PD10WRGBGBEB08.doc

NON-SENSITIVE

PD10WRGBGBEB08

28 January 2010

CAGE 98752

PURCHASE DESCRIPTION

ADAPTER KIT, AIRCRAFT MAINTENANCE, BORESIGHT ADAPTERS

1.0 SCOPE.

1.1 Scope. This Purchase Description (PD) covers an adapter kit designed for F-15E and F-16C/D versions, blocks 30, 40, and 50 aircraft maintenance. This adapter kit is used in conjunction with the Common Multi-Platform Boresight System (CMBS), PD number PD09WRGBGBEB12.

1.2. Types. The types of adapter kits are as follows (see 6.2):

Type I - F-15 adapter kit (NSN 4920-01-552-8580)

Type II - F-16 adapter kit (NSN 4920-01-552-8581)

1.3 Part or Identifying Number (PIN). PINs to be used for an adapter kit acquired to this PD are created as follows:

PD

09WRGBGBEBxx- Type Comments, suggestions, or questions on this document should be addressed to: WR-ALC/642 CBSG/GBEB, Robins AFB GA 31098-1813.

2.0 APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in section 3 and 4 of this specification. This section does not include documents in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements documents cited in sections 3, 4 and 5 of this specification, whether or not they are listed. If tests were accomplished and passed by a previously released version of the referenced documents on identical items, then the contractor shall submit the test results as compliance to the requirements in question.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/37038

COLOR Lusterless Black

FED-STD-595C/31136

COLOR Lusterless Red

FED-STD-595C/26173

COLOR Gray

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-PRF-23377J

Primer Coatings: Epoxy, High-Solids

MIL-PRF-26915D

Primer Coating, for Steel Surfaces

MIL-PRF-85285D

Coating: Polyurethane, Aircraft and Support Equipment

MIL‑DTL‑0053030

Intermediate Primer

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N

US Military Property, Identification Marking of MIL-STD-882D System Safety

MIL-STD-810G

Environmental Engineering Considerations and

Laboratory Tests

MIL-STD-889B

Dissimilar Metals

MIL-STD-1472F

Human Engineering (Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.

2.3 Order of precedence. In the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3.0 REQUIREMENTS

3.1 First article. When specified (see 6.2), one sample shall be subjected to first article inspection in accordance with section 4.

3.2 Adapter kit descriptions. The Type I adapter kit shall interface with an F-15E aircraft using the alignment fixture points already established by the aircraft manufacturer for the purpose of boresighting and allow the CMBS to successfully perform “boresighting” functions. The Type II adapter kit shall interface with F-16C/D Blocks 30, 40 and 50 aircraft using the alignment fixture points already established for the aircraft and allow the CMBS to successfully perform “boresighting” functions. Adapters (within the adapter kit) shall not require any modifications to the aircraft. Adapters shall be factory calibrated to the tolerances set forth within this document. Adapters shall have technical data calibration procedures, training aids and training materials. Adapter kit architecture shall meet or exceed the performance and repeatability standards of the existing optical adapters used on the F-15 and F-16 aircraft. The contractor shall research, develop, and verify aircraft interface data to ensure the fit and accuracy of the adapters. When specified (see 6.2), the contractor shall provide the Government with the verified data.

3.3 Design and construction. The adapter kit shall be designed and constructed so that no parts will work loose in service. They shall be built to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. They shall be weatherproof and designed to prevent the intrusion of water and sand into critical operating components.

3.4 Preproduction samples. One Type I adapter kit and one Type II adapter kit shall be subjected to preproduction inspection in accordance with 4.3.

3.5 Environmental conditions and limits. The adapter kits shall be designed and tested to meet the requirements specified herein. .

3.5.1 Operating temperature range. The adapter kit shall be capable of operating in ambient temperatures ranging from 22oF to 122oF. (see 4.9.1, 4.10.2 and 4.10.4)

3.5.2 Storage temperature range. The adapter kit shall be capable of storage in ambient temperatures ranging from -40ºF to 180ºF without system failure; objective -80oF to 224oF. (see 4.10.1 and 4.10.3)

3.5.3 Altitude. The adapters shall be capable of operating at any altitude from sea level to 8,000 feet without derating. The adapters shall be capable of storage and transportation at any altitude from sea level to 12,500 feet. Derating of the adapters shall be allowed at altitudes above 25,000 feet (4.9.1, 4.10.5 and 4.10.6).

3.5.4 Humidity. The adapters shall be subject to natural high humidity conditions that randomly vary the temperature between 79° and 95°F with the relative humidity reaching between 85% and 95% over a 24 hour period (see 4.10.7). The adapters shall be inspected during the test, and there shall be no leakage, damage, evidence of degradation, failure, or impending failure of any portion of the system.

3.5.5 Fungus. All materials used shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The adapters shall be suitable for operation and storage as specified in 4.9.1 and 4.10.11.

3.5.6 Rain. The adapter kit shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10-inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6-inches of rain per hour impinging on the adapter kit at angles from vertical to 45°. Examine the item and conduct a visual inspection and test as specified in 4.10.15. The system shall be inspected during the test, and there shall be no leakage, damage, evidence of degradation, failure or impending failure of any portion of the system.

3.5.7 Salt fog. The adapters shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance as specified in 4.10.12.

3.5.8 Sand and dust. The adapters shall be capable of storage and operation during exposure to

0.61 grains per cubic foot wind-blown sand (particle size 150-1,000 microns) for 90 minutes or dust (particle size 10-150 microns) at wind speeds up to 60 mph for 12 hours without damage or deterioration of performance as specified in 4.10.13.

3.5.9 Explosive atmosphere. The adapters shall be capable of operation in a fuel-air atmosphere without ignition as specified in 4.10.14.

3.5.10 Vibration.

3.5.10.1 Loose cargo. The adapters shall be capable of operation following exposure to vibration as specified in 4.10.8. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the adapters or the CMBS.

3.5.11 Shock,

3.5.11.1 Transit drop. The adapters shall be capable of operation after sustaining a drop, based on its size, as specified in 4.10.10. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the adapters or the CMBS.

3.5.11.2 Shock meter. The adapters shall include a 100G accelerometer (shock meter) to determine abuse in the field or during shipping.

3.5.11.3 Bench handling. The adapters shall be capable of operation after sustaining a 4 inch drop onto a hard surface as specified in 4.10.9. The system shall be inspected during the test, and there shall be no damage such as loosening of parts, breakage of fasteners, or breaking of anything else that will impair the function of the adapters or the CMBS.

3.5.12 Solar radiation. The adapter kit shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments (see 4.9.1).

3.6 Human factors. The adapters shall be designed in accordance with MIL-STD-1472F for ease of operation, inspection, and maintenance, including but not limited to the use of arctic mittens and Mission-Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

3.7 System components. Each aircraft adapter kit shall be designed and manufactured for that specific type of aircraft and shall include all accessories required by the CMBS to boresight the same aircraft. Adapters shall interface with the boresight stations detailed herein for the F-15E and F-16C/D aircraft with the required accuracies called out in TABLE II.

3.7.1 Adapter kit common hardware. The adapter kits shall include all hardware, associated accessories, and handling enclosures required for use with the CMBS. Special tools and calibration equipment required for calibration or operation shall be furnished as part of the adapters’ common hardware. Instruction shall be provide allowing the adapters to be calibrated by regional precision measurement equipment laboratories PMELs.

3.8 F-16C/D Aircraft boresight adapter kit (Type II). The adapter shall include all necessary hardware for mounting on the various weapons stations as detailed within TABLE II. The adapter kit shall be compatible with the aircraft and CMBS. Additionally, the adapter kit shall include all associated hardware necessary for adjustments to the F-16C/D.

3.9 F-15E Aircraft boresight adapter kit (Type I). The adapter kit shall include all necessary hardware for mounting on the various weapons stations as detailed within TABLE IV. The adapter kit shall be compatible with the aircraft and CMBS. Additionally, the adapter kit shall include all associated hardware necessary for adjustments to the F-15E.

3.10 Transit cases. The adapter kit shall be housed in ruggedized transportation cases to protect the adapters from contact with any object which could affect the boresight equipment accuracy in interface or functional characteristics. The cases shall be equipped with handles for two-man lifting as required per MIL-STD-1472F and a pressure relief valve.

3.11 Basic operation. The adapters shall ensure that the boresight operators will not have to remove the external fuel tank for the boresighting process. The aircraft shall not require jacking, leveling or repositioning. The established aircraft reference centerline shall be used. The boresight process shall take no more than eight hours or sixteen man-hours from set-up to aircraft returned to mission-ready condition; plus potting cure time(objective: boresight completion time shall be no more than four hours or eight man-hours). The adapters shall also provide the capability to perform boresight alignment confidence checks or minor boresight alignments without LRU removal.

3.12 System size. Adapter size and weight shall be as small as practically possible while meeting the performance requirements specified herein. Each adapter case shall be two-man lift capable between 5th percentile female and 95th percentile male per DoD-HDBK-743A. A complete kit shall fit on one 463L pallet (NSN 1670-00-820-4896); 88”x 108” with usable space of 84”x104”. Total weight of adapter kit plus the weight of the CMBS shall not exceed 800 lbs and total height shall not exceed 102”. (4.9.1)

3.13 Calibration. The adapters shall maintain a calibration cycle no less than 24 months. The adapters shall be designed to be calibrated by regional PMELs within the Government.

3.14 Materials, Protective Coatings, and Finish

3.14.1 Materials. Components and materials shall be selected with consideration given to the minimum acceptable service life and the environmental conditions stated herein. The use of recovered or recycled materials is highly encouraged. Materials defined as Class 1 or Class 2 Ozone Depleting Compounds/Substances (ODC/ODS) shall not be used.

3.14.1.1 Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

3.14.2 Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during service shall not be used or shall have a means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Fasteners, handles, and fittings used in the assembly of the adapters shall also be primed and painted. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications. Ferrous structures and surfaces shall be primed with zinc rich primer or equivalent in accordance with MIL-PRF-26915D, Type II, Class B; this shall be followed, within four hours, by a coat of MIL‑DTL‑0053030 intermediate primer in a wet-to-wet primer application. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with strontium chromate based corrosion inhibitor or equivalent, Type I, Class C2 of MIL-PRF-23377J. Raw metal edges shall be coated with the primer before top coating. Topcoat shall be polyurethane in accordance with Type I, Class H of MIL-PRF-85285D; Chemical Agent Resistant Coating (CARC) shall not be used. Topcoat shall be applied to a dry film thickness of 1.6 to 2.4 mils in all instances, regardless of the primer system utilized. The coating shall be free from runs, sags, orange peel, or other defects.

3.14.3 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotively compatible abutting surfaces is acceptable. The use of dissimilar metals only when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

3.14.4 Drain holes. Adapters shall be designed to eliminate pockets where debris and water might accumulate. All structural configurations shall allow water run-off, or shall have adequate sized and placed drain holes.

3.15 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130 Painted markings shall be one inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than one-half inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of FED-STD-595B, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of FED-STD-595B.

3.15.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the adapters including each adapter in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). In addition the identification plate shall include three blank lines across the bottom for future etching by the United States Air Force (USAF). Universal identification (UID) information in accordance with MIL-STD-130M shall also be permanently affixed to the adapters, near the identification plate.

3.16 Finish. The exterior finish color of the storage cases shall be Gray, color 26173, per FED-STD-595/MIL-PRF-85285.

3.17 Transportability. The adapter kit shall be transportable via all modes of shipment: as loose cargo; with the associated vibrations.

3.18 Life expectancy. The adapter kit shall be designed to have a service life of no less than 20 years and shall be suitable for storage in an outside environment for no less than 25 years. (4.9.1)

3.19 Workmanship. The adapters, including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include, but are not limited to, freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of soldering, welding, brazing, painting, wiring, and riveting; marking of parts and assemblies; alignment of parts and tightness of assembly fasteners.

3.20 Welding. Welding procedures shall be in accordance with American Welding Society code. The contractor shall make available to the Government certifications for all welders being utilized on the adapter kit. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings.

3.21 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.22 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes, and in full contact with the surface of the component.

3.23 Cleaning. The adapters shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

3.24 F-16 adapter kit. For the F-16 Aircraft, the adapter kit shall support the F-16 C/D versions of aircraft. It shall provide aircraft sensors for the following weapon systems: Radar, Heads-Up-Display (HUD), Gun, Rate Sensor Unit (RSU), Inertial Navigation Unit (INU), Angle-of-Attack (AOA), and LANTIRN pods. Mounting fixtures required for positioning the weapons system mounts shall also be provided as part of the kit and will attach to the already established alignment mounting points on the aircraft, reference TABLE I and TABLE II.

TABLE I. Existing F-16 aircraft boresight system fixtures.

(Used at aircraft centerline stations)

Forward ABRL Boresight Fixture

HUD Alignment

Boresight Tool

Boresight Fixture

Adapter Assembly Fixture

INU Mount

Rate Sensor Unit (RSU)

Positioning Fixture

Boresight and

Positioning Fixture

Left Pod Mounts

Boresight Transfer

Fixture

Right Pod Boresight

Check Fixture

Left Pod

Boresight Check Fixture

Right Pod Mount

Positioning Fixture

Left Pod Mount

Positioning Fixture

Left and Right Pod

Fixture

Boresight Checking

Fixture

F-16 Aircraft

The adapter kit shall support the F-16 C/D versions of aircraft. It shall provide aircraft sensors for the following weapon systems: Radar, Heads-Up-Display (HUD), Gun, Rate Sensor Unit (RSU), Inertial Navigation Unit (INU), Angle-of-Attack (AOA), and LANTIRN pods. Mounting fixtures required for positioning the weapons system mounts shall also be provided as part of the kit and will attach to the already established alignment mounting points on the aircraft. The overall CMBS tolerances shall be no greater than the legacy system tolerances.

TABLE II.

The F-16 aircraft boresight accuracy.

Required Measurement Accuracies

RADAR Antenna

& AoA

INU

& RSU

NOTE: 1 milliradians (mr) = 3’-26.26”

PDR=Purchase Description Performance Requirement

3.25 F-15 adapter kit For the F-15 aircraft, the adapter kit shall provide aircraft adapters for the following weapon systems: Radar, HUD, Gun, INU, JHMCS Cockpit Mapping Robot and LANTIRN (hard point) pods. Mounting fixtures required for positioning the weapons system mounts shall also be provided as part of the kit and will attach to the already established alignment mounting points on the aircraft, reference TABLE III and TABLE IV. The overall CMBS tolerances shall be no greater than the legacy system tolerances.

TABLE III.

Existing F-15 aircraft boresight system fixtures.

Common Hardware

(Used at all" Stations) Optical Boresight Kit Includes

Precision Inclinometer and

Optical Alignment Collimator

Aircraft Boresight Reference

Plane (BRP) BRP Boresight Fixture Kit includes

Target Adapter and Telescope

Adapter with Clinometers Platform

Adapter

20MM M61A1 Gun Alignement Adapter

Alignment Telescope Adapter

Mount Alignment Adapter

Attitude Heading Reference Set

Alignment Adapter (for AHRS Gyro)

RADAR Antenna Mount Alignment

Adapter

Fixture

Left Pod Mount Positioning

Fixture

Mount Alignment Adapter

MAD Mount Boresight Adapter

TABLE IV.

The F-15E aircraft boresight accuracy.

Required Measurement Accuracies

Station Measured

20MM

2.0

3.0

Yaw

Roll

Yaw

Roll

NOTE: All figures are in milliradians (mr) unless otherwise stated. 1 mr = 3’-26.26” *PDR=Purchase Description Performance Requirement

4.0 VERIFICATION

4.1 General. The operational characteristics of the adapter kit shall meet all performance and function requirements specified in section 3. Unless otherwise specified (see 6.2), the following preproduction inspections may be performed in any order, as determined by the contractor. Inspection shall be performed on F-15 and F-16 aircraft. Submit test plans and test procedures within 30 days for Government approval. Government reserves the right to be present during all testing and shall be notified 30 days before start of testing. Adapters shall not be fielded until a successful preproduction inspection is completed.

4.2 Classification of Inspections. The inspection requirements specified herein are classified as follows:

a. Preproduction inspection (see 4.3).

4.3 Preproduction inspection. The preproduction adapter kits shall be subjected to the examinations, tests, and analyses described herein (see 4.4 through 4.14.2). The contractor shall provide or arrange for all test equipment and facilities.

4.4 Government furnished equipment for testing. No government furnished equipment shall be provided. The contractor will be given access to operational aircraft for testing.

4.5 Inspection requirements.

4.5.1 Apparatus and instruments. Apparatus and instruments used in conjunction with the contractor-conducted calibration and testing specified herein shall be of laboratory precision-type, calibrated at proper intervals to ensure laboratory accuracy and traceable back to National Institute of Standards Technology, National Standards Testing Laboratory, or other Standards laboratory.

4.5.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data and/or shorter intervals shall be provided as appropriate for any specific test. The Contractor shall submit the resulting test report for Government approval.

a. Date

b. Time started

c. Time finished

d. Ambient temperature

e. Ambient light

f. Humidity

g. Aircraft tail number

h. Fixture name and part number

i. Test performed

j. Test standard (commercial/military) call out

4.5.3 Test rejection criteria. Throughout all tests specified herein, the adapter kits shall be closely observed for the conditions shown below, which shall be cause for rejection. A failure during Government functional testing is described as any failure which causes the adapters to not enable the CMBS unit to perform its full operational capabilities as prescribed by the specification. Failure shall be documented in the area of aircraft type and boresight station. If a failure is correctable, documentation shall be furnished on what action was taken to correct it and prevent it from reoccurrence.

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Structural failure of any component, including permanent deformation, or evidence of impending failure.

c. Evidence of excessive wear.

d. Misalignment of components.

e. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

f. Evidence of corrosion or deterioration.

4.8 Test conditions.

4.8.1 Standard atmosphere conditions. Contractor conducted testing shall be conducted at atmospheric pressure (approximately 29.92 inches Hg) and at ambient temperature

(22°F to 122°F conditions. When tests are conducted with atmospheric pressure or ambient temperature differing materially from the above values, proper allowance and documentation shall be made for the difference from the specified conditions. The contractor shall perform its calibration on the adapters in accordance with each instrument’s original equipment manufacturer’s recommended calibration instructions. All test equipment used during the testing of the adapters shall be calibrated or have been calibrated and have a current certificate on file available for review by Government personnel.

4.8.2 Contractor-conducted preliminary run in. Any preliminary run-in of the adapters as recommended by the manufacturer shall be performed by the manufacturer prior to submission of the boresight system for performance testing. A calibration date, list of standards used, calibration test points, as found and as left data, uncertainties, environmental conditions at time of calibration and a traceability statement stating that the calibration is traceable to NIST or other nationally recognized standards, etc shall be included in the calibration report. The calibration certificate requirements can be found in AF Technical Order 00-20-14, Section 4.5.1.4

4.9 Detailed inspection requirements.

4.9.1 Examination of product. Each adapter kit shall be examined to verify compliance with the requirements herein. A contractor-generated, Government-approved checklist that identifies each relevant requirement not verified by a test or analysis and the inspection results shall be used. Particular attention shall be given to materials, workmanship, dimensions, surface finishes, protective coatings and sealants and their application, welding, fastening, and markings. Proper operation of each adapter function shall be verified. Certifications and analyses shall be provided in accordance with TABLE V. Each production adapter kit shall be inspected to a Government-approved reduced version of the checklist. Compliance with the human engineering requirements of 3.4 shall be demonstrated.

TABLE V. Certifications and analyses.

Required Certifications and Analyses

3.3.4 Altitude.

Contractor certification of the altitude testing.

3.16 Service life.

Contractor analysis of service life requirement.

3.18. 3.5.2 Storage temperature test.

Contractor certification of storage temperature range

3.5.4 Humidity.

Contractor certification of humidity testing.

3.5.10.1 Loose cargo vibration.

Contractor certification of loose cargo vibration testing.

3.5.11.2 Bench handling shock test.

Contractor certification of shock test.

3.5.11.1 Transit drop shock test.

Contractor certification of drop shock test.

3.5.7 Salt fog exposure.

3.5.8 Sand and dust exposure.

Contractor certification of salt fog exposure.

Contractor certification of sand and dust exposure.

4.10 Environmental testing. 3.5

4.10.1 High temperature storage test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 501.5, Procedure I, to demonstrate operational functionality following storage in a high temperature environment with a maximum temperature of at least 180˚F; objective 224ºF. Test duration shall be a minimum of seven 24-hour cycles as specified by test method.

4.10.2 High temperature operation test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 501.5, Procedure II, to demonstrate operational functionality in a high temperature environment with a maximum temperature of at least 122˚F. Test duration shall be a minimum of three 24-hour cycles as specified by test method.

4.10.3 Low temperature storage test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 502.5, Procedure I, to demonstrate operational functionality following storage in a low temperature environment with a minimum temperature of at most -40˚F; objective -80˚F. Test length shall be a minimum of 6 hours following stabilization at minimum specified temperature.

4.10.4 Low temperature operation test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 502.5, Procedure II, to demonstrate operational functionality in a low temperature environment with a minimum temperature of at most -4 ˚F. Test length shall be a minimum of 2 hours following stabilization at minimum specified temperature.

4.10.5 Altitude storage test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 500.5, Procedure I, to demonstrate operational functionality following storage in a low pressure environment equivalent to an altitude of at least 12,500 feet; objective 15,000 feet.

4.10.6 Altitude operation test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 500.5, Procedure II, to demonstrate operational functionality in a low pressure operation environment equivalent to an altitude of at least 8,000 feet; objective 10,000 feet.

4.10.7 Humidity test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 507.5, to demonstrate operational functionality in a high humidity environment of at least 95% relative humidity. Test duration shall be a minimum of ten 24-hour cycles.

4.10.8 Loose cargo vibration test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 514.6, Procedure II, to demonstrate operational functionality following exposure to vibration profile as specified by MIL-STD-810G, Method 514.6, Category 5.

4.10.9 Bench handling shock test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 516.6, Procedure VI, to demonstrate operational functionality following exposure to shock impulses as specified by test method.

4.10.10 Transit drop shock test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 516.6, Procedure IV, to demonstrate operational functionality following exposure to shock impulses as specified by test method.

4.10.11 Fungus resistance test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 508.6, to demonstrate resistance to fungal growth as specified by test method.

4.10.12 Salt fog exposure test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 509.5, to demonstrate operational functionality and resistance to corrosion following exposure to a salt fog environment as specified by test method.

4.10.13 Sand and dust resistance test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 510.5, Procedures I and II, to demonstrate operational functionality following exposure to an environment of blowing dust as specified by test method.

4.10.14 Explosive atmosphere test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 511.5, Procedure I, to demonstrate operational functionality in a fuel-air explosive atmosphere without ignition as specified by test method.

4.10.15 Rain test. A preproduction adapter kit shall be tested in accordance with MIL-STD-810G, Method 506.5, Procedure III, to demonstrate operational functionality and resistance to water penetration as specified by test method.

4.11 Calibration. The contractor shall calibrate each component of the adapter kit and each aircraft interface adapter prior to delivery of all systems. The calibration procedures shall indicate existing fixture required accuracies and the contractor's replacement adapter's requirements clearly verifying those accuracies are equal to or being higher in accuracy and repeatability than those required by the existing boresight adapter kit. The calibration and verification shall be witnessed by Government representatives from HQ AFMETCAL Det 1 and WR-ALC/642 CBSG/GBEB or their designated representatives. Failure to meet existing accuracy requirements shall be cause for rejection. Any repeat of boresight fixture calibration/verification failure shall be cause for rejection and remanufacture.

4.12 Adapter kit testing. The F-15 and F-16 boresight adapters shall be tested during the respective CMBS testing per PD09WRGBGBEB12.

4.13 Physical examination.

4.13.1 Ozone, dissimilar metals, and material certification. The contractor shall provide certification that no ozone depleting substances are used in the construction of the adapter kit, any dissimilar metals are suitably isolated or treated, and no explicitly prohibited materials are utilized. Verify compliance with requirements of 3.14.

4.13.2 Riveting, welding, assembly, and workmanship inspection. The adapter kit shall be inspected to verify compliance with the requirements of 3.17, 3.18, 3.19, and 3.20.

4.13.3 Paint certification. The contractor shall provide certification that all parts are treated, primed, and painted in accordance with the requirements of 3.14.

4.13.4 Markings inspection. The adapter kit shall be inspected to verify compliance with the requirements of 3.15.

4.14 Functional testing.

4.14.1 Transportability. An engineering analysis shall be performed to demonstrate compliance with 3.15. The engineering analysis shall utilize the data for air and road transportation modes referenced in MIL-STD-810G section 514.6 Vibration procedure I, 3-axis test.

4.14.2 Life expectancy. An engineering analysis shall be performed to demonstrate compliance with the adapter kit life expectancy requirement of 3.18.

5.0 PACKAGING

For acquisition purposes, the packaging requirements shall be as specified in the contract or order. When actual packaging of materiel is to be performed by DoD personnel, these personnel need to contact the responsible packaging activity to ascertain requisite packaging requirements. Packaging requirements are maintained by the Inventory Control Point's packaging activity within the Military Department or Defense Agency, or within the Military Department's System Command. Packaging data retrieval is available from the managing Military Department's or Defense Agency's automated packaging files, CD-ROM products, or by contacting the responsible packaging activity.

6.0 NOTES

(This section contains information of a general or explanatory nature which may be helpful, but is not mandatory.)

6.1 Background. Boresight procedures on aircraft are performed to verify and align the critical weapons' systems used by the pilot and aircraft avionics. Boresighting is performed when excessive G-loads or unusually violent maneuvers occur, where there is a hard landing, where there has been aircraft structural damage or repairs performed, where the pilot reports a discrepancy, when timed scheduled boresighting is required, or where the local aircraft maintenance chief has determined there is a need. The present manual optical boresight system requires complex calibration procedures to insure instrument readiness and executing alignment of weapon systems on aircraft. The aircraft mission sortie rate is very high and weapon system alignment and accuracy requirements become more necessary under such conditions. Therefore, there exists the common need for synchronization of the aircraft weapons' systems with clear and precise procedures within aggressive environments using the most expeditious methods possible.

6.2 Acquisition requirements. Acquisition documents must specify the following:

a. Title, number, and date of this purchase description.

b. If preproduction sample inspection is required.

c. Packaging requirements.

d. Type I or Type II adapter kit.

e. One sample shall be subjected to first article inspection in accordance with section 4.

f. When specified the contractor shall provide the government with aircraft adapter interface data per 3.2.

Type: 1 - Type I - F15 Adapter kit

Type: 2 - Type II - F16 Adapter kit

Specification number

PD prefix

AMSC N/A

FSC 4920

Distribution Statement A. Approved for public release; distribution is unlimited.