- Component Maintenance Manual: Container Type H1
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Component Maintenance Manual CONTAINER TYPE H1 SERIES: VARIATIONS: CLASSIFICATION: CERTIFICATION:
H1-V-( ) See page 2 NAS 3610-2K2C, Rev.10 JTSO-C90c; TSO-C90c
Manufacturer : Driessen AIS Europe BV Toermalijnstraat 16, 1812RL Alkmaar The Netherlands Phone: +31 (0)88 374 3800 Fax: +31 (0)88 374 3805
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Record of Revisions REV. NO.
ISSUE DATE
INSERTED DATE
BY
–
JUN 2000
JUN 2000
Bretschneider
1
JAN 2009
JAN 2009
M. Manathanya
2
AUG 2011
AUG 2011
P. Plapiriyakit
The approval of the EASA covers the variations as described on page 2.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Revisions REV.
1
2
25-50-186 Revisions Aug 2011
PAGE
DESCRIPTION
Rec. of revisions
LBA replaced by EASA
502
Information added
513A
added
All
Update to Lightweight
DATE
SIGN.
JAN 09
MM
AUG 11
PPL
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
List of effective pages I Chapter/Section
Page
Title page Revision Record Revisions List of effective pages I List of effective pages II Table of contents Introduction Service Bulletin List 1 2 3 4 5 101 201 301 302 303 304 305 306 307 308
Date AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11
Page 309 310 311 312 313 314 315 316 317 318 319 401 402 403 404 405 406 407 408 409 410 501 502
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
List of effective pages II Chapter/Section
Page 503 504 505 506 507 508 509 510 511 512 513 514 515
25-50-186 List of effective pages II Aug 2011
Date AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11
Page 516 517 518 519 520 521 601 701 702 703 704 801 901
Date AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11 AUG 11
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Table of Contents Description …………………………………………………………………………………
1
Variations of series H1-V-( ) ……………………………………………………………..
2
Limits ………………………………………………………………………………………..
4
Statement in accordance with TSO-C90c …………………………………………….
5
Disassembly ……………………………………………………………………………….
101
Cleaning ……………………………………………………………………………………
201
Inspection ………………………………………………………………………………….
301
Repairs …………………………………………………………………………….……….
401
Assembly …………………………………………………………………………………..
501
Storage Instructions ……………………………………………………………………..
601
Special Tools, Fixtures and Equipment ………………………………………………
701
Final Inspection ………………………………………………………………….………..
801
Illustrated part list ……………………………………………………………….………..
901
25-50-186 Table of contents Aug 2011
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Introduction This Component Maintenance Manual is applicable to the units classified and listed on the title page. It complies with the requirements of JTSO/TSO-C90c and includes instructions for keeping the equipment in an airworthy condition. This manual is prepared in accordance with Air Transport Association Specification No. 100. Each unit is marked with the series number. Example : Series number :
H1 – V – 1 1 2
one flex. door non forklift base (2 for forklift base) one piece door webbing door
Container type H1
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Service bulletin list Service Bulletin Issue
Service Bulletin Issue
25-50-186 S-B-List Aug 2011
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Description Purpose : For baggage, cargo and mail in the lower deck of A320 aircrafts. Weight : Empty weight: Series: Aluminium versions
H1-V-( ) minimum 78 kg/172 lb
Empty weight: Series: Herculight versions
H1-V-( ) minimum 69 kg/152 lb
Max. gross weight: 1587 kg/3500 lb Construction : Base, sides, roof and doors are joined together through flanges by means of bolts and nuts or lockbolts. Base non forklift : The base consists of a frame of hollow extrusions joined by inserted corner pieces, a sheet is riveted into this frame. Base forklift : The base consists of a frame of hollow extrusions joined by inserted corner pieces, top and lower sheets are riveted into this frame. As support connections U-extrusions are riveted between two sheets. Body : Lower outboard, top outboard and backwall panels are flat sheets (aluminium or herculight). Sides forward left/right and backwall are made of hollow extrusions and an inserted aluminium sheet, polycarbonate or herculight sheet clamped together by means of gussets, lockbolts or bolts and nuts. The roof consists of two welded frames, into each frame is a sheet riveted. This roof parts are joint together by rivets and a “piano hinge”. Doors : Flexible doors consist of highly tear-resistant PVC coated polyester reinforced by webbings.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Variations of series H1-V-( ) 1. Non forklift base variations H1-V-112
Container with non forklift base and one 1-piece flexible door
2. Forklift base variations H1-V-122
Container design according to H1-V-112, however with forklift base
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Limits Qualification According to JTSO-C90c, NAS 3610-2K2C, Rev. 10 (TSO-C90c) Ultimate Load Criteria: according to Table II, Load Condition 30. Restraint Criteria: according to Table III, Restraint Condition 25. Shifting of Center of Gravity:
Longitudinal Lateral Height:
+/- 0.153 m/6.04 in +/- 0.156 m/6.15 in max 0.86 m/34.0 in above the bottom surface of the base
Burn Rate: according to FAR 25.853 (a)-(1)-(iv).
Max. Gross Weight Actual gross weight limits for a device in a given airplane are determined in compliance with FAR 25 and listed in the Approved Weight and Balance Manual for that airplane. Base Pressure: max 980 kg/m2 (200 lb/sqft). Secure Cargo Over: 400 kg/m3 (25 lb/cuft). Internal Tie Down Capacity: 8.9 kN (2000 lb)
After loading, the container is to be closed, the door straps must be tightened The container must be moved on tracks with ballmats (grid pattern min 250 mm, ball min. Ø 25 mm) or 1 – 3 rows of rollers (spacing: longitudinal min. 250 mm; lateral min. 660 mm; roller size min. 40 mm Ø x 60 mm). Special ground equipment, e. g. high loaders, dollies, etc. are to be used for handling. The container without forkliftable base must not be moved by fork-lift whether loaded or unloaded. During flight, the container must be restrained as follows according to NAS-3610-2K2C, Rev. 10, fig. 33 and 35. Down:
by three roller tracks
Up and side: Forward and aft:
by four guides restraining the base on the inboard and outboard side. by two stops securing up to seven containers.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Statement in accordance with TSO-C90c The conditions and tests required for TSO approval of this article are minimum performance standards. It is the responsibility of those desiring to install the article on or within a specific type or class of aircraft to determine that the aircraft operating conditions are within the TSO standards. The article may be installed only if further evaluation by the user/installer documents an acceptable installation and is approved by the Administrator.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Disassembly The container should be disassembled only to the extent necessary for repair or exchange of panels. Disassembly procedure is exactly the reverse of that for assembly (see page 501 and follows). The lock bolts are unfastened with the break off tool (see page 701) per the instructions on page 504.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Cleaning a)
Aluminium version Interior surfaces should be vacuumed prior to cleaning with a detergent. The container may be cleaned with commercial detergents specified for aluminium. After cleaning, the detergent should be carefully removed with sufficient water especially from corners and crevices to prevent corrosion. Steam cleaning of the container is acceptable with the exception of the fabric door.
b)
Polycarbonat version Clean polycarbonat panels with water and regular soap or mild detergent using sponge or soft cloth. Rinse well with clear water. Warning: Do not use abrasive, highly alkaline or organic cleaners, acetone or carbon tetrachloride, benzene, gasoline or paraffin on polycarbonat panels. Do not use razor blades or other sharp instruments.
c)
Herculight version Clean Herculight panels with water and regular soap or mild detergent using sponge or soft cloth. Rinse well with clear water. Warning: Do not use abrasive, highly alkaline or organic cleaners, acetone or carbon tetrachloride, benzene, gasoline or paraffin on Herculight panels. Do not use razor blades or other sharp instruments
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Inspection 1. General These instructions are applicable to the checking and inspection of certified unit load devices.
1.1 Definitions Operation:
Loading, transport and unloading of the unit for the purpose of transporting cargo and baggage.
Serviceability: Degree to which unit is suitable for proposed purpose and shows no evidence of substantial damage or defect. Checking:
Examination of unit to determine its operational serviceability.
Airworthiness: Degree to which unit exactly coincides with the container specification and design documents. Inspection:
Examination of unit for the purpose of determination its airworthiness.
2. Serviceability checks 2.1 Checking intervals The unit should always be checked as to its service condition a) before loading and transport b) after every small repair
2.2 Responsibility Checks may be made by any container operator. The responsibility for a proper check lies with the operator of the carrying aircraft.
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2.3 Extent of checking The following checks are to be carried out: Visual:
for damage, missing parts, condition of special equipment and accessories, condition of markings.
Functional:
all movable parts and mechanism, e.g. locks and safety devices.
2.4 Damage procedure The degree of serviceability is to be determined and the prescribed procedure carried out. Damage classified under Class II :
the resulting operational deficiencies are to be clearly marked on the unit and remain for as long as the unit is in this condition.
Damage classified under Class III :
the unit is to be clearly marked as unserviceable and withdrawn from use.
2.5 Certificate of Inspection Checks to determine the serviceability of units need neither certifying nor recording.
3. Inspections 3.1 Inspection intervals Unit is to undergo inspection to ascertain their airworthiness:
after each major repair after each major design change at the request of airworthiness authorities following usage involving special operating conditions
3.2 Responsibility Inspections are to be made by independent inspectors, approved maintenance and repair shops or the manufacturer. Responsibility for inspection rests with the company which transports the unit in the aircraft.
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3.3 Extent of Inspection Inspections are to be made to ascertain:
the proper execution of a repair or design change the serviceability of the unit that the unit conforms to the appropriate container specification correct coding and marking of the unit
3.4 Certification Inspections are to be duly certified (on the appropriate airworthiness authority forms). Deviations from this instruction need the approval of the airworthiness authority.
4. Classification of Damage 4.1 Types of damage The effect of any damage on the further use of the unit is to be defined. Class I – Minor Damage Such damage has no substantial influence on the airworthiness of the unit and it can remain in service. Unrepaired damage should be noted for future observation. Class II – Medium Damage Use of the unit is to be limited, e. g. the total weight must be reduced accordingly and the decreased load capacity clearly marked. Should this damage not be immediately repaired, the unit must be marked accordingly and kept under observation, nevertheless repair must be carried out as soon as possible. Class III Major Damage This is damage whereby the unit is clearly not airworthy and therefore it is to be marked accordingly and withdrawn from service.
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4.2 Procedure The required procedure following the detection of damage is as follows: Solid Base
Part
Damage
Class
Procedure/Remarks
Sheet
–
Up to 2 tears 100 mm (4”) long and up to 2 holes Ø20 mm (0.8”), distance between damages min. 350 mm (13.8”), distance damage-rivet line min. 100 mm (4”).
I
mark with color
–
Base sheets with cracks must be replaced, Indentation up to 6.4 mm (0.25”) deep
III
not airworthy
–
Hole up to Ø15 mm (0.6”), Longitudinal crack up to 50 mm (2”), lateral crack up to 10 mm (0.4”)
I
mark with color
–
Hole up to Ø20 mm (0.8”), Longitudinal crack up to 80 mm (3.2”), lateral crack up to 15 mm (0.6”)
II
50% load capacity
–
Holes or cracks exceeding those dimensions III
not airworthy
–
Crack up to 10 mm (0.4”)
mark with color
–
Crack larger than 10 mm (0.4”)
–
Loose rivets with axial free motion (play) up to 0.6 mm (.023 in) do not affect the airworthiness of the unit
I
mark with color
–
3 missing rivets per edge extrusion min. distance 300 mm (11.81”)
II
50% load capacity
–
more than 3 missing rivets per edge rail or less than 300 mm distance (11.81”)
III
not airworthy
–
Total height of deformed base may not exceed 33 mm (1.3”)
Edge rails
Corners
Rivets
Panel
I
must be welded to avoid damage to transport system
* However, in order to protect the aircraft cargo system against damage, repair should carried out as soon as possible.
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Panels Shear panels fwd/aft left and right
Part
Damage
Class
Procedure/Remarks
Aluminium sheets
–
One hole or crack according to details on pages 307 and 318
I
Mark with color
–
Up to 3 holes or cracks distance min. 300 mm (12”)
II
50% load capacity
–
More than 3 holes or cracks
III
not airworthy
–
Two holes or crack according to details on pages 307 and 318
I
Mark with color
–
Up to 6 holes or cracks distance min. 300 mm (12”)
II
50% load capacity
–
More than 6 holes or cracks
III
not airworthy
–
No damage is allowed
III
not airworthy
Herculight sheets
Polycarbonate sheets
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Part
Damage
Panel extrusion except door posts and roof extrusions of the movable roof part (forward) and middle extrusions
–
Door posts
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Class
Procedure/Remarks
Hole up to Ø15 mm (0.6”) longitudinal crack up to 50 mm (2”) lateral crack up to 10 mm (0.4”)
I
Mark with color
–
Hole up to Ø20 (0.8”) mm longitudinal crack up to 80 mm (3.2”) lateral crack up to 15 mm (0.6”)
II
50% load capacity
–
Distortion/indentation of up to half length of extrusion, max. depth: 10 mm (0.4”)
I
Mark with color
–
Distortion/indentation of up to whole length of extrusion, max. depth: 5 mm (0.2”)
II
50% load capacity
–
Hole, crack, indentation exceeding these dimensions
III
not airworthy
–
Repair welding is acceptable
–
Indentations/delves up to a depth of max. 5 mm (0.2”) and together max. 25% of the affected profile length resp. the width of door at the roof section, if no cracks or holes arise.
I
Mark with color
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Of aluminium sheet Area within which a 100 mm (4”) hole or cut is allowed Of polycarbonate sheet No damage allowed, sheet must be replaced or repaired Of Herculight sheet Area within which two 150 mm (6”) holes or cuts are allowed
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Side outboard top; Side outboard bottom and Backwall Part
Damage
Aluminium sheets
–
Herculight sheets
Stiffener
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Class
Procedure/Remarks
One hole or crack according on pages 309, 310, 311 and 321
I
Mark with color
–
Up to 3 holes or cracks distance between holes or cracks min. 350 mm (13.8”)
II
50% load capacity
–
More than 3 holes or cracks
III
not airworthy
–
Two holes or crack according on pages 309, 310, 311 and 321
I
Mark with color
–
Up to 6 holes or cracks distance between holes or cracks min. 350 mm (13.8”)
II
50% load capacity
–
More than 6 holes or cracks
III
not airworthy
–
Damaged stiffeners must be replaced
Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Of aluminium sheet Area within which a 100 mm (4”) hole or cut is allowed Of Herculight sheet Area within which two 150 mm (6”) holes or cuts are allowed
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Of aluminium sheet Area within which a 100 mm (4”) hole or cut is allowed Of Herculight sheet Area within which two 150 mm (6”) holes or cuts are allowed
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Backwall Of aluminium sheet Area within which a 100 mm (4”) hole or cut is allowed Of Herculight sheet Area within which two 150 mm (6”) holes or cuts are allowed
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Roof (piano hinged) Part
Damage
Class
Procedure/Remarks
Stiffeners
Damaged stiffeners must be replaced
Rivets (panel)
–
up to 2 loose or missing rivets per edge extrusion, min. distance between loose or missing rivets 150 mm (6”)
I
Mark with color
–
3 loose or missing rivets per edge extrusion, min. distance 150 mm (6”)
II
50% load capacity
–
more than 3 loose or missing rivets per edge extrusion, or less than 150 mm (6”) separation
III
not airworthy
–
up to 3 faulty rivets on each hinge half, min. distance 150 mm (6”)
I
mark with color
–
up to 5 faulty rivets on both hinge halfs, min. distance 150 mm (6”)
II
50% load capacity
–
more than 5 faulty rivets on both hinge halfs or less than 150 mm (6”) separation
III
not airworthy
Piano hinge
–
damaged hinge must be replaced completely or in part
Roof extrusions of the movable part and middle extrusions.
–
Deflection of the roof beam sections up to 15 mm (0.6”) if it does not affect functions of the door and does not protrude over the max. permissible container contour. Any buckling is unacceptable.
–
No holes or cracks are allowed
III
not airworthy
–
Damaged posts or roof extrusions must be completely replaced
–
Welding is not acceptable
Rivets (piano hinge)
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Aluminium Roof sheets
Herculight Roof sheets
–
One hole or crack according on pages 314 and 318
I
Mark with color
–
Up to 3 holes or cracks distance between holes or cracks min. 350 mm (13.8”)
II
50% load capacity
–
More than 3 holes or cracks
III
not airworthy
–
Two holes or crack according on pages 314 and 318
I
Mark with color
–
Up to 6 holes or cracks distance between holes or cracks min. 350 mm (13.8”)
II
50% load capacity
–
More than 6 holes or cracks
III
not airworthy
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Of aluminium sheet Area within which a 100 mm (4”) hole or cut is allowed Of Herculight sheet Area within which two 150 mm (6”) holes or cuts are allowed
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Flexible door
Door cover Holes or cuts are allowed according to pages 316. Holes up to 10mm diameter and cuts up to 25mm length minimum distance between holes/ cuts 25mm. From quantity 25 of damages per door a repair or exchange is recommended. Webbings No cuts, no wearing off allowed. Hardware (footman loops, nuts and bolts, buckle, Hooks) No damaged or missing hardware allowed. Velcro No damages allowed. Worn-out or damaged Velcro must be replaced.
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General Damaged Manufacturer Data Plate There shall be no missing signs. All data on the Manufacturer Data Plate shall be readable.
Lockbolts or screws/nuts Loose or missing lockbolts must be replaced.
Stiffeners and butt straps Damaged stiffeners and butt straps must be completely replaced.
Gussets No holes or cracks are allowed
Deflection No deflection beyond IATA contour is allowed
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TOLERABLE HOLES IN SKIN
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Responsibility Responsibility of judging whether a unit is still airworthy rests with the company which transports the unit in the aircraft.
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Repairs Requirements Maintenance and repair work, with the exception of that mentioned below, must be carried out by an approved maintenance and repair station or by the producer. Skilled men and equipment are required for working on sheets, extrusions and aluminium sandwich panels, etc. Work is to be inspected.
Repair work without approval: Exchange of damaged bases, sides, roofs and doors as described in assembly and disassembly instructions, replacement of base, corners forward or aft stiffeners and joint extrusions. Loose, damaged or missing lockbolts have to be replaced, screws have to be tightened or replaced.
Approved repair materials For panel sheet repairs please use Rivet MS 20470-AD4-3 for panel sheet repairs Blind rivet GFB No 315720, Ø4.8/0.8-3.2mm grip Welding wire ALMg5 (AA5056) ca. 1 mm dia. Base rivet dia. 5mm x10mm (original) Washer R6.6/22×2 DIN 440
P/N 927034 or P/N 927237 (or equivalent) P/N 924993 P/N 927865 P/N 970036 (repair polycarbonate sheet) (hole .259in.; dia 27/32in.; thickness .08in.)
All other parts are to be purchased according to the illustrated part catalogue from the manufacturer except in case of standardized or commercial items.
Repair of the base a)
Edge extrusions Loose or damaged rivets are to be drilled out and replaced (as well as missing rivets) by new ones, one number larger than the original rivet if required. Extrusions which are considerably damaged can be exchanged by removing all rivets on one edge.
b)
Corners Damaged or missing parts are to be replaced. Cracked corners of the base may be welded.
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c)
Base sheet Damaged, uneven and distorted sheets and extrusions have to be replaced or repaired. Small damages One crack per 1 m2 (10.8 sq.ft.) up to a length of 100 mm (4”) or one hole with a maximum diameter of 20 mm (0.8”). Distance between damages minimum 350 mm (13.7”). These damages can be repaired as follows. Drill stop holes and close the damages by welding. Grind welding flush on upper and lower surface. Stop holes should not be welded. Larger damages Larger damages then described above can be repaired as follows. Work out the damaged area – min. 10 mm (0.4”) radii in the corners, no sharp edges. A doubler being on all sides min. 30 mm (1.2“) larger than the worked-out damage area has to be riveted to the sheet. Distance between the rivets max. 30 mm (1.2”). Edges and corners of the doubler have to be rounded off, no sharp edges. Rivets should have equal or better strength then original base rivets. Doubler thickness min. 3.0 mm (0.12”) and material should be equal or better then original base sheet alloy. A filling piece that fits properly in the worked-out area should be riveted to the doubler as to create a flush bottom surface of the base sheet.
d)
Rivets Loose, missing or damaged rivets have to be removed and replaced by new ones, possibly one number larger than the original rivet. Base rivets: 927849 – Ø5.0 x 10 (original) 927046 – Ø6.4 x 14 (GFB 304621), for repair All rivets must have the proper grip-length. When riveting, sheets and extrusions must be firmly fixed together.
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Repairs of shear panels fwd/aft, side and roof panels Protruding edges and corners which, as a result of damage or repairs, being potentially hazardous to persons or freight must always be removed. Uneven panels are to be re-leveled. a)
General All damaged extrusions of the container, except roof panels, can be completely replaced by removing of bolts and gussets. In case of roof repair welding the WIG process shall be used. Rivets and sealings must be removed to provide adequate access to the welding area, to prevent sealings from burning. Welded areas are to be previously degreased. If necessary, the surface of the welded area is to be ground, and the panel to be redressed. Finally, the repaired area between skin and frame is to be sealed.
b)
Stiffeners Damaged stiffeners must be replaced.
c)
Aluminium panel sheets The damaged part is to be carefully drilled and cut out with at least 5 mm (3/16 in.) radius in the corners. A new piece of sheet, having approx. 20 mm radius and at least 20 mm (25/32 in.) overlap on all sides is to be prepared. Match drill the patch and the panel, diameter 4.8 mm (3/16 in.). Fix the patch the damage to the flat sheet of the panel by means of blind rivets (see page 401). Max. distance between rivets 50 mm (2 in.), min. distance from edge of the patch and of the cut out 9 mm (11/32 in.). Sheet gauge min. 0.7 mm (.028 in.).
d)
Polycarbonate panel sheets The damaged part is to be carefully drilled and cut out with at least 5 mm (3/16 in.) radius in the corners. A new piece of polycarbonate sheet, having approx. 20 mm radius and at least 25 mm (1 in.) overlap on all sides is to be prepared (please see page 404). Match drill the patch and the panel, diameter 8 mm (5/16 in.). Fix the patch over the damaged area to the flat polycarbonate sheet of the panel by means of lockbolts, washers and collars (or screws, washers and nuts 1/4 in.), see figure below. Max. distance between the bolts 50 mm (2 in.), min. distance from edge of the patch and of the cut out 12 mm (15/32in.). Polycarbonate gauge min. 1.5 mm (.059 in.).
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e)
Herculight panel sheets
Inspect the panel area to be repaired for any burrs or frayed edges. Trimming should be performed only for protrusions that extend beyond the plane of the panel. Trimming may be accomplished with scissors, utility knife, or other trimming tool. A patch may be cut any shape as long as a minimum of 38 mm (1,5”) patch overlap around the damaged area is maintained. Prepare the area for patching and the patch itself by thoroughly cleaning the surfaces with an industrial grade 2-propanol (isopropyl alcohol). A patch should be applied within 30 minutes after cleaning, if not the surfaces should be re-cleaned. For Damages falling under limits of class I – Allowable Damage Prepare a patch by applying 3M 9472LE double sided tape around the outer perimeter of the patch. Additional tape may be applied in the centre area of the patch if required. Alternatively, pre-manufactured patches may be used. Before peeling the paper backing from the patch, test fit the patch over the damaged area to 25-50-85 Page 404 Aug 2011
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pre-locate and align the patch for installation. Remove the backing paper from the patch and firmly press the patch over the damaged area. Apply pressure to the full area of the tape to create a proper bond. If ambient temperature is below 20ºC (70ºF), the patch should be heated with the use of a standard hair dryer before pressure is applied to create proper bonding. Any Damage Exceeding Allowable Damage Apply a patch by means of hot welding using hot air tool Leister Triac PID (or equivalent) set to 200ºC (392ºF). Apply heat to patch and panel, then apply pressure with a silicone pressure roller to create proper bonding. A minimum of 38 mm (1,5”) patch overlap must be welded to the panel being repaired. Inspect areas for improper welding. If required, apply heat to such areas and apply pressure with the silicone pressure roller again until proper welding is obtained. f)
Locks Severely damaged parts are to be replaced.
g)
Fabric A piece of new fabric, being 30 to 40 mm larger on all sides, must be welded to the existing fabric, or in the case of lengthier tears, sewn on. Adhesive should not be used. The corners of the repair material are to be rounded off.
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Repair of the door webbings General The webbing can be brought to a serviceable condition by repairing and/or replacing components which are damaged by rough usage, improper load or accidents. The amount and classification of damage determines the method of repair and/or replacement. For repair work standard aircraft methods and techniques shall be used. Repair work shall be performed as described in the following chapter and fulfill the requirements of chapter Inspection. The repair instructions as described in the following chapters can give a general view only upon general repair work, and may be used as guiding principles. CAUTION: REPAIR OF MINOR AND MAJOR DAMAGES REQUIRES AN INSPECTION FOR CONTINUING AIRWORTHINESS WHICH SHALL BE ATTESTED BY A CERTIFICATE OF INSPECTION FOR CONTINUING AIRWORTHINESS. Material:
Webbing
Material:
Thread
Polyester width 25 mm (1”) Min. breaking strength 20 kN (4409 lb) Polyester 550 dtex, S380-490x3Z 250-350 Min. average breaking strength 85 N (19 lb)
Webbing All materials used in the repair of webbings should be of the same or better quality and strength as those used in the original manufacture. 1.
Stitching Worn out and broken stitching shall be restitched with the original pattern and thread size after removal of old stitching (Fig. 1). CAUTION:
CUT OLD STITCHING WITH CARE TO PREVENT DAMAGE TO WEBBING.
2.
Webbing When webbing is damaged or torn to at least approx. 20% of its strands it should be repaired as shown in Fig. 2 Webbings have to be cut with a hot wire for searing ends.
3.
Hardware Due to the constructive characteristics of all hardware it is more practical to replace it than to perform a repair. Damaged hardware can be replaced as shown in Fig. 3 and 4. Repair procedure for broken webbing is also shown.
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Figure 3
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Figure 4
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Assembly Note: for Herculight panels only, reinforced panel edges should always face inwards of the container. Exception: only the reinforced area of the lower outb bottom that fixes to the base assembly has the reinforced area towards the outside of the container.
I.
Applicable for non-forkliftable container:
Procedure with two men is as follows: 1)
Place base on the workplace floor so that it is accessible from all sides.
2)
Bolt the shear panels forward left / right with the preassembled gussets onto the base by means of steel lockbolts. Note: posts have to be in vertical position. See fig. 1
3)
For backwall one piece: attach the backwall to the preassembled gussets onto the base by means of steel lockbolts. See fig. 1
4)
For backwall three piece: bolt the shear panels aft left / right with the preassembled gussets onto the base by means of steel lockbolts. See fig. 1a
5)
For backwall three piece: align and fix the backwall sheet by means of a lockbolt each. See fig. 1a
6)
Place the roof onto the shear panels forward and aft, left / right. Sheets outside, gussets inside. See fig. 2
7)
Align and fix sides outboard bottom together with Al-strips to the base, shear panels forward and aft, left / right by means of the assembly tools. For Herculight only, also fix an outboard bottom reinforcement strip, and washers between the side outboard bottom and lockbolt collars at the stiffeners attachment points (if applicable). See fig. 3 and fig. 3A
8)
Align and fix sides outboard top to the shear panels forward and aft, left / right, roof and sides out-board bottom by means of the assembly tools. See fig. 4
9)
Fix sides outboard bottom with Al-strips in the center to the base by means of a lockbolt each. See fig. 3
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10)
Fix sides outboard bottom and sides outboard top together with butt straps in the center by means of a lockbolt each. See fig. 4
11)
Install pull straps on sides outboard top, panels forward left / right and backwall by means of a lockbolt each. Note: lockbolt to be pulled from inside. See fig. 5
12)
Install the two securing straps from the roof flap to inside top of shear panels left/right and the strap with hook on the backwall. The securing straps will be installed at the 4th hole from left/right of the roof flap profile to the hole in center of shear panel left / right. The optimum roof flap opening angle after installation of the securing strap is 135° See fig. 6 and fig. 6a
13)
Install all lockbolts on sides outboard bottom/base with the gussets fwd/aft, sides outboard bottom/shear panels forward and backwall, sides outboard bottom/sides outboard top and sides outboard top/shear panels forward, backwall and roof together with gussets top (from inside). See fig. 7 and fig. 8
14)
Align and install all lockbolts backwall/roof. Installation to be made starting from middle of backwall sheet in order to have the sheet sitting close to the roof flange. Align and install the lockbolts shear panels fwd./roof. See fig. 8
15)
Place the door into the C-slotted section of the roof and secure it by means of screws left/ right. Fix the door diagonal webbings to the roof section in the prepared holes by means of steel lockbolts. See fig. 9
16)
Final assembly of container is then made by fixing all lockbolts, bolts, washers and nuts. Attention:
17) 18)
In order to have the sheets sitting close to the flanges, the lockbolts must always be set starting from the center to the edges. Corners, have to be sealed. Check whether container is assembled in accordance with above instructions, and that all fasteners are properly mounted and tightened and the door and sliding bolts can be closed and opened properly. Use the assembly tool (P/N 827070) to center the holes if necessary. The item numbers in the figures correspond to the item numbers in the detailed parts list figure 1.
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II. Applicable for forkliftable container
Procedure with two men is as follows: 1)
Place base on the workplace floor so that it is accessible from all sides.
2)
Screw panels forward left/right to the preassembled gussets onto the base. Note: posts have to be in vertical position. See fig. 10
3)
Fix the backwall together with distance strip backwall/base to the preassembled gussets onto the base by means of steel lockbolts. See fig. 10
4)
Place the roof onto the panels forward left/right and backwall. Sheets outside, gussets inside. See fig. 11
5)
Align and fix sides outboard bottom together with L-sections and Al-strips to the base, panels forward left/right and backwall by means of the assembly tools. For Herculight only, also fix a outboard bottom reinforcement strip, and washers between the side outboard bottom and lockbolt collars at the stiffeners attachment points. See fig. 12 and fig. 3A
6)
Align and fix sides outboard top to the panels forward left/right, backwall, roof and sides outboard bottom by means of the assembly tools. See fig. 4
7)
Fix sides outboard bottom with L-sections and Al-strips in the center to the base by means of a screw each. See fig. 12
.
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1 Now follow please the instructions under part I., from item 9. to 17
Detachment of Lock Bolts
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The assembly of the container is made by Magna-grip bolts. Nevertheless each magna-grip bolt can be replaced by. P/N
927026 screw 1/4” UNF/AN4-5A 927044 washer AN960-416 927043 nut 1/4” UNF/MS20364-428
Use magna-grip bolts/collars under consideration of following Inspection Data:
INSPECTION DATA
Attention: For magna grip installation only the nose assembly from Huck Manufactories Companies must be used.
HUCK P/N 99-1458
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*= for Herculight only
Fig. 3a
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Driessen AIS Europe BV Component Maintenance Manual Container Type H1
Storage Instructions Container Each container will be carefully packed into a cardboard box or on a pallet suitable for air, rail and road transport. Sea transport requires that the cardboard or pallet units are shipped in an approved ISO Container or under equivalent protection. The packed unit must be carefully protected from rain and moisture during transport and storage. Wet cardboard attacks the aluminium surface and results in a corrosion that cannot be removed. All shipments are to be inspected upon receipt since the transport insurance companies will only accept claims within a limited period. The container can be stored during an unlimited period in its cardboard box until assembly of unit. The quality of the sealing sections is to be checked only after more than five years.
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Special Tools, Fixtures and Equipment Assembly Tools
Part Number
1. Pneumatic installation tool incl. nose assembly
P/N 827016
2. Pneumatic installation tool without nose assembly
P/N 827011
3. Nose assembly for magna-grip
P/N 827017
4. Spanner for 1/4 ” hexagonal nuts with ratchet
Local supplier
5. Fork spanner for 1/4 ” hexagonal nuts
Local supplier
6. Assembly tool (recommendation use 16 pce) (see figure a)
P/N 827070
7. Collar break off tool (see figure b)
P/N 827005
8. Leister Triac PID (see figure c)
P/N P0000039 (for 120V) P/N P0000040 (for 230V)
9. Leister wide slot nozzle 40 mm (see figure d)
P/N P0000041
10. Leister one-arm pressure silicone roller 40 mm (see figure e)
P/N P0000042
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Fig. c:
Fig. e:
Leister Triac PID
Fig. d:
Leister wide slot nozzle
Leister pressure silicone roller
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Work Shop Equipment Normal equipment in use for metal sheet work is required, in particular a drilling machine and pneumatic hand tool for solid rivets, blind rivets and special bolts. A WIG welding machine is useful to repair damaged panel frames. There is no need for further special tools, jigs and gauges.
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Final Inspection a)
Basic requirements The advanced inspection is to be carried out by the manufacturer, a workshop approved by F.A.A., or by a local aviation administration.
b)
Extent All repairs except the repairs indicated on page 401 of this manual are to be inspected. All used materials must conform with the approved technical data and the repairs must conform with the standards described in this manual.
c)
Marking and advanced inspection certificate It is to confirm that all parts are marked with the part number, that the panels are marked with the manufacture and the latest repair date and inspection signed. The repair is to be certified in a locally approved form.
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Illustrated part list CONTAINER TYPE H1 SERIES H1-V-( ) Refer to Illustrated Part List 25-50-186 for spare part information and assembly
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