Engine Trailer Winch Modification Kit Technical Requirements.pdf

T4000 and T4100 Engine Trailer Winch Modification Kit Technical Requirements

The T4000 and T4100 series of engine trailers provide safe removal, transfer, and installation of aircraft engines and other comparable heavy aircraft and missile components, up to 10,000 pounds.

To enable complete interoperability with the B1-B aircraft, the latest T4000 and T4100 engine trailers designed and manufactured by MCT Industries via contract FA8533-14-D-0006, as P/N 1330-1000-00, NSN 1730-01-632-2207 and P/N 1330-2000-00 and NSN 1730-01-632-2211, require the addition of a winch capability as found on the fleet of United States Air Force (USAF) legacy engine trailers in this same classification.

The existing legacy winch assembly includes the following components: winch (with manual, mechanical drive mechanism), attachment bar, track, and overload protection device. See Figure 1, below.

The legacy winch assembly is used to facilitate moving a load onto the trailer when the rails are in an inclined position. The legacy winch assembly is capable of being removed from the trailer and stored when not required for daily operations. The legacy winch assembly is constructed of materials suitable for safe inter-operation with the legacy engine trailers including world-wide deployable environmental and corrosion conditions encountered during indoor/outdoor operation and storage.

The USAF is seeking to add the legacy winch capability to the aforementioned T4000 and T4100 engine trailers designed and produced by MCT Industries. This capability shall be added to the trailers in the form of an all-inclusive winch modification kit including: (a) all winch assembly components, (b) winch installation components, (c) winch installation instructions, and (d) any required T4000 and T4100 engine trailer modification components and instructions.

Winch modification kit general performance requirements:

The winch modification kit shall duplicate the legacy winch assembly functionality although the same winch assembly components are not required to be used.

The winch modification kit shall utilize a “universal” winch, designed and rated for 10,000 lbs.

load. Attachment points and attachment methods may vary between the T4000 engine trailer and the T4100 trailer, however the winch itself shall be designed and rated for the higher T4100 engine trailer rated load of 10,000 lbs.

The winch modification kit shall have a similar form as the legacy winch assembly in that a manual, mechanical geared drive mechanism shall be utilized in the design.

The winch modification kit shall be designed to be easily removable from the T4000 and T4100 engine trailers when not required for daily operation. The initial winch modification kit installation shall require 10 man hours or less and any follow-on installation and removal of the winch modification kit shall be done in 2 man-hours or less. by trained 5 Level Organizational maintainers utilizing the engine trailer technical order (with winch kit supplemental instructions) via common hand tools.

The winch modification kit shall be designed to minimize any design changes and/or modifications to the T4000 and T4100 engine trailers. Repetitive installation, use, and removal of the winch modification kit shall not damage, degrade, deform, or interfere with the existing trailer over the service life of the trailer and the winch modification kit.

The winch modification kit shall be constructed of materials suitable for safe inter-operation with the T4000 and T4100 engine trailers including world-wide deployable environmental and corrosion conditions encountered during indoor/outdoor operation and storage (rated for and suitable for use in the same environmental conditions as the engine trailers themselves).

The winch modification kit shall be designed for 15 years of service life.

Winch modification kit specific performance requirements:

1. Installation. The winch modification shall be designed and constructed for installation between the engine trailer rails. See Figure 2, below.

Figure 2. MCT Engine Trailer.

2. Winch. A hand-operated, positive–control winch shall be provided on the engine trailer lift frame on a center with the engine trailer parallel rails. The winch shall be geared to enable the rated load (10,000 lbs.) to be moved on the rails with four rollers by hand cranking when the rails are tilted 10º from the horizontal (fore and aft). The maximum load permissible to be exerted on the winch handle shall not exceed 26 pounds. The winch shall operate in either a compression or tension loading direction. The winch shall have the capability to support a 5,500 lbs. engine, or other similarly sized and weighted component, fully extended (telescoped) with the engine for 3 hours at 10 degree incline and sitting on the trailer (not fully extended position) for up to 8 hours.

3. Attachment bar. The winch shall have a telescoping attachment bar that is adjustable from 35 to 60 inches for attachment to the engine or component and for driving the component along the rails. A quick, positive means shall be provided for changing the attachment bar for different attachment points on the engine or component or reversed to the opposite end to permit movement on the rails.

4. Track. The winch shall be provided with a track or travel media of a minimum length of 112 inches total travel and shall have a static factor of safety of at least 5.0 based on minimum material ultimate tensile strength.

5. Overload protection device. The winch shall be provided with an overload protection device to prevent damage to the aircraft, engine, or other similarly sized and weighted component, while the component is being installed or removed. The overload protection device shall be set to release at 2,400 to 2,700 pounds tension.

T4000 and T4100 Engine trailer general characteristics:

The winch kit design shall fully inter-operate with the lifting mechanism and lifting characteristics of the T4000 and T4100 engine trailers. Pertinent details of the engine trailer are provided below and in Table 1.

The engine trailer lift mechanism is designed to permit the center of gravity of the rated load to be transferred to either end and to prevent tipping. Once the rated load is transferred to either end, the center of gravity, either side of center, does not exceed 38 inches for the T4000 or 49 inches for the T4100.

The engine trailer lift mechanism is capable of adjusting the height of the rails from a low position without spacers to a maximum height with spacers under the rails. These maximum and minimum heights for each trailer type are specified in Table 1, below. The engine trailer is designed to raise or lower the loads to any position within these limits.

Table 1. T4000 and T4100 Engine Trailer General Characteristics.

Requirement

T4000 T4100

Rated load (pounds) 8,000 10,000 Proof load (pounds) 16,000 20,000 Center of Gravity above center of rails (inches)

18 29

Minimum height without spacers (inches)

29 29

Maximum height without spacers (inches)

79 105

Maximum weight 3850 lbs. 4400 lbs.

Rail length (inches) 152 ± 0.25 174 ± 0.25 Wheelbase (inches) 126 148 Overall width (inches) 80±1.0 80±1.0

Tread (inches) 72±1.0 72±1.0 Minimum turning radius (feet) 22 25

Materials, protective coatings, and finishing.

1. Recycled, recovered, or environmentally preferable materials. Recycled, recovered, or environmentally preferable materials should be used to the maximum extent possible provided that the material meets or exceeds the operational and maintenance requirements, and promotes economically advantageous life cycle costs. However, used, rebuilt, or refurbished items shall not be provided.

2. Protective coatings. Materials that deteriorate when exposed to sunlight, weather, or operational conditions normally encountered during the service life of the item shall not be used or shall have means of protection against such deterioration that does not prevent compliance with the performance requirements specified herein. Protective coatings that chip, crack, or scale with age or extremes of climatic conditions or when exposed to heat shall not be used. Exposed surfaces of fasteners, handles, and fittings shall also be primed and painted.

2.1 Surface preparation and pretreatment. Surface preparation and pretreatment shall be in accordance with the respective primer and topcoat specifications. Structures shall be cleaned, degreased, and scuffed or blasted prior to priming; primer shall be applied before any oxidation or rusting occurs. Aluminum surfaces shall have MIL-DTL-81706, Type II, Class 1A, chemical conversion coating applied in accordance with the manufacturer’s directions, or shall be anodized in accordance with MIL-A-8625, Type II, Class 1, prior to priming.

2.2 Primer. Raw metal edges, to include fastener and drain holes, shall be coated with primer before applying topcoat.

2.2.1 Ferrous surfaces. Ferrous structures and surfaces shall be primed with zinc rich primer in accordance with MIL-PRF-26915, Type I, Class A. This shall be followed with a compatible intermediate epoxy primer, following manufacturer’s curing and overcoat recommendations.

Specification for intermediated epoxy primer will be either MIL-DTL-53030 or MIL-DTL-53022, Type IV. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating.

2.2.2 Aluminum and mixed aluminum and ferrous surfaces. Aluminum and mixed aluminum and ferrous structures and surfaces shall be primed with an epoxy primer, Type I, Class N of MIL- PRF-23377. This single part primer system shall yield a dry-film thickness of 0.6 to 0.8 mils.

2.3 Topcoat. Topcoat shall be polyurethane in accordance with Type I or Type IV, Class H of MIL-PRF-85285. Neither Chemical Agent Resistant Coating (CARC) nor powder coating shall be used. Topcoat shall be applied to a dry film thickness of 1.6 to 2.4 mils in all instances, regardless of the primer system utilized. The coating shall be free from runs, sags, orange peel, or other defects.

2.4 Dissimilar metals. Dissimilar metals, as defined in MIL-STD-889, shall not be in contact with each other. Metal plating or metal spraying of dissimilar base metals to provide electromotively compatible abutting surfaces is acceptable. The use of dissimilar metals only when separated by suitable insulating material is permitted, except in systems where bridging of insulation materials by an electrically conductive fluid can occur. Sealants or gel type gasket materials shall be used between faying surfaces and butt joints.

2.5 Finish. The exterior finish color of the engine trailer shall be Gray, Color Number 26173 of

FED-STD-595.

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