TO 1-1-700 - Robins Air Force Base

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TO 1-1-700 c. Riveted joints shall be tight, and each of the joined parts shall be undamaged. d. Riveting shall not be used to mount components such as capacitors, transformers, resistors, reactors, etc. unless directed by an equipment system specific technical manual or specification. 2.2.5 Welding. Improper welding can be the cause of severe corrosion problems. Use these general precautions and techniques during welding operations to minimize in-service corrosion problems on welded components. Consult Chapter 1 of TO 31-1-75 for additional information on welding. Welding operations produce high heat, highly toxic fumes, injurious radiation, metal slag, and airborne particles. Welding goggles and/or face mask with properly tinted lenses, protective apron or jacket, and welder's boots and gloves are required. Adequate ventilation with air flow from behind the welder and toward the work piece is usually sufficient. a. Make sure welds are of ample size with thorough penetration and good fusion and are free of scabs, blisters, abnormal pockmarks, bruises, spatter, and any other harmful defects. This will prevent corrosion due to moisture entrapment in crevices created by incomplete and/or poor welds. b. Arc welding electrodes shall be a type that produces a weld having chemical and physical properties very similar to the parent metal properties. This will prevent galvanic corrosion associated with the weld due to dissimilar metal contact. MIL-PRF-81733, SEALING AND COATING COMPOUND, CORROSION INHIBITIVE 48 c. When tack/spot welds are used to permanently secure parts together, a sufficient number of welds shall be made to provide adequate joint strength and rigidity to hold the parts together, with a minimum of two welds being required. This type of welded structure is highly susceptible to crevice corrosion due to moisture intrusion between the parts by capillary action. To prevent this from happening, apply a continuous bead of MIL- PRF-81733, Type IV-12, Class 1, Grade A corrosion inhibiting sealant around the entire periphery of the faying or contacting surfaces of the parts according to procedures in Chapter 12 of this manual. Mate the parts and tack/spot weld them together while the sealant is still wet. 2.2.6 Wiring and Cabling (Wire and Cable Runs). Wire and cable runs should be inspected for defects such as cuts, cracks, kinks, crushed areas, abraded or deteriorated insulation that exposes the wire/cable conductors. If any of these conditions are found, the wire/cable should be replaced per the criteria in Chapter 1 of TO 31-1-75 as soon as possible to prevent moisture from contacting the conductors and causing them to corrode and/or short out. Using insulation sleeving to repair insulation defects should be avoided if at all possible because moisture can be wicked under the sleeving by capillary action, become trapped, and cause corrosion of the metal conductors. Wires and cables shall be protected from cuts and abrasion; shall not be sharply bent around corners or edges to prevent cutting and cracking of the insulation; and when passing through a hole in sheet metal with a thickness of 1/8 inch or less, shall be protected by using a suitable rubber grommet. Wire and cable runs, including hookup wiring, shall be properly supported to prevent undue stress on their conductors and the terminals to which they are attached. 2.2.7 Grounding. All C-E-M equipment shall be properly grounded. See Chapter 8 of this manual for further information on grounding. 2.3 SPECIFIC GENERAL REQUIREMENTS. 2.3.1 Fixed Capacitors. All fixed capacitors should be inspected for swelling; leakage or breaks in the protective covering; cracked or chipped terminal insulation bushings; or leaking gaskets, seams, or bushings. If any of these conditions are found, the capacitor should be replaced with a like item and clean up any leaked dielectric to prevent corrosion of the surrounding circuitry due to the leaked dielectric in conjunction with moisture and the internal areas of the capacitor itself due to moisture intrusion. 2.3.2 Variable Capacitors. Inspect the plates of variable/ tunable capacitors for corrosion and determine that the tuning shaft is free moving. Remove minor/surface corrosion from the plates with A-A-58054, Type I, Class 1, Grade A (very fine) abrasive mat per procedures in Chapters 11 and 12 of this manual and Chapter 5 of TO 1-1-691. Lubricate the tunable shaft of the capacitor with MIL-L-87177, Grade B or MIL- PRF-81309, Type III avionics grade, water displacing lubricant/corrosion preventive compound (CPC) per procedures in Chapter 7 of this manual. 2.3.3 Controls. Inspect controls and moving parts of switches, rheostats, and potentiometers for the presence of any corrosion; smooth mechanical operation at all points with no 2-4
TO 1-1-700 dead spots, binding, scraping, or excessive backlash; and for proper electrical operation with good electrical contact without any cut-outs or erratic operation. Remove minor/surface corrosion from these parts with A-A-58054, Type I, Class 1, Grade A (very fine) abrasive mat per procedures in Chapters 8 and 11 of this manual and Chapter 5 of TO 1-1-691. Lubricate the tunable shafts of these parts with MIL-L-87177, Grade B or MIL-PRF-81309, Type III avionics grade, water displacing lubricant/corrosion preventive compound (CPC) per procedures in Chapter 7 of this manual. 2.3.4 Dials and Pointers. Inspect dials and pointers for the presence of any corrosion; clear and complete marking with proper alignment to indicate the correct values and/or settings; secure attachment to either the equipment case or control shaft as applicable; and freedom of movement throughout their entire operational range with no binding or sticking. Remove minor/surface corrosion from these parts with A-A-58054, Type I, Class 1, Grade A (very fine) abrasive mat per procedures in Chapters 8 and 11 of this manual and Chapter 5 of TO 1-1-691. Lubricate the tunable shafts of these parts with MIL- L-87177, Grade B or MIL-PRF-81309, Type III avionics grade, water displacing lubricant/corrosion preventive compound (CPC) per procedures Chapter 7 of this manual. 2.3.5 Frameworks, Cabinets, and Mechanical Assemblies. Frameworks, cabinets, and assemblies will conform to the original/modified system specific specifications and be free of broken, cracked, distorted, and corroded members. a. Metal cases and cabinets will be free of corroded areas, cracks, deep cuts, and holes or openings (except those required by the system specific equipment specifications and/or drawings). b. Minor damage, such as discolored or tarnished surfaces that do not effect operational performance, slight scratches, dents, and chipped edges that can be readily smoothed out are permissible as long as the defects are properly noted in the equipment maintenance forms, and the tarnish is removed and the other defects are properly touched-up as soon as practical. c. Removable assemblies will fit securely in their proper places and be easily removed and reinstalled without sticking or binding due to mechanical distortion and/or corrosion. 2.3.6 Finishes. Finish systems are applied to C-E-M equipment and its shelters, vans, and radomes to provide corrosion protection to the equipment, and they shall be maintained in good condition. The exterior and interior of C-E-M equipment shall be completely covered with a corrosion preventive finish system consisting of plating, chemical conversion coating, primer, paint/coating topcoat, or an appropriate combination of them as required by the original system specific specifications and drawings, the system specific maintenance manuals, and/ or MIL-HDBK-454. Finish systems shall conform to the required Military or Federal Specification. Either touch-up, complete overcoat, or complete recoating is satisfactory for maintaining the finish system. Complete recoating/refinishing shall not be done solely to match the colors, shades, and glosses of the various components or to replace a wrinkle finish of an electronic system and is not required if the cost of touch-up and/or overcoat is less than 65% of the cost to completely refinish the item. Touch-up plating (brush plating) and/ or complete replating shall be done per the appropriate section of TO 42C2-1-7. Application of conversion coatings shall be done per Chapter 7 of this manual. Touch-up painting/maintenance painting, overcoating, and complete repainting shall be done per procedures in Chapter 7 of this manual. The color, shade, and gloss of paint used for touch-up operations shall match the FED-STD-595 color number of the original finish system; but it should be understood that exact matching of an old finish system is very unlikely. NOTE MIL-E-4158, Wrinkle Finish, is not used for newer C-E-M equipment. If touch-up or complete refinishing of an older piece of equipment having a wrinkle finish is required, use a flat polyurethane coating that is available in the Air Force supply system and matches as close as possible the original finish system chosen from FED-STD-595. 2.3.7 Gaskets. Gaskets can prevent corrosion if they seal effectively or they can be the cause of corrosion if improperly mounted and/or do not seal properly. a. Inspect gaskets to ensure they are live/resilient and have no breaks, cracks, or chips that prevents them from providing a tight seal thus allowing moisture to enter a piece of equipment and cause corrosion. In addition, ensure that an installed gasket meets all mating edges/ surfaces evenly with no high spots and look for places where the gasket does not make complete contact with the seal flanges that would allow moisture to wick between the gasket and the flange surface and cause corrosion. b. Replace cork or paper gaskets when they are disturbed by removal of parts from a piece of equipment. Cork and paper gaskets are notorious for absorbing moisture and causing corrosion of the metal seal plane surfaces; so if at all possible, replace them with a new closed cell rubber gasket with the approval of the equipment System Program Manager (SPM). 2-5
Page 1 and 2: TO 1-1-700 TECHNICAL MANUAL CORROSI
Page 3 and 4: TO 1-1-700 TABLE OF CONTENTS Chapte
Page 5 and 6: TO 1-1-700 TABLE OF CONTENTS - CONT
Page 13 and 14: TO 1-1-700 LIST OF ILLUSTRATIONS -
Page 15 and 16: TO 1-1-700 FOREWORD 1. PURPOSE. The
Page 17 and 18: TO 1-1-700 List of Related Publicat
Page 19 and 20: TO 1-1-700 SAFETY SUMMARY 1. GENERA
Page 21 and 22: TO 1-1-700 AMS-G-6032, GREASE, PLUG
Page 23 and 24: TO 1-1-700 MIL-DTL-64159, COATING,
Page 25 and 26: TO 1-1-700 MIL-PRF-27617, GREASE, A
Page 27 and 28: TO 1-1-700 O-L-164, DRESSING, LEATH
Page 29: TO 1-1-700 MIL-T-81772, THINNER, PO
Page 32 and 33: TO 1-1-700 tronics equipment and th
Page 34 and 35: TO 1-1-700 cleaning situation, syst
Page 38 and 39: TO 1-1-700 c. Remove and replace an
Page 40 and 41: TO 1-1-700 MIL-L-87177, LUBRICANT,
Page 42 and 43: TO 1-1-700 Figure 3-1. Simplified C
Page 44 and 45: TO 1-1-700 resistant, and also at t
Page 46 and 47: TO 1-1-700 is first noticeable as a
Page 48 and 49: TO 1-1-700 3.7.8 Oxygen Concentrati
Page 50 and 51: TO 1-1-700 Figure 3-14. Concentrati
Page 52 and 53: TO 1-1-700 Figure 3-17. Galvanic Se
Page 54 and 55: TO 1-1-700 Figure 3-20. Aluminum Su
Page 56 and 57: TO 1-1-700 3.8.7 CRES/Stainless Ste
Page 58 and 59: TO 1-1-700 3.9.10 Climate. Warm, mo
Page 60 and 61: TO 1-1-700 3.11 PREVENTATIVE MAINTE
Page 63 and 64: TO 1-1-700 CHAPTER 4 COMPOSITE AND
Page 65 and 66: TO 1-1-700 4.4.4.4 Glass parts shal
Page 67 and 68: TO 1-1-700 CHAPTER 5 PACKAGING (STO
Page 69 and 70: TO 1-1-700 extent of damage dependi
Page 71 and 72: TO 1-1-700 5.15 PRECAUTIONS FOR VCI
Page 73 and 74: TO 1-1-700 c. Secure the desiccant
Page 75 and 76: TO 1-1-700 Figure 5-8. Shock Isolat
Page 77 and 78: TO 1-1-700 Figure 5-9. Examples of
Page 79 and 80: TO 1-1-700 5.24.10 Rigid or Flexibl
Page 81 and 82: TO 1-1-700 CHAPTER 6 MOISTURE AND F
Page 83 and 84: TO 1-1-700 c. 6.2.6 Felt. Examine f
Page 85 and 86: TO 1-1-700 a. After first directing
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TO 1-1-700 6.4.5.14 Terminals, scre
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TO 1-1-700 NOTE • Authorized clea
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TO 1-1-700 Table 7-1. Cleaning of S
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TO 1-1-700 7.3.1.2.3 Portable, 45 g
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TO 1-1-700 Table 7-2. Common Milita
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TO 1-1-700 inactivity, storage, or
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TO 1-1-700 7.5.6.5.1 Grade 1 - A th
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TO 1-1-700 Table 7-4. Corrosion Pre
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TO 1-1-700 Table 7-5. Preservation
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TO 1-1-700 either case, MIL-PRF-269
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TO 1-1-700 MIL-PRF-85285, COATING,
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TO 1-1-700 c. Cadmium plated surfac
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TO 1-1-700 a. Scuff sand and feathe
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TO 1-1-700 7.7.7.2 If surface is no
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TO 1-1-700 7.7.9.2 Where only parti
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TO 1-1-700 7.8.1 Type I Application
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TO 1-1-700 Extend (Loctite) 32150 J
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TO 1-1-700 There are three ways to
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TO 1-1-700 vulnerable surfaces clea
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TO 1-1-700 Table 8-2. Materials, Th
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TO 1-1-700 Table 8-4. Electronic Cl
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TO 1-1-700 Table 8-5. Accessories o
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TO 1-1-700 Table 8-5. Accessories o
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TO 1-1-700 f. Devices with permanen
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TO 1-1-700 Table 8-7. Cleaning and
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TO 1-1-700 MIL-PRF-87937, CLEANING
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TO 1-1-700 of contamination). Maint
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TO 1-1-700 8.8.2 Protective Coating
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TO 1-1-700 • Tube clamps. • Min
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TO 1-1-700 a. For bonding/grounding
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TO 1-1-700 vertently destroy the mo
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TO 1-1-700 doors, and other corrosi
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TO 1-1-700 CHAPTER 10 CORROSION PRO
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TO 1-1-700 MIL-PRF-81733, SEALING A
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TO 1-1-700 d. After corrosion is re
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TO 1-1-700 (3) Stainless/CRES steel
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TO 1-1-700 10.9 WATER ENTRAPMENT AR
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TO 1-1-700 f. Shield equipment from
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TO 1-1-700 b. Use e-inch rivnuts of
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TO 1-1-700 10.17.3 If the plating s
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TO 1-1-700 Figure 10-16. Dissipatio
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TO 1-1-700 (2) If allowable damage
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TO 1-1-700 Table 11-1. Recommended
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TO 1-1-700 11.6 3M CO. SCOTCH-BRITE
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TO 1-1-700 11.11.2 Control of Mecha
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TO 1-1-700 11.12.2 Mechanical Damag
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TO 1-1-700 MIL-DTL-81706 (ALODINE),
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TO 1-1-700 11.13.2.3 Application of
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TO 1-1-700 only when there is no da
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TO 1-1-700 NOTE SEMCO PASA-JELL 101
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TO 1-1-700 (CRES), lead, ceramic, g
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TO 1-1-700 11.13.7.2 Treatment of C
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TO 1-1-700 MIL-A-46106, ADHESIVE/SE
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TO 1-1-700 Table 12-1. Sealing Comp
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TO 1-1-700 used to apply sealants i
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TO 1-1-700 Figure 12-2. Sealant App
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TO 1-1-700 Figure 12-4. Rivet Appli
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TO 1-1-700 Figure 12-6. Sealant Inj
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TO 1-1-700 below and adhere very po
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TO 1-1-700 Table 12-2. Time Require
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TO 1-1-700 Table 12-2. Time Require
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TO 1-1-700 of 20 to 25 seconds in a
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TO 1-1-700 d. Remove all uncured se
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TO 1-1-700 Figure 12-12. Typical Me
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TO 1-1-700 may be used for low temp
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TO 1-1-700 Figure 12-14. Sealing Pr
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TO 1-1-700 - Robins Air Force Base

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