a Assembly manual RRM 594A DPN container - ABX Air 1222-40-0100Assembly manual i) Unique Load Dns Document information Date 01 October 2015 Issue 1 Prepared J.WJ.W. Rouwers AEE Checked B, Lanser Approved W.M. van der Velden Wn ud This document is confidential. All information contained herein is the sole property of Van Riemsdijk Rotterdam BV. No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be reproduced or disclosed to a third party without the express written consent of Van Riemsdijk Rotterdam BY. This document and its content shall not be used for any purpose other than that for which itis supplied.Assembly manual i) RRM 594A - DPN container - ABX Air— 1222-40-01 Urata Load Denes Index 2. Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi a) 2A FAStENETSnnnnninnnnnnninsninininnnninnninimsinsnnsmnnnnnnnnnnnnnnnnnin 2.6 MatkingSernnnn ssn nn 3 3. Required t00l5 mmm sna ol 4, Assemble instructions mmmmmnnnmnnnnnin snnnnnnnninnnsnnnnnnnneannnnnnie 16 41 Step 1: Assemble the pallet... susestsennseistanennonnenstnenaienstnennmnenennenasenensennomnsnse VD Required parts. seestsennennstnennenatntennsnnetntnennnenenntnvnntnttennounieninte owe V7 Required too! 7 Step 2: Fasten extrusions to the pallet ru.inmmsmiinninnnnniinnnsnnininmnnnnannsenl® Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi al9 Required t0015....unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi al9 Step Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi 2 : Assemble top base nuisnnsnsnnnnnsninnnnniinninnnnnnsnnnnnnsnnnsnsnnnnmnine 2 Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi 2 Step 4: Assemble Inboard panel vu.snnsnsnimnnninnnnnnnnninsninnnnnninnnnnsnsen 2 Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi on 2A Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi on 2A Step 5: Assemble Shear panel aftiumn nrsnnnnsnsnnnnnseinsninnnnsninnnnseD® Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi 226 Required t0015....unsn nistninnnniennnsnsiinnnnnssnsi 226 Step 6: Assemble Shear panel Front wrsnnnsnsnssnnsnnnniisnnnnsnn sno 29 Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi 229 Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi 229 ight VRRAssembly manual i) RRM 594A - DPN container - ABX Air— 1222-40-01 nit Load Desies 4.6.3 INStTUCION srnssnnnnnnninnnnnnnsi nisnnnsnninsnnnnnnsinsnininnsnsnininmnnnsne 3 47 Step7: ATA Required pattern nisnsnnnnnniesinnnsienninininiinnnnsnnisi 2033, 2033, 47.3 INSETUCTION sennnnnmnnnnnnnni srnnnnnitinnnnneinnnnnnnnnnenamnn 34 ISseMbe ROOF PANlveuinssnsnsnsnnnnnnsiennninnnnnnsinsnininnnaninnnnnssnniindS AT2 Required t00l$..rsnunso nistninnnniennnsnsiinnnnnssnsi 48 Step 8: Assemble the Solid d00fiu.s:mnsninnnninsinnnininnnnnininnnnnsinnmnnsnsnseenie ST 48.1 Required pattsorunnmuo nisnsnnnnnniesinnnsienninininiinnnnsnnisi 37 48.2 Required t00lS..rnunso nisnsnnnnnniesinnnsienninininiinnnnsnnisi 238 483 INSTTUCION srnssonnnninnininnnnsnsi minnie 38 4.9 Step 9:Place the panels..u.s:unsnsnsninnnisnnnnnnnnnnsnsi ennsnsinsnsnnnnnssenc 49.1 Required pattsonunnnun nisnsnnnnnniesinnnsienninininiinnnnsnnisi wn A3, 49.2 Required t00lS..runnnso nisnsnnnnnniesinnnsienninininiinnnnsnnisi wn A3, 4.9.3 INSTTUCLION srnssnnnsnnninnnnnnsi nrstnnnnnninnnnnnsinnnininnnsinnnnssnsnld 4.10 Step 10: Place parts on outboard Sid€..numninsninninninnininnnninnninnnnnnsennncA® 4.10.1 Required patts.nrnunso nisnsnnnnnniesinnnsienninininiinnnnsnnisi AB, 4.10.2 Required t00IS..rnunso nisnsnnnnnniesinnnsienninininiinnnnsnnisi AB, 4103 INStTUCION srnssennsnnninnnnnnnsn nrsnnninsnnnnnnnsnnininnnnsnnnmnssnsin Ad 4.11 Step 11:Place internal extrusions ..u.u.nnsnninninnnnnninnnnninnnininnnnsnnansnnnneS2 BALI Required pattem rnin 52 AML2 Required t00|$.emnmnn rnin 52 A113 INStTUCION srnssennnnnninnnnninsn minnnnninsnnnnnnsinnsninnnsnsnnnmsnsnsnnn SS 4.12 Step 12: Place interior extrusions 07 BASC.nunnsnnsnnnnnnninannnnnnninsnsi ann.) ss 256 4.12.2 Required t00lS..csnunso nisnsnnnnnniesinnnsienninininiinnnnsnnisi 256 412.1 Required pattsnnunumio mists A123. INSTTUCHION sensi snsinininainnnsmnnnninnnnamnnannnssneST 4.13 Step 13: Place Interior extrusions to roof. 8 4.13.1 Required pattSnmmnn sna 58 58 4.13.3 INStUCtION senmmnnnnmnonnn snsnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnSS 4.14 Step 14: Assemble Outboard shelf wmmnmnnnnsnnnnnnnnnninnnnnnn rn 59 414.1 Required patts.nmmnn sna 59 4.13.2 Required t00lS..csnmnso nistninnnniennnsnsiinnnnnssnsi 414.2 Required t00lS..cununso nisnsnnnnnniesinnnsienninininiinnnnsnnisi 59 4143 INStTUCION srnssennsnsnninnnnnsnsi nisnnnniinnnnnnsinsiininnnsninnnnsnsns6O 4.15 Step 15: Assemble the Outboard top Shelf s.u.nu.sniinnansnninnninnnnnisnnnnnnsnnnnsnnel © Copyright VARAssembly manual RRM 59. 415.1 4.15.2 4153 4.16 4.16.1 4.16.2 4.16.3 417 4171 417.2 4173 418 418.1 4.18.2 4.183 419 4.19.1 4.19.2 4.193 4.20 4201 4.20.2 4.203 421 4211 422 4213 422 422.1 4.22.2 4223 423 423.1 4.23.2 DPN container - ABX Air — 1222-40-01 Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 16: Assemble the Inboard top Shelf sru.snnsnsnnnnnnssn enn Required parts..unn Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 17: Assemble Cross DeAM ssnunsnsnnsnsennnsnnsnsiinnninninisninannnnnmnsnnsi Required parts..unn nistninnnniennnsnsiinnnnnssnsi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 18: Stanchion frame uruisssnisnnsnnnninnninninanininnninniiennnsnsnn Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 19: Assemble Tube assemblruissnisnnnnninsnnsn enna Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 20: Installing interior in the ContaINET mi.mnsnsnnnsrnnnninnnnenn Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 21: Assemble RAMP vruinuisnsnsiinnnnsnsnnininnnainiinnsnnnnennnsnsnsi Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required tool INStrUCtION ..e Step 22: Seal the containers nistninnnniennnsnsiinnnnnssnsi Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Step 23: Place Pull straPS.snunuinsnsnsnnnnsnsinniininnnniniiennnnnnnnnsninsi Required parts..unn nisnsnnnnnniesinnnsienninininiinnnnsnnisi Required t0015....unsn nisnsnnnnnniesinnnsienninininiinnnnsnnisi ight VRR ® nit Load Desies 61 61 v2, 64 a4, a4, eS 66 66 66 vse T 68 68 68 en69 n oT oT svn sername 2 wT wT ve 7 aT 7 one ne 80 80 80 one 82 82 82Assembly manual i) RRM 594A DPN container X Air 1222-40-0100 4.23.3 Instruction 424 Step 23: Place Solid door. 4.24.1 Required parts... 4.24.2 Required tool: 4.243 Instruction 425 Step 25: Place Marking 4.25.1 Required parts... 4.25.2 Required tools. 4.25.3 Instruction. 4.26 Step 25: Final inspection... Appendix A. © Copyright VAR 7 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Unt Lad Deszes 1. General This assembly manual has been written to describe the assembly procedure of the DPN container with the following part number: 1222-40-0100. The container is aairworthy product and has to be assembled in a certified repair station or certified assembly facility. In this manual you can find a list of the required materials, tools and instructions how to assemble the container, Al partsin this kit are properly marked and the part numbers on the parts correspond with the part numbers mentioned in this assembly manual © Copyright VRR 8 of 89Assembly manual i) nit Load Desies 2. Required parts The following parts are required to assemble the DPN container: 2.1 Extrusions Qty. Description Part number Remarks 2 Tube (40x40x3) 2000-00-6652 1 Tube (50x50x3) 2000-00-6653 1 Tube (50x25x3) 2000-00-6715 1 Tube (50x50x3) 2000-00-6732 1 Tube (50x30x3) 2000-00-6733 20 Lextrusion 2000-00-6755 2 Lextrusion 20X20X3 2000-00-6935 2 Lextrusion 20X20X3 2000-00-6936 2 Lextrusion 60X20X3 2000-00-6937 2 Extrusion RR115 2000-01-4245 1 Tube (40x40x3) 2000-01-9602 1 Extrusion RR104 2000-01-9884 1 Extrusion RR106 2000-01-9896 1 Tube (50x15x2) 2000-01-9966 1 Extrusion RR109 2000-02-0563 2 Extrusion RR115 2000-02-3797 2 Extrusion RR110 2000-02-3800 4 Extrusion RR110 2000-02-3803 20 = Tube 120x30x3 2000-02-3804 1 Lextrusion 25X25X3 2000-02-3806 1 Lextrusion 25X25X3 2000-02-3807 4 Lextrusion 60X20X3 2000-02-3810 2 Lextrusion 60X20X3 2000-02-3811 1 Extrusion RR104 2000-02-3815 1 Extrusion RR104 2000-02-3816 2 Extrusion RR109 2000-02-3819 1 Extrusion RR104 2000-02-3823 1 Extrusion RR104 2000-02-3824 1 Extrusion RR101 2000-02-3827 1 Extrusion RR101 2000-02-3828 2 Tube (40x4) 2000-02-3832 2 Lextrusion (40x30x3) 2000-02-3838Assembly manual a eas = (eo es fe bec, es NANNNN Bend L-extrusion Extrusion 30x20x2 Extrusion 30x20x2 Extrusion RR106 Extrusion RR116 Extrusion RR116 Extrusion RR117 Extrusion RR116, Extrusion RR109. Extrusion 30x20x2 extrusion 25X25X3 Tube (50x25x3) Tube (50x25x3) Extrusion RR103 Extrusion RR104 Extrusion RR108, Seatrack 5002 Extrusion RR111 Extrusion RR111 Extrusion RR111 U-Extrusion 20x40x20x3, extrusion 40X40x3 Tube 13x1,50 2000-02-3840 2000-02-3845 2000-02-3849 2000-02-3922 2000-02-3943 2000-02-3945 2000-02-3947 2000-02-3949 2000-02-3951 2000-02-5341 2000-02-7501 2000-02-7696 2000-02-7697 2000-02-7699 2000-02-7707 2000-02-7709 RR1.008-000 RR4111.111 RR4.111.121 RR4.111.122 RR4.800.010 RR4.810.020 R7.230.000 nit Load DesiesAssembly manual Qty. Feo ro es ene N w Qty. oS A MS Ble 6 Sheets Description Sheet, bent: lock bracket Ramp lock plate Sheet, bent (alu.5754H12) Pallet Sheet (7021-T6: 3 mm) Sheet (base:alu.6082-16:3 mm) Sheet aft Lower Outboard Sheet Outboard sheet Sheet: shear front Sheet: roof Top Shelf sheet Shelf Bend sheet (RR113) Door sheet Sheet, bent: Ramp Top Shelf sheet Sheet: shear Aft Inboard sheet Metal Strip Sheet (plate:AISI 304:2 mm) Gussets Description Sheet (gusset) Sheet (qussetialu.6082-T6:2 mm) Gusset shelf beam Sheet (gussetialu.6082-T6:2 mm) Sheet (gusset:alu.6082-T6:2 mm) Sheet (qussetialu.6082-T6:2 mm) Sheet (qussetsalu.6082-T6:2 mm) Sheet (qussetialu.6082-T6:2 mm) Sheet (gusset:alu.6082-T6:2 mm) Sheet (gussetsalu.6082-T6:3 mm) Sheet (gussetialu.6082-T6:3 mm) Sheet (gussetialu.6082-T6:3 mm) Part number Remarks 2000-00-9576 2000-01-8783 2000-01-9960 2000-02-3798 2000-02-3805 2000-02-3812 2000-02-3820 2000-02-3821 2000-02-3825 2000-02-3829 2000-02-3843 2000-02-3847 2000-02-3942 2000-02-3946 2000-02-3957 2000-02-5340 2000-02-7679 2000-02-7708 RR1.070-004 RR7.200.020 Part number Remarks 2000-00-6811 2000-00-7175 2000-02-7706 RR6.203.011 RR6.203.021 RR6.203.031 RR6.203.041 RR6.203.061 RR6.203.091 RR6.303.011 RR6.303.031 RR6.303.051 nit Load DesiesAssembly manual i) nit Load Desies 2.4 Fasteners Qty. Description Part number Remarks. 40 BkSt.Auto-bulb 6.4 BK-ABP-R8-MS 282 BkSt. Auto-bulb 6.4 BK-ABP-RE-M6 24 BkSt. Auto-bulb 64 BK-ABP-RE-M9 258 CskSt. Magna-lok6.4 BK-MGL100-R8-8 304 BkSt Magnalok6.4 BK-MGLP-R8-6 2 Magna-grip Alu. BK-MGPB-E8-10 2 Magnagrip Collar Alu. BK-MGCF8 457 VGrip Rivet (Stee!) BK-VG21-04810511 4 VGrip Rivet (Stee!) BK-VG21-04816511 2 Plain Washer Large B0-7093-08-A2 2 Wood Washer B0-7094-06-A2 8 —_ Nord-Lock Washer M6 BO-NORDLCK-06-44 8 Torx Socket Button Screw 80-7380T-06016-A2 © Copyright VARAssembly manual 25 Qty. VRRRNSsvetansssunnage Qty. = an a ee ee Loose items Description Lock Pin levis pin with head AKN flight kit Net Strap 45 mm. Wheel strap-Buckle part Safety Walk strip Hinge Strap Velcro Hook Locking Pin Assy Cornerpiece Base Net Bracket (alu) CORNERPIECE Grasp Handle Grasp Handle Pull Strap Red Twisted Drukveer D-190E Lanyard 6" Cableclamp steelcable 2mm Hairpin Spring Tube of sealant (grey) Markings Description TSO Plate ID Sticker Weight Marking Markings: Do not remove Marking: logo Marking: logo Marking: Black/Red strips Marking: Black/Red strips Marking: Black/Red strips Marking: Black/Red strips Cardholder Red nit Load Desies Part number Remarks 2000-00-6780 2000-00-6895 2000-00-7059 2000-01-7191 2000-01-7193 2000-01-8299 2000-02-3955 2000-02-7733 2000-02-7735 RR3.407.010 RR7.110.010 RR7.220.085, RR7.310.010 RR7.400.060 RR7.400.063 RR8.930.115 VE-D-190E BO-CL102-KAO6 SL-KABEL_2_KLEM VE-11024D-25 LESIL.SEALAT.TRGRUS Part number Remarks 2000-02-3925 2000-02-3927 2000-02-5345 2000-02-5346 2000-02-5385 2000-02-5387 2000-02-7719 2000-02-7720 2000-02-7721 2000-02-7722 RR1,070-105Assembly manual 3. Required tools The following tools are required to assemble the container: Description 1 Rivetgun 2 Rivet gun 3 Bonding plug (green) 4 Bonding plug (white) 5 Sealant gun 6 Combination pliers 7 Torx screwdriver 730 Part number Proset 3400 Proset 2500 ® nit Load Desies Remarks Can be used forthe following rivets: BK-MGL100-R8-8 BK-MGLP-R8-6 BK-ABP-R8-M5 BK-ABP-R8-M6 BK-ABP-R8-M9. Can be used forthe following rivets: > BK-VG21-04810-511 » BK-VG21-04816-511 Can be used to temporarily bond the sheets and gussets with holes of 04.8. Can be used to temporarily bond the sheets and gussets with holes of 06.4 To seal the container Can be used to make cable assemblies Can be used to fasten and loosen screws veyyyAssembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 TT ne _@ © Copyright VAR 15 of 89Assembly manual i) nit Load Desies 4, Assemble instructions In this chapter you can find an extensive description how toassemble the DPNcontainer. ‘A minimum of two persons is required to assemble the container. Alwaysmake sure that the assembly of the container takes place in a safe environment to prevent accidents will happen. The assembly of the container has beendivided in several steps. In each step we will describe the required partsand tools. The following steps are defined: 1 Assemble the pallet 2 Fasten extrusions to the pallet 3. Assemble top base 4 Assemble Inboard panel 5 Assemble Shear panel aft 6 Assemble Shear panel Front 7 Assemble Roof panel 8 Assemble Solid door 9 Place the panels 10 Place parts on outboard side 11 Place internal extrusions 12 Place interior extrusions on base 13 Place interior extrusions to roof 14 Assemble Outboard shelfs 15 Assemble the Outboard shelfs 16 Assemble the Inboard top shelf 17 Assemble Cross beam 18 Assemble Stanchion frame 19 Assemble Tube assembly 20 Installing interior in the container 21 Assemble Ramp 22. Seal the container 23 Place Pullstraps 24 Place Solid door 25 Place Markings 26 Final inspecti © Copyright VARAssembly manual RRM 594A DPN container 4.1 Step 1:Assemble the pallet 222-40-0100 ni Land Denes Slide cornerpieces in extrusions and use rivets to fasten extrusions to pallet sheet. 4.1.1 Required parts The following parts are required for this step: QTY. Description 1 Pallet Sheet 2 Extrusion RRI15 2 Extrusion RRI15 4 Cornerpiece Base 80 Csk. St. Magna-lok 6,4 4.1.2. Required tools The following tools are required for this step: Description Rivet gun 4.1.3 Instruction 1. Part number 2000-02-3798 2000-01-4245 2000-02-3797 RR7.110.010 BK-MGL100-88-8 Part number Proset 3400 /2000-01-4245}| 2000-02-3797, RR7.110.010 “ © Copyright VAR aAssembly manual i) RRM \- DPN container - ABX Air — 1222-40-0100 Unique Load Desices 2000-02-3798 BK-MGL100-R8-8} © Copyright VAR 18 0f89Assembly manual 42 4.2.1. Required parts The following parts are required for this step: QTY. Description 20 Tube 120x30x3 2 Extrusion RR110 4 Extrusion RR110 2 Extrusion RR111 2 Extrusion RRI11 2 Extrusion RR111 36 St. Magnatok 6,4 40 Csk.St. Magna-lok 06,4 nit Load Desies Step 2: Fasten extrusions to the pallet Fasten Tubes 120x30x3 to the pallet. Fasten RR110 and RR111 extrusions to the pallet. Do this according to picture 1 and 2. 4.2.2. Required tools The following tools are required for this step: Description Rivet gun © Copyright VAR Part number 2000-02-3804 2000-02-3800 2000-02-3803 RR4.111.111 RR4.111.121 RR4.111.122 BK-MGLP-R8-6 BK-MGL100-88-8 Part number Proset 3400 19 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes 4.2.3 Instruction 1. BK-MGL100-R8-8] [2000-02-3803| RR4.111.122] RR4.111.111 > (RR4.111.121] [2000-02-3803} RR4.111.121 RR4.111.117 gy RR4.111.122| BK-MGLP-R8-6| opyrtight VRR 200f89Assembly manual 4.3. Step 3:Assemble top base In this step you will complete the base. ® nit Load Desies » Picture 1: Fasten L-extrusion 60x20x3 to the inside of base, place the Sheet, bent on the outside. » Picture 2: Fasten L-extrusion 60x20x3 to the inside of base. » Picture 3: Fasten Floor sheet with countersunk rivets to tubes. » Picture 4: Fasten L-extrusion 25x25x3 on top of Floor sheet. 43.1. Required parts The following parts are required for this step: QTY. Description 1 Sheet, bent 1 Floorsheet P base 1 Lextrusion 25x25x3 1 Lextrusion 25x25x3 1 Lextrusion 25x25x3 2 Lextrusion 60x20x3 2 Lextrusion 60x20x3 2 Lextrusion 60x20x3 4 Lextrusion 60x20x3 2 Lextrusion 60x20x3 40 Csk, St. Magnalok @ 6,4 96 St. Magnalok 6,4 4.3.2. Required tools The following tools are required for this step: Description Rivet gun © Copyright VAR Part number 2000-01-9960 2000-02-3805 2000-02-3795 2000-02-3806 2000-02-7501 2000-00-6935 2000-00-6936 2000-00-6937 2000-02-3810 2000-02-3811 BK-MGL100-R8-8 BK-MGLP-R8-6 Part number Proset 3400 21 0f 89Assembly manual RRM 594A- DPN container - ABX Air — 1222-40-0100 4.3.3, Instruction 1 nit Load Desies [2000-00-6936| 2000-00-6937| [2000-00-6935] [2000-01-9960] |2000-00-6935} BK-MGLP-R8-6| 2 2000-02-3811 |2000-02-3810} © Copyright VRR [2000-02-3810] “SY [B-MGLP-R8-6| [2000-02-3811 22 of 89Assembly manual ea RRM 594A- DPN container - ABX Air — 1222-40-0100 Unique Lead Devices BK-MGL100-R8-8] [20-02-3805] |2000-02-3806) BK-MGLP-R8-6| [2000-02-7501 |2000-02-3807) © Copyright VRR 2 of 89Assembly manual Be nit Load Desies 44 Step 4: Assemble Inboard panel In this step you will assemble the Inboard panelof the container. » Picture 1: Place marking on sheet as shown, pierce all holes that are covert by the marking. Holes in the red circle need to be in the top right corner. Degrease sheet before applying marking, » Picture 2: Fasten parts withV-grip rivets from inside. Pay close attention how the rivets are placed. 4.4.1. Required parts The following parts are required for this step: QTY. Description Part number 1 Inboard sheet 2000-02-7708 1 Extrusion RR104 2000-01-9884 1 Extrusion RR104 2000-02-7707 1 Marking: Black/Red strips 2000-02-7719 26 Vatip rivet BK-VG21-04810-511 44.2. Required tools The following tools are required for this step: Description Part number Rivet gun Proset 2500 4.4.3 Instruction 1. mm 2000-02-7708} 2000-02-7719| BOTTOMAssembly manual i) 1222-40-0100 nit Load Desies RRM 594A - DPN container BK-VG21-04810-511 Perre ggg f(y rrr tidg gy 2000-02-7707 2000-02-7708 2000-01-9884 © Copyright VAR 25 of 89Assembly manual i) 45 nit Load Desies Step 5: Assemble Shear panel aft In this step you will assemble the shear panel aft. » » » » 45.1 Picture 1: Place marking on sheet as shown, pierce all holes that are covert by the marking. Degrease sheet before applying marking, Picture 2: Fasten parts with bounding plugs. Picture 3: Place V-grip rivets from inside. Picture 4: Place Autobulb rivets from inside, Required parts The following parts are required for this step: ary. 29 Description Part number Sheet; Shear Aft 2000-02-7679 Extrusion RR104 2000-02-3823 Extrusion RR104 2000-02:3824 Extrusion RR106 2000-01-9896 Gusset RR6.203.031 Gusset RR6.203.061 Marking: Black/Red strips 2000-02-7721 Autobulb 06.4 BK-ABP-R8-M6 V-grip rivet BK-VG21-04810-511 4.5.2. Required tools The following tools are required for this step: Description Part number Rivet gun Proset 2500 Rivet gun Proset 3400 Bonding Plugs (White) -Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes 4.5.3 Instruction 1. [2000-02-7679| [2000-02-7721 [2000-02-7679| 12000-02-3824] RR6.203.031] |2000-01-9896) & Y a. . (le. 2 [2000-02-3823] NS com opytight VRR 27 of 89Assembly manual RRM 594A- DPN container - ABX Air — 1222-40-0100 [BK-VG21-04810-511 ase []BK-ABP- z '8-M6| © Copyright VRR nit Load Desies 28 of 89Assembly manual i) nit Load Desies 4.6 Step6: Assemble Shear panel Front In this step you will assemble the shear panel aft. Picture 1: Place marking on sheet as shown, pierce all holes that are covert by the marking Picture 2: Fasten parts with bounding plugs. Picture 3: Place V-grip rivets from inside. Picture 4: Place Autobulb rivets from inside, Picture 5: Fasten parts with -grip rivets. veyey 4.6.1 Required parts The following parts are required for this step: QTY. Description Part number 1 Sheet; Shear Aft 2000-023825 2 Reinforcement plate RR7.200.020 1 Extrusion RR104 2000-023815 1 Extrusion RR104 2000-023816 1 Extrusion RR106 2000-02392 1 Gusset RR6.203.031 1 Gusset RR6.303.051 1 Marking; Black/Red strips 2000-02-7721 10 Autobulb 06.4 BK-ABP-RE-M6 33 V-grip rivet BK-VG21-04810511 46.2. Required tools The following tools are required for this step: Description Part number Rivet gun Proset 2500 Rivet gun Proset 3400 Bonding Plugs (White) -Assembly manual i) nit Load Desies 4.6.3 Instruction 1. [20-02-3825 2000-02-7721 2000-02-3815| | 2000-02-3825| I. RR6.203.031 /2000-02-3922 '2000-02-3816| RR6.303.051 © Copyright VAR 30 of 89Assembly manual i) 1222-40-0100 DPN container - ABX Air Uniqs Load Devices RRI ! i i BK-VG21-04810-511 BK-ABP-R8-M6) 31 of 89 © Copyright VRRAssembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies BK-VG21-04810-511 IRR7.200.020) Ko © Copyright VRR 320f89Assembly manual i) nit Load Desies 47 Step7:Assemble Roof panel In this step you will assemble the Roof panel Picture 1: Connect the 4 Extrusions (RR101 and RR103) to each other with Cornerpieces. Picture 2: Fasten Roof sheet, Gussets and Extrusion RR109 to frame extrusions with bonding plugs. Picture 3: Fasten Roof sheet with V-grip rivets to the extrusions. Picture 4: Place Gussets and Extrusion RR1090n the inside and fasten with Autobulb M6 rivets. Place rivets from the outside. Picture 5: Fasten 5 Net brackets to Extrusion RR109 with Autobulb M9 rivets. Fasten also Extrusion R109 to roof sheet with 3 V-grip rivets. Place rivets from the outside. veey x 4.7.1 Required parts The following parts are required for this step: QTY. Description Part number 1 Roof sheet 2000-02-3829 4 Sheet, Gusset RR6.203.011 4 Sheet, Gusset RR6.203.021 1 Extrusion RR101 2000-02-3827 1 Extrusion RR101 2000-02-3828 2 Extrusion RR108 2000-02-7699 1 Extrusion RR109 2000-02-0563 5 Net bracket RR7.220.085, 4 Comerpiece RR7.310.010 40 Autobulb 06.4 BK-ABP-R8-M6 10 Autobulb 06.4 BK-ABP-R8-M9 59 V-grip BK-VG21-04810-511 4.7.2. Required tools The following tools are required for this step: Description Part number Rivet gun Proset 2500 Rivet gun Proset 3400 Bonding Plugs (White) -Assembly manual i) RRM \- DPN container - ABX Air — 1222-40-0100 Unique Load Desices 4.7.3 Instruction [2000-02-3828) [2000-02-7699] [2000-02-3827] [2000-02-7699] RR7.310.010] RR6.203.011 RR6.203.021 |2000-02-3829} © Copyright VRRAssembly manual i) RRM 594A- DPN container - ABX Air— 1222-40-0100 Uniqs Load Devices aa prttt Hl BK-VG21-04810-511 |2000-02-3829| BK-ABP-R8-M6| opytight VRR 35 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes BK-ABP-R8-M9} RR7.220.085} © Copyright VRR 36 0f 89Assembly manual i) 48 nit Load Desies Step 8: Assemble the Solid door In this step you will assemble Solid door 48.1 » veyy ve Picture 1: Place Marking on sheet as shown, pierce all holes that are covert by the Marking, Mind the orientation of the sheet. Degrease sheet before applying Marking. Picture 2: Slide L-extrusion inside extrusions (RR116, RR117 and RR118). Picture 3: Place Door sheet, Gussets and Extrusion RR109 and fasten with bonding plugs. Picture 4; Fasten Door sheet and Extrusion RR109 with V-grip rivets Picture 5: Fasten Gussets and Extrusion with Autobulb M5 rivets. Fasten Bend sheet to Extrusion R117 with Autobulb MS rivets, Picture 6: Fasten Grasp handle with Magna-grip and washers. Use V-grip for the Lock brackets. Picture 7: Assemble lock (Picture A), place locking pin through hole in extrusion and fasten with V-grip rivets (BK-VG21-04816-511) (Picture B). Picture 8: Fasten Net bracket with Strap on the inside of the door with Autobulb M9 rivets. Fasten Velcro Hook with V-grip rivets. Required parts The following parts are required for this step: ary. = > Be Bo Bs ed — ed — ed Description Part number Sheet, bent; lock bracket 2000-00-9576 Bend sheet (RR113) 2000-023942 Door sheet 2000-02-3946 Sheet (gussetialu.6082-Te RR6.203.091 Sheet (gussetialu.6082-Te RR6.203.011 Hinge 2000-02-3955 Strap 2000-02-7733 Extrusion RR118 2000-023943, Extrusion RR116 2000-02-3945 Extrusion RR117 2000-02-3947 Extrusion RR116 2000-02-3949 Extrusion RR109 2000-023951 Lextrusion 40X40X3 RR4.810.020 U-Extrusion 20x40x20x3 RR4.800.010 Grasp handle RR7.400.063 Net Bracket (alu) RR7.220.085 Velcro Hook 2000-02-7735 Locking Pin Assy RR3.407.010 ‘Compres. Spring D-190E VE-D-190E Marking: Black/Red strips 2000-02-7722 BkSt. Auto-bulb 6.4 BK-ABP-RE-MS BkSt. Auto-bulb 6.4 BK-ABP-R8-M9Assembly manual Be nit Load Desies 95 V-grip Rivet (Steel) BK-VG21-04810-511 V-grip Rivet (Steel) BK-VG21-04816-511 2 Magna-Grip Alu. Bolt BK-MGPB-E8-10 2 Magna-Grip Alu. Collar BK-MGC-F8 16 BkSt. Magnalok 6,4 BK-MGLP-R8-6 2 Plain Washer Large BO-7093-08-A2 48.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Bonding Plugs (White) B 4.8.3 Instruction 1 2000-02-3946) 2000-02-7722|Assembly manual i) RRM 594A - DPN container - ABX Air— 1222-40-0100 nit Load Desies RR6.203.011 © Copyright VAR 39 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies BK-VG21-04810-511 IBK-ABP-R8-M5| |2000-02-3942| © Copyright VRR 40 of 89Assembly manual Be RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies '2000-00-9576] '2000-02-3955| BK-VG21-04810-511 60. 7053-08-87 RR7.400.063) BK-MGPB-E8-10+BK-MGC-F8| =J eT BK-VG21-04816-511| © Copyright VRR 41 of 89Assembly manual i) DPN container - ABX Air—1222-40-0100 Uniqs Load Devices © Copyright VRR 42.0f 89Assembly manual i) nit Load Desies 4.9 Step9:Place the panels In this step you will assemble the panels onthe container: Picture 1:Fasten Inboard, Shear Front and Shear Aft panel with bonding plugs to the base. Picture2: Fasten Gussets to base and Inboard Panel. Picture 3: Fasten Roof panel and Gusset with bonding plugs to theother panels. Picture 4: Place Marking on sheet as shown, pierce all holes that are covert by the Marking, Mind the orientation of the sheet. Degrease sheet before applying Marking, Picture 5: Fasten Sheet aft with V-grip rivets to container. Place also the V-grip rivets in the Inboard panel as shown, Picture 6: Fasten all Gussets on the Aft and Inboard side with Autobulb Mé rivets. Picture 7: Fasten Gussets to Shear Front panel and Roof panel. Use Autobulb M6 rivets. Place also 1V-grip rivet (shown with red line). » Picture &: Fasten all Gussets around door opening with Autobulb M6 rivets. Place rivets from the outside. voveyy ve 4.9.1. Required parts The following parts are required for this step: QTY. Description Part number 1 Base 1 Shear Front Panel - 1 Shear Aft Panel - 2 Inboard Panel - 1 Roof Panel - 8 Sheet (gusset) RR6.203.011 1 Sheet (gusset) RR6.203.041 2 Sheet (gusset) RR6.303.011 1 Sheet (gusset) RR6.303.031 1 Sheet Aft 2000-02-3812 1 Marking: Black/Red strips 2000-02-7720 92 Vgrip rivet (steel) 04.8 BK-VG21-04810-511 72 Autobulb 06.4 BK-ABP-R8-M6 4.9.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Bonding Plugs (White) -Assembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 4.9.3 Instruction a [Shear Aft Panel] 4{RR6.203.011 a RR6.303.011) © Copyright VRR 44 of 89Assembly manual Be (eee 3. Roof Panel RR6.203.047}~_ > RR6.203.011 ey RR6.303.011 RR6.203.011| fi. 7 % I RR6.303.031 4 961mm [2000-02-3812 2000-02-7720Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies © Copyright VRR 46 of 89Assembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 7. BK-VG21-04810-511] | > i 8 © Copyright VRR [BK-ABP-R8-M6| nit Load Desies BK-ABP-R8-M6 47 of 89Assembly manual ® nit Load Desies Step 10: Place parts on outboard side step you will place the parts on the outboard side. » Picture 1: Fasten parts with bonding plugs to the container. » Picture 2: Place Marking on sheet as shown, pierce all holes that are covert by the Marking, Mind the orientation of the sheet. Degrease sheet before applying Marking. » Picture 3: Fasten Outboard sheet with bonding plugs to the container. » Picture 4: Place the V-grip rivets from the inside. » Picture 5:Place Autobulb at given loc: 4.10.1 Required parts The following parts are required for QTY. Description 2 Extrusion RR109 Extrusion RR108 Lower Outboard sheet Outboard sheet Sheet (gusset) Sheet (gusset) Marking: Black/Red strips 72 V-griprivet (steel) 04.8 40 Autobulb 06.4 es ee 4.10.2 Required tools The following tools are required for Description Rivet gun Rivet gun Bonding Plugs (White) is step: ns from the inside, Part number 2000-02-3819 2000-02-7709 2000-02-3820 2000-02-3821 RR6.203.011 RR6.203.021 2000-02719 BK-VG21-04816-511 BK-ABP-R8-M6 Part number Proset 3400 Proset 2500Assembly manual Be nit Load Desies 4.10.3 Instruction 2000-02-3820}5 2000-02-7709) RR6.203.0211 RR6.203.011 2000-02-3821}— 2000-02-7719Assembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 3. ® nit Load Desies RR6.203.011 20-02-3821 RR6.203.021 Kf bel] 4BK-VG21-04810-517 © Copyright VRR 50 of 89Assembly manual i) RRM 594A - DPN container - ABX Air— 1222-40-0100 nit Load Desies BK-ABP-R8-M6| © Copyright VRR 51 of 89Assembly manual i) nit Load Desies 4.11 Step 11: Place internal extrusions In this step you will place the internal extrusions: » Picture 1: Slide the Gusset in the Tube and fasten with bounding plugs to the outboard side of the, container. » Picture 2:Place Autobulb rivets (black lines) and V-grip rivets (red lines) from outside. » Picture 3: Slide the Gusset in the tube and fasten with bounding plugs to the outboard side of the container. » Picture 4: Place Autobulb rivets (black lines) and V-grip rivets (red lines) from outside. » Picture 5: Place the Tube to the aft sheet in the container » Picture 6: Place V-grip rivets (red lines) from outside. 4.11.1 Required parts The following parts are required for this step: QTY. Description Part number 1 Tube 50x15x2 2000-01-9966 2 Tube 50x25x3 2000-02-7696 2 Tube 50x25x3 2000-02-7697 4 Gusset shelf beam 2000-02-7706 40 Vgriprivet (steel) 04.8 BK-VG21-04810-511 56 Autobulb 06.4 BK-ABP-R8-M6 4.11.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Bonding Plugs (White) - © Copyright VARAssembly manual i) nit Load Desies 4.11.3 Instruction 1. == —) me WUT ee) i | wT | | . i i 2000-02-7696]} \ . | | "| . i [2000-02-7706) a | : ! lf : | 5 ol +{2000-02-7706] WW sal ‘ os [BK-ABP-R8-M6| BK-VG21-04810-511| © Copyright VARAssembly manual i) J |BK-VG21-04810-511 BK-ABP-R8-M6| © Copyright VAR 54 0f89Assembly manual RRM 594A - DPN container - ABX Air— 1222-40-0100 |2000-01-9966) v |BK-VG21-04810-511 © Copyright VRRAssembly manual ® nit Load Desies 4.12 Step 12: Place interior extrusions on base In this step you will assemble interior partson the base of the container: » Picture 1:First fasten Net brackets to Tube, then fasten Tubes and L-extrusions to base. » Picture 2: Fasten Seattrack to Tubes and L-extrusions. 4.12.1 Required parts The following parts are required for this step: QTY. Description 1 Tube (50x30x3) 1 Tube (50x30x3) 2 Lextrusion (40x30x3) 12. Seattrack 5002 5 Net bracket 44 Magnadok 06.4 24 Csk.Magnalok 06.4 4.12.2 Required tools The following tools are required for this step: Description Rivet gun © Copyright VAR Part number 2000-06715 2000-00-6733 2000-02-3838 RR1.008-000 RR7.220.085, BK-MGLP-R8-6 BK-MGL100-R8-8 Part number Proset 3400 56 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies 4.12.3 Instruction 1. BK-MGLP-R8-6| |2000-00-6733 '2000-02-3838| RR7.220.085] [2000-00-6715| 2000-02-3838] © Copyright VRR 57 of 89Assembly manual Be RRM 594A- DPN container - ABX Air — 1222-40-0100 nit Load Desies 4.13 Step 13: Place Interior extrusions to roof In this step you will place interior extrusions to the roof. Fasten rivets atthe front (door side) from the outside of the container. Fasten rivets at the aft from the inside of the container. See also picture 1. 4.13.1 Required parts The following parts are required for this step: QTY. Description Part number 2. Bend L-extrusion -2000-02-3840 16 Autobulb 06.4 BK-ABP-R8-M6 4.13.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 4.13.3 Instruction 1 |2000-02-3840} BK-ABP-R8-M6| © Copyright VRR 58 of 89Assembly manual ® nit Load Desies 4.14 Step 14: Assemble Outboard shelfs In this step you will assemble the 2 Outboard shelts. » Picture 1: Fasten Extrusions to shelf with csk. Magnaok rivets and fasten Net brackets with Magna-lok rivets. » Picture 2: Fasten Clevis pin assemblies to the shelf with csk. Magna-lok ‘Toassemble the Clevis pin assembly follow the steps: » Fasten lanyard to Hairpin spring with cable clamp. » Fasten lanyard toL-extrusion with a V-grip rivet. » Place the Clevis pin in theL-extrusion and place the Hairpin spri pin. in one of the holes of the Clevis 4.14.1 Required parts The following parts are required for this step: QTY. Description Part number 8 — Lextrusion (40x40x3) 2000-00-6755 6 Extrusion (30x20x2) 2000-02-3849 2 Shelf 2000-02-3847 8 — Clevis pin with head 2000-00-6895 10 Net bracket RR7.220.085 8 Hairpin spring VE-11024D-25 8 Lanyard 6" BO-CL102-KA06 8 — Cableclamp steelcable 2mm SLKABEL_2_KLEM 8 VGriprivet (steel) 048 BK-VG21-04810-511 20 Magnaok 06.4 BK-MGLP-R8-6 62 Csk. Magnaok 06.4 BK-MGL100-R8-8 4.14.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Combination pliersAssembly manual RRM 594A- DPN container - ABX Air 4.14.3 Instruction BK-MGL100-R8-8] 1. 2000-02-3847) /2000-02-3849 1222-40-0100 nit Load Desies BK-MGLP-R8-6] RR7.220.085} BK-MGL100-R8-8| [2000-00675] BK-VG21-04810-511 [BO-CL102-Ka0g (SLKABEL_2 KLEM [2000-00-685} '2000-00.6755] © Copyright VRR |Clevis Pin assembly} 60 of 89Assembly manual i) nit Load Desies 4.15 Step 15: Assemble the Outboard top shelf In this step you assemble the Outboard top shelf. Do this according pictures 1-3. Assemble Clevis pin assembly as shown in chapter 4.14 4.15.1 Required parts The following parts are required for this step: QTY. Description Part number 6 — Lextrusion (40x40x3) 2000-00-6755 3° Extrusion (30x20x2) 2000-02-3845 1 Tube (40x40x3) 2000-01-9602 1 Top Shelf Sheet 2000-02-3843 1 Ramp lock plate 2000-01-8783 6 — Clevis pin with head 2000-00-6895 10 Net bracket RR7.220.085, 6 Hairpin spring VE-11024D-25 6 Lanyard 6” BO-CL102-KA06 6 — Cableclamp steel cable 2mm SL-KABEL_2_KLEM 6 Vegriprivet(steel) 948 BK-VG21-04810-511 22 Magnaok 06.4 BK-MGLP-R8-6 69 Csk. Magna-lok 06.4 BK-MGL100-R8-8 4.15.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Combination pliers -Assembly manual Be RRM 594A- DPN container - ABX Air — 1222-40-0100 4.15.3 Instruction 2000-02-3843 2000-01-9602 BK-MGL100-R8-8 1 Clevis Pin assembly © Copyright VRR 62 of 89Assembly manual Be RRM 594A- DPN container - ABX Air— 1222-40-0100 Unique Lead Devices BK-MGLP-R8-6| owe RR7.220.085) /2000-01-8783} © Copyright VRR 63 of 89Assembly manual i) nit Load Desies 4.16 Step 16: Assemble the Inboard top shelf In this step you assemble the Inboard top shelf. Do this according picture 1. Assemble Clevis pin assembly as shown in chapter 4.14, 4.16.1 Required parts The following parts are required for this step: QTY. Description Part number 4 Lextrusion (40x40x3) 2000-00-6755 3. Extrusion (30x20x2) 2000-02-5341 1 Top Shelf Sheet 2000-02-5340 4 Clevis pin with head 2000-00-6895 4 Hairpin spring \VE-11024D-25 4 Lanyard 6” BO-CL102-KAO6 4 Cableclamp steelcable 2mm SL-KABEL_2_KLEM. 4 Vegrip rivet (steel) 94.8 BK-VG21-04810-511 37 Csk. Magnatok 06.4 BK-MGL100-R8-8 4.16.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Combination pliers - © Copyright VARAssembly manual Be RRM 594A- DPN container - ABX Air— 1222-40-0100 Unique Lead Devices 4.16.3 Instruction 1 BK-MGL100-R8-8} 2000-02-5341 2000-02-5340) Clevis Pin assembly © Copyright VRR 65 of 89Assembly manual nit Load Desies 4.17. Step 17: Assemble Cross beam In this step you will assemble the Cross beam Do this according to pictures 1 and 2. Fasten Lanyard to Hairpin spring as described in chapter 4.14. 4.17.1 Required parts The following parts are required for this step: QTY. Description 1 Tube (40x40x3) Sheet Gusset levis pin with head Hairpin spring Lanyard 6” Cableclamp steelcable 2mm Vegrip rivet (steel) 04.8 Magna-ok 06.4 a 4.17.2 Required tools The following tools are required for this step: Description Rivet gun Rivet gun Combination pliers Part number 2000-00-6653 2000-00-6811 2000-00-6895 VE-11024D-25 BO-CL102-KA06 SL-KABEL_2_KLEM BK-VG21-04810-511 BK-MGLP-R8-6 Part number Proset 3400 Proset 2500Assembly manual Be RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes 4.17.3 Instruction 1 r BK-VG21-04810-511 |2000-00-6653 BO-CL102-KA06| SL-KABEL_2_KLEM} \VE-11024D-25 SZ BK-MGLP-R8-6] |2000-00-6811 BK-VG21-04810-511 2000-00-6895) 2000-00-6653} BO-CL102-KA06} WVE-11024D-25, SL-KABEL_2_KLEM) BK-MGLP-R8-6| |2000-00-6811 © Copyright VRR 67 of 89Assembly manual i) nit Load Desies 4.18 Step 18: Assemble Stanchion frame In this step you will assemble the Stanchion frame. Do this according to pictures 1, 2 and 3. At picture 1 and 2 note how thenet brackets are placed on top of the gussets. Fasten Lanyard to Hairpin spring as described in chapter 4.14 4.18.1 Required parts The following parts are required for this step: QTY. Description Part number 1 Tube (40x40x3) 2000-00-6652 1 Tube (40x30x3) 2000-06732 4 Sheet Gusset 2000-00-7175 5 Net bracket RR7.220.085 4 Clevis pin with head 2000-00-6895 4 Hairpin spring VE-11024D-25 4 Lanyard 6” BO-CL102-KA06 4 Cableclamp steelcable 2mm SLKABEL_2_KLEM 4 Voriprivet (steel) 04.8 BK-VG21-04810-511 30 Magna-lok 06.4 BK-MGLP-R8-6 4.18.2 Required tools The following tools are required for this step: Description Part number Rivet gun Proset 3400 Rivet gun Proset 2500 Combination pliers -Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes 4.18.3 Instruction [2000-00-6732| '2000-00-7175| BK-MGLP-R8-6| [2000-00-6652| (2000.00:7175| [BKNGLP REG) RR7.220.085] BK-MGLP-R8-6],. opytight VRR 69 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes © Copyright VRR 70 0f89Assembly manual i) RRM 594A - DPN container 222-40-0100 XAir—1 dra Lind evn 4.19 Step 19: Assemble Tube assembly In this step 2 Tube assemblies will be assembled Do this according to picture 1 4.19.1 Required parts The following parts are required for this step: QTY. Description Part number 2 Tube (40x4) 2000-02-3832 4 Lock Pin 2000-00-6780 8 Nord-Lock Washer M6 BO-NORDLCK-06-44 8 Torx Socket Button Screw BK-7380T-06016-A2 4.19.2 Required tools The following tools are required for this step: Description Part number Torx screwdriver T30 - 4.19.3 Instruction 1. 2000-02-3832| ‘ex BO-NORDLCK-06-A4] 7 Kw 7 BO-7380T-06016-A2| © Copyright VAR 71 of 89Assembly manual i) nit Load Desies 4.20 Step 20: Installing interior in the container In this step the interior will be installed in the container. » Picture 1: Place the shelfs in the container > Picture 2: Shows the placement of the shelfs. Thered numbers are the number of holes between shelts. > Picture 3: Place stanchion frame in het container. Detail A shows how to fasten the frame to the roof and Detail B shows how to fasten the frame to the base. > Picture 4: Place straps at the tube assemblies. » Picture 5: Place the tube assemblies in the container. The red numbers are the number of holes between shelfs, » Picture 6: Place crossbeam and Top shelf Inboard the same way as the other shelfs. » Picture 7: Place the AKN flight kit Nets by fastening them to the net brackets that are located on the shelfs. 4.20.1 Required parts The following parts are required for this step: QTY. Description Part number Top shelf Outboard - Top shelf Inboard - Outboard shelf - Crossbeam - Stanchion frame - Tube assembly - AKN flight kit Net 2000-00-7059 Strap 45mm 2000-01-7191 Wheel strap buckle 2000-01-7193 PS) less es ee 4.20.2 Required tools The following tools are required for this step: Description Part number Torx screwdriver T30 -Assembly manual i) RRM \- DPN container - ABX Air — 1222-40-0100 Uniqs Load Devices 4.20.3 Instruction | 4 2. 2 ° eo yg ee ~ es q 7 Frop Outboard she 5 i . [Outboard shelf| . P| q © Copyright VAR 2 of 89Assembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 20-01-7191 —_ Tube assembly] [2000-01-7193] © Copyright VRR Thof89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 Urata Load Denes Top shelf inboard [Crossbeam| © Copyright VAR 75 of 89Assembly manual Be RRM 594A- DPN container - ABX Air — 1222-40-0100 Unique Lead Devices |2000-00-7059} © Copyright VRR 76 0f89Assembly manual i) nit Load Desies 4.21 Step21:Assemble Ramp. In this step you will assemble the Ramp. » Picture 1: Fasten Clevis pin assemblies with Magna-lok rivets to the ramp. See chapter 4.14 for more detail on how to assemble the Clevis pin assembly. » Picture 2: Fasten Grasp handles to the Ramp. » Picture 3: Degrease Ramp before placing Safety walk strips on the Ramp. » Picture 4: Place the Ramp in the container. 4.21.1 Required parts The following parts are required for this step: QTY. Description Partnumber 1 Sheet, bent; Ramp 2000-00-3957 3 Safety Walk strip 2000-01-8299 2 Grasp Handle R7.400.060 2 Clevis pin with head 2000-00-6895 2 Hairpin spring \VE-11024D-25 2 Lanyard 6” BO-CL102-KAO6 2 Cableclamp steel cable 2mm. SL-KABEL_2_KLEM 2 Veriprivet (steel) 04.8 BK-VG21-04810-511 8 — Magnadok 06.4 BK-MGLP-R8-6 6 — Csk.Magnatok 06.4 BK-MGL100-R8-8 4.21.2 Required tools The following tools are required for this step: Description Part number 1 Rivet gun Proset 3400 © Copyright VARAssembly manual RRM 594A - DPN container - ABX Air—1222-40-0100 4.21.3 Instruction 1 [BK-MGLP-R8-6] 7 RR7.400.060] BKNGLP-REGL © Copyright VRR @ nit Load Desies Clevis pin assembly [20-02-3957] BK-MGL100-R8-8] BO-7094-06-A2| *+——_|Bi-MGL100-R8-8| 78 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies 3. 2000-01-8299 © Copyright VAR 79 of 89Assembly manual i) RRM 594A - DPN container - ABX Air—1222-40-0100 nit Load Desies 4,22 Step 22: Seal the container In this step you have to seal the container as described below. Only use sealant on the red lines. 4.22.1 Required parts The following parts are required for this step: QTY. Description Part number 2 Tube of sealant (grey) LISIL.SEALAT-TR.GRUS 4.22.2 Required tools The following tools are required for this step: Description Part number 1 Sealant gun - 4.22.3 Instruction 1. opytight VRR 80 of 89Assembly manual i) RRM 594A- DPN container - ABX Air— 1222-40-0100 Uniqs Load Devices © Copyright VRR 81 of 89Assembly manual 4.23. Step 23: Place Pull straps nit Load Desies In this step you will place the Pull straps on the inboard and outboard side. Do this according to pictures 1 and 2. 4.23.1 Required parts The following parts are required for this step: QTY. Description 4 Net bracket 4 Pullstrap 8 — Autobulb M9 06.4 4.23.2 Required tools The following tools are required for this step: Description 1 Rivet gun © Copyright VAR Part number RR7.220.085 RR8.930.115 BK-ABP-R8-M9 Part number Proset 3400Assembly manual © Copyright VARAssembly manual RRM 5: |A- DPN container - ABX Air 4.24 Step 23: Place Solid door 1222-40-0100 nit Load Desies In this step you will place the Solid door. Do this according to picture 1. 4.24.1 Required parts The following parts are required for this step: QTY. Description 1 Solid door 17 Magna-Lok 06.4 4.24.2 Required tools The following tools are required for this step: Description Rivet gun 4.24.3 Instruction 1. ‘Solid Door} © Copyright VRR Part number BK-MGLP-R8-6 Part number Proset 3400 BK-MGLP-R8-6}Assembly manual 4.25 Step 25: Place Markings In this step you have to apply the stickers on the container. Degrease the container before applying the stickers. For this you have to use the Markings drawing in Apendix A. Besides the markings you also have to install the TSO-plate and document holder. Note: ® nit Load Desies Place the TSO plate with the lowest serial number and the ID stickers with the lowest ID Code on the same container! 4.25.1 Required parts The following parts are required for this step: QTY. Description eal fea) nfo — fn) — TSO Plate Cardholder Red Metal Strip Weight Marking ID Sticker Markings: Do not remove Marking: logo Marking: logo V-grip Rivet (Steel) 4.25.2 Required tools The following tools are required for this step: Description Rivet gun Part number 2000-02-3925 RR1.070-105 RR1.070-004 2000-02-5345 2000-02-3927 2000-02-5346 2000-02-5385 2000-02-5387 BK-VG21-04810-511 Part number Proset 2500Assembly manual i) RRM DPN container nit Load Desies 4.25.3 Instruction 1. 2000-02-3925 RR1.070-004} RR1.070-105 BK-VG21-04810-511 © Copyright VAR 86 of 89Assembly manual i) nit Load Desies 4.26 Step 26: Final inspection The container is fully assembled. The following things have to be checked: Check Checked Check if ll parts out of the part list have been used. INSIDE Is theinside of the container cleaned? Is the interior assembled in the container? Are all rivets placed (from inside except door opening area and top of roof)? OUTSIDE ‘Are all markings applied on the container? Check this by using the drawing out of appendix A Are all ID numbers on one container the same? Is sealant applied on the container? Arethe grasp handles assembled? an the solid door easily be opened or closed? (0. Can the solid door locks easily be opened or closed?Assembly manual nit Load Desies RRM 594A - DPN container - ABX Air—1222-40-0100 Appendix A ee ee y6e-70-0002 ms (Seaeonres 88 of 89 © Copyright VRRyr (N Assembly manual @ ing and manufacturing dedicated solutions for air cargo. We build customized Unit Load Devices (ULDs) for any shape, size, weight and value of goods. Whatever your cargo, our solutions comply with the requirements of al the world’s airlines and aircraft. Because of the complexity of these products and their exclusivity, we offer our customers Unique Load Devices. VRR is your specialist with regard to design, manufacturing and maintenance services of aircraft products in both civil and military environments. In this, your unique cargo is our challenge! Please contact us for any question you may have. Van Riemsdijk Rotterdam BV Stolwijkstraat 57 3079 DN Rotterdam ‘The Netherlands 1 +31 104798100 E info@vrraviation.com | www.vrraviation,com