NAVAIR 01-1A-509-2 TM 1-1500-344-23-2 TECHNICAL MANUAL CLEANING AND CORROSION CONTROL VOLUME II AIRCRAFT This publication supersedes NAVAIR 01-1A-509-2/TM 1-1500-344-23-2, dated 01 March 2005. DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. DESTRUCTION NOTICE - For unclassified, limited documents, destroy by any method that will prevent disclosure of contents or reconstruction of the document. PUBLISHED BY DIRECTION OF COMMANDER, NAVAL AIR SYSTEMS COMMAND ' GQ !!"( 15 APRIL 2009 Change 1 - 31March 2010 NAVAIR 01-1A-509-2 15 April 2009 TM 1-1500-344-23-2 Change 1 - 31 March 2010 LIST OF EFFECTIVE PAGES Dates of issue for original and changed pages are: Original........................ 0 ..........................15 Apr 2009 Change ....................... 0 ......................... 15 Sep 1993 (Includes IRAC 1) Change ....................... x ........................ xx XXX 199X Change ....................... 1 ..........................31 Mar 2010Change x xx XXX 199XCha Insert latest changed pages; dispose of superseded pages in accordance with applicable regulations. NOTE: On a changed page, the portion of the text affected by the latest change is indicated be a vertical line, or other change symbol in the outer margin of the page. Change in illustrations are indicated by miniature pointing hands. Changes to wiring diagrams are indicated by shaded areas. Total number of pages in this manual is 234, consisting of the following: Page *Change Page *Change Page *Change No. No. No. No. No. No. Title ........................................ 1 2-34 ........................................ 1 8-9 - 8-10 ............................... 1 A ............................................. 1 2-35 ........................................ 0 9-1 - 9-5 ................................. 0 i .............................................. 1 2-36 Blank .............................. 0 9-6 .......................................... 1 ii - v ........................................ 0 3-1 - 3-7 ................................. 0 9-7 - 9-10 ............................... 0 vi Blank .................................. 0 3-8 Blank ................................ 0 9-11 - 9-12 ............................. 1 vii ............................................ 0 3-9 - 3-15 ............................... 0 9-13 - 9-15 ............................. 0 viii Blank ................................. 0 3-16 Blank .............................. 0 9-16 Blank .............................. 0 TPDR-1 .................................. 0 4-1 - 4-18 ............................... 0 A-1 - A-32 ................................ 0 TPDR-2 Blank ........................ 0 4-19 ........................................ 1 B-1 .......................................... 0 HMWS-1 - HMWS-5 .............. 0 4-20 - 4-22 ............................. 0 B-2 Blank ............................... 0 HMWS-6 ................................ 1 5-1 - 5-6 ................................. 0 B-3 .......................................... 0 1-1 - 1-4 ................................. 0 6-1 - 6-2 ................................. 0 B-4 Blank ............................... 0 2-1 .......................................... 0 6-3 .......................................... 1 B-5 .......................................... 0 2-2 - 2-5 ................................. 1 6-4 - 6-9 ................................. 0 B-6 Blank ................................ 0 2-6 - 2-13 ............................... 0 6-10 ........................................ 1 B-7 - B-15 ................................ 0 2-14 - 2-17 ............................. 1 6-11 ........................................ 0 B-16 Blank .............................. 0 2-18 ........................................ 0 6-12 Blank .............................. 0 B-17 - B-19 .............................. 0 2-19 ........................................ 1 7-1 - 7-27 ............................... 0 B-20 Blank .............................. 0 2-20 - 2-22 ............................. 0 7-28 Blank .............................. 0 B-21 - B-27 .............................. 0 2-23 - 2-25 ............................. 1 8-1 - 8-5 ................................. 0 B-28 Blank .............................. 0 2-26 - 2-31 ............................. 0 8-6 - 8-7 ................................. 1 B-29 - B-33 .............................. 0 2-32 Blank .............................. 0 8-8 .......................................... 0 B-34 Blank .............................. 0 2-33 ........................................ 0 *Zero in this column indicates an original page. iiA Change X 15 April 2009 NAVAIR 01-1A-509-2 Change 1 - 31 March 2010 TM 1-1500-344-23-2 TABLE OF CONTENTS Chapter Page Chapter Page LIST OF ILLUSTRATIONS ........................................ iv 3 INSPECTION AND CORROSION LIST OF TABLES ........................................................ v PRONE AREAS HOW TO USE THIS MANUAL .................................. vii LIST OF TECHNICAL PUBLICATIONS SECTION I. INSPECTION AND DEFICIENCY REPORTS (TPDR) EVALUATION ......................................... 3-1 INCORPORATED ............................TPDR-1 WARNINGS APPLICABLE TO HAZARDOUS 3.1. General ........................................... 3-1 MATERIALS ...................................... HMWS-1 3-2. Inspection Methods ......................... 3-2 3-3. Evaluation of Corrosion Damage .... 3-6 1 INTRODUCTION 3-4. Degrees of Corrosion ...................... 3-7 1-1. General ........................................... 1-1 SECTION II. CORROSION 1-2. Purpose ........................................... 1-1 PRONE AREAS ...................................... 3-9 1-3. Scope .............................................. 1-1 1-4. Arrangement of Manual .................. 1-1 3-5. Common Corrosion Prone Areas .... 3-9 1-5. Related Publications ....................... 1-1 1-6. Consumables and Equipment ......... 1-1 4 CORROSION REMOVAL 2 CLEANING 4-1. Purpose ........................................... 4-1 4-2. Responsibility .................................. 4-1 SECTION I. CLEANING AND 4-3. Corrective Maintenance .................. 4-1 LUBRICATION ........................................ 2-1 4-4. Paint Removal ................................. 4-1 4-5. Mechanical Paint Removal ............. 4-1 2-1. Introduction ..................................... 2-1 4-6. Chemical Paint Removal................. 4-5 2-2. Reasons for Cleaning ..................... 2-1 4-7. Minor Paint Damage Repair............ 4-8 2-3. Frequency of Cleaning .................... 2-1 4-8. Corrosion Removal ......................... 4-8 2-4. Water Quality .................................. 2-1 4-9. Corrosion Removal Equipment 2-5. Cleaning Compounds ..................... 2-2 and Materials ................................ 4-9 2-6. Steam Cleaning............................... 2-5 4-10. Corrosion Removal Procedures .... 4-17 2-7. Cleaning Equipment ........................ 2-5 4-11. Surface Finish ............................... 4-20 2-8. Equipment Operating Procedures ................................... 2-8 5 SURFACE TREATMENT 2-9. Cleaning Procedures .................... 2-10 2-10. Fresh Water Rinsing ..................... 2-26 5-1. Purpose ........................................... 5-1 2-11. Post Cleaning Procedures ............ 2-27 5-2. Surface Preparation ........................ 5-1 2-12. Treatment and Disposal of 5-3. Precautions ..................................... 5-1 Wash Rack Waste ...................... 2-28 5-4. Chemical Conversion Coating ........ 5-2 2-13. Lubricants...................................... 2-28 5-5. MIL-DTL-81706 Chemical Conversion Coating for SECTION II. SPECIAL CLEANING.......... 2-33 Aluminum Alloys ........................... 5-2 5-6. AMS-M-3171 Chemical 2-14. Introduction ................................... 2-33 Conversion Coating for 2-15. Cleaning After Exposure to Magnesium Alloys ........................ 5-4 Volcanic Ash ............................... 2-33 5-7. Troubleshooting .............................. 5-5 2-16. Cleaning After Desert 5-8. Expired Service Life ........................ 5-5 Operations or Exposure to 5-9. Post Treatment................................ 5-5 Sand Environments .................... 2-33 5-10. Temporary Preservation ................. 5-6 i NAVAIR 01-1A-509-2 15 April 2009 TM 1-1500-344-23-2 6 TREATMENT OF SPECIFIC AREAS 8-5. Time Limitations of CPCs ............... 8-1 8-6. Description of CPCs ........................ 8-1 6-1. Introduction ..................................... 6-1 8-7. Preservation of Specific Areas ........ 8-5 6-2. Air Intake Ducts for Jet Aircraft ....... 6-1 8-8. Preservation Application 6-3. Battery Compartments, Boxes, Methods ........................................ 8-5 and Adjacent Areas ...................... 6-1 8-9. Application of Polish and Wax ........ 8-9 6-4. Beryllium-Copper Alloys.................. 6-2 8-10. Preservation of Assemblies and 6-5. Cables, Steel ................................... 6-3 Parts Removed from 6-6. Depleted Uranium Aircraft During Maintenance ......... 8-9 Counterweights............................. 6-3 6-7. Electrical and Electronic 9 EMERGENCY PROCEDURES Equipment..................................... 6-3 6-8. EMI Seals and Gaskets .................. 6-4 9-1. Purpose ........................................... 9-1 6-9. Fasteners and Attaching Parts ....... 6-6 9-2. Responsibility .................................. 9-1 6-10. Faying Surfaces, Joints, and 9-3.