Attachment 2 Technical Manual TO 00-85-20 - F135 Specifc.pdf

TO 00-85-20

TECHNICAL MANUAL

ENGINE SHIPPING INSTRUCTIONS

PREPARED BY AFLCMC PROPULSION PROGRAM OFFICE

THIS PUBLICATION SUPERSEDES TO 00-85–20, DATED 1 FEBRUARY 2018 AND ALL CHANGES.

DISTRIBUTION STATEMENT A - APPROVED FOR PUBLIC RELEASE; DISTRIBUTION IS UNLIMITED. PA CASE NUMBER 72ABW-2015- 0021. SUBMIT RECOMMENDED CHANGES OR PROBLEMS WITH THIS TECHNICAL ORDER TO AFLCMC/LPSZB, TINKER AFB OK 73145-3031.

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE

1 NOVEMBER 2020

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . .1 November 2020

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 162, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - vii viii Blank ix - x 1-1 - 1-3 1-4 Blank 2-1 2-2 Blank 3-1 - 3-9 3-10 Blank 4-1 - 4-22 5-1 - 5-13 5-14 Blank 6-1 - 6-92 7-1 - 7-6

TO 00-85-20

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 DESTROY SUPERSEDED PAGES.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.

* Zero in this column indicates an original page.

A USAF

6.22 LOADING AND TRANSPORTATION FOR F137 ENGINE INSTALLED IN 23057530 SHIPPING/STOR-

AGE STAND.

6.22.1 Ground Shipment of The F137 Engine. Ground shipment of the F137 engine installed in the 23057530 ship-ping/storage stand shall be accomplished using only air ride or equivalent truck or trailer.

6.22.2 Shipping Instructions.

Do not place straps or chains over top of engine.

Ship with casters removed from shipping/storage stand and stowed in the brackets located inside the forward outer frame.

Fork lift shipping stand onto trailer bed.

6.23 LOADING AND TRANSPORTATION FOR F135 ENGINE.

6.23.1 Purpose. This procedure will provide the information and instructions for loading, securing, and unloading the F135 engine for surface transportation.

6.23.2 General Information.

Table 6-4. Engine Shipping Weights

Engine Weight Device Weight Gross Weight P4109806 Trailer - 1,850 STOVL 10,130

P4109660 ESS - 1,020 CTOL/CV 9,292

L=229 inches, W=100 inches, H=101 inches

STOVL 7,260 STOVL 10,540

CTOL/CV 6,422 CTOL/CV 9,702

P4109906 Trailer - 2,080

P4109905 ESS - 1,200

L=229 inches, W=90 inches, H=101 inches

P4109931 Trailer-2,112

P4109930 ESS-1,500 STOVL 10,872

L=229 inches, W=90 inches, H=101 inches CTOL/CV 10,034 Weight is indicated in pounds.

NOTE

Engine shipments shall use the F135 Engine Shipping System (ESS) P/N P4109905 and the P4109906 Mainte-nance and Transportation Trailer (MTT) or P4109660 ESS with P41098 MTT or P4109930 ESS with P4109931 MTT. The MTT must use tire size 9.0x 10, 10 ply rating, inflated to 75-85 PSI. The engine inlet must be mounted towards trailer towbar, but the trailer may face fore or aft with respect to the transporting aircraft.

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6.23.3 Inspection of Transportation Trailer.

NOTE

Prior to mounting and packaging the engine and ESS on the trailer, a thorough pre-use inspection of the trailer must be performed. Anomalies discovered during the pre-use inspection that affect form, fit, function or safety must be corrected prior to mounting or packaging the engine on that trailer. Inspections and packing should be accomplished prior to transporting engine shipment to loading area.

6.23.4 Positioning of F135/ESS on Transportation Trailer.

a. Ensure the F135 engine and ESS is mounted on the trailer with engine inlet towards towbar.

b. Make sure engine/ESS is positioned such that center of gravity (CG) symbol is located in line with center mark of trailer. See Figure 6-39.

c. Make sure eight ESS roller clamps [2] are secured. If loose, tighten bolt [1] 150-160 lb-ft. See Figure 6-40.

d. Make sure all hand parking brakes are functional and set. See Figure 6-41.

Any time steering or towing bar is not in use, steering lock pin for axle must be installed in lock position and steering and tow bar stored securely on the side of the trailer. See Figure 6-43.

e. If required, rotate handle socket [1] counterclockwise to raise the trailer jacks [2] to full up position. See Figure 6-42.

NOTE

All four jacks are to remain in stowed (fully retracted) position for shipment. The ESS and engine weight is to be borne by the trailer tires.

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Figure 6-38. ESS and Trailer Features

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Figure 6-39. CG Reference Points

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Figure 6-40. ESS Roller Clamps

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Figure 6-41. Trailer Hand Brakes

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Figure 6-42. Trailer Jacks

Figure 6-43. Trailer P4109806 Tow Bar and Steering Bar Lock Feature

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Figure 6-44. Trailer P4109806

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6.23.5 F135 Engine Ground Transport Instructions.

Wear proper personnel protective equipment (leather gloves, hard hat, etc.) approved for the materials and tools being used as required.

• A minimum 102 inch wide tractor trailer bed with at least a partially wooden surface (adequate for chocking) and adequate tie down locations must be used for ground transportation of F135 engines utilizing ESS P4109806 and Trailer P4109660.

Or

• A minimum 96 inch wide tractor trailer bed with at least a partially wooden surface (adequate for chocking) and adequate tie down locations must be used for ground transportation of F135 engines utilizing ESS P4109905 and Trailer P4109906 or ESS P4109930 and MTT P4109931.

• The average height of engine with ESS on trailer is 8.5 feet. Ensure overhead clearances have minimum height of 14 feet. Prior to backing into building, check with truck driver to ensure truck and engine clearances are maintained.

The preferred method to load/unload an F135 engine to/from a ground transportation trailer is the roll-on/roll-off method described in Paragraph 6.23.5.1 and Paragraph 6.23.5.4. The F135 may also be loaded/un-loaded to/from a ground transpor-tation trailer using any of four approved hoisting procedures described in Paragraph 6.23.5.2 and Paragraph 6.23.5.5.

NOTE

Highway Transportation of a properly secured F135 engine can be accomplished using either an air ride suspen-sion tractor/trailer or a conventional spring ride suspension tractor/trailer

6.23.5.1 Roll-On Loading Procedures (Preferred Method).

Ensure the tug/tow vehicle operator has clear unobstructed view of the personnel providing tow guidance at all times. Proper material handling equipment must be used during ON and OFF loading operations to prevent injury to personnel and damage to the engine.

There must be sufficient personnel on hand to safely handle the combined weight of the F135, ESS and trailer.

a. Ensure the parking brake is set on the ground transportation tractor trailer/semi truck.

NOTE

Use a suitable tow vehicle or tug to push the F135/ESS/trailer onto the transporting vehicle. If a forklift or tug is unavailable, manually push the F135/ESS/trailer onto the transporting vehicle.

b. Position the tug/tow vehicle to allow the tow bar to attach to the pintle hook. Lock pintle hook in place.

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Any time the steering bar is in use, it must be manned to maintain control of the motion of the engine shipment.

c. Remove steering lock pin and place in storage position for towing axle. Slide Lockout feature to desired location if required for P4109906 and P4109931 trailers. See Figure 6-43.

NOTE

Steering bar and tow bar may be used in conjunction with each other to facilitate all wheel steering. Steering lock pin for the steering axle must be removed from the lock position and placed in the storage position, see Figure 6-43

Never stand between the ESS and something that you could be pinned against. Never ride on the ESS while it is being transported or lifted.

Any time the steering or towing bar is not in use, the steering lock pin for the axle must be installed in the lock position.

NOTE

When use of steering bar is no longer required, steering bar must be removed and placed in the storage position and steering lock pin must be installed in the lock position, see Figure 6-43.

d. Disengage all four brakes on the trailer and on tug/tow vehicle, see Figure 6-41.

e. Ground guide (spotter) will direct loading onto ground transportation trailer.

NOTE

There should be only one ground guide (spotter) who signals the tug/tow vehicle operator.

A tractor trailer with at least a partially wooden surface (adequate for chocking) and adequate tie down locations will be used for all forms of ground transportation, tractor trailer, semi truck.

f. Position the engine and trailer assembly parallel with truck bed, centered laterally.

g. Engage all four brakes on the trailer assembly and on tug/tow vehicle.

h. Unlock Pintle Hook and remove tug/tow vehicle.

i. Install forward and aft steering lock pins, slide Lockout feature to desired location if required for P4109906 and P4109931 trailers, remove tow bar and steering bar and stow in storage brackets on the trailer; see Figure 6-43.

j. Tie-down and chock engine and trailer assembly in accordance with Paragraph 6.23.5.3.

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6.23.5.2 Hoist Loading for Ground Transportation. The F135 engine/trailer assembly may be hoist loaded using any of four methods onto the ground transportation trailer tractor trailer/semi truck. The common hoist loading procedure is below.

The unique procedures for the four methods are in Paragraph 6.23.5.2.2 (one point), Paragraph 6.23.5.2.3 (two point at axle location), Paragraph 6.23.5.2.4 (two point counter-axis), and Paragraph 6.23.5.2.5 (four point).

6.23.5.2.1 Common Hoist Loading Procedures.

Chains or nylon straps shall not be used if signs of excessive wear, corrosion, kinking, or other defects are discovered, or they don’t pass manufacture requirements.

• At no time should a chain or nylon strap be allowed to make contact with engine or engine bag. A safety buffer of at least 1 inch must be maintained between engine bag and chain.

• A visual pre-use inspection of hoist load hook must be conducted by hoist operator to detect cracks, nicks, gouges, and deformation of hook and damage or malfunction of throat latch, if provided. If load hook is not equipped with a throat latch, a suitable safety hook with throat latch must be used at attachment point.

• Lift engine shipment with four chains or nylon straps of equal length. Chains must be connected to trailer lift point rings, not ESS tie-down rings.

NOTE

Chains or Nylon lifting straps may be used in the following lifting procedures. Chains or nylon straps must be of sufficient load rating to lift the F135 engine, trailer and ESS assembly for the selected m ethod. Combinations of chains and nylon straps is not allowed. Met hod selected must be executed using all chains or all nylon straps.

a. Inspect and position the trailer according to Paragraph 6.23.3 and Paragraph 6.23.4.

b. Visually inspect trailer lift points for defects, especially for cracks. See Figure 6-45.

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c. Remove trailer tow bar and steering bar (as required) and stow in storage brackets on trailer.

d. Visually inspect chain attachment points (shackles, bolts, and hardware) to make sure chains are serviceable and have an adequate weight capacity.

e. Make sure engine shipment weights are within limitations of hoist (crane).

f. Attach chains from hoist attachment point to trailer lift points. Follow the appropriate unique procedures for the three methods in Paragraph 6.23.5.2.2 (one point), Paragraph 6.23.5.2.3 (two point at axle location), Paragraph 6.23.5.2.4 (two point counter-axis), and Paragraph 6.23.5.2.5 (four point). See Figure 6-45. Exercise caution to avoid contact between lifting chains and engine shipment.

g. Place foam padding, or secure a wooden protective device between chains and any edges or points of contact that may cause damage to ESS, engine and/or trailer. Padding of ESS P4109930 is optional as the system has integrated padding blocks. See Figure 6-46.

Figure 6-45. Trailer Lift and Attachment Points

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Tether lines should be attached to FWD and AFT section of trailer to maintain positive control of ESS and trailer assembly.

h. Attach tether lines with appropriate length for operation.

Figure 6-46. Protective Device

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Personnel shall stay clear of objects during hoist operations or when the engine/aircraft is supported by temporary transition supports. Unless specified in procedures, personnel shall not work on objects suspended or supported by temporary transition supports. Personnel shall be prepared for potential unbalance conditions during hoist opera-tions. Failure to comply may result in death or injury to personnel.

NOTE

There should be only one ground guide (spotter) who signals the crane operator.

i. Raise hoist at direction of ground guide (spotter) until tension is applied to chains. Make sure all chains are securely connected to trailer lift points and attachment point(s).

j. Lift engine shipment until slightly above floor. If engine shipment begins to spin, stop lift until spinning stops. Do not approach suspended engine shipment.

k. Continue lift until sufficient clearance is obtained to load engine onto ground transportation trailer (tractor trailer).

l. Carefully lower engine shipment onto ground transportation trailer (tractor trailer) while ensuring engine is positioned parallel with truck bed, centered laterally.

m. Once engine shipment is positioned on ground transportation trailer, disconnect chains from trailer lift points and move hoist and chains away from engine shipment. Exercise caution to ensure lift chains do not make contact with engine shipment.

n. Tie-down and chock engine and trailer assembly in accordance with Paragraph 6.23.5.3.

6.23.5.2.2 Unique Hoist Procedures for One Attachment Point.

a. Ensure slings meet strength and length requirements for single point sling lift.

b. Complete all steps in the common hoist loading/unloading procedures in Paragraph 6.23.5.2.1 and Paragraph 6.23.5.5.1.

During step f, refer to Figure 6-45 and Figure 6-47 for sling and attachment point configuration.

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6.23.5.2.3 Unique Hoist Procedures for Two Attachment Points at Axle Location. This method is ideal for hoisting using a bridge crane with two point hook-up at axle location and points are aligned to the axis of the truck; see Figure 6-48.

This method can facilitate upload and download from a trailer. Refer to Figure 6-49 and Figure 6-50.

a. Ensure slings meet strength and length requirements for two attachment points at axle location.

If this method is used, the distance between the hook attachment points must be less than or equal to 105 inches (Figure 6-49).

b. Complete all steps in the common hoist loading/unloading procedures in Paragraph 6.23.5.2.1 and Paragraph 6.23.5.5.1.

During step f/e refer to Figure 6-49 and Figure 6-50 for sling and attachment point configuration.

NOTE

The distance between the engine and chain depends on the route of the chain.

Figure 6-47. Hoist with Single Attachment Point

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Figure 6-48. Two Point Hoisting at Axle Location

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Figure 6-49. Two Point Hoisting at Axle Location - View A

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6.23.5.2.4 Unique Hoist Procedures for Two Attachment Points Counter-Axis.

• Because of the possibility of the longitudinal center of gravity shifting beyond the tie down attachment points, proceed with caution.

• The ground and hook attachment points “X” on Figure 6-53 must be greater than or equal to 100 inches. The lateral distance between hook attachment points “Y” on Figure 6-53 should be approximately 60 inches. A one inch minimum safety buffer shall be maintained between the hoisting chain and engine.

a. Ensure slings meet strength and length requirements for two attachment points counter-axis.

b. Complete all steps in the common hoist loading/unloading procedures in Paragraph 6.23.5.2.1 and Paragraph 6.23.5.5.1.

During step f/e refer to Figure 6-51, Figure 6-52, and Figure 6-53 for sling and attachment point configuration.

Figure 6-50. Two Point Hoisting at Axle Location - View B

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Figure 6-51. Two-Point Hoisting Counter-Axis

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Figure 6-52. Two-Point Hoisting Counter-Axis - View A

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Figure 6-53. Two-Point Hoisting Counter-Axis - View B

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When using this hoisting method, the engine may tilt when hoisting. Use caution when hoisting the engine; see Figure 6-54.

c. Four hoisting chains shall be used. Each hoisting chain will have separate connections from the hoist attachment to the trailer attachment point.

6.23.5.2.5 Unique Hoist Procedures for Four Attachment Points.

a. Ensure slings meet strength and length requirements for two attachment points counter-axis.

b. Complete all steps in the common hoist loading/unloading procedures in Paragraph 6.23.5.2.1 and Paragraph 6.23.5.5.1.

During step f/e refer to Figure 6-53 for sling and attachment point configuration. Use caution to ensure the sling positions and angles remain in the acceptable (green) zone of Figure 6-55.

Figure 6-54. Cautionary Example of Two-Point Hoisting Counter-Axis

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6.23.5.3 Tie-Down and Chocking Procedure. This paragraph applies to both roll-on and hoist loading for ground transportation.

Restraint applied from truck bed to the engine load is required to be applied to the ESS tie-down rings, not the transportation trailer lift point rings.

NOTE

All four jacks are to remain in the stowed (fully retracted) position for shipment. The engine weight is to be borne by the trailer tires.

Figure 6-55. Sling Safe Hoisting Zones

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a. Apply tie-down chains (restraint) from ESS tie-down rings to truck bed. See Figure 6-56, Figure 6-57, and Figure 6-58.

b. Place chamfered wooden wheel chocks (4x4 inches) forward and aft of each wheel. Toenail the chocks to truck bed.

See Figure 6-56, Figure 6-57, and Figure 6-58.

c. Place side tire chocks (4x4) one inch from inner side wall of each tire and fasten to truck bed with nails. See Figure 6-57.

d. Tighten tie down chains incrementally with roughly equal tensions so that engine/ESS/trailer cannot move.

e. Completely cover engine/ESS/trailer with a tarp and secure to truck bed.

Figure 6-56. Tie Down and Chock Configuration - View A

Figure 6-57. Tie Down and Chock Configuration - View B

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f. The following steps can be used in lieu of chocking process described above:

(1) Secure four pieces of 2x4 inch lumber to truck bed using nails. Lumber must span the width of engine trailer’s wheelbase and be positioned forward and aft of front and rear wheels to resist movement of engine shipment. See Figure 6-59 and Figure 6-60.

(2) Secure four additional pieces of 2x4 inch lumber one inch from inner side walls of each tire using nails. See Figure 6-59 and Figure 6-60.

g. The following process may be used if trailer bed is metal and nailing is not possible.

(1) Secure four additional chains to trailer lifting/tiedown point’s inboard toward trailer centerline. Chains may not contact trailer wheels. See Figure X.

(2) Reserved

Figure 6-58. Tie Down and Chock Configuration - View C

Figure 6-59. Alternate Chocking Method - Overall View

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6.23.5.4 Roll-Off Unloading Procedures (Preferred Method).

a. Ensure the parking brake is functional and applied on the ground transportation trailer (tractor trailer).

b. Remove forward steering lock pin and attach tow bar assembly to trailer assembly. See Figure 6-43.

Never stand between the engine and trailer assembly and something that you could be pinned against. Never ride on the engine and trailer assembly while it is being transported or lifted.

Any time the steering bar is in use, it must be manned to maintain control of the motion of the ESS.

NOTE

Steering Bar and Tow Bar may be used in conjunction with each other to facilitate all wheel steering.

c. Position the tug/tow vehicle to allow the tow bar to attach to the pintle hook. Lock the pintle hook in place.

d. Engage all four brakes on the trailer assembly and on the tug/tow vehicle.

e. Remove all tie-downs and wood blocks or chocks.

f. Disengage all four brakes on the trailer.

Figure 6-60. Alternate Chocking Method - Detailed View

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g. Ground guide (spotter) will direct unloading of ground transportation trailer tractor trailer/semi truck.

There should be only one ground guide (spotter) who signals the tug/tow vehicle operator.

h. Unload the engine/ESS/trailer assembly from the transportation trailer and tow to engine/ESS/trailer to appropriate location.

i. Engage all four parking brakes on the trailer assembly and on tug/tow vehicle.

• All four parking brakes are to be engaged any time the trailer is not connected to the tow vehicle.

• Manual maneuvering of the engine is not recommended, but if attempted, the tow bar must be installed and manned (the steering bar can also be installed and manned, if necessary). In addition, each parking brake must be manned for the entire maneuvering process.

j. Remove the tow bar and steering bar and stow in storage brackets on the trailer assembly.

6.23.5.5 Hoist Unloading Ground Transportation. The F135 engine/ESS/trailer assembly may be hoist unloaded using any of four methods onto the ground transportation trailer tractor trailer/semi truck. The common hoist loading procedure is below. The unique procedures for the four methods are in Paragraph 6.23.5.2.2 (one point), Paragraph 6.23.5.2.3 (two point at axle location), Paragraph 6.23.5.2.4 (two point counter-axis), and Paragraph 6.23.5.2.5 (four point).

6.23.5.5.1 Common Hoist Unloading Procedures.

Chains shall not be used if signs of excessive wear, corrosion, kinking, or other defects are discovered, or they don’t pass manufacture requirements.

• At no time should a chain be allowed to make contact with engine or engine bag. A safety buffer of at least 1 inch must be maintained between engine bag and chain.

• A visual pre-use inspection of hoist load hook must be conducted by hoist operator to detect cracks, nicks, gouges, and deformation of hook and damage or malfunction of throat latch, if provided. If load hook is not equipped with a throat latch, a suitable safety hook with throat latch must be used at attachment point.

• Lift engine shipment with four chains of equal length. Chains must be connected to trailer lift point rings, not ESS tie-down rings.

a. Visually inspect trailer lift points for defects, especially for cracks. See Figure 6-45.

b. Visually inspect chain attachment points (shackles, bolts, and hardware) to make sure chains are serviceable and have an adequate weight capacity.

c. Make sure engine shipment weights are within limitations of hoist (crane).

d. Position the hoists such that the attachment points are aligned with the center of the engine load.

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e. Attach chains from hoist attachment point to trailer lift points and crane. Follow the appropriate unique procedures for the three methods are in Paragraph 6.23.5.2.2 (one point), Paragraph 6.23.5.2.3 (two point at axle location), Paragraph

6.23.5.2.4 (two point counter-axis), and Paragraph 6.23.5.2.5 (four point). See Figure 6-45. Exercise caution to avoid contact between lifting chains and engine shipment.

f. Place foam padding, or secure a wooden protective device between chains and any edges or points of contact that may cause damage to ESS, engine and/or trailer. See Figure 6-46.

NOTE

Tether lines should be attached to FWD and AFT section of trailer to maintain positive control of ESS and trailer assembly.

g. Attach tether lines with appropriate length for operation.

Personnel shall stay clear of objects during hoist operations or when the engine/aircraft is supported by temporary transition supports. Unless specified in procedures, personnel shall not work on objects suspended or supported by temporary transition supports. Personnel shall be prepared for potential unbalance conditions during hoist opera-tions. Failure to comply may result in death or injury to personnel.

h. Raise hoist at direction of ground guide (spotter) until tension is applied to chains. Make sure all chains are securely connected to trailer lift points and attachment point(s).

NOTE

There should be only one ground guide (spotter) who signals the crane operator.

i. Lift engine shipment until slightly above trailer floor. If engine shipment begins to spin, stop lift until spinning stops.

Do not approach suspended engine shipment.

j. Continue lift until sufficient clearance is obtained under engine shipment.

k. Direct ground transportation trailer (tractor trailer) to pull away from the engine shipment.

l. Carefully lower engine shipment onto the ground.

m. Once engine shipment is positioned on ground, disconnect chains from trailer lift points and move hoist and chains away from engine shipment. Exercise caution to ensure lift chains do not make contact with engine shipment.

n. Remove wood blocks or chocks from transportation trailer.

o. Remove tow bar assembly from storage location and attach to end of trailer closest to engine inlet.

p. Remove steering lock pin and place in storage position for towing axle, see Figure 6-43.

q. Position the tug/tow vehicle to allow the tow bar to attach to the pintle hook. Lock the pintle hook in place and set parking brake on tug/tow vehicle.

r. Disengage all four brakes on trailer and tug/tow vehicle and tow engine/ESS/trailer to appropriate location.

s. Engage all four parking brakes on the trailer assembly and on tug/tow vehicle.

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• All four parking brakes are to be engaged any time the trailer is not connected to the tow vehicle.

• Manual maneuvering of the engine is not recommended, but if attempted, the tow bar must be installed and manned (the steering bar can also be installed and manned, if necessary). In addition, each parking brake must be manned for the entire maneuvering process.

t. Remove the tow bar and steering bar and stow in storage brackets on the trailer assembly.

6.24 LOADING F135 ENGINE ON TRANSPORT AIRCRAFT.

6.24.1 Purpose. This procedure will provide the information and instructions for loading, securing, and unloading the F135 engine for air transportation.

6.24.2 General Information. The engine inlet must be mounted towards trailer towbar, but the trailer may face fore or aft with respect to the transporting aircraft.

Table 6-5. Engine Shipping Weights - Air Transport

Engine Weight Device Weight Gross Weight P4109806 Trailer - 1,850 STOVL 10,130

P4109660 ESS -1,020 CTOL/CV 9,292

L=229 inches, W=100 inches, H=101 inches

STOVL 7,260 P4109906 Trailer - 2,080 STOVL 10,540

CTOL/CV 6,422 P4109905 ESS - 1,200 CTOL/CV 9,702

L=229 inches, W=90 inches, H=101 inches

P4109931 Trailer - 2,112 STOVL 10,872

P4109930 ESS - 1,500 CTOL/CV 10,044

L=229 inches, W=90 inches, H=101 inches Weight is indicated in pounds.

NOTE

Engine shipments shall use the F135 Engine Shipping System (ESS) P/N P4109905 and the P4109906 Mainte-nance and Transportation Trailer (MTT) or P4109660 ESS with P4109806 MTT or ESS P4109930 and MTT P4109931. The MTT must use tire size 9.0 x 10, 10 ply rating, inflated to 75-85 PSI.

6.24.3 Inspection of Transportation Trailer.

NOTE

Prior to mounting and packaging the engine and ESS on the trailer, a thorough pre-use inspection of the trailer must be performed. Anomalies discovered during the pre-use inspection that affect form, fit, function or safety must be corrected prior to mounting or packaging the engine on that trailer. Inspections and packing should be accomplished prior to transporting engine shipment to loading area.

6.24.4 Positioning of F135/ESS on Transportation Trailer.

a. Ensure the F135 engine and ESS is mounted on the trailer with engine inlet towards towbar.

b. Make sure engine/ESS is positioned such that center of gravity (CG) symbol is located in line with center mark of trailer. See Figure 6-62.

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c. Make sure eight ESS roller clamps [2] are secured. If loose, tight bolt [1] 150-160 lb–ft. See Figure 6-63.

d. Make sure all hand parking brakes are functional and set. See Figure 6-64.

Any time steering or towing bar is not in use, steering lock pin for axle must be installed in lock position and steering and tow bar stored securely on the side of the trailer. See Figure 6-66.

e. If required, rotate handle socket [1] counterclockwise to raise the trailer jacks [2] to full up position. See Figure 6-65.

NOTE

All four jacks are to remain in stowed (fully retracted) position for shipment. The ESS and engine weight is to be borne by the trailer tires.

Figure 6-61. ESS and Trailer Features - Air Transport

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Figure 6-62. CG Reference Points - Air Transport

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Figure 6-63. ESS Roller Clamps - Air Transport

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Figure 6-64. Trailer Hand Brakes - Air Transport

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Figure 6-65. Trailer Jacks - Air Transport

Figure 6-66. Trailer P4109806 Tow Bar and Steering Bar Lock Feature - Air Transport

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Figure 6-67. Tow Bar and Steering Bar Lock Feature

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6.24.5 F135 Engine Air Transport Instructions.

Wear proper personnel protective equipment (leather gloves, hard hat, etc.) approved for the materials and tools being used as required.

The average height of engine with ESS on trailer is 8.5 feet. Ensure overhead clearances have been measured.

The only approved method to load/unload an F135 engine to/from an air transporting aircraft is the roll-on/roll-off method described in Paragraph 6.24.5.1 and Paragraph 6.24.5.2.

NOTE

The F135 engine may be air transported on C-130, C-5, and C-17 transport aircraft provided the aircraft are fitted with appropriate floor tiedown receptacles.

6.24.5.1 Roll-On Loading Procedure.

Ensure the tug/tow vehicle operator has clear unobstructed view of the personnel providing tow guidance at all times. Proper material handling equipment must be used during ON and OFF loading operations to prevent injury to personnel and damage to the engine.

• There must be sufficient personnel on hand to safely handle the combined weight of the F135, ESS and trailer.

• The packaged F135/ESS/trailer must be pulled into the transporting aircraft engine inlet first. Failure to observe this caution may result in damage to engine exhaust nozzle tip.

NOTE

• Lift on or hoist loading is NOT permitted.

• The aircraft loadmaster shall supervise all aspects of loading, positioning, and securing the packaged F135/ ESS/trailer into the transport aircraft.

• Steering Bar and Tow Bar may be used in conjunction with each other to facilitate all wheel steering.

a. Pull the packaged F135/ESS/trailer into the transport aircraft by attaching the internal aircraft winch to the towbar of the trailer.

b. Position the trailer parallel with the aircraft cargo bed, laterally centered, symmetrical with floor tiedown receptacles.

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Never stand between the ESS and something that you could be pinned against. Never ride on the ESS while it is being transported or lifted.

c. Engage all four brakes on the trailer, see Figure 6-64.

d. Disconnect the aircraft winch from the tow bar and remove the tow bar and steering bar and stow in storage brackets on the trailer assembly.

Tiedown chains must be attached per tiedown geometry per Figure 6-68, Figure 6-69, and Figure 6-70.

e. Attach tiedown chains (restraint) to ESS tiedown rings and to aircraft cargo bed per Figure 6-68.

Restraint applied from aircraft cargo bed to the engine load is required to be applied to the ESS tie-down rings, not the transportation trailer lift point rings.

f. Tighten tiedown chains with roughly equal tensions so that transportation trailer cannot move.

NOTE

All four jacks are to remain in the stowed (fully retracted) position for shipment. The engine weight is to be borne by the trailer tires.

Figure 6-68. Tie Down Configuration - View A

6-90

6.24.5.2 Roll-Off Unloading Procedures.

a. Remove forward steering lock pin and attach tow bar assembly to trailer assembly; see Figure 6-66.

Figure 6-69. Tie Down Configuration - View B

Figure 6-70. Tie Down Configuration - View C

6-91

Never stand between the engine and trailer assembly and something that you could be pinned against. Never ride on the engine and trailer assembly while it is being transported.

Any time the steering bar is in use, it must be manned to maintain control of the motion of the ESS.

NOTE

Steering bar and tow bar may be used in conjunction with each other to facilitate all wheel steering.

b. Position the aircraft winch hook to the tow bar.

c. Engage all four brakes on the trailer assembly.

d. Remove all tie-downs.

e. Disengage all four brakes on the trailer.

f. Unload the engine/ESS/trailer assembly from the transporting aircraft using the aircraft winch.

g. Position the tug/tow vehicle to allow the tow bar to attach to the pintle hook. Lock the pintle hook in place.

h. Tow engine/ESS/trailer to appropriate location.

i. Engage all four parking brakes on the trailer assembly and on tug/tow vehicle.

All four parking brakes are to be engaged any time the trailer is not connected to the tow vehicle.

j. Disconnect tug/tow vehicle from trailer and remove the tow bar and stow in storage brackets on the trailer assembly.

6-92

CHAPTER 7

ENGINE SHIPPING DEVICE MANAGEMENT

7.1 GENERAL.

The Comprehensive Engine Management System (CEMS) will provide the Base Engine Manager with a means of main-taining the on-hand quantity and serviceability of non-EMO engine shipping devices by type. This capability will be provided by the automatic decrementing and incrementing of a counter each time an AF FORM 1534, which contains engine shipping device information in block 13, is entered into a 4 character alpha numeric code. These four codes, when combined, will provide exact information as to what type of trailer was used, if it was serviceable, and what type of adapter was installed. Guidelines on the use of this expanded feature is outlined below.

a. Type Engine Shipping Device. The first position of this four character alpha numeric code will be used to identify the type of engine shipping device used, i.e., container, trailer, stand, dolly, box, or pallet and its serviceability, if appli-cable. For example, this first column identifier (Table 7-1) would use a “T” to indicate the item is a serviceable trailer or an “F” to indicate it is a serviceable full container, etc.

b. Engine Trailers. The second and third column identifier, when used in conjunction with the first column identifier for trailers, serves to provide more specific information about the trailer. The second and third column identifiers (Table 7-2) correspond to a specific engine trailer stock number. For example, “AL” is the code assigned to engine trailer

NSN 1740-00-516-7930.

c. Engine Shipping Containers. When the first column identifier indicates the item is an engine container, the second, third and fourth column identifiers are combined to specify exactly which container (Table 7-4), by NSN, is being used. For example, code “ABT” represents NSN 8145-00-285-6110. This code, when combined with a first column identifier (Table 7-1) for containers such as “J”, would indicate the stock number of the container plus indicate that it was a non-serviceable half container.

d. Adapters. The fourth column identifier is used to identify the type of adapter on the engine trailer identified by the second and third column identifiers. For example, if adapter NSN 1730-00-589-9465 were used, its code would be “N” (Table 7-3).

e. Other Codes. In addition to providing codes for trailers, containers and adapters, a single character code is provided for stands, dollies, boxes and pallets (Table 7-1). This single code serves as the first column identifier while the second, third and fourth column identifiers remain blank. Also, to preclude duplicate counting of containers, pallets, etc., when more than one engine/module is shipped in the same container a “9” code is used. This code is inserted in block 13 of the AF FORM 1534 for the second, third, etc., engine/module shipped in the same container and fills all four column identifiers (i.e., 9999).

NOTE

Until CEMS is implemented, only the first position code (Table 7-1) will be repeated on the AF FORM 1534.

f. Identification and Marking. All engine shipping devices, containers, adapters, and trailers will be marked with the proper NSN using the following methods.

(1) If the manufacturers data plate contains a valid and legible NSN, no further marking is required for that item.

(2) For trailers, metal containers, and fiberglass containers, use a paper stencil of the NSN (1/2” letters) and spray paint the NSN on the device in a conspicuous plate.

(3) For adapters, select a smooth surface that will always be visible and vibropeen the NSN on the adapter.

(4) All base engine managers are responsible for ensuring that the devices at their stations be properly identified.

7-1

Table 7-1. Engine Shipping Devices - First Column Identifier Codes

Noun Code Description TRAILER T Serviceable Trailer TRAILER U Nonserviceable CONTAINER F Full Container Serviceable CONTAINER G Full Container Nonserviceable CONTAINER H Half Container Serviceable CONTAINER J Half Container Nonserviceable

STAND/DOLLY S -

BOX B -

PALLET P -

NOTE

These codes are not used to account for the shipment of empty engine devices (trailer, containers, adapters, boxes, etc.). These must be deleted or added to Shipping Device Status (SDS) system by the housekeeping TRIC Engine Status Update (ESU) since no AF FORM 1534 will be involved.

Table 7-2. Engine Shipping Devices - Trailers - Second and Third Column Identifier Codes

Code NSN P/N TMS

AA 1740-00-294-3638 340552 T56

AB 1740-00-106-8512 200-000-101 T56

AC 1740-00-718-1579 404190-1 T56

AD 1740-00-488-9469 U533747 TF39

AE 1740-00-602-6365 4S30031-101A TF39

AF 1740-00-711-3135 60-H7553 J69

AG 1740-00-690-5284 107238 J60, T58

AH 1740-00-580-0494 MILT 26232 Multi-engine AJ 1740-00-554-1667 104624 Multi-engine AK 1740-00-534-0595 101671 Multi-engine AL 1730-00-516-7930 100315 Multi-engine AM 1730-00-655-7736 100315-500 Multi-engine AN 1740-00-516-7929 100334 Multi-engine AP 1740-00-713-5908 107640 Multi-engine

AQ 1740-00-713-5908 107640 TF33

AR 1740-00-051-3535 PDG0324 J60, J85

AS 1740-00-058-4955XD 11020MEC J60

AT 1740-00-713-5908 107640 T64

AU 1740-01-127-4954 STC90856-1 F108

AV 1740-00-554-1667 104624 F100-GE102

AW 1740-00-713-5908 107640 F100-PW-100/200/220/220/229

Table 7-3. Engine Shipping Devices - Adapters - Fourth Column Identifier Codes

Code NSN P/N

A 1730-00-036-7271 PDG4352

B 1730-00-051-3536 PDG0325

C 1730-00-051-3539 PDG0328E

D 1730-00-052-4450 PDA2675

7-2

Table 7-3. Engine Shipping Devices - Adapters - Fourth Column Identifier Codes - Continued

Code NSN P/N E 1720-00-238-8019 68E25591-1 F 1730-00-485-8615 F71401 G 1730-00-573-5113 105064 H 1730-00-573-5114 105065 J 1730-00-573-5115 105067 K 1730-00-573-5116 105069 L 1730-00-574-2109 105003 M 1730-00-589-9464 105001 N 1730-00-589-9465 105004 P 1730-00-626-5691 105901 Q 1730-00-654-8388 106355 R 1730-00-657-1178 105865 T 1730-00-676-6848 8-96398-1 U 1730-00-676-6850 8-96398-5 V 1730-00-875-5399 F71401-2 W 1740-00-103-0870 P41640 X 1740-00-522-2754 101164

Y 1740-00-523-3572 PDG4543

Z 1740-00-734-6470 60D7559-3-5 1 1740-00-911-1026 P33003 2 4920-00-591-6975 21C5270G01 3 1730-00-238-8019 68E2559-1

4 1730-00-708-7948CN 6865331

5 1730-00-503-7625 P4006409 6 Other/Wrong Adapter 7 No Adapter Installed 8 1730-00-764-2441 21C2206G003 9 1740-00-059-7339 65700-70016-045

10 1740-01-189-4164 3C3461-G02

Table 7-4. Engine Shipping Devices - Containers - Second, Third and Fourth Position Codes

Code NSN Engine TMS

AAA 8115-00-526-2868 T56

AAB 8145-00-005-8744 J85-17/17A

AAC 8145-00-032-6705 J85-21

AAD 8145-00-044-8858 J85-T/13

AAE 8145-00-049-5204 T58-A7-A9

AAF 8145-00-200-2411 R2800

AAH 8145-00-292-9642 J69-T25

AAJ 8145-00-390-5561 R2800

AAK 8145-00-390-5563 R1830/R2000

AAL 8145-00-390-5565 R1300/R1820

AAM 8145-00-390-5574 J65

AAN 8145-00-399-6066 R3350-93/93A

AAP 8145-00-451-5228 T56-A15

AAQ 8145-00-465-6373 T400-GB400

AAR 8145-00-465-6374 T400-CP400

7-3

Table 7-4. Engine Shipping Devices - Containers - Second, Third and Fourth Position Codes - Continued

Code NSN Engine TMS

AAS 8145-00-550-7451 T56-A7-A9-A15

AAT 8145-00-614-4805 T53-L11A

AAU 8145-00-661-2972 G56-A7-A9-A15

AAV 8145-00-663-9802 T56-A7-A9

AAW 8145-00-687-8110 T56-A7-A9

AAX 8145-00-839-8418 T56-A7, A9-A15

AAY 8145-00-845-7668 J60

AAZ 8145-00-845-7670 J85-5/7/13

ABA 8145-00-111-5843PL T64

ABB 8145-00-871-8557 O-300,IO-360D,O-470-11B,G50-480-540

ABC 8145-00-887-1949 G56-A7-A9-A15

ABD 8145-00-888-3698 T56-A7-A9-A15

ABF 8145-00-927-1744 R1820/R2000

ABG 8145-00-929-9454 J85-5/13

ABH 8145-00-988-3676 J85-21/13

ABJ 8145-00-994-3822 J85-7

ABK 8145-00-994-3823 J85-5/13

ABM 8145-00-031-1497 J47-25/25A/27

ABN 8145-00-111-5843 T64-7/7A

ABP 8145-00-113-8946 T64-7/7A

ABQ 8145-00-113-8947 T64-7/7A

ABR 8145-00-193-8877 TF41-2/400

ABT 8145-00-285-6110 J47-25/25A/27

ABU 8145-00-290-1386 J79-2/3/7/11/15/15A

ABV 8145-00-390-5568 J33-35/35A

ABW 8145-00-390-5573 J33-35/35A

ABY 8145-00-390-5581 J33-35/35A

ACB 8145-00-391-0487 J47-25/25A/27

ACC 8145-00-439-2463 TF41-2/400

ACD 8145-00-550-6205 J79-2/3/7/11/15/15A/17/17A/17C

ACE 8145-00-587-2431 J57-13/19/21/23

ACF 8145-00-590-4854 J79-2/3/7/11/15/15A/17

ACG 8145-00-597-5771 J47-25/25A/27

ACJ 8145-00-664-9558 J75-17/19/19W

ACK 8145-00-785-4807 J79-2/3/7/11/15/15A/17/17A

ACL 8145-00-785-4808 J79-2

ACM 8145-00-785-4809 J79-2/7/11/15/15A/17/17A/17C

ACP 8145-00-785-4811 J79-2/7/11/15/15Z/17/17A/17C

ACQ 8145-00-844-0050 TF33-3/11A

ACR 8145-00-855-0549 T58-3

ACS 8145-00-887-9328 J79-2/3/7/11/15/15A/17/17A/17C

ACT 8145-00-901-6327 T64-7/7A

ACW 8145-00-928-4859 T58-5

ACY 8145-00-988-3674 T58-3

ACZ 8145-00-988-3679 T58-3

ADA 8145-00-901-6327 T64

ADB 8115-00-901-6327 T64

ADC 8115-NL GTCP8570//85180/85397/T62

ADD 8145-00-390-5572PJ J33

7-4

Table 7-4. Engine Shipping Devices - Containers - Second, Third and Fourth Position Codes - Continued

ADG 8145-00-394-6561PT (Metal) F100-23C/24C Fan Drive

8145-01-116-9590PT

ADH 8145-00-394-6566PT (Metal) F100-23A/24A Inlet Drive

8145-01-116-9588PT

ADJ 8145-00-394-6673PT (Metal) F100-23G/24G Gearbox

8145-01-116-9586PT

ADK 8145-00-390-5575 R4360-59B63A

ADM 8145-00-251-9495 J85-17/17A

ADN 8145-00-901-6427 T64

ADQ 8145-00-394-6562PT (Metal) F100-23F-24F Augmentor

ADS 8145-00-772-7866 T53

ADT 8145-01-116-9586PT (Fiber-glass) F100-23G/24G Gearbox

ADU 8145-01-116-9587PT (Fiber-glass)

F100-23B/24B Core

ADV 8145-01-116-9588PT (Fiber-glass)

F100-23A/24A Inlet Drive

ADW 8145-01-116-9589PT (Fiber-glass)

F100-23F/24F Augmentor

ADX 8145-01-116-9590PT (Fiber-glass)

F100-23C/24C Fan Drive

ADY 8145-01-035-1387PT (Metal) F100-23H/24H HPT ADZ 8145-00-396-2056PT (Metal) F100-23B/24B Core

AEA 8145-00-394-6566PT F100-24A

AEB 5305-00-558-5047 J79

AEC 8145-00-785-4810AN J79

AED 8145-00-292-9642AS J69

AEE 8145-00-813-4558 J60

AEF 8145-00-048-7394RU J57

AEG 8145-00-626-3681AN J57/J75

AEH 8145-00-674-7656AN J57/J75

AEJ 8145-00-405-3279PQ TF30

AEK 8145-00-070-3684AN J79

AEL 8145-00-319-4329AN J79

AEM 8145-00-785-4812AN J79

AEN 8145-00-785-4813AN J79

AEP 8145-00-785-4814AN J79

AER 8145-00-661-2972AS T56

AES 8145-00-887-1949AS T56

AEU 8145-01-070-5771RV TF33

AEV 8145-01-070-5772RV TF33

AEW 8145-01-057-2235RT J75

AEX 8145-01-057-2236RT J75

AEY 8145-00-097-1441 J57

AFA 8145-00-168-6895 TF41

AFB 8145-00-182-6302 TF41

AFC 8145-00-104-5568PQ TF30

AFD 8145-00-139-6187 TF30

AFE 8145-00-413-0987PQ TF30

AFF 8145-00-927-5373PQ TF30

7-5

Table 7-4. Engine Shipping Devices - Containers - Second, Third and Fourth Position Codes - Continued

AFG 8145-00-927-5380 TF30

AFH 8145-00-998-4932 TF30

AFJ 8145-00-998-4935 TF30

AFK 8145-00-832-9706 T76

AFL 8145-01-125-1478AN F107-101

AFM 1680-00-677-5227 M9A

AFN 8145-00-839-8418AS T56A7/A9/A15

AFQ 8145-01-125-1473AN F107-400 Engine AFR 8145-01-116-9590PT F100-24C (Metal) AFS 8145-00-394-6562PT F100-24F (Metal) AFT 8145-00-394-6673PT F100-24B (Metal)

AFU 8145-00-928-4859AN T58-100

AFV 8145-01-059-5689AN T700/T701C/T701D

AFW 8145-01-206-9889AN F112-WR-100

AFX 8145-01-221-3623PT F100-P100

AFY 8145-01-226-7980PT F100-P100

AFZ 8145-01-230-5085PT F100-P100

AGA 8145-01-302-1026 T700/T701C/T701D

7-6

5.9 COMPACT AIRCRAFT SUPPORT PACKAGE