16W41-4-2 (Illustrated Parts Breakdown).pdf

TO 16W41-4-2

TECHNICAL MANUAL

OPERATION, MAINTENANCE, AND DEPOT

OVERHAUL INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

AIRCRAFT CARGO POD

PART NO. 400850-3

(HK Consulting, Inc.)

THIS PUBLICATION SUPERSEDES TO 16W41-4-2 DATED 8 DECEMBER 2004.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval or the originating United States agency.

DISTRIBUTION STATEMENT - C. Distribution authorized to U.S. Government agencies and their contractors only, administrative or operational use, 1 March 2000. Other requests for this document shall be referred to AFLCMC/EBHEC, Hill AFB, UT 84056-5820.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act. (Title 22, U.S.C., Sec 2751 et seq.) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 et seq.). Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of AFI 61-204.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER THE AUTHORITY OF THE SECRETARY OF THE AIR FORCE

5 MAY 2016

LIST OF EFFECTIVE PAGES INSERT 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 DESTROY SUPERSEDED PAGES.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 of the page.

Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . . . . . . . . . . . . . . . 5 May 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 42 CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i–iii iv Blank v vi Blank vii–xi xii Blank 1-1–1-2 2-1–2-2 3-1–3-6 4-1–4-11 4-12 Blank 5-1–5-6

*Zero in this column indicates an original page

A USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS ........................................................................................................................................... iii

LIST OF TABLES ........................................................................................................................................................... iii

FOREWORD................................................................................................................................................................... v

SAFETY SUMMARY .................................................................................................................................................... vii

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

1.1 Purpose......................................................................................................................................................... 1-1

1.2 Scope............................................................................................................................................................ 1-1

1.3 Major Characteristics ................................................................................................................................... 1-1

1.4 Maintenance Concepts ................................................................................................................................. 1-1

1.5 Description Information............................................................................................................................... 1-1

1.5.1 NGCP........................................................................................................................................................... 1-1

1.5.1.1 Physical Description, NGCP........................................................................................................................ 1-1

1.5.1.2 Functional Description, NGCP .................................................................................................................... 1-1

2 MASTER LIST OF SPECIAL TOOLS, TEST EQUIPMENT, EXPENDABLE ITEMS AND CONSUMABLES...... 2-1

2.1 Common Tools............................................................................................................................................. 2-1

2.2 Master List of Special Tools ........................................................................................................................ 2-1

2.3 Master List of Test Equipment..................................................................................................................... 2-1

2.4 Master List of Expendable Items and Consumables.................................................................................... 2-1

3 LOADING OF THE NEXT GENERATION CARGO POD .......................................................................................... 3-1

3.1 Next Generation Cargo Pod (NGCP) Cargo Loading.................................................................................. 3-1

3.2 NGCP Cargo Tie-Down............................................................................................................................... 3-1

4 REPAIR AND INSPECTION.......................................................................................................................................... 4-1

4.1 General......................................................................................................................................................... 4-1

4.2 Special Tools ................................................................................................................................................ 4-1

4.3 Disassembly ................................................................................................................................................. 4-1

4.4 Inspection..................................................................................................................................................... 4-1

4.5 NGCP Repair or Replacement ..................................................................................................................... 4-1

4.6 Weld Repair Procedures............................................................................................................................... 4-3

4.7 Rework Criteria for NGCP Structure........................................................................................................... 4-7

4.8 Filler Compound .......................................................................................................................................... 4-7

4.9 Surface Preparation...................................................................................................................................... 4-8

4.10 Refinish NGCP Surfaces.............................................................................................................................. 4-9

4.11 Spray Markings............................................................................................................................................ 4-10

4.12 Interior Surface Treatment ........................................................................................................................... 4-10

4.13 Anodized Surfaces ....................................................................................................................................... 4-10

4.14 Coated Surfaces ........................................................................................................................................... 4-10

4.15 Exterior Surface Treatment.......................................................................................................................... 4-11

5 ILLUSTRATED PARTS BREAKDOWN....................................................................................................................... 5-1

SECTION I FOREWORD.................................................................................................................................................. 5-1 i

TABLE OF CONTENTS – Continued

Chapter Page

5.1 General......................................................................................................................................................... 5-1

5.2 Model Covered............................................................................................................................................. 5-1

5.3 Finding Part Numbers, Illustration, Description.......................................................................................... 5-1

5.4 Similar Assemblies ...................................................................................................................................... 5-1

5.5 Usable on Code ............................................................................................................................................ 5-1

5.6 Source, Maintenance, and Recoverability (SMR) Code Column................................................................ 5-1

5.7 Part Standardization ..................................................................................................................................... 5-1

5.8 MPL ............................................................................................................................................................. 5-1

5.8.1 Figure and Index Number Column .............................................................................................................. 5-1

5.8.1.1 Sheet Number Explanation .......................................................................................................................... 5-1

5.8.2 Part Number Column ................................................................................................................................... 5-2

5.8.3 Commercial and Government Entity (CAGE) Column............................................................................... 5-2

5.8.4 Description Column..................................................................................................................................... 5-2

5.8.4.1 Indentation ................................................................................................................................................... 5-2

5.8.5 Units Per Assembly Column........................................................................................................................ 5-2

5.8.6 Numerical Index (NI)................................................................................................................................... 5-2

5.9 Symbols and Abbreviations ......................................................................................................................... 5-2

5.10 List of Related Publications ......................................................................................................................... 5-2

5.11 List of Applicable Time Compliance Technical Orders (TCTOs)............................................................... 5-2

5.12 Improvement Reports................................................................................................................................... 5-2

5.13 How to use the IPB ...................................................................................................................................... 5-3

SECTION II MAINTENANCE PARTS LIST ................................................................................................................... 5-5 ii

LIST OF ILLUSTRATIONS

Number Title Page

1-1 NGCP, Part No. 400850-3 ..................................................................................................................................... 1-2 3-1 NGCP Tie-Down System....................................................................................................................................... 3-3 3-2 Forward and Aft Sections Tie-Down Examples (Sheet 1)..................................................................................... 3-4 3-3 Center Section Tie-Down Examples...................................................................................................................... 3-6 4-1 NGCP External Surface Scratch Repair Limits ..................................................................................................... 4-2 4-2 NGCP Skin Patch Repair (Sheet 1) ....................................................................................................................... 4-4 5-1 NGCP..................................................................................................................................................................... 5-5

LIST OF TABLES

Number Title Page

1-1 NGCP Leading Characteristics .............................................................................................................................. 1-1 2-1 Master List of Special Tools .................................................................................................................................. 2-1 2-2 Master List of Test Equipment............................................................................................................................... 2-1 2-3 Master List of Expendable Items and Consumable Materials ............................................................................... 2-1 3-1 NGCP Weight Distribution .................................................................................................................................... 3-2 4-1 Inspection and Maintenance Criteria ..................................................................................................................... 4-1 4-2 NGCP Inspection Checklist ................................................................................................................................... 4-11 iii/(iv blank)

FOREWORD

1. PURPOSE.

This technical manual provides general safety precautions and instructions that users will understand and apply during operation and maintenance of the Next Generation Cargo Pod (NGCP), part No. 400850-3, manufactured by Sargent Fletcher, Inc., to ensure personal safety and health, and the protection of DOD property.

2. USE OF THIS MANUAL.

The table of contents indicates chapter, paragraph, title, and page numbers to facilitate location of information. Illustrations, tables, and diagrams, when applicable, are located throughout the publication to supplement the text material. A list of illustrations and a list of tables indicates the number, title, and location. Abbreviations, phrases, and words which are on a decal, a placard or an engraving are set forth in the text exactly as they appear on the decal, the placard or the engraving.

3. USE OF WORDS.

The word SHALL is used in this manual to express a provision that is binding. The words SHOULD and MAY are used to express nonmandatory provisions. The word WILL is used to express a declaration of purpose, and can be used to describe future events.

4. LIST OF RELATED PUBLICATIONS.

The following publications are referenced in and used in this manual:

List of Related Publications.

Number Title

AFMAN 48-155 Occupational and Environmental Health Exposure Controls TO 00-25-195 Air Force Technical Order System Source, Maintenance, and

Recoverability Coding of Air Force Weapons Systems and Equipment

TO 1-1-3 Inspection and Repair of Aircraft Integral Tanks and Fuel Cells TO 1-1-8 Application and Removal of Organic Coatings, Aerospace and

Non-Aerospace Equipment TO 1-1-691 Aircraft Weapons Systems Cleaning and Corrosion Control TO 1-1A-1 General Manual for Structural Repair TO IF-16( )-2-12JG-00-2 NGCP Loading/Unloading Info TO IF-16( )-36 Nondestructive Inspection TO 42A-1-1 Safety, Fire Precaution, and Health Promotion Aspects of

Painting and Paint Removal

5. SYMBOLS AND ABBREVIATIONS.

The following nonstandard symbols and abbreviations are used in this manual:

AFSC Air Force Systems Command AN Air Force-Navy

NAS Naval Aircraft Standards NGCP Next Generation Cargo Pod

6. IMPROVEMENT REPORTS.

Recommended changes to this manual shall be submitted on AFTO Form 22 In accordance With (IAW) TO 00-5-1.

v/(vi blank)

SAFETY SUMMARY

1. GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes, which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs, and NOTESs included in the task shall be reviewed and understood.

1.1. Handling Hazardous Materials. Procedures contained in this manual may involve the handling of hazardous materials.

The user of this manual shall obtain the Safety Data Sheets (SDS), Occupational Safety and Health Act (OSHA) Form 20, or equiv-alent, from the manufactures or suppliers to be used. The user must become completely familiar with the manufacturer/supplier information and adhere to the procedures, recommendations, warnings, and cautions of the manufacture/supplier for the safe use, handling, storage, and disposal of these materials.

1.2. Safety Training. The safety requirements contained herein will be complied with during all operations. All personnel en-gaged in operations involving hazardous materials shall be thoroughly trained in safety. The shall be capable of recognizing haz-ardous situations and conditions. Thinking safety and working safely must become a habit when working with or near items that can create a hazard due to their flammable, toxic or other characteristics.

1.3. Eliminating Hazards. Lack of safety requirement in this technical manual does not mean that safeguards are not needed.

Prompt action will be taken to control any hazard. If a danger is encountered, all operations in the immediate area will be shut down.

Supervisory personnel will be called for help in eliminating hazard. Operations will not be resumed until hazard has been eliminated.

2. WARNINGS, CAUTIONS, AND NOTES.

WARNING, CAUTION, and NOTE statements have be strategically placed throughout this text prior to operating or maintenance procedures, practices or conditions considered essential to the protection of personnel (WARNING) or equipment and property (CAUTION) or when essential to highlight a practice (NOTE). A WARNING, CAUTION or NOTE will apply each time the step to which it refers is repeated. Prior to starting any task, the WARNINGS, CAUTIONS, and NOTES for that task will be reviewed and understood. Refer to the materials list table at the beginning of the appropriate chapter for material used during maintenance of this equipment. The detailed warnings for hazardous materials are listed separately in this safety summary in the HAZARDOUS MATERIALSWARNINGS paragraph. These detailed warnings are referenced using the index number beside the materials nomen-clature under each icon through the text. Other warnings, cautions, and notes which appear in this manual are not listed separately in this safety summary, and are defined as follows:

WARNING

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury to, or death of, personnel or long term health hazards.

CAUTION

Highlights an essential operation or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition or statement.

3. HAZARDOUS MATERIALS WARNINGS.

Hazardous materials warnings are provided through use of hazard symbols listed below. Consult the HAZARDOUS MATERIALS DESCRIPTION below or SDS, OSHA Form 20, or equivalent, for specific information on hazards, effects, and protective equip-ment requirements. If you do not have an SDS for the material involved, contact your supervisor, base safety or bioenvironmental engineering offices.

3.1. Hazardous materials Icons. The following icons are used throughout Air Force technical manuals to indicate the use of hazardous materials:

vii

The abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to your life or health.

The symbol of drops of liquid onto a hand shows that the material will cause burns or irritation to human skin or tissue.

The rapidly expanding symbol shows that the material may explode if subjected to high temperatures, sources of ignition or high pressure.

The symbol of a person wearing goggles shows that the material will injure your eyes.

The symbol of a flame shows that the material can ignite and burn you.

The symbol of a skull and crossbones shows that a material is poisonous or is a danger to life.

The symbol of three circular wedges shows that the material emits radioactive energy and can injure human tissue or organs.

The symbol of a human figure in a cloud shows that vapors of a material present a danger to your life or health.

3.2. Hazardous Materials Description. The following detailed hazardous material warnings pertain to materials or substances used in connection with procedures called out or described in this technical manual. Use these advisory warnings and their associated precautions in conjunction with current SDS for each material or substance. If there is conflict between this safety summary and the SDS, the SDS takes precedence.

Chemical-Conversion Material, Specification MIL-DTL-5541 1

HAZARD: Can cause severe irritation to eyes, skin, and respiratory tract.

APPLICATIONS: Do not get in eyes, on skin or on clothing. Wear protective clothing, chemical resistant gloves, and chemical goggles or face shield. Respiratory protection not normally required. If significant vapor/mist are generated, use a National Institute for Occupational Safety and Health (NIOSH)-approved respirator.

DISPOSAL: Dispose of in compliance with all applicable federal, state, and local regulations.

Filler Compound, 1751 B/A 2

HAZARD: Can cause severe irritation to eyes, skin, and respiratory tract.

APPLICATIONS: Do not get in eyes, on skin or on clothing. Wear protective clothing, chemical resistant gloves, and chemical goggles or face shield. Good general ventilation is normally adequate. Respiratory protection not normally required. If significant vapor/mist are generated, use a NIOSH-approved respirator.

DISPOSAL: Dispose of in compliance with all applicable federal, state, and local regulations.

viii

Cleaning Solvent, Federal Specification A-A-59281 3

HAZARD: Is flammable and toxic to eyes, skin, and respiratory tract.

APPLICATIONS: Avoid repeated/prolonged contact. Good general ventilation is normally adequate. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal procedures.

Degreasing Solvent, Specification MIL-PRF-680 4

HAZARD: Is flammable and toxic to eyes, skin, and respiratory tract.

APPLICATIONS: Avoid repeated/prolonged contact. Good general ventilation is normally adequate. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal procedures.

Aliphatic Naphtha, Federal Specification TT-N-95B 5

HAZARD: Can cause severe irritation to eyes, skin, and respiratory tract. Is flammable and may explode if exposed to high temper-atures. Avoid contact with strong oxidizing agents.

APPLICATIONS: Do not get in eyes, on skin or on clothing. Wear protective clothing, chemical resistant gloves, and chemical goggles or face shield. Respiratory protection not normally required. If significant vapor/mist are generated, use a NIOSH-approved respirator.

DISPOSAL: Dispose of in compliance with all applicable federal, state, and local regulations.

Isopropyl Alcohol, Federal Specification TT-I-735A 6

HAZARD: Is flammable and toxic to eyes, skin, and respiratory tract.

APPLICATION: Avoid repeated/prolonged contact. Good general ventilation is normally adequate. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal of materials and empty containers.

Thinner, Federal Specification ASTM-D1153 7

HAZARD: Is flammable and toxic to eyes, skin, and respiratory tract.

APPLICATION: Avoid repeated/prolonged contact. Wear NIOSH-approved chemical cartridge respirator/powered air-purifying respirator. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal of materials and empty containers.

Polyurethane Paint, Specification MIL-PRF-85285 8

HAZARD: Is flammable and may explode if exposed to high temperatures. Toxic to eyes, skin, and respiratory tract.

APPLICATION: Avoid repeated/prolonged contact. Wear NIOSH-approved chemical cartridge respirator/powered air-purifying respirator. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal procedures.

ix

Primer, MMS-425 9

HAZARD: Is flammable and may explode if exposed to high temperatures. Toxic to eyes, skin, and respiratory tract.

APPLICATION: Avoid repeated/prolonged contact. Wear NIOSH-approved chemical cartridge respirator/powered air-purifying respirator. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal procedures.

Ethyl Alcohol, Federal Specification A-A-59282 or A-A-53880 10

HAZARD: Is flammable and toxic to eyes, skin, and respiratory tract.

APPLICATION: Avoid repeated/prolonged contact. Wear NIOSH-approved chemical cartridge respirator/powered air-purifying respirator. Wear protective clothing as directed by local bioenvironmental engineer. If over exposed, seek medical aid. Keep away from all sources of ignition.

DISPOSAL: Consult with local bioenvironmental engineer for disposal procedures.

4. SAFETY PRECAUTIONS.

The following safety precaution shall be observed while performing procedures in this technical manual:

a. When an abnormal condition is noted and procedures in this manual do not specifically cover the abnormal condition, stop work. Call technically qualified personnel for guidance before continuing work.

b. Personnel working with or near high voltage equipment should be familiar with modern methods of resuscitation. Such information can be obtained from the base medical facility. Do not attempt internal service of adjustment of equipment unless another person capable or rendering aid and resuscitation is present.

c. Do not wear rings, watches or other metal jewelry while working on electrical equipment. Remove rings, watches, and other metallic objects that could cause shock or burn hazards.

d. Stay away from live circuits. Do not replace components or make adjustments inside equipment when power is turned on.

To avoid injuries, always remove power. Adhere to all lockout/tagout requirements.

e. Personnel must be aware of the hazards associated with unguarded capacitors and energy sources. Lockout/tag out the energy source before performing maintenance adjustments or other procedures that would bypass safety guards, barriers or otherwise expose personnel to hazardous energy sources.

f. Ensure that all external power sources have been checked for proper wiring and grounding.

g. Use an adequate number of personnel or an adequately rated lifting device to move equipment.

h. Any indoor operations involving painting and cleaning of items, other than stenciling and marking, will comply with the provisions of TO 42A-1-1.

i. Using compressed air can create an environment of propelled particles. Do not direct airstreams toward yourself or other personnel. Air pressure shall not exceed 30 psi and be used with effective chip guarding and Personal Protection Equip-ment (PPE).

j. When using approved agents for minor cleaning operations, personnel shall routinely use rubber gloves, chemical goggles, and/or face shield. Operations where splash hazards are likely, i.e., air pressure drying, brushing threaded fastener, etc., necessitate additional protection in the form of face shields and aprons. If necessary, the bioenvironmental engineer for the base safety engineer should be contacted for guidance.

k. When spray painting, personnel shall refer to appropriate SDS and/or bioenvironmental engineer for specific protective equipment and ventilation requirements.

x

l. Use extreme care when using cleaning agents. Cleaning solvents are highly flammable and shall be used only in areas where adequate ventilation exists and fire or ignition sources do not exist. Use dangerous and toxic solutions and agents with approved adequate ventilation only. Avoid internal consumption, prolonged breathing of vapors or repeated skin contact. All ventilation shall meet the requirements of AFMAN 48-155.

m. When using cleaning fluids, use care to prevent saturation of electrical connectors. Saturating electrical connectors may cause failure of electrical circuity.

n. When storing cleaning agents, maintain minimum quantities required to accomplish tasks. Agents shall be contained in approved safety containers. Consult the local bioenvironmental engineer and/or appropriate SDS for specific protective equipment and ventilation requirements.

o. If fire occurs, evacuate the area and notify fire-fighting personnel.

xi/(xii blank)

CHAPTER 1

INTRODUCTION

1.1 PURPOSE.

This chapter provides general safety precautions and instruc-tions that users will understand and apply during operation and maintenance of the Next Generation Cargo Pod (NGCP), part No. 400850-3, to ensure personal safety and health, and the pro-tection of DOD property.

1.2 SCOPE.

Instructions for storage, handling, inspection, maintenance, and preparation for use of the NGCP are provided. When followed, these instructions will prevent accidents and incidents and pro-vide for safe operations. This publication describes processes that may require the use of chemicals, solvents, paints or other commercially available material. These operations may involve hazardous materials. The user shall ensure that Safety Data Sheets (SDS) (formerly known as Material Safety Data Sheets or MSDS) or the Occupational Safety Health Act (OSHA) Form 20, or equivalent, are readily available for review by personnel using thematerials. The SDS or OSHAForm 20 can be obtained from the material manufacturers or suppliers. The user will be-come completely familiar with the manufacturer/supplier infor-mation and adhere to the procedures, recommendations, warn-ings, and cautions of the manufacturer/supplier for the safe use, handling, storage, and disposal of these materials.

1.3 MAJOR CHARACTERISTICS.

Table 1-1 provides information applicable to the NGCP.

1.4 MAINTENANCE CONCEPTS.

Maintenance and repair operations for the NGCP include load-ing, repair, and inspection.

1.5 DESCRIPTION INFORMATION.

The following subparagraphs provide physical and functional descriptions of the NGCP. Leading characteristics of the NGCP are listed in Table 1-1.

1.5.1 NGCP.

1.5.1.1 Physical Description, NGCP. The NGCP is man-

ufactured by Sargent Fletcher, Inc., and is a converted F-16, 300-gallon external fuel tank. The NGCP is elliptical in shape.

The pod has a removable access panel on both sides of the center section to allow for loading a variety of cargo in size and length, up to a maximum of 600 pounds. The cargo compartment con-tains a metal floor and the cargo tie-down system which consists of tie-down rings, straps, and tie-down chains in the center sec-tion to provide multiple attach points for strapping in items of varying shapes and sizes. (See chapter 3.)

1.5.1.2 Functional Description, NGCP. The NGCP is de-

signed to be carried externally, in a nonjettisonable mode, on aircraft having a 30-inch stores capability. (See Figure 1-1.)

Table 1-1. NGCP Leading Characteristics.

Part No. Empty Weight

Center of Gravity (CG) Location Moment

Store Length Store Diameter

Door Opening

400850-3 320 pounds 15-inch Aft Forward Lug

(AFL)

153 inches Elliptical (23 x 34 inches)

23-1/2 x 35 inches

1-1

Figure 1-1. NGCP, Part No. 400850-3.

1-2

CHAPTER 2

MASTER LIST OF SPECIAL TOOLS, TEST EQUIPMENT, EXPENDABLE ITEMS

AND CONSUMABLES

2.1 COMMON TOOLS.

WARNING

Improper use of tools and equipment may cause injury to personnel and damage to equipment.

A substitute itemmay be used in place of any common tool if the use does not degrade the condition and reliability of the material or safety of operation.

2.2 MASTER LIST OF SPECIAL TOOLS.

As indicated in Table 2-1, special tools are needed for operations covered in this technical manual.

2.3 MASTER LIST OF TEST EQUIPMENT.

As indicated in Table 2-2, test equipment is not needed for op-erations covered in the technical manual.

2.4 MASTER LIST OF EXPENDABLE ITEMS AND

CONSUMABLES.

Table 2-3 lists all consumables required to perform tasks de-scribed by this manual. Items are listed in alphabetical order.

Table 2-1. Master List of Special Tools.

Part No./Specification No./NSN CAGE Code Figure/Index No. Nomenclature Use

Heat Lamp Curing

Scale, 0 to 10 Gram Graduations

Weighting Compounds

Spatulas, Plastic, Wood or Metal

Compound Application

Thermometer, 0 to 400°F

Monitor Temperature

Table 2-2. Master List of Test Equipment.

Part No./Specification No./NSN CAGE Code Figure/Index No. Nomenclature Use

N/A N/A N/A N/A N/A

Table 2-3. Master List of Expendable Items and Consumable Materials.

Nomenclature Part No./Specification

No./NSN CAGE Code Use Reference

Abrasive Cloth, 320-grit

UAMA B74.18 81348 Metal Surface Preparation

Chapter 4

Abrasive Cloth, 400-grit

UAMA B74.18 81348 Metal Surface Preparation

Chapter 4

Abrasive Material, 280-grit paper

A-A-58054 81349 Metal Surface Preparation

Chapter 4

Aliphatic Naphtha TT-N-95B 16528 Metal Cleaning Chapter 4

2-1

Table 2-3. Master List of Expendable Items and Consumable Materials – Continued.

Nomenclature Part No./Specification

No./NSN CAGE Code Use Reference

Aliphatic Polyurethane MMS-420 76301 Finishing Paint Chapter 4

Brush H-B-118 81348 Application Chapter 4

Cheesecloth CCC-C-440 81348 Cleaning Chapter 4

Chemical-Conversion Material

MIL-DTL-5541 81349 Corrosion Protection Chapter 4

Crocus Cloth PC-MC-8068 61136 Metal Surface Preparation

Chapter 4

Epoxy Primer MIL-PRF-23377 81349 Primer Chapter 4

Ethyl Alcohol A-A-59282 or A-A-53880

11936 Cleaning Chapter 4

Filler Compound 1751 B/A 04963 Dent/Scratch Filler Chapter 4

Isopropyl Alcohol TT-I-735A 81348 Cleaning Chapter 4

Masking Tape, 1-inch wide

ASTM-D6123 81348 Metal Surface Preparation

Chapter 4

Nonwaxed Paper Cup A-A-2577B 81348 Container Chapter 4

Solvent, Degreasing MIL-PRF-680 81348 Metal Cleaning Chapter 4

Primer MMS-425 76301 Epoxy Coat Primer Chapter 4

Thinner ASTM-D1153 81349 Metal Surface Preparation

Chapter 4

2-2

CHAPTER 3

LOADING OF THE NEXT GENERATION CARGO POD

3.1 NEXT GENERATION CARGO POD (NGCP)

CARGO LOADING.

WARNING

• The total cargo weight shall at no time exceed 600 pounds.

• Weight will be distributed to maintain Center of Gravity (CG) between suspension lugs and will be slightly nose heavy. Aft heavy loads can ad-versely affect aircraft CG.

CAUTION

• Do not use frayed or damaged tie-down straps.

Inspect chains and clevises for damage. Check tie-down rings for looseness or damage.

• Pad sharp corners that come in contact with the pod skin to prevent damage.

• If the load bearing surfaces of the cargo are sharp or concentrated to a small area, place a flat piece of dense material, such as plywood, between the cargo and pod floor to prevent dam-age to the pod. Weight of this material must be included in the total weight of the cargo.

NOTE

The pod can be loaded on or off the aircraft. If the pod is off the aircraft, position it on a suitable cradle while loading.

a. Remove access door(s) and put in a safe place to pre-vent damage to the door(s).

b. If the cargo does not have its weight stenciled on it, weigh the cargo before loading.

NOTE

It is recommended that weights be stenciled on cargo routinely placed in the pod. It is also rec-ommended containers be designed specifically for the pod to make loading and tying down quicker and easier.

c. When planning the load, center of balance should be between the suspension lugs. For weight distribution, refer to Table 3-1.

d. Where possible, load smaller items in the narrower parts of the forward and aft sections working toward the center with larger items. (See Figure 3-3.)

3.2 NGCP CARGO TIE-DOWN.

WARNING

All cargo must be secured before flight with straps. Use filler as needed/required.

CAUTION

Cargo must be restrained using tie-downs and/or filler material to prevent movement in case of an arrested landing.

NOTE

Plan ahead when loading. Some tie-down straps may have to be maneuvered over cargo as it is being loaded.

a. Cargo that can not be adequately secured, because of shape or size, will be placed in well constructed con-tainers that can be secured.

b. To provide stability, cargo items may be strapped to-gether before being loaded and strapped down in the pod. (See Figures 3-2 and 3-3.)

NOTE

For convenience, the chains may be removed un-til pod is loaded.

c. In the center section, cargo must be secured with straps running from right to left and forward to aft.

Tie-down chains in center section provide multiple attach points for strapping in items of varying shapes and sizes. (See Figure 3-3.)

d. Chains may be attached to the tie-down rings in the center section corners on the pod floor, or to tie-down rings mounted above the floor on the pod support rings. (See Figure 3-1.)

e. Cargo placed in the forward and aft sections will be secured with straps placed straight or crossed depend-ing on position or shape of cargo. (See Figure 3-2.)

f. To help prevent cargo movement during flight, fill voids with filler material such as Styrofoam, bubble wrap, honeycomb cardboard, etc. Soft cargo such as luggage, chemical gear kits, technical orders, techni-cal manuals, etc. can be used as filler. (See Figure 3-2.)

g. Replace access door(s). Ensure that all fasteners are present and fully engaged.

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Table 3-1. NGCP Weight Distribution.

Total Weight Nose Weight Percent of Weight Center Weight

Percent of Weight Tail Weight

Percent of Weight

600 pounds 234 39% 192 32% 174 29%

550 pounds 214.5 39% 176 32% 159.5 29%

500 pounds 195 39% 160 32% 145 29%

450 pounds 175.5 39% 144 32% 130.5 29%

400 pounds 156 39% 128 32% 116 29%

350 pounds 136.5 39% 112 32% 101.5 29%

300 pounds 117 39% 96 32% 87 29%

250 pounds 97.5 39% 80 32% 72.5 29%

200 pounds 78 39% 64 32% 58 29%

150 pounds 58.5 39% 48 32% 43.5 29%

100 pounds 39 39% 32 32% 29 29%

50 pounds 19.5 39% 16 32% 14.5 29%

NOTE

Loads weighing less than 50 pounds may be loaded entirely in the center section, space permitting. Loads that are light in weight, but large in volume, can be distributed through the pod slightly nose heavy.

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Figure 3-1. NGCP Tie-Down System.

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Figure 3-2. Forward and Aft Sections Tie-Down Examples. (Sheet 1 of 2)

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Figure 3-2. Forward and Aft Sections Tie-Down Examples. (Sheet 2)

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Figure 3-3. Center Section Tie-Down Examples.

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CHAPTER 4

REPAIR AND INSPECTION

4.1 GENERAL.

Repairs to the Next Generation Cargo Pod (NGCP) will consist mainly of replacing screws, rivets, straightening dents, and re-placing tie-down straps and chains.

4.2 SPECIAL TOOLS.

There are no special tools required for maintenance of the pod.

4.3 DISASSEMBLY.

Complete disassembly is, in most cases, not required. Disas-semble the pod assembly only so far, as required, to make the necessary repairs or replacement.

4.4 INSPECTION.

Inspect all parts for serviceability In Accordance With (IAW) Table 4-1. If any doubt exists concerning the serviceability of a part, replace the part.

4.5 NGCP REPAIR OR REPLACEMENT.

NOTE

• For damage and repairs not addressed, contact the appropriate Air Logistics Center (ALC) en-gineering for disposition.

• Replace all unserviceable parts that cannot be re-paired or for which repairs are not authorized.

a. If threads on suspension lugs are damaged in any way, replace part.

Table 4-1. Inspection and Maintenance Criteria.

Nomenclature Inspect For Repair Ready Storage Extended Storage

All Parts Check for nicks, scratches, burrs, pitting, corrosion, and obvious damage.

Repair minor damage.

Refer to para. 4.5.

N/A N/A

Threaded Parts Check for cross threading and stripping.

Repair threads. Refer to para. 4.5. Replace all self-locking nuts in critical locations.

N/A N/A

Suspension Lugs and Adapters

Check for damaged threads, corrosion, and cracks. Perform flourescent-penetrant inspection after record hard landing or high G forces.

No defects acceptable.

Replace.

N/A N/A

Internal and External Sheet Metal Parts

Cracks, particularly at welded seams and rivet holes. Dents, scratches, gouges, nicks or pitting.

Refer to para. 4.5. N/A N/A

Door Fasteners Missing, broken or will not engage properly.

Replace. N/A N/A

Tie-Down Straps, Chains, and Rings

Broken, corrosion, frayed, deterioration;

security of attachment.

Replace. N/A N/A

Drain Valves Operation and obstructions.

Replace, if not serviceable.

N/A N/A

4-1

b. Repairminor dents in skin by contouringwith a rubber mallet. Maximum repairable dent exhibiting cracks, abrasions, and sharp corners shall not exceed 4 inches in diameter and 1/2 inch in depth. Do not attempt to straighten damaged areas if repair may result in weak-ening or cracking of skin. A locally manufactured plug, in same contour of first 8 to 10 inches of nose cone, will aid in removing dents in this area of nose cone.

c. Negligible damage and smooth dents are defined as any area, regardless of size, that is free from cracks, abrasions, and sharp corners, which do not interfere with any integral structure. Small nicks, scratches or corrosion in nonwelded areas of skin that have a max-imum depth of no greater than 40% of the skin thick-ness, as defined in Figure 4-1, are considered negligi-ble. Nicks, scratches or corroded area on parts other than outer skins which have a maximum depth of no greater than 0.016 inch, provided material thickness is

0.04 inch or greater or a depth of 0.006 inch, for ma-terial thickness of 0.032 inch or less, are considered negligible. Nicks, scratches, gouges, and minor abra-sions are allowed on weld fillets (beads) as long as the depth of the damage does not go below the surround-ing skin surface. If fillet nicks, scratches or gouges go below skin surface, or weld fillet is ground off to or below surrounding skin surface, contact appropri-ate ALC engineering for repair instructions.

NOTE

The above parameters are not valid for weld-af-fected areas, defined as 0.5 inch either side of a fusion weldment as shown in Figure 4-1.

d. Linear gouges which do not exceed the limits given above for nicks and scratches andwhich do not exceed 0.25-inch width may also be considered as negligible.

NOTE

Scratches and gouges that exceed above limits shall be repaired per WELD REPAIR PROCE- DURES (para. 4.6).

e. Blend exterior skin surfaces as follows:

Figure 4-1. NGCP External Surface Scratch Repair Limits.

4-2

(1) Sand off rough edges with abrasive mat.

CAUTION

Chemicals, solvents, sealant/filler compounds, and other products used to repair aircraft fuel tanks and cells may be classified as flammable or combustible depending on their flashpoint. In addition to the fire hazard, these solvents, chemi-cals, and products may contain toxic substances.

To prevent ignition of, or overexposure to these products, the requirements of this technical man-ual and the applicable AFMAN standards shall be followed. A Safety Data Sheet (SDS) shall be available for each solvent, chemical or prod-uct used. Manufacturer’s warnings and cautions shall be observed. Contact the local base envi-ronmental services for guidance on Personal Pro-tection Equipment (PPE) and refer to TO 1-1-3 for clothing requirements and emergency treat-ment.

(2) Smooth area with 320-grit coated abrasive cloth.

(3) Perform dye-penetrant check IAWTO1F-16( )-36 on blended area to determine if any cracks exist or if all damage has been removed.

(4) If evidence of a crack exists, remove more skin surface by sanding, but do not allow blended area to exceed negligible limits of the part.

(5) Repeat dye-penetrant check.

(6) If cracks still exist, replace damaged part.

(7) If no crack is shown, polish reworked area with 400-grit coated abrasive cloth.

(8) Clean reworked area.

CAUTION

Chemicals, solvents, sealant/filler compounds, and other products used to repair aircraft fuel tanks and cells may be classified as flammable or combustible depending on their flashpoints. In addition to the fire hazard, these solvents, chemi-cals, and products may contain toxic substances.

To prevent ignition of, or overexposure to these products, the requirements of this technical man-ual and the applicable AFMAN standards shall be followed. A SDS shall be available for each solvent, chemical or product used. Manufac-turer’s warnings and cautions shall be observed.

Contact the local base environmental services for guidance on PPE and refer to TO 1-1-3 for cloth-ing requirements and emergency treatment.

(9) Using a brush, apply a thin film of chemical con-versionmaterial to reworked surface IAWTO1-1- 691.

(10) Refinish exterior surface of skin. Refer to EXTE- RIOR SURFACE TREATMENT (para. 4.15).

f. Minor scratches and corrosion (negligible damage) on aluminum parts may be removed by polishing lightly with crocus cloth.

4.6 WELD REPAIR PROCEDURES.

a. Dents with sharp corners or exceeding 0.03 inch in depth, punctures, deep abrasions, cracks, and gouges may be repaired by welding and patching per the fol-lowing:

NOTE

All repairs must be accomplished using 4043 or A5356 welding rod and the Heliarc welding process. Welding technician must be qualified

IAW SAE-AMS-STD-1595.

(1) Cracks and linear gouges not exceeding 16 inches in length should be repaired by welding only.

(Reference Figure 4-2 and TO 1-1A-1 for weld-ing criteria.)

(2) Damage other than cracks or linear gouges which do not exceed 4 inches in any direction will be repaired by removing damage in a circular pattern, andwelding in a plug patch (reference Figure 4-2).

(3) Damage other than cracks or linear gouges which exceed 4 inches, but not exceeding 12 inches in any direction, will be repaired by removing dam-age in a circular or oval pattern, and welding in an internal doubler and plug patch (reference Figure 4-2).

b. Limitations for repair.

(1) Patch material must be 6061-T6 aluminum alloy, same gauge as NGCP skin.

(2) Patches to be formed before welding.

(3) Doublers to be 6061-T6 aluminum alloy, one gauge thicker than NGCP skin.

(4) When welding, penetration must be 100% to tie the patch, skin, and doubler together.

(5) Welding must be completed in one pass.

(6) No heat treatment is required after welding.

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Figure 4-2. NGCP Skin Patch Repair. (Sheet 1 of 3)

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Figure 4-2. NGCP Skin Patch Repair. (Sheet 2)

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Figure 4-2. NGCP Skin Patch Repair. (Sheet 3)

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(7) Repairs must maintain contour smoothness re-quirements IAW applicable directives.

4.7 REWORK CRITERIA FOR NGCP STRUCTURE.

The following is a description and criteria for rework of NGCP internal structure.

a. Structure. The NGCP internal structure consists of support rings of aluminum alloy sheet. Supporting the rings are spliced channels and plates, angles, and stiffeners of aluminum alloy. The support structure consists of two internal support castings of aluminum alloy and two suspension lugs of corrosion-resistant steel.

b. Negligible damage. The following damage limits to NGCP structure are classified as negligible:

(1) Scratches: 20% of basic material thickness, un-limited length blended.

(2) Nicks, gouges, and corrosion: 20% of basic mate-rial thickness, contained within a 2-inch circle af-ter blending.

c. Smooth dents free of sharp corners, cracks, and abra-sions: 0.1 inch in depth with the radius of depression a minimum of 20 times the depth.

d. Repairs other than specified above will require an en-gineering disposition from the applicable ALC.

4.8 FILLER COMPOUND.

WARNING

Filler compounds and metal cleaning solvents used in the following procedures are toxic and highly flammable. Do not use near sparks or open flame. Use in well-ventilated area.

a. Filler compound is a filler material used to fill scratches and dented areas of skin panels, unless otherwise stated. It shall not be used to fill gaps around removable doors and openings in skin pan-els. Because of the short work life of mixed filler compounds, the surface to which the compound is applied should be prepared before the compound is mixed. Compound composition, preparation, appli-cation, and surface preparation for filler compounds are discussed in the following paragraphs.

b. The filler compound used on the NGCP is an alu-minum epoxy resin.

c. Tools:

(1) Heat lamp, Infrared (IR) 250 watt.

(2) Scale, balance,…