AIR COMBAT SYSTEMS PACKAGING …...*3.1.1.3 Use 2” wide MD-11, Tape, 3M #2693 to tape in place protective paper and protective foam on fuselage assembly from 383 Bulkhead to aft

N PACKAGING AND

TRANSPORTABILITY MANUAL SECTION

5 SPECIFICATION NO.

P-2047 AIR COMBAT SYSTEMS PAGE REV

PACKAGING SPECIFICATION 1 of 14 C SPECIFICATION TITLE EFFECTIVE

PREPARATION FOR DELIVERY OF F/A-18 E/F CTR/AFT FUS 09 April 2002 DURING ENGINEERING MANUFACTURING DEVELOPMENT RELEASE DOCUMENT

(EMD), LOW RATE OF INITIAL PRODUCTION (LRIP) I, II, III F94145 AND FULL RATE PRODUCTION (FRP), BY TRACTOR TRAILER SUPERSEDES

27 July 2000 * Denotes Revision 1.0 Scope

This specification establishes the preservation, packaging, packing, loading and unloading requirements for the F/A-18 E/F Center/Aft Fuselage Assembly when shipping between Northrop Grumman Air Combat Systems (ACS, El Segundo, California, and The Boeing Company / McDonnell Aircraft and Missile Systems, St. Louis, MO., on the SC74A000001-501 PHST / SC74A000001-501 PHST, Rev. A, Shipping Fixture by tractor/trailer in accordance with the requirements specified in NOR 93-309A ACS Transportability Report.

2.0 Applicable Documents

2.1 The following documents form a part of this specification to the extent specified herein.

2.2 Military

2.2.1 MIL-P-116 Preservation, Methods of

2.2.2 MIL-B-117 Bags, Sleeves, and Tubing-Interior Packaging

2.2.3 MIL-B-121 Barrier Material, Greaseproofed, Waterproofed, Flexible

2.2.4 L-P-378 Plastic Sheet and Strip Thin Gauge, Polyolefin

2.2.5 PPP-C-795 Cushioning Material Flexible, Cellular, Plastic Film

*2.2.6 LPS, No. 3 Corrosive Preventative Compound or Equivalent

2.2.7 MIL-STD-2073 DoD Material Procedures for Development and Application of Packaging Requirements

2.2.8 MIL-C-16173 Corrosion Preventative Compound. Solvent Cutback. Cold Application

*2.2.9 A-A-59281 Cleaning Compound, Solvent Mixtures

2.2.10 MIL-T-43435 Tape, Lacing, and Tying

*2.2.11 DELETED

2.3 Boeing Company / McDonnell Aircraft and Missile Systems

*2.3.1 SC74A000001-501, Shipping Fixture F/A-18 E/F Center/Aft Fuselage PHST, Rev. A

2.3.2 74A901001 Finish Specification for F/A-18 Aircraft

2.3.3 SC74A000001-501 PHST Shipping Fixture - F/A- 18 E/F Center/Aft Fuselage

*2.3.4 DELETED

2.3.5 TC74A000001-501 PHST Protective Cover

*2.3.6 HFLA74-000005-5103TD Arresting Hook Pin

*2.3.7 HFLA74A000110-5005/-5006 Wing Lug Interface Fittings

PACKAGING AND TRANSPORTABILITY MANUAL

PAGE REVISION LETTER

SECTION SPECIFICATION NUMBER

2 of 14 C 5 P-2047

2.4 Commercial

2.4.1 SMC (Caps) Scott Machine Co.

2.4.2 SMP (Plugs) Scott Machine Co.

2.4.3 Plastic Edg-Pak, #8 PLA

2.4.4 G.B. Woodcock Co. No. 10543 Neoprene Rubber Edge Protector

2.4.5 Misc. Sized Plastic Caps

2.4.6 ASTM D4727 Corrugated and solid fiberboard sheetstock

*2.4.7 Permatex, Part No. 133A Anti-seize Lubricant (Or Equivalent)

*2.4.8 Ideal Hose Clamp, No. 5203 Wormdrive Clamp (5/16” to 7/8”) (Or Equivalent)

*2.4.9 Ideal Hose Clamp, No. 5202 Wormdrive Clamp (1/4” to 5/8”) (Or Equivalent)

*2.4.10 VC3.125-56 Nurad HB Antenna Cover (Caplug)

*2.4.11 VC3.625-52 Nurad HB Antenna Cover (Caplug)

*2.4.12 VC3.500-52 Rwr HB Antenna Cover (Caplug)

*2.4.13 VC2.687-24 Nav Tail Light Cover (Caplug)

*2.4.14 VC3.625-52 Hi/Lo RCV Antenna Cover (Caplug)

2.5 Northrop Grumman

2.5.1 SK-18-0011 F/A-18 E/F Rudder Edge Protector

2.5.2 SPT74A240300-5001 Rudder Restraint Link

2.5.3 Form 20-879 Preservation and Packaging Instructions

2.5.4 MD-11 Pressure Sensitive Tape

*Attachments

*N3906-94-092 Structural Door Requirements for Shipping F/A-18 E/F Ctr/Aft Fuselage Assemblies.

*7D45-00-002 Authorization to Rest The Arresting Hook Fitting Lobes on The Tooling Platform on The Assembly Line.

3.0 Requirements

The requirements of this document apply to the complete Center/Aft Fuselage with vertical stabilizers installed, when Not Installed Parts (NIP), Cost Center 2010 Completion kits, and loose parts are to be included in the shipment, they will be preserved, packaged, and packed in accordance with Level “C” of MIL-STD-2073 and secured on the transportation trailer where space is available.

Form 20-879 shall be used to correct all anomalies to this Specification found during the preparation for delivery. The form shall include identification of the relevant aircraft. The form shall be included with the delivery records.




3 of 14 C 5 P-2047

3.1 Preservation / Packaging / Packing

3.1.1 Openings in Fuselage

3.1.1.1 *Openings in fuselage created by the omission of doors and covers shall be covered with a minimum of 1 layer of MIL-B-121, Type 1, Grade A, waterproof paper, secured in place with 2” wide MD-11, Tape, 3M #2693. Paper to extend a minimum of one inch beyond open space or fastener pattern, whichever is greater. Main engine inlets shall be covered with ASTM D4727 corrugated sheet stock and secured with 2” wide MD-11, Tape, 3M #2693. Cover sheet stock with a minimum of 1 layer of MIL-B-121, Type 1, Grade A, waterproof paper secured in place with 2” wide MD-11, Tape, 3M #2693. Paper to extend a minimum of 1 inch beyond sheet stock.

*Note: Where tape will contact primed, painted, or composite surfaces, 2” wide MD-11, Tape, 3M #2693 shall be used.

3.1.1.2 *Plastic Edg-Pak, #8 PLA shall be installed on the edge of fuselage skins at forward end of center fuselage, also on the edges of the “turkey feathers” and secure with 2” wide MD-11, Tape, 3M #2693.

*3.1.1.3 Use 2” wide MD-11, Tape, 3M #2693 to tape in place protective paper and protective foam on fuselage assembly from 383 Bulkhead to aft end, including the “Turkey Feathers”. Tape in place an extra layer of foam on the dorsal area between the Vertical Stabilizers

*3.1.1.4 Add protective foam to prevent wire harnesses from abrading on 383 Bulkhead, upper and lower areas.

*3.1.1.5 On “E” models only, tie nylon straps from upper longerons to wire harnesses to provide support, 383 Bulkhead, upper area.

*3.1.1.6 Use 2” wide MD-11, Tape, 3M #2693 to cover six (6) pylon plug holes, three (3) holes forward, and three (3) holes Aft in access Cover 74A325601 (Cover #27). Area that is to be taped should be cleaned prior to installation of tape. Trim tape so that it does not come into contact with any of the FIP seal.

*3.1.1.7 Use protective covers (VCX.XXX-XX) to protect antennae and position light, tape in place with 2” wide MD-11, Tape, 3M #2693. Where antennae or position light are not installed, cover with protective paper and protective foam and tape in place with 2” wide MD-11, Tape, 3M #2693, both Vertical Stabilizers.

3.1.2 Miscellaneous

3.1.2.1 Electrical cables, wires, and wire harnesses shall be coiled and taped a minimum of three places, cushioned to prevent abrasion and secured to aircraft structure with 2” wide MD-11, Tape, 3M #2693. Ties made with polyester lacing tape meeting the requirements of MIL-T-43435 Type II, Finish C may be used in lieu of tape for all bundling and securing requirements herein.

CAUTION: Minimum bend radius of wires shall be 6 times O.D. of wire. Minimum bend radius of cables or bundles shall be 10 times O.D. of cable or bundle.

3.1.2.2 *Electrical cables, wires, and wire harnesses impractical to coil shall be taped as required, cushioned to prevent abrasion and secured to the structure with 2” wide MD-11, Tape, 3M #2693.

3.1.2.3 Unmated connectors on cables, wires and wire harnesses shall be closed with plastic or aluminum caps or plugs. Electrical bond lugs, studs and bare wire ends shall not be covered.

Note: All bare unconnected electrical wires are extra length and are to be trimmed to length at next assembly. Corrosion protection of ends is not required.

3.1.2.4 Mechanical cables shall be coiled and taped as in paragraph 3.1.2.1.

CAUTION: Minimum bend radius of coil is 25 times O.D. of cable.




4 of 14 C 5 P-2047

3.1.2.5 *Cables impractical to coil, shall be tied, cushioned to prevent abrasion and secured to the structure with 2” wide MD-11, Tape, 3M #2693.

3.1.2.6 Electrical/Hydraulic interface valves with unmated connectors shall be handled as in paragraph 3.1.2.3.

3.1.2.7 Oxygen, defog, air conditioning line ends shall be closed with plastic or aluminum caps or plugs. Open hydraulic lines and fittings shall be closed with appropriate sized caps and plugs. (See paragraph 3.3).

3.1.2.8 *Free line ends capable of vibration by normal hand oscillation shall be cushioned to prevent abrasion, secured to structure with a minimum of two plies of 2” wide MD-11, Tape, 3M #2693 or polyester lacing tape per MIL-T-43435, Type 2 finish C, spaced 180° apart. Sufficient tension shall be applied to prevent vibration. Care shall be taken when tension is applied to avoid damaging lines.

3.1.2.9 Long ends of unsupported line ends incapable of vibration dampening by taping or tying shall be cushioned, stiffened with lengths of wood and secured to structure with tape or ties.

3.1.2.10 *Sharp edges or protrusions of the F/A-18 E/F Assembly that might damage the protective cover, after it is installed for shipment, should be covered with a layer/layers of ¼” foam sheet, secured in place with 2” wide MD-11, Tape, 3M #2693.

3.2 *Bare Metal bolts and bushings and unpainted metal surfaces other than mold line skin surfaces shall be preserved with corrosion preventive compound MIL-C-16173, Grade 2 and wrapped or covered with greaseproofed paper MIL-B-121 Grade “A”. Secure wrap or cover with 2” wide MD-11, Tape, 3M #2693.

*3.3 Fluid Systems All hydraulic lines, and hydraulic components shall be preserved with approved hydraulic fluid as specified on engineering drawings.

Close all open hydraulic lines or fittings with caps or plugs (SMC/SMP respectively), as shown below

*3.3.1 All hydraulic lines with male or female connections shall use the caps or plugs listed below, and shall be torqued to the value as shown to prevent hydraulic fluid leakage during transit.

PLUG SIZE CONNECTION

CAP SIZE CONNECTION

SMP-4 ¼ SMC-4 ¼ SMP-6 3/8 SMC-6 3/8 SMP-8 ½ SMC-8 ½ SMP-10 5/8 SMC-12 ¾ SMP-12 ¾ SMC-16 1

TORQUE REQUIREMENTS FOR CAPS & PLUGS IS 40 IN/LBS +0/-10 IN/LBS

*3.3.2 Eight hydraulic lines, located at the manufacturing break forward of the 383 bulkhead that will be spliced at Boeing, St. Louis, ranging in size from ¼” dia. shall have plastic caps covering their ends and then worm drive clamps securing the caps to the tubes. Use Ideal hose clamps (or equivalent) No. 5202 (1/4” to 5/8”) and No. 5203 (5/16” to 7/8”).

3.4 Hydraulic Cylinders Exposed surfaces of pistons shall be protected with a coating of MIL-P-16173 Grade 2 Corrosion Preventive Compound and wrapped in MIL-B-121 “A” paper. Secure wrap with MD-11, No.1 Tape, 3M #231.

3.5 Mounting F/A-18 E/F Fuselage in Shipping Fixture SC74A000001-501 PHST.

3.5.1 Attach overhead crane to strongback (HFHT 74A000110-5001). Align the strongback in position and lower it over Ctr/Aft Fuselage. Connect strongback to forward and aft hoist points of the fuselage.




5 of 14 C 5 P-2047

CAUTION: The attach point (overhead crane to strongback) for lifting the strongback only, and lifting the strongback with Ctr/Aft Fuselage are not the same. Check attach point between overhead crane and strongback for every lift operation to avoid mishap. Four (4) guide ropes must be attached to the (4) corners (extremities) of the fuselage for control while it is suspended.

3.5.2 HFLA 74A000110-5005/5006 Wing Lug Interface Fittings are already installed on the Ctr/Aft Fus Assy at the bulkhead wing attach points.

*3.5.2.1 Position attach point (overhead crane to strongback ) to temporarily lift aft end of Ctr/Aft Fus Assy approximately 3 inches vertically.

*3.5.2.2 Mounting F/A-18 E/F Fuselage in Shipping Fixture SC74A000001-501 PHST, Rev. A

*3.5.2.2.1 Clean HFLA 74-000005-5103 TD Arresting Hook Pin and Arresting Hook Fitting on aircraft with A-A-59281 solvent, or equivalent. Wipe dry with lint free rags. Apply Antiseize Lubricant to Arresting Hook Pin, the internal upright support faces of the arresting hook fitting, external threads, and internal threads of nut.

*3.5.2.2.2 Install HFLA 74-000005-5103 TD Arresting Hook Pin after removal of HFLA 74A000110-5007 Tooling Adapter and hand tighten.

*3.5.2.2.3 Carefully lower Ctr/Aft Fus Assy so that the Arresting Hook Fitting rests on HFLD 74A000110-5001 Tooling Post.

*3.5.2.2.4 Reposition attach point (overhead crane to strongback) for lifting Ctr/Aft Fus Assy.

*3.5.2.3 Inspect the fuselage to ensure that all doors and access panels are closed and secured, all holes and openings are covered, and all protruding hardware, cables, etc. are protected as specified herein.

*3.5.2.4 Inspect shipping fixture (SC74A000001-501 PHST, Rev. A) to ensure that the surfaces are clear of tools or other loose materials, and attach fittings, and mating surfaces are clean and dry.

*3.5.2.5 Position lower half of the Protective Cover (TC 74A000001-501 PHST) on the Shipping Fixture prior to attaching Ctr/Aft Fus Assy.

*3.5.2.6 Clear immediate loading area prior to lifting Ctr/Aft Fus Assy from HFLD 74A000110 Tooling Fixture.

*3.5.2.7 Arresting Hook Fitting, on Shipping Fixture, parts required (see fig. 7):

-14 Cap (2) -17 Nut (2) -16 Bolt (2) -21 Safety Pin (2) Arresting Hook Fitting attached to Shipping Fixture

*3.5.2.7.1 Remove –14 Caps, -16 Bolts, -17 Nuts, -21 Safety Pins from Arresting Hook Fitting attached to Shipping Fixture.

*3.5.2.8 Attaching Fuselage to Shipping Fixture

*3.5.2.8.1 Lower the fuselage over the Shipping Fixture, adjusting as necessary to align the fittings with the respective mating surfaces.

CAUTION: The fuselage weight must be supported from overhead crane with Strongback HFHT 74A000110-5001 until both HFLA 74A 000110-5005/-5006 Winglug Interface Fittings and HFLA 74-000005-5103 TD Arresting Hook Pin are secured to the Shipping Fixture.

*3.5.2.8.2 Reinstall –14 Caps, -16 Bolts, and –17 Nuts in Arresting Hook Fitting on Shipping Fixture. Reinstall –21 Safety Pins and “torque stripe” (see fig.7). Install a 91015A038 jam nut on threaded portion of hook pin assembly adjacent to HFLA74-000005-5013. Torque “91015A038 jam nut snugly. Apply inspection seal to jam nut to prevent assembly backing off during shipment and to maintain span dimension of 6.905 max.




6 of 14 C 5 P-2047

3.5.2.9 For the next procedure go to para. 3.6.4 and proceed from there.

*3.5.3 DELETED

*3.5.3.1 DELETED

*3.5.3.2 DELETED

*3.5.3.3 DELETED

*3.5.3.4 DELETED

*3.5.3.5 DELETED

*3.5.3.6 DELETED

*3.5.3.7 DELETED

*3.5.3.8 DELETED

*3.5.3.9 DELETED

*3.5.3.10 DELETED

*3.5.3.11 DELETED

*3.5.3.12 DELETED

*3.5.4 DELETED

*3.5.5 DELETED

*3.5.6 DELETED

*3.5.7 DELETED

*FIGURE 1 DELETED

*FIGURE 2 DELETED

*3.6 Attaching Fuselage To Fixture and Draining Residual Hydraulic Fluid

*3.6.1 DELETED

*3.6.2 DELETED

*3.6.3 Follow the instructions in figure 7 to prepare and attach the fuselage arresting hook to the fixture.

*3.6.4 Lower fuselage until HFLA 74A000110-5005/-5006 Wing lug Interface Fittings Detail 14’s align and rest in grooves of -501 Details 3 and 4 (Fig. 5). Slide -501 PHST Detail 6 into -501 PHST Detail 3 until .50 dia hole (-501 PHST Detail 6) aligns with .50 dia. hole in -501 PHST Detail 3. Insert -501 PHST Detail 17 thru -501 PHST Detail 6 and into -501 PHST Detail 3 and rotate until handle of -501 PHST Detail 17 is retained by -501 PHST Detail 18, Slide -501 PHST Detail 7 into -501 PHST Detail 4 until .50 dia hole (-501 PHST Detail 7) aligns with slotted hole in -501 PHST Detail 4. Insert -501 PHST Detail 17 thru -501 PHST Detail 7 and into -501 PHST Detail 4 and rotate until handle of -501 PHST Detail 17 is retained by -501 PHST Detail 18. Inspection seal to be added over Detail 18.

3.6.5 Inspect attach details to ensure that all items have been installed correctly, torque value applied to bolt and safety wired, and safety snap pins are in place and secured. The fuselage weight must now be gradually transferred to the shipping fixture, and the strong back released from the fuselage hoist points.




7 of 14 C 5 P-2047

*3.6.5.1 Allow fuselage to normalize for 24 hours. Remove Caps/Plugs from hydraulic lines on y383 Bulkhead. Using Forklift, elevate Aft end Approximately 8 degrees or two (2) feet to allow residual hydraulic fluid to drain from fuselage for approximately 10 minutes. Wipe with “Rymple” cloth and “Turco 4460” on outer structure. Reinstall removed caps / plugs to hydraulic lines on Y383 bulkhead per paragraph 3.3.2. Apply “Diasorb” sand to absorb drained fluid under unit at floor level. Insure that floor is cleaned and materials used are properly disposed of.

*FIGURE 3 DELETED

*FIGURE 4 DELETED

3.7 Protection of Ctr/Aft Fus Assy During Transportation




8 of 14 C 5 P-2047

*3.7.1 Install SPT74A240300-5001 Rudder Restraint Links (Fig. 6), wrap one layer of MIL-B-121, Type 1, Waterproof Paper, over full length of Rudder Trailing Edge, and secure with 2” wide MD-11 tape, 3M #2693. Secure Neoprene Rubber Edge Protector over full length of Rudder Trailing Edge and secure with 2” wide MD-11 tape, 3M #2693. Install SK-18-0011 Rudder Edge Protector over full length of Rudder Trailing Edge and secure with 2” wide MD-11 tape, 3M #2693. Position segments of Protective Cover (TC74A000001-501 PHST) over Ctr/Aft Fus Assy, mounted on the shipping fixture, and secure to lower half of cover.

Note: Fabrication information for SPT74A240300-5001 Rudder Restraint Links is detailed in Fig. 6 of this Specification.

3.7.2 Personnel to ensure that the Protective Cover is properly fitted over Ctr/Aft Fus Assy.

3.8 Loading Trailer for Transportation

3.8.1 The weight of the Ctr/Aft Fus Assy and Shipping Fixture combined is approx. 17,000 Ibs. For transporting mounted fuselage assembly to trailer loading area, a forklift capable of moving loads of 20,000 Ibs., or greater, on 60 inch load centers is required, with forks a minimum of 72 inches in length (96 inches preferred).

3.8.2 Care must be exercised when running forks into shipping fixture slots to avoid forklift contact with any part of the Ctr/Aft Fus Assy (leading edge extension which protrudes just forward of the wing attach bulkheads).

3.8.3 Transport Ctr/Aft Fus Assy to trailer loading area and place on ground.

*3.8.4 Use the 20,000 lb. lift capacity forklift to load the Ctr/Aft Fus Assy on the trailer. Two transportation employees are required for this operation. One to operate the forklift and one to guide the positioning of the fixture on to the truck. If the single heavy lift forklift is unavailable, two same size forklifts with a combined capacity over 20,000 lbs may be used as follows: Position second forklift on opposite side of shipping fixture. First one forklift to insert forks into forklift slots on shipping fixture, then forklift on opposite side does the same. Overlap of forks permissible.

*3.8.5 Coordinate lifting of Ctr/Aft Fus Assy, on Shipping Fixture, with the forklift or forklifts to a height that allows the double drop trailer to be positioned under it.

3.8.6 Sections of 2 X 4s, or equivalent, may have to be placed between the skids of the shipping fixture and trailer-bed to compensate for crown of trailer-bed.

3.8.7 Driver of tractor-trailer will secure shipping fixture to trailer-bed and transport to St. Louis, MO.

3.9 Unloading Trailer at St. Louis

3.9.1 Remove Protective Cover from Ctr/Aft Fus Assy.

3.9.2 Check fuselage for damage, any damage that may have occurred en route. Record all damage with a written record and with photographs .

3.9.3 Tractor-trailer driver will release shipping fixture from trailer- bed .

3.9.4 Position two fork-lifts, one on each side of the shipping fixture.

3.9.5 Fork-lifts to insert forks into slots of shipping fixture, being careful not to contact any part of the Ctr/Aft Fus Assy.

3.9.10 With coordinated lifting, the Ctr/Aft Fus Assy should be raised to a height that will allow the trailer to be removed from beneath it. After the trailer is removed, the shipping fixture can be placed on the ground. Remove fork-lifts.

3.10 Removal of Fuselage From Shipping Fixture




9 of 14 C 5 P-2047

3.10.1 Attach strongback to forward and aft hoist points of the fuselage, strongback attached to overhead crane.

*3.10.2 Remove -501 PHST Details shown in figure 7.

3.10.3 Remove -501 PHST Detail 17 both sides of Shipping Fixture. Remove -501 PHST Detail 6 and 7.

*3.10.4 DELETED

Note: HFLA74A000110-5005 and -5006 Winglug Interface Fittings are to remain on the Ctr/Aft Fus Assy as it starts into production.

3.10.5 Ctr/Aft Fus Assy can now be removed from the Shipping Fixture.

*3.10.6 Removed Details of the shipping fixture, as follows:

(1 Item) DIFRU Cover 74A342621-5001

(2 Items) Anti-Ice Duct Stow Plates 74A501801-5001

(2 Items) Wing Fuselage Root Holding Fixture HFLA74A000110-5005 & -5006

(2 Items) Vertical Support SPT74A240300-5001

(1 Item) Transportation Cover Fuselage Tarp

(2 Items) Transportation Cover Vertical Tarp

(1 Item) Arresting Hook Pin & Assorted Hardware HFLA74-000005-5103

(2 Items) Transportation Left & Right Fwd Attach Fitting

(2 items) Rudder Restraint Link SPT 74A240300-5001

(1 Item) Shipping Fixture For Transportation 74A000001-501 PHST

can now be placed on the trailer for return to NGACS.




10 of 14 C 5 P-2047

FIGURE 6

FIGURE 7




11 of 14 C 5 P-2047

4.0 Quality Assurance

4.1 Quality Assurance shall verify that the materials, tools, equipment, and procedures for preservation, packaging and packing of the Ctr/Aft Fus Assy, and installation into the Shipping Fixture are as specified herein.

5.0 PREPARATION FOR DELIVERY

5.1 This section is not applicable to this specification.

6.0 Notes

*6.1 Information pertaining to this specification may be obtained from:

Northrop Grumman Corp. Air Combat Systems Support Equipment & Transportability Engineering Dept. 7E80/W3 El Segundo, CA 90245




12 of 14 C 5 P-2047




13 of 14 C 5 P-2047




14 of 14 C 5 P-2047