ying

surf

ace

seal

ing,

wet

-ins

talla

tion

offa

sten

ers,

over

coat

ing

fast

ener

s,an

dse

alin

gjo

ints

and

seam

sin

fuel

wet

area

s;an

dfo

rno

n-st

ruct

ural

adhe

sive

bond

ing.

Tre

atbo

ndsu

rfac

esw

ithSA

EA

MS

3100

adhe

sion

prom

oter

toen

hanc

ese

alan

tad

hesi

on.

Cla

ssD

(thi

ck)

-fo

rho

lean

dvo

idfil

ling

Peel

stre

ngth

:20

inlb

wid

th(m

in)

Cla

ssE

(thi

ck)

-fo

rau

tom

atic

rive

ting

equi

pmen

tap

plic

a-tio

n

No

corr

osio

nin

hibi

tors

Res

ists

fuel

,oi

l,an

dhy

drau

licflu

id

PR-1

773

(sup

erse

des

PR-1

403G

),Se

alin

gC

ompo

und,

Non

-Chr

o-m

ate

Cor

rosi

onIn

hibi

tive

Poly

sulfi

deR

ubbe

rC

AG

EC

ode

#835

74

Cla

ssB

(thi

ck)

-fo

rse

alan

tgu

nor

spat

ula

appl

icat

ion

Two

com

pone

nts

Pref

erre

dse

alan

tfo

rge

nera

lpu

rpos

e,lo

wad

hesi

onse

al-

ing

ofac

cess

door

s,flo

orpa

nels

and

plat

es,

rem

ovab

lepa

nels

,an

dfo

rmed

inpl

ace

(FIP

)ga

sket

sin

non-

fuel

area

s.C

anbe

used

tore

pair

defe

cts

inFI

PG

aske

ts.

Roo

mte

mpe

ratu

recu

reSe

rvic

ete

mp:

-65°

to25

0°F

(-54

°to

+12

1°C

)Pe

elst

reng

th:

2in

lbw

idth

(max

)C

orro

sion

inhi

bito

rsR

esis

tsfu

el,

oil,

and

hydr

aulic

fluid

.SA

EA

MS

3267

/1,

/2,

/3,

and

/4(s

uper

sede

sM

IL-S

-878

4),

Seal

ing

Com

poun

d,L

owA

d-he

sion

,C

orro

sion

Inhi

bitin

g,fo

rR

emov

able

Pane

lsan

dFu

elTa

nkIn

spec

tion

Plat

es

Cla

ssA

(thi

n)-

for

brus

hap

-pl

icat

ion

Two

com

pone

nts

Poly

sulfi

deru

bber

seal

ing

com

poun

dfo

rfil

let

and

fay

surf

ace

seal

ing

ofre

mov

able

stru

ctur

essu

chas

acce

ssdo

ors,

floor

pane

lsan

dpl

ates

,re

mov

able

pane

ls,

and

fuel

tank

insp

ectio

npl

ates

.N

otfo

rhi

ghte

mpe

ra-

ture

area

sor

perm

anen

tst

ruct

ures

.

Cla

ssB

(thi

ck)

-fo

rse

alan

tgu

nor

spat

ula

appl

icat

ion

Roo

mte

mpe

ratu

recu

re

Serv

ice

tem

p:-6

5°to

250°

F(-

54°

to+

121°

C)

/1=

Cla

ssA

-½Pe

elst

reng

th:

4in

lbw

idth

(max

)/2

=C

lass

B-½

Cor

rosi

onIn

hibi

tors

/3=

Cla

ssA

-2R

esis

tsfu

el,

oil,

and

hydr

aulic

fluid

./4

=C

lass

B-2

TO 1-1-691

6-14

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seSA

EA

MS

3374

/1,

/2,

/3,

and

/4(s

uper

sede

sM

IL-S

-382

49),

Seal

ing

Com

poun

d,A

ircr

aft

Fire

wal

l

Type

1(o

ne-p

art

high

tem

p.si

licon

e)-

cond

ensa

tion

cure

d

One

com

pone

nt,

Type

1;Tw

oco

mpo

nent

s,Ty

pes

2,3,

and

4Se

alin

gfir

ewal

lst

ruct

ures

ex-

pose

dto

very

high

tem

pera

-tu

res

agai

nst

the

pass

age

ofai

ran

dva

pors

.C

ures

onex

posu

reto

air.

/1=

Type

1Ty

pe2

(tw

o-pa

rthi

ghte

mp.

silic

one)

-ad

ditio

ncu

red

Roo

mte

mpe

ratu

recu

re

/2=

Type

2Ty

pe3

(tw

o-pa

rthi

ghte

mp.

silic

one)

-co

nden

satio

ncu

red

Serv

ice

tem

p:-6

5°to

+40

0°F

(-54

°to

+20

4°C

)w

ithst

ands

flash

tem

pera

ture

of20

00°

F(1

093°

C)

/3=

Type

3Ty

pe4

(tw

o-pa

rtpo

lysu

lfide

)Pe

elst

reng

th:

10in

lbw

idth

(min

)/4

=Ty

pe4

No

corr

osio

nin

hibi

tors

Res

ists

fuel

,oi

l,an

dhy

drau

licflu

idM

IL-S

-854

20,

Seal

ing

Com

-po

unds

,Q

uick

Rep

air,

Low

Tem

pera

ture

Cur

ing

Poly

sul-

fide,

for

Air

craf

tSt

ruct

ures

Cla

ssA

(thi

n)-

for

brus

hap

-pl

icat

ion

Two

com

pone

nts

Qui

ckre

pair

seal

ing

ofai

rcra

ftst

ruct

ures

atlo

wte

mpe

ra-

ture

s.U

seon

lyw

ithth

ere

c-om

men

ded

adhe

sion

pro-

mot

er/p

rim

erfo

rop

timum

resu

lts.

Whe

ncu

red

ata

tem

pera

ture

ofat

leas

t75

°F

(24°

C),

the

fly-a

way

time

is2

to3

hour

s.W

hen

cure

dat

ate

mpe

ratu

reas

low

as45

°F

(7°

C),

the

fly-a

way

time

is4

hour

sfo

rTy

peII

seal

-an

tsan

d8

hour

sfo

rTy

peI

seal

ants

.T

his

seal

ant

shou

ldbe

stor

edat

ate

mpe

ratu

reno

tto

exce

ed+

80°

For

poor

adhe

sion

will

resu

lt.

Type

I-

Dic

hrom

ate

cure

syst

emC

lass

B(t

hick

)-

for

seal

ant

gun

orsp

atul

aap

plic

atio

nL

owte

mpe

ratu

recu

re

Type

II-

Man

gane

secu

resy

stem

Serv

ice

tem

p:-6

5°to

200°

F(-

54°

to+

93°

C)

Peel

stre

ngth

:10

inlb

wid

th(m

in)

No

corr

osio

nin

hibi

tors

Res

ists

fuel

,oi

l,an

dhy

drau

licflu

id.

TO 1-1-691

6-15

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seSA

E-A

MS3

277

(MIL

-S-2

9574

),Se

alin

gC

ompo

und,

Poly

thio

-et

her,

for

Air

craf

tSt

ruct

ures

,Fu

elan

dH

igh

Tem

pera

ture

Res

ista

nt,

Fast

Cur

ing

atA

m-

bien

t(R

oom

)Te

mpe

ratu

rean

dL

owTe

mpe

ratu

res

Cla

ssA

(thi

n)-

for

brus

hap

-pl

icat

ion

Two

com

pone

ntM

ultip

urpo

seai

rcra

ftst

ruct

ure

and

inte

gral

fuel

tank

seal

-an

tsw

ithra

pid

ambi

ent

(roo

m)

and

low

tem

pera

ture

curi

ngca

pabi

litie

s.U

seof

man

ufac

ture

rsre

com

men

ded

prim

eris

requ

ired

prio

rto

appl

ying

this

seal

ant

for

prop

erad

hesi

on.

Type

Ica

nbe

used

asan

alte

rnat

efo

rSA

EA

MS-

S-88

02(M

IL-S

-88

02)

infu

elta

nkap

plic

a-tio

nsan

dTy

peII

can

beus

edas

anal

tern

ate

for

MIL

-PR

F-81

733.

Type

I,N

oco

rros

ion

inhi

bito

rsin

term

itten

tus

eto

+40

0°F

(204

°C

)G

rade

A,

Gen

eral

use,

fuel

tank

san

dai

rcra

ftst

ruct

ures

Gra

deA

1,A

mbi

ent

orim

med

iate

heat

cure

afte

rap

plic

atio

nat

tem

psup

to35

0°F

(175

°C

)C

lass

esB

&C

only

Gra

deB

(enh

ance

dcr

aze

resi

stan

cefo

rai

rcra

ftac

rylic

tran

spar

enci

es)

Cla

ssB

(thi

ck)

-fo

rse

alan

tgu

nor

spat

ula

Low

(dow

nto

+20

°F/

-7°

C)

and

ambi

ent

(roo

m)

tem

pera

ture

curi

ng;

Type

I,G

rade

A1

only

-ca

nbe

heat

cure

dat

tem

pera

-tu

res

upto

+35

0°F

(+17

5°C

)

Type

II,

Cor

rosi

onin

hibi

tive

in-

term

itten

tus

eto

360°

F(1

82°

C)

Cla

ssC

(sem

i-th

ick)

-ex

tend

edas

sem

bly

times

for

fayi

ngsu

rfac

ese

alin

g

Serv

ice

tem

p:-8

0°to

+30

0°F

(-68

°to

+15

0°C

)w

ithin

ter-

mitt

ent

use

to+

400°

(+20

4°C

)fo

rTy

peI

and

+36

0°F

(+18

2°C

)fo

rTy

peII

Peel

stre

ngth

:20

inlb

wid

th(m

in)

Cor

rosi

onin

hibi

ting

-Ty

peII

only

Type

Iha

sno

corr

osio

nin

hibi

tors

Res

ists

fuel

,oi

l,an

dhy

drau

licflu

id.

TO 1-1-691

6-16

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seM

IL-A

-461

46,A

dhes

ive

-Se

al-

ants

,Si

licon

e,R

oom

Tem

pera

-tu

reV

ulca

nizi

ng(R

TV

),N

on-

corr

osiv

e(f

orus

ew

ithSe

nsiti

veM

etal

san

dE

quip

-m

ent)

Gro

upI

-G

ener

alpu

rpos

eO

neco

mpo

nent

Con

veni

ent

one

com

pone

nt,

nonc

orro

sive

,R

TV

silic

one

seal

ant

for

use

with

sens

itive

met

als

and

equi

pmen

t.N

otto

beus

edw

here

resi

stan

ceto

fuel

s,oi

ls,

orhy

drau

licflu

ids

isre

quir

ed.

Che

ckm

anuf

actu

rer’

sin

stru

ctio

nsfo

rpr

imer

requ

irem

ents

onth

em

etal

subs

trat

ebe

ing

seal

ed,

and

appl

yth

esp

eci-

fied

prim

erbe

fore

appl

ying

the

seal

ant.

Gro

upII

-H

igh

stre

ngth

Roo

mte

mpe

ratu

recu

reG

roup

III

-H

igh

tem

pera

ture

,ea

chgr

oup

has

two

type

s.Se

rvic

ete

mp:

-70°

to+

400°

F(-

57°

to+

204°

C)

for

Gro

ups

I&

IIan

d-7

0°to

+60

0°F

(-57

°to

+31

6°C

)fo

rG

roup

III

Type

I-

Thi

xotr

opic

past

ein

lbs

Peel

stre

ngth

:G

roup

I,Ty

peI:

15in

lbs

wid

th(m

in),

Type

II:

4in

lbs

wid

th(m

in),

Gro

ups

II&

III:

(bot

hty

pes)

:40

inlb

sw

idth

(min

)Ty

peII

-Se

lf-l

evel

ing

liqui

dN

oco

rros

ion

inhi

bito

rsL

ong

shel

flif

eSh

ort

cure

time

SAE

AM

S32

55,

Seal

ing

Tape

,Po

lyte

trafl

uoro

ethy

lene

,E

x-pa

nded

(EPT

FE)

Oil

and

Wat

erR

esis

tant

;(S

kyfle

x(®

))

Cla

ss1:

Con

tinuo

usR

ibbe

d,in

clud

es:

Skyfl

ex®

PN’s

:Pr

efor

med

gask

etta

pew

ithno

adhe

sive

onei

ther

side

exce

ptas

note

din

“Int

ende

dU

se”

colu

mn

Seal

ing

offa

ying

surf

aces

,ac

cess

/rem

ovab

lepa

nels

,flo

orbo

ards

,an

dw

ind-

scre

ens.

Not

for

fuel

soak

edor

very

high

tem

pera

ture

appl

icat

ion.

Non

haza

rdou

sal

tern

ativ

eto

low

adhe

sion

,tw

oco

mpo

nent

seal

ants

.So

me

ofth

ese

seal

ing

tape

sha

vea

low

peel

stre

ngth

adhe

sive

onon

esi

deto

hold

the

tape

inpl

ace

onon

esu

r-fa

cew

hile

the

mat

ing

part

isbe

ing

inst

alle

d.

GU

A-1

071-

1-

for

fay

surf

aces

≤1in

wid

eN

om

ixin

g,m

aski

ng,

orcu

ring

requ

ired

GU

A-1

001-

1-

for

fay

surf

aces

≤1in

wid

eSe

rvic

ete

mp:

-65°

to+

450°

F(-

54°

to+

232°

C)

with

shor

tte

rmex

posu

reto

600°

F(3

15°

C)

GU

A-1

001-

2-

for

fay

surf

aces

≤1in

wid

ew

here

thic

ker

tape

isne

eded

tofil

lfa

ysu

r-fa

cega

p

Peel

stre

ngth

:2

lb/in

wid

th(m

ax)

for

side

with

adhe

sive

only

GU

A-1

017-

1-

for

fay

surf

aces

≤1in

wid

eN

oco

rros

ion

inhi

bito

rs

TO 1-1-691

6-17

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seG

UA

-140

1-1

-fo

rfa

ysu

rfac

es≤1

inw

ide

indr

yar

eas

offlo

orbo

ards

and

whe

rea

thic

ker

tape

isne

eded

tofil

lfa

ysu

rfac

ega

ps

Res

ists

wat

er,

fuel

,oi

l,an

dhy

-dr

aulic

fluid

GSC

-21-

8076

7-00

-fo

rfa

ysu

rfac

es<

1in

inhi

ghm

ois-

ture

area

sof

floor

boar

dsan

dw

here

thic

ker

tape

isne

eded

tofil

lfa

ysu

rfac

ega

psC

lass

2:C

ontin

uous

Non

-R

ibbe

d,in

clud

es:

Skyfl

exPN

’sG

UA

-100

3-1

-fo

rco

mpe

nsa-

tion

tape

ana

rrow

un-r

ibbe

dta

peus

edto

fill

irre

gula

ritie

son

ase

alin

gsu

rfac

eor

repa

irm

inor

dam

age

toa

prev

i-ou

sly

appl

ied

tape

seal

GU

A-1

057-

1-

for

fay

surf

aces

<1

inw

ide,

used

assh

im/

barr

ier

tore

sist

min

orch

af-

ing

GU

A-1

058-

1-

for

fay

surf

aces

<1

inw

ide,

used

asa

shim

/ba

rrie

rto

resi

stm

inor

chaf

-in

gG

UA

-105

9-1

-fo

rfa

ysu

rfac

es>

1in

wid

e,us

edas

shim

/ba

rrie

rto

resi

stm

inor

chaf

-in

gG

UA

-130

1-1

-fo

rfa

ysu

rfac

e<

1in

wid

ew

ithth

ick

gaps

TO 1-1-691

6-18

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seA

v-D

ec®

HiT

ak®

Poly

uret

hane

Tape

Seal

ant

(PN

HT

3935

-7-

XX

X)

Pref

orm

edga

sket

tape

with

adhe

-si

veon

both

side

san

dth

inpo

lyet

hyle

nere

leas

efil

mon

one

side

For

fay

surf

ace

seal

ing

ofar

-ea

sw

here

fluid

intr

usio

nis

apr

oble

msu

chas

airc

raft

floor

pane

lsan

dca

rgo

tiedo

wn

fittin

gs.

For

max

imum

seal

ing,

rem

ove

the

rele

ase

film

for

adhe

sion

tobo

thsu

rfac

es.

For

easi

erpa

nel

rem

oval

and

max

imum

reus

-ab

ility

,le

ave

the

rele

ase

film

inpl

ace

onth

esi

deco

ntac

t-in

gth

ere

mov

able

pane

l.D

amag

edse

ctio

nsof

the

tape

are

easi

lyre

pair

edas

itha

sve

rygo

odad

hesi

onto

itsel

f.

-100

for

fay

surf

aces

≤1in

wid

eN

om

ixin

g,m

aski

ng,

orcu

ring

requ

ired

-150

for

fay

surf

aces

≤1in

upto

1.5

inw

ide

Serv

ice

tem

p:(8

5°to

+27

5°F

(65°

to+

135°

C)

will

with

-st

and

shor

tno

n-co

ntin

uous

expo

sure

tohi

gher

tem

pera

-tu

res

-200

for

fay

surf

aces

>1.

5in

upto

2in

wid

ePe

elst

reng

th:

1-4

inlb

wid

th

-250

for

fay

surf

aces

>2

inup

to2.

5in

wid

eN

oco

rros

ion

inhi

bito

rs

Res

ists

wat

er,

deic

ing

fluid

s,fu

el,

oil,

and

hydr

aulic

fluid

(inc

lud-

ing

Skyd

rol

LD

-4)

TO 1-1-691

6-19

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

seA

v-D

ec®

HiT

ak®

Tuf

Seal

TM

Poly

uret

hane

Tape

Seal

ant

(PN

HT

3000

-XX

X)

Pref

orm

edga

sket

tape

with

adhe

-si

veon

one

side

and

ape

rma-

nent

Teflo

nfil

mba

ckin

gon

the

oppo

site

side

For

fay

surf

ace

seal

ing

ofno

n-pe

rman

ent

stru

ctur

esu

chas

acce

ssan

din

spec

tion

pane

ls/

cove

rson

airc

raft

,m

issi

les,

and

equi

pmen

tto

prev

ent

fluid

entr

yin

toth

efa

ying

surf

ace

area

san

dth

eca

vi-

ties

over

whi

chth

epa

nels

/co

vers

are

inst

alle

d.T

heTe

flon

back

ing

ishi

ghly

abra

sion

resi

stan

tan

dpe

r-m

itssl

ight

mov

emen

tof

the

cove

rsw

ithou

tda

mag

ing

the

stru

ctur

eto

whi

chit

isat

-ta

ched

.T

heta

peis

very

du-

rabl

e,so

itm

aybe

reus

edm

any

times

once

itis

in-

stal

led,

and

dam

aged

sec-

tions

are

easi

lyre

pair

edas

itha

sve

rygo

odad

hesi

onto

itsel

f.

-100

for

fay

surf

aces

≤1in

wid

eN

om

ixin

g,m

aski

ng,

orcu

ring

requ

ired

-150

for

fay

surf

aces

>1

inup

to1.

5in

wid

eSe

rvic

ete

mp:

(85°

to+

275°

F(6

5°to

+13

5°C

)-2

00fo

rfa

ysu

rfac

es>

1.5

inup

to2

inw

ide

Peel

stre

ngth

:2-

5in

lbw

idth

ad-

hesi

vesi

deon

ly,

the

othe

rsi

deha

sa

perm

anen

tTe

flon

film

back

ing

No

corr

osio

nin

hibi

tors

Res

ists

wat

er,

deic

ing

fluid

s,fu

el,

oil,

and

hydr

aulic

fluid

(inc

lud-

ing

Skyd

rol

LD

-4)

Av-

Dec

®Se

lfL

evel

ingT

MG

reen

(PN

HT

3326

-5-X

XX

)an

dT

hixo

flex

Ora

nge

Inje

ctab

le(P

NT

F221

9)Se

alan

ts

Self

Lev

elin

gG

reen

-fo

rfil

ling

void

san

d/or

cavi

ties

onho

ri-

zont

alsu

rfac

esw

here

ase

lf-

leve

ling

liqui

dm

aybe

used

;su

pplie

din

eith

er50

CC

(-05

0)or

200

(-20

0)ca

r-tr

idge

s

Two

com

pone

ntse

alan

ts;

both

are

supp

lied

indu

alsy

ring

esco

ntai

ning

the

requ

ired

amou

nts

ofre

sin

and

hard

ener

for

mix

ing

onsi

te

The

Self

Lev

elin

gTM

Gre

ense

alan

tis

inte

nded

tofil

lvo

ids/

cavi

ties

onho

rizo

ntal

surf

aces

such

asai

rcra

ftse

attr

ack

depr

essi

ons

topr

even

tflu

ids

from

accu

mul

atin

gin

them

and

caus

ing

corr

osio

nw

hile

still

bein

gea

sily

re-

mov

edfo

rre

quir

edin

spec

-tio

nsan

d/or

oper

atio

nal

use.

Als

ous

eful

tofil

lca

vitie

sar

ound

ante

nna

conn

ecto

rs.

Thi

xofle

xTM

Ora

nge

-fo

rfil

l-in

gvo

ids/

cavi

ties

onho

ri-

zont

al,

vert

ical

,or

over

head

surf

aces

whe

rea

past

em

ate-

rial

isre

quir

ed;

supp

lied

in50

CC

cart

ridg

es

Mix

ing

and

disp

ensi

ngis

acco

m-

plis

hed

with

acce

ssor

ies

ob-

tain

edfr

omth

eve

ndor

per

the

vend

or’s

inst

ruct

ions

Serv

ice

tem

p:-6

0°to

+26

0°F

(-51

°to

+12

7°C

)(e

ither

type

)

TO 1-1-691

6-20

Tabl

e6-

1.Se

alin

gC

ompo

unds

-C

onti

nued

Spec

ifica

tion

Type

sA

vaila

ble

Prop

ertie

sIn

tend

edU

sePe

elst

reng

th:

both

1-4

inlb

wid

thT

heT

hixo

flexT

MO

rang

ese

al-

ant

isin

tend

edfo

rfil

ling

the

sam

evo

ids/

cavi

ties

asab

ove

asw

ell

asth

ose

onve

rtic

alan

dov

erhe

adsu

rfac

esw

hile

still

bein

gea

sily

rem

oved

for

requ

ired

insp

ectio

nsan

d/or

oper

atio

nal

use.

No

corr

osio

nin

hibi

tors

Res

ists

wat

er,

deic

ing

fluid

s,fu

el,

oil,

and

hydr

aulic

fluid

(inc

lud-

ing

Skyd

rol

LD

-4)

TO 1-1-691

6-21

6.6 SEALANT APPLICATION PROCEDURES.

• Solvents are flammable. Never use near igni-tion sources, i.e. lighted cigarettes, electricalarcing, heat sources, etc.

• When cleaning an area prior to applying a seal-ant, apply a small amount of solvent to a cleancloth, wipe the surface, and follow by wipingwith a clean, dry cloth. Immediately after use,place used rags into an appropriate HAZMATcontainer, and then dispose of per local direc-tives. This minimizes exposure of personnel toand release of solvent vapors into the environ-ment.

• Sealants, with the exception of SAE AMS 3255(Skyflex®) EPTFE and Av-Dec® sealant tapes,are toxic to the skin, eyes, and respiratory tract.Wear rubber or polyethylene gloves and chemi-cal proof goggles and/or face shield when us-ing these materials and make sure ventilation isadequate in the area where they are used. Washhands thoroughly with soap and water beforeeating or smoking.

• MIL-PRF-81733 is not suitable for use on theinterior of integral fuel tanks and shall not beused for these applications. SAE AMS-S-8802(MIL-S-8802) and SAE-AMS3277 (MIL-S-29574) are the authorized sealants for the inte-rior of integral fuel tanks.

• No RTV sealant which produces acetic acid,such as those conforming to MIL-S-46106,shall be used on aircraft. No RTV sealant shallbe used in areas where exposure to fuels andoils will be encountered. If RTV sealants arerequired by the structural repair manual, ensurethat the sealant conforms to MIL-A-46146, Ad-hesives/Sealants, Silicone, RTV, Noncorrosive(for use on sensitive metals and equipment),and/or is listed in Appendix A as being a non-corrosive RTV silicone sealant.

• SAE AMS-S-8802 (MIL-S-8802) sealantshould not be exposed to fuel or overcoateduntil it is tack-free as it will not cure properly.SAE AMS-S-8802 is used to fillet and brushseal on the interior of integral fuel tanks only.

• Do not use SAE AMS 3267 (MIL-S-8784) seal-ant in high temperature areas or for permanentstructural installations. These sealants have nohigh temperature resistance and very low peelstrength. Some typical uses of SAE AMS 3267(MIL-S-8784) sealants include sealing aircraftfloor panels and plates and fuel tank inspectionplates.

6.6.1 Cleaning. If the surfaces have been contaminatedfollowing corrosion removal and surface treatment per in-structions in Chapter 5, clean the area with a clean CCC-C-440, Type I or II, Class 2 cheesecloth, an SAE AMS 3819,Class 2, Grade A cleaning cloth, or a CCC-C-46, Type I,Grade 7 non-woven cleaning cloth saturated with eitherA-A-59281, Type I or SAE AMS 3166 solvent. Begin at thetop of the area to be sealed and work downward. Dry thesurfaces immediately with a clean cloth. Do not allow sol-vent to evaporate from the surface because it will allow someor all of the oil, dirt, etc., to redeposit, making it impossibleto remove with a dry cloth. Use a stiff, bristle brush to cleanaround bolts, rivets, etc. Always use clean cloth as each newarea is cleaned.

NOTE

Always pour solvent on the cloth to avoid con-taminating the solvent supply. Reclaimed solventsor soiled cleaning cloths shall not be used. Aftersurface treatment, do not contaminate areas to besealed with soiled hands or tools.

6.6.2 Masking. To prevent sealant from contacting adja-cent areas during application and smoothing out operations,the surrounding area not being sealed can be masked offwith AMS-T-21595, Type I masking tape. (Refer Figure 6-8).In cases where the tape is likely to remain in place for morethan two days on items exposed to direct sunlight and wheretape residue on the surface cannot be tolerated, use AMS-T-22085, Type II (3M Co., PN 481 or 225) preservation andsealing tape. Masking tape is very useful during fillet sealingof exterior surface lap and butt seams.

Table 6-2. Time Requirements for Sealants When Used at 75° F (24° C) and 50% RH

Specification Type or Class1 Assembly Time(Hr)

Tack-FreeTime (Hr)

Approximate FlyAway Time (Hr)

Application Meth-od(s)

MIL-PRF-81733(supersedes MIL-S-81733)

I, CL 2-¼ - 4 - Brush

TO 1-1-691

6-22

Table 6-2. Time Requirements for Sealants When Used at 75° F (24° C) and 50% RH - Continued


Tack-FreeTime (Hr)



I-½ CL1-16CL2-8

- Brush

I-2 - CL1-24CL2-16

- Brush

II, CL 1-1/16 - 4 - Gun or spatulaII-¼ - CL1-8

CL2-1- Gun or spatula

II-½ - CL1-16CL2-2

- Gun or spatula

II-2 - CL1-24CL2-12

- Gun or spatula

II-4 - 32 - Gun or spatulaIII-1 - 8 - SprayIV-4 8 40 - Brush or spatulaIV-12 24 120 - Brush or spatulaIV-24 48 180 - Brush or spatulaIV-40 120 600 - Brush or spatulaIV-48 168 1008 - Brush or spatula

SAE AMS-S-8802(supersedes MIL-S-8802)

A-½ - 10 40 Brush

A-1 - 20 55 BrushA-2 - 40 72 BrushB-½ - 10 30 Gun or spatulaB-1 - 20 55 Gun or spatulaB-2 - 40 72 Gun or spatulaB-4 - 48 90 Gun or spatulaC-12 12 - - Brush or spatulaC-20 20 96 - Brush or spatulaC-80 80 120 - Brush or spatulaC-96 96 - - Brush or spatula

SAE AMS 3276(supersedes MIL-S-83430)

A-½ - 10 30 Brush

A-2 - 24 72 BrushA-4 - 36 90 BrushB-¼ - 6 16 Gun or spatulaB-½ - 10 30 Gun or spatulaB-1 - 12 36 Gun or spatulaB-2 - 24 72 Gun or spatulaB-4 - 36 90 Gun or spatulaB-6 - 48 120 Gun or spatulaB-12 - 120 240 Gun or spatulaC-½ - 10 30 Brush or spatulaC-2 - 24 72 Brush or spatulaC-8 20 96 120 Brush or spatulaD-¼ - 6 16 Gun or spatulaD-½ - 10 30 Gun or spatula

TO 1-1-691

6-23



Tack-FreeTime (Hr)



E 6 120 240 Used w/auto rivetequipment

PR-1773 (super-sedes PR-1403G)

B-½ - 4 6 Gun or spatula

PRC-DeSoto Int. B-2 - 8 16 Gun or spatulaSAE AMS 3267/1

(supersedes MIL-S-8784)

A-½ - 10 24 Brush

SAE AMS 3267/3(supersedes MIL-S-8784)

A-2 - 24 72 Brush


B-½ - 10 24 Gun or spatula


B-2 - 24 72 Gun or spatula


1- N/A - 6 14 days Gun or spatula


2-4 - 24 7 days or 1 day @120° F (49° C)

Gun or spatula


3-4 - 6 14 days Gun or spatula


4-½ - 2 7 days Gun or spatula

MIL-S-85420 Ty I, C1A-1/6 - 2 (ST), 4(LT)2

4 (ST), 8 (LT)2 Brush

Ty I, C1B-1/6 - 2 (ST), 6(LT)2

4 (ST), 8 (LT)2 Gun or spatula

Ty II, C1A-1/6 - 2 (ST), 4(LT)2

4 (ST), 6 (LT)2 Brush

Ty II, C1B-1/6 - 1 ¼ (ST), 4(LT)2

4 (ST), 6 (LT)2 Gun or spatula

SAE-AMS3277 A-¼ - 1 / 3 / 6 1.5 / 4 / 83 Brush(MIL-S-29574) A-½ - 1.5 / 3 / 63 3 / 8 / 163 Brush

A-2 - 9 14 BrushB-¼ - 1 /3 / 63 1.5 / 4 / 83 Gun or spatulaB-½ - 2 / 6 / 63 3 / 8 / 163 Gun or spatulaB-2 - 9 14 Gun or spatulaC-4 8 - 24 Brush or spatula

MIL-A-46146 Gp I, Ty I - 5 - Gun or spatulaGp I, Ty II - 5 - PourGp II, Ty I - 5 - Gun or spatulaGp II, Ty II - 5 - PourGp III, Ty I - 5 - Gun or spatulaGp III, Ty II - 5 - Pour

TO 1-1-691

6-24



Tack-FreeTime (Hr)



SAE AMS 3255EPTFE SealingTape (Skyflex®)

Class 1 - 0 0 Peel and stick

Av-DecTM

HT3935-7 &HT3000 Series

Class 2 - 0 0 Peel and stick

Polyurethane Seal-ing Tapes

- - 0 0 Peel and stick

Av-DecTM Inject-able Polyure-thane Sealants

SelfLevelingTM

Green,HT3326-5

<20 (minutes) 45 (minutes)max

- Gun with syringe

ThixoflexTM Or-ange, TF2219

<3 (minutes) 7 (minutes)max

- Gun with syringe

1 The number after the dash (-) indicates the room temperature working life of the sealant after it is mixed.2 (ST) = Standard Temperature of +75° F (+24° C); (LT) = Low Temperature of +45° F (+7° C).3 1st # @ +75° F (+24° C); 2nd # @ +40° F (+4° C); 3rd # @ +20° F (-7° C).

6.6.3 Adhesion Promoters. In some cases, it may benecessary to improve the adhesion of sealants by the use ofadhesion promoters. Adhesion promoters are solvents thatcontain additives which leave a residue on the surface aftersolvent evaporation to promote adhesion. To apply, clean thearea per Paragraph 6.6.1, brush or wipe the surface to besealed with the liquid solution, and allow the treated surfaceto dry by evaporation without touching the treated areas for30 minutes to an hour before applying sealant. AMS 3100adhesion promoter, PN PR-148 or PR-182 is essential to re-pairing integral fuel tanks where new polysulfide sealant willbe applied over aged, fuel soaked polysulfide sealant. If apolythioether sealant is to be applied over a polysulfide seal-ant, PN PR-186 is recommended for use at the sealant inter-face. If the surface becomes contaminated or sealant is notapplied within 2 hours after applying an adhesion promoter,reclean the area and reapply the adhesion promoter per theabove instructions. Refer to Appendix A for informationrelative to purchasing/ordering these adhesion promoters.

6.6.4 Brush Spatula or Caulking Gun Application. Priorto masking and sealing, prepare and clean the surface inaccordance with Paragraph 6.6.1.

Do not contaminate areas to be sealed with hands,tools, etc., after surface treatment and primer ap-plication.

a. To prevent sealant from contacting adjacent areas dur-ing application and smooth out, outline the areas beingsealed with masking tape, AMS-T-21595, Type I sothat each tape strip is 1/16 to 3⁄8 in from the edge ofbutt seams and the upper surface edge of a lap seam,and ¼ to 3⁄8 in from the lower surface edge of a lapseam. If tape residue on these surfaces is excessive,remove adhesive residues using TT-N-95 aliphaticnaphtha. Masking may be very beneficial during filletsealing of exterior surface lap seams and filling exte-rior surface butt seams.

TO 1-1-691

6-25

b. Apply sealant between the pieces of tape.

(1) Thick sealants may be applied with a non-metal-lic spatula or spreader to fillet seal lap seams orflush fill butt seams as shown in Figure 6-8. Avoidthe entrapment of air. Work sealant into recessesby sliding the edge of the spatula firmly back overrecesses. Smoothing will be easier if the non-me-tallic spatula is first dipped in water.

(2) Brushable sealants are applied with a brush andsmoothed until the desired thickness is reached.

(3) Thick sealants may be applied with a caulkinggun, and if done carefully, will not usually re-quire masking. This method is especially adapt-able to filling seams or the application of form-in-place gaskets. On exterior surfaces whereaerodynamic smoothness is required, masking isnecessary to allow smoothing the sealant after ap-plication without smearing it onto surroundingsurfaces.

c. Remove masking tape after the sealant has been ap-plied and before it begins to set. Cure time depends onthe application life of the sealant materials used, thetemperature, and the RH. When sealant no longer feelstacky, prime and topcoat as necessary and required bysystem specific technical data per application instruc-tions in TO 1-1-8.

d. Remove all uncured sealant residue by wiping the areawith an SAE AMS 3819, Class 2, Grade A, or equiva-lent, cleaning cloth wetted with a liquid product knownas Sky Wash® distributed by AeroSafe Products Inc.and wiping dry with a clean, dry cloth of the sametype.

NOTE

MEK conforming to ASTM D 740 may be used asan alternate solvent for cleaning up uncured seal-ant residues as long as it is not environmentallyprohibited and the aircraft SPD and/or the missileor equipment SPM approves its use and requires itin system specific technical data.

6.6.5 Spray Gun Application. Prior to masking and seal-ing, prepare surface in accordance with Paragraph 6.6.1.

If any dirt or oil residues accumulate after conver-sion coating, clean thoroughly with solvent to en-sure adequate adhesion of paint, primer, and seal-ant.

a. Mask off adjacent areas with either MIL-PRF-121,Type I or II or MIL-PRF-131, Class 1 barrier materialheld in place with AMS-T-21595, Type I masking tapeto minimize overspray on adjacent areas.

b. Apply MIL-PRF-81733, Type III sprayable sealant in asolid, continuous pattern per the manufacturer’s in-structions and TO 1-1-8.

NOTE

The dry film thickness (DFT) of spray sealantcoatings shall be in the range of 3 to 5 mils (0.003to 0.005 in).

6.6.6 Peel and Stick Application; SAE AMS 3255EPTFE Skyflex® and Av-Dec® HT3935-7 and HT3000Sealing Tapes. Prior to application, prepare surface in ac-cordance with Paragraph 6.6.1.

After surface treatment and any required primerapplication, do not contaminate areas to be sealedwith soiled hands or tools as contamination pre-vents proper sealing tape adhesion.

a. Examine faying surfaces to be sealed and build up anyuneven areas on the aircraft, missile, or equipmentframe flange. Use Skyflex®, PN GUA-1003-1 com-pensation tape or a small piece of the same type ofSkyflex® tape that will be used for SAE AMS 3255sealing tape applications and a small piece of the same

Figure 6-8. Non-Metallic Spatula

TO 1-1-691

6-26

type of Av-DecTM tape that will be used for HT3935-7and/or HT3000 sealing tape applications. This willcreate a level faying surface for panel sealing.

b. Select the proper PN sealant tape so that it will coverthe full width of the faying surface to be sealed. Tapemay be applied to either the aircraft, missile, or equip-ment frame flange or to the panel faying surface.

(1) Measure and cut the required length of sealanttape.

(2) For corners, cut the ends of the tape at a 30°angle so that the sealant tape from the convergingside will overlap by one-quarter to one-half inch.Do not fold the tape in corners as this will resultin triple layer thickness.

Use care not to pull or stretch the sealant tape as itis applied. The stretched SAE AMS 3255 EPTFEand Av-Dec® HT3000 tapes will retract even ifclamped between faying surfaces and the Av-Dec®HT3935-7 tapes will be reduced in thickness. Ineither case, inadequate sealing may result.

(3) Peel the non-stick backing paper off the sealanttape a little at a time as the tape is applied to theaircraft, missile, or equipment frame flange ormating panel surface.

NOTE

• Applying a small amount of extra pressure tothe upper surface of the sealant tape will causethe pressure sensitive adhesive to adhere betterto the faying surface on which it is being ap-plied and it will create indentations/discolor-ation at the fastener holes allowing for easierlocation/identification. If done with Av-Dec®3935-7 sealant tapes, it must be done beforethe non-stick backing paper is removed.

• If an SAE AMS 3255 sealant tape without apressure sensitive adhesive backing has beenordered for use in areas where fluid exposure isexpected, 3M Co., PN Scotchgrip® 847 or 1099plastic adhesive (refer to Appendix A), may beused to hold the sealing tape in place duringpanel installation.

(4) After applying the full length of the sealant tape,run fingers back and forth on the upper surface ofthe sealant tape to press the tape against the air-craft, missile, or equipment frame flange or theaccess panel surface to promote adherence of theadhesive.

NOTE

For Av-Dec® HT3935-7 sealant tapes, this mustbe done before the non-stick backing is removed.

(5) Puncture all fastener holes using an object with asharp point such as an awl or a scribe.

NOTE

As fasteners are installed, the sealant materialpushed into the fastener holes will help to sealagainst moisture intrusion.

(6) Install the access door/panel.

NOTE

No curing time is required. All fasteners should bewet installed with MIL-PRF-16173, Grade 4;MIL-PRF-63460 CPC material specified in thespecific aircraft, missile, or equipment system spe-cific maintenance manual.

6.7 SEALING OF SPECIFIC AREAS.

6.7.1 Faying Surface Sealing. Faying surfaces are sealedby applying sealants to the connecting surfaces of two ormore parts. (Refer to Figure 6-9). It is a very effective sealand should be used for all assembly or reassembly. Whenpossible, it should be used in conjunction with fillet sealing.There are two types of faying surface seals, removable andpermanent. Removable seals are used around access doors,removable panels, inspection plates, etc. A removable sealcan be formed using a low adhesion sealant that adheres toboth surfaces or by using a high adhesion sealant that ad-heres to one surface and a parting agent on the mating sur-face. Permanent seals are created using high adhesion seal-ants between permanently fastened structures. To create apermanent seal, coat either one or both mating surfaces witha high adhesion sealant before assembling the parts and thenassembling them while the sealant is still wet. Apply enoughsealant to force a bead to squeeze out along the joint afterassembly and also install all fasteners wet with the sealant.Assemble parts within the rated application life and/or as-sembly life of the sealant while taking into account the ef-fects of temperature and humidity on these times.

a. For permanent structure, all faying surfaces, seams,and lap joints outside of fuel wet and high temperatureareas shall be protected with MIL-PRF-81733, Type IIor IV, Class 1 or 2, Grade A sealant. Apply the sealingcompound to one or both surfaces and squeeze the parttogether to ensure the complete coating of the entiremating or faying surface. Excess material squeezed outshall be removed so that the fillet remains at the jointedges. The fillet width shall not be less than ¼ inch.For seams, the sealant shall fill the seam entirely up toflush with the surface. Joint, joggle, or cavity areas

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which could hold water shall be filled with MIL-PRF-81733, Type II, Class 1 or 2, Grade A, SAE AMS-S-8802, Class B, or SAE AMS 3276, Class B sealant.

b. If sealing is impossible because of mechanical or otherfactors, prime both surfaces with two coats of MIL-PRF-23377, Type I, Class C epoxy primer or TT-P-2760, Type I, Class C polyurethane primer per instruc-tions in TO 1-1-8.

c. Faying surfaces that are to be adhesive bonded shall betreated and processed as specified by the approvedbonding procedure in the applicable system specificmaintenance manual.

d. On faying surfaces, seams, or joints which require dis-assembly for maintenance, either SAE AMS 3267 orPN PR-1773 low adhesion sealant shall be used. (PNPR-1773 sealant contains non-chromate corrosion in-hibitors).

NOTE

SAE AMS 3255 (Skyflex®) sealing tapes or Av-Dec® HT3935-7 and HT3000 sealing tapes maybe used in lieu of the low adhesion curing typesealants in many removable joint areas requiring

periodic disassembly for maintenance when ap-proved by the aircraft SPD and/or the missile orequipment SPM.

e. On plastic components, the joints shall be suitablysealed and faired into the adjacent surfaces with MIL-PRF-81733, Type II or IV, Class 1 or 2, Grade A, SAEAMS-S-8802, Class B, or SAE AMS 3276 sealant, un-less otherwise specified in the applicable system spe-cific maintenance manuals, to stop the formation ofpockets which will entrap moisture, dirt, etc.

NOTE

MIL-PRF-81733, Type II or IV, Class 1 or 2,Grade A sealant shall be used for rivets that re-quire wet installation on plastic components.

6.7.2 Fillet Sealing. The fillet, or seam, as shown in Fig-ure 6-10, is the most common type found on an aircraft,missile, or piece of equipment. Fillet seals are used to coverstructural joints or seams along stiffeners, skin butts, walls,spars, and longerons, and to seal around fittings and fasten-ers. This type of sealing is the most easily repaired. It shouldbe used in conjunction with faying surface sealing and inplace of it if the assembly sequence restricts the use of fay-ing surface sealing.

6.7.3 Injection Sealing. This type of seal, as shown inFigure 6-11, is used primarily to fill voids created by struc-tural joggles, gaps, and openings. Use only those sealantsrecommended by the aircraft, missile, or equipment manu-

facturer. Force sealant into the areas using a sealant gun.This method is a means of producing a continuous seal where

Figure 6-9. Faying Surface Sealing

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it becomes impossible to lay down a continuous bead ofsealant while fillet sealing. Clean the voids of all dirt, chips,burrs, grease, and oil before injection sealing.

6.7.4 Fastener Sealing. Figure 6-12 illustrates techniquesused to seal different types of fasteners. Fasteners are sealedeither during assembly or after assembly. Install them wetwith sealant in accordance with requirements in the appli-cable system specific maintenance manual for fasteners inpermanent structures. To seal during assembly, apply thesealant to the hole or dip the fastener into sealant, and installfastener while sealant is wet. For removable parts, coat thelower side of the fastener head only. Do not coat the hole orthe fastener shank or threads, as this makes future removalalmost impossible without damage to the part. To seal afterassembly, cover the pressure side of the fastener with sealantafter installation. Corrosion damaged areas in the counter-sinks around removable and fixed fasteners may be filledwith the fastener in place. Cadmium coated fasteners thathave been blasted or abraded during corrosion removal shallbe primed in accordance with the applicable system specificmaintenance manual and TO 1-1-8 and then coated withMIL-PRF-81733, Type I, Class 1 or 2, Grade A sealant.

6.7.5 Integral Fuel Cells/Tanks and Removable FuelTanks. Refer to TO 1-1-3 and/or the aircraft’s system spe-cific maintenance manual for fuel area sealing procedures.

6.7.6 Form-In-Place (FIP) Gasket Sealant Repair. Af-ter removal of all loose sealant material, thoroughly cleanthe area to be resealed per Paragraph 6.6.1. Areas of the oldseal to which new sealant will be added must be cleaned andabraded using an abrasive mat or abrasive cloth (refer toAppendix A), to expose a clean, fresh surface.

a. Apply MIL-PRF-81733, Type II-½, Class I, Grade A,PR-1773, Class B-½, or SAE AMS 3276, Class B-½sealant, preferably with a sealant gun. The new sealantshould match the configuration of the removed sealantbut should be of sufficient depth to ensure contact withthe mating surface.

b. Apply a very thin film of MIL-PRF-32033 oil or VV-P-236 petrolatum to the mating surface of the accessdoor/panel and close and/or install the access door/panel. If installed with fasteners, lubricate them withthe same material used on the door/panel mating sur-face, install ½ of the required fasteners (every otherfastener), and torque to ½ to ¾ of the specified torquefor the assembly.

Figure 6-10. Typical Fillet Seal

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c. Do not open or remove the door/panel for a minimumof 24 hours.

NOTE

The main function of the pressure sensitive adhe-sive backing on the SAE AMS 3255 (Skyflex®)sealant tape is to hold the EPTFE sealant tape inplace during access door/panel assembly. The ad-hesive on one side of the Av-Dec® HT3000 seal-ant tape acts as a seal as well as holding the seal-ant tape in place. Peeling/delamination of theadhesive from the aircraft, missile, or equipmentframe flange or access door/panel requires replace-ment of the sealant tape if the tape is no longerlocated in the faying surface. Visually inspect seal-ant tape material for nicks, cuts, gouges and de-lamination/separation.

6.7.7 SAE AMS 3255 EPTFE (Skyflex®) and Av-Dec®HT3000 and HT3935-7 Sealing Tape Gasket Repair. Inorder to preserve seal integrity, it is necessary to inspect thesealant tape each time an access panel is removed.

NOTE

Av-Dec® HT3935-7 sealing tape requires com-plete replacement each time an access door/panelsealed with it is removed as it has an adhesive onboth sides. Scrape the old tape off with a plastictool and apply a new length of tape as done origi-nally.

a. Cut and remove damaged section of sealant tape.

b. Measure and cut a new piece of SAE AMS 3255 (Sky-flex®) or Av-Dec® HT3000 sealant tape approximatelyone inch longer than the removed section.

c. Peel the non-stick backing paper off and install a newsection of sealant tape so it overlaps the previouslyinstalled sealant tape by one-quarter to one-half of aninch on each side of the repair site.

NOTE

Ends of the repair splice must overlap the existingsealant tape to ensure seal integrity. Use care notto pull or stretch the sealant tape patch as it isapplied. The stretched SAE AMS 3255 EPTFE andAv-Dec® HT3000 sealant tape patches will retracteven if clamped between faying surfaces and in-adequate sealing may result.

d. Once the sealant tape patch is applied, run fingers backand forth on the upper surface of the sealant tape patchto promote adherence of the adhesive.

NOTE

Applying a small amount of extra pressure to theupper surface of the sealant tape patch will causethe pressure sensitive adhesive to adhere better tothe faying surface and overlapped areas of oldsealant tape and it will create indentations/discol-oration at the fastener holes allowing for easierlocation/identification.

Figure 6-11. Typical Injection Seal

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e. Puncture any affected fastener holes with a sharppointed object such as an awl or a scribe.

NOTE

As fasteners are installed, the sealant materialpushed into the fastener holes will help seal againstmoisture intrusion.

f. Install access panel.

NOTE

No curing time is required. All fasteners should bewet installed with MIL-PRF-16173, Grade 4 CPC,MIL-PRF-63460 CPC, or CPC material specifiedin the specific aircraft, missile, or equipment sys-tem specific maintenance manual.

6.7.8 External Aircraft Structure. If, during normal main-tenance, it becomes necessary to remove and replace compo-nents (wing planks, skin, spar caps, fasteners, fittings, etc.,)they shall be sealed when reinstalled, even if they were notsealed originally. The only exception to this requirement is atemporary repair accomplished for a one time flight to a de-pot or overhaul facility. Refer to Figure 6-13 through Figure6-16 for typical sealing methods.

6.7.9 Depressions. When the thickness of metal is re-duced by more than 15 mils (0.015 in) in the removal ofcorrosion damage, fill the depression with MIL-PRF-81733,Type II, Class 1 or 2, Grade A sealant after applying achemical conversion treatment per Section II of Chapter 5.

NOTE

The above procedure does not apply to the use ofSAE AMS 3255 EPTFE and Av-Dec® HT3935-7or HT3000 sealing tapes or to the use of SAEAMS-S-8802 (MIL-S-8802) sealant inside integralfuel tanks.

6.7.10 Damaged Sealant. Many areas on aircraft, mis-siles, and equipment are sealed either at the factory or bydepots during rework. Fresh sealant shall be applied when-ever the previously applied sealant is damaged. Remove thedamaged sealant with a plastic scraper and, if necessary, pre-pare the metal surface in accordance with Section II ofChapter 5. Slightly roughen a strip of the undamaged sealantapproximately one inch wide around the boundary of thestripped area with an A-A-58054, Type I, Grade C abrasivemat and then clean the area per Paragraph 6.6.1. Apply the

Figure 6-12. Typical Methods of Sealing Fasteners

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new sealant by brush, sealant gun, or spatula and then smoothout the surface with a spatula, as required. The new sealantshould overlap onto the roughened area of the old sealant.

NOTE

• To assist with removal of damaged sealant, aliquid product known as Sky Restore® distrib-uted by AeroSafe Products Inc., (refer to Ap-pendix A), may be applied to the damaged areawith a non-metallic bristle brush, an SAE AMS3819, Class 2, Grade A, or equivalent, cleaningcloth, or a pump spray bottle and allowed todwell for 15 to 50 minutes until the sealant issoftened. A plastic scrapper may then be usedto remove the damaged sealant. This materialhas a fairly obnoxious odor so it must be usedeither in a well ventilated area or personnelmust wear an appropriate respirator in all con-fined areas.

• After the damaged sealant is scrapped away,the area must be neutralized and cleaned with aliquid product known as Sky Wash® distrib-uted by AeroSafe Products Inc., (refer to Ap-pendix A), applied in the same manner as above,scrubbed with the same type of brush or clothas used above, and wiped dry.

• Other tools useful for sealant removal are the3M Co. SR Radial Bristle Discs and plastic SRCutters, the Kell-Strom Tool Co., OZ7000pneumatic sealant removal kit, The RDS001Rapid Desealing System (RDS), OZ7006manual sealant removal kit or a rubber palmsupport handle with a set of plastic scrapers.(Refer to Appendix B).

6.7.11 Extensive Repair. If corrosion damage is so ex-tensive that structural repair is necessary, all faying surfacesbetween patches (or doublers) and skins shall receive a sur-face treatment per Section II of Chapter 5 before the repairparts are installed. Coat the faying surfaces with MIL-PRF-81733, Type IV, Class 1 or 2, Grade A sealant prior to instal-lation of patch and install all fasteners wet with MIL-PRF-81733, Type I or IV, Class 1 or 2, Grade A sealant.

6.7.12 High Temperature Areas. In areas where the tem-perature is expected to rise above 250° F (121° C), a one-part silicone sealant, MIL-A-46146, Type I or III or SAEAMS 3374, Type 1, 2, 3, or 4 silicone sealant should be usedfor temperatures up to +400° F (+204° C). SAE AMS 3276(MIL-S-83430) sealant may be used in areas that experienceintermittent temperatures up to +360° F (+182° C). Applica-tion of these sealants is by spatula or sealant (caulking) gunper Paragraph 6.6.4.

6.7.13 Low Temperature Curing. When cold climates in-terfere with sealing operations by prolonging the sealant cur-ing reaction, use MIL-S-85420 or SAE-AMS3277 (MIL-S-29574). For better adhesion, an adhesion promoter can beused. Refer to Paragraph 6.3.3. SAE AMS 3255 EPTFE andAv-DecTM HT3935-7 or HT3000 sealant tape gasket materi-als may be used for low temperature sealing operations whenspecified in system specific technical data and/or is approvedby the aircraft SPD and/or the missile or equipment SPM.

6.8 STORAGE/SHELF LIFE CONTROL OF SEAL-ANTS.

All sealants have a specified shelf life. The date of manufac-ture and the shelf life are listed on each container. The shelflife is dependent on storing the sealant in its original, un-opened container in an area where the temperature does notexceed 80° F (27° C). Sealants shall not be stored in areaswhere the temperature exceeds 80° F (27° C). Prior to use,sealant containers shall be inspected to determine if the ma-terial has exceeded its shelf life. If a sealant has exceeded itsoriginal shelf life, then it shall not be used until the updatetesting has been performed. Sealants may be extended one-half of their original shelf life after passing the required tests.Updating may be repeated until sealant fails to pass testing.No sealant shall be used if it fails testing. Minimum updatetesting can be performed as follows:

a. Select one kit of sealant from each manufacturer’sbatch of material to be tested for updating.

b. Visually examine the content of each can in the kit. Ifthe base polymer is lumpy or partially cured or cannotbe mixed with the curing agent, dispose of the openedkit and all kits from that batch of sealant.

c. If the kit can be blended to form a homogeneous mix-ture, determine whether the working time is suitablefor the intended purpose by applying the mixture to aclean scrap of metal. If the working time is not accept-able, dispose of the opened kit and all others from thatbatch.

d. If the working time is acceptable, the applied sealantshall be tested for proper cure time by periodicallychecking its hardness. The batch of sealant representedby applied test sealant can be extended one-half itsoriginal shelf life if it achieves approximately the samehardness as sealant from kits of another batch whichare within their established shelf life.

e. This updating process may be repeated until the seal-ant fails to pass any of the above tests.

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Figure 6-13. Typical Lap Skin Sealing

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Figure 6-14. Sealing Procedures for Typical Aircraft Fitting

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Figure 6-15. Typical Spar Cap Sealing

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Figure 6-16. Sealing of Access Doors

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CHAPTER 7TREATMENT OF SPECIFIC AREAS

7.1 INTRODUCTION.

This chapter describes the procedures recommended fortreating and protecting against corrosion in several specificareas known to be corrosion prone areas and contains illus-trations to aid in inspections. This chapter is not all inclu-sive. Applicable system specific maintenance manuals forspecific aircraft, missiles, and/or equipment should be con-sulted also to determine all corrosion prone areas on a spe-cific system, and the required treatment and preventive mea-sures in these areas as well as any existing expanded oramplified instructions for areas covered by this chapter.

7.2 BATTERY COMPARTMENTS, BOXES, AND AD-JACENT AREAS.

Observe precautions listed in previous chapters (orreferences) for cleaning compounds, solvents, sur-face treatments, sealants, and paints as these ma-terials can injure personnel if used improperly.

The battery, battery cover, battery box, and adjacent areas(especially areas below the battery compartment where bat-tery electrolyte may have seeped) are subject to the corro-sive action of the battery electrolyte. Two different types ofbatteries are encountered on aerospace and non-aerospaceequipment: lead-acid, having a sulfuric acid electrolyte andnickel-cadmium, having a potassium hydroxide electrolyte.Methods for cleaning up and neutralizing spilled and/orleaked electrolytes are given in Table 3-2.

7.2.1 Preparation of Solutions for Cleaning and Neu-tralizing Battery Electrolytes.

• When handling electrolytes, chemical splashproof goggles and chemical resistant rubbergloves and aprons shall be worn. If any electro-lyte contacts the skin or eyes, flood the affectedarea immediately with water and report to theBase Medical Facility. An emergency showerand an eye wash station in the area where workinvolving electrolytes is being performed arerequired.

• Isopropyl alcohol, TT-I-735 is highly flam-mable. Use only in a well ventilated area andkeep away from all sources of ignition.

Both sulfuric acid and potassium hydroxide bat-tery electrolytes will cause severe corrosion ofmetallic structures. Avoid dripping electrolyte onor allowing contaminated gloves, rags, sponges,etc., to come in contact with aircraft, missile, orequipment structures. Place all items contaminatedwith electrolyte in a leak-proof plastic containerprior to removing them from the area of the air-craft, missile or piece of equipment. Remove anybattery box which contains spilled electrolyte fromthe aircraft, missile, or piece of equipment prior tocleaning it. Electrolyte spilled on aircraft, missileor equipment structure shall be cleaned up as soonas possible after it has been detected.

NOTE

The use of indicating solutions can sometimes beavoided and/or at least limited in scope by usingtest strips of litmus paper. When trying to initiallydetect electrolyte spills from acid batteries (suchas lead-acid), apply a strip of blue litmus paper tothe wet surface. A color change to red indicates anacid is present. When trying to detect spills fromalkaline batteries (such as nickel-cadmium), applyred litmus paper to the wet surface. A color changeto blue indicates an alkaline solution is present.

There are four different solutions needed for the detection,neutralization, and cleanup of spilled and/or leaked batteryelectrolytes. Indicating solutions (litmus solution for lead-acid batteries and bromothymol blue solution for nickel-cad-mium batteries) are required for cleaning areas subjected toelectrolyte spills to determine the location of contaminatedareas and to indicate if these areas have been completelyneutralized. A 10% by weight sodium bicarbonate (ordinarybaking soda) solution is required to neutralize sulfuric acidfrom lead-acid batteries and a 3% by weight boric acid ormonobasic sodium phosphate solution is required to neutral-ize potassium hydroxide from nickel-cadmium batteries.These solutions are prepared per the following procedures:

7.2.1.1 Litmus Indicating Solution. Pour one pint of amixture containing 70% by volume of TT-I-735 isopropylalcohol and 30% by volume distilled water into a plasticspray bottle with a hand squeeze pump. Add one tablespoonof litmus powder into the solution, and mix thoroughly untila deep blue color is observed.

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7.2.1.2 Bromothymol Blue Indicating Solution. Pour onepint of bromothymol blue solution into a plastic bottle with ahand squeeze pump. Using an eye dropper, add one drop at atime of phosphoric acid into the solution with subsequentmixing after each drop until the color of the solution changesfrom blue to gold or amber.

7.2.1.3 Sodium Bicarbonate Neutralizing Solution.Pour one pint of distilled water into a 500ml polyethylenewash bottle, add ¾ of an ounce of ASTM D 928 sodiumbicarbonate powder, and mix thoroughly.

7.2.1.4 Boric Acid and/or Monobasic Sodium Phos-phate Neutralizing Solutions. Pour one pint of distilledwater into a 500ml polyethylene wash bottle, add ¾ of anounce of either A-A-59282 boric acid powder or ANSI/AWWA B504 monobasic sodium phosphate powder, and mixthoroughly.

7.2.2 Cleaning and Neutralizing Procedures.

a. Determine the type of electrolyte involved by dippinga small strip of blue and a small strip of red litmuspapers into the liquid puddle. If the red litmus staysred and the blue litmus turns red, the liquid is acid. Ifthe blue litmus stays blue and the red litmus turns blue,the liquid is basic or alkaline.

b. Remove any standing liquid or puddles with a squeezebulb type syringe, absorbent cloth, or sponge. Placethe used items in a leak proof container for disposal toprevent the contamination of other areas.

c. Spray the entire suspected area with the proper indica-tor solution, using the minimum amount needed to wetthe entire surface. For spills/leaks from lead-acid bat-teries, use the litmus solution which will change incolor from deep blue to a bright red in areas contami-nated by sulfuric acid. For spills/leaks from nickel-cadmium batteries, use the bromothymol blue solutionwhich will change in color from amber or gold to adeep blue in areas contaminated by potassium hydrox-ide.

d. Apply the correct neutralizing solution to the areaswhere the indicating solution has been applied. Forspills/leaks from lead-acid batteries, use a sodium bi-carbonate solution. For spills/leaks from nickel-cad-mium batteries, use either a boric acid or monobasicsodium phosphate solution. Ensure that the area is wellsaturated including all seams and crevices where elec-trolyte could collect. Use care to prevent neutralizingsolutions from spreading to adjacent areas and on air-craft, ensure that bilge area drains are open. Allow flu-ids to flow overboard from these drains on aircraft.Allow the neutralizing solution to remain on the sur-face for at least 5 minutes or until all bubbling actionceases, whichever is longer.

NOTE

When neutralizing sulfuric acid, the litmus indi-cating solution will change back from its brightred color to a light blue as the neutral point isreached. When neutralizing potassium hydroxide,the bromothymol blue indicating solution willchange back from its deep blue color to a lightamber color as the neutral point is reached.

e. Rinse the area thoroughly with a liberal amount ofclean tap water and remove any standing liquid orpuddles, as specified in step b.

f. Reapply the indicator solution, as in step c. If the so-lution does not change color, rinse the area, as in stepe and dry the area with clean cloths or rags. If thesolution changes color, repeat step d and step e.

g. Remove any corrosion noted per procedures in SectionI of Chapter 5, apply conversion coating treatment perprocedures in Section II of Chapter 5, apply sealantspecified by the applicable system specific maintenancemanual and Chapter 6 using procedures in Chapter 6,and apply primer and paint coatings per the applicablesystem specific maintenance manual using proceduresin TO 1-1-8 if bare metal is exposed. If bare metal wasnot exposed, or when the paint system applied is curedto a tack-free state, apply a protective film of eitherMIL-PRF-81309, Type II or MIL-L-87177, Type I orII, Grade B CPC to the area.

7.2.3 Paint Systems. Special acid and/or alkali resistantcoatings are usually required for battery compartments,boxes, and areas. Refer to the applicable system specific air-craft, missile, or equipment maintenance manual for the spe-cific paint system requirements.

7.3 RELIEF TUBE AREAS.

O-D-1435 disinfectant solutions are highly alka-line and can burn the eyes and the skin. Wearchemical resistant splash proof goggles and/or faceshield and chemical resistant rubber gloves whenusing these solutions.

Interior and exterior relief tube areas shall be inspected andcleaned after each flight. Cleaning shall be accomplished byprocedures outlined in Chapter 3. After cleaning, the exposedareas shall be disinfected by wiping down with a cloth wet-ted with an O-D-1435 disinfectant solution prepared per themanufacturer’s instructions. The interior of the tubes shall bedisinfected by pouring the solution through them. Rinse thedisinfectant solution from the area with fresh tap water andwipe dry with a clean, dry cloth. After cleaning and disin

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fecting, remove any corrosion noted per procedures in Sec-tion I of Chapter 5. For areas having exposed bare metal,apply the type of conversion coating material required forthe specific metal alloy involved per procedures in Section IIof Chapter 5. Touch up the paint system in the area, as re-quired, with the primer and topcoat specified in the appli-cable system specific maintenance manual with applicationper procedures in TO 1-1-8.

7.4 CORROSION TREATMENT FOR STEELCABLES.

• Consult the applicable system specific mainte-nance manual for cable detensioning and ten-sioning requirements prior to performing anymaintenance.

• Do not use metallic wools to clean installedsteel control cables. The use of metallic woolwill cause dissimilar metal particles to becomeembedded in the cables and create further cor-rosion problems (galvanic corrosion). Use onlya clean cloth dampened with A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, degreas-ing solvent to clean steel control cables. Exces-sive solvent will remove internal cable lubricantand allow the cable strands to abrade and fur-ther corrode.

If the surface of a cable is corroded, relieve cable tensionand carefully force the cable open by reverse twisting. Visu-ally inspect the interior. Corrosion on the interior strandsconstitutes failure and the cable must be replaced. If no in-ternal corrosion is detected, remove loose external rust andcorrosion with a clean, dry, coarse-weave rag or fiber brush.Clean the control cables with a clean cloth dampened withA-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680,degreasing solvent. After thorough cleaning, apply a thin filmof either MIL-PRF-81309, Type II, MIL-L-87177, Type I orII, Grade B, or MIL-PRF-16173, Class II, Grade 3 waterdisplacing CPC to the cable surface by aerosol spray or acloth dampened with the CPC followed by a liberal applica-tion of MIL-PRF-16173, Class II, Grade 4 CPC with a non-metallic brush. Wipe off any excess CPC. If excessive CPCis allowed to build up, it will interfere with the operation ofcables at fairleads, pulleys, or grooved bell-crank areas.

7.5 PIANO TYPE HINGES.

Corrosion inhibiting solid film lubricants are often applied tohinge pins and nodes to provide lubrication and to reducecorrosion problems. Refer to Section II of Chapter 3 for pro-cedures on touch-up and replacement of these lubricantswhen hinges are disassembled. Each time an aircraft, missileor piece of equipment is washed, make sure that all hingesare cleaned in accordance with Chapter 3. After washing,apply a coating of a water displacing CPC. Use either MIL-

PRF-63460, MIL-PRF-81309, Type II, or MIL-L-87177,Type I or II, Grade B followed by MIL-PRF-32033 to thenode and hinge pin areas of all piano hinges including thosecoated with solid film lubricants.

7.6 INTEGRAL AND EXTERNAL FUEL TANKS ANDDROP TANKS.

For additional instructions on materials and procedures usedin aircraft fuel tank areas. Refer to TO 1-1-3.

7.6.1 Corrosion Removal and Rework of Pitted Areasof Integral Fuel Tanks. Complete removal of corrosionproducts is required to prevent recurrence of corrosion in theaffected areas.

Power abrasive removal operations create airborneparticles. Eye protection is required. Good generalventilation is normally adequate.

a. Remove corrosion by mechanical methods in Section Iof Chapter 5 using materials and procedures listed therefor aluminum alloys, except that abrasive blasting shallnot be used. In general, a power driven abrasive on aflexible shaft is the most effective means of corrosionremoval in this area. Corrosion removal shall be fol-lowed by hand sanding with 280 grit abrasive paper orcloth followed by 400 grit abrasive paper or cloth toproduce a smooth surface finish. The system specificaircraft -3 and -23 manuals shall be consulted to assurestructural limits are not exceeded.

To prevent injury to personnel, exercise cautionwhen using sharp or pointed tools.

b. After sanding operations are completed, clean abrasiveresidue off reworked areas with a clean cloth and in-spect for small shiny patches which appear muchbrighter than the base metal. These generally indicateexfoliation underneath the exposed shiny surface be-low a blister from which the top has been partiallyremoved. As the surface is being sanded during re-work, these blisters, being high points, receive most ofthe abrasive action, leaving the blister area muchbrighter than the surrounding base metal. To com-pletely remove this corrosion, the blisters must be bro-ken open to fully expose the exfoliation and powderycorrosion deposits underneath. It is usually much fasterand easier to pry the top off the blister with a sharpinstrument. This operation requires extreme caution toprevent unnecessary gouges or scratches in the basemetal. Pitted and exfoliated areas must be reworked toa depth sufficient to remove all the corrosion and the

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resulting depression must be blended into the surround-ing surface. All loosened material must be removedfrom the fuel tank by vacuuming prior to further treat-ment.

c. Abrade the bare metal reworked area to remove theoxide film which forms on it and the surface of theSAE AMS-C-27725 (MIL-C-27725) fuel tank coatingadjacent to the reworked areas to remove the glossfrom it with A-A-58054, Type I, Grade A abrasive mat.

A-A-59281 (MIL-C-38736) solvents are flam-mable and toxic to skin, eyes, and respiratory tract.Chemical resistant splash proof goggles and/orface shield and chemical resistant rubber glovesare required. Respirators are required when usingthis solvent in enclosed areas.

d. Clean the areas thoroughly to remove all residue, oil,and grease with a clean, lint free cloth conforming toeither A-A-2522, Grade A, Color 1, CCC-C-440, TypeI or II, or SAE AMS 3819, Class 2, Grade A wettedwith A-A-59281, Type I (MIL-C-38736, Type I) sol-vent. Do not allow solvent to dry by evaporation, wipethe area dry with a clean cloth to prevent redepositingthe soils on the surface.

e. Apply MIL-DTL-5541/MIL-DTL-81706, Class 1Aconversion coating to the reworked area per Section IIof Chapter 5.

PR-148 adhesion promoter is flammable and toxicto skin, eyes, and respiratory tract. Chemical orsplash proof goggles and rubber gloves are re-quired. Respirators are required when using thismaterial in enclosed areas.

f. Apply PR-148 (PRC-DeSoto Int. Corp.) adhesion pro-moter to the reworked area and the dulled area of thecoating around the reworked area and allow it to dryfor 30 minutes minimum to 2 hours maximum.

MIL-PRF-81733 sealants are moderately toxic toskin and body (if ingested). Wear chemical resis-tant gloves and avoid other skin contact. Washhands thoroughly before eating, drinking, or smok-ing after using these sealants.

g. Using an acid brush which has had the bristles clippedoff to half their original length, scrub MIL-PRF-81733,

Type I or II sealant onto the reworked area while mak-ing sure the sealant wets the entire area and overlapsslightly on to the dulled area of the coating around thereworked area. Add more sealant with the brush until aslight mound is formed and smooth the surface withthe brush.

h. Replace any fillet or brush coat sealant removed tofacilitate rework of a corroded area per instructions inTO 1-1-3.

Polyurethane coatings are flammable and toxic tothe skin, eyes, and respiratory tract. Chemical re-sistant splash proof goggles and/or face shield,chemical resistant rubber gloves, and an organicvapor face mask are required. Avoid all skin con-tact. Exhaust ventilation is required when usingthis material in enclosed spaces/areas. Keep allopen flames and any other sources of ignitionaway from the area in which this material is beingused.

i. When sealant applied in step g and step h above istack-free, overcoat the sealant with a MIL-C-83019clear flexible polyurethane coating. Overlap of thiscoating onto the dulled area of the SAE AMS-C-27725(MIL-C-27725) coating around the reworked area shallnot exceed ¼ inch.

7.6.2 Removal of Corrosion and Rework of AluminumExternal Fuel Tanks/Drop Tanks. Complete removal ofcorrosion products is required to prevent recurrence of cor-rosion in the affected areas.

7.6.2.1 Tank Exterior Surfaces.

Tanks which have contained fuel are hazardousuntil all vapors and residual fuel deposits havebeen removed. They are potential explosion andhealth hazards and should be treated as such. Re-fer to TO 1-1-3 for proper purging procedures.

Remove corrosion from these surfaces and rework the areaper the following procedure:

a. If painted, remove paint from area where corrosion issuspected per instructions in TO 1-1-8 such that a mar-gin of good metal around the suspected area is ex-posed.

b. Remove and treat corrosion using an appropriate me-chanical method in Section I of Chapter 5.

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c. Apply MIL-C-5441/MIL-DTL-81706, Class 1A con-version coating to bare metal areas per procedures inSection II of Chapter 5.

d. Touch up area from which paint was removed per in-structions in the applicable system specific -23 aircrafttechnical order using procedures in TO 1-1-8.

7.6.2.2 Tank Interior Surfaces. Remove corrosion fromthese surfaces and rework the area per the following proce-dure:

NOTE

The interior surface of aluminum alloy tanks shallnot be painted.

a. If a preservative mixture is present, remove it onlyfrom the immediate area requiring corrosion removaland treatment. Mix one part MIL-PRF-87937, Type IVcleaner with nine parts fresh tap water by volume. Ap-ply the cleaner solution to the area with a sponge, softbrush, or cloth. Scrub the area thoroughly, remove pre-servative, and rinse with fresh tap water. Use a clean,dry, lint free cloth to dry the area.

b. Remove and treat corrosion using an appropriate me-chanical method in Section I of Chapter 5, exceptabrasive blasting shall not be used.

c. Apply MIL-DTL-5541/MIL-DTL-81706, Class 1Aconversion coating to bare metal areas per proceduresin Section II of Chapter 5.

d. Per direction of TO 00-85A-03-1, preserve the interiorof assembled tanks by fogging with preservative orapplying it with a clean, lint free cloth soaked in apreservative solution. The preservative solution shallconsist of one part of MIL-C-6529, Type 1 CPC andthree parts of MIL-PRF-6081, Grade 1010 oil. If spray-ing the preservative to protect the entire tank interior,spray with a pressure spray that provides complete at-omization, and vent the tank at the farthest practicabledistance from the introduction point of the oil mixtureduring spraying operations. The amount of preserva-tive shall be a minimum of 0.12 CC per square foot ofinternal surface.

NOTE

• Tanks containing foam baffling shall not bepreserved.

• This preservative compound is compatible withgasoline and jet type fuels, so it need not beremoved before placing tank in service.

7.7 FAYING SURFACES AND ATTACHMENTPOINTS.

NOTE

Treat and process faying surfaces of parts, compo-nents, or structures which are assembled by adhe-sive bonding in accordance with the applicablesystem specific aircraft, missile, or equipmentmaintenance manual that covers adhesive bond-ing.

7.7.1 Faying Surfaces, Joints, and Seams. When re-pairs are made on equipment or accessories and/or compo-nents are installed or structures are reinstalled, the attachingor faying surfaces shall be protected by sealing all metal tometal and composite to metal contact surfaces. All perma-nent structures shall be installed with faying surfaces wetwith MIL-PRF-81733, Type I or IV, Class 1 or 2, Grade Asealant. All removable structures such as access doors, in-spection plates, floor panels and plates, and other removablepanels (components requiring frequent removal for mainte-nance requirements) shall either be installed with faying sur-faces wet with SAE AMS 3367, Class A or B or PR-1773,Class B sealant or with SAE AMS 3255 (Skyflex®) or Av-DecTM HT3935-7 or HT3000 sealant tape in the joints asspecified by the system specific maintenance manual. In ad-dition to faying surface sealing, fillet seal all critical interiorseams (those in corrosive areas such as aircraft bilges andlatrines) and all exterior seams (those exposed to the outsideenvironment) on permanent structure so that fillet is flushwith the surface for butt seams and fairs smoothly into theadjoining surface for lap seams using MIL-PRF-81733, TypeII, Class 1 or 2, Grade A sealant. Fillet seal all critical inte-rior and all exterior butt and lap seams on removable struc-tures that were faying surface sealed with SAE AMS 3367 orPR-1773 sealant in the same manner with SAE AMS 3267,Class B or PR-1773, Class B sealant. Refer to Chapter 6 foradditional details on sealant selection and application proce-dures. The coating system on all structures adjacent to thesealed seams and joints shall be touched up after sealantinstallation to match the surrounding structure in accordancewith the applicable system specific maintenance manual withapplication per TO 1-1-8 procedures.

7.7.2 Attaching Parts and Hardware. Attaching parts,such as nuts (standard, speed, and self-locking), bushings,spacers, washers, screws (standard and self-tapping), sleevesfor shake-proof fastener studs, clamps, bolts, etc., do notneed to be painted in detail except when dissimilar metal orwood contact is involved with the materials being joined orexposure to a corrosive interior environment or the exteriorenvironment will occur in service. However, all parts shallbe installed wet with sealant. For permanent installations,use MIL-PRF-81733, Type I or IV, Class 1 or 2, Grade Asealant and coat the entire mating surface of the parts. For

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removable installations, use SAE AMS 3367, Class A or PR-1773, Class B sealant and coat only the lower side of theheads of screws and bolts with sealant. For removable instal-lations, do not coat the threads and shanks of screws andbolts or the holes into which they are inserted because thiswill make future removal almost impossible without damag-ing the parts. As an alternate for removable installations, theshanks, threads, and lower side of the heads of standardscrews and bolts may be coated with MIL-PRF-63460, MIL-PRF-16173, Class II, Grade 3, or MIL-PRF-32033 CPC be-fore they are installed. Close tolerance bolts and parts shallbe coated with corrosion inhibiting, solid film lubricant. UseSAE AS5272 (MIL-PRF-46010, heat curing type) on non-aluminum parts when 400° F (205° C) ovens are available.Use MIL-L-23398 or MIL-PRF-46147 (air curing type) onaluminum parts and on all types of metallic parts when 400°F (205° C) ovens are unavailable. The solid film lubricantshall be applied and completely cured prior to assembly.(Refer to Section II of Chapter 3 for application and curingprocedures). Bolts shall be coated on shanks and threadsonly. A thin bead of sealant shall be applied under the bolthead to impart a wet seal. If possible, bolt head, nut, and boltend shall be fillet sealed after installation. MIL-PRF-81733,Type II, Class 1 or 2, Grade A shall be used for sealing.

NOTE

The following does not apply to parts which arelubricated in the joint areas immediately before orafter installation or to close tolerance bolts andparts which are removed frequently for mainte-nance requirements.

a. All rivets shall be installed wet with MIL-PRF-81733,Type I or IV, Class 1 or 2, Grade A sealant. In fuelcontact areas, the exposed rivet head and approxi-mately ¼ in of the adjacent structure shall be brush-over-coated with SAE AMS-S-8802 (MIL-S-8802),Class A sealant.

b. All machine screws, countersunk fasteners, bolts (headend), and nuts which are used in contact with magne-sium shall be installed with 5056 aluminum alloywashers. These parts, including the washers, shall beinstalled wet with MIL-PRF-81733, Type II, Class 1,Grade A sealant and shall be completely fillet sealedwith the same material after installation.

c. Adjustable parts, such as tie rod ends and turnbucklesshall be installed as follows:

(1) If possible, surfaces and threads shall be lubri-cated and protected before assembly with a filmof SAE AS5272 (MIL-PRF-46010, heat curingtype) or MIL-L-23398 or MIL-PRF-46147 (aircuring type) corrosion inhibiting, solid film lubri-cant which shall be completely cured prior to as-sembly. (Refer to Section II of Chapter 3 for ap-plication and curing procedures). Afterinstallation, apply a thin coating of DOD-L-25681

lubricant to all surfaces of these parts located inhigh temperature areas. Apply a thin coating ofMIL-PRF-63460, MIL-PRF-16173, Class II,Grade 3, MIL-PRF-32033, MIL-PRF-81309, TypeII, or MIL-L-87177, Type 1 or 2, Grade B waterdisplacing, CPC to all surfaces of these parts lo-cated in other lower temperature areas.

(2) If solid film lubricants cannot be applied, use athin coating of DOD-L-25681 lubricant on allsurfaces before and after assembly when locatedin high temperature areas. Apply a thin coating ofMIL-PRF-63460, MIL-PRF-16173, Class II,Grade 3, MIL-PRF-32033, MIL-PRF-81309, TypeII, or MIL-L-87177, Type 1 or 2, Grade B waterdisplacing, CPC after assembly when located inother lower temperature areas.

d. If possible, slip fit parts shall be assembled with mat-ing surfaces wet with MIL-PRF-81733, Type I or IV,Class 1 or 2, Grade A sealant. If not possible, coat theID of the holes in the receiving part, which is normallythe larger structure, with a corrosion inhibiting, solidfilm lubricant conforming to MIL-L-23398 or MIL-PRF-46147 (air curing types) and the OD of the mat-ing part with one conforming to MIL-PRF-46010 (heatcuring type) or one conforming to MIL-L-23398 orMIL-PRF-46147 (air curing types). The solid film lu-bricant shall be applied and completely cured prior toassembly. (Refer to Section II of Chapter 3 for appli-cation and curing procedures).

e. Press fit parts shall be installed with faying surfaces(the OD of the part and the ID of the hole) wet withMIL-PRF-81733, Type IV, Class 1 or 2, Grade A seal-ant and the edges of these parts shall be fillet sealedwith MIL-PRF-81733, Type II, Class 1 or 2, Grade Asealant after installation.

f. All cut edges and holes drilled or reworked for bolts,screws, rivets, studs, and bushings of aluminum alloyand magnesium alloy structures or parts shall receive achemical conversion coating treatment prior to the in-stallation of the fasteners or bushings and prior to in-stalling or refinishing the structure or parts. Apply aMIL-DTL-5541/MIL-DTL-81706, Class 1A chromateconversion coating to aluminum alloy parts and SAEAMS-M-3171 (MIL-M-3171), Type VI chromic acidbrush-on pretreatment to magnesium alloy parts perprocedures in Section II of Chapter 5.

7.7.3 Severely Corroded (Rusted) Hardware. Severelycorroded common hardware such as screws, bolts, and wash-ers should be replaced. Economic consideration shall begiven to replacement of other corroded screws, bolts, nuts,washers, etc., instead of cleaning and recoating or replating.However, major replacements should be accomplished dur-ing overhaul and/or scheduled depot maintenance. When aprotective coating, such as cadmium plating on bolts, screws,

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etc., is damaged, immediate action shall be taken to apply anappropriate protective finish to prevent corrosion (rusting).Refer to Section III of Chapter 3 for proper corrosion pre-ventative materials.

7.8 NATURAL AND SYNTHETIC RUBBER PARTS.

Natural and synthetic rubber shall not be painted or oiled. Asa general rule, grease should not be applied to rubber parts,but some parts, such as O-rings, require a grease coating(consult the appropriate system specific maintenancemanual). Many types of rubber are subject to fungus growth(e.g. mold, mildew) which can cause deterioration of therubber and corrosion of surrounding metal surfaces. If fun-gus is noted on rubber parts, clean the parts and remove thefungus per procedures in Section I of Chapter 3.

7.9 POTABLE WATER TANKS.

The interior surface of aluminum alloy potable water tanksshall not be painted or conversion coated. Remove corrosionby using the mechanical methods outlined in Section I ofChapter 5 and ensure all debris is removed.

7.10 SURFACES AND COMPONENTS EXPOSEDTO EXHAUST GASES, GUN GASES, AND ROCKETBLAST.

Residues from exhaust gases, gun gases, and rocket blast arevery corrosive and can cause deterioration of paint systems.Frequent cleaning of these areas to remove residue is re-quired and shall be accomplished in accordance with SectionI of Chapter 3.

7.11 ELECTRICAL AND ELECTRONIC EQUIP-MENT.

Avionic and electrical equipment are easily damaged by con-tamination with corrosion removal debris and by applicationof improper corrosion control materials. Many of the con-ventional corrosion treatment methods used on airframe,missile, and equipment structural components are also usedon areas adjacent to or supporting avionic equipment, elec-trical equipment, wire bundles, and other electrical parts.Personnel performing airframe corrosion control tasks on oraround this equipment shall be familiar with materials andprocedures used for corrosion prevention and control on

electrical and electronic equipment to ensure that no damageto electrical or avionic equipment will occur. For more spe-cific information, refer to TO 1-1-689 series, TO 00-25-234,TO 1-1A-14, and the specific system specific equipmentmaintenance manuals.

7.11.1 Grounding and Bonding Connections. After thegrounding or bonding connection has been made, overcoatthe entire connection, including all bare areas on the metalsurface, with MIL-PRF-81733, Type II, Class 1 or 2, GradeA sealant.

7.11.2 Conduit and Junction Boxes. Electrical conduit(exterior) and junction boxes (interior and exterior) shall beprimed with two coats of MIL-PRF-23377, Type I, Class Cepoxy primer or TT-P-2760, Type I, Class C polyurethaneprimer applied per procedures in TO 1-1-8. If corrosion isfound, remove it by mechanical methods outlined in SectionI of Chapter 5. Before applying the primer, apply a MIL-DTL-5541/MIL-DTL-81706, Class 1A chromate conversioncoating to aluminum alloy parts and SAE AMS-M-3171(MIL-M-3171), Type VI chromic acid brush-on pretreatmentto magnesium alloy parts per procedures in Section II ofChapter 5 to all reworked areas and any other bare metalareas.

7.11.3 Wires and Cables. Electrical wires and cableshaving plastic jacket insulation and/or braided wire exteriorshielding shall not be painted or coated except as requiredfor moisture and fungus proofing. Consult TO 1-1-689 se-ries, TO 1-1A-14, and TO 00-25-234 for additional informa-tion.

7.11.4 Deleted.

7.11.5 Moisture and Fungus Proofing of Electrical andElectronic Equipment. Consult TO 1-1-689, TO 1-1A-14,and TO 00-25-234 for information on fungus proofing thisequipment.

7.11.6 Antennas. Dissimilar metal (Galvanic) corrosionoften occurs at antenna attach points. Refer to TO 1-1-689series for repair information. Refer to the system specificmaintenance manuals for information on paint touch-up andfinishing. Apply paint and coatings per procedures in TO1-1-8.

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Change 10 7-7

7.12 STRUCTURAL TUBING MEMBERS AND AS-SEMBLIES.

Only non-powered mechanical procedures and materialsspecified in Section I of Chapter 5 shall be used to removecorrosion on structural tubing. Reworked areas shall alwaysbe polished to a smooth surface, using 400 to 600 grit abra-sive mat, paper, or cloth as the final step in the corrosionremoval procedure. The following paragraphs outline gen-eral practices for the protection of structural tubing.

7.12.1 Structural Aluminum Alloy Tubing. Treat andpaint the exterior surfaces of all tubing and the interior sur-faces of open ended tubing closed off by riveted or boltedend surfaces with the finish system designated in the appli-cable system specific maintenance manual. Apply paint perprocedures in TO 1-1-8. All bolted or riveted caps or com-ponents shall be installed with faying surfaces and fastenerswet with MIL-PRF-81733, Type I or IV, Class 1 or 2, GradeA sealant. Interior surfaces of tubing closed by welded endplugs or components shall be coated with MIL-PRF-16173,Class II, Grade 2 or 4 CPC using the fill and drain method ofapplication through holes located near each end of the tubes.These holes shall subsequently be closed by installing blindrivets wet with MIL-PRF-81733, Type II, Class 1 or 2, GradeA sealant and overcoating the rivet head with the same ma-terial after installation.

7.12.2 Structural Magnesium Alloy Tubing. All surfacesof magnesium tubing shall be treated with a SAE AMS-M-3171 (MIL-M-3171), Type VI chromic acid brush-on pre-treatment coating per procedures in Section II of Chapter 5and painted with the finish system designated in the appli-cable system specific maintenance manual with applicationper procedures in TO 1-1-8. Install all parts onto the tubingwith all faying surfaces and fasteners wet with MIL-PRF-81733, Type I or IV, Class 1 or 2, Grade A sealant.

7.12.3 Structural Copper Alloys, Stainless Steel(CRES) Alloys, and Heat Resistant Alloy Tubing. Theinterior and exterior surfaces of these types of tubing do notrequire a finish system. However, to prevent galvanic corro-sion of other metals with which these types of tubing are incontact, install parts and attach tubing with faying surfacesand fasteners wet with MIL-PRF-81733, Type I or IV, Class1 or 2, Grade A sealant when located in areas not exposed tohigh temperatures or SAE AMS 3374, Type 1, 2, 3, or 4sealant for high temperature areas.

7.12.4 Structural Carbon Steel Tubing.

7.12.4.1 Exterior. All exterior surfaces of steel tubing as-semblies shall be finished with one coat of MIL-PRF-26915,Type I or II, Class A or B, zinc-rich primer, MIL-PRF-23377,Type I, Class C or MIL-PRF-85582, Type I, Class C2 epoxyprimer, or TT-P-2760, Type I, Class C polyurethane primer

followed by two coats of MIL-PRF-85285 polyurethane top-coat with the color as specified in the applicable system spe-cific maintenance manual. After corrosion (rust) is removedand before applying a primer, apply an appropriate MIL-C-10578 film per Section I of Chapter 5 or a MIL-C-8514 orDOD-P-15328 wash primer coating to bare metal areas perprocedures in TO 1-1-8. Apply primer and topcoat materialsper procedures in TO 1-1-8.

7.12.4.2 Interior. For tubing assemblies without weldedor crimped ends, coat all interior surfaces with MIL-PRF-23377, Type I, Class C epoxy primer or MIL-PRF-26915,Type I or II, Class A or B, zinc-rich primer using a fill-and-drain procedure. Where practical, in lieu of the fill-and-drainprocedure, two coats of primer may be spray applied to in-terior surfaces of all assemblies using a spray gun with anextension wand.

7.12.4.3 Sealing. After coating the interior, clean the ex-terior surfaces of all assemblies adjacent to holes in the tubewalls by solvent wiping to remove any oil, grease, or othercontamination. Seal all holes in tube walls by installing blindrivets in the holes wet with MIL-PRF-81733, Type II, Class1 or 2, Grade A sealant and overcoating the rivet heads withthe same material after installation. Assemble all tubing as-semblies manufactured by riveting or bolting members to-gether with fittings with faying surfaces and fasteners wetwith MIL-PRF-81733, Type I or IV, Class 1 or 2, Grade Asealant.

7.13 NON-STRUCTURAL TUBING MEMBERS ANDASSEMBLIES.

Use the same procedures and materials specified for corro-sion removal on structural tubing members and assembliesin Paragraph 7.12 to remove corrosion from non-structuraltubing.

7.13.1 Aluminum Alloy Tubing.

Do not use A-A-59601, MIL-PRF-32295, Type IIand/or MIL-PRF-680 degreasing solvents or othersolvents that are not oxygen compatible in areasinvolving oxygen storage, including transfer sys-tems, and on the surfaces of missiles using liquidpropellant. Failure to observe these precautionscan result in serious or fatal injury to personneland complete destruction of the equipment.

Protect aluminum tubing exposed directly to the outside en-vironment during either flight or ground operations by ap-plying the exterior finish system specified in the applicable

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7-8 Change 5

system specific maintenance manual with application perprocedures in TO 1-1-8. Treat aluminum tubing according tothe following procedures:

a. Clean in accordance with Section I of Chapter 3.

b. Remove corrosion in accordance with Paragraph 7.12,using non-powered mechanical methods specified inSection I of Chapter 5.

c. Apply a MIL-DTL-81706, Class 1A chemical chromateconversion coating to all interior and exterior surfacesof tubing per procedures in Section II of Chapter 5,except coat only the exterior surfaces of oxygen lines.For new tubes, apply conversion coating to the entiretube after fabrication and prior to the installation. Ifcorrosion has been removed from tubing, apply con-version coating to all bare, reworked areas.

No paint or corrosion preventive compound shallbe applied to any tubular interior surface. Takenecessary precautions to prevent primer or paintfrom entering the interior areas of tubing. Wheredouble flares are used (e.g., on oxygen systems),cap the ends and apply the finish system after theflaring operation. Paint end fittings after installa-tion on the aircraft, missile, or equipment. Use ex-treme care to prevent contamination of interiorsurfaces of hydraulic, oxygen, and air speed indi-cator tubing during painting operations.

d. No paint or corrosion preventive compound shall beapplied to any interior surfaces of non-structural tub-ing. Apply the specified exterior finish system to allexterior surfaces or reworked areas of tubing exposedto the environment in the same sequence given abovefor structural aluminum tubing. Touch-up any coatingsystems damaged during tubing installation with thecoating system specified in the system specific mainte-nance manual with application per procedures in TO1-1-8.

7.13.2 Stainless Steel (CRES) Tubing.

• Do not use A-A-59601, MIL-PRF-32295, TypeII or MIL-PRF-680 degreasing solvents or other

solvents that are not oxygen compatible in ar-eas involving oxygen storage, including trans-fer systems, and on the surfaces of missiles us-ing liquid propellant. Failure to observe theseprecautions can result in serious or fatal injuryto personnel and complete destruction of theequipment.

• SAE AMS 3166 wipe solvent is flammable andtoxic to the skin, eyes, and respiratory tract.Eye and skin protection is required. Use onlyin a well ventilated area.

• Apply a small amount of SAE AMS 3166 sol-vent to a clean cloth and wipe the surface. Fol-low by wiping with a clean cloth or dry rag.This minimizes the amount of solvent used aswell as preventing redepositing contaminationon the surface.

• To control solvent odor, used rags should beimmediately placed in sealed plastic bags orcovered containers and disposed of in accor-dance with local directives.

Protect stainless (CRES) steel tubing exposed directly to theoutside environment, either during flight or ground opera-tions, by applying the exterior finish specified in the appli-cable system specific maintenance manual with applicationper procedures in TO 1-1-8. Austenitic (3XX series) stain-less (CRES) steels are highly susceptible to pitting, crevicecorrosion, and stress corrosion cracking when exposed tomoist, salt-laden air and when deposits of dirt and debris areallowed to collect on areas of the tubing covered by metalbrackets or parts. Treat stainless steel (CRES) tubing accord-ing to the following procedures:


b. Remove corrosion in accordance with Paragraph 7.12,using non-powered mechanical methods specified inSection I of Chapter 5.

c. Immediately before painting, wipe areas which will bepainted with a lint free cloth moistened with SAE AMS3166 wipe solvent and dry with a clean cloth. Do notallow drying by evaporation, since soils will redepositon the surface.

d. Apply the finish system specified for stainless steel(CRES) tubing in the system specific technical manu-als per TO 1-1-8 procedures.

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Change 5 7-9

7.13.3 Cadmium Plated Steel Tubing.

• SAE AMS 3166 wipe solvent is flammable andtoxic to the skin, eyes, and respiratory tract.Eye and skin protection is required. Use onlyin a well ventilated area.

• Apply a small amount of SAE AMS 3166 sol-vent to a clean cloth and wipe the surface. Fol-low by wiping with a clean cloth or dry rag.This will minimize the amount of solvent usedas well as preventing redepositing contamina-tion on the surface.

• To control solvent odor, used rags should beimmediately placed in sealed plastic bags orcovered containers and disposed in accordancewith local directives.

Bare cadmium plating deteriorates rapidly when subjected toabrasion, most bases (alkalis) and acids, and marine, indus-trial, and very humid environments. It should always be pro-tected with a paint system to prevent corrosion. Treat cad-mium plated steel tubing in accordance with the followingprocedures.


b. Remove deteriorated plating and corrosion on basemetal (steel) in accordance with Paragraph 7.12, usingnon-powered mechanical methods specified in SectionI of Chapter 5.

c. Immediately before painting, wipe areas which will bepainted with a lint free cloth moistened with SAE AMS3166 wipe solvent and dry with a clean cloth. Do notallow drying by evaporation since soils will redepositon the surface.

d. Apply the specified finish system for steel tubing inthe system specific technical manuals per TO 1-1-8procedures.

7.13.4 Special Instructions for Tubing Fittings andSleeves. Corrosion often occurs on sleeves and their fittingsand/or on the tubing in contact with them due to the crevicespresent at their attachment points. Galvanic corrosion oftenoccurs because the type of sleeve or fitting chosen is notelectrochemically compatible with the tubing. When corro-sion is found on these areas or when tubing, fittings, or

sleeves are replaced, consult the applicable system specificmaintenance manual to determine the proper types of sleevesand fittings. Fillet seal all fittings located in areas which areinaccessible for inspection and refinishing during operationalservice at the joint area with MIL-PRF-81733, Type II, Class1 or 2, Grade A sealant at the time of installation and prior topainting. After sealant is tack-free, paint the tubing, fittings,and sealant as directed in tubing in the system specific tech-nical manuals per TO 1-1-8 procedures.

7.13.5 Removable Installations.

• Do not use MIL-PRF-16173 corrosion preven-tive compounds on any oxygen line fittings.These materials contain petroleum solvents thatare not Liquid Oxygen (LOX) compatible. Ex-plosion may occur if oxygen contacts these ma-terials and if the resulting mixture is subjectedto sudden pressure or impact. After installation,apply the exterior paint system specified in theapplicable system specific maintenance manualwith application per procedures in TO 1-1-8 toexposed tubing, sleeves, and back portions ofthe B nuts of these fittings and a LOX compat-ible grease/lubricant to the gap at the front endof the B nut and the adjacent tubing for a lengthof one inch.

• Provide adequate ventilation when using A-A-59601, MIL-PRF-32295, Type II and/or MIL-PRF-680 degreasing solvents. Avoid repeatedor prolonged skin contact of inhalation orvapors.

Do not apply the finish system on fittings and adjacent tub-ing for a distance of one inch from the back and front endsof the fittings on tubing areas requiring periodic removaland/or opening during service. Clean all old preservativecoatings and dirt from the fitting, sleeves, and tubing endswith a clean, lint free cloth wetted with either A-A-59601,MIL-PRF-32295, Type II, or MIL-PRF-680, degreasing sol-vent and wipe dry with a clean, dry, lint free cloth beforereinstalling tubing and tightening fittings. Except for oxygenline fittings, apply a MIL-PRF-81309, Type II, MIL-L-87177,Type I or II, Grade B, or MIL-PRF-16173, Class II, Grade 3water displacing, CPC by spray or brush to all fitting sur-faces after they are tightened, including the exposed areas ofthe sleeves and the unfinished areas of the tubing. Allow theCPC to dry for at least 1 hour and apply MIL-PRF-16173,

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7-10 Change 5

Class II, Grade 4 or MIL-DTL-85054 CPC over the sameareas by spraying or brushing.

7.14 CORROSION REMOVAL FROM THIN METAL(0.0625 INCH THICKNESS AND LESS).

Do not allow metallic or corrosion particles tobuild up around the area being polished or on thepolishing tool (abrasive cloth or paper) during thepolishing operation. Damage to thin metal surfacesmay result.

Moderate to severe pitting and all intergranular and/or exfo-liation corrosion on thin metal requires removal by mechani-cal methods specified in Section I of Chapter 5 as appropri-ate for the type of metal involved. Use extreme care andconsult the applicable system specific maintenance manualfor structural damage limits when removing corrosion fromthin metal. When stains, surface corrosion, and mild pittingare found on thin structural skins (i.e., aircraft, missile, andequipment skins), chemical methods specified in Section I ofChapter 5, as appropriate for the type of metal involved, maybe used to remove the corrosion. In lieu of chemical corro-sion removal, the following convenient and effective me-chanical method for the removal of minor corrosion or stainson all metals may be used.

a. Mix ground SS-P-821, Grade F pumice powder abra-sive with clean tap water to form a paste. Using aclean, soft cloth (such as CCC-C-440 cheesecloth), ap-ply the paste to the area being treated and abrade thearea with a light rubbing motion.

b. When the pumice paste has dried to a white powder,wipe it off with a clean, dry, soft cloth. If corrosionproducts (observed as stubborn stains) still exist, use a600 grit wet or dry abrasive paper, cloth, or mat andwater to remove the remaining corrosion. Wipe cleanwith a clean, soft, dry cloth.

c. Refer to Section II of Chapter 5 for the required sur-face treatment on the type of metal involved andtouch-up the area with the finish system specified inthe applicable system specific maintenance manualwith application per procedures in TO 1-1-8.

7.15 AIR INTAKE DUCTS FOR JET AIRCRAFT.

Air intake ducts are fabricated from materials (usually 5000Series aluminum), which have high corrosion resistance.Certain components of these ducts may be cast aluminum ormagnesium. Frequent cleaning of the ducts is usually suffi-cient to preclude attack by corrosion. Aircraft performinglow level missions or take-offs and landings over salt water

or in highly saline atmospheres may require the ducts to bepainted to reduce corrosion attack. A requirement for a coat-ing as determined and/or recommended by the operating unitshall be coordinated with the MAJCOM Corrosion Manager,the aircraft SPD, and the Air Force Corrosion Prevention andControl Office (AFCPCO). The MIL-PRF-23377, Type I,Class C epoxy primer/MIL-PRF-85285 or APC polyurethanetopcoat paint system, color to match the surrounding area, isusually recommended for painting the ducts, but the finaldetermination of the coating to be used shall be made by theaircraft SPD in conjunction with the AFCPCO.

7.16 CLOSELY COILED SPRINGS.

Springs which are so tightly coiled that the areas betweenthe coils can not be plated or painted for corrosion protectionshall be coated with a MIL-PRF-81309, Type II, MIL-L-87177, Type I or II, Grade B, or MIL-PRF-16173, Class II,Grade 3 water displacing CPC applied by spraying or dip-ping and allowing it to dry for at least 1 hour. After drying, acoating of MIL-PRF-16173, Class II, Grade 4 CPC shall beapplied to the springs by spraying or dipping.

NOTE

These requirements do not apply to springs oper-ating in oil or hydraulic fluids.

7.17 CORROSION PREVENTION ON ASSEMBLIESAND PARTS REMOVED FROM AIRCRAFT DURINGMAINTENANCE, 30 DAY SHORT TERM STORAGE,AND OVER 30 DAY LONG TERM STORAGE RE-QUIREMENTS.

7.17.1 Short Term Storage. Short term storage is definedas any period up to 30 days for the purposes of this manual.When assemblies or parts are removed from the aircraft,missile, or equipment for repair, or to gain access to areas ofthe aircraft, missile, or equipment for maintenance, they shallbe treated to prevent corrosion prior to placement into shortterm storage. All items shall be stored indoors in a coveredarea to protect them from the elements. Refer to TO 1-1-17and the applicable system specific maintenance manual and(-17) storage manual for specific details on storage of a par-ticular part or assembly.

a. Assemblies or parts having bare metal surfaces, suchas internal and working surfaces on landing gear com-ponents, shall be properly lubricated or protected bycoating with the aircraft, missile, or equipment greases,hydraulic fluids, or oils normally applied in operationalservice.

b. High strength steel components which are stripped oftheir protective coatings shall have a film of MIL-PRF-81309, Type II, MIL-L-87177, Type I or II, Grade B,or MIL-PRF-16173, Class II, Grade 3 water displacing

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CPC applied to all bare surfaces whenever there is alapse of 2 hours or more in the rework cycle. The partshall then be loosely over-wrapped with MIL-PRF-121,Type II, Grade A, Class 1 barrier paper.

c. Completely painted parts need no other special protec-tive measures, except in marine or high humidity envi-ronments. In these cases, a MIL-PRF-81309, Type II,MIL-L-87177, Type I or II, Grade B, or MIL-PRF-16173, Class II, Grade 3 water displacing CPC shallbe applied to the part. The part shall then be looselyover-wrapped with MIL-PRF-121, Type II, Grade A,Class 1 barrier paper.

d. Prior to rework or reapplication of the required protec-tive coating, remove old CPC with solvent and reapplythe appropriate aircraft, missile, or equipment lubri-cant to areas requiring lubrication. The CPC compoundapplied to provide temporary protection shall not beused for lubrication in lieu of the appropriate lubricantspecified for use on a particular part or assembly.

7.17.2 Long Term Storage. If the storage of assembliesor parts will exceed 30 days, increased protective measuresare required, particularly on critical parts and high strengthsteel components. All items shall be stored indoors in a cov-ered area to protect them from the elements. Refer to TO1-1-17 and to the applicable system specific maintenanceand (-17) storage manuals for specific details on storage of aparticular part or assembly.

a. All bare metal surfaces and surfaces with damagedplating or paint, shall be coated with MIL-PRF-81309,Type II, MIL-L-87177, Type I or II, Grade B, or MIL-PRF-16173, Class II, Grade 3 water displacing CPCfollowed by application of a coating of MIL-PRF-16173, Class II, Grade 4 long term CPC. The part shallthen be over-wrapped with MIL-PRF-121, Type II,Grade A, Class 1 barrier paper.

b. Completely repainted parts need no other special pro-tective measures, except in marine or high humidityenvironments. In these cases, surfaces shall be coatedwith MIL-PRF-81309, Type II, MIL-L-87177, Type Ior II, Grade B, or MIL-PRF-16173, Class II, Grade 3water displacing CPC followed by application of acoating of MIL-PRF-16173, Class II, Grade 4 longterm CPC. The part shall then be over-wrapped withMIL-PRF-121, Type II, Grade A, Class 1 barrier paper.

c. Depending on the length of time in storage, reapplica-tion of CPC’s may be required. Refer to Section III ofChapter 3 for time limitation information on CPC’s.

d. Prior to returning the part or assembly to service, re-move CPC’s with solvent and reapply the appropriateaircraft, missile, or equipment lubricant to areas re-quiring lubrication. The CPC compound applied to

provide temporary protection shall not be used for lu-brication in lieu of the appropriate lubricant specifiedfor use on a particular part of assembly.

7.18 DEPLETED URANIUM COUNTERWEIGHTS.

Many aircraft control surfaces such as ailerons and elevatorsare equipped with counterweights fabricated from depleteduranium for mass balancing purposes. Depleted uranium isused because of its very high weight per unit of volume(density). To protect the depleted uranium from corrosion,many of the counterweights are plated with a copper strike,followed with a nickel strike, followed by a full thicknesscadmium plate and then overcoated with the organic finish(paint) system specified for the specific aircraft. These coun-terweights are usually impression stamped for identificationas follows; “Caution: Radioactive Material, Depleted Ura-nium, High Salvage Value, Manufactured by - - -, Fabrica-tion No. - - -, Finished Weight - - - lb. Unauthorized Altera-tions Prohibited.” All personnel shall observe the followingrequirements of the Nuclear Regulatory Commission relativeto depleted uranium.

To restrict radiation exposure to a maximum of10% of the Nuclear Regulatory Commission’s es-tablished limits for radioactive materials workersand to comply with the requirements in AFI 40-201, observe these precautions to control exposureto radiation emitted from these weights. Failure tocomply may result in overexposure to radiationand the need for medical attention.

a. All work on depleted uranium counterweights shallconform to the requirements of AFI 40-201.

b. Chemical or mechanical processing of depleted ura-nium counterweights, other than repair or restorationof plating, organic finish system, and/or other cover-ing, requires a Nuclear Regulatory Commission li-cense.

c. Do not machine, grind, file, sand, drill, weld, or other-wise mechanically work these counterweights at field/organizational maintenance units. Depleted uraniumand its oxide corrosion products in the form of dust,fumes, or particles are highly toxic if ingested.

d. If at all possible, remain at least two feet away fromthe depleted uranium counterweights since radiation isalmost nil at this distance and greater. If any part ofthe body comes within 1 foot of a depleted uraniumcounterweight, keep a record of the exposure time anddo not allow the total exposure time to exceed 40 hoursper calendar quarter. If it becomes necessary to touch a

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depleted uranium counterweight, keep a record of theexposure time and do not allow the total exposure timeto exceed 13 hours per calendar quarter.

e. If an aircraft with control surfaces having depleteduranium counterweights is being transferred to anotherunit or the aircraft or one of its control surfaces isbeing scrapped, notify the receiving unit and/or sal-vage personnel of their presence and bring these pre-cautions to their attention.

f. Remove the depleted uranium counterweights and/orthe control surfaces containing them from the aircraftafter any aircraft accident.

g. Dispose of depleted uranium counterweights per direc-tions in AFI 40-201.

NOTE

Refer to applicable system specific maintenancemanual to determine the location of depleted ura-nium parts and to determine any specific direc-tions for work either on the counterweights or inareas immediately adjacent to the counterweights.

7.18.1 Corrosion and Finish Damage Treatment Pro-cedures. Follow these procedures when treating finish sys-tem and/or corrosion damage on depleted uranium counter-weights.

a. Visually inspect the organic finish system (paint) forblisters and flaking. If found, peel away the paint flakesand inspect the plating for blisters and flaking. If found,peel away the plating flakes and inspect the surface ofthe depleted uranium for pitting and/or intergranularexfoliation corrosion. The corrosion products are verydark brown to gray to black color similar to rust onsteel and will flake off in the same fashion.

b. Collect all of peeling and/or flaking paint and/or plat-ing residue, check it for radioactivity, and dispose of itper instructions in AFI 40-201 if radioactivity is noted.

c. Field/organizational units are not authorized to removecorrosion found on the depleted uranium itself. Field/organizational units are limited to the following ac-tions on depleted uranium counterweights.

(1) Accomplish step a and step b above.

(2) Apply one thick coat of MIL-PRF-81733, Type Ior II, Class 1 or 2, Grade A sealant to the barearea with a brush per the manufacturer’s instruc-tions.

(3) After the sealant cures at least to a tack-free state,apply one coat of MIL-PRF-85285 polyurethane

in the color specified in the system specific tech-nical data by brush per procedures in TO 1-1-8over the sealant with a slight overlap onto thesurrounding paint surface.

(4) Make an entry in the appropriate aircraft forms toindicate a requirement for depot level repair ofthe affected counterweight at the next aircraft de-pot input for PDM or other depot level mainte-nance.

d. Depot facilities (ALC prime for the aircraft), can re-move corrosion from depleted uranium counterweightsand rework them, but only if properly licensed by theNuclear Regulatory Commission. If the prime ALC isnot licensed to perform the work, the affected counter-weights shall be removed from the control surfacesand packaged for shipment per instructions in AFI 40-201, and shipped to a properly licensed facility for ei-ther rework or disposal, as appropriate. If the primeALC performs rework of depleted uranium counter-weights after they are removed from the control sur-face, it shall be done in accordance with AFI 40-201and a definitive process order developed and approvedby the aircraft SPD in conjunction with the ALC cor-rosion prevention and control manager. This processorder shall include the following procedures as a mini-mum:

(1) Remove the affected counterweight from the con-trol surface per instructions in the applicable sys-tem specific maintenance manual.

(2) Remove the paint from the counterweight sur-faces per procedures in TO 1-1-8.

(3) Remove the plating from the counterweight sur-faces per procedures in TO 42C2-1-7.

(4) Remove any corrosion from the depleted uraniumsurfaces using an appropriate mechanical methodin Section I of Chapter 5 of this manual that isapproved and listed in the process order makingsure to observe all the precautions in the WARN-ING above and in AFI 40-201.

(5) Check all residue for radioactivity and dispose ofany residue found to be radioactive per instruc-tions in AFI 40-201.

(6) Replate the counterweight with the plating(s)specified in the applicable system specific techni-cal data per procedures in TO 42C2-1-7.

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(7) Apply a MIL-PRF-23377, Type I, Class C epoxyprimer and MIL-PRF-85285 polyurethane topcoatin the color specified in the applicable systemspecific maintenance manual per procedures inTO 1-1-8.

(8) Reinstall the counterweight on the control surfaceper instructions in the applicable system specificmaintenance manual with faying surfaces and fas-teners wet with MIL-PRF-81733 Type I or IV,Class 1 or 2, Grade A sealant.

7.19 MONEL RIVETS.

Corrosion of nickel-copper alloy (monel) is evidenced bygreen corrosion products (patina). Removal of this type ofcorrosion is not required as the corrosion products are veryadherent and provide a degree of protection to the monelbase metal. If desired, corrosion products may be removedas follows:

a. Scrub with a non-metallic bristle brush wet with solu-tion of 6 OZ of ASTM D 928 sodium bicarbonate pergallon of water.

b. Thoroughly rinse the affected area with fresh tap waterand wipe dry with a clean, lint free cloth or blow drywith oil free, low pressure air.

7.20 BERYLLIUM-COPPER ALLOYS, BERYLLIUM-ALUMINUM ALLOYS, AND BERYLLIUM OXIDE.

Dust, corrosion products (beryllium oxide), andother fine particles generated by beryllium and be-ryllium alloys are toxic when inhaled or allowedto contact skin. Severe poisoning can result if be-ryllium dust and/or fumes are inhaled and causedelayed lung injury and/or death. OSHA regula-tions require use of personal protective equipment(PPE) suitable for the task being performed. Con-sult the local Bioenvironmental Engineer for de-termination of the type of PPE required. Do notweld, drill, cut, file, sand, abrade, machine, or per-form any other mechanical action on beryllium al-loy parts that will create airborne dust particlesfrom the operation without using appropriate PPEand facility dust collection systems.

NOTE

Surface discoloration is normal and removal isneither advised nor is it necessary.

7.20.1 Corrosion Removal and Treatment. If it is notfeasible to remove the part from the aircraft, missile, or pieceof equipment for corrosion removal and treatment, the pro-

cedure may be performed on an installed part in place. Tominimize the generation of fine beryllium, beryllium oxide,beryllium-copper alloy, and/or beryllium-aluminum alloydust particles when removing corrosion from beryllium-cop-per alloy fittings such as contacts, bushings, etc., and beryl-lium-aluminum alloy parts, proceed as follows:

a. Wear disposable coveralls, gloves, hood, cartridge res-pirator, and other PPE, as required, by the local Bioen-vironmental Engineer.

b. Dampen an A-A-58054, Type I, Grade B abrasive matwith A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, degreasing solvent and abrade the corrosionproducts from the surface.

c. To prevent the spread of toxic dust, keep mat wetthroughout the corrosion removal process.

d. Clean the surface with disposable towels dampenedwith degreasing solvent after the completion of corro-sion removal and wipe dry with a clean, dry towel.

e. Apply a film of MIL-PRF-81309, Type II, or MIL-L-87177, Type I, Grade B water displacing, CPC to be-ryllium-copper bushings and MIL-PRF-81309, Type IIIor MIL-L-87177, Type I, Grade B to beryllium-coppercontacts by spraying. Apply a MIL-DTL-81706/MIL-DTL-5541, Class 1A conversion coating to the surfaceof beryllium-aluminum alloy parts per procedures inSection II of Chapter 5.

f. Wipe work area clean with disposable towels damp-ened with A-A-59601, MIL-PRF-32295, Type II, orMIL-PRF-680, degreasing solvent and wipe the areadry with a clean, dry towel.

g. Place disposable towels, abrasive mats, and coverallsin a plastic bag marked, “Beryllium ContaminatedWaste”.

h. Close the plastic bag with SAE AMS-T-23397 (MIL-T-23397), Type II aluminum foil tape.

i. Discard all in accordance with local environmental di-rectives.

j. Wash hands with soap and water immediately aftercompletion of the task.

7.20.2 Depot Maintenance. If it is feasible, operationallyacceptable, and replacement parts are readily available, be-ryllium alloy parts should not be reworked to remove corro-sion by field/organizational level maintenance personnel. Theparts should be removed from the aircraft, missile, or pieceof equipment, properly packaged, and shipped to the respon-sible depot (ALC) for rework using the following procedures:

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a. Wear disposable coveralls, gloves, cartridge respiratorand other PPE, as required, by the local Bioenviron-mental Engineer.

b. Remove the corroded part, and place it in a plastic bagmarked, “Beryllium Alloy Part”.

c. Close the plastic bag with SAE AMS-T-23397 (MIL-T-23397), Type II aluminum foil tape.

d. Package the part for shipment to the responsible depot(ALC) for rework.

e. Clean the area from which the part was removed withdisposable towels dampened with A-A-59601 or MIL-PRF-680, Type II or III degreasing solvent and wipedry with a clean, dry towel.

f. Install a new replacement part in the area from whichthe old, corroded beryllium alloy part was removedper the appropriate system specific technical data.

g. Place disposable towels and coveralls in a plastic bagmarked, “Beryllium Contaminated Waste”.

h. Close the plastic bag with SAE AMS-T-23397 (MIL-T-23397), Type II aluminum foil tape.

i. Discard all in accordance with local environmental di-rectives.

j. Wash hands with soap and water immediately aftercompletion of the task.

7.21 EMI SEALS AND GASKETS.

Radiated electromagnetic fields (produced by radar antennas;aircraft, and missile transmitters; certain poorly designedavionics units; electric motors; lightning; or any other natu-ral effects), can interfere with aircraft avionics systems caus-ing electrical and/or electronic malfunctions. This radiationis known as electromagnetic interference (EMI). To preventmalfunctions caused by EMI, electrically conductive shield-

ing is either built into the avionic device or must be added toaccess panels, doors, or covers to prevent emission of EMIfrom its own circuits and prevent susceptibility to outsideEMI. EMI seals and gaskets may also act as environmentalseals in certain locations, especially around doors and accesspanels. Since aluminum surfaces oxidize very easily, thusbecoming much less conductive and/or non-conductive, othermaterials have been used to make electrical contacts (i.e.,beryllium-copper, titanium, silver-plated aluminum, and tin-zinc coatings). However, since these contacts must provide aconductive path to an aluminum or graphite/epoxy skin, cor-rosion often occurs at the junction of these dissimilar metals.When corrosion occurs, the conductive path is lost alongwith the EMI protection, making the aircraft susceptible toelectrical and electronic malfunctions caused by external ra-diation. Examples of system malfunctions are microproces-sor bit errors, computer memory loss, false indicators(alarms, lights, read-outs), CRT ripple, false signals andpower loss. The result of such malfunctions can be cata-strophic (e.g. EMI radiation was responsible for an aircraftjettisoning a bomb while taking off from a carrier). The fol-lowing are typical EMI shielding materials: elastomeric sealsand gaskets with an embedded or attached conductor (referto Figure 7-1), conductive elastomer gaskets (refer to Figure7-2), metallic screens installed under composite covers (referto Figure 7-3), bonding cables for access doors (refer to Fig-ure 7-4), and bonding washers for avionics enclosures, (referto Figure 7-5).

7.21.1 Treatment of EMI Seals and Gaskets. Whencorrosion is observed in such areas, disassemble only theaffected areas and remove the corrosion using the mildestavailable method necessary to remove the corrosion. Care-fully clean the area with a lint free cloth wet with TT-I-735isopropyl alcohol. Dry with a clean cloth. If replacementseals are available, install them in accordance with the ap-propriate aircraft, missile, or equipment system specificmaintenance manual. If replacement seals are not availableor do not exist, spray the contacting surfaces with a lightcoating of MIL-PRF-81309, Type III avionics grade, waterdisplacing CPC, and then reassemble. Periodically inspectrepaired areas and areas known to be chronic problems.

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Figure 7-1. Beryllium-Copper Spiral Contact with Environmental Fluorosilicone Seal

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Figure 7-2. Dorsal Longeron EMI Seal

Figure 7-3. Stainless Steel (CRES) EMI Screen

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Figure 7-4. Bonding Cable from Airframe to Graphite/Epoxy Avionics Bay Door

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Figure 7-5. EMI Bonding Washers in an Avionics Bay

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CHAPTER 8EMERGENCY PROCEDURES

8.1 PURPOSE.

This chapter describes emergency procedures to be followedafter aircraft, missile, or equipment incidents or accidentsinvolving exposure to gross amounts of salt water or fireextinguishing agents. The procedures described are used toprevent further damage before more extensive cleanup at ei-ther organizational or intermediate maintenance can be per-formed and/or further treatment at depot level maintenancecan be accomplished.

8.2 RESPONSIBILITY.

• Failure to remove aircraft from dry/wet chemi-cal exposure and to remove dry/wet chemicaland dry powder agents from aircraft surfaceswill allow significant corrosion to occur on ex-posed metals.

• Failure to remove an aircraft from foam expo-sure and to remove foam from an aircraft willcompromise protective coatings on metal andallow corrosion/oxidation to occur.

• Exposure to salt water, purple K powder (PKP/potassium bicarbonate) and/or protein type firefighting foam require immediate action to pre-vent serious corrosion damage.

NOTE

In cases involving aircraft, missile, or equipmentaccidents, permission must be obtained from thesenior member of the accident investigation boardprior to the initiation of emergency procedures.

Under emergency conditions, all personnel are responsiblefor minimizing damage. Aircraft should be removed fromcontaminated aircraft hangars and other locations when ex-posed to firefighting agents as soon as approved by the BaseFire Department, Base Safety Office and BioenvironmentalOffice. Reclamation team personnel shall follow proceduresand directions as provided by the Base Safety Office. Re-moval of equipment shall be supervised by the organiza-tional unit maintenance officer in conjunction with the main-tenance superintendent. Removal of equipment shall besupervised by the organizational unit maintenance officer inconjunction with the maintenance superintendent. They shalldesignate an officer or senior NCO as the corrosion controlofficer, whose duties will include organizing and supervisingan emergency reclamation team and directing the team to

accomplish salvage operations or corrosion control action.The size and composition of the team depends on the ur-gency of the situation and/or workload. If required, addi-tional personnel from outside the maintenance squadron shallbe selected and placed under the direction of the corrosioncontrol officer. In case of fire damage, the aircraft SPD and/orthe missile or equipment SPM and cognizant ALC corrosionprevention and control manager must be contacted to deter-mine the effects of heat or excessive salt water and/or firefighting material contamination prior to continued use or re-pair of affected parts or components.

8.3 EMERGENCY PREPARATIONS.

Emergency preparations shall include the development ofpriority lists for removal of equipment, emergency reclama-tion team planning, and lists of required tools, materials, andequipment with notations of their location and availabilitywithin the organizational unit and/or where they can be ob-tained if not readily available at the unit.

NOTE

Each organizational unit maintenance officerand/or maintenance superintendent shall prepare orhave access to a list of installed equipment/com-ponents indicating removal priority from affectedaircraft, missiles, or equipment in emergency con-ditions.

8.3.1 Priority Removal List of Equipment and/or Com-ponents.

Magnesium parts are particularly susceptible tocorrosive attack when exposed to salt water or fireextinguishing materials. Avionic, electronic, elec-trical, and ordinance equipment known to containmagnesium components shall be given high prior-ity for cleaning. Contaminants shall be removedpromptly to prevent serious damage.

Table 8-1 is a tabulation of aircraft, missile, and equipmentcomponent groups arranged in order of suggested priority oftreatment. Among the factors considered in the developmentof the table were dollar value, corrosion rate, and probabilityof successful salvage. Whenever manpower or facility short-age prohibits simultaneous processing of all components,treatment shall be given in the order of the priority listing.The table should be considered as a guide and operationsmay deviate from the assigned priority when directed by

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qualified organizational unit production planning personnelor maintenance officer and/or maintenance superintendent orthe cognizant ALC SPD and/or SPM engineering personnel.

NOTE

Table 8-1 is a priority guide for removing and pro-cessing equipment which has been exposed to cor-rosive salt water or fire fighting chemicals. Varia-tions in aircraft, missile, or equipment designconfigurations and mission equipment installationsmay make it necessary to contact the affected air-craft SPD and/or missile or equipment SPM andrequest them to furnish listings of equipment andpreferred priority of removal and treatment. Prior-ity of removal and treatment should always be ori-ented toward recovery of salvageable equipment.

8.3.2 Emergency Reclamation Team.

• High expansion foam solution may fill a hangarspace to 20 feet or more. The foam bubbleswill totally obscure vision and visual referencesin a “white-out” causing complete loss of di-rection and even vertigo.

• All foam firefighting solutions will create anextreme slipping hazard especially on highlyreflective hangar floor surfaces.

The emergency reclamation team will provide expertise andfacilities for processing equipment received from accident/incident sites at the operational unit. This team shall be re-sponsible for processing equipment received. The size of theteam, its organization, and the specific equipment require-ments will be geared to the size and needs of the reclamationoperation at hand. Recommended equipment includes wash/rinse facilities, drying ovens, dip tanks (for water displacingcompounds and preservatives), and cleaning compounds.


Personal protective equipment is required duringall reclamation and emergency cleaning opera-tions. Aircraft fuels/lubricants, cleaning soaps andsolvents, and firefighting chemicals have potentialfor adverse human exposure response and may bepresent under reclamation operations.

Under the advisement of the Base Safety Office and Bioen-vironmental, all reclamation team members shall wear theapproved required personal protective equipment to preventeye, dermal, and respiratory exposure. Refer to material andequipment lists in Table 8-2, Appendix A, and Appendix B.

The Base Safety Office and Bioenvironmental have the flex-ibility to modify personal protective equipment requirementsbased on the task and circumstances of the cleaning activity.Air Force approved firefighting proximity or structural per-sonal protective equipment (PPE) provides acceptable pro-tection for reclamation and cleaning operations. Individualcomponents of firefighting PPE may be combined with theTO identified PPE components during reclamation and clean-ing operations.

8.3.2.2 Personnel Decontamination.

Failure to decontaminate personnel engaged inreclamation and emergency cleaning operationsmay expose persons outside to irritating materials.

All personnel engaged in reclamation operations shall beprovided gross decontamination and disposal of all PPE be-fore leaving the reclamation area. Personnel shall also beprovided with personal showers before leaving the installa-tion and clean clothing.

8.3.2.2.1 Consult the Installation Bioenvironmental Flightfor proper cleaning and/or disposal of contaminated clothingmaterials generated during reclamation and cleaning opera-tions. Consult the Installation Bioenvironmental Flight andInstallation Environmental Flight for proper disposal of wastematerials generated during reclamation and cleaning opera-tions.

8.3.3 Emergency Reclamation Equipment. The avail-ability of the necessary tools, materials, and equipment forthe prompt removal, cleaning, and drying of avionic, elec-tronic, and electrical equipment will significantly aid in re-ducing damage. Refer to material and equipment lists inTable 8-2, Appendix A, and Appendix B. Certain useful itemsof equipment are:

• Drying ovens.

• Portable air blowers.

• Heaters.

• Backpack pumps.

• Vacuum cleaners.

• Hoses and washing equipment.

8.3.4 Production Planning. Whenever possible, all sal-vageable components of the affected aircraft, missile, orequipment shall be treated simultaneously. To minimize dam-age and ensure that the work is accomplished in a thoroughand competent manner, the most experienced personnelavailable shall be assigned to disassemble and process the

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aircraft, missile, or equipment. Whenever possible, examina-tion and evaluation personnel shall be assigned to work withthe disassembly and preservation crew in order that thoseitems obviously beyond reclamation may be scrapped imme-diately and that only those areas exposed to corrosive saltwater or fire fighting chemicals are disassembled and treated.The time saved by this procedure may be utilized to accel-erate preservation of salvageable components.

8.4 GENERAL PROCEDURES.

Before starting emergency treatment, particularlyin those instances where fuel cells have been rup-tured and fuel or fuel vapors are present, it is im-perative that a fuel system specialist and/or thesafety officer supervise purging or inerting proce-dures and certify that the affected aircraft, missile,or equipment is fire and explosion safe. Qualifiedmissile and/or ordnance personnel shall be as-signed to handle all missiles, ordnance and associ-ated items, such as ammunition and pyrotechnics.

For cases involving aircraft, missile, or equipment accidents,permission for any treatment shall be obtained from the se-nior member of the accident investigation board prior to ini-tiating procedures for emergency reclamation to preventjeopardizing the ability to determine the cause of the inci-dent.

NOTE

Chemical, Biological and/or Radiological Con-taminated Assets. Any asset that has been contami-nated or potentially contaminated must be identi-fied, marked and decontaminated in accordancewith AFMAN 10-2503, Operations in a Chemical,Biological, Radiological, Nuclear, and High-YieldExplosive (CBRNE) Environment and TO 00-110A-1.

a. Determine from the local fire department which fireextinguishing agent was used. A review of photographstaken by public affairs and/or other media personnelmay provide information concerning areas that wereactually exposed to corrosive fire extinguishing mate-rials such as foam and purple K powder (PKP).

b. Ensure that the aircraft, missile, or equipment is safefor maintenance. Electrically ground the aircraft, mis-sile, or equipment by attaching the ground lead to theaircraft, missile, or equipment at a point outside thearea that could contain explosive vapors. Turn off allelectrical power and disarm all explosive and/or firingsystems on a missile or an aircraft, including the ejec-tion seat(s) on an aircraft.

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Table 8-1. Priority Guide for Emergency Treatment of Aircraft, Missiles, and Equipment

PriorityNumber Reciprocating Engine Gas Turbine Engine

Turboprop, Tur-boshaft Engine Helicopters

1 Engine, propeller,and accessories

Engine and accessories Engine, propeller,propeller drivegear mechanisms,and accessories

Rotor dynamic components

2 Avionic and fire con-trol equipment

Avionic and fire controlequipment

Avionic and fire con-trol equipment

Engine, rotors, and accessories

3 Instruments Instruments Instruments Avionic and fire control equip-ment

4 Fuselage, wings, andempennage

Fuselage, wings, and em-pennage

Fuselage, wings, andempennage

Instruments

5 Turrets, and rocketand missile launch-ers

Turrets, and rocket andmissile launchers

Turrets, and rocketand missilelaunchers

Fuselage

6 Drained fuel and oilsystems

Drained fuel and oil sys-tems

Drained fuel and oilsystems

Drained fuel and oil systems

7 Photographic equip-ment

Photographic equipment Photographic equip-ment

Photographic equipment

8 Landing and arrestinggear

Landing and arresting gear Landing and arrest-ing gear

Landing gear or floats

9 Safety and survivalequipment

Safety and survival equip-ment

Safety and survivalequipment

Safety and survival equipment

10 Electrical equipment Electrical equipment Electrical equipment Electrical equipment11 Armament equipment Armament equipment Armament equip-

mentArmament and rescue equipment

12 Fixed equipment(seats, etc.)

Fixed equipment (seats,etc.)

Fixed equipment(seats, etc.)

Fixed equipment (seats, etc.)

13 Miscellaneous equip-ment

Miscellaneous equipment Miscellaneous equip-ment

Miscellaneous equipment

1 Warheads Engines and accessories2 Engines and accesso-

riesInstruments

3 Guidance systemsand sensors

Electronic and electricalequipment

4 Electrical equipment Drained fuel and oil sys-tems


Fixed equipment (seats,etc.)


Suggested List of Emer-gency Reclamation Items

Table 8-2. Suggested List of Emergency Reclamation Items

PriorityNumber Accessories Specification or PN National Stock Number Unit of Issue

1 Aircraft Grounding Straps - - -2 Aircraft Washing Kits 3M Co., CAGE Code

#76381, PN 2517920-00-490-6046 KT

3 Pads, Cleaning and Polish-ing, Non-Metallic (forAircraft Washing Kits)

A-A-3100Type I (3⁄8 in thick) 7920-00-151-6120 PG (10 SH)Type II (1 in thick) 7920-00-171-1534 PG (10 SH)

TO 1-1-691

8-3

Table 8-2. Suggested List of Emergency Reclamation Items - Continued


4 Soft Bristle Scrub Brushes A-A-2074Type I, Style A (Nylon) 7920-00-619-9162 EA (4 ½ in x 1 ¾

in)Type II, Style C (Tampico) 7920-00-282-2470 EA (10 ¾ in x 2 ¾

in)Type IV, Style B (Nylon) 7920-00-061-0037 EA (8 ½ in x 5 in)Type IV, Style D (Palmyra) 7920-01-067-6203 EA (8 ½ in diam-

eter)5 Backpack Pump (5 GL) PN 5100-254B, CAGE Code

#040244320-00-289-8912 EA

6 Spray Gun, Pneumatic SAE AMS-G-952 (supersedesMIL-G-952) Type I

4940-00-248-0866 EA

7 Drying Rags Flannel, Cot-ton

A-A-50129 (supersedes CCC-C-458)

8305-00-913-5817 BO (50 YD)

8 Leather Chamois KK-C-300, Grade B, Class 2(Small)

8330-00-823-7545 Bundle (5 EA)

9 Sponges, Synthetic Clean-ing

A-A-2073 7920-00-633-9915 EA (7 in L x 4 ¼in W x 2 3⁄8 inT)

10 Air Nozzle Gun (BlastCleaning)

A-A-55543 (supersedesGGG-G-770)

Type II (push down), Style B(3⁄8 in internal threads)

4940-00-223-8972 EA

Type II (push down), Style A(¼ in internal threads)

4940-00-333-5541 EA

11 Air Hose Assembly Gen-eral Purpose, Non-Metal-lic Spray

A-A-59613 (3⁄8 in ID x 50 ft) 4720-00-289-3429 FT

Rubber, Pneumatic (Yarnand Fabric Reinforced)

A-A-59565½ in ID x 50 ft 4720-00-278-4889 FT5⁄8 in ID x 50 ft 4720-00-278-4890 FT¾ in ID x 50 ft 4720-00-278-4891 FT

12 Vacuum Cleaner, Pneu-matic (Wet/Dry Vac)

PN AT560ACF-18, CAGECode #00784

5130-01-368-5861 EA

Vacuum Cleaner w/Attach-ments

PN 15-A1080, CAGE Code#58150 Pneumatic Type)

7910-00-807-3704 EA

PN C83985-01, CAGE Code#16893 (Electric Type) (A-A-54943)

7910-01-236-0893 EA

13 Utility Pails, Plastic A-A-59253, Size 4, Style B 7240-00-246-1097 EA14 LG Trash Can Plastic

Liners- Commercial Purchase -

15 Nozzles, Garden Hose (for5⁄8 and ¾ in hose) Ad-justable

A-A-50461 Straight, Adjust-able Spray (Brass)

4730-00-223-6731 EA

Pistol Grip, Adjustable (Cop-per Alloy) w/Rubber Cover,PN 10855, CAGE Code#97141

4730-00-900-0733 EA

TO 1-1-691

8-4



16 Hose and Hose Assem-blies, Non-Metallic

A-A-59270, Type I, Class I(Rubber)

5⁄8 in ID x 50 ft L 4720-00-203-3920 EA¾ in ID x 50 ft L 4720-00-203-3912 EAType II, Grade A (PVC)5⁄8 in x 50 ft L 4720-00-729-5334 EA¾ in x 50 ft L 4720-00-729-5338 EA

17 Goggles, Industrial, Plastic PN A-A-1110 (ANSI Z87.1Safety Standard)

Standard Safety Goggles 4240-00-052-3776 PRSplash Proof Goggles 4240-00-082-8928 PRChemical Splash Proof

GogglesCommercial Items -

18 Faceshield, Industrial PN L-F-36 (ANSI Z87.1Safety Standard)

9 in L x 18 in W Plastic Win-dow Lens

4240-00-542-2048 EA

19 Apron, Rubber (Black) PN A-A-3104 (45 in L x 35in W)

8415-00-634-5023 EA

20 Gloves, Rubber, Industrial MIL-G-12223, Type II (14 inGauntlet)

X-Small (8) 8415-00-753-6550 PRSmall (9) 8415-00-753-6551 PRMedium (10) 8415-00-753-6552 PRLarge (11) 8415-00-753-6553 PRX-Large (12) 8415-00-753-6554 PR

21 Gloves, Leather Palm (forHandling Composite Ma-terials)

A-A-50016Men’s Medium Size 8415-00-268-8350 PRWomen’s 8415-00-268-8351 PR

22 Barrier Material MIL-PRF-131Class 1 (Non-Woven Plastic

Back)8135-00-282-0565 RO (36 in x 200

YD)23 Tape, Pressure Sensitive,

Preservation and SealingSAE AMS-T-220851 in W x 36 YD 7510-00-852-8179 RO2 in W x 36 YD 7510-00-852-8180 ROType II (use w/ or w/o Over-

coating)2 ½ in W x 36 YD 7510-00-885-3510 RO3 in W x 36 YD 7510-00-926-8939 RO3M Co., CAGE Code

#52152, PN 4814 in W x 36 YD 7510-00-916-9659 RO6 in W x 36 YD 7510-00-926-8941 RO

TO 1-1-691

8-5



24 Respirator, Full Face piece 3M Co., CAGE Code#76381,

PN 7800S-M (Medium) 4240-01-342-5239 EAPN 7800S-L (Large) 4240-01-301-3200 EAPN 6700 (Small) 4240-01-454-8531 BX (4 EA)PN 6800 (Medium) 4240-01-454-8535 BX (4 EA)PN 6900 (Large) 4240-01-454-8538 BX (4 EA)

25 Cartridges, Filter ( 60007000 Series)

3M Co., CAGE Code#76381,

PN 60921 4240-01-455-7353 BX (60 EA)26 Lens Assembly (for Full

Face Respirator)PN 7884 (7800 Series) 4240-01-247-8929 BX (5 EA)PN 6898 (6000 Series) Open Purchase -

27 Coveralls, Disposable A-A-55196, Type I withHood

Small/Medium 8415-01-445-6565 EALarge/X-Large 8415-01-445-6568 EAXX-Large 8415-01-445-6588 EA

28 Heater Gun, Electric A-A-59435Type I (350° - 500° F) 4940-00-357-1369 EAType II (500° - 750° F) 4940-01-028-7493 EAType III (750° - 1000° F) 4940-01-391-7046 EA

29 Corrosion Preventive Com-pounds, Water Displac-ing, Ultra-Thin Film (5GL min)

MIL-PRF-81309, Type II(Soft Film), Class 1 (Non-pressurized container/bulk)

1 GL Can 8030-00-213-3279 CN (1 GL)5 GL Can 8030-00-262-7358 CN (5 GL)55 GL Drum 8030-00-525-9487 DR (55 GL)Class 2, Grade CO2 (Pressur-

ized container - CO2 pro-pellant) CN (1 GL)

8030-00-938-1947 CN (16 OZ)

Type III (Soft Film: AvionicGrade)

Class 1 (Non-pressurized/bulk) (1 GL)

8030-01-347-0978 CN (1 GL)

Class 2 (Pressurized Aerosol)16 OZ Can

8030-00-546-8637 CN (16 OZ)

30 Corrosion Preventive Com-pounds, Water Displac-ing, Synthetic (5 GLmin)

MIL-L-87177Type I (Pressurized Aerosol),

Grade B6850-01-528-0653 CN (16 OZ)

Type II (Non-pressurized/bulk), Grade B

6850-01-326-7294 CN (5 L)

TO 1-1-691

8-6 Change 3



31 Aircraft Cleaning Com-pound

MIL-PRF-87937, Type IV1 GL Can 6850-01-429-2368 CN (1 GL)5 GL Can 6850-01-433-0873 CN (5 GL)55 GL Drum 6850-01-429-2371 DR (55 GL)24 OZ Spray Trigger Bottle 6850-01-461-0060 BT (24 OZ)16 OZ Aerosol Can 6850-01-461-0070 CN (16 OZ)MIL-PRF-85570, Type II1 GL Can 6850-01-239-0571 CN (1 GL)5 GL Can 6850-01-235-0872 CN (5 GL)15 GL Drum 6850-01-248-9828 DR (15 GL)55 GL Drum 6850-01-236-0128 DR (55 GL)

32 Engine Gas Path Cleaner MIL-PRF-85704, Type II,Ready-To-Use

5 GL Can 6850-01-370-5245 CN (5 GL)55 GL Drum 6850-01-370-5244 DR (55 GL)

33 Degreasing Solvents A-A-59601, Type II1 PT Can 6850-00-110-4498 CN (1 PT)1 GL Can 6850-00-637-6135 CN (1 GL)5 GL Can 6850-00-274-5421 CN (5 GL)55 GL Drum 6850-00-285-8011 DR (55 GL)MIL-PRF-680, Type II1 GL Can 6850-01-474-2319 CN (1 GL)5 GL Can 6850-01-474-2317 CN (5 GL)55 GL Drum 6850-01-474-2316 DR (55 GL)MIL-PRF-32295, Type II1 GL 6850-01-606-8356 CN (1 GL)5 GL 6850-01-606-8357 CN (5 GL)15 GL 6850-01-606-3293 CN (15 GL)55 GL 6850-01-606-8358 DR (55 GL)

34 Isopropyl Alcohol (IPA) TT-I-735½ PT Can 6810-00-753-4993 CN (½ PT)1 QT Can 6810-00-983-8551 CN (1 QT)1 GL Can 6810-00-286-5435 CN (1 GL)5 GL Can 6810-00-543-7915 CN (5 GL)55 GL Drum 6810-00-586-6647 DR (55 GL)

35 Fire Extinguishing Agent(AFFF)

MIL-F-24385, Type 35 GL Can 4210-01-139-4972 CN (5 GL)55 GL Drum 4210-01-144-0291 DR (55 GL)Type 65 GL Can 4210-01-056-8343 CN (5 GL)55 GL Drum 4210-01-056-0883 DR (55 GL)

c. Closely inspect the aircraft, missile, or equipment todetermine areas affected. Traces of foam type extin-guishing agents may not be evident; however, moistresidues often indicate previous foam application. Dry

powders may be present in joints, faying surfaces, etc.,so a careful examination will be necessary to deter-mine if they are present.

TO 1-1-691

Change 5 8-7

d. Wherever possible, remove components from affectedareas. Open, loosen, or remove covers, access plates,inspection doors, etc. Allow any accumulated salt wa-ter or other liquids to drain off. If dry chemical fireextinguishing materials have been used, refer to Para-graph 8.5.3.

e. Remove gross amounts of contaminants by flushingwith fresh water and draining.

f. Remove components and process in accordance withParagraph 8.4.2 and Paragraph 8.4.3.

g. Clean the aircraft in accordance with Paragraph 8.5.

h. Inspect aircraft, missile, or equipment and determinewhether it can return to operational service followinglocal organizational level maintenance action orwhether additional higher level maintenance will benecessary. If aircraft is locally repairable, repairs mustbe permanent repairs before the aircraft, missile, orequipment is released for unrestricted operational ser-vice.

8.4.1 Removal of Contaminated Installed Equipment.After salt water immersion or entry, or exposure to any cor-rosive agents, equipment must be cleaned promptly and thor-oughly. Follow the procedures in this chapter for decontami-nating specific areas and equipment. Refer to Table 8-1 forassigning priority to equipment removal and treatment.

8.4.2 Disassembly/Removal of Components. The me-chanical cutting of fuel, hydraulic and oil lines, and electri-cal leads, and other drastic operations necessary to expediteremoval of parts are left to the discretion of the maintenanceofficer and/or maintenance superintendent directing the op-erations.

8.4.2.1 Aircraft Involved in Water Crashes. When air-craft are involved in water crashes, it shall be assumed thatall components, including hollow structural and mechanical

members, are contaminated internally. All components shallbe disassembled and treated or forwarded to the appropriateALC Depot for disassembly and treatment, as required. En-sure that all contaminants have been removed and that allcorroded surfaces have been effectively treated to inhibit fur-ther attack prior to returning the aircraft to operational ser-vice.

8.4.3 Clean. Equipment and components shall be cleanedby the team in accordance with Paragraph 8.5, Paragraph8.6, and Paragraph 8.7, and then delivered to the designatedshops for further inspection and maintenance. Equipment thatcannot be removed shall be cleaned in place and inspected.

NOTE

All equipment subject to emergency reclamationteam procedures must be certified operationallyready before returning to serviceable status. In-spect equipment for corrosion, cracks, and heatdamage. Obtain the maximum available engineer-ing assistance to evaluate the extent of damage.Particular attention shall be given to dissimilarmetal joints. Avionic, electronic, and electricalequipment usually contain dissimilar metals.

8.4.4 Tagging. All parts and components removed fromthe aircraft, missile, or equipment shall be “green” tagged(DD Form 1577-3) for identification, description of the acci-dent/incident experienced, listing of the contaminants andchemical materials to which they were exposed, and to indi-cate the type of CPC applied. CPC’s shall be removed priorto reusing the equipment.

8.5 GENERAL CLEANING PROCEDURES.

Contaminated areas may be cleaned by several methods. Theprimary method is fresh water flushing. Alternate methodsmay be used when fresh water is not available. Use themethods in Paragraph 8.6 and Paragraph 8.7 for emergency

TO 1-1-691

8-8

treatment of specific components. Do not use the followinggeneral methods when specific methods are available.

8.5.1 Primary Method.

Prolonged breathing of vapors from organic sol-vents or materials containing organic solvents isdangerous. Prolonged skin contact with many or-ganic solvents or solvent containing materials canhave toxic effect on exposed skin areas. Observeprecautions listed in previous chapters, referencedmanuals, and Safety Data Sheets (SDS) for clean-ing compounds, solvents, surface treatment chemi-cals, sealants, primers, and paints.

Do not expose plastic or rubber items; avionic,electronic, or electrical components; wiring; orother components susceptible to heat damage totemperatures in excess of 130° F (54° C) and any/all other areas to temperatures in excess of 150° F(66° C) during emergency cleaning procedures.

NOTE

Always use the mildest cleaning cycle availablethat will ensure proper decontamination. Eventhough fresh water/detergent wash should not sig-nificantly affect accident investigations, permis-sion must be obtained from the senior member ofthe appointed accident investigation board beforeperforming this operation.

The primary method of removing salt water is as follows:

a. Immerse removed unit or component in clean, freshwater whenever possible.

b. Flush all areas with clean, fresh water and allow themto drain.

c. Dry the item or areas by vacuum cleaning excess wa-ter and/or blotting with a cloth or paper towels, orblowing dry with compressed air at a pressure notgreater than 10 PSI. If visual evidence of salt remains,a second cleaning should be accomplished as follows:

(1) Mix a solution of one part of MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II aircraftcleaning compound in nine parts water.

(2) Apply the solution to the affected areas and scrubwith bristle brushes, sponges, or cloths.

(3) Flush thoroughly with clean, fresh water and drainthoroughly.

(4) Dry the item or areas as before.

d. After flushing and drying, apply MIL-PRF-81309, TypeIII or MIL-L-87177, Type I or II, Grade B water dis-placing CPC/preservative on all avionic, electronic, orelectrical components and connectors. Ensure that allareas and crevices are coated. Apply a liberal amountof MIL-PRF-81309, Type II or MIL-L-87177, Type Ior II, Grade B water displacing CPC to all other areasthat cannot be properly drained or contain recesseswhich are difficult to reach. Ensure that all surfaces arecoated.

NOTE

MIL-PRF-81309, Type II water displacing CPCdeposits a thin, nonconductive film which must beremoved for proper function of contact points andother electromechanical devices where no slippingor wiping action is involved, but MIL-PRF-81309,Type III and MIL-L-87177, Type I or II, Grade Bneed not be removed as they do not interfere withproper function of these items. CPC is easily re-moved with A-A-59601, MIL-PRF-32295, Type II,or MIL-PRF-680, degreasing/dry cleaning solvent.Removal will be accomplished during subsequentmaintenance or functional test prior to issue foruse.

8.5.2 Alternate Methods. Use only when fresh water isnot available or is available only in limited supply or whentime prevents immediate flushing with fresh water.

8.5.2.1 Method One (Preferred). Spray, brush, or wipethe exterior of the affected areas and components with liberalamounts of MIL-PRF-81309, Type II or MIL-L-87177, TypeI or II, Grade B water displacing CPC/preservative.

8.5.2.2 Method Two (Alternate).

a. Apply a solution of one part MIL-PRF-87937, Type IVor MIL-PRF-85570, Type II aircraft cleaning com-pound in nine parts water by spray, brush, or cloth.

b. Brush affected areas until contaminants and cleanerbecome intermixed or emulsified.

c. Wipe off thoroughly with a clean cloth to remove bothcontaminants and cleaner.

TO 1-1-691

Change 15 8-9

d. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacingCPC to affected areas.

8.5.3 Removing Fire Extinguishing Powder (O-D-1407Potassium Bicarbonate [Purple K{PKP}], Sodium Bicar-bonate, Ammonium Phosphate Monobasic) and/orOther Dry Chemical Agents. Remove powder as follows:

NOTE

Ammonium phosphate monobasic, often identifiedas Class ABC extinguishing agent, can be highlycorrosive to aircraft components; removal andcleaning should be addressed as an emergency.

a. Vacuum up as much of the loose powder as possible.Use a HEPA-filtered vacuum to prevent further con-tanimation.

b. Use a soft, bristle brush and air pressure not greaterthan 10 PSI to dislodge contaminants between close-fitting components.

c. Vacuum clean again.

d. Remove the residual film of dry powder adhering tothe surface by wiping, brushing, or spraying with asolution of one part of MIL-PRF-87937, Type IV orMIL-PRF-85570, Type II aircraft cleaning compoundin nine parts of water.

e. Rinse thoroughly with fresh water.

f. Dry with cloths or paper towels and/or blow dry withdry, oil free compressed air at a pressure not greaterthan 10 PSI.

g. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacingCPC to the affected area.

h. Enter a notation defining the affected areas and whereand how they were treated in the appropriate aircraft,missile, or equipment forms with a requirement for aspecial inspection as corrosion prone areas at a speci-fied future time to determine if any corrosion has oc-curred.

8.5.4 Removing MIL-F-24385 Aqueous Film FormingFoam (AFFF) Fire Extinguishing Agent and Other Syn-thetic Based Foaming Agents Including High-Expansion(Hi-Ex) Foams. To remove residues of burned materials andfresh water solutions of AFFF and other synthetic foamingagents, use the following procedure:

NOTE

• Synthetic foaming agents and fresh water mix-tures act as soap solutions. While normally notbeing corrosive in and of themselves, they doremove most protective coating and expose thesurfaces to corrosive effects. Immediateclean-up of these solutions and any relatedburned materials is essential to corrosion pre-vention. Elimination of exposure and clean-upmust begin immediately once the area has beendetermined to be fire safe.

• Enter a notation defining areas and componentsthat are exposed to residue from burned mate-rials and fire extinguishing agent in the appro-priate aircraft, missile, or equipment forms witha requirement for a special inspection as corro-sion prone areas or components at a specifiedfuture time to determine if any corrosion hasoccurred.

a. Remove as much foam and foam/water solution aspossible with wet/dry vacuums and/or low pressure,clean, dry, oil-free compressed air or nitrogen.

b. Flush all affected areas with fresh, clean water whiledraining at the same time. Whenever possible, units orcomponents which have been removed, should be im-mersed in fresh water and then flushed thoroughly withfresh, clean water. Drain away the water.

c. Clean surfaces with a solution of one part MIL-PRF-87937, Type IV or MIL-PRF-85570, Type II aircraftcleaning compound in nine parts of water. Scrub af-fected areas and rinse with clean, fresh water. Drainaway excess water.

d. Dry with cloths, paper towels, and/or dry, oil free com-pressed air at a pressure not greater than 10 PSI.

e. Apply MIL-PRF-81309, Type III or MIL-L-87177,Type I or II, Grade B water displacing CPC to all avi-onic components and electrical connectors. Apply aliberal amount of MIL-PRF-81309, Type II or MIL-L-87177, Type I or II, Grade B water displacing CPC toall other areas that cannot be properly drained or con-tain recesses which are difficult to reach.

f. Enter information on affected areas and/or componentsin the appropriate aircraft, missile, or equipment formsper the instructions in the above NOTE.

g. Dismantle engine to piece part component level for allcomponents exposed to inlet flow path air.

TO 1-1-691

8-10 Change 1

h. Clean engine components exposed to AFFF or syn-thetic foaming agents per the appropriate depot levelcomponent cleaning procedure or clean per Paragraph8.7.3 through Paragraph 8.7.6.

8.5.5 Removal of Carbon Dioxide (CO2), HFC-125,Halon and 3M NOVEC 1230 Fire Extinguishing Agents.CO2, HFC-125 (Pentafluoroethane), Halon 1211 (MIL-DTL-38741, Bromochlorodifluoromethane), Halon 1301 (ASTMD 5632, Bromotrifluoromethane) and 3M NOVEC 1230evaporate rapidly. Therefore, no cleanup is required unlessmoisture or a high temperature was present at the area ofapplication; but ventilation should always be provided to re-move the vapors. If moisture or high temperature was pres-ent, use the following cleanup procedures:

NOTE

Even though carbon dioxide, HFC-125 Halon andNOVEC 1230 fire extinguishing agents leave noresidues; smoke, smudges, or other grime from afire should be removed from affected items thatare to be retained for future use.

a. After a fire has been extinguished, purge area and sur-faces with clean, dry air (dust and oil free, low mois-ture content, compressed air).

b. Clean surfaces with a solution of one part MIL-PRF-87937, Type IV or MIL-PRF-85570, Type II aircraftcleaning compound in nine parts of water. Scrub af-fected areas and rinse with clean, fresh water. Drainaway excess water.

c. Dry with cloths, paper towels, and/or dry, oil free com-pressed air at a pressure not greater than 10 PSI.

d. Apply MIL-PRF-81309, Type III or MIL-L-87177,Type I or II, Grade B water displacing CPC to all avi-onic components and electrical connectors. Apply aliberal amount of MIL-PRF-81309, Type II or MIL-L-87177, Type I or II, Grade B water displacing CPC toall other areas that cannot be properly drained or con-tain recesses which are difficult to reach.

e. Enter a notation defining the affected areas, and whereand how they were treated in the appropriate aircraft,missile, or equipment forms with a requirement for aspecial inspection as corrosion prone areas at a speci-fied future time to determine if any corrosion has oc-curred.

8.5.6 Removal of Protein Type Foam and Soda-AcidFire Extinguishing Agents. The residues left from the useof these materials can be very corrosive to aircraft, missiles,and equipment. Remove these residues as follows:

a. Thoroughly flush the affected area with fresh water.Ensure that the rinse water is completely flushed fromthe aircraft, missile, or equipment.

b. Clean surfaces with a solution of one part of MIL-PRF-87937, Type IV or MIL-PRF-85570, Type II air-craft cleaning compound in nine parts of water. Scrubaffected areas and rinse with clean, fresh water. Drainaway excess water.

c. Dry with cloths, paper towels, and/or dry, oil free com-pressed air at a pressure not greater than 10 PSI.

d. Apply MIL-PRF-81309, Type III or MIL-L-87177,Type I or II, Grade B water displacing CPC to all avi-onic components and electrical connectors. Apply aliberal amount of MIL-PRF-81309, Type II or MIL-L-87177, Type I or II, Grade B water displacing CPC toall other areas that cannot be properly drained or con-tain recesses which are difficult to reach.

e. Enter a notation defining the affected areas, and whereand how they were treated in the appropriate aircraft,missile, or equipment forms with a requirement for aspecial inspection as corrosion prone areas at a speci-fied future time to determine if any corrosion has oc-curred.

8.5.7 Treatment After Landing on a Foamed Runway.Materials used to foam runways are corrosive to aircraft. Assoon as possible after a landing on a foamed runway, exte-rior areas, wheel wells, any interior areas exposed, and en-gines shall be cleaned. Clean the exterior and wheel wells,interior areas, and engines in accordance with Section I ofChapter 3.

8.5.8 Treatment After Exposure to Volcanic Ash. Theprimary concern in removing volcanic ash is the extremeabrasiveness of the ash. It is not a significantly corrosivematerial. Aircraft, missiles, and equipment which have beenexposed to volcanic ash should be cleaned using the follow-ing procedures before the next aircraft, missile, or equipmentoperation.

a. All static ports, fuel vents, engine inlets, air condition-ing inlets, etc., should be vacuumed to remove as muchash as possible and then suitably covered to precludeadditional ash entry. Special emphasis should be placedon ducting supplying cooling air to avionics, electron-ics, and electrical equipment.

b. After covering all openings where ash may enter, theexterior of the airframe, missile, or equipment shouldhave ash removed initially using a vacuum, low pres-sure, compressed air (not to exceed 10 PSI), or bylightly dusting with clean rags. Avoid rubbing sincethis may damage painted and bare metal surfaces dueto the abrasiveness of the ash.

c. Wash entire aircraft, missile, or piece of equipment us-ing a mild MIL-PRF-87937, Type IV or MIL-PRF-85570, Type II alkaline cleaner and water solution (one

TO 1-1-691

Change 12 8-11

part cleaner to nine parts water) using procedures inSection I of Chapter 3 and rinse thoroughly with lowpressure water. Ensure that critical parts, such as flapscrews, tracks, and exposed hydraulic actuators are ad-equately cleaned. Again, caution should be taken whenwashing to avoid vigorous rubbing/scrubbing, since ashis even more abrasive when combined with water toform a slurry.

d. Check windshield wiper blades to ensure that all con-taminants are removed prior to operation.

e. If ash penetration is evident in the aircraft interior (thecockpit, cargo area, avionics compartments, and otheraccessible interior areas) or interior areas and compart-ments of missiles and equipment, they should be thor-oughly vacuumed.

f. Check lower aircraft, missile, and/or equipment struc-tures for volcanic matter and water entrapment.

g. Clear all drains and air dry structures as much as pos-sible.

h. Uncover all openings which were covered during stepa.

i. After washing, the aircraft, missile, or piece of equip-ment must be lubricated in accordance with applicablesystem specific maintenance manuals.

8.6 SPECIFIC INTERNAL AREAS.

The cockpit, ejection seats, avionic and electrical equipment,identification and modification plates, and photographicequipment require specific emergency cleaning procedures.

8.6.1 Aircraft Cockpit Area. Emergency cleaning proce-dures for the aircraft cockpit are as follows:

a. If the interior is undrainable, drill out a few fastenersat low points. If still undrainable, drill holes at lowpoints as approved and directed by the aircraft SPD.

b. Remove avionics equipment, relay boxes, circuitbreakers and switches, and clean as specified in TO1-1-689-3.

c. Clean ejection seats. (Refer to Paragraph 8.6.2).

d. Turn equipment over to the activity that has the au-thority and capability to disassemble, clean, and repairthe equipment.

e. Dry equipment that has been cleaned as much as pos-sible with dry, oil free compressed air at a pressureless than 10 PSI, drying machines, electric fans, orhand fans in a hot room of 150° F (66° C) maximumor in a well ventilated room where the humidity is low.

f. Apply MIL-PRF-81309, Type II or MIL-L-87177, TypeI or II, Grade B water displacing CPC by spraying orbrushing onto all areas that cannot be properly drainedor contain recesses which are difficult to reach.

8.6.2 Aircraft Ejection Seats.

Disarm ejection seat mechanism before cleaning.Ensure that only authorized personnel disarm seatsand perform cleaning operations.

The following emergency cleaning procedure shall be usedfor cleaning aircraft ejection seats.

a. Remove parachutes, drogue parachutes (where appli-cable), and seat pans. Return them to the local survivalequipment work center for cleaning and/or replace-ment.

b. Remove ejection seat in accordance with the applicablesystem specific maintenance manual.

c. Rinse seat thoroughly with fresh water. Continue rins-ing while directing water into crevices and close fittingparts until contaminants are removed.

d. All CAD/PAD Escape System components are consid-ered Critical Safety Items (CSI). Therefore any CAD/PAD escape system component suspected of coming incontact with fire suppression agent must be removedfrom the escape system and condemned. Disarm andremove any suspect CAD/PAD component from es-cape system in accordance with applicable technicalmanual. Suspect CAD/PAD items will be placed incondition code “P” with the following remarks “Itemhas been exposed to fire suppression agent”. Turn inremoved components to the appropriate munitions au-thorities to be reported for disposal. Contact OO-ALC/GHGJ Item Manager to requisition replacement CAD/PAD items.

e. Remove as much water as possible from equipmentwith vacuum or low pressure, clean, dry, oil free com-pressed air.

f. Dry off any remaining water with a clean cloth or pa-per towels.

g. Apply MIL-PRF-81309, Type II or MIL-L-87177, TypeI or II, Grade B water displacing CPC by either sprayor brush application to critical metal surfaces and re-cess areas which may not be completely dry. Waterdisplacing CPC protects equipment during necessaryinspections and/or inquiry and during transfer to thelocal survival equipment work center.

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8-12 Change 3

h. Wash all survival gear and pilot safety equipment withfresh water and dry thoroughly. Refer to applicablesystem specific maintenance requirements for detailedpreservation procedures. Lubricate and apply CPC’s inaccordance with the applicable system specific mainte-nance cards and Sections II and III of Chapter 3 in thismanual.

i. If necessary, send the entire ejection seat to the appro-priate ALC Depot for overhaul/repair.

8.6.3 Avionic, Electronic, and Electrical Equipment.

Ensure that all electrical power is disconnectedand all systems in the aircraft, missile, or equip-ment are deactivated before starting the cleaningoperation on avionics, electronic, or electricalequipment to prevent electrical shock.

Effective cleaning ensures that salt water, fire fighting chemi-cals, and other corrosive agents are completely removed toprevent corrosion damage. Refer to TO 1-1-689-3 for spe-cific cleaning procedures.

8.6.4 Photographic Equipment. Use the following pro-cedure for cleaning photographic equipment.

a. Immediately rinse with fresh water, drain, and rinseagain.

b. Apply MIL-PRF-81309, Type III or MIL-L-87177,Type I, Grade B water displacing CPC by spraying.

c. Return to the appropriate photographic equipment tech-nician for prompt servicing.

8.6.5 Graphite or Carbon Fiber/Epoxy, Boron Fiber/Epoxy, and Tungsten Fiber/Epoxy Composite Materials.

• The inhalation of graphite, boron, or tungstencomposite fibers resulting from aircraft, missile,or equipment fires and/or material damage maybe harmful to personnel. Wear a cartridge typerespirator and goggles when exposed to thesematerials, and, in addition, wear close weavecotton gloves when handling these materials.Request the assistance of the local Bioenviron-mental Engineer and safety officer to provide

specific information regarding hazards to per-sonnel during cleanup operations involvingthese materials and the required PPE.

• Do not put power to or start up any aircraft,missile, piece of equipment, or other avionic/electronic/electrical equipment which havebeen exposed to debris until decontaminationby vacuuming and/or washing is completed.Failure to observe these procedures may resultin electrical short circuits and fires.

Aircraft, missile, or equipment constructed utiliz-ing graphite, boron, or tungsten fiber compositematerials in contact with metal structures or sub-structures create a high potential for establishinggalvanic corrosion cells. This can result in corro-sion of the metal components if the structure isexposed to an electrolyte medium, such as saltwater.

The graphite, boron, and/or tungsten fibers of composite ma-terials may be released into the atmosphere if their epoxybinder burns; this occurs at temperatures in excess of 600º F(316º C). In addition, fibers may be released during an ex-plosion or a high impact crash. Since graphite, boron, andtungsten are very conductive, these fibers can damage unpro-tected avionic, electronic, and electrical equipment withinseveral miles of the incident site by settling on and shortingout electrical contacts. The procedures for treating damagedcomposite materials are listed below. Refer to TO 1-1-690for additional information.

8.6.5.1 Cleanup. When damaged aircraft, missiles, orequipment have graphite, boron, or tungsten fiber compositesurfaces which are broken or burned, follow these proce-dures.

a. If ventilation inlets are exposed to debris, take imme-diate action to ensure that the filtration system is prop-erly operating. If the system is not operating properly,shut down the system and provide temporary filtrationat outlets leading to compartments with electrical, avi-onic, and electronic equipment.

b. Warn the flight crew of adjacent in-flight aircraft andmaintenance control for flight line operations that thesmoke may contain hazardous electrical contaminants.

c. Spray MIL-PRF-81309, Type II or MIL-L-87177, TypeI, Grade B CPC on damaged composite surfaces. Thiswill prevent the spread of graphite, boron, or tungsten

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Change 3 8-13

fiber contamination by causing the fibers to stick to-gether and/or to the damaged surface. Cover damagedsurfaces with plastic sheet and tape it securely in place.

d. Aircraft, missiles, facilities, clothing, and equipmentthat have been exposed to debris from the aircraft,missile, or equipment fire must be vacuumed and/orwashed down prior to reuse or movement into a han-gar.

e. Decontamination of the immediate area of the aircraft,missile, or equipment wreckage may require vacuum-ing, washing, and bagging of composite material frag-ments. Use a sealed industrial vacuum and store thecollected debris in sealed plastic bags for the accidentinvestigation board. Dispose of the debris in accor-dance with applicable regulations when so directed bythe investigation team.

f. If wrapping and secure taping of the aircraft, missile,or equipment wreckage is not possible, transporting thewreckage must be planned to bypass heavily populatedand industrial areas. Aircraft, missiles, or equipmentparked or located along the planned route must havetheir canopies and access doors closed and their engineinlet and exhaust openings, air intakes and outlets, andall other vents and ports covered. In addition, the doorsand windows of surrounding buildings should be closedto minimize the probability of having wind-blown fi-bers enter areas containing electrical and electronicequipment.

8.7 SPECIFIC EXTERNAL AREAS OF AIRCRAFT.

The following external aircraft areas require emergencycleaning after exposure to fire and fire fighting agents.

8.7.1 Airframes. Use the following procedure for cleaningairframes.

a. Flush all areas with fresh, clean water while drainingat the same time. Whenever possible, units or compo-nents that have been removed from the aircraft shouldbe immersed in fresh water and then flushed thoroughlywith clean, fresh water. Drain away the water and drythe areas with cloths, paper towels, or dry, oil freecompressed air at a pressure of less than 10 PSI.

b. Clean with a solution of one part of MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II aircraft cleaner innine parts of water. Scrub affected areas with the solu-tion. Flush thoroughly with fresh water and drain awaythe excess water. Dry with cloths, paper towels, or dry,oil free compressed air at a pressure of less than 10PSI.

c. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacing

CPC by spraying or brushing to all other areas thatcannot be properly drained or contain recesses whichare difficult to reach, to aid in the removal of water.

d. If the aircraft fuselage, empennage, or wings are in arepairable condition, drain holes may be provided fordraining water by drilling out rivets at the lowestpoints. All repairable parts shall be collected and re-turned with the aircraft when shipment is made.

8.7.2 Antennas. Remove antennas per instructions in thesystem specific aircraft and/or specific equipment mainte-nance manual. Treat in accordance with TO 1-1-689-3. Ac-complish any in place cleaning as follows:

a. Check antenna insulators for damage or cracks.

b. Brush or spray a solution of one part MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II aircraft cleaningcompound in nine parts water onto the antenna and theaffected adjacent area, and scrub the area with a small,soft brush or wiping cloth dipped in the above clean-ing solution.

c. Rinse with clean, fresh water.

d. Dry the area with a clean, dry cloth.

8.7.3 Reciprocating Engines.

a. Determine the extent of contamination.

b. Drain all fluids. Partial disassembly is authorized toaccomplish thorough draining. Ensure that pressuresystems and cylinders are drained.

c. Thoroughly flush all surfaces and passages with freshwater.

d. Apply A-A-59601, MIL-PRF-32295, Type II, or MIL-PRF-680, dry cleaning/degreasing solvent to the af-fected areas with a brush, cloth, or non-atomizingspray, and scrub the area with a brush or cloth.

e. Flush all accessible interior surfaces and all passageswith either a solution of one part MIL-PRF-85704,Type II turbine engine gas path cleaning compound infour parts fresh water or use the straight undiluted formof MIL-C-85704, Type II ready-to-use (RTU) cleaner.Both the Type II and Type II RTU are aqueous clean-ers without any hydrocarbon solvents.

f. Thoroughly rinse all areas with fresh water.

g. Allow to thoroughly drain. Dry, using paper towels,cloths, or dry, oil free compressed air at a pressure ofless than 10 PSI.

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h. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacing

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Change 3 8-14.1/(8-14.2 blank)

CPC to all surfaces. This may be accomplished by fill-ing and draining (preferred), flushing, or spraying. Ro-tate the propeller shaft to coat cylinder walls. Drainexcess CPC.

i. Reassemble engine finger tight.

j. Lubricate any pressure lubrication points to displaceall contaminated lubricant.

k. For shipping, place engine in an approved dehydratedmetal container, using twice the normal amount of des-iccant. Notify the engine SPM to arrange for specialhandling, as required.

8.7.4 Turbine Engines. Engines which are contaminatedwith small amounts of sea water entering the intake shall becleaned using MIL-PRF-85704 engine gas path cleaner inaccordance with Table 3-2 and the engine system specifictechnical/overhaul manuals. Decontaminate engines that havebeen completely submerged in fresh water or sea water asfollows:

a. Drain all fluids. Partial disassembly is authorized toaccomplish thorough draining.

b. Thoroughly flush all surfaces and passages with freshwater.

c. Flush all accessible interior surfaces and all passageswith either a solution of one part MIL-PRF-85704,Type II turbine engine gas path cleaning compound infour parts fresh water or use the straight undiluted formof MIL-C-85704, Type II RTU cleaner. Both Type IIand Type II RTU are aqueous cleaners without anyhydrocarbon solvents.

d. Thoroughly rinse all areas with fresh water.

e. Drain thoroughly.

f. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacingCPC to all surfaces. This may be accomplished by fill-ing and draining (preferred), flushing, or spraying.Drain excess CPC. Repeat this procedure until alltraces of water have been removed.

g. Lubricate any pressure lubrication points to completelydisplace all contaminated lubricant.

h. For shipping, install in an approved dehydrated metalcontainer, using twice the normal amount of desiccant.Notify the engine SPM to arrange for special handling,as required.

8.7.5 Treatment for Engines Which Have Ingested FireExtinguishing Powder (Potassium Bicarbonate [PurpleK{PKP}], Sodium Bicarbonate, Ammonium PhosphateMonobasic) and/or Synthetic Foaming Agents (AFFF,Hi-Ex, AR).

NOTE

Ammonium phosphate monobasic, often identifiedas Class ABC extinguishing agent, can be highlycorrosive to aircraft components; removal andcleaning should be addressed as an emergency.

a. With the ignition off/disconnected, vacuum up as muchof the loose powder/foam as possible followed bycranking the engine and rinsing it thoroughly with wa-ter.

b. Wash the engine with MIL-PRF-85704 gas path cleanerper instructions in Table 3-2 and Paragraph 8.5.4 andParagraph 8.5.7.

c. Flush all accessible interior surfaces and all passageswith either a solution of one part MIL-PRF-85704,Type II turbine engine gas path cleaning compound infour parts fresh water or use MIL-PRF-85701, Type II,RTU cleaner undiluted. Both Type II and Type II RTUare aqueous cleaners without any hydrocarbon sol-vents.

d. Based on the high-temperatue metals and unique coat-ings/finishing materials used in the manufacturing ofthese end items, cleaning of engines exposed to anyfire or fire extinguishing products, requires consultingthe weapon system specific technical order, depot over-haul manual/procedures, original equipment manufac-turer (OEM) manual, and the appropriate engine engi-neering authority for potential additional actionsrequired such as dismantling of the engine.

e. Drain engine lubricant/oil and refill/service.

f. At the next inspection, recheck previously contami-nated areas and repeat the above procedure, ifnecessary.

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Change 1 8-15

8.7.6 Helicopter Transmission, Rotor Head, and RotorHub. Helicopter transmission, rotor head, and rotor hub casesare often constructed of magnesium. Magnesium parts ex-posed to salt water or fire fighting chemicals require imme-diate and thorough decontamination and preservation.

8.7.6.1 External Surface Contamination. Treat helicop-ter transmissions, rotor heads, and rotor hubs with externalsurface contamination as follows:

a. Rinse with fresh water.

b. Wash with a solution of one part MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II aircraft cleaningcompound in nine parts fresh water or use A-A-59921(formerly MIL-C-43616), Class 1A aerosol type sol-vent emulsion aircraft cleaner per instructions in Sec-tion I of Chapter 3, and rinse thoroughly.

c. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I, or II, Grade B, water displacingCPC to all affected areas by spraying or brushing.

d. Lubricate all pressure lubrication points to displace allcontaminated lubricant.

8.7.6.2 Internal Surface Contamination. If internal sur-face contamination of helicopter transmissions, rotor heads,and gearboxes is suspected, immediately contact the appro-priate helicopter SPD for assistance with decontaminationprocedures. Treat helicopter transmissions, rotor heads, rotorhubs, and gear boxes having internal contamination as fol-lows:

a. Drain all fluids. Partial disassembly is authorized toaccomplish thorough draining. Ensure that pressuresystems are drained.

b. Thoroughly flush all surfaces and passages with freshwater.

c. Flush all surfaces and passages with a solution of onepart MIL-PRF-87937, Type IV or MIL-PRF-85570,Type II aircraft cleaning compound in nine parts freshwater per instructions in Section I of Chapter 3.

d. Thoroughly rinse all areas with fresh water.

e. Allow to drain thoroughly.

f. Apply a liberal amount of MIL-PRF-81309, Type I orMIL-L-87177, Type I or II, Grade B water displacingCPC to all surfaces. This may be accomplished by fill-ing and draining (preferred), flushing, or spraying.With the housing full of preservative, rotate the main

shaft approximately five revolutions. After the preser-vative has remained in the housing for 4 hours, drain,and replace plugs.

g. Service the transmission, rotor head, rotor hub, and/orgear box in accordance with the applicable system spe-cific maintenance manual if going back in service orleave as preserved if the unit will be shipped out.

h. Lubricate all pressure lubrication points to displace allcontaminated lubricant.

8.7.7 Helicopter Main and Tail Rotor Blades. Helicop-ter blades that have been exposed to an excessive amount ofsalt water or to liquid fire fighting chemicals shall be treatedas follows:

NOTE

Some rotor blades have areas commonly knownas pockets or blade boxes with very small drainholes. The drain holes may require enlargement, ifblades were salt water immersed, to facilitate de-contamination of the blade spar. Enlarging drainholes destroys the affected pockets or blade boxesand requires Depot Level repair before the bladecan be reused. Enlargement of pocket access open-ings requires authorization from the appropriatehelicopter SPD and blade SPM for each blade in-volved. Where possible, flush pockets with MIL-PRF-81309, Type II or MIL-L-87177, Type II,Grade B water displacing CPC. Preserve and pack-age the blade properly before sending it to the ap-propriate ALC Depot for engineering evaluationand necessary repair.

a. Thoroughly flush all contaminated surfaces with freshwater. Pay particular attention to recesses that tend totrap debris such as mud, dirt, or salt deposits.

b. Wash with a solution of one part MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II aircraft cleaningcompound in nine parts fresh water per instructions inSection I of Chapter 3.

c. Rinse thoroughly with fresh water.

d. Dry with a cloth, paper towels or dry, oil free com-pressed air at a pressure of less than 10 PSI.

8.7.8 Armament. The following instructions are for initialtreatment of armament equipment that has undergone saltwater immersion or been subjected to fire extinguishingchemicals.

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8-16 Change 5

8.7.8.1 Safety Precautions. Before performing anycleaning chores, make certain that preliminary safety precau-tions are followed.

a. Ensure that the aircraft, missile, or piece of equipmentis safe for maintenance.

b. Disconnect all electrical power and ensure that all ar-mament switches are in the OFF or SAFE positions.

NOTE

For removal of armament equipment, refer to ap-plicable system specific maintenance/technicalmanual for the respective aircraft, missile, or pieceof equipment.

c. Remove all ordnance from the aircraft or piece ofequipment and all warheads from the missile and prop-erly dispose of contaminated ammunition and war-heads, as required.

8.7.8.2 Cleaning Procedure. After complying with thesafety precautions, clean per the following procedure.

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Change 1 8-16.1/(8-16.2 blank)

a. Rinse equipment with fresh water.

b. Disassemble, as required, and wipe away excess greasewith clean cloth dampened with A-A-59601 or MIL-PRF-680, Type II or III dry cleaning/degreasing sol-vents.

c. Immerse and agitate parts in a solution of one partMIL-PRF-87937, Type IV or MIL-PRF-85570, Type IIaircraft cleaning compound in nine parts of fresh wa-ter.

d. Rinse parts with fresh water to ensure complete re-moval of contaminants.

e. Wipe away excess water with clean, dry cloth.

f. Blow dry the cleaned equipment/parts as thoroughly aspossible with clean, dry, oil free compressed air at apressure of less than 10 PSI.

g. Inspect the equipment to determine whether it shouldbe returned to service or forwarded to the appropriateALC Depot for overhaul or repair.

h. Apply a liberal amount of MIL-PRF-81309, Type II orMIL-L-87177, Type I or II, Grade B water displacingCPC by either spray, brush, dip, or fill and drain appli-cation.

i. If shipment to the prime ALC Depot for maintenanceis required, wrap the equipment in MIL-PRF-131, Class1 barrier material, package it per the applicable in-structions, and forward it to the depot as directed.

8.7.9 Aircraft Fuel Systems. For emergency treatment ofaircraft fuel systems contaminated with water through otherthan a water crash or fire damage, refer to TO 1-1-3.

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8-17/(8-18 blank)

CHAPTER 9SOUTHWEST ASIA ENVIRONMENTS

9.1 INTRODUCTION.

The Southwest Asia (SWA) Area of Responsibility (AOR)consists of various conditions ranging from seasonal highwinds and high humidity to arid areas and low winds. Inmany locations, there are negatively charged ions (called an-ions) in soils that when combined with aggressive sandstorms, can spread throughout SWA. (Refer to Figure 9-1).The extent that sand and dust can penetrate equipment isdependent on many variables such as wind speed and direc-tion, size of the dust particles, protective shelter availabilityat the site, and equipment problems such as bad seals, gas-kets, and bent doors. Although sandstorms are usually sea-sonal, during the periods of relative calm there can be asignificant amount of airborne dust seen as a general haze inthe atmosphere. (Refer to Figure 9-2).

NOTE

Asterisks before Air Base name and locationwithin Table 3-1 designate environments consid-ered as SWA.

9.1.1 Climatic Conditions. SWA contains varied climaticand environmental conditions. Temperatures can changedrastically from day to night. A desert environment is largelytypical of SWA with the exception of coastal areas and areaswith bodies of water close by such as rivers, streams, andlakes. In certain areas of SWA, where there is low relativehumidity and rainfall, the dry air tends to decrease the cor-rosion initiation and propagation action. In contrast, flightsover bodies of water, and operations near coastal areas withhigher humidity and recurring fog, provide moisture to ex-tract soluble anions. These environments assist in the devel-opment of electrolytes for corrosion initiation. The potentialfor corrosion increases when moisture in the form of highhumidity (greater than 70%), rainfall, dew, fog, etc., com-bine with fine dust and sand containing corrosive anions suchas chlorides, sulfates, nitrates and fluorides. During the day-light hours, the equipment stored outdoors will normally heatup causing expansion of panels allowing hot moist air tomigrate into enclosed areas or under non-breathable fabriccovers. When the equipment cools, moisture condenses andcombines with dust particles and sand settling on metal sur-faces which increases the potential for corrosion. The solublematerials in the sand form a crust as they dry, making re-moval difficult.

9.1.2 Aircraft Wash. Aircraft shall be washed in accor-dance with Table 3-1. If the water quality does not meetcriteria established in Paragraph 3.1.1, the unit must requesta waiver in accordance with the NOTE in Paragraph 3.2.2.1.

9.1.3 Aircraft Clear Water Rinse (CWR). CWR require-ments in Paragraph 3.2.3 are not applicable to SWA loca-tions. If units need to remove dust and sand for operationalor specific maintenance reasons, dry cleaning processes suchas vacuum, brush, compressed air, etc., should be used to thegreatest extent possible. In rare cases where rinse operationsmust be performed to remove accumulated dust and sand,water must meet the quality specified in Paragraph 3.1.1.After these limited rinse operations have been completed,accumulated water must be removed to minimize effects ofchlorides found in many of the dusts and sands of the SWAenvironment.

9.1.4 Effects of Desert Environment. Soils in many ofthe SWA operating locations will cause or accelerate existingcorrosion if left in contact with metal surfaces in high hu-midity conditions or in the presence of other moisture. How-ever, if some type of moisture is not present, these soils,although high in potentially corrosive salts, do not supportcorrosion cell initiation or propagation. In all cases, the soilsshould be considered suspect and be regularly removed whilein country, or as soon as practical after the equipment returnsto home station.

NOTE

Recommend specific System Program Director(SPD)/System Program Offices (SPO) in conjunc-tion with affected MAJCOM Corrosion FunctionalManagers to develop a detailed checklist for eachweapon system. Standardized checklists for eachphase of a deployment for aircraft and associatedequipment will greatly improve the overall condi-tion when operating in SWA environments and in-crease equipment survivability and serviceability.Some general requirements in the absence ofweapons systems guidance are included in Para-graph 9.3 and Paragraph 9.4. This list may not beinclusive of all tasks.

9.2 PRE-DEPLOYMENT RECOMMENDATIONS.

a. Inspect entire aircraft exterior for missing and chippedprimer and/or paint. Correct all discrepancies prior todeployment.

b. Inspect and replace any worn, torn or cracked sealsand gaskets that will allow sand and dust intrusion.

c. Accomplish a complete wash prior to deployment.

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Change 14 9-1

d. Remove all standing water.

e. Inspect all drain holes and unplug if needed.

f. Minimize aircraft lubrication by removing all excessgreases to limit sand and dust entrapment.

9.3 RECOMMENDED ACTIONS WHILE DE-PLOYED.

Soils in operating locations in SWA should be consideredsuspect and be regularly removed. A constant regimen ofvacuuming, brushing, etc., to remove dust and sand accumu-

lation is necessary to reduce potential corrosion problems.Limit the use of compressed air to areas that will not causethe sand and dust to migrate and settle on other areas andcomponents.

9.3.1 High Efficiency Particulate Air (HEPA) Filtration.HEPA filtration vacuum cleaners should be used to greatestextent because SWA sand and dust particulates are commonly10 microns or smaller. Numerous manufacturer’s producecommercial off-the-shelf vacuum systems that are suitablefor SWA sand and dust removal.

9.3.1.1 Pneumatic Wheeled Units. Air volume con-sumption is 30-60 CFM. Used for cargo decks or large sur-faces where space is available.

9.3.1.2 Pneumatic Backpack. Air volume consumptionis 70 CFM. Portable for difficult to access areas in flightdecks, latrines, and medium sized wheel wells. It can beremoved from the backpack frame for hand held use.

NOTE

The units above require large volumes of air andare used in situations where electricity is unavail-able or restricted for use.

a. Electric models in floor and backpack are available in110-460 Volts @ 60 Hertz.

b. Battery pack portable units, requires 12-18 Volt batterypacks. Used for extremely small/confined areas suchas cockpits, avionics bays, and main and nose landinggear of fighter aircraft.

9.3.2 Areas to be Checked and Cleaned. Listed beloware some of the areas that should be checked and cleaned.

• Wheel Wells.

• Exposed control cables, pulleys, and gears.

• Flap wells, control surface wells, personnel restraintattach points.

• Access doors and service compartments.

• Crew entry and exit doors. Latch release doors andpanels.

• Cockpit interior and flight decks.

• Inside engine pylons and lower sections of nacelles.

• Cargo ramps and recessed areas of cargo decks.

• Avionic instruments, electrical panels and bays (re-fer to Figure 9-3), especially those with coolingvents and intake fans.

Figure 9-1. Soil Makeup in the SWA Area

Figure 9-2. Global Dust Producing Regions

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9-2 Change 14

• All areas susceptible to standing water. Keep alldrain holes open by inserting a probe, such as apipe cleaner before and after vacuuming.

NOTE

If sand is hard and crusted, gently break up withnon-metallic tool and remove with vacuum.

9.4 POST DEPLOYMENT.

a. Inspect all areas listed in Paragraph 9.3.2.

b. Remove as much entrapped sand and dust as practicalwith dry cleaning processes such as vacuum, brush,compressed air, etc.

c. Perform thorough aircraft wash (NLT 30 days), afterarrival to home station.

d. Remove all standing water.

e. Inspect exterior surfaces for areas of missing primerand paint erosion. Correct all deficiencies.

9.5 CORROSION PREVENTIVE COMPOUNDS(CPC’S).

Corrosion preventive compounds are used to protect aircraft,missile, and equipment parts and components by preventingcorrosive materials from contacting and corroding bare metalsurfaces. Section IV, Chapter 3 of this TO lists CPC typesand applications. Recommend applying these products aheadof scheduled deployment if known.

9.5.1 Recommended CPC’s. Since general purpose, soft,oily CPC’s such as MIL-PRF-81309, Type II and MIL-PRF-16173, Grades 1, 2, and 4 have a tendency to attract andhold sand and dust particles, they should not be used in SWAenvironments unless mandated in weapons system specificTO’s. In all cases, CPC’s should be used sparingly and anyexcess removed at the time of application. MIL-L-87177 andMIL-PRF-81309, Type III deposit ultra-thin films that areless susceptible to sand and dust accumulation, so theyshould continue to be used in all the applications addressedin this TO, TO 1-1-689 series, and all weapons specific TO’s.MIL-DTL-85054 produces a dry, thin film that also does notattract and hold dust and sand particles. Apply this CPC toaircraft or equipment surfaces for temporary protection ifconventional primers and topcoats are not available or otherlimitations prevent their use. This CPC is not suitable for useon the interior of electrical or electronic equipment or con-nectors.

Figure 9-3. Open Circuit Board

TO 1-1-691


CHAPTER 10REMOTELY PILOTED AIRCRAFT CORROSION PREVENTION

10.1 REMOTELY PILOTED AIRCRAFT (RPA).

An unmanned aerial vehicle is capable of being controlledfrom a distant location through a communication link. RPAscan be expendable or recoverable; however most are nor-mally designed to be recoverable.

10.1.1 Definition. RPAs range in size from micro vehiclesmeasuring inches in size to large aircraft. The RPAs are cat-egorized in Tiers as shown in Table 10-1. The maintenancerequirements for a micro/small air vehicle cannot be equatedwith those for a Tier II or higher such as a Global Hawk.Tier II RPAs are generally disassembled between missions

for transport and storage. RPAs tend to make extensive useof composite materials. Repair and maintenance of these ma-terials may require special expertise and equipment to dealwith hazardous materials.

NOTE

There is a particular concern that frequent assem-bly and disassembly of these aircraft may damagethe composite structures. Maintainers should con-sult TO 1-1-690 for information directly related tomaintenance or repair of composite materials.

Table 10-1. Air Force RPA Tiers

RPA Tier Definition Example Role Operating Altitude (Ceiling)Tier N/A Micro/Small (Man-Portable) BATMAVTier I Low Altitude, Long Endurance Gnat 750Tier II Medium altitude, Long Endurance

(MALE)MQ-1 Predator MQ-9

Reaper Less than 18,000 ft

Tier II+ High Altitude, Long Endurance Conven-tional RPA (or HALE RPA) Comple-mentary to the Tier III aircraft

RQ-4 Global HawkLess than 18,000 ft * some air-

craft in this class will exceed18,000 ft

Tier III High Altitude, Long Endurance Low-Ob-servable RPA. Same Parameters as, andcomplementary to, the Tier II+ aircraft

RQ-170 Sentinel Less than 18,000 ft

10.2 CORROSION CONTROL PROGRAM.

A comprehensive corrosion control program is necessary forthe prevention, early detection, reporting, and repair of cor-rosion damage/material degradation. An effective corrosionprevention program shall include thorough cleaning and in-spections at specific intervals. All maintenance personnelshall report corrosion promptly, in accordance with estab-lished directives.

10.3 CARBON FIBER COMPOSITES AND CORRO-SION.

The advantages of composites are many, including lighterweight, the ability to tailor the layup for optimum strengthand stiffness, improved fatigue life, and corrosion resistance.Some disadvantages of composites include adverse effects oftemperature and moisture, susceptibility to impact damage

and delamination or ply separation. Composites may also bemore difficult to repair.

10.3.1 Corrosion Concerns. One of the most seriousproblems with the use of carbon/graphite is the interface be-tween the composite containing carbon fibers and any metal-lic materials. An electrical potential exists between the twomaterials, which can be aggravated by humidity or waterimmersion or intrusion. The electrical potential over timewill cause the carbon composite to act as a cathode, allowinggalvanic corrosion, unbonding and delaminations. Designersspecify separating the carbon composite and the metal bybarriers such as fiberglass, sealants, AV-Dec gaskets or paint.Unfortunately, this treatment merely slows down the corro-sion rate, not eliminate it. The potential difference betweensteel/aluminum fasteners in carbon/graphite composites canpromote severe galvanic corrosion in the alloys.

TO 1-1-691

Change 4 10-1

10.3.2 Moisture Absorption. Absorbed moisture andmoisture intrusion is a major concern for composite materi-als. The amount of absorbed moisture depends on the mate-rial and the relative humidity or exposure to other moisturesources. Elevated temperatures increase the rate of moistureabsorption. Absorbed moisture reduces the mechanical prop-erties and causes the material to swell, which can cause thematerial to delaminate.

10.4 CORROSIVE ENVIRONMENTS.

One advantage to RPAs and corrosion protection is that theyare generally stored indoors where they are not exposed tocorrosive effects of the environment. Corrosive environments(Refer to Paragraph 2.9), which are characterized by theirpH factor, temperature, UV exposure, and moisture, continu-ously degrade composites until they cannot sustain the loadthat they were initially designed for.

10.5 APPROVED CLEANING COMPOUNDS.

• Authorized cleaning agents and equipment arelisted in this chapter, Appendix A, and Appen-dix B. Order materials and equipment by NSNfrom the list in these appendices through regu-lar supply channels, or local purchase fromvenders listed on the most current QPL/QPD ofa specification or by vender part number listedin these appendices for an authorized non-specification material.

• Do not use unauthorized cleaners. Althoughother commercial cleaners may appear to per-form as well, or better than, approved products,these materials may accelerate degradation ofnon-metallic materials causing material failureswhich may result in fluid leakage, corrosion ofsurrounding metals, electrical shorts, crazing,and/or mechanical failure.

10.5.1 MIL-PRF-87937, Type IV and MIL-PRF-85570,Type II. MIL-PRF-87937, Type IV and MIL-PRF-85570,Type II are water dilutable and biodegradable materials andare the primary cleaners for washing the exterior of aircraft.They are excellent materials for removing light to mediumsoils (grease, oils, grime, etc.) from almost all surfaces. Sincethey contain no solvents, their use is not limited, except thatapproval by the SPO is required prior to use on transparentplastics and camera lenses. These cleaners may be used invarious dilutions for hand wipe cleaning of greasy and oilyareas. Apply them from a pump spray bottle followed bydrying with a clean lint free cloth (Appendix A). When ap-plied from a spray bottle the most dilute mixture is recom-mended.

10.5.2 MIL-PRF-87937, Type III and MIL-PRF-85570,Type V. MIL-PRF-87937, Type III and MIL-PRF-85570,Type V are gel type cleaners intended for full strength appli-cation with no dilution in areas requiring special cleaning.They contain small amounts of solvents, detergents, andthickening agents, which make them cling very well to ver-tical and overhead surfaces. To be most effective, these ma-terials are applied full strength with no pre-rinsing of thesurface, allowed to dwell 5 to 15 minutes, agitated with anon-metallic bristle brush, and then rinsed thoroughly withtap water. These cleaners are not intended for and shall notbe used on transparent plastic aircraft canopies, windows,windshields/windscreens and camera lenses.

10.5.3 A-A-59921 (Formerly MIL-C-43616), Class 1AEmulsion Cleaner. A-A-59921 (formerly MIL-C-43616),Class 1A (aerosol ready-to-use with no dilution) emulsioncleaner is very effective for removal of oily and greasy soilsfrom general exterior painted and unpainted areas.

NOTE

A-A-59921 (formerly MIL-C-43616), solventemulsion cleaners shall not be used on non-poly-urethane paint systems, transparent plastics, ormarkings as their high solvent content can causethem to fade and /or streak. These cleaners alsoleave a very thin oil and/or solvent film on thesurface, so they are not suitable for use as a finalcleaner prior to painting, sealing, or adhesivebonding.

10.6 AIRCRAFT CLEANING.

Aircraft cleaning is the first step in preventing aircraft corro-sion. Cleaning requires knowledge of the materials and meth-ods needed to remove corrosion contaminates and fluids,which tend to retain contaminates. Aircraft should be cleanedregularly to:

• Prevent corrosion by removing salt deposits, othercorrosive soils, electrolytes, and fungi microbialgrowth.

• Maintain visibility though windows (camera lenses).

• Allow a thorough inspection for corrosion and cor-rosion damage.

• Maintain engine efficiency

• Reduce fire hazards by removal of accumulatedleaking fluids.

• Ensure aerodynamic efficiency of the aircraft.

TO 1-1-691

10-2 Change 5

10.6.1 Frequency of Cleaning. All aircraft should becleaned depending on usage, storage and the local environ-ment. Due to the material makeup of RPAs and concerns ofmoisture intrusion or absorption, RPAs may require less fre-quent cleaning than metallic aircraft. A more relaxed washrequirement will reduce the risk of water intrusion into theaircraft avionics bays and other vital sections of the fuselageand engine. Due to relaxed wash requirements, an extra em-phasis should be placed on waterless wipe down (Refer toParagraph 10.6.2).

10.6.1.1 Assembled RPA. Table 3-1 specifies the base orenvironmental and pollution data at each base and/or loca-tion unless a different interval is specified in a system spe-cific technical order. All assembled RPAs, should be washedas follows:

• Severe Environment every 90 days.

• Moderate/Mild Environment every 180 days.

NOTE

Micro/Small RPAs, small enough to be man-por-table, do not require scheduled washes. A water-less wipe down is sufficient prior to long-termstorage or when continuously exposed to severelycorrosive environments.

10.6.1.2 Disassembled and Container Stored RPAs.RPAs, except micro RPAs, disassembled and stored in con-tainers shall be washed prior to disassembly and storage. Itis recommended that aircraft be vacuumed or wiped clean atconnecting points and interior access points to remove alldust and contaminates. The interior of the storage containershould be visually checked for sand and debris and vacu-umed or wiped clean to ensure all contaminates are removedprior to placing aircraft parts in them for storage.

NOTE

To prevent the growth of fungus and mold all partsof aircraft should be allowed to completely dryprior to storage in containers.

10.6.2 Wipe Down or Spot Cleaning. Wipe down or spotcleaning procedures are an important process in maintainingcomposite aircraft. Composite materials are more susceptibleto contamination absorption therefore spot cleaning is rec-ommended when:

• Areas of concern from water intrusion

• Excessive exhaust gases accumulate

• Fluid leakage (oil, gas, etc.) occurs

• Exposure to salt spray, salt water, or other corrosivematerials occur.

• Oils and contaminates from maintenance being per-formed such as fingerprints, grease, etc. is present.

10.6.2.1 Wipe Down or Spot Cleaning Method. Thewipe down or spot cleaning method is as follows:

a. Using a plastic spray bottle, apply MIL-PRF-87937,Type IV or MIL-PRF-85570, Type II, (mixed one partcleaner to nine parts water) to the exterior surfaces ofthe aircraft (several square feet at a time).

b. After 30 seconds, scrub, then wipe cleaner and soilfrom the surface with a clean moistened lint-free cloth(Appendix A).

TO 1-1-691


APPENDIX ACONSUMABLE MATERIALS

A.1 INTRODUCTION.

Table A-2 provides consumable materials used for aircraft,missile, and equipment cleaning and corrosion preventionand control. Nomenclatures, specifications/PN’s, nationalstock numbers, unit of issue, and intended use of materialsare provided. Items are located by function in the followinggroupings.

• Abrasives.

• Conversion coating materials.

• Cleaning compounds.

• Cleaning pads/cloths.

• Corrosion preventive compounds.

• Lubricants.

• Neutralizing agents.

• Protective materials.

• Sealants and sealant accessories.

• Solvents.

A.1.1 Shelf Life. Specific shelf life guidance is providedin AFI 23-101 and DoD 4140.27-M. Units should use theShelf Life Extension Document (SLED) to validate the ser-viceability of materials. TO 42C-1-12 covers quality controlprocedures for chemical materials.

A.1.2 Consumable Materials Containers. Consumablematerials of a particular specification are provided in varioussized containers. If the particular sized container required isnot available or listed, ask supply department to provide thenext size container under the same specification.

A.1.3 Local Purchase. When local purchase is specified,include all procurement information, source of supply, andGSA contract number available.

A.1.4 Local Environmental Laws and Regulations.Prior to the procurement/use of any of specified products forcleaning, corrosion prevention, touch-up painting, etc., deter-mine and comply with all local environmental requirements,i.e., laws and regulations.

A.1.5 Unit of Issue Codes. The unit of issue codes in theunit of issue column and their meaning are as follows inTable A-1.

Table A-1. Unit of Issue Codes

Code Unit Code Unit Code UnitBG Bag EA Each PG PackageBO Bolt FT Foot PR PairBT Bottle GL Gallon PT PintBX Box GR Gross QT QuartCA Cartridge JR Jar RO RollCB Carboy KG Kilogram SE SetCC Cubic Cent. KT Kit SH SheetCN Can L Liter TU TubeCO Container LB Pound YD YardCS Case LG LengthDR Drum MX ThousandDZ Dozen OZ Ounce

TO 1-1-691

Change 15 A-1

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seA

BR

ASI

VE

S1

Abr

asiv

eM

ats,

Alu

-m

inum

Oxi

de,

Non

-Wov

en,

Non

-M

etal

lic

A-A

-580

54(s

uper

sede

sM

IL-A

-996

2)Ty

peI,

Cla

ss1

(9x

11in

SH)

Alu

min

umox

ide

impr

eg-

nate

dny

lon

fiber

web

bing

used

for

rem

ovin

gco

rro-

sion

prod

ucts

and

for

pain

tsc

uffin

gan

dfe

athe

r-in

ged

ges

prio

rto

touc

h-in

gup

.

Gra

deA

(Ver

yFi

ne)

5350

-00-

967-

5089

PG(1

0SH

)G

rade

B(F

ine)

5350

-00-

967-

5093

PG(1

0SH

)

Gra

deC

(Med

ium

)53

50-0

0-96

7-50

92PG

(10

SH)

2A

bras

ive

Pape

r,A

lu-

min

umO

xide

,N

on-W

ater

proo

f

(9x

11in

SH)

240

Gri

t53

50-0

0-16

1-97

15PG

(50

SH)

Dry

sand

ing

tore

mov

elig

htto

mod

erat

eco

rros

ion

prod

ucts

.18

0G

rit

5350

-01-

322-

1122

PG(5

0SH

)

3A

bras

ive

Pape

r,Si

li-co

nC

arbi

de,

Wa-

terp

roof

AN

SIB

74.1

8(s

uper

sede

sA

-A-1

047)

(9x

11in

SH)

180

Gri

t

5350

-00-

721-

8117

PG(5

0SH

)W

etor

dry

sand

ing

tore

-m

ove

light

tom

oder

ate

corr

osio

npr

oduc

ts.

240

Gri

t53

50-0

0-22

4-72

05PG

(50

SH)

320

Gri

t53

50-0

0-22

4-72

03PG

(50

SH)

4A

bras

ive

Pape

r,Si

li-co

nC

arbi

de,

Non

-W

ater

proo

f

220

Gri

t53

50-0

0-22

4-72

09PG

(50

SH)

Dry

sand

ing

tore

mov

elig

htto

mod

erat

eco

rros

ion

prod

ucts

.32

0G

rit

5350

-00-

867-

7665

PG(5

0SH

)

5A

bras

ive

Pape

rD

iscs

,Pr

essu

reSe

nsiti

veB

acki

ng,

Silic

onC

arbi

de

AN

SIB

74.1

8(s

uper

sede

sA

-A-2

697)

(6in

Ddi

sc)

180

Gri

t

5345

-01-

074-

9404

RO

(250

EA

)D

rysa

ndin

gto

rem

ove

light

tom

oder

ate

corr

osio

npr

oduc

ts.

For

use

with

pneu

mat

icdr

ills

oror

bita

lsa

nder

sw

itha

6in

chdi

-am

eter

pad.

280

Gri

t53

45-0

1-07

4-94

06R

O(2

50E

A)

6A

bras

ive

Clo

th,A

lu-

min

umO

xide

,W

a-te

rpro

of

AN

SIB

74.1

8(s

uper

sede

sA

-A-1

048)

(9x

11in

SH)

240

Gri

t

5350

-00-

865-

5948

PG(2

5E

A)

Wet

ordr

ysa

ndin

gto

re-

mov

elig

htto

mod

erat

eco

rros

ion

prod

ucts

.32

0G

rit

5350

-00-

597-

5798

PG(2

5E

A)

7A

bras

ive

Clo

th,A

lu-

min

umO

xide

,N

on-W

ater

proo

f

AN

SIB

74.1

8(s

uper

sede

sA

-A-1

048)

180

Gri

t(9

x11

inSH

)

5350

-00-

192-

5051

PG(5

0E

A)

Dry

sand

ing

tore

mov

elig

htto

mod

erat

eco

rros

ion

prod

ucts

.18

0G

rit

(3x

150

ftR

O)

5350

-00-

229-

3095

RO

(50

YD

)24

0G

rit

(9x

11in

SH)

5350

-00-

161-

9715

PG(5

0E

A)

240

Gri

t(3

x15

0ft

RO

)53

50-0

0-22

9-30

80R

O(5

0Y

D)

320

Gri

t(9

x11

inSH

)53

50-0

0-24

6-03

30PG

(50

EA

)

TO 1-1-691

A-2

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se32

0G

rit

(2x

150

ftR

O)

5350

-00-

187-

6289

RO

(50

YD

)32

0G

rit

(3x

150

ftR

O)

5350

-00-

229-

3092

RO

(50

YD

)8

Abr

asiv

eC

loth

,Si

li-co

nC

arbi

de,

Non

-W

ater

proo

f

AN

SIB

74.1

8(s

uper

sede

sA

-A-1

200)

(9x

11in

SH)

180

Gri

t

5350

-00-

192-

5051

PG(5

0SH

)D

rysa

ndin

gto

rem

ove

light

tom

oder

ate

corr

osio

npr

oduc

ts.

240

Gri

t(9

x11

inSH

)53

50-0

0-16

1-97

15PG

(50

SH)

240

Gri

t(2

x15

0ft

RO

)53

50-0

0-25

6-51

62R

O(5

0Y

D)

320

Gri

t(2

x15

0ft

RO

)53

50-0

0-48

2-55

85R

O(5

0Y

D)

9A

lum

inum

Woo

lA

-A-1

044,

Type

II,

Cla

ss1,

Form

A(M

ediu

m)

5350

-00-

286-

4851

RO

(1L

B)

Rem

ovin

gco

rros

ion

from

alum

inum

allo

ysu

rfac

es.

Type

II,

Cla

ss3,

Form

A(F

ine)

5350

-00-

312-

6129

RO

(1L

B)

10C

oppe

rW

ool

A-A

-104

4,Ty

peI,

Cla

ss3

(Fin

e)53

50-0

0-25

5-77

36R

O(1

LB

)R

emov

ing

corr

osio

nfr

omco

pper

allo

y,br

onze

,an

dbr

ass

surf

aces

.11

Stee

lW

ool,

Stai

nles

sA

-A-1

043,

Type

IV,

Cla

ss1

5350

-00-

440-

5035

RO

(1L

B)

Rem

ovin

gco

rros

ion

from

stai

nles

sst

eel

surf

aces

.12

Gla

ssB

ead

Med

ia,

Cle

anin

gan

dPe

en-

ing

AM

S24

31(A

MS

2431

/6=

AG

B-6

)(s

uper

sede

sM

IL-G

-995

4,Si

ze13

)

5350

-00-

576-

9634

BG

(50

LB

)G

lass

bead

blas

ting

med

iaus

edfo

rre

mov

ing

corr

o-si

onfr

omal

umin

umsu

r-fa

ces

byab

rasi

vebl

astin

g.13

Pum

ice

Abr

asiv

e,Po

wde

rSS

-P-8

21,

Gra

deFF

F

5350

-00-

161-

9034

CN

(5L

B)

Rem

ovin

gst

ains

orco

rro-

sion

onth

inm

etal

sur-

face

s.C

HE

MIC

AL

CO

NV

ER

SIO

NC

OA

TIN

G,

CO

RR

OSI

ON

RE

MO

VA

L,A

ND

SUR

FAC

ET

RE

AT

ME

NT

MA

TE

RIA

LS

TO 1-1-691

A-3

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se14

Cor

rosi

onR

emov

ing

Com

poun

dfo

rA

ir-

craf

tSu

rfac

es

SAE

AM

S16

40(s

uper

-se

des

MIL

-C-3

8334

)68

50-0

0-52

7-24

26C

N(5

GL

)A

conc

entr

ated

phos

phor

icac

idso

lutio

nm

ixed

1:1

with

wat

erus

edon

alum

i-nu

mal

loy

surf

aces

tore

-m

ove

surf

ace

corr

osio

n/ox

idat

ion

and

corr

osio

npr

oduc

tsfr

omco

rros

ion

pits

inco

njun

ctio

nw

ithA

-A-5

8054

nylo

nab

rasi

vem

ats.

Itis

used

tore

mov

eth

eox

ide

film

from

alum

i-nu

mal

loy

surf

aces

prio

rto

appl

icat

ion

ofa

chro

-m

ate

conv

ersi

onco

atin

gdu

ring

pain

ting

oper

atio

ns.

6850

-00-

300-

9008

DR

(55

GL

)

15C

hem

ical

Con

vers

ion

Mat

eria

lsfo

rA

lu-

min

uman

dA

lum

i-nu

mA

lloys

MIL

-DT

L-8

1706

(sup

er-

sede

sM

IL-D

TL

-81

706)

Cla

ss1A

,Fo

rmII

I(R

eady

-to-

use

pre-

mix

edliq

uid)

8030

-00-

142-

9272

CN

(1PT

)T

reat

men

tof

clea

n,ba

real

umin

uman

dal

umin

umal

loys

toim

part

apr

otec

-tiv

ech

rom

ate

coat

ing.

Usa

ble

for

appl

icat

ion

Met

hod

B-b

rush

8030

-00-

065-

0957

CN

(1Q

T)

Form

II(P

owde

r)80

30-0

0-82

3-80

39C

N(1

GL

)C

lass

1Aco

atin

gspr

ovid

em

axim

umpr

otec

tion

agai

nst

corr

osio

nw

hen

left

unpa

inte

dan

dsu

peri

orad

hesi

onw

hen

pain

tsy

s-te

ms

are

appl

ied.

Usa

ble

for

appl

icat

ion

Met

hods

A,

B,

orC

-sp

ray,

brus

h,or

imm

er-

sion

8030

-01-

429-

9504

DR

(55

GL

)Po

wde

rfo

rms

(For

ms

IIan

dV

)ha

vean

inde

finite

shel

flif

eun

tilm

ixed

with

de-

ioni

zed

(DI)

wat

er.

Form

IV(R

eady

-to-

use

pre-

mix

edliq

uid;

thix

otro

pic

solu

tion)

8030

-00-

057-

2354

JR(4

OZ

)

TO 1-1-691

A-4

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seU

sabl

efo

rap

plic

atio

nM

etho

dB

-bru

sh80

30-0

0-92

6-91

31C

O(5

LB

)C

lass

3co

atin

gsar

ein

-te

nded

for

use

asa

corr

o-si

onpr

even

tive

film

for

elec

tric

alan

del

ectr

onic

appl

icat

ions

whe

relo

wer

resi

stan

ceco

ntac

tsar

ere

quir

ed.

Form

V(P

owde

r,pr

e-m

easu

red

amou

ntfo

rth

ixot

ropi

cso

lutio

ns)

8030

-00-

720-

9739

CN

(12

LB

)

Suita

ble

for

appl

icat

ion

Met

hod

B-b

rush

8030

-00-

663-

9847

DR

(60

LB

)

Touc

h-N

-Pre

p(T

NP)

Pen

with

Alo

dine

1132

Cla

ss3

8030

-01-

460-

0246

CS

(12

EA

)T

hese

appl

icat

orpe

nspr

o-vi

dea

clea

n,ea

sy,

read

y-to

-use

met

hod

for

appl

ica-

tion

ofM

IL-D

TL

-817

06,

Cla

ss1A

chem

ical

conv

er-

sion

coat

ing

mat

eria

lsto

alum

inum

allo

ysin

touc

h-up

oper

atio

ns.

The

trea

ted

surf

aces

dono

tre

quir

eri

nsin

gor

wip

eof

f.16

Che

mic

alC

onve

rsio

nM

ater

ials

for

Alu

-m

inum

and

Alu

mi-

num

Allo

ys(N

on-

ferr

icya

nide

Cat

alyz

ed)

MIL

-DT

L-8

1706

,C

lass

1A&

3A

lodi

ne60

0,C

lass

1A,

Form

II,

Met

hod

B-b

rush

8030

-00-

811-

3723

BT

(2L

B)

Non

-fer

ricy

anid

eco

nver

sion

coat

ing

for

the

trea

tmen

tof

clea

n,ba

real

umin

umal

loy

surf

aces

toim

part

ach

rom

ate

coat

ing

whe

refe

rric

yani

dem

ater

ials

caus

epr

oble

ms

for

the

loca

lw

aste

disp

osal

/trea

t-m

ent

(sew

er)

syst

em.

Alo

dine

600,

Cla

ss3,

Form

II,

Met

hod

B-

brus

h

8030

-01-

018-

2838

CO

(10

LB

)

Tur

coat

Alu

mig

old,

Cla

ss1A

,Fo

rmII

,M

etho

dB

-bru

sh

8030

-01-

341-

8609

CN

(5L

B)

TO 1-1-691

A-5

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se17

Mag

nesi

umA

lloy,

Proc

esse

sfo

rPr

e-tr

eatm

ent

and

Pre-

vent

ion

ofC

orro

-si

onon

(Hen

kel

Proc

ess)

SAE

AM

S-M

-317

1(s

u-pe

rsed

esM

IL-M

-31

71),

Type

VI

(Chr

o-m

icac

idbr

ush-

ontr

eatm

ent)

8030

-01-

512-

2416

CO

(1Q

T)

Tre

atm

ent

ofcl

ean,

bare

mag

nesi

uman

dits

allo

ysto

impa

rta

prot

ectiv

ech

rom

ate

coat

ing

usin

gth

isH

enke

lPr

oces

spr

e-m

ixed

read

y-to

-use

chro

-m

ium

trio

xide

and

cal-

cium

sulf

ate

mix

ture

.T

hein

stru

ctio

nsfo

rpr

epar

ing

this

solu

tion

from

pow

ders

(Chr

omiu

mT

riox

ide

and

Cal

cium

Sulf

ate)

liste

din

Item

No.

18an

dIt

emN

o.19

onsi

teca

nbe

foun

din

Cha

pter

5,Se

ctio

nII

ofth

ism

anua

l.18

Chr

omiu

mT

riox

ide,

Tech

nica

l(C

hrom

icA

cid)

A-A

-558

27(s

uper

sede

sO

-C-3

03)

6810

-00-

264-

6517

CN

(5L

B)

One

oftw

och

emic

als

used

topr

epar

ea

mag

nesi

umco

nver

sion

coat

ing

solu

-tio

n(S

AE

AM

S-M

-317

1,Ty

peV

I)pe

rC

hapt

er5,

Sect

ion

IIof

this

man

ual.

19D

esic

cant

,C

alci

umSu

lfat

e,A

nhyd

rous

,Te

chni

cal

O-D

-210

6810

-00-

242-

4066

CN

(1L

B)

One

oftw

och

emic

als

used

topr

epar

ea

mag

nesi

umco

nver

sion

coat

ing

solu

-tio

n(S

AE

AM

S-M

-317

1,Ty

peV

I)pe

rC

hapt

er5,

Sect

ion

IIof

this

man

ual.

TO 1-1-691

A-6

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se20

Cor

rosi

onR

emov

ing

and

Met

alC

ondi

-tio

ning

Com

poun

d(P

hosp

hori

cA

cid

Bas

e)

MIL

-C-1

0578

,Ty

peI

(Was

h-of

f)68

50-0

0-27

0-55

51B

T(1

GL

)A

conc

entr

ated

phos

phor

icac

idso

lutio

nw

hich

isdi

-lu

ted

with

wat

eran

dus

edto

rem

ove

corr

osio

n/ru

stfr

omfe

rrou

sm

etal

sur-

face

san

dsl

ight

lyet

chth

esu

rfac

eof

ferr

ous

and

som

eno

n-fe

rrou

ssu

rfac

esto

prom

ote

adhe

sion

ofpa

int

syst

ems

and

CPC

’s.

Type

sI

&II

are

used

for

rust

rem

oval

from

ferr

ous

met

als

afte

rhe

avy,

en-

crus

ted

rust

isre

mov

edm

echa

nica

llyan

das

asu

rfac

eco

nditi

oner

for

ferr

ous

and

som

eno

n-fe

rrou

sm

etal

surf

aces

prio

rto

pain

ting

orC

PCap

plic

atio

n.Ty

peI

re-

mov

esm

ore

rust

and

re-

quir

esri

nsin

gw

ithw

ater

,w

hile

Type

IIis

wip

edof

fw

ithcl

ean

rags

.Ty

peII

Iis

used

tore

mov

eru

stfr

omch

rom

ium

plat

edst

eel

surf

aces

.Ty

peV

isus

edto

rem

ove

rust

from

ferr

ous

met

alpa

rts

im-

mer

sed

ina

dip

tank

afte

ral

lgr

ease

and

oil

have

been

clea

ned

from

the

surf

aces

.

6850

-00-

656-

1291

DR

(5G

L)

6850

-00-

926-

5298

DR

(15

GL

)

Tank

Type

II(W

ipe-

off)

6850

-00-

174-

9672

BT

(1G

L)

6850

-00-

656-

1292

DR

(5G

L)

Type

III

(Inh

ibite

d)68

50-0

085

4-79

52D

R(5

GL

)

TO 1-1-691

A-7

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seTy

peV

(Im

mer

sion

)68

50-0

1-10

7-25

51C

O(4

GL

)

Do

not

use

thes

em

ater

i-al

son

high

stre

ngth

stee

lpa

rts

asth

eyca

nca

use

hydr

ogen

embr

ittle

men

t.

6850

-00-

551-

9577

DR

(15

GL

)

CL

EA

NIN

GC

OM

POU

ND

S21

Cle

anin

gC

ompo

und,

Air

craf

t,E

xter

ior

MIL

-PR

F-85

570,

Type

I(G

ener

alpu

rpos

e,ar

o-m

atic

solv

ent

base

d)

6850

-01-

237-

7482

CN

(5G

L)

Cle

anin

gof

pain

ted

and

un-

pain

ted

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

Che

ckfo

rre

gula

tory

com

-pl

ianc

ebe

fore

usin

gTy

peI

beca

use

itco

ntai

nsar

o-m

atic

solv

ents

.

6850

-01-

237-

8003

DR

(15

GL

)68

50-0

1-23

7-80

04D

R(5

5G

L)

Type

II(G

ener

alpu

rpos

e,no

n-so

lven

tba

sed)

6850

-01-

239-

0571

GL

(1G

L)

Cle

anin

gof

pain

ted

and

un-

pain

ted

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

Wat

erba

sed

form

ula

may

beus

edon

both

high

glos

san

dca

mou

flage

pain

tsy

stem

s.

6850

-01-

235-

0872

CN

(5G

L)

6850

-01-

248-

9828

DR

(15

GL

)68

50-0

1-23

6-01

28D

R(5

5G

L)

Type

III

(Abr

asiv

esp

otcl

eane

r)68

50-0

1-23

2-91

64C

N(5

GL

)U

seon

high

glos

spa

int

sche

me

coat

ings

tore

-m

ove

stub

born

cont

ami-

nant

ssu

chas

boot

mar

ksan

dsm

udge

sas

wel

las

gun

blas

tan

dex

haus

ttr

ack

soil.

Type

IV(R

ubbe

rize

dsp

otcl

eane

r)68

50-0

1-23

5-08

73C

N(5

GL

)U

seon

low

glos

s,ca

mou

-fla

gepa

int

sche

me

coat

-in

gsto

rem

ove

stub

born

cont

amin

ants

such

asbo

otm

arks

and

smud

ges

asw

ell

asgu

nbl

ast

and

ex-

haus

ttr

ack

soil.

6850

-01-

248-

9829

DR

(15

GL

)68

50-0

1-24

8-98

30D

R(5

5G

L)

TO 1-1-691

A-8

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seTy

peV

(Gel

-typ

ecl

eane

r)68

50-0

1-23

4-02

19C

N(5

GL

)C

lean

ing

ofw

heel

wel

ls,

win

gbu

tts,

and

othe

rar

-ea

sw

here

com

plet

eri

ns-

ing

with

wat

erca

nbe

tol-

erat

ed.

Thi

xotr

opic

clea

ner

clin

gsto

vert

ical

orov

er-

head

surf

aces

.

6850

-01-

248-

9831

DR

(15

GL

)68

50-0

1-23

5-74

58D

R(5

5G

L)

22C

lean

ing

Com

poun

d,A

eros

pace

Equ

ip-

men

t

MIL

-PR

F-87

937,

Type

I(T

erpe

neba

sed,

solv

ent

emul

sion

,w

ater

di-

luta

ble)

6850

-01-

390-

7808

CN

(1G

L)

Terp

ene

base

d.G

ood

gene

ral

clea

ner

for

heav

ilyso

iled

cam

oufla

gean

dhi

ghgl

oss

pain

ted

area

san

dun

-pa

inte

dm

etal

surf

aces

.R

equi

res

adeq

uate

vent

ila-

tion

and

com

plet

eri

nsin

gof

entr

apm

ent

area

s.M

ayre

quir

eai

rcra

ftSP

Dan

d/or

mis

sile

oreq

uip-

men

tSP

Map

prov

albe

-fo

reit

isus

ed.

6850

-01-

390-

7811

CN

(5G

L)

6850

-01-

390-

7816

DR

(55

GL

)68

50-0

1-46

1-00

65B

T(2

4O

Z)

Spra

yT

rigg

er

Type

III

(Gel

-typ

ecl

ean-

ing

com

poun

d)68

50-0

1-39

0-95

30C

N(5

GL

)V

isco

us,

thix

otro

pic

gel

clea

ner

for

very

heav

ilyso

iled

area

ssu

chas

air-

craf

tco

ntro

lsu

rfac

ean

dw

heel

wel

lsw

here

alo

ngdw

ell

time

isre

quir

ed.

Use

only

inar

eas

that

tol-

erat

ehe

avy

rins

ing.

6850

-01-

390-

9453

DR

(55

GL

)

Type

IV(H

eavy

duty

,w

ater

dilu

tabl

ecl

ean-

ing

com

poun

d)

6850

-01-

429-

2368

CN

(1G

L)

Hea

vydu

tycl

eane

req

ually

suite

dfo

rhe

avily

soile

dar

eas

and

asa

gene

ral

clea

ner

for

clea

ning

cam

-ou

flage

and

glos

spa

inte

dan

dba

rem

etal

surf

aces

ofai

rcra

ft,

mis

sile

s,an

deq

uipm

ent.

In20

05,

itw

illco

mpl

etel

yre

plac

eTy

peII

clea

ner.

6850

-01-

433-

0873

CN

(5G

L)

6850

-01-

429-

2371

DR

(55

GL

)68

50-0

1-46

1-00

60B

T(2

4O

Z)

Spra

yT

rigg

er68

50-0

1-46

1-00

70C

N(1

6O

Z)

Aer

osol

TO 1-1-691

A-9

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se23

Cle

anin

gC

om-

poun

ds,A

ircr

aft

Surf

ace

A-A

-599

21(f

orm

erly

MIL

-C-4

3616

),C

lass

1A

6850

-00-

005-

5305

CN

Aso

lven

tem

ulsi

onty

pecl

eane

rfo

rre

mov

alof

oily

and

grea

syso

ils.

The

Cla

ss1A

aero

sol

mat

eria

lis

anex

celle

ntsp

otcl

eane

rfo

rth

ese

type

sof

soils

.24

Cle

anin

gC

ompo

und,

Eng

ine

Gas

Path

Cle

aner

MIL

-PR

F-85

704

Rem

oves

accu

mul

ated

salt,

dirt

,an

doi

lyre

sidu

esfr

omth

ega

spa

thof

en-

gine

s.Ty

peI

(Sol

vent

emul

sion

clea

ner

conc

entr

ate

w/h

ydro

carb

onso

lven

t)

6850

-00-

181-

7594

CN

(5G

L)

Solv

ent

conc

entr

ate

for

clea

ning

the

com

pres

sor

sect

ion

ofga

stu

rbin

een

-gi

nes

(eng

ine

off-

line;

star

ter

cran

ked)

.

6850

-00-

181-

7597

DR

(55

GL

)

Type

II(A

queo

uscl

eane

rco

ncen

trat

e)68

50-0

1-37

2-83

03C

N(5

GL

)A

queo

usco

ncen

trat

efo

rcl

eani

ngth

eco

mpr

esso

rse

ctio

nof

gas

turb

ine

en-

gine

s(e

ngin

eof

f-lin

e;st

arte

rcr

anke

d).

6850

-01-

372-

8304

DR

(55

GL

)

Type

IIR

TU

(Rea

dy-t

o-us

e)68

50-0

1-37

0-52

45C

N(5

GL

)R

eady

-to-

use

aque

ous

clea

ner

for

clea

ning

gas

turb

ine

engi

nes

(eng

ine

off-

line;

star

ter

cran

ked)

.

6850

-01-

370-

5244

DR

(55

GL

)

Type

III

(Aqu

eous

clea

ner

conc

entr

ate

w/o

hydr

ocar

bon

solv

ent)

6850

-01-

433-

6436

CN

(5G

L)

Aqu

eous

conc

entr

ate.

With

nohy

droc

arbo

nso

lven

tsfo

ron

-lin

e(fi

red)

clea

ning

ofga

stu

rbin

een

gine

sin

acco

rdan

cew

ithsp

ecifi

cen

gine

mai

nten

ance

in-

stru

ctio

ns.

6850

-01-

433-

6438

DR

(55

GL

)

Type

III

RT

U(R

eady

-to-

use)

6850

-01-

472-

1845

CN

(5G

L)

6850

-01-

472-

1846

DM

(55

GL

)

TO 1-1-691

A-10 Change 5

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se25

Cle

anin

gC

ompo

und,

for

Part

sW

ashe

rsan

dSp

ray

Cab

inet

s

MIL

-PR

F-29

602

(SA

EA

MS-

C-2

9602

),Ty

peI

(Wat

erso

lubl

eliq

uid

conc

entr

ate)

6850

-01-

431-

2269

CN

(1G

L)

Det

erge

ntfo

rus

ein

part

sw

ashe

rsan

dsp

ray

cabi

-ne

tsto

clea

nav

iatio

nw

eapo

nssy

stem

s,en

gine

,an

dsu

ppor

teq

uipm

ent

com

pone

nts.

Rem

oves

grea

se,

oil,

and

dirt

whi

char

epr

esen

ton

disa

s-se

mbl

edco

mpo

nent

s.

6850

-01-

431-

2267

CN

(5G

L)

6850

-01-

431-

2268

DR

(55

GL

)

DSF

-1,

Tele

chem

Int’

lIn

c.68

50-0

1-52

4-29

56B

X(4

GL

Con

-ta

iner

s)

PND

SF-1

Hea

vyD

uty

6850

-01-

524-

2978

CO

(5L

B)

Aqu

eous

Part

sW

ashe

r,C

lean

eran

dD

egre

aser

6850

-01-

524-

2980

DR

(55

GL

)

.Ty

peII

(Wat

erso

lubl

epo

wde

r)T

HE

MA

TE

-R

IAL

SL

IST

ED

BE

-L

OW

AR

EA

P-

PR

OV

ED

FO

RU

SEO

NL

AN

DIN

GG

EA

RC

OM

PO

-N

EN

TS

AN

DIV

DC

OA

TE

DH

IGH

STR

EN

GT

HST

EE

LPA

RT

S.

6850

-01-

053-

2789

CO

(1L

B)

Do

not

use

thes

ecl

ean-

ers

onai

rcra

ftla

ndin

gge

arco

mpo

nent

s,w

heel

s,an

dbr

akes

,or

any

IVD

alum

inum

coat

edhi

ghst

reng

thst

eel

part

sas

they

may

caus

ehy

drog

enem

-br

ittle

men

t.U

seon

lym

ater

ials

appr

oved

byan

dlis

ted

onth

ela

test

revi

sion

ofap

plic

able

tech

nica

lor

der

onai

r-cr

aft

land

ing

gear

com

-po

nent

s,w

heel

s,an

dbr

akes

,an

don

any

othe

rIV

Dal

umin

umco

ated

high

stre

ngth

stee

lpa

rts.

6850

-01-

431-

9025

CO

(50

LB

)68

50-0

1-43

1-90

24D

R(4

00L

B)

(Zip

Che

mic

alPr

oduc

tsC

o.,

CA

GE

Cod

e#1

KQ

X9)

TO 1-1-691

A-11

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

sePN

Cal

la-2

96(C

once

n-tr

ated

emul

sify

ing

type

liqui

dcl

eane

r)

6850

-01-

485-

5972

CO

(1G

L)

6850

-01-

485-

5932

CO

(5G

L)

6850

-01-

485-

5950

DR

(55

GL

)PN

Cal

la60

2LF

(Con

-ce

ntra

ted

non-

emul

sify

-in

gty

peliq

uid

clea

ner)

6850

-01-

513-

5230

CO

(1G

L)

6850

-01-

513-

5237

CO

(5G

L)

6850

-01-

513-

5233

DR

(55

GL

)26

Dei

cing

/Ant

i-Ic

ing

Flui

d,A

ircr

aft,

SAE

,Ty

peI

SAE

AM

S14

24(s

uper

-se

des

MIL

-A-8

243)

6850

-01-

435-

6471

CO

(1G

L)

Flui

dis

gene

rally

used

heat

ed,

eith

erdi

lute

dw

ithw

ater

oras

supp

lied,

for

the

rem

oval

ofan

dtim

e-lim

ited

prot

ectio

nag

ains

tde

posi

tsof

fros

t,ic

e,an

dsn

owon

exte

rior

airc

raft

surf

aces

prio

rto

take

-off

.It

isal

sous

edm

ixed

with

MIL

-PR

F-87

937,

Type

IVor

MIL

-PR

F-85

570,

Type

IIso

lutio

nsfo

rlo

wte

m-

pera

ture

clea

ning

per

Para

grap

h3.

5.2.

6.

6850

-01-

435-

6468

CN

(5G

L)

6850

-01-

435-

6465

DR

(55

GL

)68

50-0

1-44

9-94

69C

O(2

75G

LTo

te)

27D

ishw

ashi

ngC

om-

poun

d,H

and

(Syn

-th

etic

Det

erge

nt,

Solid

and

Liq

uid

Form

)

P-D

-410

,Ty

peII

(Con

-ce

ntra

ted

liqui

d,cl

ear

orop

aque

lotio

n,no

n-ph

osph

ate)

7930

-00-

880-

4454

BT

(6E

A/1

GL

)Ty

peII

liqui

dm

ixed

with

fres

hw

ater

will

rem

ove

grea

se,

oil,

and

dirt

from

aw

ide

vari

ety

ofsu

rfac

es.

7930

-00-

899-

9534

CN

(5G

L)

28C

lean

ing

Com

poun

d,So

lven

tM

ixtu

res

A-A

-592

81(s

uper

sede

sM

IL-C

-387

37),

Type

I(S

olve

ntbl

end

that

cont

ains

anar

omat

icso

lven

t)

6850

-00-

611-

7993

CN

(1PT

)T

his

solv

ent

blen

dis

used

tocl

ean

all

type

sof

soils

(bot

hpo

lar

and

non-

po-

lar)

,fr

omsu

rfac

esbe

fore

appl

ying

seal

ants

.

6850

-00-

538-

0929

CN

(1G

L)

6850

-01-

016-

3482

DR

(55

GL

)

TO 1-1-691

A-12

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se29

Dis

infe

ctan

t,G

ener

alPu

rpos

e(L

iqui

dPh

enol

icTy

pe)

A-A

-143

968

40-0

0-59

8-73

26(G

L)

Tre

atm

ent,

disi

nfec

ting/

sani

-tiz

ing,

and/

orde

odor

izin

gof

relie

ftu

bear

eas,

latr

ine

area

s,ur

inal

s,to

ilet

bow

ls,

latr

ine

buck

ets,

garb

age

rece

ptac

les,

sink

s,ga

lley

area

,an

dot

her

airc

raft

inte

rior

area

sre

quir

ing

disi

nfec

tion.

6840

-00-

598-

7327

CN

(5G

L)

6840

-00-

721-

6054

DR

(55

GL

)

Sani

tizer

,Ph

enol

icTy

pe,

Con

cent

rate

O-D

-143

5Pr

e-m

ixed

Liq

uid

(eith

erm

ater

ial)

6840

-00-

530-

7109

BX

(4E

A/1

GL

CO

)D

ilute

with

tap

wat

eras

di-

rect

edby

the

man

ufac

ture

ron

the

cont

aine

rbe

fore

use.

Pow

der

(O-D

-143

5on

ly)

6840

-00-

753-

4797

BX

(12

EA

/8O

ZPG

)M

ixon

e8

OZ

PGin

2Q

Tta

pw

ater

for

clea

ning

la-

trin

ebu

cket

s,ur

inal

s,an

dto

ilets

,an

don

e8

OZ

PGin

4G

Lta

pw

ater

for

all

othe

rcl

eani

ngpr

oces

ses.

Dis

infe

ctan

tC

lean

erfo

rA

ircr

aft

Inte

rior

(Gen

eral

Purp

ose

Liq

uid)

Cal

la®

1452

(Zip

Che

mic

alPr

oduc

tsC

o.,

CA

GE

Cod

e#1

KQ

X9)

6840

-01-

561-

3126

BX

(Con

tain

ssi

x32

FLO

Zem

pty

spra

ybo

ttles

and

six

0.25

FLO

Zbo

ttles

ofco

ncen

trat

eddi

sinf

ecta

nt)

For

gene

ral

clea

ning

ofal

lai

rcra

ftin

teri

orar

eas

re-

quir

ing

disi

nfec

tion.

Fol-

low

the

man

ufac

ture

r’s

inst

ruct

ions

for

use.

Cal

la®

1452

(AN

DPA

K,

Inc.

,C

AG

EC

ode

#258

73)

6840

-01-

600-

4177

CN

(GL

)

Aer

oDis

®71

27(Z

ipC

hem

ical

Prod

ucts

Co.

,C

AG

EC

ode

#1K

QX

9)

6840

-01-

686-

9908

CS

(Con

tain

s10

0E

Ain

di-

vidu

ally

wra

pped

pre-

satu

rate

dw

ipes

)68

40-0

1-68

6-99

17C

S(C

onta

ins

twel

ve26

OZ

spra

ybo

ttles

)

TO 1-1-691

Change 18 A-13

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se30

Wat

erR

epel

lent

,W

indo

wan

dW

ind-

shie

ld,

Gla

ssan

dPl

astic

SAE

AS

6882

(sup

er-

sede

sM

IL-W

-688

2)68

50-0

0-13

9-52

97B

T(8

OZ

)A

nti-

wet

ting

film

for

exte

-ri

orgl

ass

orac

rylic

plas

ticw

indo

ws

and

win

dshi

elds

toas

sure

good

visi

bilit

yun

der

rain

yco

nditi

ons.

31Po

lish,

Met

al,A

lum

i-nu

mA

-A-5

9318

(sup

erse

des

MIL

-P-6

888)

,Ty

peI

(Liq

uid)

7930

-00-

266-

7131

CN

(1Q

T)

Polis

hing

unpa

inte

dal

umi-

num

surf

aces

ofai

rcra

ft.

The

abra

sive

qual

ityof

the

polis

hen

able

sit

tore

mov

eta

rnis

han

dpr

o-du

cea

high

last

ing

shin

e.T

hepo

lish

shal

lno

tbe

used

onal

umin

umai

rcra

ftsu

rfac

esth

atar

eto

bepa

inte

d.

7930

-00-

267-

1224

CN

(1G

L)

Type

II(P

aste

)79

30-0

0-73

4-40

10C

N(1

QT

)

32Po

lish,

Plas

ticP-

P-56

0,Ty

peI

(Liq

uid)

7930

-00-

634-

5340

BT

(1PT

)C

lean

ing

and

polis

hing

ofpl

astic

mat

eria

lsto

re-

mov

elig

htsc

ratc

hes,

and

inth

eap

plic

atio

nof

anan

tista

ticfil

mw

hich

will

prev

ent

the

elec

tros

tatic

attr

actio

nof

dust

,lin

t,as

h,et

c.,

toac

rylic

plas

ticsu

r-fa

ces.

7930

-00-

935-

3794

BX

(24

EA

/8O

Z)

7930

-01-

133-

5375

BX

(1D

Z)

33E

rase

rs,

Rub

ber

A-A

-132

(sup

erse

des

ZZ

-E-6

61)

Rec

tang

ular

with

beve

led

ends

(25/ 8

inL

x½

inW

x7/ 8

inT

)

7510

-00-

949-

5055

BX

(1D

Z)

Rem

oval

oflig

htta

rnis

hor

corr

osio

nfr

omel

ectr

ical

conn

ecto

rsan

dco

ntac

tsan

dot

her

avio

nics

com

po-

nent

s.R

ecta

ngul

ar(2

inL

x¾

inW

x7/ 8

inT

)75

10-0

0-32

3-87

88B

X(1

DZ

)

CL

EA

NIN

GPA

DS/

CL

OT

HS

34Fa

ceR

espi

rato

rC

lean

ing

Wip

e(T

owel

ette

s)

3MC

o.,

PN50

4,C

AG

EC

ode

#OT

1L6

11x

8.5

inW

ipes

4240

-01-

372-

3078

BX

(100

PK)

Hyg

ieni

ccl

eani

ngof

resp

i-ra

tors

and

othe

rpe

rson

alpr

otec

tive

gear

/equ

ipm

ent

(alc

ohol

-fre

efo

rmul

a).

35C

lean

ing

Com

poun

d,O

ptic

alL

ens

(Rea

dy-t

o-U

se)

A-A

-591

99(s

uper

sede

sM

IL-C

-434

54),

Type

I(2

0%al

coho

l)

6850

-00-

392-

9751

BT

(2O

Z)

Cle

anin

gof

expo

sed

optic

alsu

rfac

es.

6850

-00-

227-

1887

BT

(1Q

T)

Type

II(5

7%al

coho

l)68

50-0

0-18

8-98

75B

T(1

QT

)

TO 1-1-691

A-14 Change 18

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se36

Cle

aner

,Pi

pePN

8405

07,

CA

GE

Cod

e#6

4067

9920

-00-

292-

9946

BX

(134

4E

A)

Cle

anin

gsm

all

orifi

ces

and

crev

ices

.

TO 1-1-691

Change 18 A-14.1/(A-14.2 blank)

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se37

Pad,

Cle

anin

gan

dPo

lishi

ngN

on-

Met

allic

(for

air-

craf

tcl

eani

ngki

t)

A-A

-310

0(s

uper

sede

sM

IL-C

-839

57),

Type

I(3

/ 8in

T)

7920

-00-

151-

6120

PG(1

0SH

)N

on-w

oven

,no

n-m

etal

lic,

non-

abra

sive

,po

lyes

ter

clea

ning

and

polis

hing

pads

(12″

Lx

6″W

)fo

rus

eon

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

Rep

lace

men

tpa

dsfo

rai

r-cr

aft

was

hki

t.(R

efer

toA

ppen

dix

B,

Tabl

eB

-2,

Item

No.

1).

Type

II(1

inT

)79

20-0

0-17

1-15

34PG

(10

SH)

38A

ircr

aft

Cle

anin

gPa

dsSc

otch

brite

®#3

3

3MC

o.,

PN61

-500

1-86

95-4

(3½

x5

inpa

d)

7920

-01-

519-

4141

CS

(200

EA

)N

on-w

oven

,no

n-m

etal

lic,

non-

abra

sive

,po

lyes

ter

clea

ning

and

polis

hing

pads

with

impr

egna

ted

rubb

erpa

rtic

les

for

clea

n-in

gof

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

The

sepa

dspr

ovid

eim

-pr

oved

clea

ning

effic

ienc

yov

erth

eIt

emN

o.37

pads

.

CA

GE

Cod

e#7

6381

(Im

prov

edTy

pe)

3MC

o.,

#961

,PN

61-

5000

-461

5-8

(3½

x5

inpa

dho

lder

-ha

ndhe

ld)

7920

-01-

519-

4140

CS

(10

EA

)

3MC

o.,

PN61

-500

1-86

96-2

(45/ 8

x10

inpa

d)

7920

-01-

519-

4733

CS

(100

EA

)

3MC

o.,

#250

,PN

61-

5000

-491

3-7

(45/ 8

x10

inpa

dho

lder

-ha

ndhe

ld)

7920

-01-

519-

4142

CS

(5E

A)

3MC

o.,

PN61

-500

1-86

97-0

(6x

12in

pad)

7920

-01-

519-

4736

CS

(50

EA

)

3MC

o.,

#261

,PN

61-

5000

-323

5-6

(6x

12in

pad

hold

er-

hand

le)

7920

-01-

519-

4735

CS

(1E

A)

Mel

amin

ePa

ds3.

5″X

5″X

1.2″

7920

-01-

526-

9015

BX

(200

EA

)4.

625″

X10

″X

1.3″

7920

-01-

526-

9007

BX

(100

EA

)6″

X12

″X

1.3″

7920

-01-

526-

9003

BX

(50

EA

)3″

X5″

X1″

6850

-01-

525-

7684

BX

(6E

A)

3MJE

TPA

D6″

X12

″79

20-0

1-54

8-78

87B

ox(5

0E

A)

39C

ham

ois

Lea

ther

,Sh

eeps

kin,

Oil

Tann

ed

KK

-C-3

00,

Gra

deB

,C

lass

2,Si

zeSm

all

8330

-00-

823-

7545

PG(5

EA

)G

ener

alpu

rpos

ew

ashi

ngan

dpo

lishi

ng.

TO 1-1-691

Change 14 A-15

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se40

Che

esec

loth

,C

otto

n,B

leac

hed

and

Un-

blea

ched

CC

C-C

-440

,Ty

peI,

Cla

ss2

(Ble

ache

d)83

05-0

0-26

2-33

21B

O(3

6in

x50

YD

)C

lean

ing

and

polis

hing

air-

craf

t,m

issi

le,

and

equi

p-m

ent

surf

aces

.83

05-0

0-20

5-34

95B

O(3

6in

x10

0Y

D)

Type

I,C

lass

1(U

n-bl

each

ed)

8305

-00-

222-

2423

PG(3

8.5

inx

1Y

D)

Type

II,

Cla

ss2

(Ble

ache

d)83

05-0

0-20

5-34

96PG

(36

inx

10Y

D)

8305

-00-

267-

3015

PG(3

6in

x1

YD

)41

Clo

th,

Cle

anin

g,N

on-w

oven

Fabr

icC

CC

-C-4

6,Ty

peI

(Un-

trea

ted)

Cla

ss1

(Lig

htdu

ty)

8305

-00-

753-

2967

RO

(36

inx

50Y

D)

Gen

eral

clea

ning

(e.g

.w

ip-

ing

upgr

ease

and

liqui

dsp

ills)

whe

relo

wre

sidu

alsu

rfac

eco

ntam

inat

ion

isre

quir

ed.

Cla

ss4

(Ext

rahe

avy

duty

)79

20-0

0-29

2-92

04B

X(M

X)

-15

0in

2E

AC

lass

6(L

ight

duty

,pe

r-fo

rate

dor

non-

perf

o-ra

ted)

7920

-00-

401-

8034

BX

(HD

)-

150

in2

EA

Cla

ss7

(Air

craf

tso

lven

tw

iper

)79

20-0

1-18

0-05

5618

BX

(150

EA

-8

¾x

8¼

in)

7920

-01-

180-

0557

BX

(800

EA

-16

¾in

x20

¾in

)42

Clo

thes

,C

lean

ing

for

Air

craf

tPr

imar

yan

dSe

cond

ary

Stru

ctur

alSu

rfac

es

SAE

AM

S38

19,

Cla

ss2,

Gra

deA

(Dup

ont-

Sont

-ar

a®A

CT

MA

ircr

aft

Wip

es;

Dis

trib

utor

-C

AG

EC

ode

#1B

L94

)PN

AC

9165

6850

-01-

487-

2859

8B

X(1

00E

A-

9x

16½

in)

Use

dfo

rcl

eani

ngsu

rfac

esre

quir

ing

exce

ptio

nally

low

resi

dual

surf

ace

con-

tam

inat

ion.

PNA

C12

165

6850

-01-

487-

2861

BX

(250

EA

-12

x16

½in

)43

Clo

th,

Flan

nel,

Cot

-to

n(B

lue

inco

lor)

A-A

-501

29(s

uper

sede

sC

CC

-C-4

58)

8305

-00-

913-

5817

BO

(50

YD

)C

lean

ing

and

polis

hing

ofpl

astic

surf

aces

such

asca

nopi

es,

win

dscr

eens

,et

c.

TO 1-1-691

A-16

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se44

Clo

th,

Cle

anin

g,L

ow-L

int

(Whi

tein

colo

r)

A-A

-593

23(s

uper

sede

sM

IL-C

-850

43),

Type

I(C

lean

room

use,

ultr

a-cl

ean,

low

lint

wip

es)

7920

-00-

165-

7195

BX

(10

LB

)H

ydra

ulic

clea

nro

oman

d

fluid

syst

ems

clea

ning

.

Do

not

use

thes

ecl

oths

with

flam

mab

leso

lven

tsas

fire

may

resu

ltw

hen

used

with

thes

eso

lven

ts.

Type

II(G

ener

alus

ere

-qu

irin

glo

wlin

t,hi

ghly

abso

rben

tw

ipes

but

not

tocl

ean

room

stan

-da

rds)

7920

-00-

044-

9281

BX

(10

LB

)

CO

RR

OSI

ON

PRE

VE

NT

IVE

CO

MPO

UN

DS,

OIL

S,G

RE

ASE

S,A

ND

LU

BR

ICA

NT

S45

Cor

rosi

onPr

even

tive

Com

poun

d,So

lven

tC

utba

ck,

Col

dA

p-pl

icat

ion

MIL

-PR

F-16

173

(sup

er-

sede

sM

IL-C

-161

73),

Cla

ssII

,G

rade

1-

Har

dFi

lm(L

owV

OC

≤2.8

#/G

L)

8030

-01-

396-

5731

CN

(1PT

)T

hick

,w

ax-l

ike,

hard

film

cons

iste

ncy

for

long

term

prot

ectio

nof

met

alsu

r-fa

ces

agai

nst

corr

osio

nw

ithor

with

out

cove

ring

s(i

ndoo

rsor

outd

oors

).T

his

mat

eria

lw

illcr

ack

and

peel

off

the

surf

ace

ator

belo

wa

tem

pera

ture

of0°

F(-

18°

C).

8030

-01-

396-

5732

CN

(1G

L)

8030

-01-

347-

0970

CN

(5G

L)

8030

-01-

396-

5237

DR

(55

GL

)

TO 1-1-691

A-17

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seC

lass

I,G

rade

2-

Soft

film

(Hig

hV

OC

>2.

8#/

GL

)

8030

-00-

118-

0666

CN

(11

OZ

)A

eros

olT

hick

,gr

ease

-lik

eco

nsis

-te

ncy

for

prot

ectin

gm

etal

surf

aces

agai

nst

corr

osio

ndu

ring

rew

ork

orst

orag

e.In

clud

esex

tend

edin

door

prot

ectio

nof

inte

rior

orex

teri

orsu

rfac

esw

ithou

tth

eus

eof

barr

ier

mat

eri-

als.

For

outd

oor

prot

ec-

tion,

this

mat

eria

lca

non

lybe

used

for

alim

ited

time

whe

rete

mpe

ratu

reis

not

extr

emel

yho

t.It

will

ad-

here

tosu

rfac

esan

dpr

o-vi

depr

otec

tion

atte

m-

pera

ture

sdo

wn

to-4

0°F

(-40

°C

).

8030

-01-

149-

1731

CN

(1Q

T)

8030

-00-

244-

1297

CN

(1G

AL

)80

30-0

0-24

4-12

98C

N(5

GA

L)

8030

-00-

244-

1295

DR

(55

GL

)

Cla

ssII

,G

rade

3-

Soft

oily

film

(Low

VO

C≤2

.8#/

GL

)

8030

-01-

396-

5735

CN

(1PT

)So

ft,

oily

mat

eria

lus

edto

disp

lace

wat

er,

incl

udin

gsa

ltw

ater

,fr

omm

etal

sur-

face

san

djo

int

area

san

dto

prot

ect

them

from

cor-

rosi

onfo

rlim

ited

peri

ods

(30

days

orle

ss).

Use

dto

prot

ect

criti

cal

bare

stee

lan

dph

osph

ated

stee

lsu

r-fa

ces

ofpa

rts

awai

ting

repa

iror

bein

gsh

ippe

dto

ade

pot

for

repa

ir.Pr

o-vi

des

inde

finite

prot

ectio

nfo

rpa

rts

with

inse

aled

barr

ier

mat

eria

lco

ntai

ners

.

8030

-01-

396-

5748

CN

(1G

L)

8030

-01-

347-

0971

CN

(5G

L)

8030

-01-

396-

5734

DR

(55

GL

)

TO 1-1-691

A-18

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seC

lass

II,

Gra

de4

(Tra

ns-

pare

nt,

non-

tack

yso

ftfil

m)

8030

-01-

396-

5738

CN

(1PT

)T

hin,

tran

spar

ent,

wat

erdi

s-pl

acin

g,ta

ck-f

ree

prot

ec-

tive

film

for

prot

ectio

nof

met

alsu

rfac

esag

ains

tco

r-ro

sion

duri

ngin

door

stor

-ag

eor

whe

nlo

cate

din

inte

rior

area

sof

airc

raft

,m

issi

les,

oreq

uipm

ent

and

for

limite

dou

tdoo

rpr

eser

-va

tion.

Use

onco

ntro

lca

bles

,fa

sten

ers,

bare

met

alar

eas,

oran

ywhe

rete

mpo

rary

(30

days

orle

ss)

prot

ectio

nis

need

edan

dfo

rlo

ngte

rmst

orag

eof

part

sw

ithin

seal

edba

r-ri

erm

ater

ial

cont

aine

r.It

will

adhe

reto

surf

aces

and

prov

ide

prot

ectio

nat

tem

pera

ture

sdo

wn

to-4

0°F

(-40

°C

).

8030

-01-

396-

5743

CN

(1G

L)

8030

-01-

347-

0972

CN

(5G

L)

8030

-01-

396-

5736

DR

(55

GL

)

46C

orro

sion

Prev

entiv

eC

ompo

und

(AM

L-

GU

AR

D)

MIL

-DT

L-8

5054

,Ty

peI

(Pre

ssur

ized

/aer

osol

can)

Cla

ss13

4AH

CFC

prop

ella

nt

8030

-01-

347-

0979

CN

(14

OZ

)Te

mpo

rary

repa

irof

smal

lpa

int

dam

age

area

sfr

omch

ips,

scra

tche

s,or

crac

ks.

Inte

nded

for

use

onno

n-m

ovin

gpa

rts

not

requ

irin

ga

lubr

icat

edsu

rfac

e,su

chas

fast

ener

s,se

ams,

acce

sspa

nels

,jo

ints

,un

pain

ted

met

al,

etc.

Dri

esto

aha

rdfil

m.

Type

II(B

ulk

form

)80

30-0

1-34

7-09

83B

T(3

2O

Z-

Pum

psp

ray)

8030

-01-

347-

0981

CN

(1Q

T)

8030

-01-

347-

0982

CN

(5G

L)

TO 1-1-691

A-19

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se47

Cor

rosi

onPr

even

tive

Com

poun

ds,

Wat

erD

ispl

acin

g,U

ltra-

Thi

nFi

lm

MIL

-PR

F-81

309,

Type

II(S

oft

film

)W

ater

disp

laci

ngC

PCw

hich

may

beap

plie

dby

dip-

ping

,sp

rayi

ng,

brus

hing

,or

from

pres

suri

zed

con-

tain

ers.

Cla

ss1

(Non

-pre

ssur

ized

cont

aine

r/bu

lk)

8030

-00-

213-

3279

CN

(1G

L)

Suita

ble

for

use

onan

ym

etal

surf

ace

exce

ptav

i-on

ics/

elec

tron

ics

appl

ica-

tions

for

indo

oran

dsh

ort

term

outd

oor

prot

ectio

nw

here

surf

aces

can

bere

-coa

ted

whe

nre

quir

ed.

8030

-00-

262-

7358

CN

(5G

L)

NO

TE

Itsh

ould

not

beus

edar

ound

LO

Xfit

tings

.

8030

-00-

524-

9487

DR

(55

GL

)

Cla

ss2,

Gra

deC

O2

(Pre

ssur

ized

cont

aine

r-

CO

2pr

opel

lant

)

8030

-00-

938-

1947

CN

(16

OZ

)

Type

III

(Sof

tfil

m;A

vi-

onic

grad

e)C

lass

1(N

on-p

ress

uriz

edco

n-ta

iner

/bul

k)

8030

-01-

347-

0978

CN

(1G

L)

Wat

erdi

spla

cing

CPC

for

use

onex

teri

ors

ofav

ioni

ceq

uipm

ent,

elec

tric

alco

n-ne

ctor

plug

s,an

dco

ntac

tpo

ints

.C

lass

2(P

ress

uriz

edco

n-ta

iner

/aer

osol

-no

nO

DS

prop

ella

nt)

8030

-00-

546-

8637

CN

(16

OZ

)

TO 1-1-691

A-20 Change 10

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se48

Lub

rica

nts,

Cor

rosi

onPr

even

tive

Com

-po

und,

Wat

erD

is-

plac

ing,

Synt

hetic

MIL

-L-8

7177

A,

Type

I(P

ress

uriz

edca

n/ae

ro-

sol)

;G

rade

B(w

ithad

ded

corr

osio

nin

hibi

-to

r)

6850

-01-

528-

0653

CN

(16

OZ

)W

ater

disp

laci

ngC

PCw

hich

may

beap

plie

dby

dip-

ping

,br

ushi

ng,

orsp

ray-

ing

(pum

psp

raye

ror

aero

sol

spra

y).

Suita

ble

for

use

onan

ym

etal

sur-

face

incl

udin

gex

tern

alsu

rfac

esof

avio

nics

/ele

c-tr

onic

seq

uipm

ent,

elec

tri-

cal

conn

ecto

rs,

and

con-

tact

poin

tsfo

rin

door

and

shor

tte

rmou

tdoo

rpr

otec

-tio

nw

here

surf

aces

can

bere

-coa

ted

whe

nre

quir

ed.

Itca

nbe

used

asan

alte

r-na

te/s

ubst

itute

for

MIL

-PR

F-81

309,

Type

sII

and

III.

Type

II(N

on-p

ress

uriz

edco

ntai

ner/

bulk

);G

rade

B(w

ithad

ded

corr

o-si

onin

hibi

tor)

6850

-01-

326-

7294

CN

(5L

)

Do

not

use

arou

ndL

OX

fittin

gsas

fire

may

resu

lt.

49C

orro

sion

Prev

entiv

eC

ompo

und

(Hig

hZ

inc

Dus

tC

onte

ntPa

int)

Com

mer

cial

Prod

uct

ZR

CPr

od.

Co.

,C

AG

EC

ode

#079

57,

PN82

81-1

0000

8030

-01-

015-

1550

CN

(12

OZ

)A

eros

olA

high

zinc

dust

cont

ent

epox

ypa

int

type

corr

osio

npr

even

tive

com

poun

d(a

lso

know

nas

“col

dga

l-va

nize

”)us

edfo

rre

pair

ofde

fect

sin

galv

aniz

edco

at-

ings

,to

over

coat

wel

ded

area

son

galv

aniz

edst

eel,

and

topr

ovid

eco

rros

ion

for

area

sw

here

corr

osio

nw

asre

mov

edon

stee

lst

ruct

ures

ofsu

ppor

teq

uipm

ent,

elec

tron

icva

ns,

ante

nna

tow

ers,

and

vehi

cles

.

Dev

con

Cor

p.,

CA

GE

Cod

e#1

6059

8010

-00-

501-

5798

CN

(16

OZ

)A

eros

olPN

DE

VC

ON

Z&

NH

CC

orp.

,C

AG

EC

ode

#209

13,

PNH

Y-Z

INC

TO 1-1-691

Change 10 A-21

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seD

evco

nC

orp.

,C

AG

EC

ode

#160

59,

PN’s

1703

&12

030

8010

-00-

360-

3369

CN

(1G

L)

50L

ubri

catin

gO

il,G

en-

eral

Purp

ose,

Pre-

serv

ativ

e(W

ater

Dis

plac

ing,

Low

Tem

pera

ture

)

MIL

-PR

F-32

033

9150

-00-

836-

8641

BT

(½O

Z)

Age

nera

lpu

rpos

e,w

ater

disp

laci

ng,

low

tem

pera

-tu

rera

ted

(-40

°F/

-40°

C)

oil

that

can

beap

plie

dby

dipp

ing,

brus

hing

,or

spra

ying

for

lubr

icat

ing

and

shor

tte

rmco

rros

ion

prot

ectio

nof

met

alpa

rts;

airc

raft

,m

issi

le,

and

equi

pmen

thi

nges

;an

dsm

all

arm

s.

9150

-00-

261-

8146

BT

(1O

Z)

9150

-00-

273-

2389

CN

(4O

Z)

9150

-00-

458-

0075

CN

(16

OZ

)A

eros

ol

9150

-01-

374-

2021

BT

(16

OZ

)Pu

mp

Spra

y91

50-0

0-23

1-66

89C

N(1

QT

)91

50-0

0-23

1-90

45C

N(1

GL

)91

50-0

0-23

1-90

62C

N(5

GL

)91

50-0

0-28

1-20

60D

R(5

5G

L)

TO 1-1-691

A-22

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se51

Lub

rica

nt,

Cle

aner

and

Pres

erva

tive

for

Wea

pons

and

Wea

pons

Syst

ems

(CL

P)

MIL

-PR

F-63

460

9150

-01-

102-

1473

BT

(½O

Z)

Lub

rica

tion

and

shor

tte

rmpr

eser

vatio

nof

airc

raft

,m

issi

le,

and

equi

pmen

thi

nges

,an

dsm

all

and

larg

eca

liber

wea

pons

.C

anbe

used

asan

alte

r-na

teor

subs

titut

efo

rM

IL-

PRF-

3203

3.

9150

-01-

079-

6124

BT

(4O

Z)

9150

-01-

054-

6453

BT

(16

OZ

)Pu

mp

Spra

y

Do

not

use

MIL

-PR

F-63

460

onru

bber

orot

her

elas

tom

eric

mat

e-ri

als

asit

may

dam

age

them

.U

seon

lyin

area

sw

here

the

cont

aine

dso

lven

tsca

nre

adily

evap

orat

e.

9150

-01-

327-

9631

BT

(32

OZ

)Pu

mp

Spra

y

9150

-01-

053-

6688

BT

(1G

L)

TO 1-1-691

A-23

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se52

Cor

rosi

onPr

even

tive

Com

poun

d,Pe

tro-

leum

,H

otA

pplic

a-tio

n

MIL

-C-1

1796

,C

lass

1(H

ard

film

com

poun

d)80

30-0

0-23

1-23

54C

N(5

LB

)Pr

eser

vatio

nof

inte

rior

sur-

face

sof

unse

aled

stru

c-tu

ral

stee

lan

dal

umin

umal

loy

tubi

ngas

sem

blie

san

dot

her

met

alar

eas

that

mus

tre

mai

nba

rean

dar

eex

pose

dto

eith

erex

teri

oror

inte

rior

envi

ronm

ents

inse

rvic

e.C

lass

1an

d1A

mat

eria

lsca

nbe

used

topr

otec

tm

etal

part

sin

un-

shie

lded

outd

oor

stor

age

orus

efo

rlim

ited

peri

ods

(90

days

)an

dun

limite

din

door

use

orst

orag

eei

-th

erpa

ckag

edor

unpa

ck-

aged

.C

lass

3m

ater

ials

can

beus

edto

prot

ect

part

ssu

chas

anti-

fric

tion

bear

ings

inin

door

stor

age.

Pref

erab

ly,

use

only

Cla

ss1A

mat

eria

lson

inse

rvic

est

ruct

ures

asth

eyar

eno

n-sl

ick

and

won

’tco

llect

dirt

asw

ell

asre

sist

ing

high

eram

bien

t(r

oom

)te

mpe

ratu

res

(+15

0°F/

+66

°C

)w

ithou

tm

eltin

gan

dru

nnin

gof

fsu

rfac

esto

whi

chit

isap

plie

d.

8030

-00-

597-

3288

CN

(35

LB

)

8030

-00-

231-

2352

DR

(400

LB

)

Cla

ss1A

(Har

dfil

m,

non-

slic

kco

mpo

und)

8030

-00-

823-

8054

CN

(35

LB

)

8030

-00-

514-

1843

DR

(400

LB

)

Cla

ss3

(Sof

tfil

mco

m-

poun

d)80

30-0

0-59

8-59

15C

N(1

PT)

8030

-00-

231-

2353

CN

(5L

B)

8030

-00-

285-

1570

CN

(35

LB

)53

Lin

seed

Oil,

Boi

led

AST

MD

260

(sup

er-

sede

sA

-A-3

71),

Type

I80

10-0

0-24

4-89

61C

N(1

PT)

Pres

erva

tion

ofin

teri

orsu

r-fa

ces

ofse

aled

stru

ctur

alca

rbon

stee

ltu

bing

asse

m-

blie

s.

8010

-00-

152-

3245

CN

(1G

L)

8010

-00-

684-

8789

CN

(5G

L)

8010

-00-

242-

6114

DR

(55

GL

)L

UB

RIC

AN

TS

TO 1-1-691

A-24

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se54

Gre

ase,

Air

craf

t,G

ener

alPu

rpos

e,W

ide

Tem

pera

ture

Ran

ge;

NA

TO

Cod

eG

-395

(-65

°to

+35

0°F/

-54°

to+

177°

C)

MIL

-PR

F-81

322

(sup

er-

sede

sM

IL-L

-813

22)

NG

LI,

Gra

de1

9150

-01-

378-

0744

TU

(8O

Z)

Lub

rica

ting

airc

raft

arre

stin

gge

arsh

eave

spac

ers

and

othe

req

uipm

ent

that

oper

-at

eun

der

high

cont

act

load

san

dhi

ghsl

idin

gsp

eeds

.

9150

-01-

378-

0559

CN

(1.7

5L

B)

9150

-01-

378-

0693

CN

(6.5

LB

)

NG

LI,

Gra

de2

9150

-00-

181-

7724

TU

(8O

Z)

Lub

rica

ting

airc

raft

whe

elbe

arin

gsan

din

tern

albr

ake

whe

elas

sem

blie

s,an

ti-fr

ictio

nbe

arin

gs,

gear

boxe

s,an

dpl

ain

bear

-in

gs.

9150

-01-

262-

3358

CA

(14

OZ

)

9150

-00-

944-

8953

CN

(1.7

5L

B)

55G

reas

e,A

ircr

aft

and

Inst

rum

ent,

Gea

ran

dA

ctua

tor

Scre

w;

NA

TO

Cod

eG

-354

(-10

0°to

+25

0°F/

-73°

to+

121°

C)

MIL

-PR

F-23

827

(sup

er-

sede

sM

IL-G

-238

27),

Type

I(M

etal

licso

apth

icke

ned)

9150

-00-

985-

7244

TU

(4O

Z)

Lub

rica

ntfo

rus

ein

ball,

rolle

ran

dne

edle

bear

ings

,ge

ars,

and

onsl

idin

gan

dro

lling

surf

aces

ofsu

cheq

uipm

ent

asin

stru

men

ts,

cam

eras

,el

ectr

onic

gear

s,an

dai

rcra

ftco

ntro

lsy

s-te

ms

that

are

subj

ect

toex

trem

em

arin

ean

dlo

wte

mpe

ratu

reco

nditi

ons.

It’s

extr

emel

ylo

wvo

latil

-ity

prev

ents

itfr

omfo

g-gi

ngup

optic

alin

stru

-m

ents

.It

can

beus

edfo

rro

lling

and

slid

ing

sur-

face

sof

equi

pmen

tha

ving

low

mot

ivat

ing

pow

er(l

owto

rque

equi

pmen

t).

Als

oin

tend

edfo

rge

nera

lus

eon

airc

raft

,m

issi

le,

and

equi

pmen

tge

ars,

ac-

tuat

orsc

rew

s,an

dot

her

equi

pmen

tre

quir

ing

alu

-br

ican

tw

ithhi

ghlo

adca

rryi

ngca

paci

ty.

9150

-00-

985-

7245

TU

(8O

Z)

9150

-00-

935-

4017

CA

(14

OZ

)

9150

-00-

985-

7246

CN

(1.7

5L

B)

9150

-00-

985-

7247

CN

(6.5

LB

)

9150

-00-

985-

7248

CN

(35

LB

)

TO 1-1-691

A-25

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se56

Gre

ase,

Plug

Val

ve,

Gas

olin

eO

il,an

dW

ater

Res

ista

nt;

NA

TO

Cod

eG

-363

SAE

AM

S-G

-603

2(s

u-pe

rsed

esM

IL-G

-603

2),

Type

I(B

ulk

form

)

9150

-00-

190-

0926

CN

(8O

Z)

Lub

rica

tion

ofta

pere

dpl

ugva

lves

.T

hetw

oty

pes

pro-

vide

for

the

use

inhi

ghpr

essu

relu

bric

atio

neq

uip-

men

tor

for

serv

icin

gth

ose

valv

esw

hich

requ

ire

ast

ick

type

lubr

ican

t.A

lso

may

beus

edas

aga

sket

lubr

ican

tor

seal

and

for

gene

ral

plug

valv

ese

rvic

ein

syst

ems

whe

rega

solin

e,oi

l,al

coho

l,or

wat

erre

-si

stan

ceis

requ

ired

.

Type

II(S

tick

form

)91

50-0

0-25

7-53

60C

N(1

.75

LB

)C

lass

A(¼

Dx

7/ 8

inL

)91

50-0

0-26

1-82

87B

X(2

4E

A)

Cla

ssB

(13/

32D

x1

3/ 8

inL

)91

50-0

0-26

1-82

89B

X(2

4E

A)

Cla

ssC

(35/

64D

x2

inL

)91

50-0

0-26

1-82

90B

X(2

4E

A)

Cla

ssD

(21/

32D

x2

7/16

inL

)91

50-0

0-26

1-82

91B

X(2

4E

A)

Cla

ssG

(55/

64D

x3

3/ 8

inL

)91

50-0

0-26

1-82

92B

X(2

4E

A)

57G

reas

e,A

ircr

aft

and

Inst

rum

ent,

Fuel

and

Oxi

dize

rR

e-si

stan

t

MIL

-PR

F-27

617

(sup

er-

sede

sM

IL-G

-276

17),

Type

I-

NA

TO

Cod

eG

-397

(-65

°to

+40

0°F/

-54°

to+

204°

C)

9150

-01-

007-

4384

TU

(8O

Z)

Lub

rica

tion

ofta

per

plug

valv

es,

gask

ets,

and

bear

-in

gsin

fuel

syst

ems

ofai

rcra

ftan

dgr

ound

sup-

port

equi

pmen

t.A

lso

suit-

able

for

use

inL

OX

sys-

tem

sas

alu

bric

ant

for

valv

es,

thre

ads,

and

bear

-in

gsin

aero

spac

eve

hicl

esan

dsu

ppor

teq

uipm

ent.

May

not

besu

itabl

efo

ral

umin

uman

dm

agne

sium

dyna

mic

bear

ing

lubr

ica-

tion

beca

use

ofpo

ssib

leig

nitio

nha

zard

s.Ty

peII

Iis

mor

eco

mm

only

know

nas

“Kry

tox”

and

isL

OX

com

patib

le.

9150

-01-

311-

9771

CN

(1.7

5L

B)

9150

-01-

088-

0498

TU

(2O

Z)

Type

II-

NA

TO

Cod

eG

-398

(-40

°to

+40

0°F/

-40°

to+

204°

C)

9150

-00-

961-

8995

TU

(8O

Z)

9150

-01-

358-

5154

CN

(1L

B)

TO 1-1-691

A-26

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seTy

peII

I-

NA

TO

Cod

eG

-399

(-30

°to

+40

0°F/

-34°

to+

204°

C)

9150

-01-

353-

5788

CR

(1L

B)

Type

IV-

NA

TO

Cod

eG

-135

0(-

100°

to+

400°

F/-7

3°to

+20

4°C

)

9150

-01-

393-

1749

TU

(2O

Z)

58G

reas

e,M

olyb

denu

mD

isul

fide,

Low

and

Hig

hTe

mpe

ratu

res;

NA

TO

Cod

eG

-353

(-10

0°to

+25

0°F/

-73°

to+

121°

C)

MIL

-G-2

1164

9150

-00-

935-

4018

CA

(14

OZ

)L

ubri

cant

for

acce

ssor

ysp

lines

,he

avy

load

edsl

id-

ing

stee

lsu

rfac

es,

orfo

ran

ti-fr

ictio

nbe

arin

gsca

r-ry

ing

high

load

san

dop

er-

atin

gth

roug

hw

ide

tem

-pe

ratu

rera

nges

whe

rem

olyb

denu

mdi

sulfi

dew

illpr

even

tor

dela

yse

izur

ein

the

even

tof

inad

equa

telu

bric

atio

n.Sh

ould

not

beus

edfo

rw

heel

bear

ings

orfo

rot

her

than

stee

lsu

r-fa

ces

with

out

auth

oriz

a-tio

n.

9150

-00-

754-

2595

CN

(1.7

5L

B)

9150

-00-

223-

4004

CN

(6.5

LB

)91

50-0

0-96

5-20

03C

N(3

5L

B)

9150

-01-

219-

1629

DR

(20

KG

)

59G

reas

e,Pn

eum

atic

Syst

em;

NA

TO

Cod

eG

-392

SAE

AM

S-G

-434

3(s

u-pe

rsed

esM

IL-G

-434

3)91

50-0

0-11

9-92

91T

U(2

OZ

)L

ubri

cant

betw

een

rubb

eran

dm

etal

part

sof

pneu

-m

atic

syst

ems.

Itm

ayal

sobe

used

for

pres

suri

zed

cabi

nbu

lkhe

adgr

omm

ets

and

othe

rm

echa

nism

sre

quir

ing

rubb

erto

met

allu

bric

atio

n.

9150

-00-

269-

8255

CN

(1.7

5L

B)

60G

reas

e,A

ircr

aft,

He-

licop

ter

Osc

illat

ing

Bea

ring

;N

AT

OC

ode

G-3

66(-

65°

to16

0°F/

-54°

to+

71°

C)

MIL

-G-2

5537

9150

-00-

478-

0055

CA

(14

OZ

)L

ubri

catio

nof

bear

ings

hav-

ing

osci

llato

rym

otio

nof

smal

lam

plitu

de.

9150

-00-

616-

9020

CN

(1.7

5L

B)

9150

-00-

721-

8570

CN

(6.5

LB

)91

50-0

0-72

1-85

81C

N(3

5L

B)

TO 1-1-691

A-27

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se61

Gre

ase,

Air

craf

t,B

all

and

Rol

ler

Bea

ring

;N

AT

OC

ode

G-3

72(-

100°

to45

0°F/

-73

°to

+23

2°C

)

MIL

-G-2

5013

9150

-00-

823-

8048

TU

(8O

Z)

Bal

lan

dro

ller

bear

ing

lubr

i-ca

tion.

Itm

aybe

used

onai

rcra

ftac

tuat

ors

and

gear

boxe

s,an

dot

her

sim

ilar

equi

pmen

tan

dan

ti-fr

ic-

tion

bear

ings

whe

reop

era-

tion

oflo

wto

rque

equi

p-m

ent

requ

ires

lubr

icat

ion

for

exte

nded

peri

ods

oftim

ew

hen

auth

oriz

edby

the

appl

icab

lesy

stem

spe-

cific

mai

nten

ance

man

ual.

9150

-00-

935-

4019

CA

(14

OZ

)91

50-0

0-14

1-67

70C

N(1

.75

LB

)91

50-0

0-14

1-67

71C

N(3

5L

B)

62L

ubri

cant

,M

olyb

de-

num

Dis

ulfid

e,Si

li-co

ne;

NA

TO

Cod

eS-

1735

DO

D-L

-256

8191

50-0

0-54

3-72

20L

B(1

LB

)L

ubri

cant

for

use

onsl

ow-

spee

dsl

idin

gsu

rfac

esin

airc

raft

gas

turb

ine

en-

gine

san

dot

her

area

sof

airc

raft

,m

issi

les,

and

equi

pmen

tsu

bjec

tto

high

tem

pera

ture

sup

to+

752°

F/+

400°

Can

das

anan

ti-se

ize

com

poun

don

thre

aded

part

sw

hich

oper

-at

eat

tem

pera

ture

sup

to+

1400

°F

(760

°C

).

TO 1-1-691

A-28

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se63

Lub

rica

nt,

Solid

Film

,H

eat-

Cur

ed,

Cor

rosi

onIn

hibi

t-in

g

SAE

AS5

272,

Type

sI

&II

(rep

lace

sM

IL-P

RF-

4601

0,Ty

pes

I&

II)

Lub

rica

ntfo

rus

eto

redu

cew

ear

and

prev

ent

galli

ng,

corr

osio

n,an

dse

izur

eof

met

als.

Idea

lfo

rsl

idin

gm

otio

nap

plic

atio

nssu

chas

plai

nan

dsp

heri

cal

bear

ings

,fla

ptr

acks

,hi

nges

,th

read

,an

dca

msu

rfac

es.

Itis

also

usef

ulw

here

aso

lven

tre

sist

ant

coat

ing

isre

quir

ed,

lubr

i-ca

tion

and

corr

osio

npr

o-te

ctio

nfo

rar

eas

that

expe

-ri

ence

slig

htvi

brat

ory

mot

ion,

lubr

icat

ion

and

corr

osio

npr

otec

tion

ofm

echa

nism

sha

ving

infr

eque

ntop

erat

ion

inte

r-va

lsor

lifet

ime

lubr

ica-

tion,

and

whe

relo

ng-t

erm

corr

osio

npr

otec

tion

isne

eded

unde

rst

atic

cond

i-tio

ns.

TO 1-1-691

A-29

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seTy

peI

(cur

e@

+30

0°F/

+14

9°C

)91

50-0

0-83

4-56

08C

N(1

PT)

NO

TE

SAE

AS5

272,

Type

Ian

dM

IL-P

RF-

4601

0cu

red

at+

300°

F(+

149°

C)

are

usab

leon

all

met

alsu

rfac

es,

but

SAE

AS5

272,

Type

IIan

dM

IL-P

RF-

4601

0cu

red

at+

400°

F(+

204°

C)

shou

ldno

tbe

used

onal

umin

umal

loys

orot

her

met

als

adve

rsel

yaf

fect

edby

expo

sure

toth

ishi

gher

tem

pera

ture

.B

efor

eus

ing

MIL

-PR

F-46

010

(alo

wV

OC

ma-

teri

al)

inlie

uof

SAE

AS5

272,

Type

sI

and

II,

auth

oriz

atio

nfr

omth

eai

rcra

ftSP

Dor

the

mis

-si

leor

equi

pmen

tSP

Mis

requ

ired

.D

ono

tus

eth

ese

mat

eria

lson

rolle

rbe

arin

gsor

inar

eas

ex-

pose

dto

LO

X.

9150

-00-

985-

7255

CN

(1G

L)

Type

II(c

ure

@+

400°

F/+

205°

C)

9150

-00-

948-

6912

CN

(1Q

T)

9150

-00-

948-

7025

CN

(1G

L)

MIL

-PR

F-46

010

(sup

er-

sede

sM

IL-P

RF-

4601

0),

Type

III,

Col

or1

(Nat

ural

)

9150

-01-

416-

9506

CN

(1G

L)

Col

or2

(Bla

ck)

9150

-01-

416-

9509

CN

(1G

L)

TO 1-1-691

A-30

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se64

Lub

rica

nt,

Solid

Film

,Air

-Cur

ed,

Cor

rosi

onIn

hibi

t-in

g;N

AT

OC

ode

S-74

9

MIL

-L-2

3398

,Ty

peI

(Bul

k)91

50-0

0-95

4-74

22C

N(1

QT

)L

ubri

cant

can

beap

plie

dby

dipp

ing,

brus

hing

,or

spra

ying

for

use

onst

eel,

titan

ium

,or

alum

inum

bear

ing

surf

aces

whe

rem

oder

ate

wea

rlif

ean

dco

rros

ion

prot

ectio

nis

desi

red.

Itis

suita

ble

for

slid

ing

mot

ion

appl

ica-

tions

such

asin

plai

nsp

heri

cal

bear

ings

,fla

ptr

acks

,hi

nges

and

cam

surf

aces

,es

peci

ally

whe

reit

isno

tfe

asib

leto

use

the

type

ofso

lidfil

mlu

bric

ant

whi

chre

quir

esba

king

atan

elev

ated

tem

pera

ture

.U

sed

tore

pair

defe

cts

inSA

EA

S527

2an

dM

IL-

PRF-

4601

0co

atin

gs.

Type

II(P

ress

uriz

edSp

ray)

9150

-01-

260-

2534

CN

(16

OZ

)A

eros

olM

IL-P

RF-

4614

7,Ty

peI

(18

hour

cure

)Fo

rm1

(Bul

k)

9150

-01-

360-

1907

CN

(1Q

T)

Col

or1

(Nat

ural

)91

50-0

1-14

2-93

61C

N(1

GL

)

Col

or2

(Bla

ck)

9150

-01-

360-

1908

CN

(1Q

T)

9150

-01-

360-

1909

CN

(1G

L)

Form

2(P

ress

uriz

edSp

ray)

9150

-01-

360-

1903

CN

(12

OZ

)A

eros

olC

olor

1(N

atur

al)

9150

-01-

360-

1905

CN

(16

OZ

)A

eros

olC

olor

2(B

lack

)91

50-0

1-36

0-19

04C

N(1

2O

Z)

Aer

osol

9150

-01-

360-

1906

CN

(16

OZ

)A

eros

olN

EU

TR

AL

IZIN

GA

GE

NT

SA

ND

IND

ICA

TO

RM

AT

ER

IAL

S

TO 1-1-691

A-31

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se65

Fire

Ext

ingu

ishi

ngA

gent

,Aqu

eous

Film

Form

ing

Foam

(AFF

F)L

iq-

uid

Con

cent

rate

,fo

rFr

esh

and

Sea

Wat

er

MIL

-F-2

4385

,Ty

pe3

4210

-01-

139-

4972

CN

(5G

L)

Con

cent

rate

isin

tend

edfo

rus

ein

mec

hani

cal

foam

gene

ratin

geq

uipm

ent

such

asfir

efig

htin

gtr

ucks

orfo

amsp

rink

ler

syst

ems

for

extin

guis

hing

fires

.D

ilute

,an

dus

eth

eA

FFF

agen

tw

ithfr

esh

wat

erin

the

follo

win

gpr

opor

tion

toac

hiev

eop

timum

perf

or-

man

ce:

Type

3-3

part

sof

conc

entr

ate

to97

part

sw

ater

byvo

lum

ean

dTy

pe6-

6pa

rts

conc

entr

ate

to94

part

sw

ater

byvo

lum

e.

4210

-01-

144-

0291

DR

(55

GL

)

Type

642

10-0

1-05

6-83

43C

N(5

GL

)

4210

-01-

056-

0883

DR

(55

GL

)

66A

mm

oniu

mH

ydro

x-id

e,Te

chni

cal

A-A

-593

70(s

uper

sede

sO

-A-4

51),

Type

I(2

0to

30%

asam

mon

ia)

6810

-00-

584-

3793

BT

(1PT

)U

sed

asa

neut

raliz

ing

agen

tfo

rac

ids

inur

ine.

6810

-00-

817-

9929

BT

(1G

L)

Type

III

(9to

10%

asam

mon

ia)

6810

-00-

527-

2476

BT

(1Q

T)

67So

dium

Bic

arbo

nate

,Te

chni

cal

(Bak

ing

Soda

)

A-A

-374

(AST

MD

928)

6810

-00-

264-

6618

BX

(1L

B)

Use

dto

neut

raliz

esu

lfur

icac

idel

ectr

olyt

ede

posi

tsfr

omle

ad-a

cid

batte

ries

.68

10-0

0-29

7-00

92B

G(5

0L

B)

68So

dium

Phos

phat

e,M

onob

asic

,Anh

y-dr

ous,

Tech

nica

l

AN

SI/A

WW

AB

504

(su-

pers

edes

MIL

-S-1

3727

)68

10-0

0-28

1-18

58B

G(1

00L

B)

Use

dto

neut

raliz

epo

tass

ium

hydr

oxid

eel

ectr

olyt

ede

-po

sits

from

nick

el-c

ad-

miu

mba

tteri

es.

69B

oric

Aci

dA

-A-5

9282

(sup

erse

des

O-C

-265

)68

10-0

0-26

4-65

35B

T(5

00G

M)

Use

tone

utra

lize

pota

ssiu

mhy

drox

ide

elec

trol

yte

de-

posi

tsfr

omni

ckel

-cad

-m

ium

batte

ries

.

6810

-00-

824-

9090

BT

(3K

G)

6810

-00-

153-

0191

BX

(25

LB

)

TO 1-1-691

A-32

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se70

Phos

phor

icA

cid,

Tech

nica

l(O

r-th

opho

spho

ric

Aci

d)

A-A

-558

20(s

uper

sede

sO

-O-6

70),

Cla

ss1

(85%

acid

)

6810

-00-

264-

6722

BT

(7L

B)

One

oftw

oco

mpo

nent

sus

edto

mak

ebr

omot

hy-

mol

blue

indi

catin

gso

lu-

tion

tode

term

ine

the

loca

-tio

nof

cont

amin

atio

n(e

lect

roly

tesp

ills)

from

nick

el-c

adm

ium

batte

ries

and

toin

dica

tew

heth

erth

ese

area

sha

vebe

enco

mpl

etel

yne

utra

lized

.71

Bro

mot

hym

olB

lue

Indi

cato

rSo

lutio

nM

IL-B

-118

4568

10-0

0-28

1-42

70B

T(½

L)

One

oftw

oco

mpo

nent

sus

edto

mak

ean

indi

cato

rso

lutio

nfo

rde

tect

ing

nick

el-c

adm

ium

batte

rysp

ills

and

tode

term

ine

whe

ther

area

sha

vebe

enco

mpl

etel

yne

utra

lized

.

6810

-00-

281-

4271

BT

(4O

Z)

72L

itmus

Pape

rC

omm

erci

alIt

em-

CA

GE

Cod

e#2

2537

Blu

eL

itmus

Pape

r

6640

-00-

290-

0146

HD

(100

SH)

Col

orch

ange

tore

din

di-

cate

sac

idpr

esen

t(l

ead-

acid

batte

ries

).R

edL

itmus

Pape

r66

40-0

0-29

0-01

47H

D(1

00SH

)C

olor

chan

geto

blue

indi

-ca

tes

base

/alk

ali

pres

ent

(nic

kel-

cadm

ium

batte

r-ie

s).

PRO

TE

CT

IVE

MA

TE

RIA

LS

73B

arri

erM

ater

ials

,G

reas

epro

of,

Wa-

terp

roof

,Fl

exib

le,

Hea

t-Se

alab

le

MIL

-PR

F-12

1,Ty

peI

(Hea

vydu

ty)

Gra

deA

,C

lass

1

8135

-00-

292-

9719

RO

(36

inx

100

YD

)G

ener

alpu

rpos

em

aski

ngm

ater

ial

used

for

prot

ect-

ing

equi

pmen

tan

dsu

p-pl

ies

duri

ngtr

ansp

orta

tion

and

stor

age

unde

ral

lcl

i-m

ate

cond

ition

san

dm

ask-

ing

area

sre

quir

ing

prot

ec-

tion

duri

ngcl

eani

ng,

corr

osio

nre

mov

al,

surf

ace

trea

tmen

t,an

dpa

intin

gop

erat

ions

.

8135

-00-

233-

3871

RO

(36

inx

200

YD

)

8135

-00-

543-

6574

RO

(48

inx

100

YD

)

Type

II(M

ediu

mdu

ty)

Gra

deA

,C

lass

181

35-0

0-22

4-88

85R

O(3

6in

x20

0Y

D)

8135

-00-

543-

6573

RO

(12

inx

200

YD

)

TO 1-1-691

A-33

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se74

Bar

rier

Mat

eria

l,Fl

exib

le,

Gre

asep

roof

Wat

erR

esis

tant

,H

eat-

Seal

able

MIL

-PR

F-13

1(s

uper

-se

des

MIL

-B-1

31),

Cla

ss1

(Non

-wov

enpl

astic

back

)

8135

-00-

282-

0565

RO

(36

inx

200

YD

)U

sed

for

pres

erva

tion

(e.g

.se

alin

gai

rcra

ft,

mis

sile

,or

equi

pmen

top

enin

gs,

pro-

tect

ion

ofca

nopi

es,

tem

-po

rary

wal

kway

prot

ec-

tion)

duri

ngcl

eani

ng,

corr

osio

nre

mov

al,

surf

ace

trea

tmen

t,an

dpa

intin

gop

erat

ions

.It

isal

sous

edto

prot

ect

part

sin

stor

age

orbe

ing

tran

spor

ted

whi

chre

quir

ean

abso

lute

moi

s-tu

reva

por

proo

fba

rrie

r.

NO

TE

Alw

ays

inst

all

with

the

plas

ticco

ated

side

to-

war

dth

epa

rtan

d/or

surf

ace.

75K

raft

Pape

r,U

n-tr

eate

d,(B

row

nin

Col

or)

A-A

-203

(sup

erse

des

UU

-P-2

68),

Styl

e1

(She

ets)

30Po

und

ba-

sis

wei

ght

8135

-00-

290-

3408

SH(2

x3

ft;

850

EA

)G

ener

alw

rapp

ing

appl

ica-

tions

and

prot

ectio

nof

surr

ound

ing

surf

ace

area

sdu

ring

abra

sive

blas

ting,

spra

ypa

intin

g,se

alan

tap

plic

atio

n,et

c.,

whe

rea

wat

erpr

oof

and/

orm

ois-

ture

vapo

rpr

oof

mas

king

mat

eria

lis

not

requ

ired

.

70Po

und

basi

sw

eigh

t81

35-0

0-29

0-55

04SH

(3x

4ft

;20

0E

A)

Styl

e2

(Rol

ls)

50Po

und

basi

sw

eigh

t81

35-0

1-33

7-53

70R

O(3

x20

0ft

)

8135

-00-

160-

7764

RO

(3x

980

ft)

60Po

und

basi

sw

eigh

t81

35-0

0-16

0-77

68R

O(3

x82

0ft

)81

35-0

0-16

0-77

69R

O(4

x82

0ft

)70

Poun

dba

sis

wei

ght

8135

-00-

160-

7771

RO

(3x

700

ft)

8135

-00-

160-

7772

RO

(4x

700

ft)

80Po

und

basi

sw

eigh

t81

35-0

0-16

0-77

76R

O(3

x61

5ft

)81

35-0

0-16

0-77

78R

O(4

x61

5ft

)

TO 1-1-691

A-34

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se76

Pain

tM

aski

ngPa

per

with

Adh

esiv

eB

ack

(Lig

htB

row

nin

Col

or)

Rea

dy-M

askt

TM

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

850D

C

Ope

nPu

rcha

seR

O(2

inx

180

ft)

Pape

rm

aski

ngta

pew

ithad

hesi

veal

ong

one

edge

.Pr

otec

tssu

rfac

esfr

ompa

int

spla

tters

and

over

-sp

ray.

Eas

yto

appl

yan

dco

mes

off

clea

nly

with

noad

hesi

vetr

ansf

er.

Ope

nPu

rcha

seR

O(3

inx

400

ft)

Ope

nPu

rcha

seR

O(3

¼in

x75

ft)

77Pl

astic

Shee

t,Po

ly-

olefi

n(C

lear

)A

-A-3

174

(sup

erse

des

L-P

-378

),Ty

peI

(Nor

-m

alst

reng

thpo

lyet

hyl-

ene)

,C

lass

1(n

on-f

ood

use)

,G

rade

A(l

owsl

ip),

Fini

sh1

(un-

trea

ted)

8135

-00-

584-

0610

RO

(8ft

x10

0ft

)Pr

otec

tion

ofac

rylic

airc

raft

cano

pies

duri

ngw

ashi

ngop

erat

ions

.

78Ta

pes,

Pres

sure

Sen-

sitiv

eA

dhes

ive,

Pres

erva

tion

and

Seal

ing

(Bla

ckin

Col

or)

SAE

AM

S-T-

2208

5(s

u-pe

rsed

esM

IL-T

-220

85)

7510

-00-

852-

8179

RO

(1in

x36

YD

)Pl

astic

pres

erva

tion

and

seal

ing

tape

used

for

hold

-in

gm

ost

barr

ier

mat

eria

lsin

plac

edu

ring

stor

age

orsh

ipm

ent

and

clea

ning

and

corr

osio

nre

mov

alop

era-

tions

.E

ffec

tive

for

man

you

tdoo

rap

plic

atio

nsan

dca

nbe

used

onm

etal

sor

pain

ted

surf

aces

with

clea

nre

mov

alup

to2

year

saf

ter

initi

alus

e.

7510

-00-

852-

8180

RO

(2in

x36

YD

)

Type

II(u

sew

/or

w/o

anov

erco

atin

g)75

10-0

0-88

5-35

10R

O(2

½in

x36

YD

)

7510

-00-

926-

8939

RO

(3in

x36

YD

)

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

481

7510

-00-

916-

9659

RO

(4in

x36

YD

)

7510

-00-

926-

8941

RO

(6in

x36

YD

)N

OT

E

Do

not

use

onac

rylic

orpo

lyca

rbon

ate

cano

pies

and

win

dscr

eens

.

TO 1-1-691

A-35

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se79

Tape

s,Pr

essu

reSe

n-si

tive

Adh

esiv

e,M

aski

ng,

Non

-st

aini

ng,

for

Air

-cr

aft

Pain

ting

Ap-

plic

atio

ns

SAE

AM

S-T-

2159

5(s

u-pe

rsed

esM

IL-T

-21

595)

,Ty

peI

(Cre

pepa

per

back

ing)

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

231/

Nat

u-ra

lC

olor

7510

-01-

371-

3239

RO

(½in

x60

YD

)C

onfo

rmab

lecr

epe

pape

rta

peus

edfo

rm

aski

ngof

eith

erfla

tor

cont

oure

dsu

rfac

espr

ior

topa

intin

gan

dse

alan

tap

plic

atio

ns.

Tape

can

beus

edat

bak-

ing

tem

pera

ture

sup

to+

250°

F(+

121°

C)

for

1ho

uran

dca

nbe

rem

oved

with

out

adhe

sive

tran

sfer

.Ta

pesh

all

not

besu

b-je

cted

topr

olon

ged

peri

-od

sof

outd

oor

expo

sure

orsu

nlig

htbe

caus

eit

will

beco

me

very

diffi

cult

tore

mov

ean

dw

illle

ave

tape

and

adhe

sive

resi

-du

es.

7510

-01-

371-

3234

RO

(¾in

x60

YD

)75

10-0

1-37

1-32

38R

O(1

inx

60Y

D)

7510

-01-

371-

3236

RO

(1½

inx

60Y

D)

7510

-01-

371-

3237

RO

(2in

x60

YD

)75

10-0

1-37

1-32

35R

O(3

inx

60Y

D)

Type

III

(Pla

stic

back

ing)

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

218/

Lig

htG

reen

Col

or;

Fine

Lin

eTa

pe®

7510

-01-

158-

0035

RO

(¼in

x60

YD

)T

hin,

plas

ticta

peus

edfo

rfin

elin

em

aski

ng,

inpa

r-tic

ular

whe

reco

lor

sepa

ra-

tion

isin

volv

ed,

and

dur-

ing

pain

tto

uch-

up,

and

for

othe

rm

aski

ngan

dho

ldin

gap

plic

atio

ns.

Tape

shal

lno

tbe

subj

ecte

dto

pro-

long

edpe

riod

sof

outd

oor

expo

sure

orsu

nlig

htbe

-ca

use

itw

illbe

com

eve

rydi

fficu

ltto

rem

ove

and

will

leav

eta

pean

dad

he-

sive

resi

dues

.

7510

-01-

158-

6606

RO

(½in

x60

YD

)75

10-0

1-15

8-77

78R

O(¾

inx

60Y

D)

7510

-01-

158-

6605

RO

(1in

x60

YD

)75

10-0

1-15

8-66

04R

O(1

½in

x60

YD

)75

10-0

1-15

8-66

03R

O(2

inx

60Y

D)

7510

-01-

158-

6607

RO

(3in

x60

YD

)

TO 1-1-691

A-36

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se80

Tape

s,Pr

essu

reSe

n-si

tive

Adh

esiv

e,fo

rM

aski

ngD

urin

gPa

int

Rem

oval

Op-

erat

ions

SAE

AM

S-T-

2339

7(s

u-pe

rsed

esM

IL-T

-23

397)

,Ty

peII

(Alu

-m

inum

foil

back

ing

-72

hour

prot

ectio

n)

7510

-00-

806-

4669

RO

(½in

x60

YD

)A

lum

inum

foil

back

mas

k-in

gta

peus

edfo

rpr

otec

t-in

gsu

rrou

ndin

gsu

rfac

esdu

ring

pain

tre

mov

alop

-er

atio

nsan

dch

emic

alan

dso

me

mec

hani

cal

corr

o-si

onre

mov

alop

erat

ions

.A

lum

inum

back

ing

pro-

vide

sex

celle

ntre

flect

ion

ofbo

thhe

atan

dlig

ht.

Tape

can

beus

edei

ther

indo

ors

orou

tdoo

rsfo

rm

any

long

term

appl

ica-

tions

.U

seta

pean

dde

cal

appl

icat

or,

Item

No.

83,

toap

ply

this

tape

tosu

rfac

es.

7510

-00-

654-

9811

RO

(¾in

x60

YD

)75

10-0

0-72

0-75

16R

O(1

inx

60Y

D)

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

425

7510

-00-

684-

8803

RO

(2in

x60

YD

)N

OT

E

Use

only

3MC

o.,

PN42

5ta

pefo

rai

rcra

ftch

emic

alpa

int

rem

oval

oper

atio

ns,

asal

lot

her

tape

sw

illno

tho

ldup

for

thes

eex

tend

eddw

ell

time

oper

atio

ns.

7510

-00-

816-

8077

RO

(3in

x60

YD

)75

10-0

0-98

2-39

55R

O(4

inx

60Y

D)

7510

-01-

179-

0662

RO

(6in

x60

YD

)

TO 1-1-691

A-37

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se81

Tape

s,Pr

essu

reSe

n-si

tive

Adh

esiv

e,M

aski

ng

A-A

-883

(sup

erse

des

PPP-

T-42

),Ty

peII

(Fla

tpa

per

back

ing)

7510

-01-

026-

4661

RO

(½in

x60

YD

)T

his

solv

ent

resi

stan

tta

peis

idea

lfo

rst

raig

htlin

epa

int

mas

king

oper

atio

ns.

The

1in

wid

thof

the

3MC

o.,

PN25

0ta

peis

the

re-

quir

edta

pefo

rpe

rfor

min

gth

epa

int

wet

tape

adhe

-si

onte

st.

Bec

ause

ofits

high

stre

ngth

,it

isgo

odfo

rho

ldin

g,bu

ndlin

g,an

dw

rapp

ing

ona

vari

ety

ofsu

rfac

es.

Itis

not

reco

m-

men

ded

for

outd

oor

expo

-su

rebe

caus

eit

beco

mes

very

diffi

cult

tore

mov

e.

7510

-00-

290-

2024

RO

(¾in

x60

YD

)

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

250/

Tan

Col

or

7510

-00-

283-

0612

RO

(1in

x60

YD

)

7510

-00-

290-

2027

RO

(1½

inx

60Y

D)

7510

-00-

290-

2026

RO

(2in

x60

YD

)75

10-0

0-26

6-66

94R

O(3

inx

60Y

D)

82A

bras

ive

Bla

stin

gTa

pe,

Impa

ctR

e-si

stan

t(L

ight

Gre

enin

Col

or)

Com

mer

cial

Prod

uct

3MC

o.,

CA

GE

Cod

e#5

2152

,PN

500

7510

-01-

300-

2124

RO

(1in

x10

YD

)U

sed

for

mas

king

topr

otec

tai

rcra

ft,

mis

sile

,an

deq

uipm

ent

surf

aces

duri

ngab

rasi

vebl

astin

gco

rros

ion

rem

oval

oper

atio

ns.

7510

-01-

300-

2125

RO

(2in

x10

YD

)75

10-0

1-30

0-21

26R

O(3

inx

10Y

D)

7510

-01-

300-

2127

RO

(4in

x10

YD

)83

App

licat

or,

Tape

and

Dec

al(M

ade

ofH

ard

Plas

tic)

Com

mer

cial

Prod

uct

3MC

o.,

CA

GE

Cod

e#7

6381

,PN

P.A

.-1

5120

-00-

628-

5569

BX

(25

EA

)Id

eal

for

appl

ying

mas

king

tape

s(e

spec

ially

Item

No.

80al

umin

umfo

ilta

pe),

anti-

eros

ion

lead

ing

edge

tape

,de

cals

,et

c.(H

ard

plas

ticto

olw

ithta

pere

ded

ges;

4in

Lx

2¾

inW

)Ta

pe,

Pres

sure

Sens

i-tiv

e,fo

rW

etTa

pePa

intA

dhes

ion

Test

ing

3MC

o.,

CA

GE

Cod

e#7

8381

,PN

250

7510

-00-

266-

6694

RO

(1in

Wx

60Y

DL

)U

sed

tope

rfor

mw

etta

pead

hesi

onte

stin

gon

new

lyap

plie

dan

dol

dpa

int

sys-

tem

sto

dete

rmin

epr

oper

pain

tad

hesi

on.

TO 1-1-691

A-38

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seSE

AL

AN

TS

AN

DSE

AL

ING

AC

CE

SSO

RIE

SK

T-

Two-

Part

Can

Kit

(Bas

ean

dA

ccel

erat

or)

PMF

-Pr

e-m

ixed

and

Froz

enSC

-Se

mki

tC

artr

idge

84Se

alin

gan

dC

oatin

gC

ompo

und,

Cor

ro-

sion

Inhi

bitiv

e

MIL

-PR

F-81

733

(sup

er-

sede

sM

IL-S

-817

33),

Cla

ss1

(Pol

ysul

fide)

;G

rade

A(C

hrom

ate

Inhi

bito

rs),

Type

I(B

rush

able

)

Use

dfo

rse

alin

gfa

ying

sur-

face

san

dw

etin

stal

latio

nof

fast

ener

son

perm

anen

tst

ruct

ures

.It

isal

soth

epr

efer

red

seal

ant

for

form

-in

-pla

ce(F

IP)

seal

son

door

s,re

mov

able

pane

ls,

and

seal

ing

gaps

and

seam

s.I-

½80

30-0

0-00

8-72

07K

T(1

PT)

NO

TE

Do

not

use

onin

side

ofin

tegr

alfu

elta

nks.

8030

-00-

009-

5022

KT

(1Q

T)

I-2

8030

-00-

008-

7196

KT

(1PT

)80

30-0

0-76

2-88

07K

T(1

QT

)80

30-0

1-36

1-18

14SC

(3½

OZ

)Ty

peII

(Gun

orsp

atul

aap

plic

atio

n) II-½

8030

-00-

008-

7198

KT

(1PT

)80

30-0

1-09

7-45

19K

T(1

GL

)80

30-0

1-18

4-03

28SC

(2½

OZ

)80

30-0

1-18

4-03

29SC

(6O

Z)

II-2

8030

-01-

124-

7622

KT

(½PT

)80

30-0

0-00

9-50

23K

T(1

PT)

8030

-00-

008-

7200

KT

(1Q

T)

8030

-01-

333-

3954

PMF

(2½

OZ

CA

)80

30-0

1-33

3-48

21PM

F(6

OZ

CA

)80

30-0

1-19

6-19

58SC

(2½

OZ

)

TO 1-1-691

A-39

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se80

30-0

1-18

4-03

30SC

(6O

Z)

II-4

8030

-00-

008-

7201

KT

(1PT

)80

30-0

0-00

8-72

02K

T(1

QT

)Ty

peII

I(S

pray

gun

ap-

plic

atio

n) III-

180

30-0

0-00

8-72

03K

T(1

PT)

8030

-00-

871-

8489

KT

(1G

L)

Type

IV(F

ayin

gsu

rfac

eap

plic

atio

ns;

gun

orsp

atul

a;ex

tend

edcu

retim

e)IV

-12

8030

-01-

395-

2726

KT

(1PT

)80

30-0

0-15

1-99

73K

T(1

GL

)IV

-24

8030

-01-

395-

2728

KT

(1PT

)80

30-0

0-00

8-72

06K

T(1

QT

)80

30-0

1-36

3-65

04PM

F(6

OZ

CA

)IV

-48

8030

-01-

192-

2807

KT

(½PT

)80

30-0

1-39

5-27

29K

T(1

PT)

8030

-00-

028-

8495

KT

(1Q

T)

85Se

alin

gC

ompo

und,

Tem

pera

ture

Res

is-

tant

,In

tegr

alFu

elTa

nks

and

Fuel

Cel

lC

aviti

es,

Hig

hA

dhes

ion

(Pol

ysul

-fid

e)

SAE

AM

S-S-

8802

(su-

pers

edes

MIL

-S-8

802)

,Ty

peII

(Man

gane

sedi

oxid

ecu

red)

Cla

ssA

(Bru

shab

le)

Use

dfo

rfil

let

and

brus

hse

alin

gin

inte

gral

fuel

tank

san

dfu

elce

llca

vi-

ties.

Thi

sse

alan

tis

man

-ga

nese

diox

ide

cure

dan

ddo

esn’

tco

ntai

nan

ych

ro-

mat

esor

othe

rco

rros

ion

inhi

bito

rs.

A-½

8030

-00-

753-

4596

KT

(½PT

)80

30-0

0-96

5-20

04K

T(1

PT)

8030

-00-

842-

8127

KT

(1G

L)

8030

-00-

753-

5008

SC(2

½O

Z)

8030

-00-

753-

5010

SC(6

OZ

)A

-180

30-0

1-38

6-36

56K

T(1

QT

)A

-280

30-0

0-75

3-45

98K

T(½

PT)

8030

-00-

753-

5343

KT

(1PT

)

TO 1-1-691

A-40

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se80

30-0

0-72

3-53

44K

T(1

QT

)80

30-0

0-84

1-68

32K

T(1

GL

)80

30-0

1-36

3-66

71PM

F(2

½O

ZC

A)

8030

-01-

363-

6505

PMF

(6O

ZC

A)

8030

-00-

753-

5003

SC(2

½O

Z)

8030

-00-

753-

5009

SC(6

OZ

)C

lass

B(G

unan

dsp

atul

aap

plic

atio

n) B-½

8030

-00-

753-

4597

KT

(½PT

)80

30-0

0-17

4-25

99K

T(1

PT)

8030

-00-

080-

1549

KT

(1Q

T)

8030

-00-

841-

6831

KT

(1G

L)

8030

-00-

753-

5007

SC(2

½O

Z)

8030

-00-

753-

5004

SC(6

OZ

)B

-180

30-0

1-33

7-94

08SC

(2½

OZ

)80

30-0

1-37

6-85

04K

T(1

GL

)B

-280

30-0

0-75

3-45

99K

T(½

PT)

8030

-00-

723-

2746

KT

(1PT

)80

30-0

0-68

5-09

15K

T(1

QT

)80

30-0

0-57

9-84

53K

T(1

GL

)80

30-0

1-33

3-48

23PM

F(2

4E

A,

2½

OZ

CA

)80

30-0

1-33

3-48

22PM

F(2

4E

A,

6O

ZC

A)

8030

-00-

753-

5006

SC(2

½O

Z)

8030

-00-

753-

5005

SC(6

OZ

)B

-480

30-0

0-17

4-25

98K

T(1

PT)

8030

-00-

850-

5717

KT

(1Q

T)

8030

-00-

850-

0759

SC(2

.5O

Z)

8030

-00-

850-

0758

SC(6

OZ

)C

lass

C(E

xten

ded

as-

sem

bly

time)

TO 1-1-691

A-41

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seC

-20

8030

-01-

048-

3772

KT

(1PT

)80

30-0

0-42

7-26

61K

T(1

GL

)80

30-0

0-15

2-00

12SC

(6O

Z)

C-8

080

30-0

0-70

9-32

78K

T(1

QT

)80

30-0

0-43

2-15

44K

T(1

GL

)86

Seal

ing

Com

poun

d,In

tegr

alFu

elTa

nks,

and

Gen

eral

Purp

ose,

Inte

rmit-

tent

Use

to36

0°F

(182

°C

)(P

olys

ul-

fide)

SAE

AM

S32

76(s

uper

-se

des

MIL

-S-8

3430

),C

lass

A(B

rush

able

)

Use

for

fille

tse

alin

gof

join

tsan

dse

ams

and

brus

hse

alin

gor

over

coat

-in

gof

fast

ener

sin

inte

gral

fuel

tank

san

dfu

elce

llca

vitie

s,in

part

icul

arw

here

tem

pera

ture

sof

360°

F(1

82°

C)

are

expe

-ri

ence

don

anin

term

itten

tba

sis.

Thi

sse

alan

tis

man

-ga

nese

diox

ide

cure

dan

ddo

esn’

tco

ntai

nan

ych

ro-

mat

esor

othe

rco

rros

ion

inhi

bito

rs.

A-½

8030

-00-

602-

0107

KT

(½PT

)

8030

-01-

395-

5474

KT

(1PT

)

8030

-01-

036-

6936

KT

(1Q

T)

8030

-00-

312-

6128

SC(6

OZ

)A

-280

30-0

0-60

2-00

49K

T(½

PT)

8030

-00-

602-

0051

KT

(1G

L)

8030

-01-

387-

1001

PMF

(6O

Z)

Cla

ssB

(Gun

orsp

atul

aap

plic

atio

n) B-¼

8030

-01-

214-

0374

SC(6

OZ

)B

-½80

30-0

0-60

2-00

39K

T(½

PT)

8030

-00-

348-

7888

KT

(1PT

)80

30-0

1-25

2-79

63SC

(2½

OZ

)80

30-0

0-60

2-00

45SC

(6O

Z)

TO 1-1-691

A-42

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seB

-280

30-0

0-48

5-32

37K

T(1

PT)

8030

-01-

066-

6444

KT

(1Q

T)

8030

-00-

585-

4900

KT

(1G

L)

8030

-01-

383-

4185

PMF

(2½

OZ

)80

30-0

1-38

3-39

53PM

F(6

OZ

CA

)80

30-0

0-56

0-87

58SC

(6O

Z)

B-4

8030

-01-

195-

0655

KT

(1Q

T)

B-6

8030

-00-

602-

0035

SC(6

OZ

)80

30-0

1-38

7-10

61PM

F(6

OZ

CA

)C

-½80

30-0

1-31

1-56

53K

T(1

QT

)87

Seal

ing

Com

poun

d,L

owA

dhes

ion,

Cor

rosi

onIn

hibi

t-in

g(N

on-C

hro-

mat

e),

Poly

sulfi

de

PNPR

-177

3(s

uper

sede

sPR

-140

3G)

CA

GE

Cod

e#8

3574

Thi

sm

ater

ial

isa

two-

part

,no

n-ch

rom

ate

type

corr

o-si

onin

hibi

ting,

low

adhe

-si

on,

fuel

resi

stan

tse

alan

tus

edfo

rfa

ysu

rfac

ese

al-

ing

ofac

cess

door

s,re

-m

ovab

lepa

nels

and

stru

c-tu

res,

and

the

head

sof

thei

rat

tach

ing

fast

ener

s.It

can

also

beus

edto

mak

eFI

Pga

sket

san

dre

pair

dam

aged

area

sof

FIP

gas-

kets

.It

shou

ldno

tbe

used

for

seal

ing

insi

dein

tegr

alfu

elta

nks,

inhi

ghte

m-

pera

ture

area

s,or

onpe

r-m

anen

tlyin

stal

led

stru

c-tu

res.

Cla

ssB

(Gun

orsp

atul

aap

plic

atio

n) B-½

8030

-01-

418-

5414

SC(2

½O

Z)

8030

-01-

418-

5418

SC(6

OZ

)

B-2

8030

-01-

104-

5396

KT

(1Q

T)

8030

-01-

418-

5415

SC(2

½O

Z)

8030

-01-

418-

5417

SC(6

OZ

)

TO 1-1-691

A-43

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se88

Seal

ing

Com

poun

d,L

owA

dhes

ion,

Cor

rosi

onIn

hibi

t-in

g,fo

rR

emov

able

Pane

lsan

dFu

elTa

nkIn

spec

tion

Plat

es

SAE

AM

S32

67(s

uper

-se

des

MIL

-S-8

784)

Thi

sm

ater

ial

isa

two-

part

,lo

wad

hesi

on,

fuel

resi

s-ta

ntse

alan

tth

atdo

esn’

tco

ntai

nan

yco

rros

ion

in-

hibi

tors

.It

can

beus

edfo

rfa

ysu

rfac

ese

alin

gof

re-

mov

able

stru

ctur

essu

chas

acce

ssdo

ors,

floor

pane

lsan

dpl

ates

,fu

elta

nkin

-sp

ectio

npl

ates

,an

dot

her

rem

ovab

lepa

nels

.It

shou

ldno

tbe

used

for

seal

ing

insi

dein

tegr

alfu

elta

nks,

inhi

ghte

mpe

ratu

rear

eas,

oron

perm

anen

tlyin

stal

led

stru

ctur

es.

Cla

ssA

(Bru

shab

le)

A-½

8030

-00-

291-

8380

KT

(½PT

)

A-2

8030

-00-

584-

4399

KT

(½PT

)

8030

-01-

127-

8281

KT

(1PT

)80

30-0

0-15

2-00

62SC

(2½

OZ

)C

lass

B(G

unor

spat

ula

appl

icat

ion) B-½

8030

-00-

598-

2910

KT

(½PT

)80

30-0

0-88

1-39

33K

T(1

PT)

8030

-01-

028-

4336

KT

(1Q

T)

8030

-01-

065-

0306

KT

(1G

L)

8030

-00-

152-

0022

SC(2

.5O

Z)

8030

-01-

365-

3912

SC(6

OZ

)80

30-0

0-15

2-00

21SC

(8O

Z)

B-2

8030

-00-

616-

9191

KT

(½PT

)80

30-0

0-68

0-20

41K

T(1

PT)

8030

-01-

371-

9247

PMF

(24

EA

,2½

OZ

CA

)80

30-0

1-37

1-92

46PM

F(2

4E

A,

6O

ZC

A)

8030

-01-

383-

4993

SC(6

OZ

)

TO 1-1-691

A-44

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se89

Seal

ing

Com

poun

d,A

ircr

aft,

Fire

wal

lSA

EA

MS

3374

(sup

er-

sede

sM

IL-S

-382

49),

Type

1(O

neco

mpo

-ne

nt;

silic

one)

8040

-01-

168-

0077

CA

(12

OZ

)Se

alin

gai

rcra

ftfir

ewal

lst

ruct

ures

expo

sed

tove

ryhi

ghte

mpe

ratu

res

topr

e-ve

ntth

epa

ssag

eof

air

and

vapo

rs.

Itw

illw

ith-

stan

d40

0°F

(204

°C

)co

ntin

uous

lyan

d20

00°

F(1

093°

C)

for

atle

ast

15m

inut

es.

Type

4(T

wo

com

pone

nt;

SAE

AM

S33

74/4

and/

orM

IL-S

-382

49,

Type

I)

8030

-00-

783-

8898

KT

(½PT

)

8030

-00-

723-

5345

KT

(1PT

)

8030

-01-

033-

3485

KT

(1G

L)

8030

-01-

364-

7362

PMF

(24

EA

,2

½O

ZC

A)

8030

-01-

365-

0049

PMF

(24

EA

,6

OZ

CA

)80

30-0

1-36

4-73

59SC

(2½

OZ

)80

30-0

0-78

3-88

86SC

(6O

Z)

90Se

alin

gC

ompo

und,

Poly

thio

ethe

r,fo

rA

ircr

aft

Stru

ctur

es,

Fuel

and

Hig

hTe

mpe

ratu

reR

esis

-ta

nt,

Fast

Cur

ing

atA

mbi

ent

(Roo

m)

and

Low

Tem

pera

-tu

res

SAE

-AM

S327

7,G

rade

A,

Type

I(F

uel

resi

s-ta

nt-

use

at-8

0°to

+30

0°F/

-62°

to+

149°

Cco

ntin

uous

and

inte

r-m

itten

tto

+40

0°F/

+20

4°C

)

Use

dfo

rfa

ysu

rfac

ese

alin

gan

dre

pair

ing

fille

tan

dfa

sten

erse

als

inin

tegr

alfu

elta

nks.

Itca

nal

sobe

used

for

over

coat

ing

fas-

tene

rsan

dse

alin

gse

ams

and

join

ts.

Cla

ssA

(Bru

shab

le)

NO

TE

•Ty

peI

com

poun

dsre

quir

eth

eus

eof

anad

hesi

onpr

omot

er(e

.g.

PR-1

86)

whe

reas

Type

IIco

mpo

unds

dono

t.

•N

otfo

rus

eon

air-

craf

tw

inds

hiel

dsan

dca

nopi

es.

A-½

8030

-01-

330-

6568

SC(2

½O

Z)

8030

-01-

330-

0730

SC(6

OZ

)

A-1

8030

-01-

330-

0735

SC(2

½O

Z)

Cla

ssB

(Gun

orsp

atul

aap

plic

atio

n)

TO 1-1-691

A-45

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seB

-¼80

30-0

1-29

0-51

34SC

(2½

OZ

)80

30-0

1-29

0-51

35SC

(6O

Z)

B-½

8030

-01-

290-

5136

SC(2

½O

Z)

8030

-01-

290-

5137

SC(6

OZ

)B

-280

30-0

1-29

0-51

38SC

(2½

OZ

)80

30-0

1-29

0-51

39SC

(6O

Z)

Type

II(F

uel

resi

stan

t,co

rros

ion

inhi

bitin

g;us

eat

-80°

to+

300°

F/-

62°

to+

149°

Cco

n-tin

uous

and

inte

rmit-

tent

to+

360°

F/+

182°

C)

Cla

ssB

(Gun

orSp

atul

aap

plic

atio

n) B-¼

8030

-01-

364-

3883

SC(2

½O

Z)

8030

-01-

364-

3886

SC(6

OZ

)B

-½80

30-0

1-36

4-38

82SC

(2½

OZ

)80

30-0

1-36

4-38

85SC

(6O

Z)

B-2

8030

-01-

364-

3881

SC(2

½O

Z)

8030

-01-

364-

3884

SC(6

OZ

)

TO 1-1-691

A-46

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se91

Adh

esiv

es-S

eala

nts,

Silic

one,

RT

V,

Non

corr

osiv

e(f

orU

sew

ithSe

nsiti

veM

etal

san

dE

quip

-m

ent)

MIL

-A-4

6146

,G

roup

I(G

ener

alpu

rpos

e)Ty

peI

(Thi

xotr

opic

/pas

tety

pe)

Whi

te

8040

-01-

331-

7133

TU

(3O

Z)

The

sear

ero

omte

mpe

ratu

revu

lcan

izin

g(R

TV

)si

li-co

nese

alan

tsus

edon

sen-

sitiv

em

etal

san

deq

uip-

men

t,in

part

icul

aron

elec

tron

ics

equi

pmen

tan

dan

tenn

as,

atte

mpe

ratu

res

upto

+40

0°F

(204

°C

).T

hey

cure

atro

omte

m-

pera

ture

upon

cont

act

with

moi

stur

ein

the

air.

Toim

prov

ead

hesi

on,

use

thes

ese

alan

tsaf

ter

appl

y-in

ga

prim

er(I

tem

No.

92)

spec

ified

byth

em

anuf

ac-

ture

rto

the

surf

aces

.K

it(K

T)

incl

udes

the

requ

ired

prim

er,

but

tube

(TU

)an

dca

rtri

dge

(CA

)do

not.

Whi

te80

40-0

1-33

1-80

46C

A(1

2O

Z)

Whi

te80

40-0

0-11

8-26

95K

T(3

OZ

TU

w/½

OZ

BT

prim

er)

Whi

te80

40-0

1-93

8-15

35K

T(1

2O

ZC

Aw

/10

OZ

BT

prim

er)

NO

TE

The

sese

alan

tsar

eno

tfu

elre

sist

ant

and

they

shal

lno

tbe

used

infu

elw

etar

eas

Gra

y80

40-0

1-05

7-00

91C

N(1

PT)

Gra

y80

40-0

1-39

4-20

26K

T(5

GL

CO

w/½

GL

BT

prim

er)

Cle

ar80

40-0

1-14

8-17

59C

N(1

PT)

Cle

ar80

40-0

1-38

0-64

28T

U(3

OZ

)C

lear

8040

-00-

845-

4304

PT(1

6O

Z)

Cle

ar80

40-0

1-39

4-20

24K

T(5

GL

CO

w/½

GL

BT

prim

er)

Type

II(S

elf-

leve

ling

liqui

dty

pe)

Cle

ar80

40-0

1-33

1-71

27T

U(3

OZ

)

Cle

ar80

40-0

1-33

1-71

34C

N(1

PT)

TO 1-1-691

A-47

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seC

lear

8040

-00-

927-

1513

KT

(1PT

CN

w/1

0O

ZB

Tpr

imer

)C

lear

8040

-01-

009-

1562

KT

(3O

ZT

Uw

/½O

ZB

Tpr

imer

)G

roup

II(H

igh

stre

ngth

),Ty

peII

I;Ty

peI

for

old

spec

ifica

tion;

(Thi

xo-

trop

ic/p

aste

type

)C

lear

8040

-00-

117-

8510

TU

(3O

Z)

Cle

ar80

40-0

1-39

4-37

35T

U(3

OZ

)C

lear

8040

-01-

450-

4013

TU

(3O

Z)

Cle

ar80

40-0

1-37

5-48

03C

A(6

OZ

)C

lear

8040

-01-

082-

9128

CA

(12

OZ

)G

ray

8040

-00-

145-

0020

TU

(3O

Z)

Gra

y80

40-0

1-37

5-48

05T

U(3

OZ

)G

ray

8040

-01-

331-

7128

CA

(12

OZ

)G

ray

8040

-01-

275-

5052

KT

(12

OZ

CA

w/1

OZ

BT

prim

er)

Tra

nslu

cent

8040

-01-

450-

5419

CA

(6O

Z)

Tra

nslu

cent

8040

-01-

450-

9184

KT

(5G

LC

Ow

/½G

LB

Tpr

imer

)Ty

peII

(Sel

f-le

velin

gliq

uid

type

)C

lear

8040

-01-

441-

0671

KT

(3O

ZT

Uw

/½O

ZB

Tpr

imer

)G

roup

III

(Hig

hte

mpe

ra-

ture

)Ty

peI

(Thi

xo-

trop

ic/p

aste

type

)G

ray

8040

-01-

450-

6545

TU

(3O

Z)

92Pr

imer

for

RT

VSi

li-co

neA

dhes

ive-

Seal

ants

(for

Use

with

Item

No.

91)

GE

Co.

,C

AG

EC

ode

#011

39,

PNSS

4004

Stra

w

8040

-00-

893-

4815

CN

(1PT

)U

sed

for

impr

ovin

gad

he-

sion

ofR

TV

silic

one

ad-

hesi

ve-s

eala

nts

(Ite

mN

o.91

).PN

SS40

04Pi

nk80

40-0

0-08

3-84

03C

N(1

PT)

Dow

Cor

ning

Co.

,C

AG

EC

ode

#719

84,

PND

C12

00R

ed

8040

-00-

111-

2682

CN

(1PT

)

TO 1-1-691

A-48

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

sePN

DC

1200

Cle

ar80

40-0

0-84

5-43

04C

N(1

PT)

PND

C12

00R

ed80

40-0

0-87

0-08

77C

N(1

QT

)PN

DC

1200

Pink

8040

-00-

914-

6970

CN

(1G

L)

PND

C12

04C

lear

8040

-01-

042-

1422

CN

(1PT

)PN

DC

1204

Cle

ar80

40-0

1-06

3-75

09C

N(1

GL

)93

Seal

ing

Tape

,Po

lyte

t-ra

fluor

oE

thyl

ene,

Exp

ande

d(E

PTFE

)O

ilan

dW

ater

Re-

sist

ant

(Sky

flex

Tape

-W

.L

.G

ore

Ass

ocia

tes

Inc.

,C

AG

EC

ode

#0A

MD

8&

1721

7)

SAE

AM

S32

55,

Cla

ss1

(Rib

bed)

PNG

UA

-10

01-1

8030

-01-

367-

7357

RO

(15/ 8

inx

100

ft)

Seal

ing

offa

ying

surf

aces

,pr

essu

rize

dan

dno

n-pr

es-

suri

zed

acce

sspa

nels

,flo

orbo

ards

,an

dw

ind-

scre

ens

whe

nap

prov

edby

the

airc

raft

SPD

orth

em

issi

leor

equi

pmen

tSP

M.

Do

not

use

inin

te-

gral

fuel

tank

s,fu

elso

aked

orhi

ghte

mpe

ra-

ture

appl

icat

ions

(+25

0°F/

+12

1°C

orhi

gher

).E

n-vi

ronm

enta

llypr

efer

red

nonh

azar

dous

alte

rnat

ive

totw

o-co

mpo

nent

,so

l-ve

nt-b

ased

seal

ants

.T

heC

lass

1/R

ibbe

dta

pes

are

pref

erre

dfo

rm

ost

seal

ing

oper

atio

nsw

here

thes

eta

pes

are

appr

oved

for

use.

PNG

UA

-100

1-2

8030

-01-

475-

1368

RO

(1½

inx

100

ft)

PNG

UA

-101

7-1

8030

-01-

368-

7208

RO

(1in

x10

0ft

)

PNG

UA

-140

1-1

(3ri

bs)

8030

-01-

454-

7419

RO

(1.1

inx

100

ft)

PNG

SC-2

1-80

767-

00(5

ribs

)80

30-0

1-45

4-74

18R

O(1

.1in

x10

0ft

)C

lass

2(N

on-r

ibbe

d)PN

GU

A-1

003-

180

30-0

1-36

8-72

07R

O(¼

inx

100

ft)

Com

pens

atio

nta

pe:

fills

gaps

and

repa

irs

min

orse

alde

fect

s.PN

GU

A-1

058-

180

30-0

1-38

1-15

84R

O(½

inx

100

ft)

Thi

n:us

eas

shim

topr

even

tch

afing

.PN

GU

A-1

057-

180

30-0

1-37

7-30

84R

O(1

inx

100

ft)

Thi

n:us

eas

shim

topr

even

tch

afing

.

TO 1-1-691

A-49

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

sePN

GU

A-1

038-

180

30-0

1-46

3-64

59R

O(1

.42

inx

100

ft)

Thi

n:us

eas

shim

topr

even

tch

afing

.PN

GU

A-1

059-

1O

pen

Purc

hase

RO

(1½

inx

100

ft)

Thi

n:us

eas

shim

topr

even

tch

afing

.PN

GU

A-1

301-

1O

pen

Purc

hase

RO

(1in

x10

0ft

)T

hick

:us

efo

rfa

ying

sur-

face

sw

ithw

ide

gaps

.94

Av-

Dec

®Po

lyur

e-th

ane

Tape

s&

Seal

ants

,C

AG

EC

ode

#1N

PE1

Hi-

TakT

MPo

lyur

etha

neTa

pew

ithA

dhes

ive

onB

oth

Side

s

PNH

T39

35-7

-100

8030

-01-

494-

5206

RO

(1in

x12

ft)

Fay

surf

ace

seal

ing

area

sw

here

fluid

intr

usio

nis

apr

oble

mbu

tea

seof

com

-po

nent

rem

oval

isre

-qu

ired

,su

chas

airc

raft

floor

pane

lsan

dtie

dow

nfit

tings

.Fo

rm

axim

umse

alin

g,re

mov

eth

ere

-le

ase

film

sobo

thsi

des

ofth

eta

pead

here

toth

esu

r-fa

ces.

For

easi

erpa

nel

rem

oval

,le

ave

the

rele

ase

film

inpl

ace

onth

esi

deof

the

tape

inco

ntac

tw

ithth

ere

mov

able

pane

l.D

amag

edar

eas

are

easi

lyre

pair

edas

the

tape

ad-

here

sw

ell

toits

elf.

PNH

T39

35-7

-150

8030

-01-

494-

5209

RO

(1½

inx

12ft

)PN

HT

3935

-7-2

0080

30-0

1-49

4-52

07R

O(2

inx

12ft

)PN

HT

3935

-7-2

5080

30-0

1-49

4-41

36R

O(2

½in

x12

ft)

TO 1-1-691

A-50

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seT

ufSe

alFR

TM

Poly

-ur

etha

neTa

pew

ithPe

rman

ent

Teflo

n®B

acki

ngon

One

Side

PNH

T30

00-1

00O

pen

Purc

hase

RO

(1x

12ft

)Fa

ysu

rfac

ese

alin

gof

non-

perm

anen

tst

ruct

ures

such

asac

cess

and

insp

ectio

npa

nels

/cov

ers

onai

rcra

ft,

mis

sile

s,an

deq

uipm

ent

topr

even

tflu

iden

try

into

the

fayi

ngsu

rfac

ear

eas

and

the

cavi

ties

cove

red

byth

ein

stal

led

pane

ls/c

over

s.T

heTe

flon®

back

ing

ishi

ghly

abra

sion

resi

stan

tan

dpe

rmits

slig

htm

ove-

men

t(v

ibra

tion,

etc.

,)of

the

pane

ls/c

over

sw

ithou

tda

mag

ing

the

stru

ctur

eto

whi

chth

eyar

eat

tach

ed.

Thi

sta

peis

very

dura

ble,

soit

can

bere

used

inpl

ace

man

ytim

esaf

ter

initi

alin

stal

latio

n.D

am-

aged

sect

ions

are

easi

lyre

pair

edby

cutti

ngth

emou

tan

dsp

licin

gin

ane

wse

ctio

nth

atsl

ight

lyov

er-

laps

onto

the

cut

edge

sof

the

old

tape

seal

.

PNH

T30

00-1

50O

pen

Purc

hase

RO

(1½

inx

12ft

)PN

HT

3000

-200

Ope

nPu

rcha

seR

O(2

inx

12ft

)PN

DR

4000

FR-1

0080

30-0

1-49

8-90

79R

O(1

x12

ft)

PND

R40

00FR

-150

8030

-01-

498-

8779

RO

(1½

inx

12ft

)PN

DR

4000

FR-2

0080

30-0

1-49

8-90

78R

O(2

inx

12ft

)PN

DR

4000

FR-2

5080

30-0

1-49

8-90

76R

O(2

½in

x12

ft)

Self

Lev

elin

gTM

Gre

enPo

lyur

etha

neSe

alan

t

PNH

T33

26-5

-50

8030

-01-

494-

9650

CA

(50

CC

)T

his

seal

ant

isin

tend

edfo

rfil

ling

void

s/ca

vitie

son

hori

zont

alsu

rfac

es,

such

asai

rcra

ftse

attr

ack

de-

pres

sion

s,to

prev

ent

fluid

from

accu

mul

atin

gin

them

and

caus

ing

corr

o-si

onw

hile

still

bein

gea

syto

rem

ove

for

requ

ired

insp

ectio

nsan

d/or

oper

a-tio

nal

use.

Itis

also

usef

ulfo

rfil

ling

cavi

ties

arou

ndan

tenn

aco

nnec

tors

.

TO 1-1-691

A-51

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seT

hixo

flexT

MO

rang

ePo

lyur

etha

neSe

al-

ant

PNT

F221

9-50

8030

-01-

494-

7677

CA

(50

CC

)T

his

seal

ant

isin

tend

edfo

rfil

ling

the

sam

ety

pes

ofvo

ids/

cavi

ties

asth

eSe

l-fL

evel

ingT

MG

reen

seal

-an

t,bu

tit

can

also

beus

edon

vert

ical

and

over

-he

adsu

rfac

esas

itis

ave

ryth

ick

mat

eria

lth

atw

illre

mai

nin

plac

ew

ith-

out

runn

ing

whi

leit

cure

s.It

isal

soea

sily

rem

oved

for

requ

ired

insp

ectio

nsan

d/or

oper

atio

nal

use.

Seal

ant

Dis

pens

erPN

UG

9811

08-0

1(5

0C

Cca

paci

ty)

5120

-01-

494-

7678

EA

95A

dhes

ion

Prom

oter

for

Poly

sulfi

deSe

alin

gC

om-

poun

dsSo

lven

tB

ased

(Blu

eso

lu-

tion)

SAE

AM

S31

00/1

,PN

PR-1

48,

CA

GE

Cod

e#8

3574

8030

-00-

560-

8756

CN

(1PT

)So

lven

tba

sed

solu

tion

for

enha

ncin

gth

ead

hesi

onof

poly

sulfi

deco

mpo

unds

toa

wid

eva

riet

yof

sub-

stra

tes

(e.g

.in

tegr

alfu

elta

nks)

.App

lyby

brus

hor

clea

ncl

oth.

Mat

eria

ldr

ies

atro

omte

mpe

ratu

rein

appr

oxim

atel

y30

min

utes

leav

ing

atit

anat

efil

mon

the

surf

ace

that

enha

nces

seal

ant

adhe

sion

.W

ater

Bas

ed(P

ink

solu

tion)

SAE

AM

S31

00/3

,PN

PR-1

82,

CA

GE

Cod

e#8

3574

8030

-01-

131-

3228

CN

(1PT

)V

OC

com

plia

ntso

lutio

nfo

ren

hanc

ing

adhe

sion

ofpo

lysu

lfide

seal

ants

tow

ide

vari

ety

subs

trat

es(e

.g.

inte

gral

fuel

tank

s).

App

lyby

brus

hor

clea

ncl

oth.

Itdr

ies

atro

omte

mpe

ratu

rein

30m

inut

esle

avin

gan

adhe

sion

en-

hanc

ing

film

.

TO 1-1-691

A-52

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se96

Adh

esio

nPr

omot

erfo

rPo

lyth

ioet

her

Seal

ing

Com

-po

unds

Solv

ent

Bas

edSi

lane

Solu

-tio

n(Y

ello

wso

lu-

tion)

PNPR

-186

,C

AG

EC

ode

#835

7480

30-0

1-36

3-66

82B

T(1

OZ

)So

lven

tba

sed

sila

neso

lutio

nfo

ren

hanc

ing

the

adhe

-si

onof

poly

thio

ethe

rse

al-

ants

tocu

red

poly

sulfi

deor

poly

thio

ethe

rse

alan

tsan

da

vari

ety

ofco

ated

met

alsu

rfac

es(e

.g.

inte

-gr

alfu

elta

nks)

.App

lyby

brus

hor

clea

ncl

oth.

Ma-

teri

aldr

ies

atro

omte

m-

pera

ture

inap

prox

imat

ely

30m

inut

esle

avin

ga

si-

lane

film

that

enha

nces

seal

ant

adhe

sion

.

8030

-01-

363-

6679

BT

(2O

Z)

8030

-01-

363-

6678

BT

(16

OZ

)

97Pl

astic

Adh

esiv

efo

rSA

EA

MS

3255

EPT

FE(S

kyfle

x®)

Seal

ing

Tape

with

noA

dhes

ive

Bac

k-in

g(R

ed-b

row

nin

Col

or)

Scot

ch-G

rip

847

(Liq

uid)

CA

GE

Cod

e#1

A9T

380

40-0

1-03

3-75

07T

U(5

OZ

)U

seto

hold

EPT

FEse

alin

gta

pew

ithno

adhe

sive

back

ing

inpl

ace.

Fast

dry-

ing

and

resi

sts

wea

ther

ing,

wat

er,

oil,

plas

ticiz

erm

i-gr

atio

nan

dal

ipha

ticfu

els.

(Am

ber

inC

olor

)M

MM

-A-1

89Sc

otch

-Gri

p10

99(B

rush

orSp

ray)

CA

GE

Cod

e#1

A9T

3

8040

-01-

126-

1422

CN

(1Q

T)

Scot

ch-G

rip

1099

-L(B

rush

)C

AG

EC

ode

#1A

9T3

8040

-00-

043-

1717

TU

(2O

Z)

SOLV

EN

TS

98D

ryC

lean

ing

and

Deg

reas

ing

Sol-

vent

s

A-A

-596

01,

Type

II68

50-0

0-11

0-44

98C

N(1

PT)

Gen

eral

purp

ose

clea

ning

solv

ent

for

rem

ovin

goi

l,gr

ease

,pa

intin

gpr

eser

va-

tion

com

poun

ds,

etc.

,fr

ompa

inte

dor

unpa

inte

dm

etal

surf

aces

.D

ono

tus

eas

afin

alcl

eane

rpr

ior

to.

(Hig

hFl

ash

Poin

t+

140°

F/+

61°

C)

6850

-00-

637-

6135

GL

(1G

L)

6850

-00-

274-

5421

CN

(5G

L)

6850

-00-

285-

8011

DR

(55

GL

)

TO 1-1-691

A-53

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

seTy

peII

I68

50-0

1-37

7-19

16C

N(4

OZ

)Id

eal

for

use

inlo

calit

ies

whe

reTy

peII

ofth

ism

a-te

rial

isre

stri

cted

orpr

o-hi

bite

ddu

eto

itshi

gher

VO

Cco

nten

t,va

por

pres

-su

re,

and/

orlo

wer

flash

poin

t.(V

ery

Hig

hFl

ash

Poin

t+

200°

F/+

93°

C)

6850

-01-

377-

1811

CN

(1PT

)N

OT

E

Thi

sso

lven

tm

ust

bew

iped

off

the

surf

ace

com

plet

ely

asit

has

ave

rysl

owev

apor

atio

nra

te.

6850

-01-

377-

1808

CN

(1Q

T)

6850

-01-

377-

1809

CN

(1G

L)

6850

-01-

331-

3349

CN

(5G

L)

6850

-01-

331-

3350

DR

(55

GL

)

MIL

-PR

F-68

0,Ty

peII

Gen

eral

purp

ose

clea

ning

solv

ent

for

rem

ovin

goi

l,gr

ease

,et

c.,

from

met

alsu

rfac

es.

Do

not

use

asa

final

clea

ner

prio

rto

pain

ting

orap

plyi

ngpr

es-

erva

tion

com

poun

ds,

etc.

,on

pain

ted

orun

pain

ted

surf

aces

.Sa

me

asA

-A-

5960

1,Ty

peII

.

(Hig

hFl

ash

Poin

t+

140°

F/+

61°

C)

6850

-01-

474-

2319

CN

(1G

L)

6850

-01-

474-

2317

CN

(5G

L)

6850

-01-

474-

2316

DR

(55

GL

)

Type

III

6850

-01-

474-

2318

CN

(1G

L)

Idea

lfo

rus

ein

loca

litie

sw

here

Type

IIof

this

ma-

teri

alis

rest

rict

edor

pro-

hibi

ted

due

toits

high

erV

OC

cont

ent,

vapo

rpr

es-

sure

,an

d/or

low

erfla

shpo

int.

Sam

eas

A-A

-59

601,

Type

III.

TO 1-1-691

A-54

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se(V

ery

Hig

hFl

ash

Poin

t+

200°

F/+

93°

C)

6850

-01-

474-

2320

CN

(5G

L)

NO

TE

Thi

sso

lven

tm

ust

bew

iped

off

the

surf

ace

com

plet

ely

asit

has

ave

rysl

owev

apor

atio

nra

te.

6850

-01-

474-

2321

DR

(55

GL

)

99W

ipe

Solv

ent,

Low

Vap

orPr

essu

reP-

W-2

891,

Type

I(F

ast

Eva

pora

tion;

Flas

hPo

int

+10

0°F/

+38

°C

min

imum

)C

lass

A(i

ncom

patib

lew

/acr

yl-

ics

&po

lyca

rbon

ates

)

7930

-01-

436-

8085

CN

(1PT

)C

lean

ing

ofai

rcra

ftsu

rfac

espr

ior

topa

intin

g,se

alin

g,no

n-st

ruct

ural

adhe

sive

bond

ing,

etc.

,as

anal

ter-

nativ

efo

rM

EK

,M

IBK

,M

IL-T

-817

72,

and

A-A

-59

281.

Type

II,

Cla

ssB

mat

eria

lsar

esa

feto

use

onw

indo

ws,

win

dshi

elds

/w

inds

cree

ns,

and

cano

-pi

es.

7930

-01-

436-

8023

CN

(1Q

T)

7930

-01-

436-

8077

CN

(1G

L)

7930

-01-

436-

7959

CN

(5G

L)

7930

-01-

436-

8019

DR

(55

GL

)Ty

peII

(Slo

wE

vapo

ra-

tion;

Hig

hFl

ash

Poin

t+

140°

F/+

61°

Cm

ini-

mum

)C

lass

B(A

cryl

ican

dpo

lyca

rbon

ate

com

patib

le)

7930

-01-

436-

8024

CN

(1Q

T)

7930

-01-

436-

7904

CN

(1G

L)

7930

-01-

436-

7953

BX

(4E

A,

1G

LB

T)

7930

-01-

436-

7944

CN

(5G

L)

7930

-01-

436-

8013

DR

(55

GL

)M

IL-P

RF-

3229

5,Ty

peII

;68

50-0

1-60

6-83

561

GL

Gen

eral

purp

ose

clea

ning

solv

ent

for

rem

ovin

goi

l,gr

ease

,et

c.fr

omm

etal

surf

aces

.D

ono

tus

eas

afin

alcl

eane

rpr

ior

topa

intin

gor

appl

ying

pres

-er

vatio

nco

mpo

unds

,et

c.,

onpa

inte

dor

unpa

inte

dsu

rfac

es.

Hig

hFl

ash

Poin

t14

2°F

6850

-01-

606-

8357

5G

L(6

1.1°

C)

6850

-01-

606-

3293

15G

L68

50-0

1-60

6-83

5855

GL

TO 1-1-691

Change 5 A-55

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

se10

0So

lven

ts,

Cle

anin

g,fo

rC

lean

ing

Prio

rto

Seal

antA

pplic

a-tio

n

SAE

AM

S31

66,

PND

S-10

8,C

AG

EC

ode

#302

56

7930

-01-

367-

0994

BX

(24

EA

,1

PTB

TSq

ueez

eT

rig-

ger)

Cle

anin

gof

airc

raft

,m

issi

le,

and

equi

pmen

tpr

imar

yan

dse

cond

ary

stru

ctur

al(i

.e.,

met

alan

dco

mpo

site

)su

rfac

espr

ior

tose

alin

g,bo

ndin

g,an

dap

plic

atio

nof

adhe

sion

prom

oter

s,et

c.

7930

-01-

367-

0995

BX

(4E

A,

1G

LB

T)

7930

-01-

367-

0996

CO

(5G

L)

7930

-01-

367-

0997

DR

(55

GL

)10

1Is

opro

pylA

lcoh

ol,

Tech

nica

l(I

PA,

2-Pr

opan

ol,

and/

orIs

opro

pano

l)

TT-

I-73

568

10-0

0-75

3-49

93C

N(½

PT)

Use

dfo

rre

mov

alof

fung

i(m

olds

)an

dcl

eani

ngof

elec

tric

alan

del

ectr

onic

com

pone

nts

and

conn

ec-

tors

.

6810

-00-

983-

8551

CN

(1Q

T)

6810

-00-

286-

5435

CN

(1G

L)

Do

not

use

onac

rylic

plas

ticm

ater

ials

asit

may

caus

ecr

azin

g.

6810

-00-

543-

7915

CN

(5G

L)

6810

-00-

586-

6647

DR

(55

GL

)

102

Alip

hatic

Nap

htha

TT-

N-9

5,Ty

peII

(for

Cle

anin

gA

cryl

icPl

as-

tics)

6810

-00-

238-

8119

CN

(1G

L)

Use

dfo

rcl

eani

ng/d

egre

asin

gac

rylic

plas

tics

(i.e

.,w

ind-

scre

ens

and

cano

pies

).68

10-0

0-26

5-06

64C

N(5

GL

)68

10-0

0-23

8-81

17D

R(5

5G

L)

103

Seal

ant

Rem

over

,C

hem

ical

Type

Aer

osaf

ePr

oduc

tsIn

c.,

CA

GE

Cod

e#1

LFP

0C

omm

erci

alIt

ems

Sky

Res

tore

®,

PNL

M30

6/1

(Thi

nso

lu-

tion)

8030

-01-

466-

4432

PG(6

EA

,1

LB

T)

Use

dto

assi

stin

poly

sulfi

dese

alan

tre

mov

alby

soft

en-

ing

the

seal

ant

befo

reus

-in

ga

plas

ticsc

rape

ror

tool

.App

lied

byno

n-m

e-ta

llic

brus

h,cl

oth,

orpu

mp

spra

y.

TO 1-1-691

A-56 Change 5

Tabl

eA

-2.

Con

sum

able

Mat

eria

ls-

Con

tinu

ed

Item No.

Nom

encl

atur

eSp

ecifi

catio

n/PN

Nat

iona

lSt

ock

Num

ber

Uni

tof

Issu

eIn

tend

edU

sePN

LM

307/

1(T

hick

so-

lutio

n)80

30-0

1-46

6-44

33PG

(6E

A,

1L

BT

)

Thi

sm

ater

ial

has

anob

noxi

ous

odor

.U

sein

aw

ell

vent

ilate

dar

eaan

d/or

requ

ire

pers

onne

lto

wea

ran

appr

opri

ate

resp

irat

orif

ina

con-

fined

area

.

Sky

Was

h®,P

NL

M30

8/1

8030

-01-

466-

4431

PG(6

EA

,1

LB

T)

Use

dto

neut

raliz

eth

ear

eafr

omw

hich

seal

ant

was

rem

oved

with

the

abov

em

ater

ial.

App

lied

byno

n-m

etal

licbr

ush,

clot

h,or

pum

psp

ray,

scru

bbed

with

ano

n-m

etal

licbr

ush

ora

clot

han

dth

enw

iped

dry

with

acl

oth.

PNL

M60

2/4

8030

-01-

477-

7897

EA

(100

EA

)

TO 1-1-691

Change 5 A-57/(A-58 blank)

APPENDIX BEQUIPMENT FOR CLEANING AND CORROSION PREVENTION AND

CONTROL

B.1 INTRODUCTION.

Table B-2 provides a list of accessories used for aircraft,missile, and equipment cleaning and corrosion preventionand control. Refer to AFI 23-101 for EAID authorization ofadditional equipment. The Table B-2 column headings list:Nomenclature, Specifications/PN’s, National Stock Numbers,Unit of Issue, and Intended Use. Items are divided into func-tional groupings as follows:

• Cleaning accessories.

• Corrosion removal accessories.

• Conversion coating accessories.

• Lighting accessories.

• Safety accessories.

• Sealing accessories.

B.1.1 Unit of Issue Codes. The unit of issue codes usedunder the unit of issue column are shown and explained asfollows in Table B-1.

Table B-1. Unit of Issue Codes

Code Unit Code Unit Code UnitBG Bag EA Each PG PackageBO Bolt FT Foot PR PairBT Bottle GL Gallon PT PintBX Box GR Gross QT QuartCA Cartridge JR Jar RO RollCB Carboy KG Kilogram SE SetCC Cubic Cent. KT Kit SH SheetCN Can L Liter TU TubeCO Container LB Pound YD YardCS Case LG LengthDR Drum MX ThousandDZ Dozen OZ Ounce

TO 1-1-691

Change 15 B-1

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

CL

EA

NIN

GE

QU

IPM

EN

T1

Air

craf

tW

ashi

ngK

it,E

xter

ior,

Con

form

able

3MC

o.,

CA

GE

Cod

e#7

6381

,PN

251

(Con

-fo

rmab

leap

plic

ator

head

&2

EA

ofea

chty

peof

pad)

7920

-00-

490-

6046

KT

Gen

eral

clea

ning

ofai

rcra

ft,

mis

sile

,an

deq

uipm

ent

surf

aces

.U

ses

12in

Lx

6in

Wx

1in

orus

ere

-pl

acem

ent

pads

liste

din

App

endi

xA

,Ta

ble

A-2

,It

emN

o.37

.2

Spon

ge,

Synt

hetic

L-S

-626

,C

lass

1,G

rade

Bor

A-A

-207

3,Ty

peI,

Styl

eB

,C

lass

1

7920

-00-

633-

9915

EA

(7in

Lx

4¼

inW

x2

3⁄8

inT

)

Fine

pore

synt

hetic

spon

gefo

rap

plic

atio

nof

clea

ning

com

poun

dson

and

scru

b-bi

ngof

pain

ted

and

un-

pain

ted

surf

aces

byha

nd.

3Sc

rub

Bru

shA

-A-2

074

(sup

erse

des

H-B

-149

0),

Type

I,St

yle

A(N

ylon

Bri

stle

s)

7920

-00-

619-

9162

EA

(4½

inx

1¾

in)

App

licat

ion

ofcl

eani

ngco

mpo

unds

and

scru

bbin

gof

pain

ted

and

unpa

inte

dai

rcra

ft,

mis

sile

and

equi

p-m

ent

surf

aces

.Ty

peII

,St

yle

C(T

ampi

coB

rist

les)

7920

-00-

282-

2470

EA

(10

¾in

x2

¾in

)Ty

peIV

,St

yle

B(N

ylon

Bri

stle

s)79

20-0

0-06

1-00

37E

A(8

½in

x5

in)

Type

IV,

Styl

eD

(Pal

myr

aB

rist

les)

7920

-01-

067-

6203

EA

(8½

inD

)

4B

rush

,Air

craf

tC

lean

ing

MIL

-B-2

3958

,Ty

peI

(Ny-

lon

Bri

stle

s)St

yle

179

20-0

0-05

4-77

68E

A(5

3⁄8

inD

)A

pplic

atio

nof

clea

ning

com

poun

dsan

dsc

rubb

ing

ofpa

inte

dan

dun

pain

ted

airc

raft

,m

issi

lean

deq

uip-

men

tsu

rfac

es.

Styl

e2

7920

-00-

051-

4386

EA

(6in

x2

in)

Styl

e3

7920

-00-

051-

4383

EA

(12

inx

3½

in)

Type

II(T

ampi

coB

rist

les)

Styl

e2

7920

-00-

957-

5945

EA

(6in

x2

½in

)Ty

peII

I(N

ylon

/Tam

pico

Bri

stle

s)St

yle

179

20-0

0-05

1-43

84E

A(5

3⁄8

inD

)

Styl

e2

7920

-00-

051-

4387

EA

(6in

x2

in)

Styl

e3

7920

-00-

051-

4385

EA

(12

inx

3½

in)

TO 1-1-691

B-2

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

5W

indo

wB

rush

,W

ater

proo

f(H

orse

hair

Bri

stle

s)

Type

I(R

ound

)79

20-0

0-24

0-71

76E

A(4

.5in

D)

Scru

bbin

gai

rcra

ft,

mis

sile

,an

deq

uipm

ent

pain

ted

and

unpa

inte

dsu

rfac

es,

win

dow

s,w

inds

hiel

ds,

and/

orw

inds

cree

ns.

7920

-00-

297-

1509

EA

(8in

D)

Type

II(R

ecta

ngul

ar)

7920

-01-

136-

8892

EA

(6in

x4

in)

6To

othb

rush

,So

ftB

rist

le,

Stra

ight

Lin

eD

esig

n

A-A

-59

(Chi

ldre

n’s

-30

Tuf

ts)

8530

-01-

293-

1388

DZ

Cle

anin

gin

tric

ate

part

s.B

e-fo

reus

ing,

ensu

rech

emi-

cals

will

not

diss

olve

orso

ften

brus

hha

ndle

and

bris

tles.

A-A

-123

(Adu

lt’s

-30

Tuf

ts)

8530

-01-

293-

1387

DZ

7H

andl

es,

Woo

d,A

cme

Thr

eade

dan

dTa

pere

dE

nds

A-A

-308

2(s

uper

sede

sN

N-

H-1

04),

Type

I(T

hrea

ded

met

alen

d)7/ 8

inD

x4

ftL

7920

-00-

982-

6512

EA

Han

dles

for

use

with

scru

b/cl

eani

ngbr

ushe

s(I

tem

No.

3an

dIt

emN

o.4)

,an

dai

rcra

ftw

ashi

ngki

t(I

tem

No.

1).

Type

II(T

aper

eden

d)15

/16

inD

x4

½L

7920

-00-

177-

5106

EA

15/1

6in

Dx

5ft

L79

20-0

0-26

3-03

28E

A1

inD

x4

½L

7920

-00-

141-

5452

EA

1in

Dx

8ft

L79

20-0

0-26

3-03

27E

A1

inD

x4

¼ft

L79

20-0

0-26

3-03

24E

A8

Han

dle,

Acm

eT

hrea

ded

End

(Tel

esco

pic)

A-A

-146

4(7

/ 8in

D)

7920

-00-

926-

5146

EA

A5

ftto

10ft

exte

ndab

leal

umin

umha

ndle

for

scru

b/cl

eani

ngbr

ushe

s(I

tem

No.

3an

dIt

emN

o.4)

,or

airc

raft

was

hing

kit

(Ite

mN

o.1)

,to

clea

nhi

ghsu

rfac

eson

airc

raft

oreq

uipm

ent.

9N

ozzl

es,

Gar

den

Hos

e(f

or5/ 8

and

¾in

Hos

e)A

d-ju

stab

le

A-A

-504

61St

raig

ht,A

d-ju

stab

leSp

ray

(Bra

ss)

4730

-00-

223-

6731

EA

Spra

ying

and

rins

ing

ofai

r-cr

aft,

mis

sile

s,an

deq

uip-

men

tdu

ring

clea

ning

op-

erat

ions

.Pi

stol

Gri

p,A

djus

tabl

e(C

oppe

rA

lloy

w/R

ubbe

rC

over

)PN

1085

5,C

AG

EC

ode

#971

41

4730

-00-

900-

0733

EA

TO 1-1-691

B-3

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

10H

ose

and

Hos

eA

s-se

mbl

ies,

Non

-M

etal

lic(R

ubbe

r,Pl

astic

)

A-A

-592

70(s

uper

sede

sL

-H-5

20),

Type

I,C

lass

I(R

ubbe

r)5/ 8

inID

x50

ftL

4720

-00-

203-

3920

EA

Spra

ying

and

rins

ing

ofai

r-cr

aft,

mis

sile

s,an

deq

uip-

men

tdu

ring

clea

ning

op-

erat

ions

.¾

inID

x50

ftL

4720

-00-

203-

3912

EA

Type

II,

Gra

deA

(PV

C)

5/ 8

inx

50ft

4720

-00-

729-

5334

EA

¾in

x50

ft47

20-0

0-72

9-53

38E

A11

Pum

p,B

ackp

ack

(5G

Lca

paci

ty)

PN51

00-2

54B

,C

AG

EC

ode

#040

2443

20-0

0-28

9-89

12E

AL

ocal

ized

smal

lar

eacl

ean-

ing

and

rins

ing

ofai

rcra

ft,

mis

sile

,an

deq

uipm

ent

surf

aces

.12

Spra

yers

Inse

cti-

cide

,M

anua

lly-

Car

ried

,H

and

Ope

rate

d-C

om-

pres

sion

A-A

-557

48(s

uper

sede

sM

IL-S

-141

02)

3740

-00-

191-

3677

EA

(1G

Lca

pac-

ity)

Use

dto

appl

yso

ilba

rrie

rm

ater

ial

onai

rcra

ftsu

r-fa

ces.

3740

-00-

641-

4719

EA

(2G

Lca

pac-

ity)

13G

uns,

Spra

y,O

ilsan

dSo

lven

tSA

EA

MS-

G-9

52(s

uper

-se

des

MIL

-G-9

52),

Type

I

4940

-00-

248-

0866

EA

Non

-ato

miz

ing,

trig

ger

oper

-at

edsp

ray

nozz

lefo

rsp

rayi

ngcl

eani

ngco

m-

poun

dson

airc

raft

,m

is-

sile

s,an

deq

uipm

ent.

14C

lean

ing

Uni

t,Po

r-ta

ble,

Foam

Gen

-er

atin

gSt

ainl

ess

Stee

lTa

nk(P

orta

-Fo

amer

)

PN00

20SS

,C

AG

EC

ode

#213

6149

40-0

1-05

8-52

67E

A(1

5G

Lca

-pa

city

)Fo

amap

plic

ator

for

MIL

-PR

F-87

937

and

MIL

-PR

F-85

570

clea

ning

com

-po

unds

for

clea

ning

airc

raft

,m

issi

le,

and

equi

pmen

tex

teri

ors.

Use

sco

mpr

esse

dai

rto

spra

yw

ater

dete

rgen

tso

lutio

ns.

May

also

beus

edto

appl

ycl

eani

ngso

lven

tsfo

rcl

eani

ngen

gine

san

dot

her

equi

pmen

t.A

gun

type

spra

yw

and

and

nozz

leis

incl

uded

.

PN94

88-7

023,

CA

GE

Cod

e#8

5884

4940

-01-

041-

5680

EA

(45

GL

ca-

paci

ty)

TO 1-1-691

B-4

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

15C

lean

er,

Pres

sure

,So

lven

t-W

ater

(Uni

vers

alW

ash

Uni

t)

PN21

C24

38G

01,

CA

GE

Cod

e#9

9207

4940

-01-

185-

6215

EA

Use

dto

appl

ycl

eani

ngco

m-

poun

dso

lutio

nsin

ano

n-fo

amst

ate

toai

rcra

ft,

mis

-si

le,

and

equi

pmen

tex

teri

orsu

rfac

esat

ara

teof

2½

GL

/min

at30

PSI

pres

sure

.16

Car

t,C

orro

sion

Con

trol

(Tur

bine

Eng

ine

Cle

anin

g)

Mod

el#6

2555

,PN

65A

102J

1,C

AG

EC

ode

#0G

ZN

8

4920

-00-

930-

1801

EA

Port

able

clea

ning

mac

hine

for

clea

ning

and

rins

ing

airc

raft

turb

ine

engi

nes.

17D

eice

r,A

ircr

aft

(Tru

ckM

ount

ed)

Mod

el#5

8323

,PN

D40

-D,

CA

GE

Cod

e#5

8323

&93

408

1730

-01-

093-

6517

EA

Tru

ckm

ount

edsp

ray

unit

used

tosp

ray

deic

ing

and

anti-

icin

gflu

ids

onai

rcra

ftex

teri

orsu

rfac

es.

18H

eate

r,G

un,

Ele

c-tr

icTy

peA

-A-5

9435

,Ty

peI

(350

°-5

00°

F)49

40-0

0-35

7-13

69E

ATo

thaw

ordr

yeq

uipm

ent/

com

pone

nts

orto

shri

nkhe

atsh

rink

type

insu

latin

gtu

bing

asso

ciat

edw

ithel

ectr

ical

appl

icat

ions

.

Type

II(5

00°

-750

°F)

4940

-01-

028-

7493

EA

Type

III

(750

°-1

000°

F)49

40-0

1-39

1-70

46E

A

19V

acuu

mC

lean

er,

Pneu

mat

icPN

AT

560A

CF-

18,

CA

GE

Cod

e#0

0784

5130

-01-

368-

5861

EA

Smal

l,lig

htw

eigh

t,al

umi-

num

,ve

ntur

ity

pe,

hand

held

vacu

umcl

eane

rw

ith18

inL

flexi

ble

hose

for

rem

ovin

gdi

rtan

dde

bris

from

airc

raft

,m

issi

le,

and

equi

pmen

tin

teri

ors.

20V

acuu

mC

lean

er(w

ithA

ttach

-m

ents

)

Pneu

mat

icTy

pe,

PN15

-A

1080

,C

AG

EC

ode

#581

50

7910

-00-

807-

3704

EA

For

rem

ovin

gdi

rt,

debr

is,

and

fluid

sfr

omai

rcra

ft,

mis

sile

,an

deq

uipm

ent

inte

rior

s.E

lect

ric

Type

(A-A

-549

43),

PNC

8398

5-01

,C

AG

EC

ode

#168

93

7910

-01-

208-

6017

EA

For

rem

ovin

gdi

rt,

debr

is,

and

fluid

sfr

omai

rcra

ft,

mis

sile

,an

deq

uipm

ent

inte

rior

s.T

his

vacu

umcl

eane

rca

nal

sobe

used

tore

mov

ein

fect

ious

was

tem

ater

ials

.

TO 1-1-691

B-5

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

21B

ottle

,App

licat

or,

16O

ZC

apac

ity(A

djus

tabl

eSp

ray

Noz

zle)

A-A

-280

681

25-0

0-48

8-79

52E

ASp

rayi

ngof

clea

ning

com

-po

und

solu

tions

onsm

all

area

sof

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

22Sp

ray

Kit,

Self

Pres

suri

zed

Tri

g-ge

rSp

ray,

Poly

-et

hyle

neB

ottle

(32

OZ

Cap

acity

)

PN43

82T

1,C

AG

EC

ode

#394

2849

40-0

1-36

4-87

61E

ASp

rayi

ngof

clea

ning

com

-po

und

solu

tions

onsm

all

area

sof

airc

raft

,m

issi

le,

and

equi

pmen

tsu

rfac

es.

23U

tility

Pail,

Plas

tic(3

GL

Cap

acity

)A

-A-5

9253

(sup

erse

des

L-P

-65)

,Si

ze4,

Styl

eB

7240

-00-

246-

1097

EA

Con

tain

erfo

rho

ldin

gw

ater

and

chem

ical

solu

tions

for

clea

ning

and

corr

osio

ntr

eatm

ent

oper

atio

ns.

CO

NV

ER

SIO

NC

OA

TIN

GE

QU

IPM

EN

T24

Bru

sh,A

cid

Swab

-bi

ng(M

etal

Han

dle/

Hor

seha

ir&

Hog

Bri

stle

Bru

sh)

A-A

-289

,Ty

peII

,C

lass

1,Si

ze1

7920

-00-

514-

2417

GR

(5¾

inL

x3⁄8

inW

)D

ispo

sabl

ebr

ush

for

appl

y-in

gch

emic

alco

nver

sion

coat

ing

solu

tions

and

som

ebr

usha

ble

seal

ants

.

25M

oist

ener

,Pa

per

Seal

ing,

Foun

-ta

in-T

ype

(Spo

nge

Moi

st-

ener

Stic

k)

A-A

-137

(sup

erse

des

GG

-M

-571

)75

20-0

0-24

1-29

81E

AA

pplic

atio

nof

chem

ical

conv

ersi

onco

atin

gso

lu-

tions

tosm

all

area

s.

26W

ash

Bot

tle,

Lab

o-ra

tory

,Po

lyet

hyl-

ene

(250

ml.

Ca-

paci

ty)

Com

mer

cial

Item

,C

AG

EC

ode

#255

1866

40-0

0-29

9-84

93E

AB

X(1

2E

A)

Use

dfo

rri

nsin

gch

emic

ally

trea

ted

surf

aces

.

CO

RR

OSI

ON

RE

MO

VA

LE

QU

IPM

EN

T27

Dri

ll,Pn

eum

atic

,Po

rtab

le(¼

inC

huck

;32

00R

PM)

OO

-D-6

91,

Type

I,St

yle

C(S

trai

ght

Dri

ve,

Pist

olG

rip)

5130

-00-

294-

9511

EA

Cor

rosi

onre

mov

alan

dsc

uff

sand

ing.

Type

I,St

yle

A(9

0°A

ngle

Dri

ve,

Bod

yG

rip)

5130

-00-

293-

1977

EA

28K

ey,

Dri

llC

huck

(¼in

Dri

ve)

A-A

-509

66,

PNK

1,C

AG

EC

ode

#750

7834

60-0

0-26

4-55

77E

ASe

curi

ngor

rele

asin

gdr

illbi

t.Fo

rus

ew

ithIt

emN

o.27

drill

mot

or.

TO 1-1-691

B-6

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

29Sa

nder

,Pa

d,Pn

eu-

mat

ic(O

rbita

lM

otio

n)6,

000

-9,

000

RPM

A-A

-268

7(O

O-S

-101

,Ty

peI,

Styl

e1)

5130

-00-

606-

9694

EA

Cor

rosi

onre

mov

alan

dbl

end

out

asw

ell

assc

uff

sand

ing,

finis

hsa

ndin

g,an

dfe

athe

red

ging

/ble

nd-

ing

ofpa

int

surf

aces

.30

Sand

er,

Dis

c,Pn

eu-

mat

ic,

Port

able

(Ran

dom

Orb

ital)

Dua

lM

otio

n,V

ertic

alD

rive

with

6in

Dm

axPa

d&

7000

RPM

max

(Unl

oade

d)

A-A

-269

0(O

O-S

-101

,Ty

peII

,St

yle

3)51

30-0

0-20

4-06

23E

AC

orro

sion

rem

oval

and

blen

dou

tas

wel

las

scuf

fsa

ndin

g,fin

ish

sand

ing,

and

feat

her

edgi

ng/b

lend

-in

gof

pain

tsu

rfac

es.

The

sand

er’s

rand

omor

bita

lac

tion

prev

ents

scra

tche

san

dsw

irl

mar

ks.

31Sa

nder

,D

isc,

Pneu

-m

atic

,Po

rtab

le(R

ight

Ang

le)

Rig

htA

ngle

Dri

vew

ith7

inD

Pad

max

&60

00R

PMm

ax(U

n-lo

aded

)

A-A

-268

9(O

O-S

-101

,Ty

peII

,St

yle

2)51

30-0

0-59

6-11

76E

AC

orro

sion

rem

oval

and

blen

dou

t.R

ight

angl

edr

ive

mak

esit

easi

erto

use

inco

rner

s,al

ong

edge

s,an

din

tight

spac

es.

32D

ryH

onin

gM

a-ch

ine,

Port

able

,A

ir-O

pera

ted

(Vac

u-B

last

er)

PN41

303

CA

GE

,C

ode

#625

5549

40-0

0-87

2-17

12E

AA

com

pact

,se

lf-c

onta

ined

,lig

htw

eigh

tab

rasi

vebl

astin

gun

itus

edfo

rth

esa

fean

dco

nven

ient

re-

mov

alof

corr

osio

npr

od-

ucts

from

airc

raft

,m

issi

lean

deq

uipm

ent

surf

aces

and

thei

rco

mpo

nent

sw

ithno

haza

rdou

spa

rtic

leem

issi

ons.

All

abra

sive

part

icle

s,co

rros

ion

prod

-uc

ts,

and

pain

tch

ips

are

draw

nba

ckin

toth

em

a-ch

ine

whe

rere

sidu

esar

efil

tere

dou

tan

dco

llect

edfo

rdi

spos

al,

and

the

abra

-si

vepa

rtic

les

are

recy

cled

.

TO 1-1-691

B-7

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

33E

lect

rica

lPu

mp

Kit

for

Dry

Hon

ing

Mac

hine

(Ite

mN

o.32

)

PN91

8708

,C

AG

EC

ode

#625

5549

40-0

0-94

8-38

10E

AT

heel

ectr

icpu

mp

for

the

Dry

Hon

ing

Mac

hine

al-

low

sus

eof

low

pres

sure

/lo

wvo

lum

eai

rto

oper

ate

inst

ead

ofth

elo

wpr

es-

sure

/hig

hvo

lum

eai

rre

-qu

ired

toop

erat

eun

itseq

uipp

edw

ithth

eai

rej

ec-

tor

pum

p.34

Gun

,Air

Blo

w(B

last

Cle

anin

g)A

-A-5

5543

(sup

erse

des

GG

G-G

-770

),Ty

peII

(Pus

hbu

tton)

,St

yle

B(3

⁄8in

Int.

Thd

.)

4940

-00-

223-

8972

EA

Use

tore

mov

ech

ips,

dirt

,an

dw

aste

mat

eria

lfr

omm

achi

nes,

wor

kpi

eces

,or

benc

hes.

Type

II(P

ush

butto

n),

Styl

eA

(¼in

Int.

Thd

.)49

40-0

0-33

3-55

41E

A

35A

irH

ose

Ass

em-

blie

s,G

ener

alPu

rpos

eH

ose

and

Hos

eA

ssem

blie

s,N

on-M

etal

licSp

ray

A-A

-596

13,

3⁄8

inID

x50

ft47

20-0

0-28

9-34

29FT

Hos

eas

sem

blie

sus

edw

ithpn

eum

atic

tool

s,pa

int

spra

ygu

ns,

and

dry

hon-

ing

mac

hine

s.

Hos

e,R

ubbe

r,an

dH

ose

Ass

embl

ies,

Rub

ber,

Pneu

-m

atic

(Yar

nan

dFa

bric

Rei

n-fo

rced

)

A-A

-595

65,

½in

IDx

50ft

4720

-00-

278-

4889

FT

5/ 8

inID

x50

ft47

20-0

0-27

8-48

90FT

¾in

IDx

50ft

4720

-00-

278-

4891

FT

36C

oupl

ing

Hal

ves,

Qui

ck-D

isco

nnec

tA

-A-5

9439

(sup

erse

des

MIL

-C-4

109)

,Ty

peII

(Mal

e)¼

inN

PT/M

end

(Sty

le1)

4730

-00-

494-

3271

EA

Mal

equ

ick

disc

onne

ctha

lves

for

use

with

pneu

-m

atic

tool

san

dpa

int

spra

ygu

ns.

3⁄8

inN

PT/F

end

(Sty

le2)

4730

-00-

293-

7182

EA

3⁄8

inSh

ank

end

(Sty

le3)

4730

-00-

277-

5679

EA

½in

NPT

/Men

d(S

tyle

1)47

30-0

0-29

3-71

65E

AM

ale

quic

kdi

scon

nect

halv

esfo

rus

ew

ithpo

r-ta

ble

dry

honi

ngm

a-ch

ines

.

½in

NPT

/Fen

d(S

tyle

2)47

30-0

1-23

3-34

34E

A¾

inN

PT/M

end

(Sty

le1)

4730

-00-

293-

7180

EA

TO 1-1-691

B-8

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Type

I(F

emal

e)¼

inN

PT/F

end

(Sty

le2)

4730

-01-

177-

0987

EA

Fem

ale

quic

kdi

scon

nect

halv

esfo

rus

ew

ithpn

eu-

mat

icto

ols

and

pain

tsp

ray

guns

.3⁄8

inN

PT/M

end

(Sty

le1)

4730

-00-

203-

0178

EA

3⁄8

inSh

ank

end

(Sty

le3)

4730

-00-

494-

3272

EA

½in

NPT

/Men

d(S

tyle

1)47

30-0

0-20

3-48

47E

AFe

mal

equ

ick

disc

onne

ctha

lves

for

use

with

por-

tabl

edr

yho

ning

ma-

chin

es.

½in

Shan

ken

d(S

tyle

3)47

30-0

0-90

5-97

94E

A¾

inN

PT/M

end

(Sty

le1)

4730

-00-

293-

7043

EA

37H

ose

Cla

mp

A-A

-525

06(s

uper

sede

sW

W-C

-440

)47

30-0

0-90

8-31

94E

AM

etal

hose

clam

pus

edfo

rat

tach

ing

flexi

ble

duct

sor

hose

son

toeq

uipm

ent.

38H

and

Pad

Hol

der

(for

Use

with

App

endi

xA

,Ta

ble

A-2

,It

emN

o.1)

3MC

o.,

PN95

2(I

NST

A-

LO

K),

CA

GE

Cod

e#2

8124

Com

mer

cial

Item

Ope

nPu

rcha

seE

AH

and

tool

for

hold

ing

abra

-si

vepa

ds.

39H

olde

r,D

isk

Pad,

Hoo

kan

dL

oop

Type

(for

Use

with

Item

No.

47)

3MC

o.,

CA

GE

Cod

e#2

8124

,PN

9215

Com

mer

cial

Item

EA

Bac

kup

pad

toru

nsu

rfac

eco

nditi

onin

gdi

scs

ona

drill

mot

or.

(1½

inD

on¼

insh

ank)

Ope

nPu

rcha

sePN

0480

11-0

7494

-8C

omm

erci

alIt

emC

S(1

0E

A)

(2in

Don

¼in

shan

k)O

pen

Purc

hase

PN92

3(3

inD

on¼

insh

ank)

5345

-01-

342-

5932

EA

PN04

8011

-074

92-4

Com

mer

cial

Item

CS

(5E

A)

(4in

Don

¼in

shan

k)O

pen

Purc

hase

PN04

8011

-056

80-7

Com

mer

cial

Item

EA

(5in

Don

¼in

shan

k)O

pen

Purc

hase

40Pa

d,A

bras

ive

Dis

kH

olde

r(f

orU

sew

ithA

ppen

dix

A,

Tabl

eA

-2,

Item

No.

5)

3MC

o.,

CA

GE

Cod

e#2

8124

,PN

0511

44-

0557

6

5130

-01-

075-

8137

EA

Bac

kup

pad

toru

n6

inD

abra

sive

pape

rdi

scs

ona

dual

mot

ion

type

sand

er.

41M

andr

els

(for

Use

with

Item

No.

42an

dIt

emN

o.43

)

3MC

o.,

CA

GE

Cod

e#2

8124

,PN

990

(3⁄8

insh

ank)

Ope

nPu

rcha

seB

X(5

EA

)Fo

rus

ew

ith2

to3

inD

radi

albr

istle

disc

sst

acke

dfr

om1⁄8

to½

inW

.

TO 1-1-691

B-9

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

PN99

1(3

⁄8in

shan

k)O

pen

Purc

hase

BX

(5E

A)

For

use

with

2to

3in

Dra

dial

bris

tledi

scs

stac

ked

from

¾in

to1

inW

.PN

933

(2in

L;

¼in

shan

kw

/1in

Dw

ashe

r)34

60-0

1-04

4-26

26E

AFo

rus

ew

ith2

to3

inD

abra

sive

disc

s.PN

934

(31/

16in

L;

¼in

shan

kw

/2½

inD

was

her)

3460

-00-

150-

7164

EA

For

use

with

3to

6in

Dab

rasi

vedi

scs.

PN93

5,Sp

litM

ini

Man

-dr

el(2

inL

;¼

insh

ank)

3460

-00-

150-

7163

EA

For

use

with

1in

Wx

1½

inL

piec

esof

abra

sive

mat

eria

lto

fitin

totig

htar

eas

for

corr

osio

nre

-m

oval

.42

Rol

ocT

MD

isc

Pad

Hol

ders

for

In-

line

Bri

stle

Dis

cs(I

tem

No.

45)

and

Rol

ocT

MC

oate

dA

bras

ive

Dis

cs(I

tem

No.

46)

3MC

o.,

CA

GE

Cod

e#2

8124

Com

mer

cial

Item

sU

sed

toho

ldR

oloc

TM

in-

line

bris

tledi

scs

and

coat

edab

rasi

vedi

scs

for

inst

alla

tion

onei

ther

in-

line

orri

ght

angl

edr

illm

otor

s.

PN05

1144

-451

01(1

inD

Hol

der)

Ope

nPu

rcha

seB

X(5

EA

)

PN05

1144

-450

95-4

(2in

DH

olde

r)O

pen

Purc

hase

BX

(5E

A)

PN05

1144

-450

92-3

(3in

DH

olde

r)O

pen

Purc

hase

BX

(5E

A)

PN05

1144

-451

79-1

(4in

DH

olde

r)O

pen

Purc

hase

BX

(5E

A)

PN05

1144

-451

02-9

(¼in

Dth

read

edsh

aft)

Ope

nPu

rcha

seE

A

43W

heel

,Fl

apB

rush

,A

bras

ive

(Non

-W

oven

Nyl

onFl

aps

with

Alu

mi-

num

Oxi

deA

bra-

sive

;M

aroo

nin

Col

or)

(6in

Dx

1in

Wx

2in

arbo

rho

le)

3MC

o.,

CA

GE

Cod

e#2

8124

Com

mer

cial

Item

sR

emov

ing

mild

corr

osio

nfr

oman

dpo

lishi

ngof

sur-

face

s.A

lso

for

mec

hani

cal

rem

oval

and

feat

heri

ngof

pain

tsy

stem

s.M

axim

umop

erat

ing

spee

d(M

OS)

is34

00R

PM.

Use

don

PN93

4m

andr

el(I

tem

No.

41ab

ove)

.

PN5A

FN6X

1X2

(Fin

egr

it)53

45-0

0-15

1-79

36E

A

PN5A

MD

6X1X

2(M

e-di

umgr

it)53

45-0

0-15

7-97

90E

A

TO 1-1-691

B-10

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

44St

acka

ble

Rad

ial

Bri

stle

Dis

cs,

(Reg

alite

TM

/Alu

-m

inum

Oxi

de&

Cub

itron

Abr

a-si

ve)

3MC

o.,

CA

GE

Cod

e#2

8124

,3

inD

-M

an-

drel

Mou

nted

Com

mer

cial

Item

sR

emov

ing

mild

corr

osio

nan

dpo

lishi

ngsu

rfac

esan

dde

-bur

ring

.Als

ofo

rm

e-ch

anic

alre

mov

alof

cure

dse

alan

ts,

adhe

sive

s,pa

ints

,an

dfe

athe

ring

ofpa

int

syst

ems.

Use

with

adr

illan

da

#934

,99

0,or

991

man

drel

,as

appr

opri

ate.

Can

beus

edto

reac

hin

tode

epde

pres

sion

san

dca

vi-

ties.

Can

beus

edon

in-

line

orri

ght

angl

edr

illm

otor

s.T

heM

OS

is25

,000

RPM

.

PN04

8011

-242

79-8

(Gra

de50

-G

reen

Col

or)

Ope

nPu

rcha

seC

S(4

0E

A)

PN04

8011

-242

80-4

(Gra

de80

-Y

ello

wC

olor

)O

pen

Purc

hase

CS

(40

EA

)

PN04

8011

-242

81-1

(Gra

de12

0-

Whi

teC

olor

)O

pen

Purc

hase

CS

(40

EA

)

PN05

1131

-075

44-3

(Gra

de12

0-

Whi

teC

olor

;T

hick

Bri

stle

s)

3460

-01-

509-

1789

CS

(40

EA

)

Rol

ocT

MD

isc

Pad

Hol

der

Mou

nted

,PN

0480

11-

2427

6-7

(Gra

de50

-G

reen

Col

or)

Ope

nPu

rcha

seS

(40

EA

)

PN04

8011

-242

77-4

(Gra

de80

-Y

ello

wC

olor

)O

pen

Purc

hase

CS

(40

EA

)

PN04

8011

-242

78-1

(Gra

de12

0-

Whi

teC

olor

)O

pen

Purc

hase

CS

(40

EA

)

Rol

ocT

MD

isc

Pad

Hol

der

for

thes

eR

adia

lB

rist

leD

iscs

,PN

0511

44-

4510

1-2

Ope

nPu

rcha

seB

X(5

EA

)

TO 1-1-691

B-11

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

45R

oloc

TM

In-l

ine

Bri

stle

Dis

cs(R

e-ga

liteR

oloc

TM

/A

lum

inum

Oxi

de&

Cub

itron

Abr

a-si

ve)

3MC

o.,

CA

GE

Cod

e#2

8124

,1

inD

w/

5/ 8

inL

bris

tles

Com

mer

cial

Item

sR

emov

ing

mild

corr

osio

nan

dpo

lishi

ngsu

rfac

esan

dde

-bur

ring

.Als

ofo

rm

e-ch

anic

alre

mov

alof

cure

dse

alan

ts,

adhe

sive

s,an

dpa

ints

and

feat

heri

ngof

pain

tsy

stem

s.C

anbe

used

onin

line

orri

ght

angl

edr

illm

otor

saf

ter

mou

ntin

gon

anap

prop

ri-

ate

Rol

ocT

Mdi

scpa

dho

lder

(Ite

mN

o.42

).T

hem

axim

umop

erat

ing

spee

d(M

OS)

depe

nds

onth

edi

amet

erof

the

disc

.

PN04

8011

-186

98-6

(Gra

de50

-G

reen

Col

or)

Ope

nPu

rcha

seC

S(8

0E

A)

PN04

8011

-187

06-8

(Gra

de80

-Y

ello

wC

olor

)O

pen

Purc

hase

CS

(80

EA

)

PN04

8011

-187

10-5

(Gra

de12

0-

Whi

teC

olor

)2

inD

w/5

/ 8in

Lbr

istle

s

Ope

nPu

rcha

seC

S(4

0E

A)

PN04

8011

-187

30-3

(Gra

de50

-G

reen

Col

or)

Ope

nPu

rcha

seC

S(4

0E

A)

PN04

8011

-187

32-7

(Gra

de80

-Y

ello

wC

olor

)53

45-0

1-43

2-30

32C

S(4

0E

A)

PN04

8011

-187

33-4

(Gra

de12

0-

Whi

teC

olor

)3

inD

w/5

/ 8in

Lbr

istle

s

3460

-01-

509-

1806

PN04

8011

-187

34-1

(Gra

de50

-G

reen

Col

or)

Ope

nPu

rcha

seC

S(4

0E

A)

PN04

8011

-187

36-5

(Gra

de80

-Y

ello

wC

olor

)O

pen

Purc

hase

CS

(40

EA

)

PN04

8011

-187

37-2

(Gra

de12

0-

Whi

teC

olor

)34

60-0

1-50

9-18

29C

S(4

0E

A)

TO 1-1-691

B-12

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

46R

oloc

TM

Coa

ted

Abr

asiv

eD

iscs

(Reg

alite

TM

/Alu

-m

inum

Oxi

de&

Cub

itron

Abr

a-si

ve)

and

Nyl

onM

atD

iscs

(Alu

-m

inum

Oxi

deA

bras

ive)

(for

Use

with

Item

No.

42)

3MC

o.,

CA

GE

Cod

e#2

8124

Com

mer

cial

Item

sFo

rre

mov

alof

mod

erat

eto

seve

reco

rros

ion

from

thic

kcr

oss

sect

ion

alum

i-nu

m,

stee

l,an

dm

agne

-si

umst

ruct

ures

whe

nm

ount

edon

Item

No.

42di

scpa

dho

lder

san

din

-st

alle

don

eith

erin

-lin

eor

righ

tan

gle

drill

mot

ors.

Use

ofth

ese

abra

sive

disc

ssh

ould

befo

llow

edby

smoo

thin

gou

tth

ear

eaw

itha

less

aggr

essi

veab

rasi

vedi

scsu

chas

anIt

emN

o.47

surf

ace

con-

ditio

ning

disc

(ver

yfin

egr

it).

Gra

de-

80gr

itPN

0511

44-1

4661

-1(2

inD

disc

)53

45-0

1-42

0-14

57C

S(2

00E

A)

PN-0

5114

4-76

634-

5(3

inD

disc

)O

pen

Purc

hase

CS

(200

EA

)

PN05

1144

-836

93-2

(4in

Ddi

sc)

Ope

nPu

rcha

seC

S(1

00E

A)

Gra

de-

100

grit

PN05

1144

-805

08-2

(2in

Ddi

sc)

Ope

nPu

rcha

seC

S(2

00E

A)

PN05

1144

-805

09-9

(3in

Ddi

sc)

Ope

nPu

rcha

seC

S(2

00E

A)

PN05

1144

-836

94-9

(4in

Ddi

sc)

Ope

nPu

rcha

seC

S(1

00E

A)

Gra

de-

120

grit

PN05

1144

-805

12-9

(2in

Ddi

sc)

5345

-01-

420-

1453

CS

(200

EA

)

PN05

1144

-805

13-6

(3in

Ddi

sc)

Ope

nPu

rcha

seC

S(2

00E

A)

PN05

1144

-836

95-6

(4in

Ddi

sc)

Ope

nPu

rcha

seC

S(1

00E

A)

Ver

yFi

neG

rit

(Blu

eC

olor

)PN

0480

11-0

5523

(2in

D-S

cotc

hB

rite

Dis

c)53

45-0

1-36

7-76

80C

S(2

00E

A)

PN04

8011

-055

30(3

inD

-Sco

tch

Bri

teD

isc)

5345

-01-

397-

5253

CS

(100

EA

)

TO 1-1-691

B-13

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

47Su

rfac

eC

ondi

tion-

ing

Dis

cs,A

lum

i-nu

mO

xide

(for

Use

with

Item

No.

39)

3MC

o.,

CA

GE

Cod

e#2

8124

Com

mer

cial

Item

sC

orro

sion

rem

oval

and

sur-

face

prep

arat

ion.

The

disc

spr

oduc

em

inim

alm

etal

/su

bstr

ate

rem

oval

.T

hey

perf

orm

best

onri

ght

angl

ety

pedr

illm

otor

sbu

tca

nbe

used

succ

essf

ully

onin

-lin

edr

illm

otor

s.D

iscs

are

mou

nted

onth

eap

prop

riat

esi

zed

disc

pad

hold

er(I

tem

No.

39),

whi

chis

then

mou

nted

into

eith

eran

in-l

ine

ora

righ

tan

gle

drill

mot

or.

Ver

yFi

neG

rit

(Blu

eC

olor

)PN

0480

11-0

4T75

-6(1

½in

D)

Ope

nPu

rcha

seC

S(2

00E

A)

PN04

8011

-04T

77-0

(3in

D)

Ope

nPu

rcha

seC

S(1

00E

A)

PN04

8011

-042

78-7

(4in

D)

Ope

nPu

rcha

seC

S(1

00E

A)

PN04

8011

-043

03-6

(5in

D)

Ope

nPu

rcha

seC

S(5

0E

A)

Med

ium

Gri

t(M

aroo

nC

olor

)PN

0480

11-0

4122

-3(1

½in

D)

Ope

nPu

rcha

seC

S(2

00E

A)

PN04

8011

-074

59-7

(2in

D)

Ope

nPu

rcha

seC

S(2

00E

A)

PN04

8011

-041

24-7

(3in

D)

Ope

nPu

rcha

seC

S(1

00E

A)

PN04

8011

-074

51-1

(4in

D)

Ope

nPu

rcha

seC

S(1

00E

A)

PN04

8011

-006

43-7

(5in

D)

Ope

nPu

rcha

seC

S(5

0E

A)

48C

OM

BI-

SW

heel

with

Spin

dle

Mou

nt,A

lum

i-nu

mO

xide

,M

a-ro

onC

olor

(3in

Dx

1¾

inW

w/¼

inD

shan

k)

3MC

o.,

CA

GE

Cod

e#2

8124

,12

0gr

it,PN

0511

44-8

0678

Ope

nPu

rcha

seE

AC

ombi

natio

nof

alum

inum

oxid

eco

ated

abra

sive

and

non-

wov

enny

lon

mat

eria

lus

edfo

rfin

ishi

ng,

blen

d-in

g,an

dre

mov

ing

light

tom

ediu

mco

rros

ion.

MO

Sis

8000

RPM

.

180

grit,

PN05

1144

-807

99O

pen

Purc

hase

EA

TO 1-1-691

B-14

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

49A

bras

ive

Whe

els,

Non

-Wov

enN

y-lo

n,R

esin

Rei

n-fo

rced

(Alu

mi-

num

Oxi

deA

bras

ive)

A-A

-592

92(s

uper

sede

sM

IL-W

-813

19),

Type

I,C

lass

2(L

amin

ated

)G

rade

C(M

ediu

m)

-15

0gr

it(3

inD

x¾

inW

on¼

inD

shaf

t)

5345

-00-

732-

9989

EA

Rem

ovin

gm

ediu

mto

seve

reco

rros

ion

(e.g

.in

terg

ranu

-la

r,ex

folia

tion)

from

thic

km

ater

ials

.

Gra

deA

(Ver

yFi

ne)

-28

0gr

it(2

inD

x½

inW

on¼

inD

shaf

t)

5345

-00-

935-

7869

EA

The

sew

heel

sar

eve

ryag

gres

sive

and

will

re-

mov

em

etal

subs

trat

eas

wel

las

corr

osio

npr

oduc

ts.

Gra

deB

(Fin

e)-

180

Gri

t(6

inD

x¾

inW

with

½in

arbo

rho

le)

3460

-01-

479-

5941

EA

50A

bras

ive

Dis

kK

it(C

ompo

site

Mat

e-ri

alR

epai

r)

PN65

001,

CA

GE

Cod

e#0

0179

5345

-01-

015-

1419

KT

For

use

inre

pair

ofco

mpo

s-ite

and

hone

ycom

bm

ater

i-al

sO

NLY

.C

omes

with

3di

scho

lder

s(1

in,

2in

,an

d3

inD

size

s)an

d15

0di

scs

ofas

sort

edgr

its(5

0in

each

size

).

TO 1-1-691

B-15

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

51Fi

les,

Rot

ary,

Con

eSh

ape,

Hig

hSp

eed

Stee

lor

Tun

gste

nC

arbi

de

A-A

-511

76,

Type

II(T

ung-

sten

Car

bide

)St

yle

A(R

Hsp

iral

flute

)C

lass

B(M

ediu

m),

Size

5(¼

inD

x½

inL

)

3455

-00-

293-

3560

EA

Rem

ovin

gse

vere

corr

osio

n(e

.g.

inte

rgra

nula

ran

dex

folia

tion)

and

unde

rly-

ing

met

al;

atta

chto

ast

raig

htin

-lin

epn

eum

atic

drill

.St

yle

B(R

Hsp

iral

flute

w/c

hip

brea

ker)

,C

lass

C(F

ine)

,Si

ze6

(¼in

Dx

¾in

L)

3455

-00-

293-

3559

EA

Rot

ary

files

are

ex-

trem

ely

aggr

essi

veto

ols

and

can

easi

lyre

mov

eto

om

uch

met

alsu

b-st

rate

.Pa

yst

rict

atte

n-tio

nan

dta

keex

tra

care

whe

nus

ing

thes

eto

ols.

Styl

eA

,C

lass

C,

Size

7(¼

inD

x1

inL

)34

55-0

0-29

3-35

61E

A

52A

ircr

aftA

dhes

ive

and

Dec

alR

e-m

oval

Dis

c(A

AD

R),

Non

-A

bras

ive

3MC

o.,

CA

GE

Cod

e#5

2152

Com

mer

cial

Item

sU

sed

ona

pneu

mat

icdr

illto

rem

ove

adhe

sive

s,se

al-

ants

,de

cals

,gr

aphi

cs,

vi-

nyl

stri

ppin

gta

pes,

doub

le-s

ided

mol

ding

tape

s,an

dle

adin

ged

geta

pes

with

out

rem

ovin

g/da

mag

ing

the

unde

rcoa

t-in

gs.

Rec

omm

ende

dop

er-

atin

gsp

eed

is26

00R

PM;

dono

tex

ceed

4000

RPM

.

PN05

1131

-074

98(6

inD

x5⁄8

inW

onR

oloc

TM

Hol

der

w/3

⁄8in

Dsh

ank)

3460

-01-

447-

8021

CS

(5E

AD

iscs

w/1

Hol

der)

PN04

8011

-241

05-0

(1E

A2

in,

3in

,4,

5,6

inD

x5⁄8

inW

Dis

cw

/1E

AR

oloc

TM

Hol

der

w/3

⁄8in

Dsh

ank)

Ope

nPu

rcha

seC

S(5

EA

Dis

csw

/1H

olde

r)N

OT

E

Do

not

use

onac

rylic

lacq

uer

pain

tsan

dpo

ly-

carb

onat

eor

acry

licpl

astic

s(c

anop

ies,

win

-do

ws,

and

win

dscr

eens

).

TO 1-1-691

B-16

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

53Se

alan

t(M

astic

)R

emov

alK

itsK

ell-

Stro

mTo

olC

o.In

c.,

CA

GE

Cod

e#7

5245

Com

mer

cial

Item

sU

sed

tore

mov

ecu

red

seal

-an

tth

atov

erco

ats

fast

ener

patte

rns

orfil

let

seal

sat

stru

ctur

eed

ges

with

shar

pene

dpl

astic

and/

orst

eel

blad

esm

ount

edin

apn

eum

atic

pow

ered

vibr

a-to

ryto

olor

am

anua

lha

ndhe

ldsu

ppor

tha

ndle

.C

anal

sobe

used

tore

mov

ean

ti-sk

idm

ater

ials

from

airc

raft

floor

s/de

cks.

Pneu

mat

icV

ibro

Gun

Seal

ant

Re-

mov

alK

it-

Cas

eC

onta

inin

g1

Vi-

bro

Gun

with

Air

Hos

e,B

lade

Shar

pene

rw

ithA

ggre

gate

Dis

can

dV

acuu

m,

Ex-

tra

Dis

c(P

NO

Z70

05)

and

Vac

uum

Bag

s(P

NO

Z70

04),

6E

A1

inW

(PN

OZ

7001

)&

2E

A½

inW

(PN

OZ

7002

)R

igid

Plas

ticB

lade

s,&

1E

A2

inW

(PN

OZ

7003

)Fl

exib

leSt

eel

Bla

de

PNO

Z70

00(V

ibro

Gun

Seal

ant

Rem

oval

Kit)

4920

-01-

500-

8087

EA

PNO

Z70

06(V

ibro

Gun

only

)49

20-0

1-50

0-80

84E

A

PNO

Z70

07(H

and

Type

Seal

ant

Rem

oval

Kit)

4920

-01-

500-

8090

EA

TO 1-1-691

B-17

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Han

dTy

peSe

alan

tR

emov

alK

it-

Cas

eC

onta

inin

g1

EA

Padd

edPa

lmSu

ppor

tH

andl

e(P

NO

Z70

08),

6E

A1

inW

(PN

OZ

7001

),3

EA

½in

W(P

NO

Z70

02),

3E

A1

½in

W(P

NO

Z70

10),

&3

EA

1in

W(B

ut-

ton

Hea

dR

ivet

Ada

ptab

le)

Rig

idPl

astic

Bla

des,

2E

ASh

arpe

ning

Ston

es(P

NO

Z70

09),

&2

EA

Smal

lC

lean

-in

gB

rush

es

Ant

iSt

atic

Air

Hos

es,

PNO

Z70

13(5

0ft

L)

Ope

nPu

rcha

seE

A

PNO

Z70

14(1

00ft

L)

Ope

nPu

rcha

seE

AR

epla

cem

ent

part

s-

use

PN’s

atle

ftto

orde

rO

pen

Purc

hase

TO 1-1-691

B-18

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

54Se

alan

tR

emov

alTo

ols

(Dri

llM

o-to

rM

ount

edSR

Cut

ters

&D

iscs

)

3MC

o.,

CA

GE

Cod

e#7

6381

Com

mer

cial

Item

sT

hese

plas

ticcu

tters

and

smal

lbr

istle

disc

sar

epa

r-tic

ular

lyus

eful

for

re-

mov

alof

seal

ant

coat

ings

onan

dar

ound

prot

rudi

ngfa

sten

ers

and

lap

type

seam

s.T

hey

prov

ide

ef-

fect

ive

seal

ant

rem

oval

whi

lem

inim

izin

gco

n-ta

min

atio

nof

the

sur-

roun

ding

area

and

the

sub-

sequ

ent

requ

ired

clea

nup

.

PN61

-500

1-75

76-7

(#8

SRC

utte

r-

1in

D)

3455

-01-

509-

1769

BX

(40

EA

)

PN61

-500

1-75

77-5

(#3

SRR

otar

yC

utte

r)34

55-0

1-50

9-17

79B

X(4

0E

A)

PN61

-500

1-75

78-3

(#2

inSR

Rad

ial

Bri

stle

Dis

c)34

60-0

1-50

9-17

94B

X(4

0E

A)

PN61

-500

1-75

79-1

(#3

inSR

Rad

ial

Bri

stle

Dis

c)34

60-0

1-50

9-17

91B

X(4

0E

A)

PN61

-500

0-78

16-9

(Ro-

locT

MPa

d&

#1Pl

astic

Hol

der)

3460

-01-

509-

1784

BX

(5E

A)

PN61

-500

0-74

12-7

(Ro-

locT

MPa

d&

#7Pl

astic

Red

But

ton

for

Hol

der)

3460

-01-

509-

1812

BX

(5E

A)

PN61

-500

0-73

34-3

(#99

0M

andr

el)

3460

-01-

493-

7924

BX

(5E

A)

Env

isio

nPn

eum

atic

Seal

ant

Rem

oval

Kit

(Inc

lude

s:1

EA

Inge

rsol

l-R

and

1000

RPM

Rig

htA

ngle

Dri

ve,

¼in

Thr

eade

dC

huck

Pneu

mat

icD

rill

Mot

or;

1T

ube

with

5E

A#8

SRC

utte

rs;

and

1T

ube

with

5E

A#3

SRC

utte

rs

PNQ

A08

59D

-1,

CA

GE

Cod

e#2

A17

851

30-0

1-51

4-08

53K

it

Aer

owin

gR

apid

Des

ealin

gSy

stem

(RD

S)

RD

S001

6635

-01-

572-

5251

EA

TO 1-1-691

Change 2 B-19

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

55O

ptic

alD

epth

Mi-

crom

eter

Kit

(Dig

ital

Rea

dout

)PR

EFE

RR

ED

TO

OL

PN84

00K

,C

AG

EC

ode

#659

5666

50-0

1-22

0-89

42E

AIn

spec

tion

ofan

dde

pth,

wid

th,

and

leng

thm

ea-

sure

men

tsof

corr

osio

nda

mag

ean

dco

rros

ion

grin

dou

tar

eas.

56O

ptic

alD

epth

Mi-

crom

eter

Kit

(Ana

log,

Me-

chan

ical

Rea

dout

)A

LTE

RN

AT

ET

OO

L

PN96

6A1,

CA

GE

Cod

e#9

2541

6650

-00-

831-

5532

EA

Insp

ectio

nof

and

dept

h,w

idth

,an

dle

ngth

mea

-su

rem

ents

ofco

rros

ion

dam

age

and

corr

osio

ngr

ind

out

area

s.

57D

epth

Gau

ge,

Nee

dle

Poin

tD

ial

Indi

cato

r

PN65

2728

1,C

AG

EC

ode

#701

6852

10-0

0-71

0-43

59E

APr

ecis

ion

mea

sure

men

tof

corr

osio

nda

mag

ean

dco

r-ro

sion

grin

dou

tde

pth

with

ina

rang

eof

0.0

into

0.12

5in

.58

Mag

nify

ing

Gla

ss,

Fold

ing

Pock

etT

ripl

eL

ens

Type

(Cir

cula

rsh

ape

-½

inD

)

PN81

-23-

95,

CA

GE

Cod

e#0

6175

6650

-00-

530-

1880

EA

Insp

ectio

nof

corr

osio

n.M

agni

fyin

gpo

wer

ofth

ele

nses

are

5X,

7X,

and,

10X

.L

ense

spi

vot

for

ei-

ther

sing

leor

com

bina

tion

use.

59In

spec

tion

Mir

ror

GG

G-M

-350

,Ty

peII

(Plu

nger

Act

ivat

ed),

Cla

ss3

(Rec

tang

ular

)Si

ze1

(1½

inL

x1

¼in

W)

5120

-00-

278-

9926

EA

Aid

for

insp

ectin

gha

rdto

see

area

sfo

rco

rros

ion.

Size

2(2

inL

x1

¾in

W)

5120

-00-

618-

6902

EA

60W

ritin

gIn

stru

men

t,A

ircr

aft

Mar

king

(Non

-cor

rosi

ve)

A-A

-87,

Red

7510

-00-

174-

3205

DZ

Iden

tifica

tion/

mar

king

ofco

rrod

edar

eas.

A-A

-87,

Whi

te75

10-0

0-24

0-15

25D

ZA

-A-8

7,B

lack

7510

-01-

240-

1526

DZ

A-A

-87,

Yel

low

7510

-01-

264-

4612

DZ

A-A

-87,

Blu

e75

10-0

1-43

6-52

10D

ZPN

SAN

1340

1,C

AG

EC

ode

#86

874

7520

-01-

478-

9942

EA

PN16

001,

CA

GE

Cod

e#

8687

4,05

360

7520

-01-

004-

7846

DZ

TO 1-1-691

B-20 Change 18

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

61B

rush

,Pl

ater

’sH

and

Type

(Cur

ved

Han

dle

Styl

e)

A-A

-311

8(s

uper

sede

sH

-B-1

78),

Type

I,C

lass

2

7920

-00-

244-

7431

EA

A13

inov

eral

lle

ngth

brus

hw

itha

5¼

inL

x1

¼in

Wbr

ush

area

havi

ng4

row

sof

1in

Lbr

istle

sus

edto

rem

ove

loos

eco

r-ro

sion

prod

ucts

and

flak-

ing

pain

tan

dto

appl

ycl

eani

ngso

lven

tsan

dco

mpo

unds

.

TO 1-1-691

Change 18 B-20.1/(B-20.2 blank)

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

62H

and

Bru

sh,

Woo

den

Han

dle,

(Sta

inle

ssSt

eel

Fill)

PN15

SS,

CA

GE

Cod

e#1

7987

7920

-00-

900-

3577

EA

A7

¾in

over

all

leng

thbr

ush

with

abr

ush

area

of7/

16in

used

tore

mov

eco

rros

ion

from

alum

inum

allo

ysu

rfac

es.

63Fl

ashl

ight

,Adj

ust-

able

Bea

m,

Met

al/P

last

icC

ase,

Non

-Re-

char

geab

le

PN10

1-00

0-00

2,C

AG

EC

ode

#061

3462

30-0

1-24

7-75

49E

AU

sefo

rco

rros

ion

insp

ectio

n.

Rec

harg

eabl

ePN

106-

000-

003,

CA

GE

Cod

e#0

6134

6230

-01-

152-

5952

EA

64Sh

ears

and

Scis

sors

GG

G-S

-278

Stra

ight

Shea

rs(9

inL

)51

10-0

0-16

1-69

12E

AC

uttin

gta

pes,

chee

secl

oth,

mas

king

mat

eria

ls,

elec

tri-

cal

wir

es,

etc.

Ele

ctri

cian

’sSc

isso

rs(5

inL

w/w

ire

Stri

pN

otch

es)

5110

-00-

212-

7455

EA

65Se

para

tors

,Air

and

Wat

er,

Com

-pr

esse

dA

ir(A

irR

egul

ator

Ass

em-

bly)

A-A

-594

36(s

uper

sede

sM

IL-S

-129

28),

Cla

ss1

(1R

egul

ator

,2

Out

lets

)

4940

-00-

242-

4100

EA

Wal

l-m

ount

edse

para

tors

desi

gned

tore

mov

eoi

l,w

ater

,an

dfo

reig

npa

r-tic

les

from

com

pres

sed

air,

and

tore

gula

teth

ede

liver

ypr

essu

reof

air

used

for

spra

ypa

int

guns

and

pneu

mat

icto

ols.

Cla

ss2

(2R

egul

ator

s,4

Out

lets

)49

40-0

0-24

2-41

01E

A

66Pa

int

Bru

sh,

Flat

,M

etal

Bou

nd,

Synt

hetic

Fibe

r

H-B

-420

,Ty

peII

,G

rade

B,

1in

W80

20-0

0-26

3-38

66E

AU

sed

toap

ply

brus

habl

ese

alan

tsan

dad

hesi

ves.

2in

W80

20-0

0-55

0-83

59E

A67

Mix

ers,

Liq

uid,

Re-

volv

ing

Shaf

tan

dA

gita

tor

Type

s

A-A

-594

33(s

uper

sede

sM

IL-M

-307

0),

Type

I-

Rev

olvi

ngSh

aft,

Cla

ss1

-½

hp(1

15V

)E

lect

ric

Mot

or

4940

-00-

221-

1707

EA

Use

dto

mix

two

com

pone

ntse

alan

tsbe

fore

appl

ica-

tion.

TO 1-1-691

B-21

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

68Sp

ray

Kit,

Self

Pres

suri

zed

(Kit

Con

tain

s4

EA

Spra

yD

evic

es,

20E

AD

ipT

ubes

,4

EA

Jar

Con

tain

-er

sfo

rM

ater

ials

,an

d10

EA

cans

ofN

on-C

lass

1O

DS

Prop

ella

nt)

SAE

AS2

2805

(sup

erse

des

MIL

-S-2

2805

),M

odel

8011

Pow

erPa

k

4940

-00-

803-

6444

KT

Use

for

appl

ying

pain

ts,

degr

easi

ngco

mpo

unds

,pr

eser

vativ

es(C

PC’s

),an

dot

her

touc

h-up

mat

eria

lsw

hen

othe

rsp

ray

appl

ica-

tion

equi

pmen

tis

impr

ac-

tical

.

69Ps

ychr

omet

erA

-A-2

579

Slin

g,Po

cket

Type

6685

-00-

826-

1662

EA

Mea

sure

men

tof

rela

tive

hum

idity

and

dew

poin

tto

assi

stin

dete

rmin

atio

nof

cure

time

for

seal

ants

,ad

hesi

ves,

and

pain

ts.

Psyc

hro-

Dyn

e,PN

WE

-22

014,

CA

GE

Cod

e#6

6420

6685

-01-

263-

8370

EA

SAFE

TY

EQ

UIP

ME

NT

(Ref

erto

Figu

reB

-1th

roug

hFi

gure

B-3

atth

een

dof

this

appe

ndix

for

illus

trat

ion

ofso

me

item

sin

this

sect

ion)

.

NO

TE

Con

sult

loca

lSa

fety

and

Bio

envi

ronm

enta

lE

ngin

eeri

ngO

ffice

sfo

rPe

rson

alPr

otec

tive

Equ

ipm

ent

(PPE

)re

quir

emen

ts.

The

seof

fices

have

auth

ority

tosu

bstit

ute

equi

vale

ntsa

fety

equi

pmen

tw

hen

appr

opri

ate.

70Pa

rtic

ulat

eR

espi

ra-

tor

(½Fa

cepi

ece

Mas

k),

Dis

pos-

able

Type

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

8511

4240

-01-

247-

2348

BX

(80

EA

)Pe

rson

nel

prot

ectio

nfr

omin

hala

tion

ofdu

stan

dpa

r-tic

ulat

esdu

ring

light

sand

-in

gan

dgr

indi

ngop

era-

tions

.71

Full

Face

piec

eR

es-

pira

tor,

Air

Filte

r-in

g(w

/oC

ar-

trid

ges

orR

etai

ners

)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7800

S-S

(Sm

all)

4240

-01-

314-

2780

EA

Pers

onne

lpr

otec

tion

from

inha

latio

nof

orga

nic

va-

pors

,du

st,

part

icul

ates

,an

dpa

int

spra

ysin

non-

confi

ned

area

sdu

ring

spra

ying

,sa

ndin

g,an

dgr

indi

ngop

erat

ions

.

PN78

00S-

M(M

ediu

m)

4240

-01-

342-

5239

EA

PN78

00S-

L(L

arge

)42

40-0

1-30

1-32

00E

A

TO 1-1-691

B-22

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

72Fu

llFa

cepi

ece

Res

-pi

rato

r,A

irFi

lter-

ing

(w/o

Car

-tr

idge

sor

Ret

aine

rs)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

6700

(Sm

all)

4240

-01-

454-

8531

BX

(4E

A)

Pers

onne

lpr

otec

tion

from

inha

latio

nof

orga

nic

va-

pors

,du

st,

part

icul

ates

,an

dpa

int

spra

ysin

non-

confi

ned

area

sdu

ring

spra

ying

,sa

ndin

g,an

dgr

indi

ngop

erat

ions

.

PN68

00(M

ediu

m)

4240

-01-

454-

8535

BX

(4E

A)

PN69

00(L

arge

)42

40-0

1-45

4-85

38B

X(4

EA

)

73H

alf

Face

piec

eR

es-

pira

tor,

Air

Filte

r-in

g(w

/oC

ar-

trid

ges

orR

etai

ners

)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

6100

(Sm

all)

4240

-01-

342-

2852

BX

(24

EA

)Pe

rson

nel

prot

ectio

nfr

omin

hala

tion

ofor

gani

cva

-po

rs,

dust

,pa

rtic

ulat

es,

and

pain

tsp

rays

inno

n-co

nfine

dar

eas

duri

ngsp

rayi

ng,

sand

ing,

and

grin

ding

oper

atio

ns.

PN62

00(M

ediu

m)

4240

-01-

342-

2853

BX

(24

EA

)PN

6300

(Lar

ge)

4240

-01-

342-

2854

BX

(24

EA

)

74Fi

lter

Car

trid

ges

(Org

anic

Vap

or/

P100

Type

)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

6092

142

40-0

1-45

5-73

53B

X(6

0E

A)

For

use

with

3MC

o.ha

lfan

dfu

llfa

cepi

ece

(600

0&

7000

Seri

es)

resp

irat

ors.

75R

espi

rato

rL

ens

Ass

embl

yfo

r3M

Co.

Full

Face

-pi

ece

Res

pira

tors

(with

Plas

ticFi

lmC

over

s)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7884

4240

-01-

247-

8929

BX

(5E

A)

Rep

lace

men

tle

nsfo

r78

00S

Seri

esre

spir

ator

s.PN

6898

Ope

nPu

rcha

seB

X(5

EA

)R

epla

cem

ent

lens

for

6000

Seri

esre

spir

ator

s.

76L

ens

Cov

ers

for

3MC

o.Fu

llFa

ce-

piec

eR

espi

rato

rs(P

eel-

Aw

ayPl

as-

ticFi

lm)

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7899

-25

4240

-01-

248-

4634

PK(1

00E

A)

Len

sco

vers

for

7800

SSe

-ri

esre

spir

ator

s.PN

7899

-100

4240

-01-

248-

6435

BX

(100

EA

)L

ens

cove

rsfo

r78

00S

Se-

ries

resp

irat

ors.

PN68

8542

40-0

1-45

5-27

87B

X(1

00E

A)

Len

sco

vers

for

6800

Seri

esre

spir

ator

s.77

Inha

latio

nV

alve

for

3MC

o.Fu

llFa

cepi

ece

Res

pi-

rato

rs

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7282

4240

-01-

248-

2607

BX

(200

EA

)R

epla

cem

ent

valv

esfo

r78

00S

Seri

esre

spir

ator

s.PN

6893

4240

-01-

455-

2811

BX

(200

EA

)R

epla

cem

ent

valv

esfo

r68

00Se

ries

resp

irat

ors.

78E

xhal

atio

nV

alve

for

3MC

o.Fu

llFa

cepi

ece

Res

pi-

rato

rs

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7283

4240

-01-

248-

2608

BX

(50

EA

)R

epla

cem

ent

valv

esfo

r78

00S

Seri

esre

spir

ator

s.PN

6889

4240

-01-

455-

2809

BX

(10

EA

)R

epla

cem

ent

valv

esor

6800

Seri

esre

spir

ator

s.

TO 1-1-691

B-23

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

79Ty

vekT

MSh

roud

for

3MC

o.Fu

llFa

cepi

ece

Res

pi-

rato

rs

3MC

o.,

CA

GE

Cod

e#5

0378

,PN

7915

-542

40-0

1-32

0-19

57PG

(5E

A)

Use

dw

ithfu

llfa

cepi

ece

resp

irat

ors

topr

otec

tth

ehe

adan

dne

ckfr

ompa

int-

ing

and/

orab

rasi

vebl

ast-

ing

over

spra

y.80

Spec

tacl

eK

itfo

r3M

Co.

Full

Face

piec

eR

espi

-ra

tors

3MC

o.,

CA

GE

Cod

e#5

0378

Con

sist

sof

fram

ean

dre

-ta

iner

clip

.PN

6878

4240

-01-

455-

2346

EA

For

use

on60

00Se

ries

full

face

piec

ere

spir

ator

s.PN

7925

4240

-01-

395-

4128

EA

For

use

with

pres

crip

tion

lens

esw

ith78

00S

Seri

esfu

llfa

cepi

ece

resp

irat

ors.

81R

espi

rato

rC

lean

ing

Wip

es(A

lcoh

ol-

Free

Tow

elet

tes)

3MC

o.,

CA

GE

Cod

e#5

0378

&O

T1L

6,PN

504

4240

-01-

372-

3078

BX

(100

EA

)H

ygie

nic

clea

ning

ofre

spi-

rato

rsan

dot

her

pers

onal

prot

ectiv

ege

ar/e

quip

men

t.65

10-0

1-39

7-43

39B

X(5

00E

A)

Do

not

use

shop

air

for

brea

thin

gor

asin

let

air

for

thes

ebr

eath

able

air

pum

ps.

Itco

ntai

nsoi

l,pa

rtic

ulat

es,

and

harm

ful

gase

s.R

ead

and

follo

weq

uipm

ent

inst

ruct

ions

tode

term

ine

the

max

imum

num

ber

ofai

rlin

esto

beus

edw

itha

sing

lepu

mp.

82Pu

mp/

Com

pres

sor,

Bre

atha

ble

Air

,Pn

eum

atic

(Air

Mot

or)

Dri

ven,

Port

able

Rhi

neA

ir,

Inc.

,C

AG

EC

ode

#585

01,

PNN

F-11

00su

pers

edes

PNN

F15-

3

4240

-01-

363-

4699

EA

Use

dto

supp

lybr

eath

able

air

toho

ods

and

full

face

-pi

ece

resp

irat

ors

for

abra

-si

vebl

astin

gan

dot

her

corr

osio

nre

mov

alop

era-

tions

,as

requ

ired

,an

dpa

intin

gop

erat

ions

.T

hese

smal

l,ai

rdr

iven

,po

rtab

leco

mpr

esso

rsar

eve

ryco

n-ve

nien

tas

they

may

beea

sily

tran

spor

ted

and

set

upal

mos

tan

ywhe

reto

supp

lybr

eath

able

air.

Bul

lard

Co.

,C

AG

EC

ode

#097

29,

PNA

DP-

16/

AD

P-20

4310

-01-

168-

7302

EA

TO 1-1-691

B-24

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

NO

TE

Use

MIL

-PR

F-32

033

oil

(NSN

9150

-00-

231-

6689

/1Q

TC

N)

orM

IL-H

-176

72hy

drau

licflu

id/1

0w

t.oi

leq

uiva

lent

(NSN

9150

-00-

985-

7231

/1Q

TC

N)

tofil

lin

-lin

eoi

ler

ofai

rm

otor

afte

rea

chus

e,as

requ

ired

,to

mai

ntai

nlu

bric

atio

nan

dpr

even

tm

otor

oxid

atio

n.

83R

epla

cem

ent

Filte

rC

artr

idge

sfo

rB

reat

habl

eA

irPu

mps

Rhi

neA

ir,

Inc.

,C

AG

EC

ode

#585

01,

PNC

F808

0

4240

-01-

084-

0921

BX

(10

EA

)R

epla

cem

ent

filte

rsfo

rus

ew

ithR

hine

Air

’sN

F-11

00an

dN

F15-

3pu

mps

.

84C

ompr

esse

dA

irIn

let

Hos

eA

s-se

mbl

y,½

inI

DH

ose

w/3

⁄8in

ID

Ori

fice

Fitti

ngs

Rhi

neA

ir,

Inc.

,C

AG

EC

ode

#585

01,

PNE

D13

13B

-50

(50

ftL

)

4240

-01-

251-

8159

EA

Use

don

lyfo

rsu

pply

ing

fres

h,br

eath

able

air

toth

eai

rm

otor

onth

ebr

eath

-ab

leai

rpu

mp

unit.

PNE

D13

13B

-100

(100

ftL

)42

40-0

1-25

1-81

60E

AT

hese

inle

tho

seas

sem

blie

sca

nbe

used

with

both

Rhi

neA

iran

dB

ulla

rdun

its.

85Q

uick

Dis

conn

ect

Fitti

ngs

for

Inle

tH

ose

CA

GE

Cod

e#7

3992

,3L

25(M

ale

Plug

)47

30-0

1-44

2-18

09E

AR

epla

cem

ent

fittin

gsfo

rth

eR

hine

Air

,PN

ED

1313

Bin

let

air

hose

asse

mbl

ies.

3R25

(Fem

ale

Cou

pler

)47

30-0

1-44

2-18

08E

A86

Out

let

Man

ifol

d,Q

uick

Dis

conn

ect

(Fem

ale

Cou

pler

Ass

embl

y)

Rhi

neA

ir,

Inc.

,C

AG

EC

ode

#585

01,

PNE

D-

06-4

30

Ope

nPu

rcha

seE

AC

onne

cts

resp

irat

orai

rho

seas

sem

blie

sto

the

brea

th-

able

air

pum

p.C

anbe

used

with

both

Rhi

neA

iran

dB

ulla

rdun

its.

87G

love

s,M

en’s

&W

omen

’s(W

ork

Cot

ton

Flan

nel;

Nat

ural

inC

olor

)

A-A

-166

5,St

yle

1(K

nit

Cuf

f/R

eg.)

8415

-00-

268-

8330

PRG

ener

alpu

rpos

epr

otec

tive

wor

kgl

oves

for

hand

pro-

tect

ion

duri

ngva

riou

sm

aint

enan

ceop

erat

ions

.St

yle

2(G

aunt

let/R

eg.)

8415

-00-

634-

5027

PRSt

yle

3(R

ever

sibl

ePa

lm/

Kni

tC

uff/

Lar

ge)

8415

-00-

559-

5613

PR

88G

love

s,C

loth

,V

i-ny

lD

ippe

d(B

lack

inC

olor

)

A-A

-503

70(s

uper

sede

sM

IL-G

-822

53),

Type

1(G

aunt

let/M

ediu

m)

8415

-00-

916-

2817

PRG

ener

alpu

rpos

elig

htdu

tyty

pech

emic

alan

doi

lpr

o-te

ctiv

egl

oves

used

for

hand

prot

ectio

ndu

ring

clea

ning

and

chem

ical

,so

lven

t,an

doi

l/pre

serv

a-tiv

eap

plic

atio

ns.

Rub

ber-

ized

for

bette

rgr

ip.

Type

1(G

aunt

let/L

arge

)84

15-0

0-91

6-28

18PR

Type

2(K

nit

Wri

st/U

nive

r-sa

lon

e-si

zefit

sal

l)84

15-0

0-93

5-28

33PR

TO 1-1-691

B-25

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

89G

love

s,To

xico

logi

-ca

lAge

nts,

Pro-

tect

ive

(Bla

ckin

Col

or)

MIL

-G-1

2223

,Ty

peII

(14

inG

aunt

let)

X-S

mal

l(8

)84

15-0

0-75

3-65

50PR

Hea

vydu

tyin

dust

rial

grad

esy

nthe

ticru

bber

glov

esus

edfo

rha

ndpr

otec

tion

whi

leha

ndlin

gso

lven

ts,

chem

ical

pain

tre

mov

ers,

pain

ts,

seal

ants

,or

othe

rm

ater

ials

whi

chm

aybe

inju

riou

sto

the

skin

.

Smal

l(9

)84

15-0

0-75

3-65

51PR

Med

ium

(10)

8415

-00-

753-

6552

PRN

OT

E

The

segl

oves

are

not

desi

gned

for

prot

ectio

nin

elec

tric

alap

plic

atio

nsor

chem

ical

war

fare

activ

ities

.

Lar

ge(1

1)84

15-0

0-75

3-65

53PR

X-L

arge

(12)

8415

-00-

753-

6554

PR

90G

love

s,C

hem

ical

and

Oil

Prot

ectiv

e(G

reen

inC

olor

)

MIL

-G-8

7066

(Gau

ntle

tC

uff;

Floc

kL

inin

g)X

X-

Smal

l(7

)

8415

-01-

147-

6263

PRSy

nthe

ticru

bber

glov

esw

itha

high

degr

eeof

abra

sion

resi

stan

cean

dre

sist

ance

toch

emic

als

such

asw

a-te

r,ga

solin

e,oi

ls,

alka

lis,

and

acid

s.T

hey

are

used

topr

otec

tth

eha

nds

dur-

ing

airc

raft

,m

issi

le,

and

equi

pmen

tw

ashi

ngop

era-

tions

.

X-S

mal

l(8

)84

15-0

1-14

7-95

40PR

Smal

l(9

)84

15-0

1-01

2-92

94PR

Med

ium

(10)

8415

-01-

013-

7382

PRL

arge

(11)

8415

-01-

013-

7384

PR

91G

love

s,D

ispo

sabl

e,N

itrile

Rub

ber,

Pre-

Pow

dere

d,A

mbi

dext

rous

(Lig

htB

lue

inC

olor

)

CA

GE

Cod

e#6

2538

&4X

954,

PN70

05S

(Sm

all)

8415

-01-

352-

6556

PG(2

0B

X/1

00E

A)

Gen

eral

purp

ose

prot

ectiv

ew

ear

for

the

hand

sdu

ring

vari

ous

clea

ning

and

cor-

rosi

ontr

eatm

ent

oper

a-tio

ns.

The

segl

oves

are

heav

ier

duty

and

have

bette

rre

sist

ance

toso

me

chem

ical

sth

anth

ela

tex

rubb

ergl

oves

(Ite

mN

o.92

).

PN70

05M

(Med

ium

)84

15-0

1-35

2-65

53PG

(20

BX

/100

EA

)PN

7005

L(L

arge

)84

15-0

1-35

2-65

54PG

(20

BX

/100

EA

)PN

7005

XL

(X-L

arge

)84

15-0

1-35

2-65

55PG

(20

BX

/100

EA

)

TO 1-1-691

B-26

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

92G

love

s,D

ispo

sabl

e,L

atex

Rub

ber,

Pre-

Pow

dere

d,A

mbi

dext

rous

(Nat

ural

inC

olor

)

A-A

-535

13,

Smal

l65

15-0

1-36

5-61

83PG

(100

EA

)G

ener

alpu

rpos

epr

otec

tive

wea

rfo

rth

eha

nds

duri

ngva

riou

scl

eani

ngan

dco

r-ro

sion

trea

tmen

top

era-

tions

.T

hese

glov

esar

elig

hter

duty

and

have

som

ewha

tle

ssre

sist

ance

toso

me

chem

ical

sth

anth

eni

trile

rubb

ergl

oves

(Ite

mN

o.91

).

Med

ium

6515

-01-

364-

8553

PG(1

00E

A)

Lar

ge65

15-0

1-36

4-85

54PG

(100

EA

)

93C

over

alls

,C

otto

n,H

ook-

Pile

Fas-

tene

rTa

pe(G

reen

inC

olor

)

MIL

-C-2

202,

Type

I(O

live

Gre

en)

Smal

l(4

2)84

05-0

0-13

1-65

07E

APr

otec

tive

clot

hing

for

cor-

rosi

onm

aint

enan

cean

din

spec

tion

pers

onne

l.D

e-si

gned

prim

arily

for

wea

rov

erre

gula

r/st

reet

clot

h-in

g.

Med

ium

(46)

8405

-00-

131-

6508

EA

Lar

ge(5

0)84

05-0

0-13

1-65

09E

AX

-Lar

ge(5

4)84

05-0

0-13

1-65

10E

AX

X-L

arge

(58)

8405

-00-

131-

6511

EA

94C

over

alls

,D

ispo

s-ab

le,

Gen

eral

Purp

ose

(Whi

tein

Col

or)

A-A

-503

58,

X-S

mal

l84

15-0

0-60

1-07

92E

APr

otec

tive

clot

hing

for

cor-

rosi

onm

aint

enan

cepe

r-so

nnel

topr

otec

tag

ains

tdi

rt,

grea

se,

pain

t,an

dlo

w-h

azar

dco

ntam

inan

ts.

The

yar

eon

e-pi

ece,

fron

top

enin

g(s

lide

type

clo-

sure

)co

vera

llsm

ade

offir

ere

sist

ant

and

wat

erre

pelle

ntm

ater

ials

,an

dth

eyar

ein

tend

edto

beth

row

naw

ayw

hen

dirt

y.

Smal

l84

15-0

0-60

1-07

93E

AM

ediu

m84

15-0

0-60

1-07

94E

AL

arge

8415

-00-

601-

0797

EA

X-L

arge

8415

-00-

601-

0801

EA

XX

-Lar

ge84

15-0

0-60

1-08

02E

A

95C

over

alls

,D

ispo

s-ab

le(W

hite

inC

olor

)

A-A

-551

96(s

uper

sede

sM

IL-C

-870

69),

Type

I(w

ithH

ood)

Smal

l/Me-

dium

8415

-01-

445-

6565

EA

Prot

ectiv

eol

efin

cove

ralls

with

anat

tach

edho

odha

ving

adr

awst

ring

clo-

sure

and

atta

ched

boot

ies

for

mai

nten

ance

pers

onne

lpe

rfor

min

gw

ork

arou

ndas

best

osm

ater

ials

orw

ithfib

ergl

ass

and

othe

rco

m-

posi

tem

ater

ials

.T

hey

are

inte

nded

tobe

thro

wn

away

afte

rus

e.

Lar

ge/X

-Lar

ge84

15-0

1-44

5-65

68E

AX

X-L

arge

8415

-01-

445-

6588

EA

TO 1-1-691

B-27

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

96T

rous

ers,

Wet

Wea

ther

(Gre

enin

Col

or)

MIL

-T-8

7099

(sup

erse

des

MIL

-O-2

2776

)X

X-

Smal

l

8405

-01-

276-

1532

PRW

ater

proo

fch

loro

pren

eru

b-be

rco

ated

nylo

ntw

illtr

ouse

rsfo

rus

ein

con-

junc

tion

with

aw

etw

eath

erpa

rka

(Ite

mN

o.97

),fo

rai

rcra

ft,

mis

sile

,an

deq

uipm

ent

mai

nte-

nanc

eop

erat

ions

for

per-

sonn

elpr

otec

tion

inw

etor

wet

/col

dco

nditi

ons.

X-S

mal

l84

05-0

1-27

6-15

33PR

Smal

l84

05-0

1-27

6-15

34PR

Med

ium

8405

-01-

276-

1535

PRL

arge

8405

-01-

276-

1536

PRX

-Lar

ge84

05-0

1-27

6-15

37PR

NO

TE

Com

mer

cial

Equ

ival

ent

Wet

Wea

ther

Gea

rca

nbe

use

prov

idin

glo

cal

bio-

envi

ronm

ent,

safe

tyan

dfir

efu

nctio

nsap

prov

al.

Tro

user

s,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Woo

dlan

dco

lor)

Non

-Spe

c/

SSN

C-I

CT

heIm

prov

edR

ain

Suit

(IR

S)is

mad

eof

Sym

pa-

Tex,

alig

htw

eigh

tbr

eath

-ab

le,

wat

erpr

oof

mat

eria

lm

ade

bySy

mpa

Tex

Tech

-no

logi

esG

mbH

.Sy

mpa

-Te

xis

any

lon

mat

eria

lth

atis

plia

ble

and

moi

s-tu

re-v

apor

-sem

i-pe

rme-

able

.It

resi

stex

tern

alw

a-te

rw

hile

allo

win

gpe

rspi

ratio

nor

othe

rm

ois-

ture

totr

ansf

erfr

omin

-si

deto

outs

ide,

ther

eby

keep

ing

the

wea

rer

dry

and

com

fort

able

.

XX

-SM

AL

L84

05-0

1-44

3-94

30E

AX

-SM

AL

L84

05-0

1-44

3-94

36E

ASM

AL

L84

05-0

1-44

3-94

49E

AM

ED

IUM

8405

-01-

443-

9487

EA

LA

RG

E84

05-0

1-44

3-94

88E

AX

-LA

RG

E84

05-0

1-44

3-94

93E

AX

X-L

AR

GE

8405

-01-

443-

9498

EA

Tro

user

s,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Uni

-ve

rsal

Cam

ou-

flage

colo

r)

Non

-Spe

c/

PD99

20T

heIR

Str

ouse

rsha

vea

draw

-str

ing

atth

ew

aist

,a

cent

erzi

pper

,pa

ssth

roug

hpo

cket

s,V

elcr

ocl

osur

esat

the

ankl

es,

and

long

leg

zipp

ers

for

easy

on-o

ff.

The

seat

and

knee

sar

ere

info

rced

.

XX

-SM

AL

L84

15-0

1-52

7-15

37E

AX

-SM

AL

L84

15-0

1-52

7-15

41E

ASM

AL

L84

15-0

1-52

7-15

45E

AM

ED

IUM

8415

-01-

527-

1551

EA

LA

RG

E84

15-0

1-52

7-15

55E

AX

-LA

RG

E84

15-0

1-52

7-15

60E

AX

X-L

AR

GE

8415

-01-

527-

1561

EA

TO 1-1-691

B-28 Change 8

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Tro

user

s,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Woo

dlan

dco

lor)

Non

-Spe

c/

SSN

C-I

CT

heIR

Str

ouse

rsfo

rma

wat

erpr

oof

oute

rsh

ell

wor

nov

erot

her

clot

hing

and

gear

.It

islig

htw

eigh

tho

wev

er;

IRS

func

tions

stri

ctly

asa

rain

barr

ier,

offe

ring

little

prot

ectio

nfr

omth

eco

ld.

XX

-SM

AL

L84

05-0

1-44

3-94

30E

AX

-SM

AL

L84

05-0

1-44

3-94

36E

ASM

AL

L84

05-0

1-44

3-94

49E

AM

ED

IUM

8405

-01-

443-

9487

EA

LA

RG

E84

05-0

1-44

3-94

88E

AX

-LA

RG

E84

05-0

1-44

3-94

93E

AX

X-L

AR

GE

8405

-01-

443-

9498

EA

Tro

user

s,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Uni

-ve

rsal

Cam

ou-

flage

colo

r)

Non

-Spe

c/

PD99

20X

X-S

MA

LL

8415

-01-

527-

1537

EA

X-S

MA

LL

8415

-01-

527-

1541

EA

SMA

LL

8415

-01-

527-

1545

EA

ME

DIU

M84

15-0

1-52

7-15

51E

AL

AR

GE

8415

-01-

527-

1555

EA

X-L

AR

GE

8415

-01-

527-

1560

EA

XX

-LA

RG

E84

15-0

1-52

7-15

61E

A97

Park

a,W

etW

eath

er(G

reen

inC

olor

)M

IL-P

-870

98(s

uper

sede

sM

IL-P

-822

77)

XX

-Sm

all

8405

-01-

276-

4187

EA

Wat

erpr

oof

chlo

ropr

ene

rub-

ber

coat

edny

lon

twill

park

afo

rus

ein

conj

unc-

tion

with

wet

wea

ther

trou

sers

(Ite

mN

o.96

)fo

rai

rcra

ft,

mis

sile

,an

deq

uipm

ent

mai

nten

ance

oper

atio

nsfo

rpe

rson

nel

prot

ectio

nin

wet

orw

et/

cold

cond

ition

s.

X-S

mal

l84

05-0

1-27

6-41

88E

ASm

all

8405

-01-

276-

4189

EA

Med

ium

8405

-01-

276-

4190

EA

Lar

ge84

05-0

1-27

6-41

91E

AX

-Lar

ge84

05-0

1-27

6-41

92E

A

TO 1-1-691

Change 8 B-29

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Park

a,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Woo

dlan

dco

lor)

Non

-Spe

c/

SSC

NC

-IC

The

Impr

oved

Rai

nSu

it(I

RS)

ism

ade

ofSy

mpa

-Te

x,a

light

wei

ght

brea

th-

able

,w

ater

proo

fm

ater

ial

mad

eby

Sym

paTe

xTe

ch-

nolo

gies

Gm

bH.

Sym

pa-

Tex

isa

nylo

nm

ater

ial

that

ispl

iabl

ean

dm

ois-

ture

-vap

or-s

emi-

perm

e-ab

le.

Itre

sist

exte

rnal

wa-

ter

whi

leal

low

ing

pers

pira

tion

orot

her

moi

s-tu

reto

tran

sfer

from

in-

side

toou

tsid

e,th

ereb

yke

epin

gth

ew

eare

rdr

yan

dco

mfo

rtab

le.

XX

-SM

AL

L84

05-0

1-44

3-96

06E

AX

-SM

AL

L84

05-0

1-44

3-96

12E

ASM

AL

L84

05-0

1-44

3-96

18E

AM

ED

IUM

8405

-01-

443-

9622

EA

LA

RG

E84

05-0

1-44

3-96

26E

AX

-LA

RG

E84

05-0

1-44

3-96

30E

AX

X-L

AR

GE

8405

-01-

443-

9633

EA

Park

a,Im

prov

edW

etW

eath

er:

light

wei

ght

Bre

atha

ble

(Uni

-ve

rsal

Cam

ou-

flage

colo

r)

Non

-Spe

c/

CO

/PD

-992

0T

heIR

Spa

rkas

have

roll-

upho

odw

itha

viso

ran

ddr

awst

ring

clos

ure.

The

rear

ear

mpi

tzi

pper

sfo

rve

n-til

atio

n,a

heav

yfu

ll-le

ngth

zipp

erin

fron

tco

v-er

edby

ast

orm

flap

that

clos

esw

ithsn

aps.

The

pock

ets

are

pass

-thr

ough

toin

ner

garm

ents

.T

heel

bow

sar

ere

info

rced

and

Vel

cro

clos

ures

atth

ecu

ffs

mak

ea

tight

fit.

XX

-SM

AL

L84

15-0

1-52

7-46

10E

AX

-SM

AL

L84

15-0

1-52

7-46

11E

ASM

AL

L84

15-0

1-52

7-46

12E

AM

ED

IUM

8415

-01-

527-

4614

EA

LA

RG

E84

15-0

1-52

7-46

16E

AX

-LA

RG

E84

15-0

1-52

7-46

17E

AX

X-L

AR

GE

8415

-01-

527-

4618

EA

The

IRS

park

asfo

rma

wa-

terp

roof

oute

rsh

ell

wor

nov

erot

her

clot

hing

and

gear

.It

islig

htw

eigh

tho

wev

er;

IRS

func

tions

stri

ctly

asa

rain

barr

ier,

offe

ring

little

prot

ectio

nfr

omth

eco

ld.

TO 1-1-691

B-30 Change 8

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

98Pa

rka

and

Tro

user

s,W

etW

eath

er(W

oodl

and

Cam

-ou

flage

Patte

rn)

MIL

-P-4

3907

,C

lass

2(W

dld

Cam

Pat)

Park

a-

XX

-Sm

all

8405

-01-

053-

9202

EA

Wat

erpr

oof

poly

uret

hane

coat

edny

lon

twill

park

a(w

ithho

od)

and

trou

sers

for

use

over

oute

rga

r-m

ents

(hot

orco

ldw

eath

er)

duri

ngai

rcra

ft,

mis

sile

,an

deq

uipm

ent

mai

nten

ance

oper

atio

nsfo

rpe

rson

nel

prot

ectio

nin

wet

orw

et/c

old

cond

ition

sw

hen

cam

oufla

gepa

ttern

clot

hing

isre

quir

ed.

X-S

mal

l84

05-0

0-00

1-15

47E

ASm

all

8405

-00-

001-

1548

EA

Med

ium

8405

-00-

001-

1549

EA

Lar

ge84

05-0

0-00

1-15

50E

AX

-Lar

ge84

05-0

0-00

1-15

51E

AT

rous

ers

-X

X-S

mal

l84

05-0

1-05

3-94

00PR

X-S

mal

l84

05-0

0-00

1-80

25PR

Smal

l84

05-0

0-00

1-80

26PR

Med

ium

8405

-00-

001-

8027

PRL

arge

8405

-00-

001-

8028

PRX

-Lar

ge84

05-0

0-00

1-80

29PR

Park

aan

dT

rous

ers,

Wet

Wea

ther

(Woo

dlan

dC

am-

oufla

gePa

ttern

)

MIL

-P-2

8958

/MIL

-P-

4390

7W

ater

proo

fpo

lyur

etha

neco

ated

nylo

ntw

illpa

rka

(with

hood

)an

dtr

ouse

rsfo

rus

eov

erou

ter

gar-

men

ts(h

otor

cold

wea

ther

)du

ring

airc

raft

,m

issi

le,

and

equi

pmen

tm

aint

enan

ceop

erat

ions

for

pers

onne

lpr

otec

tion

inw

etor

wet

/col

dco

nditi

ons

whe

nca

mou

flage

patte

rncl

othi

ngis

requ

ired

.

SMA

LL

8405

-01-

443-

9449

EA

ME

DIU

M84

05-0

1-44

3-94

87E

AL

AR

GE

8405

-01-

443-

9488

EA

X-L

AR

GE

8405

-01-

443-

9493

EA

TO 1-1-691

Change 8 B-30.1

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

99Ja

cket

,E

xtre

me

Col

dW

eath

er,

Impe

rmea

ble

(Gre

enin

Col

or)

MIL

-J-8

2299

,Sm

all

8415

-00-

349-

9313

EA

Prot

ectiv

eou

terw

ear

for

air-

craf

t,m

issi

le,

and

equi

p-m

ent

mai

nten

ance

oper

a-tio

nsat

tem

pera

ture

sbe

low

+14

°F

(-10

°C

).U

sed

inco

njun

ctio

nw

ithex

trem

eco

ldw

eath

ertr

ouse

rs(I

tem

No.

100)

and

aho

od.

X-L

arge

8415

-00-

349-

9316

EA

100

Tro

user

s,E

xtre

me

Col

dW

eath

er,

Impe

rmea

ble

(Gre

enin

Col

or)

MIL

-T-2

1705

,Sm

all

(Siz

e27

to30

)84

15-0

0-57

5-12

25E

APr

otec

tive

oute

rwea

rfo

rai

r-cr

aft,

mis

sile

,an

deq

uip-

men

tm

aint

enan

ceop

era-

tions

atte

mpe

ratu

res

belo

w+

14°

F(-

10°

C).

Use

din

conj

unct

ion

with

anex

trem

eco

ldw

eath

erja

cket

(Ite

mN

o.99

)an

da

hood

.

X-L

arge

(Siz

e39

to42

)84

15-0

0-57

5-12

46E

AX

X-L

arge

(Siz

e43

to46

)84

15-0

0-57

5-12

47E

A

101

Pads

,K

nee,

Indu

s-tr

ial

PN31

861,

CA

GE

Cod

e#5

5799

4240

-00-

595-

3861

PRK

nee

prot

ectio

ndu

ring

mai

nten

ance

oper

atio

ns.

Mad

eof

hard

rubb

erw

itha

spon

geru

bber

liner

and

atta

ched

with

two

adju

st-

able

web

stra

psw

ithre

-ta

inin

gbu

ckle

s.

PN54

02T

13,

CA

GE

Cod

e#3

9428

Sam

e

PN71

H17

18,

CA

GE

Cod

e#5

3800

Sam

e

102

Fire

men

’sB

oots

(Bla

ckin

Col

or)

A-A

-503

71,

Type

II(K

nee

Len

gth

-13

½in

Hig

h)-

Size

5

8430

-00-

753-

5935

PRPr

otec

tive

oute

rfo

otw

ear

for

airc

raft

mai

nten

ance

op-

erat

ions

such

asai

rcra

ft,

mis

sile

,an

deq

uipm

ent

was

hing

.Si

ze6

8430

-00-

753-

5936

PRSi

ze7

8430

-00-

753-

5937

PRSi

ze8

8430

-00-

753-

5938

PRSi

ze9

8430

-00-

753-

5939

PRSi

ze10

8430

-00-

753-

5940

PRSi

ze11

8430

-00-

753-

5941

PRSi

ze12

8430

-00-

753-

5942

PRSi

ze13

8430

-00-

753-

5943

PRSi

ze14

8430

-00-

753-

5944

PRSi

ze15

8430

-00-

753-

5945

PR

TO 1-1-691

B-30.2 Change 8

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Type

I(¾

Len

gth

-29

inH

igh)

-Si

ze5

8430

-00-

753-

6105

PR

Size

684

30-0

0-14

7-10

32PR

Size

784

30-0

0-14

7-10

33PR

Size

884

30-0

0-14

7-10

34PR

Size

984

30-0

0-14

7-10

35PR

Size

1084

30-0

0-14

7-10

36PR

Size

1184

30-0

0-29

9-03

42PR

Size

1284

30-0

0-14

7-10

38PR

Size

1384

30-0

0-08

2-54

90PR

Size

1484

30-0

0-08

2-54

91PR

Size

1584

30-0

0-08

2-54

92PR

103

Foot

wea

rC

over

s,A

ircr

aft

Was

h-do

wn

(Cha

rcoa

lG

ray

inC

olor

)

PNM

,C

AG

EC

ode

#292

23,

Med

ium

8430

-00-

911-

2458

PRW

ater

repe

llent

cove

rsw

orn

over

boot

sto

incr

ease

trac

tion

and

prev

ent

mak

-in

gbo

otm

arks

onai

rcra

ftsu

rfac

esw

hen

wal

king

onth

emdu

ring

mai

nten

ance

and

was

hing

oper

atio

ns.

Lar

ge84

30-0

0-91

1-24

59PR

X-L

arge

8430

-00-

911-

3771

PR

104

Foot

wea

rC

over

,C

hem

ical

Prot

ec-

tive

Ove

rboo

ts(B

lack

inC

olor

)

MIL

-F-4

3987

,Sm

all

8430

-01-

118-

8712

PRO

verb

oots

for

foot

wea

r(s

hoes

and

boot

s)us

edto

prot

ect

them

from

chem

i-ca

lat

tack

duri

ngm

aint

e-na

nce

oper

atio

nsw

hich

requ

ire

use

ofch

emic

als.

The

yar

eac

id,

fuel

,oi

l,an

dfir

ere

sist

ant.

The

smal

lsi

zeis

for

use

over

size

s3

to7

½co

mba

tbo

ots

and

the

larg

esi

zeis

for

use

over

size

s8

to14

com

bat

boot

s.

Lar

ge84

30-0

1-02

1-59

78PR

TO 1-1-691

Change 8 B-30.3/(B-30.4 blank)

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

105

Ove

rsho

es,

Men

’sR

ubbe

r,5

Buc

kle

Type

(Bla

ckin

Col

or)

A-A

-503

62(s

uper

sede

sM

IL-O

-836

),Si

ze5

8430

-00-

144-

1672

PRM

ediu

mw

eigh

tov

ersh

oes

topr

otec

tre

gula

rfo

otw

ear

from

wat

eran

dot

her

liq-

uids

duri

ngm

aint

enan

ceop

erat

ions

orou

tsid

eac

-tiv

ities

duri

ngin

clem

ent

wea

ther

cond

ition

s.

Size

684

30-0

0-14

4-16

73PR

Size

784

30-0

0-14

4-16

74PR

Size

884

30-0

0-14

4-16

43PR

Size

984

30-0

0-14

4-16

44PR

Size

1084

30-0

0-14

4-16

45PR

Size

1184

30-0

0-14

4-16

46PR

Size

1284

30-0

0-14

4-16

47PR

Size

1384

30-0

0-14

4-16

48PR

Size

1484

30-0

0-14

4-16

49PR

Size

1584

30-0

0-14

4-16

82PR

106

Apr

on,

Util

ity(L

abor

ator

yB

lack

inC

olor

)

A-A

-310

4(s

uper

sede

sZ

Z-

A-6

05)

(45

inL

x35

inW

)

8415

-00-

634-

5023

EA

Afu

llle

ngth

chlo

ropr

ene

rubb

er(a

cid

resi

stan

t)pr

o-te

ctiv

eap

ron

used

topr

o-te

ctco

rros

ion

mai

nten

ance

pers

onne

lan

dth

eir

clot

h-in

gag

ains

tch

emic

alsp

lash

esw

hen

hand

ling

chem

ical

s.10

7Fa

ceSh

ield

,In

dus-

tria

l,(A

djus

tabl

eSt

rap,

Cle

arle

ns)

AN

SIZ

87.1

(sup

erse

des

L-F

-36)

(9in

Lx

18in

WPl

astic

Win

dow

/Len

s)

4240

-00-

542-

2048

EA

Use

dto

prov

ide

eye

and

face

prot

ectio

nw

hen

cut-

ting,

grin

ding

,or

chip

ping

met

alor

whe

nha

ndlin

gha

zard

ous

chem

ical

s.

NO

TE

Face

shie

ldis

not

for

prim

ary

prot

ectio

nan

dsh

ould

alw

ays

beus

edw

ithgo

ggle

s.

TO 1-1-691

B-31

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

108

Gog

gles

,In

dust

rial

,Pl

astic

Stan

dard

Safe

tyG

oggl

es(A

djus

tabl

eH

ead-

band

,Si

ngle

Cle

arPo

lyca

rbon

-at

ePl

astic

Len

s,V

ente

dC

lear

Plas

ticFr

ame)

AN

SIZ

87.1

(sup

erse

des

A-A

-111

0)42

40-0

0-05

2-37

76PR

Topr

ovid

eey

epr

otec

tion

from

flyin

gpa

rtic

les

inin

dust

rial

envi

ronm

ents

.C

anbe

wor

nov

erey

e-gl

asse

s.G

oggl

esar

eve

nti-

late

dto

redu

cefo

ggin

g.

Spla

sh-P

roof

Gog

gles

(Adj

ust-

able

Hea

dban

d,Si

ngle

Gre

enPo

lyca

rbon

ate

Plas

ticL

ens,

Lig

ht-g

reen

Plas

-tic

Fram

ew

ithIn

dire

ctV

entin

g)

4240

-01-

082-

8928

PRTo

prot

ect

eyes

from

chem

i-ca

lsp

lash

es,

impa

cts,

and

spar

ks.

Can

bew

orn

over

eyeg

lass

es.

Ven

tilat

edfo

rco

mfo

rtan

dto

prov

ide

airfl

owto

min

imiz

ele

nsfo

ggin

g.

109

Gog

gles

,C

hem

ical

Spla

shPr

oof

Type

(Adj

usta

ble

Hea

dban

d,D

oubl

eC

lear

Gla

ssL

ens,

Un-

vent

edC

lear

Plas

ticFr

ame

with

Rub

ber

Face

Pads

)

AN

SIZ

87.1

Com

mer

cial

Item

sC

omm

only

know

nas

“Nod

and

Shak

e”go

ggle

s,th

eyar

epa

rtic

ular

lyus

eful

for

eye

prot

ectio

ndu

ring

air-

craf

t,m

issi

le,

and

equi

p-m

ent

was

hing

oper

atio

ns.

The

yal

sopr

ovid

eex

cel-

lent

eye

prot

ectio

ndu

ring

chem

ical

corr

osio

nre

-m

oval

and

met

alsu

rfac

etr

eatm

ent

oper

atio

ns.

PNA

883F

,C

AG

EC

ode

#6M

644

Ope

nPu

rcha

sePR

PN55

1,C

AG

EC

ode

#160

29O

pen

Purc

hase

PR

110

Plug

,E

arD

ispo

s-ab

le(Y

ello

win

Col

or)

PN4-

375,

CA

GE

Cod

e#8

9875

&U

3216

6515

-00-

137-

6345

BX

(400

EA

)(2

00E

Aw

rapp

edpa

irs)

Com

pres

sibl

evi

nyl

foam

mat

eria

lth

atex

pand

sto

fitth

eea

rca

nal

and

prov

ide

am

oder

ate

degr

eeof

hear

ing

prot

ectio

nin

high

nois

ein

dust

rial

envi

ron-

men

ts.

TO 1-1-691

B-32

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

111

Prot

ecto

r,H

eari

ng(H

eadp

hone

Cir

-cu

mau

ral/e

arm

uff

Styl

e,C

omes

with

Ext

raSe

tof

Seal

s)

A-A

-580

8442

40-0

0-02

2-29

46E

AFi

tsse

cure

lyov

erth

eea

rsto

prov

ide

ahi

ghde

gree

ofhe

arin

gpr

otec

tion

tohe

lppr

even

the

arin

glo

ssor

dam

age

inlo

udw

ork

ar-

eas.

112

Aur

alPr

otec

tor,

Soun

dSA

EA

S23

899

(sup

erse

des

MIL

-A-2

3389

)E

arm

uff

asse

mbl

y

4240

-00-

759-

3290

EA

Fits

secu

rely

over

the

ears

topr

ovid

ea

high

degr

eeof

hear

ing

prot

ectio

nto

help

prev

ent

hear

ing

loss

orda

mag

ein

loud

wor

kar

-ea

s.

Rep

lace

men

tSe

als

4240

-00-

979-

4040

PR

SEA

LA

NT

APP

LIC

AT

ION

EQ

UIP

ME

NT

(TO

OL

S)11

3Se

alan

tD

ispe

nsin

gG

unw

ith2.

5O

ZM

etal

Ret

aine

r(M

anua

lTy

pe)

CA

GE

Cod

e#9

2108

,PN

2218

24,

(Sem

co®

Mod

el#8

50-2

.5M

)

5120

-01-

135-

8344

EA

App

licat

ion

ofse

alan

tsan

dad

hesi

ves.

114

Seal

ant

Dis

pens

ing

Gun

with

6O

ZM

etal

Ret

aine

r(M

anua

lTy

pe)

CA

GE

Cod

e#9

2108

,PN

2218

30,

(Sem

co®

Mod

el#8

50-6

M)

5120

-00-

952-

3507

EA

App

licat

ion

ofse

alan

tsan

dad

hesi

ves.

115

Seal

ant

Dis

pens

ing

Gun

with

12O

ZM

etal

Ret

aine

r(M

anua

lTy

pe)

CA

GE

Cod

e#9

2108

,PN

2218

36,

(Sem

co®

Mod

el#8

50-1

2M)

5120

-01-

373-

3805

EA

App

licat

ion

ofse

alan

tsan

dad

hesi

ves.

116

Seal

ant

Dis

pens

ing

Gun

with

2.5

OZ

Met

alR

etai

ner

(Pne

umat

icTy

pe)

CA

GE

Cod

e#9

2108

,PN

2502

55,

(Sem

co®

Mod

el#2

50A

-2½

)

5130

-00-

323-

2287

EA

App

licat

ion

ofse

alan

tsan

dad

hesi

ves.

Gun

hand

leis

rem

ovab

leto

allo

wfo

rea

sier

acce

ssin

confi

ned

area

s.R

efer

toFi

gure

6-1.

117

Seal

ant

Dis

pens

ing

Gun

with

6O

ZM

etal

Ret

aine

r(P

neum

atic

Type

)

CA

GE

Cod

e#9

2108

,PN

2500

65,

(Sem

co®

Mod

el#2

50A

-6)

5130

-00-

924-

6396

EA

App

licat

ion

ofse

alan

tsan

dad

hesi

ves.

Gun

hand

leis

rem

ovab

leto

allo

wfo

rea

sier

acce

ssin

confi

ned

area

s.R

efer

toFi

gure

6-1.

TO 1-1-691

B-33

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

118

Seal

ant

Dis

pens

ing

Gun

with

12O

ZM

etal

Ret

aine

r(P

neum

atic

Type

)

CA

GE

Cod

e#9

2108

,PN

2501

25,

(Sem

co®

Mod

el#2

50A

-12)

Ope

nPu

rcha

seE

AA

pplic

atio

nof

seal

ants

and

adhe

sive

s.G

unha

ndle

isre

mov

able

toal

low

for

easi

erac

cess

inco

nfine

dar

eas.

Ref

erto

Figu

re6-

1.11

9R

epai

rK

itfo

rSe

al-

ant

Dis

pens

ing

Gun

(Pne

umat

icTy

pe)

CA

GE

Cod

e#9

2108

,PN

2400

20O

pen

Purc

hase

KT

Val

vere

pair

kit

for

Sem

co®

Mod

el#2

50-A

seal

ant

disp

ensi

nggu

ns.

120

Rep

lace

men

tC

ar-

trid

geR

etai

ners

for

Sem

co®

Mod

el#8

50M

anua

lSe

alan

tD

ispe

nsin

gG

uns

CA

GE

Cod

e#9

2108

Sem

co®

Mod

el#8

50R

etai

ners

,PN

2268

19

5120

-01-

247-

1639

EA

Rep

lace

men

tm

etal

reta

iner

;2.

5O

Zgu

ns.

PN22

6820

5340

-01-

384-

6120

EA

Rep

lace

men

tm

etal

reta

iner

;6

OZ

guns

.PN

2268

22O

pen

Purc

hase

EA

Rep

lace

men

tm

etal

reta

iner

;12

OZ

guns

.12

1R

epla

cem

ent

Car

-tr

idge

Ret

aine

rsfo

rSe

mco

®M

odel

#250

-APn

eum

atic

Seal

-an

tD

ispe

nsin

gG

uns

CA

GE

Cod

e#9

2108

Sem

co®

Mod

el#2

50A

Ret

aine

rs,

PN22

0256

5120

-00-

693-

8069

EA

Rep

lace

men

tm

etal

reta

iner

;2.

5O

Zgu

ns.

PN22

0928

5120

-00-

693-

8070

EA

Rep

lace

men

tm

etal

reta

iner

;6

OZ

guns

.PN

2209

2351

20-0

0-69

3-80

71E

AR

epla

cem

ent

met

alre

tain

er;

12O

Zgu

ns.

122

Hos

eA

ssem

blie

sfo

rSe

mco

®M

odel

#250

-APn

eum

atic

Seal

-an

tD

ispe

nsin

gG

uns

CA

GE

Cod

e#9

2108

,H

ose

Ass

embl

yw

ithH

anse

nC

onne

ctor

Ass

embl

y,(5

ftL

)PN

2800

00

Ope

nPu

rcha

seE

AR

epla

cem

ent

hose

asse

m-

blie

san

dfit

tings

for

Sem

co®

Mod

el#2

50-A

pneu

mat

icse

alan

tdi

spen

s-in

ggu

ns.A

llho

seas

sem

-bl

ies

com

ew

itha

B-n

utfit

ting

and

aqu

ick

disc

on-

nect

atta

chm

ent

(10

ftL

)PN

2800

0147

20-0

0-95

6-53

13E

A(1

5ft

L)

PN28

0002

Ope

nPu

rcha

seE

A(2

0ft

L)

PN28

0003

4720

-01-

329-

8602

EA

(25

ftL

)PN

2800

0447

20-0

0-08

0-51

59E

A(3

0ft

L)

PN28

0005

Ope

nPu

rcha

seE

AH

anse

nC

onne

ctor

Ass

em-

bly,

PN22

9186

Ope

nPu

rcha

seE

A

B-N

utA

ssem

bly

(Gun

End

),PN

2291

8947

30-0

1-26

7-53

07E

A

TO 1-1-691

B-34

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

123

Wre

nch

for

Sem

co®

Mod

el#2

50-A

Pneu

-m

atic

Seal

ant

Dis

pens

ing

Gun

s

CA

GE

Cod

e#9

2108

,PN

2400

1851

20-0

0-99

6-15

65E

ASe

rvic

ew

renc

hfo

rad

just

ing

Sem

co®

Mod

el#2

50-A

pneu

mat

icse

alan

tdi

spen

s-in

ggu

ns.

124

Sem

co®

Dis

posa

ble

Plas

ticC

artr

idge

s,Pl

unge

rs,

Seal

s,an

dC

aps

for

Man

ual

and

Pneu

mat

icSe

al-

ant

Dis

pens

ing

Gun

s

CA

GE

Cod

e#9

2108

,C

ar-

trid

ges

(HD

Poly

ethy

l-en

e),

PN22

0316

(2.5

OZ

)

5120

-00-

694-

9082

EA

Em

pty

cart

ridg

esfo

rfil

ling

with

and

disp

ensi

ngof

two-

part

seal

ants

usin

gth

eSe

mco

®M

odel

#’s

250-

Aan

d85

0se

alan

tdi

spen

sing

guns

.PN

2203

17(6

OZ

)51

20-0

0-67

3-18

86E

APN

2203

18(1

2O

Z)

5120

-01-

454-

4210

EA

Wip

erPl

unge

rs(L

DPo

ly-

ethy

lene

),PN

2202

5951

20-0

0-27

6-94

22E

AU

sed

toas

sure

com

plet

edi

spen

sing

ofse

alan

tsan

del

imin

atio

nof

was

tean

d/or

leak

age

from

the

back

end

ofth

eca

rtri

dge.

Fits

eith

er2.

5O

Z,

6O

Z,

or12

OZ

cart

ridg

es.

WP

(Wip

erPl

unge

r)T

hrea

ded

Cap

,PN

2344

11

5365

-01-

107-

7863

EA

Use

dto

scre

win

toan

dca

pth

ene

ckor

fron

ten

dof

the

cart

ridg

eto

prev

ent

leak

age.

Fits

eith

er2.

5O

Z,

6O

Z,

or12

OZ

car-

trid

ges.

TC

-Sea

lC

ap,

Flan

geC

ap,

PN22

0238

8125

-00-

410-

8501

EA

Use

dto

snap

onto

the

back

end

ofth

eca

rtri

dge

topr

even

tco

ntam

inat

ion

ofth

ese

alan

t.Fi

tsei

ther

2.5

OZ

,6

OZ

,or

12O

Zca

r-tr

idge

s.F-

Flan

ge(S

nap

On)

Cap

125

Mec

hani

cal

Bea

mA

naly

tical

Bal

-an

ce(O

haus

Dia

l-O

-Gra

mB

alan

ce)

CA

GE

Cod

e#8

5973

(Oha

usC

orp.

),PN

1650

6670

-00-

957-

3781

EA

Use

for

wei

ghin

gou

tth

epr

oper

ratio

ofba

sean

dac

cele

rato

rco

mpo

unds

topr

epar

ean

dm

ixtw

oco

m-

pone

ntse

alan

ts.

TO 1-1-691

B-35

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

126

Sem

co®

Seal

ant

Smoo

thin

gTo

ols

(Fib

ergl

ass

Rei

n-fo

rced

Plas

tic)

CA

GE

Cod

e#9

2108

,Se

al-

ant

Spat

ulas

,PN

2313

4951

20-0

1-33

7-94

15E

ASp

atul

asan

dsp

read

ers

for

tool

ing

and

smoo

thin

gse

alan

tsan

dad

hesi

ves.

For

addi

tiona

lin

form

atio

n,re

fer

toFi

gure

6-5.

9½

inL

;ro

unde

den

ds-

9/16

inD

&¼

inD

.PN

2262

4151

20-0

1-29

7-70

15E

A7

¼in

L;

sqen

d-3

/16

inW

&rd

.en

d-

3⁄8

inD

.PN

2262

4251

20-0

1-29

7-70

16E

A7

¼in

L;

sqen

d-9

/32

inW

&rd

.en

d-

1⁄8

inD

.PN

2262

4351

20-0

1-29

7-70

17E

A7

¼in

L;

sqen

ds-

3⁄8

inW

&15

/32

inW

.Sp

atul

aK

it,PN

2262

4451

20-0

0-05

6-32

37K

TT

heki

tin

clud

essp

atul

asPN

s22

6241

,22

6242

,an

d22

6243

spat

ulas

.Se

alan

tSc

rape

r,PN

2343

5051

20-0

1-29

8-61

21E

AU

sed

for

eith

ersp

read

ing

orre

mov

alof

seal

ant

from

all

surf

aces

(513

/16

inL

;on

esq

end

-¾

inW

).Se

alan

tSp

read

er,

PN22

9394

5120

-01-

337-

9416

EA

Use

dfo

rsp

read

ing

seal

ants

orad

hesi

ves

onto

flat

sur-

face

s,in

part

icul

aron

ala

rge

area

(4in

Lx

23/

16in

W).

Com

bSp

read

er,

PN22

9395

Ope

nPu

rcha

seE

AU

sed

tosp

read

seal

ants

orad

hesi

ves

whi

lem

aint

ain-

ing

aun

ifor

mth

ickn

ess

and

agr

oove

dpa

ttern

(3in

Lx

3in

Ww

ithsa

wto

oth

edge

s).

127

Plas

ticN

ozzl

es,

Dis

posa

ble

(¼in

or½

inN

PTM

ale

Thr

eade

dE

nd)

CA

GE

Cod

e#9

2108

(Sem

co®

Mod

el#’

s)N

ozzl

esus

edfo

rdi

spen

sing

seal

ants

whe

nat

tach

edto

Sem

co®

cart

ridg

es(I

tem

No.

124)

.R

efer

toFi

gure

6-2

for

nozz

lesh

apes

tode

term

ine

the

appr

opri

ate

Mod

el#

for

the

job.

TO 1-1-691

B-36

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

Stan

dard

Noz

zles

No.

252

(PN

2205

38)

5120

-00-

167-

0150

EA

App

lyin

gse

alan

tin

butt

seam

gaps

.St

2½

inL

with

1/16

inor

ifice

.N

o.25

4(P

N22

0540

)51

20-0

0-67

3-18

85E

ASt

2½

inL

with

1⁄8

inor

i-fic

e.N

o.25

5(P

N23

3495

)O

pen

Purc

hase

EA

St2

½in

Lw

ithno

orifi

ce(c

utto

suit)

.N

o.41

0(P

N22

0542

)51

20-0

0-80

1-09

49E

ASt

4in

Lw

ith1/

32in

ori-

fice.

No.

410

(PN

2205

43)

5120

-00-

055-

4063

EA

45°

angl

ew

ith1/

32in

ori-

fice.

No.

415

(PN

2276

13)

5120

-01-

386-

4480

EA

St4

inL

with

noor

ifice

(cut

tosu

it).

No.

420

(PN

2205

44)

5120

-00-

042-

6577

EA

St4

inL

with

1/16

inor

i-fic

e.N

o.43

0(P

N22

0548

)51

20-0

0-96

7-81

51E

ASt

4in

Lw

ith3/

32in

ori-

fice.

No.

430

(PN

2205

49)

5120

-00-

055-

4062

EA

45°

angl

ew

ith3/

32in

ori-

fice.

No.

440

(PN

2205

50)

5120

-00-

773-

3791

EA

St4

inL

with

1⁄8

inor

ifice

.N

o.62

0(P

N22

0553

)51

20-0

0-16

7-01

52E

ASt

6in

Lw

ith1/

16in

ori-

fice.

No.

620

(PN

2205

54)

5120

-00-

966-

5373

EA

45°

angl

ew

ith1/

16in

ori-

fice.

No.

640

(PN

2205

55)

5120

-00-

822-

7194

EA

St6

inL

with

1⁄8

inor

ifice

.N

o.64

0(P

N22

0556

)51

20-0

0-16

7-01

53E

A30

°an

gle

with

1⁄8

inor

ifice

.N

o.64

0(P

N22

0551

)51

20-0

0-67

0-11

86E

A45

°an

gle

with

1⁄8

inor

ifice

.N

o.65

0(P

N22

4494

)O

pen

Purc

hase

EA

St6

inL

with

1⁄8

inor

ifice

.N

o.82

0(P

N22

0557

)51

20-0

0-96

6-82

70E

ASt

8in

Lw

ith1/

16in

ori-

fice.

No.

820

(PN

2205

58)

5120

-00-

966-

5371

EA

45°

angl

ew

ith1/

16in

ori-

fice.

No.

840

(PN

2205

59)

5120

-00-

966-

5372

EA

St8

inL

with

1⁄8

inor

ifice

.N

o.84

0(P

N22

0560

)51

20-0

0-96

6-53

82E

A45

°an

gle

with

1⁄8

inor

ifice

.N

o.86

90(P

N22

0606

)51

20-0

0-96

6-82

43E

A9

inve

ntdu

ckno

zzle

with

3/32

inor

ifice

.

TO 1-1-691

B-37

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

No.

1002

(PN

2205

61)

5120

-00-

055-

4055

EA

St10

inL

with

1/16

inor

i-fic

e.N

o.10

04(P

N22

0563

)51

20-0

0-05

5-40

54E

ASt

10in

Lw

ith1⁄8

inor

ifice

.N

o.10

10(P

N22

0565

)51

20-0

0-05

5-40

58E

ASt

10in

Lw

ith5/

16in

ori-

fice.

Fille

tN

ozzl

es,

No.

425

(PN

2324

99)

5120

-01-

386-

4274

EA

App

lyin

gse

alan

tfil

lets

over

lap

join

ts.

St4

inL

with

3⁄8

inx

1⁄8

inor

ifice

.N

o.42

6(P

N23

2500

)O

pen

Purc

hase

EA

St4

inL

with

3⁄8

inx

1⁄8

inor

ifice

.N

o.42

7(P

N23

2501

)O

pen

Purc

hase

EA

St4

inL

with

3⁄8

inx

1⁄8

inor

ifice

.N

o.42

8(P

N23

2502

)O

pen

Purc

hase

EA

St4

inL

with

3⁄8

inx

1⁄8

inor

ifice

.N

o.42

9(P

N23

2590

)O

pen

Purc

hase

EA

St4

inL

with

1/16

inx

½in

orifi

ce.

Rib

bon

Noz

zles

,N

o.86

07(P

N22

0568

)51

20-0

0-96

6-53

81E

AA

pply

ing

seal

ant

for

fay

surf

ace

seal

ing.

St57

/ 8in

Lw

ith1/

16in

x¼

inor

i-fic

e.N

o.86

08(P

N22

0569

)51

20-0

0-96

6-82

44E

ASt

4in

Lw

ith11

/64

inor

i-fic

e(fl

ared

tip).

No.

8610

(PN

2205

70)

5120

-00-

299-

6790

EA

St41

⁄8in

Lw

ith3/

64in

x9/

64in

orifi

ce.

No.

8613

(PN

2205

72)

5120

-00-

966-

5379

EA

St5

inL

with

3/64

inx

3⁄8

inor

ifice

.N

o.86

15(P

N22

0574

)51

20-0

0-96

6-53

78E

ASt

4in

Lw

ith1/

16in

x½

inor

ifice

.N

o.86

16(P

N22

0577

)51

20-0

1-38

5-50

74E

A2

3/16

inL

with

7/32

inor

ifice

(for

win

dshi

eld

fille

ts).

No.

8630

(PN

2205

89)

5120

-00-

966-

5377

EA

St4

inL

with

1⁄8

inx

1¾

inor

ifice

.N

o.86

30-9

(PN

2205

82)

5120

-00-

966-

5376

EA

St47

⁄8in

Lw

ith1⁄8

inx

1¾

inor

ifice

and

anat

tach

edbr

ush

spre

ader

.

TO 1-1-691

B-38

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

No.

8642

(PN

2205

85)

5120

-00-

293-

4676

EA

St4

inL

with

3/16

inor

i-fic

e.N

o.86

43(P

N22

0586

)51

20-0

0-77

5-16

70E

ASt

43⁄8

inL

with

1⁄8

inx

¾in

orifi

cean

dsp

atul

alik

eex

tens

ion

spre

ader

.N

o.86

45(P

N22

0587

)51

20-0

0-13

8-16

58E

ASt

43/

16in

Lw

ith1⁄8

inx

1in

orifi

cean

dsp

atul

alik

eex

tens

ion

spre

ader

.N

o.86

46(P

N22

0588

)51

20-0

0-96

6-53

74E

ASt

315

/16

inL

with

1⁄8

inx

¾in

orifi

cean

dsa

wto

oth

trow

elex

tens

ion

spre

ader

.N

o.86

48(P

N22

0589

)51

20-0

0-96

6-53

75E

ASt

53/

16in

Lw

ith1⁄8

inx

¾in

orifi

cean

dsp

atul

alik

eex

tens

ion

spre

ader

.E

xten

sion

Noz

zle,

No.

600E

(PN

2205

52)

5120

-00-

670-

1187

EA

63⁄8

inL

roun

dex

tens

ion

tube

.Fl

oorb

oard

Noz

zle,

PN23

1674

Ope

nPu

rcha

seE

AA

pply

ing

seal

ant

onflo

orbo

ard

fayi

ngsu

rfac

es.

St1

3⁄8

inL

with

½in

Dct

r.bu

tton

surr

ound

edw

ith12

EA

1/32

inor

ifice

s.Fu

nnel

Noz

zle,

1in

(PN

2317

18)

Ope

nPu

rcha

seE

AFi

lling

larg

eca

vitie

sw

ithse

alan

t.St

13⁄8

inL

with

½in

funn

elty

peor

ifice

.2

in(P

N23

1348

)O

pen

Purc

hase

EA

St3

1⁄8

inL

with

127

/32

infu

nnel

type

orifi

ce.

Noz

zle

Ada

pter

,PN

2293

06O

pen

Purc

hase

EA

¼in

NPT

mal

eth

read

and

½in

NPT

fem

ale

thre

adto

rece

ive

½in

NPT

thre

adno

zzle

.E

dge

Fill

Noz

zle,

No.

444

(PN

2341

64)

Ope

nPu

rcha

seE

AA

0.40

inth

ick

flang

egu

ides

ital

ong

apa

nel

edge

/cor

-ne

rto

prov

ide

asl

ight

lyro

unde

ded

ge/c

orne

rfil

l.

TO 1-1-691

B-39

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

128

Fast

ener

Seal

ing

Noz

zles

(Cou

nter

-si

nkN

ozzl

es)

CA

GE

Cod

e#9

2108

,PN

2332

44,

Size

:3/

32in

-1⁄8

in(R

ed)

Ope

nPu

rcha

seE

AU

sed

toap

ply

the

requ

ired

amou

ntof

seal

ant

inth

eco

unte

rsin

kar

eaof

fas-

tene

rho

les

prio

rto

inst

al-

latio

nof

the

fast

ener

s.T

hey

have

thre

aded

ends

tofit

into

the

Sem

co®

plas

ticca

rtri

dges

(Ite

mN

o.12

4).

The

nozz

les

are

colo

rco

ded

for

iden

tifica

-tio

n.R

efer

toFi

gure

6-3

tode

term

ine

the

appr

opri

-at

eno

zzle

confi

gura

tion

and

size

for

the

job

asw

ell

asop

erat

ion

inst

ruc-

tions

.

PN23

3243

,Si

ze:

3/16

in-¼

in(W

hite

)O

pen

Purc

hase

EA

PN23

3451

,Si

ze:

5/16

in-

3⁄8

in(B

lue)

Ope

nPu

rcha

seE

A

PN23

1319

,Si

ze:

¼in

hole

(Yel

low

)O

pen

Purc

hase

EA

PN23

1320

,Si

ze:

5/16

inho

le(G

rey)

Ope

nPu

rcha

seE

A

PN23

1321

,Si

ze:

3⁄8

inho

le(G

reen

)O

pen

Purc

hase

EA

PN23

1560

,Si

ze:

7/16

inho

le(R

ed)

Ope

nPu

rcha

seE

A

PN23

1559

,Si

ze:

½in

hole

(Blu

e)O

pen

Purc

hase

EA

TO 1-1-691

B-40

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

129

Riv

etN

ozzl

esC

AG

EC

ode

#921

08,

PN23

4285

,Si

ze:

3/32

in(G

erm

aine

Gre

en)

Ope

nPu

rcha

seE

AU

sed

toap

ply

the

requ

ired

amou

ntof

seal

ant

inth

eco

unte

rsin

kan

dho

lepr

ior

tofa

sten

ing

part

sw

ithri

vets

.T

hesp

ring

-loa

ded

tipof

the

nozz

leac

tsas

ach

eck

valv

eal

low

ing

pre-

cise

shot

sof

mat

eria

lto

bedi

spen

sed.

The

yha

veth

read

eden

dsto

fitin

toth

eSe

mco

®pl

astic

car-

trid

ges.

The

nozz

les

are

colo

rco

ded

for

iden

tifica

-tio

n.R

efer

toFi

gure

6-4

tode

term

ine

the

appr

opri

-at

eno

zzle

confi

gura

tion

and

size

for

the

job

asw

ell

asop

erat

ion

inst

ruc-

tions

.

PN22

6837

,Si

ze:

1⁄8

in(B

lue)

5130

-01-

413-

8733

EA

PN22

6838

,Si

ze:

5/32

in(B

lack

)O

pen

Purc

hase

EA

PN22

6839

,Si

ze:

3/16

in(W

hite

)O

pen

Purc

hase

EA

PN23

4260

,Si

ze:

3/16

info

r12

0°co

unte

rsin

k(G

reen

)

Ope

nPu

rcha

seE

A

PN23

4284

,Si

ze:

7/32

in(L

ight

Blu

e)O

pen

Purc

hase

EA

PN22

6840

,Si

ze:

¼in

(Red

)51

20-0

1-41

6-16

83E

A

PN23

3051

,Si

ze:

5/16

in(O

rang

e)O

pen

Purc

hase

EA

PN:

2330

52,

Size

:3⁄8

in(Y

ello

w)

Ope

nPu

rcha

seE

A

130

Rol

ler

Noz

zles

(¼in

NPT

mal

eth

read

eden

d)

CA

GE

Cod

e#9

2108

,R

olle

rN

ozzl

eA

ssem

bly,

PN23

2693

(1in

WR

olle

r)

Ope

nPu

rcha

seE

AU

sed

toap

ply

adhe

sive

san

dse

alan

tsev

enly

over

wid

ear

eas

ofsu

bstr

ate

(e.g

.fa

ying

surf

ace)

.T

hey

have

thre

aded

ends

tofit

into

the

Sem

co®

plas

ticca

r-tr

idge

s.T

hey

can

beso

l-ve

ntcl

eane

dfo

rre

use.

PN23

2692

(2in

WR

olle

r)O

pen

Purc

hase

EA

Rep

lace

men

tR

olle

r,PN

2327

01(1

inW

Rol

ler)

5120

-01-

440-

6984

EA

PN23

2702

(2in

WR

olle

r)O

pen

Purc

hase

EA

TO 1-1-691

B-41

Tabl

eB

-2.

Equ

ipm

ent

for

Cle

anin

gan

dC

orro

sion

Pre

vent

ion

and

Con

trol

-C

onti

nued

Item No.

Nom

encl

atur

eSp

ecifi

catio

ns/P

NN

atio

nal

Stoc

kN

umbe

rU

nit

ofIs

sue

Inte

nded

Use

131

Cha

lk,

Mar

king

Ass

orte

dC

olor

sA

-A-8

075

10-0

0-28

2-69

24A

TId

entifi

catio

n/m

arki

ngof

corr

oded

area

s.W

hite

A-A

-318

7510

-00-

223-

6706

GR

132

Rap

idC

urin

gD

e-vi

ce(R

CD

)R

CD

-RX

M-K

it44

40-0

1-56

9-64

26E

AU

sed

with

SPD

/SPO

ap-

prov

alfo

rac

cele

rate

dcu

r-in

gof

seal

ants

.

TO 1-1-691

B-42 Change 2

Figure B-1. Back Mounted Full Facepiece Respirator

TO 1-1-691

Change 15 B-43

Figure B-2. Front Mounted Full Facepiece Respirator

TO 1-1-691

B-44

Figure B-3. Hooded Air Respirator System

TO 1-1-691

B-45/(B-46 blank)

GLOSSARY

A

ACTIVE METAL — A metal prone to corrode or beingcorroded.

ADDITIVE — A compound added for a particular purpose;for example, additives in fuel and lubricants can prevent cor-rosion, gum formation, varnishing, sludge formation, andknocking.

AERATION (OXYGEN CONCENTRATION)CELL — An electrolytic cell in which the driving force tocause corrosion results from a difference in the amount ofoxygen in solution at one point as compared to another. Cor-rosion is accelerated in areas where the oxygen concentratedis least, for example, in a crevice or under packing or gas-kets.

ALKALINE — Having a pH of more than 7.

ALLOY — A combination of two or more metals.

ANAEROBIC — A process which is capable of occurringin the absence of oxygen.

ANION — A negatively charged ion of an electrolyte whichmigrates toward the anode. The chloride ion in sea water isan anion.

ANODE — The electrode of a corrosion cell at which oxi-dation or corrosion occurs. It may be a small area on thesurface of a metal or alloy, such as that where a pit develops,or it may be the more active metal in a cell composed of twodissimilar metals, (i.e., the one with the greater tendency togo into solution). The corrosion process involves the changeof metal atoms into cations with a liberation of electrons thatmigrate through the metal to the cathode of the cell.

ANODIC PROTECTION — The reduction or eliminationof corrosion of a metal achieved by making current flowfrom it to the solution by connecting it to the positive pole ofa source of current. Under most conditions, as the potentialof an initially active metal is gradually shifted in a morenoble direction, such as by potentiostatic means, the corro-sion current gradually increases. However, with suitablecombinations of metal and solution, a critical potential issoon reached. Imposing a potential higher than the criticalpotential, causes the current to drop to a very low value, and

the metal becomes passive. The potential of metal has to beregulated by a potentiostat.

ANODIZE — To subject (a metal) to electrolytic action asthe anode of a cell in order to coat with a protective ordecorative film (anodic oxidation film).

AUSTENITIC — A term applied to that condition of ironassociated with a change in crystal structure that makes itnon-magnetic. This occurs with ordinary iron at an elevatedtemperature. When sufficient chromium and nickel are pres-ent, steel becomes austenitic (non-magnetic) at atmospheretemperatures. This is the case with the many stainless alloysthat combine about 18% chromium and 8% or more nickelwith iron.

C

CATHODE — The less active electrode of a corrosion cell,where the action of the current causes reduction and nearlycomplete elimination of corrosion.

CATHODIC PROTECTION — The reduction or elimina-tion of corrosion of a metal that is achieved by making cur-rent flow to it from a solution, such as connecting it to thenegative pole of some source current. The source of the pro-tective current may be sacrificial metal, such as magnesium,zinc, or aluminum. The current may also be derived from arectifier, generator, or battery applied through an appropriateanode which may be connected by the applied current (as inthe case of steel), or which remains substantially unaffectedby the current, as in the case of platinum. Cathodic protec-tion becomes complete when anodic reactions are completelysuppressed and only cathodic reactions occur on the metalsurface.

CATION — A positively charged ion in an electrolyte whichmigrates toward the cathode. Metallic ions, such as iron orcopper, are cations.

CAUSTIC EMBRITTLEMENT — The result of the com-bined action of tensile stress and corrosion in an alkalinesolution that causes embrittlement. This is the most fre-quently encountered in the laps of riveted boilers where therequired concentration of the alkali in the boiler water oc-curs.

CELL — In corrosion processes, a cell is a source of elec-trical current that is responsible for corrosion. It consists of

TO 1-1-691

Glossary 1

an anode and a cathode immersed in an electrolyte and elec-trically joined together. The anode and cathode may be sepa-rate metals dissimilar areas on the same metal.

CHEMICAL CONVERSION COATING — A film delib-erately produced on a metal by immersing it in, brushing itwith, or spraying it with a selected chemical solution for thepurpose of providing improved corrosion resistance to themetal or increasing the adhesion of organic coatings to beapplied later. Coatings covered by MIL-DTL-5541 are ex-amples.

CLEAR WATER — Colorless water containing no visiblesuspended particles.

COMBUSTIBLE LIQUID — Any liquid having a flash-point at or above 100° F, but below 200° F.

CONCENTRATION CELL — An electrolytic cell consist-ing of an electrolyte and two electrodes of the same metal oralloy that develops a difference in potential as a result of adifference in concentration of ions (most often metal ions) oroxygen at different points in a solution.

CORROSION FATIGUE — A reduction in the ability of ametal to withstand cyclic stress caused by its exposure to acorrosive environment.

CORROSION RATE — The speed of corrosion attack. It isusually expressed in terms of weight loss per unit of time.

COUPLE — Two or more metals or alloys in electrical con-tact with each other so that they can act as the electrodes ofa cell if they are immersed in an electrolyte.

CRACKING — Localized breaking of a paint film to ex-pose the underlying material and breaking of metal or alloyin a brittle fashion along a narrow path or network.

CREVICE CORROSION — Corrosion occurring within acrevice formed by two or more parts of the same or differentmetals or formed by a metal and non-metallic material.Stainless steel and aluminum alloys are particularly suscep-tible to crevice corrosion.

CRITICAL HUMIDITY — The relative humidity, under aspecific set of conditions, at which a metal or an alloy willbegin to corrode. In the presence of hygroscopic (moistureabsorptive) solids or corrosion products, the critical humid-ity will be lowered. Steel will not corrode if the relativehumidity is less than 30% in a marine atmosphere.

D

DEPOSIT ATTACK — When foreign material (dirt, corro-sion products, etc.,) is deposited on the surface of a metal, itmay shield the metal from the oxygen necessary to regener-ate a protective oxide layer. An oxygen concentration cell isformed, and serious corrosion may result. Also called an ac-tive-passive cell.

E

ELECTROCHEMICAL CORROSION — Corrosionwhich occurs when current flows between cathodic and an-odic areas on metallic surfaces.

ELECTRODE — A metal or alloy that is in contact withelectrolyte and serves as the site where electricity passes ineither direction between the electrolyte and metal. The cur-rent in the electrode itself is a flow of electrons, whereas, inthe electrolyte, ions carry electric charges and their orderlymovement in solution constitutes a flow of current in theelectrolyte.

ELECTROLYSIS — In the strict sense of the term, elec-trolysis concerns chemical changes in the solution or electro-lyte due to the passage of current. Its relation to corrosionarises only if the corrosion process alters the makeup of thesolution. Hence, since the term is most closely related to thesolution phenomena than to corrosion, its use to indicate cor-rosion should be discouraged.

ELECTROLYTE — Any substance which, in solution orfused, exists as electrically charged ions that render the liq-uid capable of conducting a current. Soluble acids, bases,and salts, such as sea water, are electrolytes.

ELECTROMAGNETIC INTERFERENCE (EMI) — Ra-diation generated from electromagnetic fields which are pro-duced by radar antennas, Radio Frequency (RF) antennas,on-board transmitters, certain poorly designed avionics units,electric motors, and lightning and other natural effects. Thistype of radiation can interfere with aircraft avionics systemscausing electrical malfunctions.

ELECTROMOTIVE FORCE (EMF) SERIES — A list ofelements according to their standard electrode potentials. Themore negative the potential the greater the tendency of themetal to corrode. This series is useful in studies of thermo-dynamic properties, but does not indicate the rates of corro-sion. A hydrogen gas electrode is the standard reference andits potential is designated as zero. All potentials are positiveor negative with respect to the hydrogen electrode. In this

TO 1-1-691

Glossary 2

country, the potentials of zinc and iron are designated asnegative and those of copper and platinum as positive.

EMBRITTLEMENT — Severe loss of ductility of a metalalloy that results in a brittle fashion.

EROSION — Destruction of a metal by the combined ac-tion of corrosion and abrasion or attrition by a liquid or gaswith or without suspended matter.

EXFOLIATION — The breaking away of material from itssurface in flakes or layers.

F

FAYING SURFACES — The common surfaces betweenmating parts.

FILIFORM CORROSION — Corrosion that develops un-der coatings on metals in fine ragged hairlines, usually wavyor curved and randomly distributed.

FILM — A thin layer of material that may or may not bevisible.

FLAMMABLE LIQUID — Any liquid having a flash pointof 100° F or less.

FLASHPOINT — The minimum temperature at which aliquid gives off an ignitable vapor in any one of the closedcup flashpoint testers (Penssky-Martens, Taglibue, or Seta-Flash).

FRETTING CORROSION — Corrosion at the interface oftwo connecting surfaces, usually under high pressure andsubject to very minute slippage due to relative vibration ofsurfaces that ordinarily are not supposed to move relative toeach other, such as a shrink fit.

G

GALVANIC — The flow of direct current between dissimi-lar metals.

GALVANIC CORROSION — The accelerated corrosion ofan active metal caused by the presence of a less active metalin the same solution and in contact with the more activemetal.

GALVANIC SERIES — A list of metals and alloys arrangedin order of their relative potentials in a given environment.The order of their arrangement in this list may be different inother environments.

H

HAZARDOUS MATERIAL — A material which may posea threat to human health or the environment when improp-erly handled or disposed of.

HAZARDOUS WASTE — Waste which is characterized bythe Environmental Protection Agency (EPA) as 1) ignitable,2) corrosive, 3) reactive, or 4) toxic, as defined in 40 CFR261, or is a listed hazardous waste identified in that regula-tion.

HYDROGEN EMBRITTLEMENT — Loss of ductility ofa metal, caused by the entrance or absorption of hydrogenions into the metal, as in the pickling of metal.

I

INHIBITOR — As applied to corrosion, a chemical sub-stance or mixture which, when added in small amounts to asolution, markedly decreases corrosion.

INORGANIC COATINGS — Electroplated coatings, con-version coatings, anodic coatings, phosphate coatings, andoxide coatings.

ION — An electrically charged atom or group of atoms. Thesign of the charge is positive in the case of cations and nega-tive in the case of anions.

L

LOCAL CELL — A cell in which the driving force is dueto a difference in potential between areas on a metal or alloysurface immersed in an electrolyte. The potential differencemay be due to inclusions, lack of homogeneity, varying con-centration of the solution with respect to oxygen or metalions, etc.

M

METAL ION CONCENTRATION CELL — A cell estab-lished on a metal surface due to different concentrations ofits ions in the electrolyte which is in contact with the metal

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Glossary 3

surface. These variations in concentration result in local dif-ferences in potential, thus allowing the establishment of alocal cell.

MILL SCALE — The heavy oxide layer formed during hotfabrication or heat treatment of metals. The term is mostfrequently applied to the scale of mixed iron oxides on ironand steel.

MOTTLING — Appearance of spotting or blotches of dif-ferent color or shades of coloring.

N

NOBLE METAL — A metal usually found as an uncom-bined metal in nature. Platinum, gold, and silver are noblemetals.

NON-DESTRUCTIVE INSPECTION — A method usedto check the soundness of a material or a part without im-pairing or destroying the serviceability of the part.

O

ORGANIC COATINGS — Paints, lacquers, plastics,greases, etc.

OXIDATION — Any change involving the loss of electronsby an atom. Any corrosion process involves oxidation of themetal in a true chemical sense. It also may imply the de-struction of metal or alloy as a result of the direct action ofoxygen on the metal, e.g., the scaling of steel at high tem-peratures.

OZONE — A triatomic (O3) form of oxygen.

R

ROOM TEMPERATURE VULCANIZING (RTV) — Aprocess for curing of synthetic rubber or plastic materialswhich occurs at room temperature.

S

SOLVENT — A liquid substance capable of dissolving ordispersing one or more other substances.

T

THIXOTROPIC — Gel-like in physical property.

TITRATION — A method or the process of determining theconcentration of a dissolved substance in terms of the small-est amount of reagent of known concentration required tobring about a given effect or reaction with a known volumeof the test solution.

U

ULTRAVIOLET (UV) LIGHT — Light (electromagneticradiation) of a wavelength shorter than visible light but lon-ger than X-ray radiation. Long wavelength UV from the suncauses sunburn. Short wavelength UV from unfiltered UVlamps can damage unprotected eyes.

UNIFORM SURFACE CORROSION — Corrosive etch-ing of metal involving only the surface.

W

WORDING — The following definitions are adhered to inpreparing this manual:

MAY — is used only when a procedure is optional.

SHALL — is used only when a procedure is mandatory.

SHOULD — is used only when a procedure is recommendedbut not mandatory.

WILL — is used to indicate future action but never to indi-cate a mandatory procedure.

TO 1-1-691

Glossary 4

INDEX

Paragraph, Figure,Subject Table Number

AAIR INTAKE DUCTS FOR JET AIRCRAFT. . . . . . 7.15AIRCRAFT CLEANING. . . . . . . . . . . . . . . . . . . . 10.6

Assembled RPA . . . . . . . . . . . . . . . . . . . . . 10.6.1.1Disassembled and Container Stored RPAs . . . . 10.6.1.2Frequency of Cleaning . . . . . . . . . . . . . . . . . . 10.6.1Wipe Down or Spot Cleaning . . . . . . . . . . . . . 10.6.2Wipe Down or Spot Cleaning Method . . . . . . 10.6.2.1

APPLICATION OF POLISH AND WAX . . . . . . . . . 3.8APPLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2APPROVED CLEANING COMPOUNDS . . . . . . . . 10.5

A-A-59921 (Formerly MIL-C-43616), Class 1A Emul-sion Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.3MIL-PRF-87937, Type III and MIL-PRF-85570, TypeV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.2MIL-PRF-87937, Type IV and MIL-PRF-85570, TypeII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5.1

BBATTERY COMPARTMENTS, BOXES, AND ADJA-CENT AREAS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2

Boric Acid and/or Monobasic Sodium Phosphate Neu-tralizing Solutions . . . . . . . . . . . . . . . . . . . . . 7.2.1.4Bromothymol Blue Indicating Solution. . . . . . . 7.2.1.2Cleaning and Neutralizing Procedures. . . . . . . . . 7.2.2Litmus Indicating Solution . . . . . . . . . . . . . . . 7.2.1.1Paint Systems . . . . . . . . . . . . . . . . . . . . . . . . . 7.2.3Preparation of Solutions for Cleaning and NeutralizingBattery Electrolytes . . . . . . . . . . . . . . . . . . . . . 7.2.1Sodium Bicarbonate Neutralizing Solution . . . . 7.2.1.3

BERYLLIUM-COPPER ALLOYS, BERYLLIUM-ALU-MINUM ALLOYS, AND BERYLLIUM OXIDE . . . 7.20

Corrosion Removal and Treatment . . . . . . . . . . 7.20.1Depot Maintenance . . . . . . . . . . . . . . . . . . . . 7.20.2

CCARBON FIBER COMPOSITES ANDCORROSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3

Corrosion Concerns . . . . . . . . . . . . . . . . . . . . 10.3.1Moisture Absorption. . . . . . . . . . . . . . . . . . . . 10.3.2

CHEMICAL DEFINITIONS . . . . . . . . . . . . . . . . . . 2.3Atom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.4Electron . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.2Ions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.3

CLEANING COMPOUNDS . . . . . . . . . . . . . . . . . . 3.3A-A-59921, (Formerly MIL-C-43616), Class1A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.2.2Aliphatic Naphtha . . . . . . . . . . . . . . . . . . . . . 3.3.4.4Alkaline Cleaners . . . . . . . . . . . . . . . . . . . . . . 3.3.1Aqueous Parts Washer Cleaning Solutions . . . . . . 3.3.3


ASTM D 740 Methyl Ethyl Ketone (MEK) . . . 3.3.4.3Cleaning of Specific Areas and Components . . . . T 3-2Deicing/Anti-Icing Fluid Residue Inspection and Clean-ing Procedures . . . . . . . . . . . . . . . . . . . . . . . . T 3-3Dilution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.7General Disinfectants. . . . . . . . . . . . . . . . . . . 3.3.5.1MIL-PRF-680 Degreasing Solvent and A-A-59601 DryCleaning and Degreasing Solvent, P-D-680. . . . 3.3.4.1MIL-PRF-85570, Type III . . . . . . . . . . . . . . . 3.3.1.6MIL-PRF-85570, Type IV . . . . . . . . . . . . . . . 3.3.1.5MIL-PRF-85704, Type I. . . . . . . . . . . . . . . . . 3.3.2.1MIL-PRF-87937, Type I and MIL-PRF-85570, TypeI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1.1MIL-PRF-87937, Type III and MIL-PRF-85570, TypeV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1.3MIL-PRF-87937, Type IV . . . . . . . . . . . . . . . 3.3.1.4MIL-PRF-87937, Type IV and MIL-PRF-85570, TypeII . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.1.2MIL-T-81772, Type I (Polyurethane) and Type II (Ep-oxy) Thinner . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4.5Miscellaneous Cleaning Agents . . . . . . . . . . . . . 3.3.5Solvent Emulsion and Aqueous Cleaners for TurbineEngine Gas Path and General Area Cleaning . . . . 3.3.2Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3.4Steam Cleaning. . . . . . . . . . . . . . . . . . . . . . . . 3.3.6TT-I-735 Isopropyl Alcohol . . . . . . . . . . . . . . 3.3.4.2

CLEANING EQUIPMENT . . . . . . . . . . . . . . . . . . . 3.4Aqueous Parts Washers . . . . . . . . . . . . . . . . . . 3.4.9Determination of Capacity of the Aqueous PartsWasher . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.9.2Effectiveness of Cleaning in Aqueous PartsWashers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.9.1Foam Generating Cleaning Unit (15 Gallons) . . . F 3-1Foam Generating Cleaning Unit (45 Gallons) . . . F 3-2Front Loading Type . . . . . . . . . . . . . . . . . . . . F 3-5High Pressure/Hot Water Wash Equipment . . . . . 3.4.1Miscellaneous Equipment . . . . . . . . . . . . . . . . 3.4.10Miscellaneous Large Cleaning Equipment . . . . . . 3.4.5Pneumatic Vacuum Cleaner. . . . . . . . . . . . . . . . 3.4.7Portable, 15 Gallon, Foam Generating, CleaningUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.2Portable, 45 Gallon, Foam Generating CleaningUnit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.3Spray Cleaning Guns for Solvents . . . . . . . . . . . 3.4.6Top Loading Type. . . . . . . . . . . . . . . . . . . . . . F 3-4Turbine Engine Compressor CleaningEquipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4.4Universal Wash Unit . . . . . . . . . . . . . . . . . . . . F 3-3Universal Wash Unit . . . . . . . . . . . . . . . . . . . . 3.4.8

CLEANING PROCEDURES . . . . . . . . . . . . . . . . . . 3.5

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Change 18 Index 1


Aircraft Cleaning Procedure . . . . . . . . . . . . . . . F 3-7Alkaline Detergent and/or Solvent Emulsion Cleaning,Painted and Unpainted Surfaces; Fresh Water ReadilyAvailable . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.2.1Alkaline Detergent Cleaning with Only Limited FreshWater Available . . . . . . . . . . . . . . . . . . . . . . 3.5.2.3Application . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.7.2Automatic Water Spray Nozzle . . . . . . . . . . . . . F 3-8Bird Strike Cleaning . . . . . . . . . . . . . . . . . . . . 3.5.8Bird Strike Cleanup. . . . . . . . . . . . . . . . . . . . 3.5.8.1Bodily Fluid Cleanup . . . . . . . . . . . . . . . . . . 3.5.9.2Bodily Fluid Containment During Flight. . . . . . 3.5.9.1Bodily Fluids Contamination Cleanup. . . . . . . . . 3.5.9Cleaning Methods . . . . . . . . . . . . . . . . . . . . . . 3.5.2Clear Water Rinsing of Aircraft . . . . . . . . . . . . . 3.5.3Disinfection of Contaminated Areas . . . . . . . . . 3.5.9.3Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.1.1Fungus Growth Removal . . . . . . . . . . . . . . . . . 3.5.6Fungus Growth Removal from OrganicMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . T 3-4.1Interior Cleaning (Vacuum) . . . . . . . . . . . . . . 3.5.2.5Internal/Enclosed (Water Sensitive) AreaCleanup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.8.2Low Temperature Cleaning. . . . . . . . . . . . . . . 3.5.2.6Manual Application . . . . . . . . . . . . . . . . . . . . 3.5.3.3Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.7.1Oxygen Systems . . . . . . . . . . . . . . . . . . . . . . 3.5.1.6Personal Protection . . . . . . . . . . . . . . . . . . . . 3.5.1.2Post Cleaning Procedures . . . . . . . . . . . . . . . . . 3.5.4Post Cleaning Task Sequence . . . . . . . . . . . . . 3.5.4.1Pre-Wash Lubrication Point Protection . . . . . . . 3.5.1.9Preparation for Cleaning . . . . . . . . . . . . . . . . 3.5.1.8Recommended Dilution of Low TemperatureCleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 3-4Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.7.3Requirements . . . . . . . . . . . . . . . . . . . . . . . . 3.5.3.1Rinsing Procedures . . . . . . . . . . . . . . . . . . . . 3.5.3.4Soil Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 3.5.7Solvent Cleaning. . . . . . . . . . . . . . . . . . . . . . 3.5.2.4Special Precautions . . . . . . . . . . . . . . . . . . . . 3.5.1.7Taxi-Through Rinsing . . . . . . . . . . . . . . . . . . 3.5.3.2Treatment and Disposal of Wash Rack Waste. . . . 3.5.5Use of Aircraft Washing Applicator . . . . . . . . . . F 3-6Use of Cleaners . . . . . . . . . . . . . . . . . . . . . . 3.5.1.4Use of Solvents . . . . . . . . . . . . . . . . . . . . . . 3.5.1.3Warnings and Cautions. . . . . . . . . . . . . . . . . . . 3.5.1Water Intrusion. . . . . . . . . . . . . . . . . . . . . . . 3.5.1.5Water/Cleaning Compound Intrusion . . . . . . . 3.5.1.10Waterless Wipe Down . . . . . . . . . . . . . . . . . . 3.5.2.2

CLOSELY COILED SPRINGS . . . . . . . . . . . . . . . 7.16COMMON AREAS . . . . . . . . . . . . . . . . . . . . . . . . 4.5

Battery Compartment. . . . . . . . . . . . . . . . . . . F 4-25Battery Compartments and Battery VentOpenings . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.14Bilge Areas. . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.13


Bilge Areas . . . . . . . . . . . . . . . . . . . . . . . . . F 4-24Common Water Entrapment Areas . . . . . . . . . . F 4-23Control Cables . . . . . . . . . . . . . . . . . . . . . . . 4.5.10Control Cables . . . . . . . . . . . . . . . . . . . . . . . F 4-21Corrosion Around Fasteners . . . . . . . . . . . . . . . F 4-6Corrosion in Air Intake Duct . . . . . . . . . . . . . F 4-17Corrosion Prone Point of Air Inlet . . . . . . . . . . F 4-16Electrical Connectors and Other Components . . . 4.5.16Engine Exhaust and Gun Gas ImpingementAreas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.4Engine Frontal Areas and Air Inlet Ducts . . . . . . 4.5.7Exhaust Trail Area Corrosion Points. . . . . . . . . F 4-11F-15 Nose Landing Gear Wheel Well . . . . . . . . F 4-12Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.1Faying Surfaces and Crevices . . . . . . . . . . . . . . 4.5.2Flap and Slat Recesses . . . . . . . . . . . . . . . . . . . 4.5.6Flaps Lowered to Expose Recess Areas . . . . . . F 4-13Galvanic Corrosion of Aluminum Adjacent to SteelFasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 4-7Gun Blast Area Corrosion Points . . . . . . . . . . . F 4-10Hinge Corrosion Points . . . . . . . . . . . . . . . . . F 4-19Hinges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5.9Jet Engine Frontal Area Corrosion Points . . . . . F 4-15Magnesium Parts . . . . . . . . . . . . . . . . . . . . . . 4.5.15Personnel Relief Tube Vent. . . . . . . . . . . . . . . F 4-22Piano Hinge Lugs . . . . . . . . . . . . . . . . . . . . . F 4-20Reciprocating Engine Frontal Area CorrosionPoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 4-14Relief Tube Outlets . . . . . . . . . . . . . . . . . . . . 4.5.11Spot Weld Corrosion . . . . . . . . . . . . . . . . . . . . F 4-8Spot Welded Assemblies. . . . . . . . . . . . . . . . . . 4.5.3Spot Welded Skin Corrosion Mechanism . . . . . . F 4-9Water Entrapment Areas . . . . . . . . . . . . . . . . . 4.5.12Wheel Wells and Landing Gear . . . . . . . . . . . . . 4.5.5Wing Fold Joint . . . . . . . . . . . . . . . . . . . . . . F 4-18Wing/Fin-Fold Joints and Wing and Control SurfaceLeading Edges . . . . . . . . . . . . . . . . . . . . . . . . 4.5.8

CORRECTIVE ACTIONS. . . . . . . . . . . . . . . . . . . . 5.3CORROSION CONTROL PROGRAM . . . . . . . . . . . 1.1

Facilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.3Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.2Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1.1

CORROSION CONTROL PROGRAM . . . . . . . . . . 10.2CORROSION PREVENTION ON ASSEMBLIES ANDPARTS REMOVED FROM AIRCRAFT DURING MAIN-TENANCE, 30 DAY SHORT TERM STORAGE, ANDOVER 30 DAY LONG TERM STORAGEREQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . 7.17

Long Term Storage . . . . . . . . . . . . . . . . . . . . 7.17.2Short Term Storage . . . . . . . . . . . . . . . . . . . . 7.17.1

CORROSION PREVENTIVE COMPOUNDS(CPC’s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

Recommended CPC’s. . . . . . . . . . . . . . . . . . . . 9.5.1CORROSION REMOVAL . . . . . . . . . . . . . . . . . . . 5.5

3M Co. Inline Bristle Disc . . . . . . . . . . . . . . . . F 5-5

TO 1-1-691

INDEX - CONTINUED

Index 2 Change 17


3M Co. Radial Bristle Disc . . . . . . . . . . . . . . . F 5-33M Co. Roloc Discs . . . . . . . . . . . . . . . . . . . . F 5-43M Co. RolocTM Disc and Radial DiscAbrasives. . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3.83M Co. Scotch-BriteTM Flap Brush andMandrel . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 5-13M Co. Scotch-BriteTM Finishing FlapBrushes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3.3Abrasive Blasting . . . . . . . . . . . . . . . . . . . . . . 5.5.4Abrasive Blasting Equipment . . . . . . . . . . . . . . F 5-6Abrasive Cloth . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.2Abrasive Cloth and Paper. . . . . . . . . . . . . . . . 5.5.3.5Abrasive Flap Wheels . . . . . . . . . . . . . . . . . . 5.5.3.4Abrasive Flap Wheels with Spindle Mount . . . . . F 5-2Abrasive Mats . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.1Abrasive Paper . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.3Conventional Equipment . . . . . . . . . . . . . . . . 5.5.4.1Grades of Abrasive Mats . . . . . . . . . . . . . . . . . T 5-1Grades of Steel Wool . . . . . . . . . . . . . . . . . . . T 5-2Material Compatibility . . . . . . . . . . . . . . . . . . 5.5.1.2Mechanical Compatibility. . . . . . . . . . . . . . . . 5.5.1.1Mechanical Methods . . . . . . . . . . . . . . . . . . . . 5.5.1Metallic Wools . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.4Non-Powered Tools and Materials . . . . . . . . . . . 5.5.2Pneumatic Drill Motors . . . . . . . . . . . . . . . . . 5.5.3.1Pneumatic Sanders . . . . . . . . . . . . . . . . . . . . 5.5.3.2Portable Vacuum Abrasive Blast Equipment . . . 5.5.4.2Power Tools and Materials . . . . . . . . . . . . . . . . 5.5.3Powered Wire Brushes. . . . . . . . . . . . . . . . . . 5.5.3.6Pumice Powder. . . . . . . . . . . . . . . . . . . . . . . 5.5.2.6Recommended Non-Powered Abrasives for CorrosionRemoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 5-4Recommended Powered Abrasives for CorrosionRemoval . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 5-3Rotary Files . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.3.7Scrapers . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.7Wet Abrasive Blasting Equipment . . . . . . . . . . 5.5.4.3Wire Brushes . . . . . . . . . . . . . . . . . . . . . . . . 5.5.2.5

CORROSION REMOVAL-CHEMICAL . . . . . . . . . . 5.9Aluminum Alloys . . . . . . . . . . . . . . . . . . . . . . 5.9.1Application of Organic Coatings . . . . . . . . . . . 5.9.1.3Application of Organic Coatings . . . . . . . . . . . 5.9.2.3Application of Organic Coatings . . . . . . . . . . . 5.9.3.3Application of Organic Coatings . . . . . . . . . . . 5.9.4.4Application of Organic Coatings . . . . . . . . . . . 5.9.5.3Application of Organic Coatings . . . . . . . . . . . 5.9.6.3Application of Organic Coatings . . . . . . . . . . . 5.9.7.5Chemical Corrosion Removal Materials for AluminumAlloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.1.2Chemical Corrosion Removal Materials for MagnesiumAlloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.2.2Chemical Corrosion Removal Materials for Titaniumand Titanium Based Alloys. . . . . . . . . . . . . . . 5.9.6.2Chemical Corrosion Removing Materials for Copperand Copper Based Alloys . . . . . . . . . . . . . . . . 5.9.5.2


Chemical Corrosion Removing Materials for FerrousMetal Alloys Other Than Stainless Steels(CRES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.3.2Chemical Corrosion Removing Materials for StainlessSteel (CRES) and Nickel Based Alloys. . . . . . . 5.9.4.2Control of Corrosion Removal/Pickling Action of Ni-tric-Acid-Hydrofluoric Solutions . . . . . . . . . . . . T 5-9Copper and Copper Based Alloys. . . . . . . . . . . . 5.9.5Ferrous Metal (Steel) Alloys Other Than StainlessSteels (CRES). . . . . . . . . . . . . . . . . . . . . . . . . 5.9.3Magnesium Alloys. . . . . . . . . . . . . . . . . . . . . . 5.9.2Passivation of Stainless Steel (CRES) AlloyParts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.4.3Plated and Phosphated Surfaces . . . . . . . . . . . . . 5.9.7Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.1.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.2.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.3.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.4.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.5.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.6.1Preparation . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.7.1Stainless Steel (CRES) and Nickel BasedAlloys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.4Titanium and Titanium Based Alloys . . . . . . . . . 5.9.6Treatment of Corroded Areas on Cadmium or ZincPlated Surfaces . . . . . . . . . . . . . . . . . . . . . . . 5.9.7.2Treatment of Corroded Areas on PhosphatedSurfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9.7.4Treatment of Corroded Areas on Plated Surfaces ExceptCadmium or Zinc Plating . . . . . . . . . . . . . . . . 5.9.7.3Typical Chemical Corrosion Removal of Titanium andTitanium Base Alloys . . . . . . . . . . . . . . . . . . T 5-11Typical Chemical Corrosion Removal Procedures forAluminum Alloy Parts and Assemblies. . . . . . . . T 5-5Typical Chemical Corrosion Removal Procedures forCopper and Copper Alloys . . . . . . . . . . . . . . . T 5-10Typical Chemical Corrosion Removal Procedures forFerrous Metals Other Than Stainless Steel(CRES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 5-7Typical Chemical Corrosion Removal Procedures forMagnesium Alloys . . . . . . . . . . . . . . . . . . . . . T 5-6Typical Chemical Corrosion Removal Procedures forPlated and Phosphated Surfaces . . . . . . . . . . . T 5-12Typical Chemical Corrosion Removal Procedures forStainless Steel (CRES) and Nickel BasedAlloys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 5-8

CORROSION REMOVAL FROM THIN METAL (0.0625INCH THICKNESS AND LESS) . . . . . . . . . . . . . . 7.14CORROSION REMOVALPROCEDURES-MECHANICAL . . . . . . . . . . . . . . . 5.8

Abrasive Blasting Corrosion Removal . . . . . . . . 5.8.4Abrasive Blasting Procedures . . . . . . . . . . . . . 5.8.4.1Acceptable Clean-Up of Pitting Corrosion on CriticalStructure . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 5-8Limited Clearance. . . . . . . . . . . . . . . . . . . . . . F 5-9

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Mechanical Damage . . . . . . . . . . . . . . . . . . . 5.8.1.2Non-Powered Mechanical Corrosion Removal . . . 5.8.2Personal Protection . . . . . . . . . . . . . . . . . . . . 5.8.1.1Powered Mechanical Corrosion Removal . . . . . . 5.8.3Shaping Reworked Areas . . . . . . . . . . . . . . . . . F 5-7Warnings and Cautions. . . . . . . . . . . . . . . . . . . 5.8.1

CORROSION TREATMENT FOR STEELCABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4CORROSIVE ENVIRONMENTS. . . . . . . . . . . . . . . 2.9

Animal Damage . . . . . . . . . . . . . . . . . . . . . . 2.9.14Bacteria . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.15.1Climate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.8Condensed Moisture . . . . . . . . . . . . . . . . . . . 2.9.1.1Desert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.8.1Effect of Moisture . . . . . . . . . . . . . . . . . . . . . 2.9.1.2Factors of Influence in Tropical Environments . . . 2.9.9Failed Chromium Plating . . . . . . . . . . . . . . . . F 2-23Industrial and Ship Emitted Air Pollutants . . . . . 2.9.13Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . 2.9.10Microbial Growth Requirements . . . . . . . . . . 2.9.15.2Microbial Nutrients . . . . . . . . . . . . . . . . . . . 2.9.15.3Microorganisms . . . . . . . . . . . . . . . . . . . . . . . 2.9.15Moisture . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.1Other Industrial Pollutants . . . . . . . . . . . . . . . . 2.9.5Ozone . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.4Salt Atmospheres. . . . . . . . . . . . . . . . . . . . . . . 2.9.3Sand, Dust, and Volcanic Ash . . . . . . . . . . . . . . 2.9.6Shipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.12Solar Radiation . . . . . . . . . . . . . . . . . . . . . . . . 2.9.7Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.11Temperate Zones. . . . . . . . . . . . . . . . . . . . . . 2.9.8.2Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.2Tropics . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9.8.3

CORROSIVE ENVIRONMENTS. . . . . . . . . . . . . . 10.4

DDEFINITION OF CORROSION . . . . . . . . . . . . . . . 2.2DEGRADATION OF NON-METALS . . . . . . . . . . . 2.10DEGREES OF CORROSION . . . . . . . . . . . . . . . . . 4.4

Light Corrosion. . . . . . . . . . . . . . . . . . . . . . . . 4.4.1Moderate Corrosion . . . . . . . . . . . . . . . . . . . . . 4.4.2Optical Depth Micrometer (Analog Mechanical ReadOut Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . F 4-3Optical Depth Micrometer (Digital Read OutType) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 4-4Severe Corrosion. . . . . . . . . . . . . . . . . . . . . . . 4.4.3Typical Use of a Straight Edge to Determine if SuspectAreas Have Been Previously Reworked . . . . . . . F 4-5

DEPLETED URANIUM COUNTERWEIGHTS . . . . 7.18Corrosion and Finish Damage TreatmentProcedures . . . . . . . . . . . . . . . . . . . . . . . . . . 7.18.1

DEVELOPMENT OF CORROSION. . . . . . . . . . . . . 2.5Corrosion Under Painted Surfaces . . . . . . . . . . . 2.5.1


EELECTRICAL AND ELECTRONICEQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11

Antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.6Conduit and Junction Boxes . . . . . . . . . . . . . . 7.11.2Deleted . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11.4Grounding and Bonding Connections . . . . . . . . 7.11.1Moisture and Fungus Proofing of Electrical and Elec-tronic Equipment . . . . . . . . . . . . . . . . . . . . . . 7.11.5Wires and Cables . . . . . . . . . . . . . . . . . . . . . . 7.11.3

EMERGENCY PREPARATIONS . . . . . . . . . . . . . . . 8.3Emergency Reclamation Equipment . . . . . . . . . . 8.3.3Emergency Reclamation Team. . . . . . . . . . . . . . 8.3.2Personal Protection . . . . . . . . . . . . . . . . . . . . 8.3.2.1Personnel Decontamination. . . . . . . . . . . . . . . 8.3.2.2Priority Removal List of Equipment and/orComponents . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3.1Production Planning. . . . . . . . . . . . . . . . . . . . . 8.3.4

EMI SEALS AND GASKETS . . . . . . . . . . . . . . . . 7.21Beryllium-Copper Spiral Contact with EnvironmentalFluorosilicone Seal . . . . . . . . . . . . . . . . . . . . . F 7-1Bonding Cable from Airframe to Graphite/Epoxy Avi-onics Bay Door . . . . . . . . . . . . . . . . . . . . . . . F 7-4Dorsal Longeron EMI Seal. . . . . . . . . . . . . . . . F 7-2EMI Bonding Washers in an Avionics Bay . . . . . F 7-5Stainless Steel (CRES) EMI Screen . . . . . . . . . . F 7-3Treatment of EMI Seals and Gaskets . . . . . . . . 7.21.1

EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4Application Nozzles. . . . . . . . . . . . . . . . . . . . . 6.4.2Injection Gun . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.3Sealant Gun . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4.1Sealant Kits (Semkits®) . . . . . . . . . . . . . . . . . . 6.4.4Sealant Removal and Application Tools . . . . . . . 6.4.5

EVALUATION OF CORROSION DAMAGE. . . . . . . 4.3

FFACTORS INFLUENCE CORROSION . . . . . . . . . . 2.6

Anode and Cathode Surface Area. . . . . . . . . . . . 2.6.3Biological Organisms . . . . . . . . . . . . . . . . . . . . 2.6.9Dissimilar Metal Coupling (GalvanicCorrosion) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.2Effect of Area Relationship in Dissimilar MetalContacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-5Effect of Sea Water on Galvanic Corrosion . . . . . F 2-3Electrolyte Concentration . . . . . . . . . . . . . . . . . 2.6.8Electrolytes . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.6Elimination of Corrosion by Application of an OrganicFilm to a Metal Surface. . . . . . . . . . . . . . . . . . F 2-2Galvanic Corrosion in a Flashlight Battery . . . . . F 2-4Heat Treatment and Grain Direction . . . . . . . . . . 2.6.5Mechanical Stress . . . . . . . . . . . . . . . . . . . . . 2.6.10

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Oxygen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.7Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.4

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Change 9 Index 4.1/(Index 4.2 blank)


Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.11Type of Metal . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1

FAYING SURFACES AND ATTACHMENTPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7

Attaching Parts and Hardware . . . . . . . . . . . . . . 7.7.2Faying Surfaces, Joints, and Seams . . . . . . . . . . 7.7.1Severely Corroded (Rusted) Hardware . . . . . . . . 7.7.3

GGENERAL CLEANING PROCEDURES . . . . . . . . . 8.5

Alternate Methods . . . . . . . . . . . . . . . . . . . . . . 8.5.2Method One (Preferred) . . . . . . . . . . . . . . . . . 8.5.2.1Method Two (Alternate). . . . . . . . . . . . . . . . . 8.5.2.2Primary Method . . . . . . . . . . . . . . . . . . . . . . . 8.5.1Removal of Carbon Dioxide (CO2), HFC-125, Halonand 3M NOVEC 1230 Fire ExtinguishingAgents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.5Removal of Protein Type Foam and Soda-Acid FireExtinguishing Agents . . . . . . . . . . . . . . . . . . . . 8.5.6Removing Fire Extinguishing Powder (O-D-1407 Potas-sium Bicarbonate [Purple K{PKP}], Sodium Bicarbon-ate, Ammonium Phosphate Monobasic) and/or OtherDry Chemical Agents . . . . . . . . . . . . . . . . . . . . 8.5.3Removing MIL-F-24385 Aqueous Film Forming Foam(AFFF) Fire Extinguishing Agent and Other SyntheticBased Foaming Agents Including High-Expansion (Hi-Ex) Foams . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.4Treatment After Exposure to Volcanic Ash . . . . . 8.5.8Treatment After Landing on a FoamedRunway . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5.7

GENERAL PROCEDURES. . . . . . . . . . . . . . . . . . . 8.4Aircraft Involved in Water Crashes . . . . . . . . . 8.4.2.1Clean. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.3Disassembly/Removal of Components . . . . . . . . 8.4.2Priority Guide for Emergency Treatment of Aircraft,Missiles, and Equipment . . . . . . . . . . . . . . . . . T 8-1Removal of Contaminated InstalledEquipment . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.1Suggested List of Emergency ReclamationItems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 8-2Tagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4.4

IINSPECTION METHODS . . . . . . . . . . . . . . . . . . . 4.2

Analog Mechanical Read-Out Type . . . . . . . . . 4.2.4.1Depth Dimension of Corrosion Pits . . . . . . . . . . F 4-1Depth Gauge . . . . . . . . . . . . . . . . . . . . . . . . . 4.2.2Digital Read-Out Type. . . . . . . . . . . . . . . . . . 4.2.4.2Eddy Current Inspection . . . . . . . . . . . . . . . . . . 4.2.6Evidence of Corrosion . . . . . . . . . . . . . . . . . . 4.2.1.1Fiber Optic Borescope . . . . . . . . . . . . . . . . . . . F 4-2Fluorescent Penetrant Inspection . . . . . . . . . . . . 4.2.5Limitations of Penetrant Inspection . . . . . . . . . 4.2.5.1


NDI Inspection Tools for Various Types ofCorrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . T 4-1Optical Depth Micrometers . . . . . . . . . . . . . . . . 4.2.4Radiographic Inspection . . . . . . . . . . . . . . . . . . 4.2.8Ultrasonic Inspection . . . . . . . . . . . . . . . . . . . . 4.2.7Use of Depth Gauges . . . . . . . . . . . . . . . . . . 4.2.2.1Visual inspection . . . . . . . . . . . . . . . . . . . . . . . 4.2.1Visual Inspection with aBorescope/Videoscope . . . . . . . . . . . . . . . . . . . 4.2.3

INTEGRAL AND EXTERNAL FUEL TANKS ANDDROP TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6

Corrosion Removal and Rework of Pitted Areas of Inte-gral Fuel Tanks . . . . . . . . . . . . . . . . . . . . . . . . 7.6.1Removal of Corrosion and Rework of Aluminum Exter-nal Fuel Tanks/Drop Tanks . . . . . . . . . . . . . . . . 7.6.2Tank Exterior Surfaces. . . . . . . . . . . . . . . . . . 7.6.2.1Tank Interior Surfaces . . . . . . . . . . . . . . . . . . 7.6.2.2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.2Aircraft Clear Water Rinse (CWR)Requirements . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3Aircraft Stationed Within 1.25 Miles of SaltWater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3.1Cleaning Frequency. . . . . . . . . . . . . . . . . . . . 3.2.2.1Deployed Aircraft Wash Requirements . . . . . . . . 3.2.5Immediate Cleaning . . . . . . . . . . . . . . . . . . . . . 3.2.4Low Level (Below 3,000 Feet) Salt Water RunwayApproach. . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2.3.2Reasons for Cleaning . . . . . . . . . . . . . . . . . . . . 3.2.1Search, Rescue, and Recovery Missions and Low-LevelFlight Operations Under 3,000 Feet . . . . . . . . . 3.2.3.3When to Accomplish Work . . . . . . . . . . . . . . . . 3.2.2

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.6Application of Conventional Lubricants . . . . . . . 3.6.3Common Military Greases and Their Uses . . . . . T 3-5Conventional Lubricants . . . . . . . . . . . . . . . . . . 3.6.1Grease Gun Application . . . . . . . . . . . . . . . . . 3.6.3.1MIL-PRF-46147 and/or MIL-L-23398 . . . . . . . 3.6.2.3SAE AS5272 (MIL-PRF-46010) . . . . . . . . . . . 3.6.2.2Solid Film Lubricants. . . . . . . . . . . . . . . . . . . . 3.6.2Surface Preparation for Solid Film Lubricants . . 3.6.2.1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 3.7Brushing . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.7.1Corrosion Preventive Compounds . . . . . . . . . . . T 3-7Description of CPC’s . . . . . . . . . . . . . . . . . . . . 3.7.5Dipping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.7.2MIL-DTL-85054, Corrosion Preventive Compound,Clear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5.2MIL-PRF-16173, Corrosion Preventive Compound, Sol-vent Cutback, Cold Application. . . . . . . . . . . . 3.7.5.3MIL-PRF-32033, Lubricating Oil, General Purpose,Preservative, Water Displacing . . . . . . . . . . . . 3.7.5.5MIL-PRF-63460, Lubricant, Cleaner, and Preservativefor Weapons and Weapon Systems. . . . . . . . . . 3.7.5.4

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Change 17 Index 5


MIL-PRF-81309, Corrosion Preventive Compound, Wa-ter Displacing, Ultra Thin Film and MIL-L-87177, Lu-bricants, Corrosion Preventive, Water Displacing,Synthetic . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.5.1Non-Operational Preservation . . . . . . . . . . . . . . 3.7.2Non-Water Displacing Compounds . . . . . . . . . 3.7.3.2Operational Preservation. . . . . . . . . . . . . . . . . . 3.7.1Preservation Application Methods . . . . . . . . . . . 3.7.7Preservation of Specific Areas . . . . . . . . . . . . . . 3.7.6Preservation of Specific Areas andComponents. . . . . . . . . . . . . . . . . . . . . . . . . . T 3-8Spraying . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7.7.3Time Limitations for CPC’s . . . . . . . . . . . . . . . T 3-6Time Limitations of CPC’s . . . . . . . . . . . . . . . . 3.7.4Types of CPC’s. . . . . . . . . . . . . . . . . . . . . . . . 3.7.3Water Displacing Compounds . . . . . . . . . . . . . 3.7.3.1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 7.1INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 9.1

Aircraft Clear Water Rinse (CWR) . . . . . . . . . . . 9.1.3Aircraft Wash . . . . . . . . . . . . . . . . . . . . . . . . . 9.1.2Climatic Conditions . . . . . . . . . . . . . . . . . . . . . 9.1.1Effects of Desert Environment . . . . . . . . . . . . . . 9.1.4

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . A.1Consumable Materials. . . . . . . . . . . . . . . . . . . T A-2Consumable Materials Containers . . . . . . . . . . . A.1.2Local Environmental Laws and Regulations . . . . A.1.4Local Purchase . . . . . . . . . . . . . . . . . . . . . . . . A.1.3Shelf Life . . . . . . . . . . . . . . . . . . . . . . . . . . . A.1.1Unit of Issue Codes . . . . . . . . . . . . . . . . . . . . A.1.5Unit of Issue Codes . . . . . . . . . . . . . . . . . . . . T A-1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . B.1Back Mounted Full Facepiece Respirator . . . . . . F B-1Equipment for Cleaning and Corrosion Prevention andControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . T B-2Front Mounted Full Facepiece Respirator. . . . . . F B-2Hooded Air Respirator System . . . . . . . . . . . . . F B-3Unit of Issue Codes. . . . . . . . . . . . . . . . . . . . . B.1.1Unit of Issue Codes . . . . . . . . . . . . . . . . . . . . T B-1

INTRODUCTION TO CORROSION THEORY . . . . . 2.1

MMATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3METALS AFFECTED BY CORROSION . . . . . . . . . 2.8

Aluminum . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.3Aluminum Surface Corrosion Products . . . . . . . F 2-21Anodized Aluminum . . . . . . . . . . . . . . . . . . . . 2.8.4Cadmium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.7Cadmium Plated Surface Conditions . . . . . . . . F 2-22Copper and Copper Alloys . . . . . . . . . . . . . . . . 2.8.6Corrosion of Metals - Type of Attack and Appearanceof Corrosion Products . . . . . . . . . . . . . . . . . . . T 2-1CRES/Stainless Steel . . . . . . . . . . . . . . . . . . . . 2.8.8Graphite/Carbon Fiber Composites . . . . . . . . . . 2.8.11


Magnesium. . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1Magnesium Corrosion Products . . . . . . . . . . . . F 2-19Nickel and Chromium . . . . . . . . . . . . . . . . . . . 2.8.9Silver, Platinum, and Gold . . . . . . . . . . . . . . . 2.8.10Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.2Steel Corrosion Products (Rust). . . . . . . . . . . . F 2-20Titanium . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.5

MONEL RIVETS. . . . . . . . . . . . . . . . . . . . . . . . . 7.19

NNATURAL AND SYNTHETIC RUBBERPARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8NON-STRUCTURAL TUBING MEMBERS ANDASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13

Aluminum Alloy Tubing . . . . . . . . . . . . . . . . . 7.13.1Cadmium Plated Steel Tubing . . . . . . . . . . . . . 7.13.3Removable Installations . . . . . . . . . . . . . . . . . 7.13.5Special Instructions for Tubing Fittings andSleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.13.4Stainless Steel (CRES) Tubing. . . . . . . . . . . . . 7.13.2

PPAINT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . 5.4PIANO TYPE HINGES . . . . . . . . . . . . . . . . . . . . . 7.5PITTING ON CRITICAL STRUCTURE . . . . . . . . . . 5.7POST DEPLOYMENT . . . . . . . . . . . . . . . . . . . . . . 9.4POTABLE WATER TANKS . . . . . . . . . . . . . . . . . . 7.9PRE-DEPLOYMENT RECOMMENDATIONS . . . . . 9.2

Global Dust Producing Regions . . . . . . . . . . . . F 9-2Soil Makeup in the SWA Area . . . . . . . . . . . . . F 9-1

PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . 2.11PREVENTIVE MAINTENANCE PROGRAM . . . . . . 3.1

Aircraft Wash Intervals . . . . . . . . . . . . . . . . . . T 3-1Preventive Maintenance . . . . . . . . . . . . . . . . . . 3.1.1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1Detailed Inspections. . . . . . . . . . . . . . . . . . . . . 4.1.4Frequency of Inspections . . . . . . . . . . . . . . . . . 4.1.2General Inspections . . . . . . . . . . . . . . . . . . . . . 4.1.3Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1

PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1PURPOSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10

A Water-Break Free Surface Compared with One withBreaks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 5-10Application of Surface Treatments . . . . . . . . . . 5.10.4Chemical Prepaint Treatments . . . . . . . . . . . . . 5.10.1Conversion Coating Using TNP Pens . . . . . . . 5.10.4.1MIL-DTL-81706 Chemical Conversion Materials forCoating Aluminum and Aluminum Alloys . . . . 5.10.1.1Notes on Conversion Coating/SurfaceTreatment . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.5Post Treatment . . . . . . . . . . . . . . . . . . . . . . . 5.10.6Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.3

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Index 6 Change 17


Prepaint Treatments for Metal Surfaces . . . . . . T 5-13SAE AMS-M-3171 (MIL-M-3171), Type VI Magne-sium Alloy, Processes for Pretreatment and Preventionof Corrosion on; Chromic Acid Brush-OnTreatment. . . . . . . . . . . . . . . . . . . . . . . . . . 5.10.1.2Surface Preparation . . . . . . . . . . . . . . . . . . . . 5.10.2Temporary Preservation . . . . . . . . . . . . . . . . . 5.10.7

PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

RRECOMMENDED ACTIONS WHILEDEPLOYED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

Areas to be Checked and Cleaned . . . . . . . . . . . 9.3.2High Efficiency Particulate Air (HEPA)Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3.1Open Circuit Board. . . . . . . . . . . . . . . . . . . . . F 9-3Pneumatic Backpack . . . . . . . . . . . . . . . . . . . 9.3.1.2Pneumatic Wheeled Units. . . . . . . . . . . . . . . . 9.3.1.1

RELIEF TUBE AREAS . . . . . . . . . . . . . . . . . . . . . 7.3REMOTELY PILOTED AIRCRAFT (RPA) . . . . . . . 10.1

Air Force RPA Tiers . . . . . . . . . . . . . . . . . . . T 10-1Definition . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1.1

REQUIREMENTS FOR SHOT PEENING. . . . . . . . 5.11RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . 5.2RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . . . . . 8.2ROTO-PEENING (ROTARY FLAP PEENING) . . . . 5.13

“A” Test Strip Arc Height Magnetic to SAE J442 Stri-pholder Conversion Chart, 0.001 Inch . . . . . . . F 5-13“A” Test Strip Magnetic to SAE J442 Stripholder ArcHeight Conversion Graph . . . . . . . . . . . . . . . . F 5-12“N” Arc Height Magnetic to SAE J442 StripholderConversion Chart, 0.001 Inch . . . . . . . . . . . . . F 5-15“N” Arc Height Magnetic to SAE J442 StripholderConversion Graph . . . . . . . . . . . . . . . . . . . . . F 5-14Arc Height Conversion. . . . . . . . . . . . . . . . . 5.13.2.1Arc Height Plotting Chart. . . . . . . . . . . . . . . . F 5-16Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . 5.13.3.3Determining Peening/Intensity . . . . . . . . . . . . . 5.13.2Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 5.13.1.1Example of Coverage . . . . . . . . . . . . . . . . . . F 5-17Flap Deflection Ranges . . . . . . . . . . . . . . . . . F 5-18Flap Operation . . . . . . . . . . . . . . . . . . . . . . 5.13.3.2Magnetic Almen Strip Holder . . . . . . . . . . . . . F 5-11Part Peening Time . . . . . . . . . . . . . . . . . . . . 5.13.3.4Peening Process Preparation . . . . . . . . . . . . . . 5.13.3Post Peening Surface Finish . . . . . . . . . . . . . . 5.13.4Rotary Tool Speed. . . . . . . . . . . . . . . . . . . . 5.13.3.1Roto-Peening Procedures . . . . . . . . . . . . . . . . 5.13.1Standard Peening Intensity (Isp) for Complete CoverageArc-Height (All Numbers in Inches) . . . . . . . . T 5-15Surface Preparation Procedure . . . . . . . . . . . . 5.13.1.2


Tool Speed Operation Requirements . . . . . . . . T 5-14

SSAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2

Materials Handling . . . . . . . . . . . . . . . . . . . . . 1.2.2Responsibility of Supervisors . . . . . . . . . . . . . . 1.2.1

SEALANT APPLICATION PROCEDURES. . . . . . . . 6.6Adhesion Promoters. . . . . . . . . . . . . . . . . . . . . 6.6.3Brush Spatula or Caulking Gun Application. . . . . 6.6.4Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.1Masking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.2Non-Metallic Spatula. . . . . . . . . . . . . . . . . . . . F 6-8Peel and Stick Application; SAE AMS 3255 EPTFESkyflex® and Av-Dec® HT3935-7 and HT3000 SealingTapes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6.6Spray Gun Application . . . . . . . . . . . . . . . . . . . 6.6.5Time Requirements for Sealants When Used at 75° F(24° C) and 50% RH . . . . . . . . . . . . . . . . . . . T 6-2

SEALANT MIXING . . . . . . . . . . . . . . . . . . . . . . . 6.5Application Life . . . . . . . . . . . . . . . . . . . . . . . 6.5.1Countersink Application Nozzles. . . . . . . . . . . . F 6-3Enhancement of Sealant Curing. . . . . . . . . . . . 6.5.1.1Injection Style Semkit®. . . . . . . . . . . . . . . . . . F 6-7Mixing MIL-PRF-81733, Type III Sprayable SealantCoating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5.3Pneumatic Sealant Gun . . . . . . . . . . . . . . . . . . F 6-1Rivet Application Nozzles . . . . . . . . . . . . . . . . F 6-4Sealant and Adhesive Smoothing Tools . . . . . . . F 6-5Sealant Application Nozzles . . . . . . . . . . . . . . . F 6-2Sealant Injection Guns. . . . . . . . . . . . . . . . . . . F 6-6Sealing Compounds . . . . . . . . . . . . . . . . . . . . T 6-1Storage Instructions . . . . . . . . . . . . . . . . . . . . . 6.5.2

SEALING COMPOUNDS. . . . . . . . . . . . . . . . . . . . 6.3Adhesion Promoters. . . . . . . . . . . . . . . . . . . . . 6.3.4Av-Dec® Polyurethane Sealant Tapes and Two Compo-nent Sealants . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.6Cartridge (CA) . . . . . . . . . . . . . . . . . . . . . . . 6.3.1.2Polysulfide, Polyurethane, and Polythioether SealingCompounds . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.2Pre-Mixed and Frozen (PMF) . . . . . . . . . . . . . 6.3.1.3SAE AMS 3255 Oil and Water Resistant, ExpandedPolytetrafluoroethylene Sealing Tape (EPTFE)Skyflex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.5Sealant Packaging . . . . . . . . . . . . . . . . . . . . . . 6.3.1Silicone Sealing Compounds . . . . . . . . . . . . . . . 6.3.3Two-Part Kit (KT) . . . . . . . . . . . . . . . . . . . . 6.3.1.1

SEALING OF SPECIFIC AREAS . . . . . . . . . . . . . . 6.7Damaged Sealant . . . . . . . . . . . . . . . . . . . . . . 6.7.10Depressions . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.9Extensive Repair . . . . . . . . . . . . . . . . . . . . . . 6.7.11External Aircraft Structure . . . . . . . . . . . . . . . . 6.7.8Fastener Sealing . . . . . . . . . . . . . . . . . . . . . . . 6.7.4

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Change 17 Index 7


Faying Surface Sealing. . . . . . . . . . . . . . . . . . . 6.7.1Faying Surface Sealing . . . . . . . . . . . . . . . . . . F 6-9Fillet Sealing . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.2Form-In-Place (FIP) Gasket Sealant Repair . . . . . 6.7.6High Temperature Areas . . . . . . . . . . . . . . . . . 6.7.12Injection Sealing . . . . . . . . . . . . . . . . . . . . . . . 6.7.3Integral Fuel Cells/Tanks and Removable FuelTanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.5Low Temperature Curing . . . . . . . . . . . . . . . . 6.7.13SAE AMS 3255 EPTFE (Skyflex®) and Av-Dec®HT3000 and HT3935-7 Sealing Tape GasketRepair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7.7Typical Fillet Seal . . . . . . . . . . . . . . . . . . . . . F 6-10Typical Injection Seal . . . . . . . . . . . . . . . . . . F 6-11Typical Methods of Sealing Fasteners. . . . . . . . F 6-12

SHOT PEENING OF METAL SURFACES . . . . . . . 5.12Metallic, Glass, or Ceramic Shot Peening . . . . 5.12.1.1Shot Peening Application . . . . . . . . . . . . . . . . 5.12.2Types of Peening . . . . . . . . . . . . . . . . . . . . . . 5.12.1

SPECIFIC EXTERNAL AREAS OF AIRCRAFT . . . . 8.7Aircraft Fuel Systems. . . . . . . . . . . . . . . . . . . . 8.7.9Airframes. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.1Antennas . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.2Armament . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.8Cleaning Procedure . . . . . . . . . . . . . . . . . . . . 8.7.8.2External Surface Contamination . . . . . . . . . . . 8.7.6.1Helicopter Main and Tail Rotor Blades . . . . . . . . 8.7.7Helicopter Transmission, Rotor Head, and RotorHub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.6Internal Surface Contamination . . . . . . . . . . . . 8.7.6.2Reciprocating Engines . . . . . . . . . . . . . . . . . . . 8.7.3Safety Precautions. . . . . . . . . . . . . . . . . . . . . 8.7.8.1Treatment for Engines Which Have Ingested Fire Extin-guishing Powder (Potassium Bicarbonate [PurpleK{PKP}], Sodium Bicarbonate, Ammonium PhosphateMonobasic) and/or Synthetic Foaming Agents (AFFF,Hi-Ex, AR). . . . . . . . . . . . . . . . . . . . . . . . . . . 8.7.5Turbine Engines . . . . . . . . . . . . . . . . . . . . . . . 8.7.4

SPECIFIC INTERNAL AREAS . . . . . . . . . . . . . . . . 8.6Aircraft Cockpit Area. . . . . . . . . . . . . . . . . . . . 8.6.1Aircraft Ejection Seats . . . . . . . . . . . . . . . . . . . 8.6.2Avionic, Electronic, and Electrical Equipment . . . 8.6.3Cleanup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5.1Graphite or Carbon Fiber/Epoxy, Boron Fiber/Epoxy,and Tungsten Fiber/Epoxy CompositeMaterials . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6.5Photographic Equipment. . . . . . . . . . . . . . . . . . 8.6.4

STORAGE/SHELF LIFE CONTROL OFSEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.8

Sealing of Access Doors . . . . . . . . . . . . . . . . F 6-16Sealing Procedures for Typical Aircraft Fitting. . F 6-14Typical Lap Skin Sealing . . . . . . . . . . . . . . . . F 6-13Typical Spar Cap Sealing . . . . . . . . . . . . . . . . F 6-15

STRUCTURAL TUBING MEMBERS ANDASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12


Exterior . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.4.1Interior . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.4.2Sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.12.4.3Structural Aluminum Alloy Tubing . . . . . . . . . . 7.12.1Structural Carbon Steel Tubing . . . . . . . . . . . . 7.12.4Structural Copper Alloys, Stainless Steel (CRES) Al-loys, and Heat Resistant Alloy Tubing. . . . . . . . 7.12.3Structural Magnesium Alloy Tubing . . . . . . . . . 7.12.2

SURFACE FINISH . . . . . . . . . . . . . . . . . . . . . . . . 5.6SURFACES AND COMPONENTS EXPOSED TO EX-HAUST GASES, GUN GASES, AND ROCKETBLAST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.10

TTHEORY OF CORROSION . . . . . . . . . . . . . . . . . . 2.4

Anode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1Cathode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.2Electrical Contact . . . . . . . . . . . . . . . . . . . . . . 2.4.4Electrolyte . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.3Elimination of Anode, Cathode, Electrolyte, or Electri-cal Contact . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.4.1Simplified Corrosion Cell . . . . . . . . . . . . . . . . F 2-1

TYPES OF CORROSION. . . . . . . . . . . . . . . . . . . . 2.7Active/Passive Cells . . . . . . . . . . . . . . . . . . . 2.7.6.3Another Example of Exfoliation . . . . . . . . . . . F 2-13Associated Hazards . . . . . . . . . . . . . . . . . . . . 2.7.6.5Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7.6.6Concentration Cell Corrosion . . . . . . . . . . . . . F 2-14Corrosion Fatigue . . . . . . . . . . . . . . . . . . . . . . 2.7.7Crevice/Concentration Cell Corrosion . . . . . . . . . 2.7.6Cross-Section of 7075-T6 Aluminum Alloy. . . . . F 2-9Cross-Section of Corrosion Pits . . . . . . . . . . . . F 2-8Example of Exfoliation . . . . . . . . . . . . . . . . . F 2-12Exfoliation Corrosion . . . . . . . . . . . . . . . . . . . . 2.7.5Filiform Corrosion. . . . . . . . . . . . . . . . . . . . . . 2.7.8Filiform Corrosion Found Under Paint Coating on aMagnesium Panel . . . . . . . . . . . . . . . . . . . . . F 2-17Fretting Corrosion . . . . . . . . . . . . . . . . . . . . . . 2.7.9Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . . 2.7.2Galvanic Corrosion of Magnesium Adjacent to a SteelFastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-6Galvanic Series of Metals and Alloys in SeaWater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-16Grain Structure of a Corroding AluminumSurface . . . . . . . . . . . . . . . . . . . . . . . . . . . . F 2-10High Temperature Oxidation (Hot Corrosion) . . . 2.7.10Intergranular Corrosion. . . . . . . . . . . . . . . . . . . 2.7.4Intergranular Corrosion of 7075-T6 Aluminum Adjacentto Steel Fastener . . . . . . . . . . . . . . . . . . . . . . F 2-11Metal Ion Concentration Cells. . . . . . . . . . . . . 2.7.6.1Oxygen Concentration Cells . . . . . . . . . . . . . . 2.7.6.2Pitting Corrosion . . . . . . . . . . . . . . . . . . . . . . . 2.7.3Pitting of an Aluminum Wing Assembly. . . . . . . F 2-7

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INDEX - CONTINUED

Index 8 Change 18


Schematic of the Development of Filiform Corrosionon an Aluminum Alloy . . . . . . . . . . . . . . . . . F 2-18Stress Corrosion Cracking . . . . . . . . . . . . . . . 2.7.6.4


Stress Corrosion Cracking . . . . . . . . . . . . . . . F 2-15Uniform Surface Corrosion . . . . . . . . . . . . . . . . 2.7.1

TO 1-1-691

INDEX - CONTINUED

Change 17 Index 9/(Index 10 blank)