35D4-4-110-1.pdf

TO 35D4-4-110-1

PRELIMINARY

TECHNICAL MANUAL

OPERATION AND SERVICE INSTRUCTIONS

AIRCRAFT MOUNTED APU HOISTING UNIT

(COMMERCIAL MANUAL)

P/N NSN

AGE70078 1730-01-532-1336

Lockheed Martin Aeronautics Company

F33657-02-C-2000

DISTRIBUTION STATEMENT E - Distribution authorized to DoD Components only (Proprietary Information), (15 August 2009). Other requests for this document shall be referred to 406 SCMS/GUHA, Robins AFB, GA, 31098. Questions concerning technical content shall be referred to 579 CBSS/GBLC.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401 et seq.

Violations of these export laws are subject to severe criminal penalties.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

THIS DOCUMENT CONTAINS COMMERCIAL PROPRIETARY TECHNICAL DATA. USE, COPYING, AND/OR DISCLOSURE BY THE U.S. GOVERNMENT OF THE TECHNICAL DATA CONTAINED HEREIN IS GOVERNED BY THE TERMS OF DFARS

252.2277015 TECHNICAL DATA COMMERCIAL ITEMS (NOV 1995).

© 2009 LOCKHEED MARTIN CORPORATION. ALL RIGHTS RESERVED

Published Under Authority of the Secretary of the Air Force

15 AUGUST 2009

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F33657-02-C-200F33657-02-C-200

- Distribution authori- Distribution authori is document shall be ocument shall be tent shall be referred tent shall be referred cument contains technument contains techn t seqq

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AND DESTRUCTION AND DESTRUCTIONPcontents or recocontents

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TITLE PAGE, 1

ORIGINAL ISSUE: DEC 31/07

REVISION 2: AUG 15/09

CAGE: 55820

HAMILTON SUNDSTRAND POWER SYSTEMS

4400 RUFFIN ROAD

SAN DIEGO, CA 92123-1606

C5 GROUND SUPPORT EQUIPMENT

AIRCRAFT MOUNTED APU HOISTING

UNIT

MODEL NUMBER APS3400

PART NUMBER AGE70078

© 2009 Hamilton Sundstrand Corporation

NOTICE

THE DATA IN THIS DOCUMENT WERE DEVELOPED ONLY TO MAINTAIN SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. THE DATA MAY NOT BE APPLICABLE TO ANY OTHER

SYSTEMS AND/OR PARTS, REGARDLESS OF THEIR APPARENT SIMILARITY TO SYSTEMS AND/OR PARTS MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND. DO NOT RELY IN ANY WAY ON DATA IN THIS

DOCUMENT TO MAINTAIN OR OTHERWISE SUPPORT SYSTEMS AND/OR PARTS THAT WERE NOT MANUFACTURED BY OR FOR HAMILTON SUNDSTRAND OR APPROVED BY HAMILTON SUNDSTRAND WITHOUT EVIDENCE THAT THE FEDERAL AVIATION

ADMINISTRATION OR OTHER REGULATORY AGENCY HAS DETERMINED THAT THE DATA IN THIS DOCUMENT REMAINS VALID FOR

SUCH USE.

ITAR STATEMENT

INFORMATION CONTAINED HEREIN MAY BE SUBJECT TO THE INTERNATIONAL TRAFFIC IN ARMS (ITAR) OF THE UNITED STATES OF AMERICA. NEITHER THIS INFORMATION, NOR ANY PORTION OF INFORMATION CONTAINED HEREIN, MAY BE EXPORTED, RELEASED, OR DISCLOSED TO ANY FOREIGN ENTITY OR FOREIGN NATIONAL INSIDE OR OUTSIDE OF THE UNITED STATES

WITHOUT FIRST OBTAINING REQUIRED U.S. GOVERNMENT APPROVAL OR A VALIDATED EXPORT LICENSE. A VIOLATION OF THE ITAR MAY BE SUBJECT TO A PENALTY, AND/OR FINE, UNDER 22 U.S.C. 2778. INCLUDE THIS NOTICE WITH ANY REPRODUCED

SECTION OF THIS DOCUMENT. DIVERSION CONTRARY TO U.S. LAW IS PROHIBITED.

NOTICE

HAMILTON SUNDSTRAND ASSIGNS TO THE U.S. AIR FORCE UNDER CONTRACT F33457-02-C-2000, GOVERNMENT PURPOSE RIGHTS IN THE TECHNICAL DATA CONTAINED HEREIN FOR THE SOLE PURPOSE OF PERFORMING REPAIRS AND MAINTENANCE

ON THE AIRCRAFT MOUNTED APU HOISTING UNIT, PART NO. AGE70078, IN ACCORDANCE WITH DFARS CLAUSES 252.227-7013 (a)

(12) AND (b) (2) AND 227.7103-5 (b). IN THE EVENT THE INTENDED RECIPIENT IS A GOVERNMENT CONTRACTOR, THAT

CONTRACTOR MUST, PRIOR TO RELEASE OR DISCLOSRE, BE SUBJECT TO THE USE AND NON-DISCLOSURE AGREEMENT AT

DFARS 227.7103-7.

THIS DOCUMENT EMBODIES PROPRIETARY INFORMATION ORIGINATED OR OWNED BY HAMILTON SUNDSTRAND CORPORATION AND IS FURNISHED SUBJECT TO THE PROVISIONS OF HAMILTON SUNDSTRAND CORP. / LOCKHEED MARTIN PROPRIETARY

INFORMATION AGREEMENT DATED JULY 2, 2002.

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APS3400 GSE GENERATOR HOISTING UNIT AGE70078

RECORD OF REVISIONS

Aug 15/09 AGE70078

RECORD OF REVISIONS

REV NO. DATE CHANGE PAGES

Rev 1 May 31/09 Title Page, 1-4, 6-13, 16, 19, 23-24, 33-35

Rev 2 Aug 15/09 Title Page, 1-2, 7-11, 13, 14, 16 and 36

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AIRCRAFT MOUNTED APU HOISTING UNIT

1. TABLE OF CONTENTS

SUBJECT PAGE

1 – TABLE OF CONTENTS 1

2 – INTRODUCTION 1

3 – SAFETY ADVISORY 5

4 – OPERATING INSTRUCTIONS 7

5 – MAINTENANCE INSTRUCTIONS 8

6 – PREPARATION FOR USE 9

7 – CLEANING 10

8 – LUBRICATION 10

9 – INSPECTION 13

10 – REPAIR 18

11 – CALIBRATION 18

12 – DISASSEMBLY 18

13 – ASSEMBLY 20

14 – STORAGE AND SHIPMENT 25

15 – ILLUSTRATED PARTS BREAKDOWN 26

2. INTRODUCTION

A. These procedures give the operating instructions, maintenance procedures, and illustrated parts list for the Auxiliary Power Unit (APU) Hoisting Unit, part number AGE70078 (refer to Figure 1).

B. Requirements and procedures contained herein are intended for use with applicable provisions of AFOSHSTD 91-46, Materials Handling and Storage Equipment, and AFOSHSTD 91-501, Air Force Consolidated Occupational Safety Standard.

C. The APU hoisting unit provides a capability for removal and installation of the APS3400 APU, installed on the C5 aircraft. The APU hoisting unit is manually operated with two worm gear hand winches.

D. The APU hoisting unit includes two fixed rails, a rolling winch assembly, and a spreader bar with attachment cables (refer to Figure 2).

E. The APU hoisting unit has a rated load capacity of 450 lbs. (204.1 kg).

F. Follow the applicable local, state and federal environmental protection procedures when handling and disposing of hazardous materials.

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G. The using activity is required to maintain a record of the APU Hoisting Unit initial receipt date, proof load test (static load test) certifications, use dates, inspection dates, and static load test dates.

H. The APU hoisting unit component and unit weights are provided in Table 1.

Table 1 AGE70078 Hoisting Unit, APU – Component and Unit Total Weight Data*

Part Number Component Name/Description

Weight in Pounds

AGE70078-1000 Forward Rail Assembly 20.6 lbs AGE70078-1001 Aft Rail Assembly 21.0 lbs AGE70078-1002 Winch Assembly 73.3 lbs AGE70078-1003 Spreader Bar 1.6 lbs AGE70078-1004 Cable Assembly 0.4 lbs N/A Total Weight Hoisting Unit

Only

116.9 lbs

AGE70078-1005 Storage/Shipping Container

189.1 lbs

AGE70078 Hoisting Unit, APU (Overall Total)

306.0 lbs

* AGE70078 Drawing and Data Plates will be updated to match Table 1 weight data.

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APU Unit Figure 1

STORAGE CONTAINERS LID RETAINERS

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APU Hoisting Unit Figure 2

Spreader Bar

Spreader Cables

Winch Assembly Arms

Forward Rail Assembly Aft Rail Assembly

Winch Crank Handles Flexible Draw Latches (10 Places)

Lid Open

Winch Assembly

Storage Box With Hinged Lid (Lid Not Shown)

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3. SAFETY ADVISORY

A. Scope.

(1) This publication describes processes that may require the use of chemicals, solvents, paints, or other materials that can affect a person's health or safety. It may also cover high energy procedures that can affect a person's health or safety.

Warnings are placed just ahead of these procedures to bring attention to the existence of a procedure or material that can be dangerous.

B. Significance of Material Safety Data Sheets (MSDS) and how to obtain MSDS.

(1) Refer to the materials list at the beginning of each section of this manual for materials used to repair and maintain the covered equipment.

(2) If you do not have a copy of the manufacturer’s MSDS for the materials covered in the materials list, contact the manufacturer and request that a MSDS be supplied before you use the material.

C. Purpose.

(1) The warnings bring your attention to the existence of a procedure that can affect a person’s health or safety.

(2) Cautions are provided in the maintenance publication or service bulletin to alert operating and maintenance personnel to conditions that could result in equipment damage.

D. Definitions applying to warnings.

(1) Flammable: A material that can catch fire easily and can be explosive. These materials are labeled according to the flash point of the material.

(2) Flash Point: The lowest temperature at which a flammable liquid gives off fumes that can burn.

(3) Ignition Source: Includes flames, sparks, or heat.

(4) Flames: Materials that are burning such as lit matches, propane torches, or pilot lights.

(5) Sparks: Materials such as lighted cigarettes, electrical motors, or static electricity.

(6) Heat: Any source of energy that will raise the temperature of a flammable material to its flash point and could include hot parts, heated tools, or direct sunlight.

(7) Corrosive: Acidic or alkaline material that will remove human tissue or create chemical reactions with other materials.

(8) Toxic: Material that is poisonous.

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(9) Reactive: Materials that will make fumes, burn, or can be explosive when mixed with certain other materials.

(10) Shock (Electrical): The result of any source of electricity more than 50 volts that causes current to flow through a person and can result in dangerous burns to human tissues or death.

(11) Exposure: Contact with the material or physical process without protection. Contact may be by the eyes, breathing, touch, skin absorption, or swallowing.

(12) Irritation: Any sense of pain, soreness, rash, or general discomfort.

E. Reporting materials or processes not covered in this manual.

(1) Please call (815) 226-6000, FAX (815) 966-8525, or write to Hamilton Sundstrand, Technical Publications, Department 768, 4747 Harrison Avenue, P.O. Box 7002, Rockford, IL 61125-7002, if you find a material in a Hamilton Sundstrand maintenance document that is known to be covered by a material data safety sheet (MSDS) but is not covered by a warning in the procedure.

F. Warnings and cautions used in this manual.

WARNING: PERSONNEL SHALL CONSULT APPROPRIATE AFOSH/OSHA

GUIDANCE, MSDS INSTRUCTIONS, AND LOCAL PROCEDURES FOR

THE WEAR OF PERSONAL PROTECTIVE EQUIPMENT (PPE) WHILE

PERFORMING MAINTENANCE ON THIS EQUIPMENT. FAILURE TO

COMPLY COULD RESULT IN INJURY OR DEATH TO PERSONNEL.

WARNING: THE OVERALL APU HOISTING UNIT, CONTAINER AND WINCH

ASSEMBLY ARE HEAVY COMPONENTS. TO PREVENT INJURY TO

PERSONNEL AND DAMAGE TO EQUIPMENT, USE TWO PEOPLE TO

LIFT, HANDLE, AND TRANSPORT THE ASSEMBLY ITEMS.

WARNING: KEEP YOUR HANDS AWAY FROM THE DRUM, WIRE ROPE, AND

MOVING PARTS WHILE YOU ROTATE THE MANUAL WINCHES.

WARNING: KEEP PERSONNEL AWAY FROM THE PATH OF THE LOAD. A

BROKEN CABLE MAY SNAP BACK AND CAUSE INJURY.

WARNING: DO NOT USE THE APU HOISTING UNIT FOR ANY OTHER USE OR TO

LIFT ANY OTHER OBJECT BEYOND ITS DESIGN. OTHERWISE,

FAILURE OF THE HOISTING UNIT OR INJURY TO PERSONNEL MAY

OCCUR.

WARNING: INSTALL THE CABLE ASSEMBLIES SECURELY TO THE MANUAL

WINCH DRUMS. POORLY INSTALLED CABLE ASSEMBLIES MAY

COME LOOSE AND CAUSE A LOAD TO FALL.

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WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A VISUAL

CHECK TO MAKE SURE THAT NO LESS THAN TWO (2) WRAPS OF

CABLE REMAIN ON EACH WINCH DRUM AT ALL TIMES. CHECK TO

MAKE SURE THAT THIS REQUIREMENT IS MAINTAINED WHEN THE

HOISTING CABLE IS IN ITS EXTREME LOWEST POSITION.

OTHERWISE FAILURE OF THE HOISTING UNIT OR INJURY TO

PERSONNEL MAY OCCUR.

CAUTION: MAINTAIN A LIGHT TENSION ON THE HOISTING CABLES AT ALL TIMES

AND DO NOT ALLOW ANY CABLE SLACK DURING HOISTING

OPERATIONS.

CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A SPECIAL

MACHINE FOR THE CORRECT ATTACHMENT AND LENGTH. MAKE

SURE YOU REPLACE THEM WITH THE CORRECT REPLACEMENT

CABLE ASSEMBLY.

CAUTION: MAKE SURE THAT BOTH HOISTING CABLES ARE WRAPPED AROUND

THE MANUAL WINCH DRUM IN THE CORRECT DIRECTION.

4. OPERATING INSTRUCTIONS

A. The following steps must be observed when operating the APU hoisting unit:

WARNING: PERSONNEL SHALL CONSULT APPROPRIATE AFOSH/OSHA

GUIDANCE, MSDS INSTRUCTIONS, AND LOCAL PROCEDURES FOR

THE WEAR OF PERSONAL PROTECTIVE EQUIPMENT (PPE) WHILE

PERFORMING MAINTENANCE ON THIS EQUIPMENT. FAILURE TO

COMPLY COULD RESULT IN INJURY OR DEATH TO PERSONNEL.

WARNING: KEEP YOUR HANDS AWAY FROM THE DRUM, WIRE ROPE, AND

MOVING PARTS WHILE YOU ROTATE THE MANUAL WINCHES.

WARNING: KEEP PERSONNEL AWAY FROM THE PATH OF THE LOAD. A

BROKEN CABLE MAY SNAP BACK AND CAUSE INJURY.

WARNING: DO NOT USE THE APU HOISTING UNIT FOR ANY OTHER USE OR TO

LIFT ANY OTHER OBJECT BEYOND ITS DESIGN. OTHERWISE,

FAILURE OF THE HOISTING UNIT OR INJURY TO PERSONNEL MAY

OCCUR.

CAUTION: MAINTAIN A LIGHT TENSION ON THE HOISTING CABLES AT ALL TIMES

AND DO NOT ALLOW ANY CABLE SLACK DURING HOISTING

OPERATIONS.

(1) Refer to AFOSHSTD 91-46 and AFOSHSTD 91-501 for information about PPE.

(2) Visually inspect all components for damage with special attention to fasteners and any corrosion findings. Replace any damaged parts.

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(3) Visually inspect all components for security with special attention to the cable end fasteners. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

(4) Observe the APU hoisting unit and hoisting cables. Make sure that they are properly installed and aligned for hoisting operations.

(5) Observe the winch shafts and make sure that the hoisting cables are winding smoothly and evenly.

(6) Observe the APU hoisting unit for signs of hoisting cable binding or slippage.

(7) Make sure the APU is supported by hand at all times to prevent swaying or other accidental movement.

(8) Use special care when you move the manual winches inboard or outboard while the APU is suspended. Do not allow the APU hoisting unit to roll at excessive speed.

(9) Make sure that the ball lock pins are installed on the outboard end of each fixed rail to prevent the manual winches from accidentally rolling out of the fixed rail tracks.

(10) Once the inboard-outboard APU movement is in the needed position, set the screw brakes on each rail to hold the APU in place on the rails (refer to Figure 8, item 360).

(11) Do not leave a suspended load unattended.

(12) Do not use a damaged or malfunctioning APU hoisting unit or equipment failure may occur.

(13) Do not modify the APU hoisting unit in any way or equipment failure may occur.

5. MAINTENANCE INSTRUCTIONS

A. This section contains information about equipment, consumable materials and expendable parts necessary to maintain the APU hoisting unit.

(1) Equipment:

Part No./Spec. No. Name N/A Oil waste container (locally approved)

(2) Consumable Materials:

Part No./Spec. No. Name

Sandstrom 28A (MIL-PRF-46147D, Type I)

(NSN 9150-01-566-7396)

Lubricant, Solid Film, Air-Cured, Corrosion Inhibiting, Type I Natural, Form II (34227)

SHC-007 Aircraft Grease

(NSN 9150-01-549-0261)

Mobilith SHC-007, Aircraft Grease

(OTS34)

- SAE 30 Non-detergent Oil

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(3) Expendable Parts:

(a) User maintenance and replacement of parts is accomplished at the Organizational ("O") Level except where Source, Maintenance and Recoverability (SMR) coding does not permit.

(b) Refer to the Illustrated Parts Breakdown for the SMR codes.

6. PREPARATION FOR USE

A. Prepare the APU hoisting unit for use as follows:

(1) Remove the APU hoisting unit from the storage container as follows:

(a) Open the storage container.

(b) Open the two flexible draw latches and remove the forward fixed rail. Visually inspect the forward fixed rail.

(c) Open the two flexible draw latches and remove the aft fixed rail. Visually inspect the aft fixed rail.

(d) Install the forward and aft fixed rails on the aircraft. Refer to the appropriate aircraft technical order. Visually inspect both fixed rails.

WARNING: THE WINCH ASSEMBLY IS A HEAVY COMPONENT. TO PREVENT

INJURY TO PERSONNEL AND DAMAGE TO EQUIPMENT, USE

TWO PEOPLE TO LIFT, HANDLE, AND TRANSPORT THE

ASSEMBLY.

(e) Open the two flexible draw latches and carefully remove the winch assembly.

NOTE: Make sure that the cables do not catch on the storage container during removal.

(f) Install/remove the winch assembly on the aircraft. Refer to the appropriate aircraft technical order.

CAUTION: MAINTAIN A LIGHT TENSION ON THE HOISTING CABLES AT ALL

TIMES AND DO NOT ALLOW ANY CABLE SLACK DURING

HOISTING OPERATIONS.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A

VISUAL CHECK TO MAKE SURE THAT NO LESS THAN TWO (2)

WRAPS OF CABLE REMAIN ON EACH WINCH DRUM AT ALL

TIMES. CHECK TO MAKE SURE THAT THIS REQUIREMENT IS

MAINTAINED WHEN THE HOISTING CABLE IS IN ITS EXTREME

LOWEST POSITION. OTHERWISE FAILURE OF THE HOISTING

UNIT OR INJURY TO PERSONNEL MAY OCCUR.

(g) Visually inspect all components for damage with special attention to fasteners and any corrosion findings. Replace any damaged parts.

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(h) Visually inspect all components for security with special attention to the cable end fasteners. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

(i) Visually inspect the winch assembly and hoisting cables. Check to make sure there are no less than two (2) wraps of cable on each winch drum.

(j) Open the two flexible draw latches and remove the two winch handles.

(k) Install the two winch handles on the winch assembly as follows:

1 Loosen the setscrew in the winch handle.

2 Install the winch handle in the notch position.

3 Tighten the setscrew to secure the winch handle to the winch assembly.

(l) Open the covered storage box in the storage container and remove the spreader bar and the two spreader cables. Visually inspect the spreader bar and spreader cables for damage, and return them to the storage container until they are needed for use.

(m) If necessary, lubricate the components according to the Maintenance Instructions.

(n) Check to make sure that item captive features are maintained.

(2) After APU Hoisting Unit use, visually inspect the item for deformation, degradation and excessive wear.

7. CLEANING

A. Clean the APU hoisting unit as follows:

(1) Clean the manual winches every six months or when excessively dirty.

(2) Wipe all equipment with an oily rag to remove dirt and grease.

(3) Leave a light film of oil on all surfaces to prevent rust and corrosion.

(4) Wipe off any excessive amounts of oil to avoid the accumulation of dirt.

(5) Keep the APU hoisting unit in the storage container when not in use.

8. LUBRICATION

A. Lubricate the APU hoisting unit as follows:

(1) Lubricate the cable, cam followers and track rollers with Sandstrom 28A (MIL-PRF- 46147D, Type I) solid film lubricant, if required.

NOTE: Keep the solid film lubricant spray away from the pulley and mounting bolt interface and away from the winch bearings area.

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(2) Capture the waste lubricant in an approved container and dispose of the waste in accordance with local hazardous material disposition procedures.

(3) Lubricate the disc brake every six months. Put 1 to 2 drops of SAE 30 non-detergent oil into the hole in the brake housing marked “oil” (refer to Figure 3.)

(4) Lubricate the outboard bearing every six months. Put 2 to 3 drops of SAE 30 non-detergent oil into the hole in the bearing housing marked “oil”. Rotate the drum ½ turn and add 2 to 3 more drops of oil.

(5) Lubricate the winch as follows:

(a) Fill the winch with SHC-007 Aircraft Grease at the grease zerk on the side of the gear housing (refer to Figure 3).

(b) Dispose of any waste lubricant in accordance with local hazardous material disposition procedures.

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Lubrication of the Winch Figure 3

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(6) Make sure the winch is properly serviced with SHC-007 Aircraft Grease before each operation.

NOTE: Grease volume is 12.8 ounces.

9. INSPECTION

A. In addition to the procedures provided in this manual refer to AFOSHSTD 91-46 as a supplemental instruction for inspection criteria, inspection intervals, and documentation of inspection results.

B. An annual inspection of machined surfaces, pins, fasteners, structure, and hoist is required.

C. Machined surfaces (pulleys) are to be visually inspected for signs of wear and corrosion.

D. Pins and fasteners are to be visually inspected for cracks, damage and corrosion.

E. Visually inspect all components for security with special attention to the cable end fasteners.

F. Tighten any loose parts or connections and replace any cables with other than totally secure cable end fasteners.

G. Check to ensure that item captive features are maintained. Fix any problems found.

H. Visually inspect all structure for damage, weld cracks and corrosion.

I. For any corrosion findings affecting the painted metallic surfaces and which appear to require action to fix the problem, take action to control the corrosion in accordance with the aircraft surface paint technical order instructions.

J. If the APU Hoisting Unit remains in storage for an extended period of time (twelve plus months), visually inspect for corrosion, other extended storage related degradation and damage at a frequency consistent with local shop policy (must be inspected at least annually – once a year).

K. Do these inspections of the APU hoisting unit before every use or load test inspection or at a minimum of once every 12 months:

(1) Do a visual inspection of the APU hoisting unit as follows:

(a) Check all parts for visible damage.

(b) Inspect the track rollers for chipped or cracked surfaces.

(c) Make sure the hoisting cables and track rollers are properly lubricated.

(d) Inspect for loose or stripped fasteners.

(2) Do a visual inspection of the APU hoisting unit cables as follows:

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CAUTION: MAINTAIN A LIGHT TENSION ON THE HOISTING CABLES AT ALL

TIMES AND DO NOT ALLOW ANY CABLE SLACK DURING

HOISTING OPERATIONS.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A

VISUAL CHECK TO MAKE SURE THAT NO LESS THAN TWO (2)

WRAPS OF CABLE REMAIN ON EACH WINCH DRUM AT ALL

TIMES. CHECK TO MAKE SURE THAT THIS REQUIREMENT IS

MAINTAINED WHEN THE HOISTING CABLE IS IN ITS EXTREME

LOWEST POSITION. OTHERWISE FAILURE OF THE HOISTING

UNIT OR INJURY TO PERSONNEL MAY OCCUR.

(a) Make sure the hoisting cables are installed correctly and anchored securely to the drums.

(b) Examine the cable end fasteners to make sure that the fasteners remain secure. If the fasteners are not secure, replace the cable.

(c) Periodically unwind the hoisting cables from the APU hoisting unit. Examine the entire length of hoisting cable for bent wires, crushed areas, birdcaging, broken or cut wires, corrosion, or other damage.

(d) While the hoisting cables are unwound, inspect the manual winch drums for roughness, sharp edges, and the presence of any foreign materials.

(e) Replace a hoisting cable when more than three wires are broken in one strand of one lay, or more than one wire is broken in one strand of a critical fatigue area (refer to Figure 4).

NOTE: A critical fatigue area is defined as the working length of the hoisting able where the hoisting cable runs over a pulley, sleeve, or roller, or any section of cable within 12 in. (30.5 cm) of a swaged-on fitting.

NOTE: Lay (twist) is defined as the helical form taken by the wires in the strand and by the strand in the wire rope is characterized as the lay (twist) of the strands or wire rope, respectively.

NOTE: Length of lay (pitch) is defined as the distance parallel to the axis of the strand or cable in which a wire or strand makes one (1) complete turn about the axis is designated as the length of lay (pitch) of the strand or wire rope (refer to Figure 4).

(f) Do a static load test when any cable is replaced.

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Hoisting Cable Inspection - Broken Wires Figure 4

(3) Do a visual inspection of both manual winches as follows:

(a) Inspect the manual winch for corrosion, pitting, or excessive wear.

(b) Check the manual winch for signs of grease or oil leakage.

(c) Dispose of waste lubricant in accordance with local hazardous material disposition procedures.

(d) Make sure the winch gearbox, brake, and outer bearing are properly lubricated.

(e) Make sure the winch handle is installed correctly and securely.

(f) Check to make sure the manual winch can rotate freely in both directions.

(g) Move the winch drum with your hands. A slight play in the shaft is normal.

Excessive movement in the shaft may indicate worn or loose gears, bearing, or shaft.

(h) Replace the manual winch when defective conditions are found.

(4) Do a visual inspection of the storage container as follows:

(a) Inspect all flexible draw latches and winch handles for security and proper operation.

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(b) Make sure all wooden supports are in good condition, with no cracks, splits, or breaks.

(c) Check the piano hinge for security and proper operation.

(d) Check to ensure that the two storage container lid retainers (refer to Figure 1) are not damaged beyond use. If damaged, repair and replace locally.

L. Static Load Test of the APU hoisting unit.

NOTE: Do not use the aircraft to perform the static load test. Use a suitable equivalent test rig.

(1) New APU Hoisting Units are supplied with a current static load test and static load test (proof load test) certification documentation. Record and maintain the test information in accordance with local shop policy.

(2) Annual static load testing requirements must be completed annually thereafter by the anniversary of the APU Hoisting Unit initial receipt date with the following exceptions:

(a) If the APU Hoisting Unit remains unused, the initial static load test continues to apply until first usage, with a new annual static load testing requirement becoming due within twelve (12) months after the first usage date.

(b) If the APU Hoisting Unit remains unused in the twelve (12) months following the last successful static load testing, then the existing static load testing certification continues to apply until the support equipment item is used again, at which time a new annual static load testing requirement becomes due within twelve (12) months after the usage date.

(c) If the APU Hoisting Unit is used at any time during the twelve (12) month period after the last static load test, then the next static load test must be completed within twelve (12) months after the last static load test date.

(d) In all cases, there is no deferral of the accompanying visual inspection requirements, which must be accomplished in accordance with the “Inspection” provisions of this technical order.

(3) In conjunction with AFOSHSTD 91-46 requirements, do a static load test annually, or when disassembled/assembled for maintenance, or when a cable assembly is replaced, or is otherwise required, as follows:

(a) Set the APU hoisting unit up for the test as shown in Figure 5.

(b) Do the static load test in accordance with Figure 5. After the test is completed inspect the unit for evidence of cracks, bending or material failure. No damage is permitted. Replace defective hardware and do the test again. Certification is required.

(4) Recertify the APU Hoisting Unit for serviceability, to include static load testing, after any modification and/or repair per this technical order.

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Static Load Test Figure 5

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10. REPAIR

A. Repair of the APU hoisting unit is accomplished by replacement of defective parts.

11. CALIBRATION

A. Not required.

12. DISASSEMBLY

A. Disassemble the APU hoisting unit as follows:

NOTE: Disassemble the APU hoisting unit only to the extent necessary to perform maintenance.

NOTE: If any cable assembly is replaced you must do the static load test. Refer to the Inspection section of this manual for the static load test instructions.

NOTE: Make sure that the item captive features are maintained at all times except during item removal and replacement.

NOTE: Item numbers in this procedure correspond to the item numbers in the Illustrated Parts Breakdown.

CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A SPECIAL

MACHINE FOR THE CORRECT ATTACHMENT AND LENGTH. MAKE

SURE YOU REPLACE THEM WITH THE CORRECT REPLACEMENT

CABLE ASSEMBLY.

(1) Disassemble the spreader bar (30) as follows:

(a) Remove the ball lock pins (20) that connect the cable assemblies (10) to the spreader bar (30).

(b) Remove the ball lock pins (20) from the cable assemblies (10).

(2) Disassemble the forward rail assembly (40) as follows:

(a) Remove the two hex head bolts (80), two split locking washers (90), and two flat washers (100) from the forward inboard bracket (110).

(b) Remove the ball lock pin (50) from the clevis (120) and ball lock pin (60) from the forward rail assembly (40).

(c) Remove the 14 flat head bolts (70) and separate the track (123) and rail cover

(126) from the forward rail assembly (40).

(d) Remove the clevis (120) from the forward rail assembly (40).

(3) Disassemble the aft rail assembly (130) as follows:

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(a) Remove the two hex head bolts (170), two split locking washers (180), and two flat washers (190) from the aft inboard bracket (200).

(b) Remove the ball lock pin (140) from the clevis (210) and ball lock pin (150) from the aft rail assembly (130).

(c) Remove the 14 flat head bolts (160) and separate the track (213) and rail cover (216) from the aft rail assembly (130).

(d) Remove the clevis (210) from the aft rail assembly (130).

(4) Disassemble the winch assembly (220) as follows:

(a) Remove the two knurled head screws (360, 400) from the forward carrier assembly (350) and aft carrier assembly (390).

(b) Unwind the entire length of cable of each cable assembly (230) from the winch assembly (220) drums.

(c) Loosen the anchor bolt that attaches each cable assembly (230) to each manual winch (500) drum (refer to Figure 6).

Cable Anchor Bolt Location Figure 6

(d) From the ball lock pin (240) end, carefully pull each cable assembly (230) through each carrier assembly (350, 390).

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(e) Remove the ball lock pin (240) from each cable assembly (230).

(f) Remove the ball lock pin (250) from each carrier assembly (350, 390).

(g) Unscrew the handle (260) to remove it from each carrier assembly (350, 390).

(h) Remove the eight hex jam nuts (290), lock washers (280), and track stud rollers (270) from each carrier assembly (350, 390).

(i) Remove the six retaining rings (310), three headless clevis pins (300), three needle roller bearings (320), and the three rollers (370, 410) from each carrier assembly (350, 390).

(j) Remove the dowel pin (330) and miniature drive roller (340) from each carrier assembly (350, 390).

(k) Remove the end bar (380, 420) from each carrier assembly (350, 390).

(l) Remove the four hex head bolts (430), eight flat washers (440), four lock washers (450) and four hex jam nuts (460) that attach each carrier assembly (350, 390), and plate (470) to the two manual winches (500).

(m) Remove the four dowel pins (480) and rollers (490) from the plate (470).

13. ASSEMBLY

A. Assemble the APU hoisting unit as follows:

NOTE: Item numbers in this procedure correspond to the item numbers in the Illustrated Parts Breakdown.

NOTE: Make sure that item captive features are maintained at all times except during item removal and replacement.

(1) Assemble the winch assembly (220) as follows:

(a) Install the four dowel pins (480) and rollers (490) on the plate (470).

(b) Install the end bar (380, 420) in each carrier assembly (350, 390).

(c) Install the miniature drive roller (340) and dowel pin (330) and secure the end bar (380, 420) to each carrier assembly (350, 390).

(d) Install carrier assemblies (350, 390) on the manual winches (500), and plate

(470) with the four hex head bolts (430), eight flat washers (440), four lock washers (450) and four hex jam nuts (460).

(e) Install the three rollers (370, 410), and the three needle roller bearings (320) on each carrier assembly (350, 390) with the three headless clevis pins (300) and six retaining rings (310).

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(f) Install the eight track stud rollers (270) on each carrier assembly (350, 390) with the eight lock washers (280) and hex jam nuts (290).

(g) Install the handle (260) on each carrier assembly (350, 390).

(h) Install the ball lock pin (250) on each carrier assembly (350, 390).

(i) Install the ball lock pin (240) on each cable assembly (230).

CAUTION: THE CABLE ASSEMBLIES ARE MANUFACTURED WITH A SPECIAL

MACHINE FOR THE CORRECT ATTACHMENT AND LENGTH. MAKE

SURE YOU REPLACE THEM WITH THE CORRECT REPLACEMENT

CABLE ASSEMBLY.

(j) Carefully thread the bare cable end of each cable assembly (230) through its associated carrier assembly (350, 390), starting from the inboard end of the carrier assembly and working toward the manual winch (500) drums.

(k) Check and make sure that the cable assemblies are properly located in the groove of the sheave rollers (370, 410).

WARNING: INSTALL THE CABLE ASSEMBLIES SECURELY TO THE MANUAL

WINCH DRUMS. POORLY INSTALLED CABLE ASSEMBLIES MAY

COME LOOSE AND CAUSE A LOAD TO FALL.

WARNING: BEFORE AND DURING ANY HOISTING OPERATIONS DO A

VISUAL CHECK TO MAKE SURE THAT NO LESS THAN TWO (2)

WRAPS OF CABLE REMAIN ON EACH WINCH DRUM AT ALL

TIMES. CHECK TO MAKE SURE THAT THIS REQUIREMENT IS

MAINTAINED WHEN THE HOISTING CABLE IS IN ITS EXTREME

LOWEST POSITION. OTHERWISE FAILURE OF THE HOISTING

UNIT OR INJURY TO PERSONNEL MAY OCCUR.

CAUTION: MAKE SURE THAT BOTH HOISTING CABLES ARE WRAPPED

AROUND THE MANUAL WINCH DRUM IN THE CORRECT

DIRECTION.

(l) Install each cable assembly (230) on each manual winch (500) drum as follows:

1 Secure the cable to the manual winch drum with the anchor bolt (refer to Figure 6).

2 Loosen the anchor bolt and place the cable assembly against the outside of the anchor bolt.

3 Wrap the cable around the manual winch drum one time and insert it between the anchor bolt and the drum flange with at least 0.5 in. (12.7

mm) of cable extending beyond the anchor bolt.

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4 Make sure the cable is routed correctly on the winch drum (refer to Figure 7). Tighten the anchor bolt firmly until it flattens cable against the manual winch drum.

5 Hold the cable taut and rotate the winch handle to wind the cable onto the manual winch drum.

NOTE: Maintain tension on the cable at all times to achieve proper cable position on the manual winch drum and to prevent accidental unwrapping.

(m) Install the two knurled head screws (360, 400) on the forward carrier assembly

(350) and aft carrier assembly (390).

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Correct Routing of Cable on Winch Drum Figure 7

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(2) Assemble the aft rail assembly (130) as follows:

(a) Put the clevis (210) in the aft rail assembly (130).

(b) Install the track (213) and rail cover (216) on the aft rail assembly (130). Make sure the holes on the track and rail cover are correctly aligned.

(c) Install the 14 flat head bolts (160) in the aft rail assembly (130).

(d) Install the two hex head bolts (170), split locking washers (180), and flat washers (190) in the aft inboard bracket (200).

(e) Secure the clevis (210) to the aft rail assembly with the ball lock pin (140).

(f) Install the ball lock pin (150) on the aft rail assembly (130).

(3) Assemble the forward rail assembly (40) as follows:

(a) Put the clevis (120) in the forward rail assembly (40).

(b) Install the track (123) and rail cover (126) on the forward rail assembly (40).

Make sure the holes on the track and rail cover are correctly aligned.

(c) Install the 14 flat head bolts (70) in the forward rail assembly (40).

(d) Install the two hex head bolts (80), split locking washers (90), and flat washers

(100) in the forward inboard bracket (110).

(e) Secure the clevis (120) to the forward rail assembly (40) with the ball lock pin (50)

(f) Install the ball lock pin (60) on the forward rail assembly (40).

(4) Assemble the spreader bar (30) as follows:

(a) Install the ball lock pins (20) on the two cable assemblies (10).

(b) Attach the two cable assemblies (10) to the spreader bar (30) with the ball lock pins (20).

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14. STORAGE AND SHIPMENT

A. Store the APU hoisting unit as follows:

(Refer to Figure 2)

(1) Open the covered storage box in the storage container. Put the spreader bar and two cables into the covered storage box as shown and close the lid of the storage box.

WARNING: THE OVERALL APU HOISTING UNIT, CONTAINER AND WINCH

ASSEMBLY ARE HEAVY COMPONENTS. TO PREVENT INJURY TO

PERSONNEL AND DAMAGE TO EQUIPMENT, USE TWO PEOPLE TO

LIFT, HANDLE, AND TRANSPORT THE ASSEMBLY ITEMS.

(2) Open the ten flexible draw latches in the storage container.

(3) Remove the two winch handles from the two manual winches and put them into the storage container. Close the two flexible draw latches to secure the winch handles.

(4) Carefully put the winch assembly arms into the area of the storage container labeled “WINCH ASSEMBLY”. Fit the remaining parts of the winch assembly in the storage box of the storage container (refer to Figure 1).

(5) Make sure that the cables do not catch on the storage container.

(6) Close the two flexible draw latches that secure the winch assembly arms.

(7) Install the forward fixed rail into the area of the storage container marked “FWD

RAIL ASSEMBLY”.

(8) Close the two flexible draw latches that secure the forward fixed rail assembly.

(9) Install the aft fixed rail into the area of the storage container marked “AFT RAIL

ASSEMBLY”.

(10) Close the two flexible draw latches that secure the aft fixed rail assembly.

(11) Close and secure the storage container as necessary. Make sure that the storage container lid retainers attached to the storage container lid are away from the storage container and lid edges when the cover is closed.

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15. ILLUSTRATED PARTS BREAKDOWN (REFER TO FIGURE 8)

A. This section includes the illustrations and tables that describe the assemblies, subassemblies, and detailed parts for the APU Hoisting Unit, part number AGE70078.

B. Vendor codes used in this manual and parts breakdown are listed below.

Code Name and Address

OTS34 ExxonMobil Lubricants and Petroleum Specialties Aviation Lubricants, L&PS Lubricants 3225 Gallows Road, Room 7C0428 Fairfax, VA 22037-0001 http://www.exxonmobil.com

12437 Thern Inc.

5712 Industrial Park Rd.

Winona, MN 55987-1448

3A054 McMaster Carr Supply Co.

9630 Norwalk Blvd.

Santa Fe Springs, CA 90670-2932

34227 Sandstrom Products Company 224 S. Main Street Port Byron, IL 61275-9501

55820 Hamilton Sundstrand Power Systems 4400 Ruffin Rd.

P.O. Box 85757 San Diego, CA 92186-5757

94222 Southco Customer Technical Support 210 N. Briton Lake Rd.

P.O. Box 0116 Concordville, PA 19331-0116

99862 Carr Lane Mfg Co.

4200 Carr Lane Ct.

St. Louis, MO 63119-2129

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APU Hoisting Unit Figure 8 (Sheet 1 of 9)

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Figure 8 (Sheet 2 of 9)

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Figure 8 (Sheet 3 of 9)

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Figure 8 (Sheet 4 of 9)

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Figure 8 (Sheet 5 of 9)

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Figure 8 (Sheet 6 of 9)

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Figure 8 (Sheet 7 of 9)

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Figure 8 (Sheet 8 of 9)

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APU Hoisting Unit Figure 8 (Sheet 9 of 9)

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FIG.

ITEM

PART

NUMBER

SMR

CODE 1 2 3 4 5 6 7 NOMENCLAT

EFF

CODE

UNITS

PER

ASSY

-1 AGE70078 PEOOZU HOISTING UNIT, APU – AIRCRAFT

MOUNTED (55820)

RF

10 AGE70078-1004 PAOOZN . CABLE ASSEMBLY (55820) 2

20 CL-4-BLPB-0.75-S-C PAOZZN . . PIN - BALL LOCK (99862) 4

30 AGE70078-1003 PEOZZN . SPREADER BAR (55820) 1

40 AGE70078-1000 PAOOZN . RAIL ASSEMBLY – FORWARD (55820) 1

50 CL-5-BLPB-0.75-S-C PAOZZN . . PIN - BALL LOCK (99862) 1

60 CL-6-BLPT-1.00-S-C PAOZZN . . PIN - BALL LOCK (99862) 1

70 AGE70078-50 PAOZZN . . BOLT - FLAT HEAD

(1/4-20 UNC-2A X 2.00) (NOTE 1)

80 AGE70078-47 PAOZZN . . BOLT - HEX HEAD

(1/4-20 UNC-2B X 2.25) (NOTE 1)

90 AGE70078-48 PAOZZN . . WASHER - SPLIT LOCKING

(1/4 NOM. I.D.) (NOTE 1)

100 AGE70078-49 PAOZZN . . WASHER - FLAT

(1/4 NOM. I.D.) (NOTE 1)

110 AGE70078-100 PAOZZN . . BRACKET - FORWARD INBOARD (55820) 1

120 AGE70078-5 PAOZZN . . CLEVIS (FLAT BAR – 1.250 X 0.875)

(55820)

123 RF1313X1.5 PAOZZN . . TRACK (55820) 1

126 AGE70078-1 PAOZZN . . RAIL (FLAT BAR – 0.625 X 1.50) (55820) 1

130 AGE70078-1001 PAOOZN . RAIL ASSEMBLY – AFT (55820) 1

140 CL-5-BLPB-0.75-S-C PAOZZN . . PIN - BALL LOCK (99862) 1

150 CL-6-BLPT-1.00-S-C PAOZZN . . PIN - BALL LOCK (99862) 1

160 AGE70078-50 PAOZZN . . BOLT - FLAT HEAD

(1/4-20 UNC-2A X 2.00) (NOTE 1)

170 AGE70078-47 PAOZZN . . BOLT - HEX HEAD

(1/4-20 UNC-2B X 2.25) (NOTE 1)

180 AGE70078-48 PAOZZN . . WASHER - SPLIT LOCKING

(1/4 NOM. I.D.) (NOTE 1)

190 AGE70078-49 PAOZZN . . WASHER - FLAT

(1/4 NOM. I.D.) (NOTE 1)

200 AGE70078-101 PAOZZN . . BRACKET - AFT INBOARD (55820) 1

210 AGE70078-5 PAOOZN . . CLEVIS (FLAT BAR – 1.250 X 0.875)

(55820)

213 RF1313X1.5 PAOZZN . . TRACK (55820) 1

216 AGE70078-9 PAOZZN . . RAIL (FLAT BAR – 0.625 X 1.50) (55820) 1

220 AGE70078-1002 PEOZZN . WINCH ASSEMBLY (55820) 1

230 AGE70078-108 PAOZZN . . CABLE ASSEMBLY (55820) 2

240 CL-4-BLPB-0.75-S-C PAOZZN . . . PIN - BALL LOCK (99862) 2

250 CL-6-BLPT-2.00-S-C PAOZZN . . PIN - BALL LOCK (99862) 2

260 CL-100-SH-S PAOZZN . . HANDLE (99862) 2

270 6461K45 PAOZZN . . ROLLER - TRACK STUD (3A054) 16

NOTE 1 - ITEM MAY BE PROCURED COMMERCIALLY.

- ITEM NOT ILLUSTRATED

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FIG.

ITEM

PART

NUMBER

SMR

CODE 1 2 3 4 5 6 7 NOMENCLATURE

EFF

CODE

UNITS

PER

ASSY

280 AGE70078-44 PAOZZN . . WASHER - LOCK

(7/16 NOM. I.D.) (NOTE 1)

290 AGE70078-45 PAOZZN . . NUT - HEX JAM

(7/16 UNC-2B) (NOTE 1)

300 93890A636 PAOZZN . . PIN - HEADLESS CLEVIS (3A054) 6

310 98408A136 PAOZZN . . RING - RETAINING - E-STYLE (3A054) 12

320 5905K63 PAOZZN . . BEARING - NEEDLE ROLLER (3A054) 6

330 AGE70078-70 PAOZZN . . PIN - DOWEL ( 1/4 X 1 3/4) 2

340 2473K14 PAOZZN . . ROLLER - MINIATURE DRIVE (3A054) 2

350 AGE70078-102 PAOOZN . . CARRIER ASSEMBLY - FORWARD

(55820)

360 CL-22-SHS-S PAOZZN . . . SCREW – KNURLED HEAD (99862)

(NOTE 1)

370 AGE70078-24 PAOZZN . . . ROLLER (ROUND BAR 1.375) (55820) 3

380 AGE70078-22 PAOZZN . . . BAR - FLAT (1.00 X 1.750) (55820) 1

390 AGE70078-103 PAOOZN . . CARRIER ASSEMBLY - AFT (55820) 1

400 CL-22-SH-S PAOZZN . . . SCREW – KNURLED HEAD (99862)

(NOTE 1)

410 AGE70078-24 PAOZZN . . . ROLLER (ROUND BAR 1.375) (55820) 3

420 AGE70078-22 PAOZZN . . . BAR - FLAT (1.00 X 1.750) (55820) 1

ATTACHING PARTS

430 AGE70078-51 PAOZZN . . BOLT - HEX HEAD

(3/8-16 UNC-2A X 1.62) (NOTE 1)

440 AGE70078-53 PAOZZN . . WASHER - FLAT

(3/8 NOM. I.D.) (NOTE 1)

450 AGE70078-54 PAOZZN . . WASHER - LOCK

(3/8 NOM. I.D.) (NOTE 1)

460 AGE70078-55 PAOZZN . . NUT - HEX JAM

(3/8-16 UNC-2B) (NOTE 1)

470 AGE70078-114 PAOZZN . . ANGLE (4.00 X 6.00 X 0.375 THICK)

(55820)

480 98381A516 PAOZZN . . PIN - DOWEL ( 3/16 HARDENED STEEL)

(3A054)

490 AGE70078-29 PAOZZN . . ROLLER (ROUND TUBE (0.500 OD X

0.058 W) (55820)

500 4622PB PAOZZN . . WINCH - MANUAL - WORM GEAR

(12437) (NOTE 1)

510 AGE70078-1005 MOOZZN . CONTAINER - STORAGE/SHIPPING

(55820)

520 J-37-20-087-10 PAOZZN . . LATCH - FLEXIBLE DRAW - T-HANDLE

STYLE (94222)

530 37-20-102-10 PAOZZN . . LATCH - FLEXIBLE DRAW - T-HANDLE

STYLE (94222)

NOTE 1 - ITEM MAY BE PROCURED COMMERCIALLY.

- ITEM NOT ILLUSTRATED

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