Boeing KC-135 Stratotanker

The Boeing KC-135 Stratotanker is an aerial refueling military aircraft. It and the Boeing 707 airliner were developed from the Boeing 367-80 prototype. The KC-135 was the US Air Force's first jet-powered refueling tanker and replaced the KC-97 Stratotanker. The Stratotanker was initially tasked to refuel strategic bombers, but was used extensively in the Vietnam War and later conflicts such as Operation Desert Storm to extend the range and endurance of US tactical fighters and bombers.

Serving with the United States Air Force (USAF) since 1957, it is one of just six military fixed-wing aircraft with over 50 years of continuous service with its original operator. The KC-135 is supplemented by the larger KC-10. Despite increased maintenance costs, studies conclude many of the aircraft could be flown until 2040. The aircraft will be replaced by the Boeing KC-46.

Tanker Characteristics:

The KC-135 possesses the following characteristics:

● Flying boom to provide fuel transfer

● Drogue to re-fuel probe-equipped aircraft (attached to the boom)

● Passenger and cargo deck located above the fuselage-mounted tanks

KC-135 Skin-Replacment

During a 13-year period ending in 1988, Boeing replaced the lower wing surfaces with an improved aluminum-alloy skin. The program included the following tasks:

● Skin replacement on 746 aircraft (1500 square feet per aircraft)

● Replacement of the engine strut fittings

● Installation of 564 parts, 32,200 steel fasteners, and 19,500 aluminum rivets

CFM-Engine Replacment

To increase takeoff and carrying capacity, improve fuel efficiency, and reduce engine noise and pollution levels, Boeing replaced the original KC-135A engines with CFM56 engines for the U.S. Air Force. The serviced aircraft were re-designated as KC-135Rs, and the engine-replacement program achieved the following results:

● Reduced fuel consumption 27%, saving 2.3 to 3.2 million barrels of fuel annually

● Reduced decibel levels from 126 to 99 decibels (98%) while reducing the noise-impact area near airports from 240 to 3 square miles

JT3D Engine-Replacment

The Air Force Reserve and Air National Guard retained Boeing to replace KC-135-A engines with refurbished JT3D engines taken from used commercial 707 airliners. The aircraft designation changed to KC-135E, and the program achieved the following results:

● Increased engine power 30%

● Reduced noise levels 85%

● Replaced/refurbished struts and cowling, brakes, cockpit controls, and instruments

Continuing Improvement

The U.S. Air Force retained Boeing to provide the following improvements: add wingtip, hose, and drogue refueling pods; modernize the cockpit; provide new compasses and radar systems; and install a global positioning system (GPS).

source: Boeing

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