On deck

Following their acceptance by the RNZAF, it was decided to perform a comprehensive conversion on the 757s to give them a main deck freight carrying capability as well as enhanced communications, thus increasing their flexibility and better augmenting the NZDF’s C- 130H Hercules fleet.

The two aircraft subsequently underwent a substantial and prolonged modification program at ST Aero’s Mobile Aerospace Engineering facility in Alabama, and with Boeing IDS in Kansas.

The upgrade included the installation of updated military and civil communications and navigation systems, the fitting of an electronic flightbag (EFB) system, the installation of a main deck cargo door and strengthened main deck cargo floor, new cargo handling systems, increased thrust for the Rolls-Royce engines, and installation of integral airstairs.

The first 757 to complete the upgrade was NZ7571 (pictured above), which arrived back with 40 Squadron at Whenuapai, near Auckland, in August 2008 after a 17 month conversion, while NZ7572 returned from its conversion work in February this year.

With the upgrade the two 757s can now be configured in seven different main deck arrangements, from all cargo to all passengers, or a mixed payload of cargo and passengers. Other configurations include an aeromedical evacuation set and a VIP interior, either of which can be installed in under 24 hours. A typical VIP configuration includes 12 first class VIP seats, 24 business and 90 economy, or alternatively, 12 VIP and 138 economy seats. In full economy trim, the aircraft can be configured with 156 pallet-mounted seats.

In a combined cargo/passenger ‘combi’ arrangement, the main deck can be configured for either seven pallets and 54 passengers, four pallets and 114 passengers, or two pallets and 138 passengers.

The key to the reconfigurable interior is the 757’s new freight roller floor which allows 105m3 of freight to be loaded on the main deck through the new 218cm x 340cm main deck cargo door. Upper deck pallets are able to carry 2. 5 tonnes each, giving the 757 the ability to better support NZDF deployments by carrying bulky loads such as spare engines and propellers.

The two lower holds have standard forward and aft loading doors. The forward underfloor hold has a volume of 20m3 and can carry up to 4672kg, while the aft hold has a volume of 31m3 and a capacity of 7320kg.

In a typical configuration, the 757s can carry about 22 tonnes of payload over a 3000nm sector such as Auckland to Darwin at a MTOW of 116 tonnes. As such the 757s offer a vast improvement over the old combi configured 727-100s they replaced, and with their roles now more clearly defined, are proving to be more efficient, faster, and cheaper to operate than the RNZAF’s C-130H Hercules, which can now focus more on tactical and theatre based roles.

The communications upgrade has seen the addition of secure HF and VHF radios, satellite phones, fax and email, and printers onboard for the VIP role. The flightdeck has been equipped with an EFB which has a global database and is slowly being brought into use as training and operations are defined, but the RNZAF says it will still be some time before they see a full paperless cockpit in the 757.

For coalition operations, an IFF Mode 4 transponder for military friend or foe indication identification, and a KY100 secure voice system have also been installed, with the latter to allow for flightdeck voice communications to be encrypted.

The 757’s Rolls-Royce RB211-535E4B engines also received a minor upgrade to increase their thrust by about 1. 5 per cent to 47,000lb (195kN) via an enhancement to their FADEC control units.

The aircraft typically operate with four cabin stewards, a loadmaster, and two maintenance crew members, and this complement can typically load and unload, and service the aircraft themselves with the aid of suitable ground support equipment.