2.02 General Repair Procedures.pdf

AG-830AC-MEB-000 003 00

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GENERAL REPAIR PROCEDURES

INTERMEDIATE/DEPOT MAINTENANCE

WITH

ILLUSTRATED PARTS BREAKDOWN

REUSABLE SHIPPING AND STORAGE

CONTAINERS - ALUMINUM

THIS WP SUPERSEDES WP 003 00 DATED 1 NOVEMBER 2008

Reference Material

Numerical Index ................................................................................................................................................................ 001 01 Guide for the Visual Examination of Welds .............................................................................................................. AWS B1.11 Identification Marking of US Military Property .................................................................................................... MIL-STD-130 NAS Certification & Qualification of Nondestructive Test Personnel ........................................................................... NAS410 Rivets, Buck Type, Preparation for and Installation of........................................................................................... MIL-R-47196 Standard Practice for Liquid Penetrant Testing for General Industry ....................................................................... ASTM E165 Standard Specification for Pressure-Sensitive Tape for Packaging, Box Closure, and Sealing ............................ ASTM D5486 Structural Welding Code - Aluminum ........................................................................................................................ AWS D1.2 Test Procedures for Packing Materials ................................................................................................................ MIL-STD-3010 Weldment, Aluminum ........................................................................................................................................... MIL-W-22248

Alphabetical Index

Subject Page No.

Classification and Disposition of Containers Container Reconditioning Procedure

Painting/Finishing Definitions of Damage Criteria Disposition of Containers After Inspection and Segregation General Repair Procedures

Wood Packaging Material Inspection and Segregation of Containers Prior to Use or Repair

Inspection Criteria Replacement Parts Special Test and Repair Procedures

Breather Valve Container Air Leak Test Container Hoisting Test Dents Fill Valve Flanges Handling Markings Holes Humidity Indicator Assembly Replacement Humidity Indicator Card Replacement Identification Marking Inspection and Replacement of Shock Mounts Installation Instructions

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Alphabetical Index (Cont)

Subject Page No.

Latch Repair Observation Window Assembly Replacement Rectangular Log Compartment Repair Replacement of Closure Flange Gaskets Welds

Support Equipment Required

Part No./Type Designation Nomenclature

— Air Hose Connector

— Hot Air Blower/Heat Lamp

— Sling/Lifting Beam

— Valve and Pressure Gage (0 - 5 PSI)

Materials Required

Specification/Part No. Nomenclature

— Emery Cloth

— Leak-Tek Master Painters Institute, Paint, Interior, Alkyd, Semi-gloss, Reference #47 MPI Gloss Level 5 Master Painters Institute, Paint, Interior, Alkyd, Gloss, Reference #48 MPI Gloss Level 6 Master Painters Institute, Paint, Interior, Alkyd, Flat, Reference #49 MPI Gloss Level 1 Master Painters Institute, Paint, Interior, Alkyd, Eggshell, Reference #51 MPI Gloss Level 3 MIL-D-16791, Type 1 Detergent, General Purpose MIL-PRF-6855 Gasket Material, Class II, Type A, Grade 40 MIL-PRF-81733 Sealing Compound, Type II SAE AS 8660 Silicone Compound

1. GENERAL REPAIR PROCEDURES.

2. General repair of the containers, requiring replacement of standard hardware items including the sealing gaskets, will be accomplished under routine maintenance practices prior to shipment or transportation from the custodial activity. Containers exhibiting damage which would adversely affect the ability to protect the designated item, shall be forwarded to the appropriate level maintenance activity for repair prior to use. Reconditioning of the entire container will take place, as necessary, concurrently with the overhaul of the item being protected. Repairs costing more than 80% of the container unit price listed on supply records will be reported to the NAVSUP WSS Item Manager, from which disposition instructions will be provided.

2A. WOOD PACKAGING MATERIAL. The following commercial heat treatment process has been approved by the American Lumber Standards Committee (ALSC) and is required for all Wood Packaging Material (WPM). WPM is defined as wood pallets, skids, load boards, pallet collars, wooden boxes, reels, dunnage, crates, frames, and cleats.

Packaging materials exempt from the requirements are materials that have undergone a manufacturing process such as corrugated fiberboard, plywood, particleboard, veneer and oriented strand board. All WPM shall be constructed from Heat Treated (HT to 56 degrees Centigrade for 30 minutes) lumber and certified by an accredited agency recognized by the ALSC in accordance with Wood Packaging Material Policy and Wood Packaging Material Enforcement Regulations. All materials must include certification markings in accordance with ALSC standards and be placed in an unobstructed area that will be readily visible to inspectors. Markings shall be applied to the skids on diagonally opposite sides and ends of the pallet and be contrasting and clearly visible. Failure to comply with the requirements of this restriction may result in refusal, destruction, or treatment of materials at the point of entry, possibly causing unacceptable delay in delivery of needed parts.

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3. REPLACEMENT PARTS.

4. Illustrated parts breakdown lists are included in each WP in this manual. Refer to numerical index (WP 001 01) for specific part numbers.

5. INSPECTION AND SEGREGATION OF

CONTAINERS PRIOR TO USE OR REPAIR.

NOTE

Under no circumstances should repairs be attempted prior to removing the item being protected.

6. Inspection. Inspection on each container shall be performed in accordance with inspection tables contained in this work package (tables 1 and 2) or the applicable work packages of this manual. An inspection and processing sheet shall be filled out noting all defects requiring repair for each container, necessitating maintenance action as required by the inspection table. A container determined serviceable shall be so tagged individually.

7. External Inspection. The external inspection shall be performed with the container in the closed configuration.

Refer to tables 1 and 2, steps 1 through 9 (QA) for items to be inspected and action required to correct defects noted.

Ensure internal pressure is released before opening container.

8. Internal Inspection. The internal inspection shall be performed with container cover removed and prior to installing designated item into container. Refer to tables 1 and 2, steps 10 through 14 (QA) for items to be inspected and action required to correct defects noted.

Table 1. General Shipping Container Inspection Criteria, Intermediate Level

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

NOTE

For specific repair procedures, reference applicable sections of repair manual.

If noted defect requires Depot level corrective action, discontinue inspection and send container to depot.

1 Cover weldment a. Cover damaged (broken, torn, punctured, cracked)

a. Repair/send to depot

Major

b. Gasket sealing surface damaged.

Container not sealing properly

b. Repair/send to depot

Major

c. Stacking blocks cracked, punctured or damaged

c. Repair/send to depot

Minor

d. Dirt, oil, grease, other foreign matter d. Clean Minor

2 Desiccant port a. Damage affecting air tight capability of container

a. Replace Major

b. Damage preventing desiccant retention

b. Replace Minor

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Table 1. General Shipping Container Inspection Criteria, Intermediate Level (Cont)

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

3 Relief valve a. Valve body damaged, automatic or manual release inoperative

a. Replace valve Major

b. Valve body loose b. Verify assembly is complete and tighten.

4 Humidity indicator a. Color card indicates excessive moisture

a. Replace desiccant and indicator card.

Minor

b. Indicator body damaged b. Replace Minor

c. Body assembly loose c. Verify assembly is

5 Records receptacle a. Body damage permits entry of water/moisture into compartment

a. Repair/replace Minor

b. Cover assembly damaged or missing b. Repair/replace Major

c. Cover assembly gasket worn or damaged

c. Replace Minor

d. Cover assembly fastener inoperative, broken, or missing

d. Repair/replace Minor

6 Latches a. Damaged, will not operate a. Repair/replace Major

b. Bracket welds cracked (on 3 or less) b. Repair Minor

c. Bracket welds cracked (on more than 3)

c. Repair Major

d. Bent d. Replace Major

7 Base weldment a. Base damaged (broken, torn, punctured, cracked)

a. Repair/send to depot

Major

b. Drain plug missing, flange rusted, corroded, or damaged threads

b. Replace plug, repair flange threads, perform corrosion control

Minor

c. Forklift pockets damaged (cracked, welds broken, bent)

c. Repair Major

d. Dirt, oil, grease, other foreign matter d. Clean Minor

e. Shock mount brackets bent, welds broken

e. Repair Major

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Table 1. General Shipping Container Inspection Criteria, Intermediate Level (Cont)

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

8 Nameplate Missing, illegible Replace Minor

9 Stenciling Missing, illegible Repair Minor

10 Installation instructions Missing, illegible Replace Minor

11 Container gasket a. Damaged, will not seal a. Replace Major

b. Gasket not properly seated b. Reseat gasket Minor

12 Suspension frame a. Bent or cracked main frame a. Repair/send to depot Major

b. Missing or loose attaching hardware b. Replace/tighten attaching hardware

Major

c. Cracked welds c. Repair/send to depot

Major

13 Shock mounts a. Cracks, separation, or deterioration a. Replace Major

b. Attaching hardware damaged, loose, or missing

b. Replace/tighten Major

c. Expired cure date c. Replace unit if over 12 years old.

14 Desiccant holder Broken welds, bent or crushed, burrs or sharp edges Repair Minor

Table 2. General Shipping Container Inspection Criteria, Depot Level

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

1 Cover weldment a. Cover damaged (broken, punctured, torn, cracked)

a. Repair/replace Major

b. Gasket seal surface damaged.

Container not sealing properly

b. Repair/replace Major

c. Stacking blocks cracked, punctured or damaged

c. Repair/replace Minor

d. Dirt, oil, grease, other foreign matter d. Clean Minor

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Table 2. General Shipping Container Inspection Criteria, Depot Level (Cont)

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

2 Desiccant port a. Damage affecting air tight capability of container

a. Repair/replace Major

b. Damage prevents desiccant retention b. Replace Minor

3 Relief valve a. Valve body damaged, valve or manual release inoperative

a. Replace valve Major

b. Valve body loose b. Verify assembly is

4 Humidity indicator a. Color card indicates excessive moisture

a. Replace desiccant and indicator card.

Minor

b. Indicator body damaged b. Replace Minor

c. Body assembly loose c. Verify assembly is

5 Records receptacle a. Body damage permits entry of water/moisture into compartment

a. Repair/replace Minor

b. Cover assembly damaged or missing b. Repair/replace Major

c. Cover assembly gasket worn or damaged

c. Replace Minor

d. Cover assembly fastener inoperative, broken, or missing

d. Repair/replace Minor

6 Latches a. Damage prevents operation a. Repair/replace Major

b. Bracket welds cracked (on 3 or less) b. Repair Minor

c. Bracket welds cracked (on more than 3)

c. Repair Major

d. Bent d. Replace Major

7 Base weldment a. Base damaged (broken, torn, punctured, cracked)

a. Repair/replace Major

b. Drain plug missing, flange rusted, corroded, or damaged threads

b. Replace plug, repair flange threads, perform corrosion control

Minor

c. Forklift pockets damaged (cracked, welds broken, bent)

c. Repair Major

d. Dirt, oil, grease, other foreign matter d. Clean Minor

e. Shock mount brackets bent, welds broken

e. Repair Major

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Table 2. General Shipping Container Inspection Criteria, Depot Level (Cont)

STEP

INSPECTION

POINTS

INSPECTION

CRITERIA

CORRECTIVE

ACTION

DEFECT

CLASS

8 Nameplate Missing, illegible Replace Minor

9 Stenciling Missing, illegible Repair Minor

10 Installation instructions Missing, illegible Replace Minor

11 Container gasket a. Damaged, will not seal a. Replace Major

b. Gasket not properly seated b. Reseat gasket Minor

12 Suspension frame a. Bent or cracked main frame a. Repair/replace Major

b. Missing or loose attaching hardware b. Replace/tighten attaching hardware

Major

c. Cracked welds c. Weld (MIL-W- 22248 or AWS D1.2)

13 Shock mounts a. Cracks, separation, or deterioration a. Replace Major

b. Attaching hardware damaged, loose or missing

b. Replace/tighten Major

c. Expired cure date c. Replace unit if 12 or more years old.

14 Desiccant holder Broken welds, bent or crushed, burrs or sharp edges Repair Minor

9. INSPECTION CRITERIA. Containers will be inspected in accordance with the following criteria prior to repair or reuse for the protection of serviceable and unserviceable aircraft components.

QUALITY ASSURANCE INSPECTION STEPS a. thru j.

a. Inspect container cover and base for dents, cracks, gouges, holes or ruptures in the surface that would affect serviceability. Dents not more than 3/4-inch (19.1 mm) deep are acceptable without repair, provided the item being protected does not come in contact with the container shell.

b. Inspect skids for broken ends, splits, (figure 1), faulty welds, and fork-lift openings for cracks and other defects that would affect serviceability.

c. Inspect braces, lifting rings, eyes or lugs, relief valves, humidity indicator, access plate gasket, record receptacle, stacking guides (figure 2) and all welded areas for cracks, ruptures, deterioration, misalignment, corrosion and other defects.

(1) All welds shall be visually inspected. Visual inspection shall include 5 power magnifications when suspect condition is to be examined beyond the capability of normal vision. A weld shall be acceptable by visual inspection if it shows the following:

(a) The weld shall have no cracks.

(b) Through fusion shall exist between adjacent layers of weld metal, and between weld metal and base metal.

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(c) Weld profiles shall be in conformance with

AWS D1.2/D1.2M:2003.

(d) Except as provided herein, undercut shall not exceed 10% of the plate thickness or 1/16 inch, which ever is lesser.

(e) Overlap will be permitted not to exceed 2T in any 6T length.

(f) A fillet weld in any single continuous weld may be less than the nominal fillet weld size required by 1/16 inch without correction, provided that the undersized portion of the weld does not exceed 10% of the length of the weld.

(g) Shrinkage contained entirely within the crater area of an intermittent fillet weld may be accepted.

(h) Porosity is not permitted.

(2) Critical and major welds may be subjected to further non-destructive testing using dye penetrant inspection to confirm the presence of surface cracks.

(3) All critical and major welds around lift points (such as lifting lugs, fabricated lift brackets) are to be visually inspected (AWS B1.11 & AWS D1.2/D1.2M).

Visual inspection shall include five power magnifications when suspect condition is to be examined beyond the capability of normal vision. Suspect welds are to be further examined by NDI method Type I & II penetrant (ASTM

E165, NAS410).

NOTE

For lift point welds/welded assemblies requiring rework/repair, contact NAVSUP WSS code N241 for engineering guidance.

d. Inspect nuts, bolts, fasteners, for cracks, burrs, elongation, misalignment, defective threads, corrosion and other mechanical defects that would affect serviceability.

Release container pressure prior to removing cover.

e. Remove cover assembly, inspect closure flange gaskets for permanent deformation, cuts, abrasion, cracking, brittleness, separation of bond or other surface defects which would affect proper sealing of the container (figure 3). Inspect for interior corrosion, drain plug, desiccant holder gaskets and any moisture collection.

f. Inspect the closure flanges for cracks, dents, misalignment, unsatisfactory welds, debris, and other defects which would affect properly sealing the container (figure 3).

g. Inspect elastomeric shock mounts for cracks, tears, bond separation, splits, brittleness, valid cure date, and other defects that would affect serviceability (figure 4). For containers utilizing a cushioning system of horse hair materials in lieu of a shock mounted platform, inspect cushions for deterioration, bond separation, firmness, and any other defects that would affect serviceability (figure 5).

Inspect hardware, straps, braces or mounting fixtures, as applicable, for security, corrosion, deterioration or any other defects that would affect serviceability.

h. Inspect shock support frame for cracks (figure 4).

i. Install cover on base assembly and ensure the cover and base assembly mate properly by securing closure fasteners (figure 6). Misalignment of the cover and base assembly will be cause for rejection.

j. Perform CONTAINER LEAK TEST (this WP).

10. DEFINITIONS OF DAMAGE CRITERIA.

11. Table 3 provides definitions of damage criteria used in this manual.

12. CLASSIFICATION AND DISPOSITION OF

CONTAINERS.

13. Following inspection, containers will be classified as either serviceable or unserviceable. Serviceable containers shall meet the following conditions:

QUALITY ASSURANCE INSPECTION STEPS a. thru h.

a. Container complete in all respects.

b. No leaks apparent, when applicable.

c. Minimum container markings and data plates are in legible condition.

d. No dents in the container surface exceeding 3/4-inch (19.1 mm) in depth or which would cause the item being protected to come in contact with the container shell or prevent proper sealing.

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Table 3. Damage Criterion Definitions

CRITERION DEFINITION

Dent Any surface impression that does not involve removal of metal and does not penetrate the surface of metal.

Gouge Any surface imperfection involving the removal of metal on unpainted surface or paint and metal on painted surfaces, but not penetrating through the metal.

Scratch Any surface imperfection involving only the removal of paint.

Crack Any narrow break or tear of material in which material is neither displaced as caused by a dent nor removed as caused by a gouge.

Puncture Any penetration through material.

Burr A thin ridge or area of roughness protruding from surface of material.

Pit Any void in surface material due to corrosion, rust or other chemical action where impact is not evident.

003001

Figure 1. Wooden Skid Deterioration on Underside of Skid (Damage not Visible Unless Can is Turned Over)

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003002

Figure 2. Partially Detached Stacking Guide

e. Air filler and relief valves operate satisfactorily on functional testing.

f. Skids and stacking guides in serviceable condition.

g. Suspension system adequately provides the designated item with protection from shock and vibration forces.

h. All critical and major welds around lift points (such as lifting lugs, fabricated lift brackets) are to be visually white light inspected. Visual inspection shall include five power magnifications when suspect condition is to be examined beyond the capability of normal vision.

Suspect welds are to be further examined by NDI method Type I & II penetrant (ASTM E165, NAS410).

(1) The weld shall have no cracks.

(2) Through fusion shall exist between adjacent layers of weld metal, and between weld metal and base metal.

(3) Weld profiles shall be in conformance with

AWS D1.2/D1.2M.

(4) Shrinkage contained entirely within the crater area of an intermittent fillet weld may be accepted.

(5) Porosity is not permitted.

NOTE

For lift point welds/welded assemblies requiring rework/repair, contact NAVSUP WSS code N241 for engineering guidance.

Under no circumstances will containers be used for the shipment of aircraft components if there are any defects in the suspension system.

14. DISPOSITION OF CONTAINERS AFTER

INSPECTION AND SEGREGATION.

15. Containers requiring only minor repairs will be reconditioned as necessary and used as required by the authorized activity. Under no circumstances will a container be used when its condition may result in further damage/repair requirements to the assembly contained therein.

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003003

Figure 3. Typical Closure Flange and Gasket on Controlled Breathing Container (Debris must be removed to permit effective container sealing)

16. CONTAINER RECONDITIONING PROCEDURE.

Materials Required

Specification/ Part No. Nomenclature

MIL-PRF-81733 Sealing Compound, Type II

17. Containers will be reconditioned only as necessary to place the container in a serviceable condition. Containers will be cleaned as necessary as part of reconditioning.

Cleaning will be performed in accordance with applicable WP. Also the following procedures will be observed as applicable:

a. Remove desiccant, inspect desiccant holder, support assembly, bolts, nuts and fasteners for corrosion.

Remove and replace excessively corroded items.

b. Ensure humidity indicator and view ports are securely attached and sealing gaskets properly installed to prevent air loss. (See figure 7 for typical installation.)

c. Remove all items which have been designated for replacement during the inspection phase.

d. Ensure pressure relief and vacuum valves operate satisfactorily.

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003004

Figure 4. Elastomeric (Rubber) Shock Mount in Need of Replacement Because of Visible Deterioration

All dirt, oils, cleaning solvents, and fire hazards will be removed prior to welding.

Cover must be removed before welding.

e. Weld/repair small cracks and tears in the container shell in accordance with paragraph 28, this WP (figures 8, 9, and 10).

f. Repair holes and ruptures in the container shell by straightening any irregularities around the damaged area and welding on a suitable patch of like alloy and thickness.

The patch must extend at least 1/2-inch (12.7 mm) in all directions beyond damaged area (figure 11).

g. Containers not designed for controlled breathing may be riveted (in accordance with MIL-R-47196) and sealed, using MIL-PRF-81733, in lieu of welding (figure 12).

h. Closure flanges will be straightened using common hand tools and routine metal shop practices.

i. Repair gussets, braces, lifting rings, stacking guides, support structures, skids, etc. by straightening as required and welding any cracks or breaks. All containers which have welding accomplished will be carefully checked for leaks/flaws in the weld area at time of pressurization. (QA)

j. Sealing compound, MIL-PRF-81733, Type II will be used at faying surfaces, discontinuous welds or other areas where atmospheric liquids may be retained by capillary action.

k. Pressure-sensitive tape in accordance with ASTM D5486 may be used for temporary repair until container can be returned to depot for permanent repairs.

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003005

Figure 5. Typical Rubberized (Horse Hair) Cushioning

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003006

Figure 6. Typically Used Closure Fasteners

003007

Figure 7. Properly Installed View Port and Humidity Indicators

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003008

Figure 8. Forklift Puncture Damage to Controlled Breathing Container

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003009

Figure 9. Typical Weld Repair of Forklift Damage

18. PAINTING/FINISHING. Most NAVSUP WSS cog reusable shipping and storage containers are fabricated of aluminum alloys which do not require painting. Many of these unpainted aluminum containers have internal mounting/support fixtures made of steel which have been painted and may require touch-up painting. Painting procedures for these containers will be found in the applicable work package.

19. SPECIAL TEST AND REPAIR PROCEDURES.

Container may explode or fasteners may fail during this test. Use protective barriers to avoid injury to personnel.

Support Equipment Required

Part No./ Type Designation Nomenclature

— Air Hose Connector

— Hot Air Blower/Heat Lamp

— Sling/Lifting Beam

Support Equipment Required (Cont)

Part No./ Type Designation Nomenclature

— Valve and Pressure Gage

(0 - 5 PSI)

Materials Required

Specification/ Part No. Nomenclature

— Emery Cloth

— Leak-Tek Master Painters Institute, Paint, Interior, Alkyd, Reference #47 Semi-gloss, MPI Gloss Level 5

Master Painters Institute, Paint, Interior, Alkyd, Reference #48 Gloss, MPI Gloss Level 6

Master Painters Institute, Paint, Interior, Alkyd, Reference #49 Flat, MPI Gloss Level 1

Master Painters Institute, Paint, Interior, Alkyd, Reference #51 Eggshell, MPI Gloss Level 3

MIL-PRF-6855 Gasket Material, Class II, Type A, Grade 40

MIL-PRF-81733 Sealing Compound, Type II

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003010

Figure 10. Typical Repair of Crack Damage

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003011

Figure 11. Patching a Rupture/Hole Welding Method

20. CONTAINER AIR LEAK TEST. The container leak test, required for all controlled breathing containers after reconditioning or overhaul will be accomplished using the following method:

Do not exceed specified test pressure.

Personnel injury and container damage (deformation/explosion) may result.

NOTE

Steps a. thru e. apply to controlled breathing containers only.

a. The container shall be prepared for testing by sealing all breathing devices and inserting suitable pressurizing fittings and gages. The container shall be closed and sealed in a normal manner. The Pneumatic- Pressure Technique of Method 5009 of MIL-STD-3010 shall be used to detect leakage. An initial pressure setting equal to 1.0 + 0.1 - 0 psig shall be used. (QA)

003012

Figure 12. Patching a Rupture/Hole Riveting Method

b. After 30 minutes stabilization, pressure shall be monitored for thirty minutes. Any loss in pressure in excess of 0.05 psig shall be considered unsatisfactory and shall be tested in order to pinpoint leakage to enable corrective action to be taken. Any deformation of the container shell, while pressurized, which is greater than three-quarters of an inch beyond its position at ambient pressure shall also be cause for rejection. (QA)

c. Apply general purpose detergent MIL-D-16791 Type 1, or equivalent, diluted with water, to the container to check for leaks. Apply solution to all welded areas, container gasket area, humidity indicator area, fill valve area, and relief valve or any other area suspected of leaking. Leaks are indicated by the formation of a bubble.

d. If leaks cannot be corrected by tightening the item(s) involved, replace the faulty item(s). If leaks are the result of holes in welds or other material surfaces, repair as indicated in METAL REPAIR in applicable WP.

e. If a leak requiring repair or item replacement is disclosed by the test, the container shall be retested after corrective action has been taken.

f. Vent container pressure. (QA)

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21. CONTAINER HOISTING TEST. The hoisting test will be performed when:

a. A container has been overhauled by a depot level activity.

b. Hoisting lugs are removed and replaced.

c. Physical damage to the hoisting lugs or lug retainers is evident.

d. Excessive corrosion and/or pitting of the hoisting lugs is evident.

To preclude injury, personnel should not be underneath any load during hoisting/crane handling, two personnel must be used with this procedure.

22. Testing Procedure. The container shall be loaded with weights until it is equal to the gross weight of the container (refer to applicable WP for appropriate gross weights). The container shall be closed and sealed in the normal manner as it would be in service. A sling, lifting beam or other device representing normal procedure shall be attached to a single hoisting lug and the container lifted until it is free of support. The container shall hang for five minutes prior to examination for damage. The above procedures will be repeated until all hoisting lugs have been tested. Upon examination, the following conditions shall be cause for rejection:

a. Permanent deformation of any part of the hoisting lug or supporting structure as the result of the performed test.

b. Creation of any unsafe or potentially dangerous handling condition. (QA)

23. INSPECTION AND REPLACEMENT OF SHOCK

MOUNTS.

a. Elastomeric Mounts. Inspect the elastomeric shock mounts while loaded with component and stationary for any cracks, splits, tears, bond separation or other defects.

(QA)

b. Inspect shock mounts for cure date. (QA)

NOTE

Shock mounts must be replaced if 12 years from date of cure have elapsed. Shock mounts must be replaced in complete sets.

c. Foam/Bound Fiber Cushioning. Cushioning material will be permanently bonded to the interior container surfaces and require replacement if exhibiting deterioration or permanent deformation.

24. REPLACEMENT OF CLOSURE FLANGE

GASKETS. Replace flange gaskets exhibiting cuts, abrasions, cracks or any other surface defects which would affect proper sealing of the container. Replacement gaskets may be obtained via local fabrication using gasket material conforming to MIL-PRF-6855, Class II, Type A, Grade 40.

25. INSTALLATION INSTRUCTIONS. Instructions shall be permanently bonded to the interior of the container with an additional set provided for storage in the record receptacle. Replace installation instructions which are not legible by reproducing on a good grade of bond paper and laminating between two pieces of clear vinyl (0.010 inch thick). Then bond to interior of container as specified on the container drawing. Also ensure an additional set is placed in the record receptacle prior to shipping.

26. IDENTIFICATION MARKING. Identification marking shall be accomplished in accordance with MIL- STD-130 and the applicable container drawing.

27. HANDLING MARKINGS. Special handling and precautionary markings are required for all aluminum containers. Refer to container work package for type and location of markings. Stencil lettering per CID A-A-56032 or Master Painters Institute, Reference #47, 48, 49 or 51.

Extreme care should be exercised when welding containers which utilize flammable cushioning materials to provide item protection.

28. WELDS. Replace cracked welds by grinding out the crack and rewelding. Aluminum welds shall be accomplished by a certified welder meeting the requirements of AWS D1.2/D1.2M. Welds shall be in accordance with MIL-W-22248, Class 4.

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a. Welding. (Aluminum). Proper controls shall be used to prevent melt through or burn through. Welder qualification shall be to AWS D1.2/D1.2M. Filler for welding 6000 series alloy shall be 4043. Filler for welding 5000 series alloys to themselves or to 6061 shall be 5356 or 5556. Welding and weld inspection shall be in accordance with MIL-W-22248, Class 4, except that visual inspection shall include 5X (5 power) magnification when a suspect condition is to be examined beyond the capability of normal vision. Critical and major welds may be subjected to further non-destructive testing (such as dye penetrant inspection) as prescribed by the buying activity.

b. Controls. Weld filler materials shall be clearly identified and segregated from each other both when in storage and at the work station. Work station environment shall be controlled to prevent conditions adverse to proper gas shielding.

c. Mechanical Means. Immediately prior to welding, mechanical cleaning methods shall be applied to the weld areas previously chemically treated to assure removal of residual or reformed oxides, if any. Acceptable methods of mechanical cleaning include stainless steel wire brushing, scraping, filing, or sanding. However, abrasives containing iron and its oxides, steel wool and wire, and copper alloy based wire, which may become embedded with galvanically active metals and accelerate corrosion of aluminum alloys shall NOT be used. Mechanical methods shall be vigorous enough to adequately remove any residual oxide films, but gentle enough to avoid forming an excessively rough surface in the comparatively soft metal underneath.

d. Acceptance Criteria. All welds shall be visually inspected. Visual inspection shall include 5 power magnifications when suspect condition is to be examined beyond the capability of normal vision. A weld shall be acceptable by visual inspection if it shows the following:

(1) The weld shall have no cracks.

(2) Through fusion shall exist between adjacent layers of weld metal, and between weld metal and base metal.

(3) Weld profiles shall be in conformance with

AWS D1.2/D1.2M:2003.

(4) Except as provided herein, undercut shall not exceed 10% of the plate thickness or 1/16 inch, which ever is lesser.

(5) Overlap will be permitted not to exceed 2T in any 6T length.

(6) A fillet weld in any single continuous weld may be less than the nominal fillet weld size required by 1/16 inch without correction, provided that the undersized portion of the weld does not exceed 10% of the length of the weld.

(7) Shrinkage contained entirely within the crater area of an intermittent fillet weld may be accepted.

(8) Porosity is not permitted.

e. Critical and major welds may be subjected to further non-destructive testing using dye penetrant inspection to confirm the presence of surface cracks.

29. DENTS. Dents less than 3/4-inch do not require repair as long as it does not impact the item. Dents greater than 3/4-inch can be reduced by bending skin back into shape.

30. HOLES. Large holes and punctures can be eliminated by bending/straightening raised or protruding metal, then covering hole with a suitably sized patch of like alloy and thickness. Pin holes may be patched by weld puddle.

31. FLANGES. Sealing flanges may be straightened by carefully bending flange back into position while maintaining the mating alignment of the upper and lower sealing flanges.

32. HUMIDITY INDICATOR CARD REPLACEMENT.

a. Remove lock screw (5, figure 13), card (7) and gasket (6) from the indicator.

b. Remove gasket and card from lock screw and discard.

c. Install new card (7) and gasket (6) on lock screw

(5) and reinstall lock screw.

33. HUMIDITY INDICATOR ASSEMBLY

REPLACEMENT.

Materials Required

Specification/ Part No. Nomenclature

SAE AS 8660 Silicone Compound

a. Remove nut (1, figure 13) and gasket (2) from humidity indicator.

b. Remove remainder of indicator from outside of container.

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c. Obtain new indicator and inspect in accordance with table 1.

d. Apply silicone compound to new gaskets except gasket (6) and insert indicator, with one gasket (4) installed, through forward end panel of container.

e. Install second gasket (2) and nut (1), tighten nut securely.

34. OBSERVATION WINDOW ASSEMBLY

REPLACEMENT.

Materials Required

Specification/ Part No. Nomenclature

SAE AS 8660 Silicone Compound

a. Remove nut (1, figure 14) and gasket (2) from observation window.

b. Remove remainder of observation window from outside of container.

c. Obtain serviceable observation window assembly.

d. Apply silicone compound to gaskets (2/4) and install observation window, one gasket (4) installed, through forward end panel of container.

e. Install second gasket (2) and nut (1) and tighten securely.

35. BREATHER VALVE. Breather (pressure/vacuum relief) valve shall be checked and replaced if necessary.

Replace breather valve as follows:

Materials Required

Specification/ Part No. Nomenclature

SAE AS 8660 Silicone Compound

a. Remove breather valve and discard.

b. Obtain serviceable breather valve.

c. Apply a light coat of silicone compound to gasket.

d. Install gasket onto breather valve body.

e. Install breather valve and tighten securely.

36. FILL VALVE. Fill valve shall be checked and replaced if necessary. Replace fill valve as follows.

Materials Required

Specification/ Part No. Nomenclature

SAE AS 8660 Silicone Compound

a. Remove filling valve and discard.

b. Obtain serviceable filling valve.

c. Apply a light coat of silicone compound to the filling valve threads.

d. Install filling valve and tighten securely.

37. LATCH REPAIR. Replacement parts for latch (05259) 17D043 can be ordered using (05259) 19C016. To replace any part of the latch, drill or punch out the two latch rivets (14, figure 15) to disassemble individual parts.

After replacement of damaged parts, reassemble using the included shoulder screw (13) and lock nut (8). Replacement parts for latch (05259) 17D058 can be ordered using (05259) 19C055. Determine parts/assemblies that are in need of replacement and order the appropriate dash number repair kit for wide, standard, or short/wide handle. Remove spring pin and slide out latch internals. Insert new components as necessary and reattach accordingly.

38. RECTANGULAR LOG COMPARTMENT REPAIR.

Replace broken or damaged parts in accordance with (05259) 19C056. In the event the cover assembly, or any of the parts attached to the cover (8, figure 16) are required, 19C056-2 can be ordered for replacement. Disengage the two quarter-turn latch studs (10) and cut the lanyard (5) to replace. If the latch receptacle (3) is broken or damaged, 19C056-3 can be ordered and riveted to the housing (1) for replacement.

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003013

Figure 13. Humidity Indicator Assembly

003014

Figure 14. Observation Window Assembly

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003015

Figure 15. Standard Latch Assembly

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003016

Figure 16. Log Compartment