35d3-3-79-1_General_Info.pdf

TO 35D3-3-79-1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS WITH

ILLUSTRATED PARTS BREAKDOWN

INTERMEDIATE MAINTENANCE

AIRCRAFT ENGINE LIFT TRAILER

PART NUMBER

PT90-F-507

PT90-F-509

MCDONNELL DOUGLAS CORPORATION

MILITARY TRANSPORT AIRCRAFT

F33657-81-C-2108

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D - Distribution authorized to the Department of Defense and U.S. DoD contractors only for administrative and operational use, 16 November 1987. Other requests shall be referred to WR-ALC/564 ACSS-TOMA, Robins AFB, GA 31098-1607.

WARNING - This document contains technical data whose export is restricted by the DoD Authorization Act of 1984 (Title 10, U.S.C., Sec. 140c and Sec 1217) and the Arms Export Control Act (Title 22, U.S.C., Sec. 2751 et seq.), or Executive Order 12470, or the Export Administration Act of 1979 as amended (Title 50, U.S.C., App. 2401 et seq.). Violation of these export-control laws is subject to severe criminal penalties.

Dissemination of this document is controlled under DoD Directive 5230.25 and AFI 61-204.

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

Published under authority of the Secretary of the Air Force

22 APRIL 2010

CHANGE 4 - 1 JULY 2011

Basic and all changes have been merged to make this a complete publication.

Title A thru B C blank i thru v vi blank vii thru xi xii blank xiii xiv blank xv thru xvii xviii blank 1-1 1-2 1-3 thru 1-4 2-1 thru 2-4 2-4A added 2-4B blank added 2-5 thru 2-7 2-8 3-1 thru 3-2 3-3 3-4 3-5 thru 3-6 3-7 3-8 4-1 4-2 4-3 thru 4-5 4-6 thru 4-7 4-8 thru 4-16 4-17 thru 4-18 4-19 thru 4-21 4-22 thru 4-24 4-25 thru 4-27 4-28 thru 4-29 4-30 thru 4-31 4-32 4-33 4-34 4-35 thru 4-37 4-38 thru 4-41 4-42 blank 5-1 5-2 5-2A added 5-2B blank added 5-3 thru 5-4 5-5 5-6 thru 5-71

5-72 5-73 5-74 thru 5-96 5-97 5-98 5-99 thru 5-100 5-101 5-102 5-103 thru 5-127 5-128 thru 5-129 5-130 thru 5-146 5-147 5-148 thru 5-159 5-160 5-161 thru 5-167 5-168 thru 5-170 5-171 5-172 thru 5-173 5-174 5-175 thru 5-176 5-177 thru 5-178 5-179 5-180 thru 5-181 5-182 5-183 5-184 thru 5-209 5-210 thru 5-212 5-212A thru 5-212B added . . . 3 5-213 5-214 thru 5-215 5-216 thru 5-238 6-1 thru 6-23 6-24 blank 6-25 6-26 blank 6-27 6-28 blank 6-29 6-30 blank 6-31 6-32 blank 6-33 6-34 blank 6-35 6-36 blank 6-37 6-38 blank 6-39 6-40 blank

6-41 thru 6-43 6-44 blank 6-45 6-46 blank 6-47 thru 6-57 6-58 blank 7-1 thru 7-4 7-5 thru 7-15 7-16 blank 7-17 thru 7-20 7-21 blank 7-22 thru 7-28 7-29 7-30 7-31 7-32 thru 7-35 7-36 blank 7-37 7-38 7-39 blank 7-40 thru 7-50 7-51 thru 7-54 7-55 blank 7-56 7-57 7-58 thru 7-62 7-63 thru 7-64 7-65 blank 7-66 thru 7-69 7-70 blank 7-71 thru 7-72 7-73 blank 7-74 thru 7-75 7-76 blank 7-77 7-78 thru 7-81 7-82 blank 7-83 7-84 7-85 blank 7-86 thru 7-90 7-91 thru 7-92 7-93 blank 7-94 thru 7-97 7-98 blank 7-99 7-100 7-101 blank 7-102

TO 35D3-3-79-1

Dates of issue for original and changed pages are:

Original . . . . . 0 . . . . . 22 Apr 10 Change . . . . . 1 . . . . . 1 Jul 10 Change . . . . . 2 . . . . . 16 Aug 10 Change . . . . . 3 . . . . . 1 Jan 11 Change . . . . . 4 . . . . . 1 Jul 11

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 672 CONSISTING OF THE FOLLOWING:

A CHANGE 4 USAF

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

*Zero in this column indicates an original page.

Page No.

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* Change No.

7-103 7-104 thru 7-108 7-109 7-110 thru 7-111 7-112 thru 7-115 7-116 blank 7-117 7-118 7-119 blank 7-120 thru 7-122 7-123 7-124 thru 7-134 7-135 7-136 7-137 thru 7-138 7-139 blank 7-140 thru 7-141 7-142 blank 7-143 thru 7-144 7-145 blank 7-146 thru 7-166 7-167 thru 7-169 7-170 thru 7-187 7-188 blank 7-189 7-190 thru 7-193 7-194 7-195 thru 7-196 7-197 7-198 thru 7-201 7-202 thru 7-206 7-207 thru 7-209 7-210 thru 7-211 7-212 thru 7-213 7-214 blank 7-215 thru 7-216 7-217 blank 7-218 7-219 thru 7-220 7-221 blank 7-222 thru 7-224 7-225 thru 7-226 7-227 blank 7-228 thru 7-230 7-231 thru 7-232 7-233 blank 7-234 thru 7-238 7-239 blank 7-240 thru 7-243 7-244 blank 7-245 7-246 7-247 7-248 7-249 blank 7-250 7-251 7-252 7-253 blank 7-254 thru 7-266 7-267 thru 7-279 7-280 blank 8-1

8-2 blank Index 1 thru Index 4

TO 35D3-3-79-1

CHANGE 4 B/(C BLANK)

LIST OF EFFECTIVE PAGES - Continued

*Zero in this column indicates an original page.

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TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . vii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . ix

LIST OF TIME COMPLIANCE TECHNICAL

ORDERS (TCTO’s) . . . . . . . . . . . . . . . . . xiii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . xv

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xvii

1 GENERAL INFORMATION . . . . . . . . . . 1-1

1-1 Function . . . . . . . . . . . . . . . . . . . 1-1 1-4 Use of this Manual . . . . . . . . . 1-1 1-6 Equipment Description . . . . . . . . . 1-1 1-15 Leading Particulars . . . . . . . . . 1-3 1-17 Difference Data Sheets . . . . . . 1-3

2 SPECIAL TOOLS, TEST EQUIPMENT

AND CONSUMABLES . . . . . . . . . . . . 2-1

2-1 Special Tools List . . . . . . . . . . . . . 2-1 2-3 Test Equipment List . . . . . . . . . . . 2-1 2-5 Consumables . . . . . . . . . . . . . . . . 2-1 2-7 Local Manufactured Items . . . . . . . 2-1

3 PREPARATION FOR USE AND

SHIPMENT . . . . . . . . . . . . . . . . . . . . 3-1

3-1 Preparation for Use . . . . . . . . . . . . 3-1 3-3 Preparation for Towing and Shipment

(Air/Ground) . . . . . . . . . . . . . . 3-2 3-5 Shoring Procedures for Air/

Ground Shipment . . . . . . 3-3 3-7 Alternate Shoring

Procedures . . . . . . . . . . . 3-4

4 OPERATION INSTRUCTIONS . . . . . . . 4-1

4-1 Theory of Operation . . . . . . . . . . . 4-1 4-3 Work Platform Assembly . . . . . 4-1 4-12 Winch Clamp Assembly . . . . . 4-1 4-14 I-Beam Cradle . . . . . . . . . . . . 4-3 4-22 Upper Frame Assembly . . . . . . 4-3 4-27 Center Section Assembly . . . . . 4-4 4-31 Lower Frame Assembly . . . . . . 4-4 4-40 Hydraulic System . . . . . . . . . . 4-5 4-48 Electrical System . . . . . . . . . . 4-5 4-63 Weighing System . . . . . . . . . . 4-9 4-70 Alarm Function . . . . . . . . . . . . . . 4-10 4-73 Function . . . . . . . . . . . . . . . . . . . 4-10

4-85 Operation Instructions . . . . . . . . . . 4-14 4-87 Preliminary Procedures . . . . . . 4-14 4-89 Setup and Positioning . . . . . . . 4-14 4-98 Operation . . . . . . . . . . . . . . . 4-32 4-100 Setting Load and Load Limit . . 4-34 4-102 Controls and Indicators . . . . . . 4-34 4-104 Emergency Operations . . . . . . . 4-34

5 MAINTENANCE INSTRUCTIONS . . . . . 5-1

5-1 General . . . . . . . . . . . . . . . . . . . . 5-1 5-3 Operational Checkout . . . . . . . . . . 5-1 5-5 Control Pendant Check . . . . . . 5-1 5-7 Brake Check . . . . . . . . . . . . . 5-1 5-9 Tire Check . . . . . . . . . . . . . . 5-2 5-11 Front and Rear Steering

Check . . . . . . . . . . . . . . . . . 5-2 5-13 Wheel Check . . . . . . . . . . . . . 5-2A 5-15 Inspection and Preventive

Maintenance . . . . . . . . . . . . . . . 5-2A 5-17 Inspection . . . . . . . . . . . . . . . 5-2A 5-19 Preventive Maintenance . . . . . . 5-5 5-21 Fault Isolation . . . . . . . . . . . . . . . 5-10 5-23 Repair . . . . . . . . . . . . . . . . . . . . . 5-70 5-25 Disassembly . . . . . . . . . . . . . 5-70 5-26 Lift Trailer Disassembly . . 5-70 5-27 Lift Trailer Ladder

Assembly . . . . . . . . . . . 5-73 5-28 Jib Crane Assembly . . . . . 5-73 5-29 Platform Assembly . . . . . . 5-76 5-35 Barrier Assembly . . . . . . . 5-81 5-42 Primary Pendant Junction

Box . . . . . . . . . . . . . . . 5-82 5-43 Hydraulic Assembly . . . . . 5-82 5-44 Winch Assembly . . . . . . . 5-83 5-45 I-Beam Cradle Assembly . . 5-83 5-46 Load Cell Amplifier

Assembly . . . . . . . . . . . 5-85 5-47 Positioning Frame

Assembly . . . . . . . . . . . 5-85 5-48 Hydraulic System . . . . . . . 5-86 5-49 Upper Frame Assembly . . . 5-89 5-50 Control Pendant

Assembly . . . . . . . . . . . 5-90 5-51 Junction Box . . . . . . . . . . 5-91 5-52 Transmission Assembly . . . 5-91 5-53 Control System Assembly

(A1A1) . . . . . . . . . . . . . 5-94

CHANGE 4 i

5-54 AC Power Filter Assembly . . . . . . . . . . . 5-96

5-55 Frame Assemblies . . . . . . . 5-97 5-56 Running Gear Brake

Lines . . . . . . . . . . . . . . 5-97 5-57 Drawbar Assembly . . . . . . 5-98 5-60 Front Axle Assembly . . . . . 5-100 5-61 Rear Axle Assembly . . . . . 5-101 5-62 Hub and Drum Assembly . . 5-101 5-63 Brake Assembly . . . . . . . . 5-101 5-64 Cleaning . . . . . . . . . . . . . 5-102 5-66 Replacement . . . . . . . . . . . . . 5-102 5-68 Retaining Cable . . . . . . . . 5-102 5-70 Strap Assembly . . . . . . . . 5-102 5-72 Snap Hook . . . . . . . . . . . 5-102 5-74 Storage Box . . . . . . . . . . . 5-103 5-76 Pad . . . . . . . . . . . . . . . . . 5-103 5-78 Storage Box . . . . . . . . . . . 5-103 5-80 Control Pendant Assembly, A7, A3 . . . . . . . . . . . . . 5-104 5-82 Connector . . . . . . . . . . . . 5-104 5-84 Joystick . . . . . . . . . . . . . . 5-104 5-86 Switch . . . . . . . . . . . . . . 5-105 5-88 Selector Switch . . . . . . . . 5-105 5-90 Switch . . . . . . . . . . . . . . 5-105 5-92 Lens . . . . . . . . . . . . . . . . 5-106 5-94 **ESD** Display Circuit

Card Assembly . . . . . . . . 5-106 5-96 Connector . . . . . . . . . . . . 5-106 5-98 Terminal Board . . . . . . . . 5-107 5-100 Storage Box . . . . . . . . . . . 5-107 5-102 Remote Control Holder . . . 5-108 5-104 Pivot Bracket . . . . . . . . . . 5-108 5-106 Gas Cylinder . . . . . . . . . . 5-109 5-108 Adapter . . . . . . . . . . . . . . 5-109 5-110 Ladder Assembly . . . . . . . 5-110 5-112 Jib Crane . . . . . . . . . . . . . 5-110 5-114 Maintenance Platform

Assembly . . . . . . . . . . . 5-111 5-116 Barrier Assembly . . . . . . . 5-111 5-118 Platform . . . . . . . . . . . . . 5-112 5-120 Handle . . . . . . . . . . . . . . 5-113 5-122 Platform . . . . . . . . . . . . . 5-113 5-124 Support Bracket . . . . . . . . 5-114 5-126 Guide Bracket . . . . . . . . . 5-114 5-128 Guide Bracket . . . . . . . . . 5-114

5-130 Hydraulic Maintenance Platform Assembly . . . . . 5-114

5-132 Cylinder Assembly . . . . . . 5-115 5-134 Hinge . . . . . . . . . . . . . . . 5-116 5-136 Platform . . . . . . . . . . . . . 5-116 5-138 Platform . . . . . . . . . . . . . 5-117 5-140 Support Bracket . . . . . . . . 5-118 5-142 Support Bracket . . . . . . . . 5-118 5-144 Clamp Assembly . . . . . . . 5-119 5-146 Winch Bracket Assembly . . 5-119 5-148 Handle . . . . . . . . . . . . . . 5-119 5-150 Winch Cable Assembly . . . 5-119 5-152 Shackle . . . . . . . . . . . . . . 5-120 5-154 Bracket . . . . . . . . . . . . . . 5-120 5-156 Pin . . . . . . . . . . . . . . . . . 5-120 5-158 I-Beam Extrusion Support

Jack . . . . . . . . . . . . . . . 5-120 5-160 I-Beam Rail Support

Jack . . . . . . . . . . . . . . . 5-121 5-162 Bracket . . . . . . . . . . . . . . 5-121 5-164 Bracket . . . . . . . . . . . . . . 5-121 5-166 Screw Jack . . . . . . . . . . . 5-121 5-168 Leg . . . . . . . . . . . . . . . . 5-122 5-170 Hose Clamp . . . . . . . . . . . 5-123 5-172 Protective Boot . . . . . . . . 5-123 5-174 Cover . . . . . . . . . . . . . . . 5-123 5-176 Base . . . . . . . . . . . . . . . . 5-124 5-178 Rail Stop . . . . . . . . . . . . . 5-124 5-181 Clamping Bracket . . . . . . . 5-124 5-183 Bow Assembly . . . . . . . . . 5-124 5-186 Rolling Plate . . . . . . . . . . 5-125 5-188 Actuator-Roll . . . . . . . . . . 5-125 5-190 Actuator Clevis . . . . . . . . 5-126 5-192 Actuator-Axial . . . . . . . . . 5-126 5-194 **ESD** Circuit Card

Assembly . . . . . . . . . . . 5-126 5-196 Enclosure . . . . . . . . . . . . 5-127 5-198 Load Cell/Slide Plate

Cover . . . . . . . . . . . . . . 5-128 5-200 Roller . . . . . . . . . . . . . . . 5-130 5-202 Ring Bolt . . . . . . . . . . . . 5-130 5-204 Bumper Pad . . . . . . . . . . . 5-130 5-206 Swivel-Ring Bolt . . . . . . . 5-130 5-208 Actuator Assembly-

Lateral . . . . . . . . . . . . . 5-131 5-210 Hydraulic Box Assembly . . 5-131

TO 35D3-3-79-1

TABLE OF CONTENTS - Continued ii CHANGE 4

5-212 Power Unit Assembly . . . . 5-136 5-214 Hydraulic Pump/Motor

Coupling . . . . . . . . . . . . 5-137 5-216 Motor/Pump Adapter . . . . . 5-137 5-218 Electric Motor . . . . . . . . . 5-137 5-220 Pump . . . . . . . . . . . . . . . 5-137 5-222 Reservoir . . . . . . . . . . . . . 5-138 5-224 Valve . . . . . . . . . . . . . . . 5-138 5-226 Pressure Filter Assembly . . 5-139 5-229 Solenoid Valve . . . . . . . . . 5-140 5-232 Valve . . . . . . . . . . . . . . . 5-140 5-234 Manifold . . . . . . . . . . . . . 5-141 5-236 Check Valve . . . . . . . . . . 5-142 5-238 Valve . . . . . . . . . . . . . . . 5-142 5-240 Foot Pad Assembly . . . . . . 5-142 5-242 Rigid Mounted Chain

Tensioner . . . . . . . . . . . 5-143 5-244 Adjustable Chain

Tensioner . . . . . . . . . . . 5-144 5-246 Chain . . . . . . . . . . . . . . . 5-144 5-248 4630-1 Sprocket . . . . . . . . 5-145 5-250 60C20 and 60B20

Sprocket . . . . . . . . . . . . 5-145 5-252 Potentiometer . . . . . . . . . . 5-145 5-254 Electric Motor . . . . . . . . . 5-146 5-256 Gear Reducer . . . . . . . . . . 5-147 5-258 Bushing . . . . . . . . . . . . . 5-147 5-260 Heater . . . . . . . . . . . . . . . 5-148 5-262 Plate . . . . . . . . . . . . . . . . 5-148 5-264 Contactor, K1 . . . . . . . . . 5-148 5-266 Relay Circuit Card

Assembly . . . . . . . . . . . 5-149 5-268 Barrier . . . . . . . . . . . . . . 5-149 5-270 Mounting Rail . . . . . . . . . 5-150 5-272 Thermal Switch S1, S2, and

S3 . . . . . . . . . . . . . . . . 5-151 5-274 Relay K3 and K4 . . . . . . . 5-151 5-276 Relay K2 . . . . . . . . . . . . . 5-152 5-278 High Current CCA A21 and

A22 . . . . . . . . . . . . . . . 5-152 5-280 Low Current CCA A20 . . . 5-153 5-282 Power Supply, PS1 . . . . . . 5-153 5-284 Wiring Duct . . . . . . . . . . . 5-154 5-286 Grounding Bus . . . . . . . . . 5-154 5-288 Power Resistor HR1 and

HR2 . . . . . . . . . . . . . . . 5-155

5-290 Power Resistor HR3 thru

HR5 . . . . . . . . . . . . . . . 5-155

5-292 Terminal Board . . . . . . . . 5-156 5-294 Analog Input Controller

A24A1 and A24A2 . . . . . 5-156 5-296 Input/Output Controller

A23A2 thru A23A4 and A24A3 . . . . . . . . . . . . . 5-157

5-298 Central Processing Unit Controller A23A1 . . . . . . 5-157

5-300 Heater Shield . . . . . . . . . . 5-158 5-302 **ESD** Electrically

Erasable Programmable Read-Only Memory Card . . . . . . . . . . . . . . . 5-158

5-304 Alarm Assembly . . . . . . . . 5-159 5-306 Lower Limit Switch . . . . . 5-159 5-308 Aft Upper Limit Switch . . . 5-160 5-310 Forward Upper Limit

Switch . . . . . . . . . . . . . 5-161 5-312 Axis Limit Switch . . . . . . 5-161 5-314 Aft Limit Switch . . . . . . . 5-161 5-316 Centering Position

Sensor . . . . . . . . . . . . . 5-162 5-318 Magnet Assembly . . . . . . . 5-162 5-320 On/Off Circuit Breaker . . . 5-162 5-322 Junction Box Harness

Assembly . . . . . . . . . . . 5-163 5-324 Error Code and/or

Maintenance Enable Switch . . . . . . . . . . . . . 5-163

5-326 Tensioner . . . . . . . . . . . . 5-163 5-328 **ESD** Relay Circuit Card

Assembly . . . . . . . . . . . 5-164 5-330 **ESD** Low Pass Filter

Assembly . . . . . . . . . . . 5-164 5-332 CPU Controller A23A1

Battery . . . . . . . . . . . . . 5-164 5-334 Power in Junction Box

Harness Assembly . . . . . . 5-165 5-336 Power in Junction Box . . . 5-165 5-338 Auxiliary Pendant Junction

Box . . . . . . . . . . . . . . . 5-166 5-340 EMI Filter . . . . . . . . . . . . 5-166 5-342 Grounding

Connector/Reel . . . . . . . . 5-167 5-344 Pintle Assembly . . . . . . . . 5-167 5-346 Drawbar Assembly . . . . . . 5-168

TO 35D3-3-79-1

TABLE OF CONTENTS - Continued

CHANGE 4 iii

5-349 Surge Actuator . . . . . . . . . 5-168 5-352 Wheel/Tire Assembly . . . . 5-169 5-354 Hub . . . . . . . . . . . . . . . . 5-170 5-356 Left Brake Assembly . . . . . 5-171 5-358 Right Brake Assembly . . . . 5-171 5-360 Brakes . . . . . . . . . . . . . . 5-172 5-362 Handbrake Lever . . . . . . . 5-172 5-364 Forward Tie Rod

Assembly . . . . . . . . . . . 5-173 5-366 Aft Tie Rod Assembly . . . . 5-173 5-368 Spindle and Knuckle . . . . . 5-174 5-370 Forward Center Arm

Assembly . . . . . . . . . . . 5-174 5-372 Locking Strut Assembly . . . 5-175 5-374 Aft Center Arm . . . . . . . . 5-175 5-376 Assembly . . . . . . . . . . . . . . . 5-176 5-378 Brake Assembly . . . . . . . . 5-176 5-379 Hub and Drum Assembly . . 5-176 5-381 Rear Axle Assembly . . . . . 5-176 5-382 Front Axle Assembly . . . . . 5-180 5-383 Drawbar Assembly . . . . . . 5-181 5-386 Running Gear Brake

Lines . . . . . . . . . . . . . . 5-182 5-387 Frame Accessories . . . . . . 5-185 5-388 AC Power Filter

Assembly . . . . . . . . . . . 5-185 5-389 Control System

Assembly . . . . . . . . . . . 5-185 5-390 Transmission Assembly . . . 5-191 5-391 Junction Box Assembly . . . 5-192 5-392 Control Pendant Box . . . . . 5-192 5-393 Upper Frame Assembly . . . 5-194 5-394 Hydraulic System . . . . . . . 5-194 5-395 Positioning Frame . . . . . . . 5-197 5-396 Load Cell Amplifier

Assembly . . . . . . . . . . . 5-197 5-397 I-Beam Cradle Assembly . . 5-198 5-398 Winch Assembly . . . . . . . 5-199 5-399 Hydraulic Assembly . . . . . 5-200 5-400 Primary Pendant Junction

Box . . . . . . . . . . . . . . . 5-200 5-401 Barrier Assembly . . . . . . . 5-201 5-408 Platform Assembly . . . . . . 5-202 5-414 Jib Crane . . . . . . . . . . . . . 5-207 5-415 Lift Trailer Ladder

Assembly . . . . . . . . . . . 5-208

5-416 Lift Trailer Assembly . . . . 5-209 5-417 Alignment . . . . . . . . . . . . . . . 5-210 5-419 Forward Running Gear

Wheel Alignment . . . . . . 5-210 5-420 Aft Running Gear Wheel

Alignment . . . . . . . . . . . 5-211 5-421 Bleed and Service Hydraulic

Brake System . . . . . . . . . . . . 5-212 5-423 Bleed and Service Surge

Actuator . . . . . . . . . . . . . . . 5-212A 5-425 Surge Actuator Assembly . . . . . 5-212A 5-428 Lunette and Plunger Assembly

Inspection and Overhaul . . . . 5-214 5-430 Master Cylinder Assembly

Inspection and Overhaul . . . . 5-215 5-432 Testing . . . . . . . . . . . . . . . . . 5-216 5-433 Functional Test Preparation . . . 5-216 5-434 Rail Movements Functional

Test . . . . . . . . . . . . . . . 5-216 5-435 Axial Movement . . . . . . . . 5-216 5-436 Lateral Movement . . . . . . . 5-217 5-437 Yaw Movement . . . . . . . . 5-217 5-438 Roll Movement . . . . . . . . 5-217 5-439 Pitch Movement . . . . . . . . 5-218 5-440 Lifting Mechanism Functional

Test . . . . . . . . . . . . . . . . . . 5-218 5-441 Lifting/Stabilizing Pads

Functional Test . . . . . . . . . . . 5-220 5-442 Rail Driver Load Limiting

Functional Test . . . . . . . . . . . 5-220 5-443 Axial Load . . . . . . . . . . . 5-220 5-445 Lateral Load . . . . . . . . . . 5-221 5-447 Roll . . . . . . . . . . . . . . . . 5-222 5-449 Hydraulic Maintenance Platform

Assembly Functional Test . . . 5-222 5-451 Weighing System Functional

Test . . . . . . . . . . . . . . . . . . 5-223 5-453 Overload Reversal System

Functional Test . . . . . . . . . . . 5-223 5-455 Out of Balance Alarm Functional

Test . . . . . . . . . . . . . . . . . . 5-224 5-457 Negative Load Functional

Test . . . . . . . . . . . . . . . . . . 5-224 5-459 Calibration of t0001 thru t0004 . . . . . . . . . . . . . . . . . 5-225 5-461 Calibration of Lower Limits for t0005, t0006, t0007, and t0008 . . . . . . . . . . . . . . . . . 5-226

TO 35D3-3-79-1

TABLE OF CONTENTS - Continued iv CHANGE 4

5-463 Calibration of Upper Limits for t0005, t0006, t0009, and t0010 . . . . . . . . . . . . . . . . . 5-228

5-465 Calibration of Off Center Limits for t0013 and t0014 . . . . . . . 5-228

5-467 Brake Burnishing . . . . . . . . . . 5-229 5-469 Hydraulic System Pressure

Test . . . . . . . . . . . . . . . . . . 5-230 5-471 Lift Trailer Towing and Steering

Test . . . . . . . . . . . . . . . . . . 5-230 5-473 Periodic Load Test . . . . . . . . . 5-231 5-475 Lower Limit Switch

Adjustment . . . . . . . . . . . . . 5-231 5-477 Upper Limit Switch

Adjustment . . . . . . . . . . . . . 5-232 5-479 Axis Limit Switch

Adjustment . . . . . . . . . . . . . 5-233 5-481 Aft Limit Switch Adjustment . . 5-234 5-483 Centering Position Sensor and

Cup Holding Magnet Assembly Adjustment . . . . . . . . . . . . . 5-234

5-485 Load Ladder Logic to Central Processing Unit Controller

(CPU) . . . . . . . . . . . . . . . . . 5-234

5-487 Pendant Switch Verification Test . . . . . . . . . . . . . . . . . . 5-235

5-489 Pendant Cable Self-Test and Display Test . . . . . . . . . . . . . 5-237

5-491 Maintenance Cycle Count Setting . . 5-237 5-493 Maintenance Cycle Count

Procedure . . . . . . . . . . . . . . . . . 5-237 5-494 Hiding Fault Code E0600

Maintenance Cycle Count Full . . 5-238

6 DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1 General . . . . . . . . . . . . . . . . . . . . 6-1

7 ILLUSTRATED PARTS

BREAKDOWN . . . . . . . . . . . . . . . . . . 7-1

7-1 Scope . . . . . . . . . . . . . . . . . . 7-1 7-4 Contents . . . . . . . . . . . . . . . . 7-1 7-6 Maintenance Parts List . . . . . . 7-1 7-8 Parts Listed . . . . . . . . . . . 7-1 7-15 Figure and Index

Number . . . . . . . . . . . . . 7-1 7-18 Part Number . . . . . . . . . . 7-1 7-23 Commercial and Government

Entity (CAGE) . . . . . . . . 7-2 7-25 Description . . . . . . . . . . . 7-2 7-36 Units per Assembly . . . . . . 7-3 7-39 Usable on Code . . . . . . . . 7-3 7-40 Source, Maintenance, and

Recoverability (SMR) Codes . . . . . . . . . . . . . . 7-3

7-41 Symbols . . . . . . . . . . . . . 7-3 7-42 Numerical Index . . . . . . . . . . . . . . 7-3 7-44 Part Number . . . . . . . . . . 7-3 7-46 Figure and Index

Number . . . . . . . . . . . . . 7-4 7-47 How to Use the Illustrated Parts

Breakdown . . . . . . . . . . . . . . . . 7-4

7-55 NUMERICAL INDEX . . . . . . . . . 7-254

8 DIFFERENCE DATA SHEETS . . . . . . . 8-1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

TO 35D3-3-79-1

TABLE OF CONTENTS - Continued

CHANGE 4 v/(vi blank)

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Aircraft Engine Lift Trailer . . . . . . . . . . 1-2

2-1 Aircraft Engine Lift Trailer Special Tools . . . . . . . . . . . . . . . . . . . . . . . 2-5

2-2 Aircraft Engine Lift Trailer Test Equipment . . . . . . . . . . . . . . . . . . . . 2-7

2-3 Aircraft Engine Lift Trailer Drive Down Adapter Tool . . . . . . . . . . . . . . . . . . 2-8

3-1 Aircraft Engine Lift Trailer Tiedown Points . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-2 Aircraft Engine Lift Trailer Shoring . . . . . 3-6

3-3 Attitude of Low Boy Loading Aircraft Engine Lift Trailer . . . . . . . . . . . . . . . 3-8

4-1 Lift Trailer Major Assemblies and Systems . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2 Hydraulic System Block Diagram . . . . . . 4-6

4-3 Electrical System Block Diagram . . . . . . 4-7

4-4 Lift Trailer Setup and Positioning . . . . . 4-17

4-5 Powered Work Platform Setup and Positioning . . . . . . . . . . . . . . . . . . . . 4-22

4-6 Winch Clamp Assembly Set Up and Positioning . . . . . . . . . . . . . . . . . . . . 4-23

4-7 Work Platform Assembly Set Up and Positioning . . . . . . . . . . . . . . . . . . . . 4-24

4-8 Jib Crane Set Up and Positioning . . . . . . 4-28

4-9 Lift Trailer Operation . . . . . . . . . . . . . . 4-33

4-10 Control Pendant . . . . . . . . . . . . . . . . . . 4-38

4-11 Lift Trailer Barrier Set Up and Positioning . . . . . . . . . . . . . . . . . . . 4-39

4-12 Cable Assembly Installation . . . . . . . . . . 4-41

5-1 Alarm Assembly . . . . . . . . . . . . . . . . . . 5-160

5-2 Brake Cylinder Orientation . . . . . . . . . . 5-177

6-1 Interconnection Block Diagram . . . . . . . 6-23

6-2 Control System Schematic Diagram . . . . 6-29

6-3 AC Power Filter Assembly Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-41

6-4 AC Power Junction Box Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-42

6-5 Primary Pendant Junction Box Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-43

6-6 Pendant Schematic Diagram . . . . . . . . . . 6-45

6-7 AC Power Filter Assembly Schematic Diagram . . . . . . . . . . . . . . . . . . . . . . 6-47

6-8 Electrical Component Connection Arrangement . . . . . . . . . . . . . . . . . . 6-48

7-1 Lift Trailer, Aircraft Engine - ETU - 119/M . . . . . . . . . . . . . . . . . . . . . . 7-7

7-2 Maintenance Platform Installation, Lift Trailer . . . . . . . . . . . . . . . . . . . . . . 7-22

7-3 Lift Trailer Ladder Assembly . . . . . . . . . 7-32

7-4 Jib Crane Assembly . . . . . . . . . . . . . . . 7-40

7-5 Maintenance Platform Assembly . . . . . . . 7-56

7-6 Barrier Assembly, Maintenance Platform Assembly . . . . . . . . . . . . . . . . . . . . 7-58

7-7 Maintenance Platform Assembly, End, FWD LH, AFT RH . . . . . . . . . . . . . 7-66

7-8 Maintenance Platform Assembly, End, FWD RH, AFT LH . . . . . . . . . . . . . 7-74

7-9 Hydraulic Maintenance Platform Assembly . . . . . . . . . . . . . . . . . . . . 7-78

7-10 Maintenance Platform Assembly, FWD LH, FWD RH . . . . . . . . . . . . . . . . . . . . 7-86

7-11 Maintenance Platform Assembly, AFT LH, AFT RH . . . . . . . . . . . . . . . . . . . . . 7-94

7-12 Winch and Bracket Assembly . . . . . . . . . 7-102

7-13 I-Beam Cradle Assembly . . . . . . . . . . . 7-104

7-14 Positioning Frame Assembly, Lift Trailer . . . . . . . . . . . . . . . . . . . . . . 7-112

7-15 Upper Frame Assembly . . . . . . . . . . . . 7-120

7-16 Aircraft Engine Lift Assembly . . . . . . . . 7-124

7-17 Aircraft Engine Installation Lift Trailer Axle . . . . . . . . . . . . . . . . . . . . . . . . 7-140

7-18 Hydraulic System . . . . . . . . . . . . . . . . 7-146

7-19 Electrical System Mechanical Installation . . . . . . . . . . . . . . . . . . . 7-172

7-20 Lift Trailer Control System Assembly (A1A1) . . . . . . . . . . . . . . . . . . . . . . 7-202

7-21 Control Pendant Assembly . . . . . . . . . . 7-212

7-22 Aircraft Engine Lift Trailer Plate Installation . . . . . . . . . . . . . . . . . . . . 7-218

CHANGE 4 vii

7-23 Brake System Installation . . . . . . . . . . . 7-222

7-24 Drawbar Assembly Engine Lift Trailer . . 7-228

7-25 Drawbar Assembly Engine Lift Trailer . . 7-234

7-26 Front and Rear Axle Assemblies . . . . . . 7-240

7-27 Axle Assemblies Hub and Drum and Brake Assemblies . . . . . . . . . . . . . . . . . . . . 7-250

TO 35D3-3-79-1

LIST OF ILLUSTRATIONS - Continued viii CHANGE 4

LIST OF TABLES

1-1 Leading Particulars . . . . . . . . . . . . . . . . 1-3

2-1 Special Tools List . . . . . . . . . . . . . . . . . 2-1

2-2 Test Equipment List . . . . . . . . . . . . . . . 2-2

2-3 List of Consumables . . . . . . . . . . . . . . . 2-3

3-1 Towing Force Calculations for Engine Lift Trailer Towing Vehicle . . . . . . . . . . . . 3-7

4-1 Controls and Indicators . . . . . . . . . . . . . 4-36

5-1 Inspection . . . . . . . . . . . . . . . . . . . . . . 5-3

5-2 Lubrication Requirements . . . . . . . . . . . 5-5

5-3 Preventive Maintenance . . . . . . . . . . . . . 5-6

5-4 Fault Isolation - No Operation or Power From Either Control Pendant. LEDS and/or Display Not Active Above 45°F . . . . . . . . . . . . . . . . . . . 5-11

5-5 Fault Isolation - No Operation From Main Control Pendant . . . . . . . . . . . . . . . . 5-12

5-6 Fault Isolation - No Operation From Remote Control Pendant . . . . . . . . . . . 5-12

5-7 Fault Isolation - No Lift Trailer System Operation With Electrical Power On Control Pendants Are Powered . . . . . . 5-13

5-8 Fault Isolation - Hydraulic Motor Does Not Operate; No Motors Operate . . . . . . . . 5-13

5-9 Fault Isolation - Fwd Lift Trailer Lift Motor and Hydraulic Motor Will Not Operate . . . . . . . . . . . . . . . . . . . . . . 5-14

5-10 Fault Isolation - Fwd Lift Motor Will Not Operate . . . . . . . . . . . . . . . . . . . . . . 5-14

5-11 Fault Isolation - Aft Lift Motor Will Not Operate . . . . . . . . . . . . . . . . . . . . . . 5-16

5-12 Fault Isolation - Hydraulic Motor Does Not Operate; Lift Trailer Cannot Be Positioned With Hydraulic Actuators . . 5-17

5-13 Fault Isolation - Hydraulic Motor Moves Slowly . . . . . . . . . . . . . . . . . . . . . . . 5-17

5-14 Fault Isolation - Fwd Lift Motors Operate In Same Direction Regardless of UP/Down Motion of Joystick (Either Pendant) . . . . . . . . . . . . . . . . . . . . . 5-18

5-15 Fault Isolation - Aft Lift Motors Operate In Same Direction Regardless of UP/Down Motion of Joystick (Either Pendant) . . . 5-19

5-16 Fault Isolation - Both Pendants Do Not Respond To Changes In Weight Or Fail To Read Actual Load on Lift Trailer . . 5-19

5-17 Fault Isolation - Main Pendant Display Does Not Respond To Changes In Weight . . . . . . . . . . . . . . . . . . . . . . . 5-21

5-18 Fault Isolation - Remote Pendant Display Does Not Respond To Changes In Weight . . . . . . . . . . . . . . . . . . . . . . . 5-22

5-19 Fault Isolation - No Lift Trailer With Electrical Power Normal, Temperature Is Low and Heaters Have Had Twenty Minutes of Warm up . . . . . . . . . . . . . 5-22

5-20 Fault Isolation - Lift Trailer In Low Temperatures Takes Long Time To Warm Up . . . . . . . . . . . . . . . . . . . . . . . . . 5-23

5-21 Fault Isolation - Lift Trailer Has Slow Forward Left Yaw . . . . . . . . . . . . . . . 5-24

5-22 Fault Isolation - Lift Trailer Has No Forward Left Yaw . . . . . . . . . . . . . . . 5-25

5-23 Fault Isolation - Lift Trailer Has Slow Forward Right Yaw . . . . . . . . . . . . . . 5-26

5-24 Fault Isolation - Lift Trailer No Forward Right Yaw . . . . . . . . . . . . . . . . . . . . 5-27

5-25 Fault Isolation - Lift Trailer Has Slow Left Aft Yaw . . . . . . . . . . . . . . . . . . . . . . 5-28

5-26 Fault Isolation - Lift Trailer Has No Left Aft Yaw . . . . . . . . . . . . . . . . . . . . . . 5-29

5-27 Fault Isolation - Lift Trailer Has Slow Right Aft Yaw . . . . . . . . . . . . . . . . . 5-30

5-28 Fault Isolation - Lift Trailer Has No Aft Right Yaw . . . . . . . . . . . . . . . . . . . . 5-31

5-29 Fault Isolation - Lift Trailer Has Slow Aft Axial Movement . . . . . . . . . . . . . . . . 5-32

5-30 Fault Isolation - Lift Trailer Has No Axial Movement . . . . . . . . . . . . . . . . . . . . 5-33

5-31 Fault Isolation - Lift Trailer Has Slow Forward Axial Movement . . . . . . . . . . 5-34

5-32 Fault Isolation - Lift Trailer Has No Forward Axial Movement . . . . . . . . . . 5-35

5-33 Fault Isolation - Slow Clockwise Rotation Of Trailer/Trailer Drifts Counterclockwise After Rotation . . . . . 5-36

CHANGE 4 ix

5-34 Fault Isolation - No Clockwise Rotation Of Trailer . . . . . . . . . . . . . . . . . . . . . . . 5-37

5-35 Fault Isolation - Slow Counter Clockwise Rotation Of Trailer/Trailer Drifts Clockwise After Rotation . . . . . . . . . . 5-38

5-36 Fault Isolation - No Counter Clockwise Rotation Of Trailer . . . . . . . . . . . . . . 5-39

5-37 Fault Isolation - No Rotation Of Trailer . . 5-40

5-38 Fault Isolation - Trailer Forward End Goes Up or Down Slow . . . . . . . . . . . . . . . 5-42

5-39 Fault Isolation - Trailer Aft End Goes Up or Down Slow . . . . . . . . . . . . . . . . . 5-42

5-40 Fault Isolation - Lift Trailer Has No Forward Lift Down . . . . . . . . . . . . . . 5-43

5-41 Fault Isolation - Lift Trailer Has No Forward Lift Up . . . . . . . . . . . . . . . . 5-44

5-42 Fault Isolation - Lift Trailer Has No Aft Lift Down . . . . . . . . . . . . . . . . . . . . 5-45

5-43 Fault Isolation - Lift Trailer Has No Aft Lift Up . . . . . . . . . . . . . . . . . . . . . . 5-47

5-44 Fault Isolation - Control Pendant Failure (Any Fault Isolated To Control Pendant) . . . . . . . . . . . . . . . . . . . . . 5-48

5-45 Fault Isolation - Lift Trailer Alarm Does Not Sound . . . . . . . . . . . . . . . . . . . . 5-49

5-46 Fault Isolation - Lift Trailer Pulls Left or Right During Tow . . . . . . . . . . . . . . . 5-50

5-47 Fault Isolation - Lift Trailer Brakes Unexpectedly When Being Towed . . . . 5-50

5-48 Fault Isolation - Lift Trailer Does Not Brake When Overrunning Tow Vehicle . . . . . . . . . . . . . . . . . . . . . . 5-51

5-49 Fault Isolation - Lift Trailer Left or Right Brakes Drag . . . . . . . . . . . . . . . . . . . 5-51

5-50 Fault Isolation - Lift Trailer Parking Brake Will Not Set . . . . . . . . . . . . . . . . . . . 5-51

5-51 Fault Isolation - Trailer Fails Axial Movement Functional Check . . . . . . . . 5-52

5-52 Fault Isolation - Trailer Fails Lateral Movement Functional Check . . . . . . . . 5-52

5-53 Fault Isolation - Trailer Fails Yaw Movement Functional Check . . . . . . . . 5-53

5-54 Fault Isolation - Trailer Fails Roll Movement Functional Check . . . . . . . . 5-54

5-55 Fault Isolation - Trailer Fails Pitch Movement Functional Check . . . . . . . . 5-54

5-56 Fault Isolation - Trailer Fails Lift Mechanism Functional Check . . . . . . . 5-55

5-57 Fault Isolation - Trailer Did Not Stop Forward or Aft Movement at 2000 Pounds During Axial Load Functional Check . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-58 Fault Isolation - Trailer Stopped Forward and Aft Movement Below 1500 Pounds During Axial Load Functional Check . . 5-56

5-59 Fault Isolation - Trailer Did Not Stop RH or LH Movement at 2000 Pounds During Lateral Load Functional Check . . . . . . 5-56

5-60 Fault Isolation - Trailer Stopped LH or RH Movement Below 1500 Pounds During Lateral Load Functional Check . . . . . . 5-57

5-61 Fault Isolation - Trailer Did Not Stop CW or CCW Movement Before 1000 Pounds During Roll Load Functional Check . . . 5-57

5-62 Fault Isolation - Trailer Stopped CW or CCW Movement Before 750 Pounds Roll Load Functional Check . . . . . . . . . . . 5-58

5-63 Fault Isolation - Operator Fault Codes . . . 5-58

5-64 Fault Isolation - Maintenance Fault Codes . . . . . . . . . . . . . . . . . . . . . . . 5-59

5-65 Engine - Trailer Override Procedure For

PT90-F-507 . . . . . . . . . . . . . . . . . . . 5-67

5-66 BIT Operations Calibration . . . . . . . . . . 5-226

5-67 Main Pendant Control Switch Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . 5-235

5-68 Remote Pendant Control Switch Verification Test . . . . . . . . . . . . . . . . . . . . . . . . . 5-236

6-1 A1 Control Assembly Wire List . . . . . . . 6-1

6-2 A1An Iso Barriers Wire List . . . . . . . . . 6-5

6-3 A4/A2 Power/Filter Interconnect Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 A1/A3 Interconnect Wire List . . . . . . . . . 6-7

6-5 A1/A5 & A1/Potentiometers Interconnects Wire List . . . . . . . . . . . . . . . . . . . . . 6-8

TO 35D3-3-79-1

LIST OF TABLES - Continued x CHANGE 4

6-6 A1/A6 Controls/Hydraulic Interconnect Wire List . . . . . . . . . . . . . . . . . . . . . 6-8

6-7 A6 Hydraulic Interconnect Wire List . . . . 6-9

6-8 A1/A7 Pendant Interconnection Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-9 A1/A7/LS1 Pendant/Alarm Interconnection Wire List . . . . . . . . . . . . . . . . . . . . . 6-11

6-10 A7 Primary Pendant Assembly Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-11 A1 Motors Wire List . . . . . . . . . . . . . . . 6-12

6-12 A1/B1/B2 Motors Interconnects Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-13 B1/B2 Motors Assembly Wire List . . . . . 6-14

6-14 LC1/LC2/LC3/LC4 Load Cells Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-15 A1/A8 and A1/A9 Centering Platform Interconnection Wire List . . . . . . . . . . 6-15

6-16 A8 Forward Position Sensor Assembly Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-17 A9 Aft Position Sensor Assembly Wire List . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-18 A1/S1/S2/S3/S4/S5/S6/S7/S8/S9 Limit Features Interconnection Wire List . . . . 6-16

6-19 Low Pass Filter Card Wire List . . . . . . . . 6-17

6-20 Voltage Reference Chart . . . . . . . . . . . . 6-17

7-1 Related Manuals List . . . . . . . . . . . . . . 7-3

TO 35D3-3-79-1

LIST OF TABLES - Continued

CHANGE 4 xi/(xii blank)

LIST OF TIME COMPLIANCE TECHNICAL ORDERS

(TCTO’s)

The following lists TCTO’s applicable to the equipment in this manual.

TCTO

NUMBER

TITLE

TCTO

DATE

APPLICABILITY

1C-17A-1272 Modification of Engine Lift and Transport Trailer Electrical Power Cable Assembly, Part No. 17G230506-501 to 17G230506-

29 AUG 02 All

35CA1-2-5-502 Modification of Electrical Power Distribu-tion Box, Part No. 17G420553-1 to 17G420553-501

29 AUG 02 All

35D3-3-79-515 Modification of Aircraft Engine Lift Trailer, Part No. PT90-F-507 to Part No. PT90- F-509, C-17 Support Equipment

01 Jan 11 Refer to TCTO

CHANGE 4 xiii/(xiv blank)

INTRODUCTION

PURPOSE OF MANUAL.

This manual provides instructions for operation and main-tenance of the Aircraft Engine Lift Trailer, Part Number (PN) PT90-F, hereafter referred to as the lift trailer.

SCOPE OF MANUAL.

This manual is arranged in eight chapters as follows:

Chapter Title and Scope

1 GENERAL INFORMATION. This chapter contains an illustration of the lift trailer; data on lift trailer function; use of this manual;

equipment description; leading particulars; in-formation concerning difference data sheets.

2 SPECIAL TOOLS, TEST EQUIPMENT AND

CONSUMABLES. This chapter contains lists of special tools, test equipment, and consum-ables; a description of local manufactured items; illustrations of special tools and test equipment not illustrated elsewhere in the manual.

3 PREPARATION FOR USE AND SHIP-

MENT. This chapter contains data to prepare the lift trailer for use upon receipt from shipping and data to prepare the lift trailer for shipment.

4 OPERATION INSTRUCTIONS. This chapter contains theory of operation; description of equipment function; operation instructions.

5 MAINTENANCE INSTRUCTIONS. This chapter contains operational checkout; inspec-tion; preventive maintenance; fault isolation;

repair; cleaning; disassembly; replacement;

assembly; alignment; test; calibration.

6 DIAGRAMS. This chapter contains all sche-matics, wire harnesses, and wire diagrams for equipment electrical components.

7 ILLUSTRATED PARTS BREAKDOWN.

This chapter contains IPB introductory infor-mation. It also lists and illustrates parts of the lift trailer necessary to requisition, store, issue, and identify replacement parts.

Chapter Title and Scope

8 DIFFERENCE DATA SHEETS. This chapter contains detailed instructions for operation and maintenance instructions for other con-figurations of the lift trailer when the manual covers multiple configurations.

RELATED PUBLICATIONS.

References to other publications may be required to supple-ment information within this manual. The technician shall be familiar with the following related publications as required:

Number Title

AFI 37-162 Managing the Processes of Printing, Duplicating and Copying

AFI 60-101 Operations and Resources

TO 00-5-1 AF Technical Order System

TO 00-25-195 AF Technical Order System Source, Maintenance, and Re-coverability Coding of Air Force Weapons, Systems, and Equipments

TO 00-25-234 General Shop Practice Re-quirements for the Repair, Maintenance, and Test of Electrical Equipment

TO 1-1A-15 General Maintenance Instruc-tions for Support Equipment

(SE)

TO 1-1-8 Application and Removal of Organic Coatings, Aerospace and Non-Aerospace Equip-ment

TO 34W4-1-5 Welding Theory and Applica-tion

TO 35-1-3 Corrosion Prevention, Painting and Marking of USAF Sup-port Equipment (SE)

CHANGE 4 xv

Number Title

TO 35-1-4 Processing and Inspection of Support Equipment for Stor-age and Shipment

TO 35CA1-2-5-1 Operation and Maintenance Instructions with Illustrated Parts Breakdown Electrical Power Distribution Box

TO 35D8-15-2-1 Operation and Maintenance Instructions with Illustrated Parts Breakdown Aircraft En-gine Cradle Assembly

TO 36-1-191 Technical and Management Reference for Motor Vehicle Maintenance

ELECTROSTATIC DISCHARGE

SYMBOL.

The lift trailer contains Electrostatic Discharge Sensitive (ESDS) components. Proper handling procedures must be followed to avoid damage to components. The Electrostatic Discharge (ESD) symbol **ESD** is used to indicate steps or processes that require ESD precautions.

When the entire paragraph and all subparagraphs are con-sidered ESD critical, the symbol will appear between the paragraph number and title. When only certain steps are ESD critical, they will be identified by the symbol placed between the step number and the text.

c To ensure ESDS parts are not damaged, all para-graphs and steps/processes identified by the ESD symbol **ESD** must be followed as written.

Handling instructions for ESDS items are contained in TO 00-25-234.

ABBREVIATIONS.

For definitions of standard abbreviations and acronyms used throughout this manual, refer to MIL-STD-12. Nonstandard abbreviations and acronyms are defined below:

Abbreviation Definition

AP Attaching Part

BPM Beats Per Minute

BIT Built-In Test

CAGE Commercial and Government Entity

DMM Digital Multimeter

EEPROM Electrically Erasable Program-mable Read-Only Memory

ESD Electrostatic Discharge

ESDS Electrostatic Discharge Sensitive

MSDS Material Safety Data Sheet

QCU Quick Change Unit

SMR Source, Maintenance, and Recoverability

ELT Engine Lift trailer

CHANGE REQUEST.

Recommendations for routine changes to this Technical Order (TO) will be on AFTO Form 22, Technical Manual (TM) Change Recommendation and Reply, in accordance with TO 00-5-1. Completed forms will be forwarded through the Command Control Point (CCP) to Boeing Airlift and Tanker, C-17 Technical Publications group mailbox at c17-techpubspcrs@boeing.com. Information copies will be sent to WR-ALC/564 ACSS-TOMA, Robins

AFB, GA.

Urgent AFTO Form 22s will be routed through the CCP to WR-ALC/564 ACSS, Robins AFB, GA. Emergency AFTO Form 22s will be transmitted by immediate message, e-mail, or fax to WR-ALC/564 ACSS. Information copies will be sent to HQ AMC/LGM, Scott AFB, IL and WR-ALC/564 ACSS-TOMA, Robins AFB, GA.

C-17 TO INFORMATION.

General C-17 TO information on addresses, the Digital Technical Order System (DTOS), Supplements (active and closed), and C-17 TO Managers can be found on the C-17 Technical Order Management Agency (TOMA) webpage at:

https://lttoweb.robins.af.mil/ xvi CHANGE 4

SAFETY SUMMARY

INTRODUCTION.

The following are general safety precautions and instruc-tions that personnel shall understand. These precautions shall be applied during phases of operation and mainte-nance. Their purpose is to ensure personnel safety, health, and the protection of Air Force property. Portions of this information may be repeated in text for emphasis.

WARNING AND CAUTION STATEMENTS.

WARNING and CAUTION statements have been placed in the text to emphasize hazards during performance of certain steps or procedures. These are inserted for the protection of personnel (WARNING) or equipment (CAUTION). A WARNING or CAUTION shall apply each time the related step is repeated, regardless of the number of times the WARNING or CAUTION is repeated throughout the text.

Prior to starting any task, the WARNINGS or CAUTIONS included in the text for that task shall be reviewed and understood.

ELECTROSTATIC DISCHARGE.

The equipment described in this manual contains parts and assemblies sensitive to damage by Electrostatic Discharge (ESD). Care must be exercised during handling of these items. Use ESD precautionary procedures when touching, removing, or inserting ESD sensitive components.

KEEP AWAY FROM LIVE CIRCUITS.

Operating personnel shall at all times observe safety regu-lations. Do not replace components or make adjustments inside the equipment with the voltage supply turned on.

Under certain conditions, dangerous potentials may exist when the power control is in the off position, due to charges retained by capacitors. To avoid injuries, always remove power from, discharge, and ground a circuit before touching

it. Adhere to all lock out/tag out requirements.

DO NOT WEAR JEWELRY.

Remove rings, watches, and other metallic objects which may cause shock or burn hazards.

DO NOT SERVICE OR ADJUST ALONE.

Do not attempt internal service or adjustment unless another person capable of rendering aid and resuscitation is present.

RESUSCITATION.

Personnel working with or near dangerous voltage shall be trained in modern methods of resuscitation. Information and training sources may be obtained from the Director of Base Medical Services.

CLEANERS/CHEMICALS/PAINTS/

PRIMERS.

Some cleaners, chemicals, paints, and primers have adverse effects on skin, eyes, and the respiratory tract. Observe manufacturer’s warning labels; Material Safety Data Sheet (MSDS) instructions for proper handling, storage, and disposal; and current safety directives. Use only in autho-rized areas. Unless otherwise indicated, use as described in this manual should not result in any immediate health concerns. Consult the local Bioenvironmental Engineer and Base Safety Office for specific protection equipment and ventilation requirements.

SAFETY-APPROVED EQUIPMENT.

When cleaners and primers are being applied, approved explosion-proof lights, blowers, and other equipment shall be used. Ensure that working firefighting equipment is readily available.

TRANSPORTING AND STORAGE.

Trailer shall not be used for transport or storage of aircraft engines, engine dummy loads, or the engine core thrust reverser assembly.

CHANGE 4 xvii/(xviii blank)

CHAPTER 1

GENERAL INFORMATION

1-1. FUNCTION.

1-2. The aircraft engine lift trailer (see Figure 1-1) func-tions as support for the aircraft engine during maintenance, removal and installation. The lift trailer incorporates work platforms, ladders, auxiliary platforms, winches and con-trols required to remove and replace an aircraft engine. The lift trailer is equipped with I-beam rails which mate with various support equipment to facilitate the removal, instal-lation, and roll transfer of a cradle mounted engine.

1-3. The I-beam rails can be raised to a height of 148 inches using the self contained electrical system, hydraulic system, and an outside power source. The lift trailer is designed to be ramp loaded on various cargo aircraft.

1-4. USE OF THIS MANUAL.

1-5. A table of contents identifies chapter, paragraph, title and page numbers to help locate information. Illustrations, tables and diagrams are used to supplement text. A list of illustrations and a list of tables indicate the number, title and location. Abbreviations, phrases and words on decals, plac-ards or engravings are set forth in this manual exactly as they appear on the equipment.

1-6. EQUIPMENT DESCRIPTION.

1-7. The lift trailer is equipped with a work platform assembly made up of various components. Ladder assem-blies are stored on the forward longitudinal platform assem-blies with pins and ladder support brackets. A jib crane is stored in the rack assemblies and is mounted on the forward longitudinal platform assemblies. Adjustable work platform assemblies are provided on the forward longitudinal plat-form assemblies to be used during engine maintenance when the lift trailer is raised to the equipment being worked

on. Two storage boxes located on the aft longitudinal work platforms, house the control pendants and various tools.

1-8. Lateral end work platforms are mounted on the fwd and aft ends of the lift trailer and have the capability to swing out and away from the lift trailer during roll transfer and jib crane installation. The supplied control pendant operates the powered work platform assembly allowing additional work space for personnel. The winch clamp assembly mounted on the rear aft lateral work platform is used during roll transfer of various support equipment onto and away from the lift trailer.

1-9. The I-beam cradle consists of the I-beam rails used during roll transfer and to mount the various support equipment and support jacks which support the I-beam rails during roll transfer procedures. The I-beam rails mate with various types of support equipment allowing for roll transfer of a cradle mounted engine and other support equipment utilizing I-beam rails. The I-beam rails and positioning frame can be maneuvered into various positions using the control pendant allowing for positioning of the lift trailer.

1-10. The upper frame assembly consists of an upper frame, actuators and four upper frame glide plates. The upper frame glide plates interface the upper frame assembly and center section assembly rollers. Actuators are used to provide various movement of the positioning frame and I-beam cradle.

1-11. The center section assembly consists of the stabi-lizing foot pad assemblies and transmission assembly. The stabilizing foot pad assemblies fully support the lift trailer during raising and lowering of the lift trailer.

1-12. The transmission assembly controls movement of the lift mechanism on the lift trailer. The lower frame assembly provides for the interface attachment of the running gear. The lower frame assembly is also equipped with hoisting and winching points and ground connector reels.

1-13. The running gear allows the lift trailer to be moved and steered, it also provides the lift trailer with braking capabilities. Steering is provided on both ends of the lift trailer using a drawbar assembly and a rear steering bar. The rear steering bar is stowed in the rack assemblies and is used during fine positioning of the lift trailer for roll transfer.

1-14. The lift trailer is equipped with a hydraulic system which provides movement and positioning of the lift trailer.

An electrical system provides a means to apply power to the lift trailer using an outside power source. The control pendants allows for alignment of the lift trailer and adjust-ing the weighing system.

1-1

Figure 1-1. Aircraft Engine Lift…