35d3-3-79-1_Insp_and_PM.pdf

CHAPTER 5

MAINTENANCE INSTRUCTIONS

5-1. GENERAL.

5-2. This chapter contains procedures for operational checkout, inspection, preventive maintenance, fault isola-tion, repair, disassembly, cleaning, replacement, assembly, and calibration of the aircraft engine lift trailer.

5-3. OPERATIONAL CHECKOUT.

5-4. Operational checkout procedures for the lift trailer consist of ensuring all components are secure and in good working order and the following checks.

5-5. CONTROL PENDANT CHECK.

5-6. There are two control pendants on the lift trailer. For control pendant operational checkout perform the following (see Figure 4-10):

NOTE

Verify that the self diagnostic sequence operates after applying power to the aircraft engine lift trailer.

1. Operate lift trailer. Refer to paragraph 4-95.

2. Press RESET button to clear the control pendant.

3. Verify the Light Emitting Diode (LED) and Liquid Cristal Display (LCD) displays on the control pendant are illuminated.

4. Perform pendant switch verification test. Refer to paragraph 5-486.

5. Disconnect the control pendant, install dust cover, and place in storage box.

6. Install cover on storage box.

5-7. BRAKE CHECK.

5-8. There are four brakes on the lift trailer. For brake operational checkout perform the following:

NOTE

The following procedure describes the operational checkout of one brake assembly, but is applicable to all four.

1. Check hand brake levers (2, 70, Figure 7-26, Sheet 2,

4) for broken cable (7, 75).

2. Pull on handbrake levers (2, 70) to apply handbrake.

3. Ensure wheels (37, Figure 7-17, Sheet 1) do not move when attempting to maneuver lift trailer in forward motion.

4. Ensure wheels and tire assembly (37, Figure 7-17, Sheet 1) do not move when maneuvering lift trailer with steering bar (87, Figure 7-2, Sheet 7).

5. Release handbrake levers (2, Figure 7-26, Sheet 2 and 70, Sheet 4).

6. For Part Number (PN) PT90-F-507, remove cap (18, Figure 7-24, Sheet 3) of surge actuator (5, Figure 7-24, Sheet 1) on drawbar assembly (32, Figure 7-17, Sheet 1).

7. For PN PT90-F-509, remove cap (35, Figure 7-25, Sheet 3) of surge actuator (6, Sheet 1) on drawbar assembly (52).

8. Check brake fluid is at proper level. Fill with brake fluid (No. 1, Table 2-3), if required.

9. For PN PT90-F-507, install cap (18, Figure 7-24, Sheet 3) on surge actuator (5, Sheet 1).

10. For PN PT90-F-509, install cap (35, Figure 7-25, Sheet 3) on surge actuator (6, Sheet 1).

11. For PN PT90-F-507, apply lever (37, Figure 7-24, Sheet 2) on drawbar assembly (32, Figure 7-17, Sheet

1) to actuate hydraulic brakes.

12. For PN PT90-F-509, apply lever (22, Figure 7-25, Sheet 2) on drawbar assembly (33, Figure 7-17, Sheet

1) to actuate hydraulic brakes.

TO 35D3-3-79-1

CHANGE 1 5-1

13. Ensure wheels and tire assembly (37, Figure 7-17, Sheet 1, continued) do not move when attempting to maneuver lift trailer with drawbar assembly (32, 33).

14. Repair or replace brake assembly as required. Refer to paragraph 5-357 and 5-359.

15. For PN PT90-F-509, perform the parking brake test as follows:

a. Position the unloaded engine lift trailer on a clean dry concrete surface free from loose debris and set parking brakes.

b. Attach a gauge (reference Table 2-1) or equal calibrated measuring device on the drawbar (33), using a strap (reference Table 2-1). Attach the other end on a tow vehicle pintle hook.

c. Drive the tow vehicle until the gauge (reference Table 2-1) and strap (reference Table 2-1) are in line with the drawbar (33).

d. Place a reference mark on trailer drawbar and floor.

e. Apply force on the drawbar (33) by slowly oper-ating the tow vehicle until the reading on the load measuring device is approximately 5620 lb.

w Once slack is removed from strap, personnel shall not be positioned between tow vehicle and trailer when tension is applied. Failure to comply may result in injury to personnel.

f. If trailer wheels rotate before reaching 5620 ±250 lb, stop, then adjust the parking brakes.

g. Repeat steps c thru f until no rotation of the wheels are observed when a force of 5620 ±250 lb is applied.

h. Remove load measuring device and strap from drawbar (33) and tow vehicle.

16. For PN PT90-F-509, perform the service braking test as follows:

a. Couple a tow vehicle to the forward drawbar (33) and attach the cable assembly (7, Figure 7-25, Sheet 2).

b. Lock the rear steering by installing the quick release pin (109, Figure 7-26, Sheet 3).

c. Make sure lift trailer is in towing condition and release parking brakes.

d. Mark two lines 20 +5 feet across the test distance.

e. Tow the engine lift trailer forward for at least 100 yards at a speed of 8 to 10 miles per hour.

f. The service brakes shall smoothly stop the un-loaded engine lift trailer within 20 +5 feet from a speed of 8 - 10 miles per hour. The engine lift trailer shall stop without pulling or skidding.

5-9. TIRE CHECK.

5-10. There are four 10.00-15 x 14 ply pneumatic tires (39, Figure 7-17, Sheet 1) on the lift trailer. For tire checkout perform the following:

NOTE

The following procedure describes operational checkout of one tire, but is applicable to all four.

1. Check tire (39) pressure to ensure proper inflation of 70 to 80 Pounds per Square Inch (PSI).

2. Check tire (39) condition In Accordance With (IAW)

TO 00-25-246.

3. Repair or replace tire (39) as required. Refer to paragraph 5-353.

5-11. FRONT AND REAR STEERING

CHECK.

5-12. For front and rear steering operational checkout, perform the following:

1. Move drawbar assembly (32, 33, Figure 7-17, Sheet 1) from side to side.

2. Ensure two front wheel and tire assembly (37) turn in conjunction with drawbar assembly (32, 33) move-ment.

3. Check for loose, broken, or missing hardware on drawbar assembly (32, 33).

5-2 CHANGE 3

4. Repair or replace, drawbar assembly or drawbar as-sembly parts as required. Refer to paragraph 5-346.

5. Remove locking strut assembly (114, Figure 7-26, Sheet 3) from center arm (98). Refer to paragraph 5-372.

6. Install steering bar (87, Figure 7-2, Sheet 7) in center arm (98, Figure 7-26, Sheet 3).

7. Maneuver the lift trailer using the steering bar (87, Figure 7-2, Sheet 7).

8. Ensure two rear wheel and tire assembly (157, Figure 7-17, Sheet 1) turn in conjunction with steering bar (87, Figure 7-2, Sheet 7) movement.

9. Check for loose, broken, or missing hardware on steering bar (87).

10. Repair or replace steering bar (87) parts as required.

Refer to paragraph 5-372.

11. Install tie rod assembly (102, Figure 7-26, Sheet 3) to center arm (98).

5-13. WHEEL CHECK.

5-14. There are four wheels on the lift trailer. For wheel checkout perform the following:

NOTE

The following procedure describes operational checkout of one wheel and tire assembly, but is applicable to all four.

1. Ensure six lug nuts (42, Figure 7-17, Sheet 1) on wheel and tire assembly (37) are secure.

2. Check wheel and tire assembly (37) for cracks or bending.

3. Check valve stem for loose needle, cracks, etc.

4. Repair or replace hub (2, Figure 7-27) as required.

Refer to paragraph 5-354.

5-15. INSPECTION AND PREVENTIVE

MAINTENANCE.

5-16. The following paragraphs and tables provide proce-dures for inspection, lubrication, and preventive mainte-nance.

5-17. INSPECTION.

5-18. Inspection for physical damage is required to deter-mine when repairs are necessary. Refer to Table 5-1. If corrosion exists, perform corrosion treatment IAW TO 1-1-8 and TO 35-1-3. If cracks or weak weld points exist, repair IAW TO 34W4-1-5. If nondestructive inspection is re-quired, inspect IAW 33B-1-1. When lubrication is required

CHANGE 3 5-2A/(5-2B blank) for moving parts, lubricate IAW TO 1-1A-15 and Table 5-2.

If painting is required, paint IAW TO 1-1-8 and TO 35-1-3 using primer (No. 2, Table 2-3) and Coating (No. 3, Table 2-3). For reflectorization and stenciling refer to TO 35-1-3.

Items requiring inspection are listed in Table 5-1 with corresponding method of inspection. Scheduled inspection for cycles of 180 and 365 day intervals and inspection for each use are found in Preventive Maintenance in Table 5-3.

Table 5-1. Inspection

Component Inspect For Remedy

Exterior painted surface Scratched or chipped paint Sand smooth and repaint (Refer to paragraph 5-17)

Frame assembly Cracks or corrosion Weld cracks or treat corrosion (Refer to paragraph 5-17)

Rail assembly Gouges or scratches less than 0.25 inch

Blend smooth and treat corrosion (Refer to paragraph 5-17)

Gouges or scratches greater than

0.25 inch

Perform NDI for cracks at dam-aged area and rail mounts. For cracks less than 0.125 inch, record in historical records and perform NDI annually (Refer to paragraph 5-17). For cracks greater than 0.125 inch, replace rail assembly (Refer to para-graph 5-17)

Broken, dented or nicked components

Replace damaged components

Corrosion Treat corrosion (Refer to paragraph 5-17)

Hydraulic system Stiff, cracked, charred, kinked, crushed, flattened or twisted hose

Replace hose (Refer to paragraph 5-211)

Leaking hose fitting Tighten fitting or replace seal (Refer to paragraph 5-24)

Bent, dented or nicked tube assembly

Replace tube assembly (Refer to paragraph 5-211)

Leaking tube fitting Tighten fitting

Low fluid Service hydraulic reservoir (Refer to Table 5-2)

Electrical system Frayed, nicked or cut wire Replace wire (Refer to Chapter 6 and TO 00-25-234)

Loose connection Tighten connection.

Damaged pendant switch Replace switch (Refer to para-graph 5-85, 5-87, 5-89, and/or 5-91)

5-3

Table 5-1. Inspection - Continued

Component Inspect For Remedy

Electrical system - continued Frayed, nicked, or cut pendant cable

Replace cable (Refer to paragraph 5-83)

Damaged breaker on junction box Replace breaker (Refer to paragraph 5-337)

Broken plugs in junction boxes Replace plugs (Refer to paragraph 5-97 and/or 5-335)

Brake system Leaking or broken hose Replace hose (Refer to paragraph 5-56 and/or 5-386)

Wire rope cable More than six broken wires in any one lay or more than three bro-ken wires in one single strand in any one lay

Replace cable assembly (Refer to paragraph 5-151)

Tire Low or flat Inflate to proper pressure (Refer to TO 36-1-191)

Worn tread, cracks, bumps, bulges or imbedded objects

Repair or replace tire (Refer to paragraph 5-353 and

TO 36-1-191)

Winch assembly More than six broken wires in any one lay or more than three bro-ken wires in one single strand in any one lay

Replace cable (Refer to paragraph 5-44)

Grounding cables Visually inspect for security of mounting and evidence of cor-rosion or damage. Frayed or nicked cables will not exceed 25% of original diameter

Replace reel (Refer to paragraph 5-343)

Load cell pads. Dirty grease on load cell pads and stainless steal plates

Clean and lubricate load cell pads and stainless steal plates (Refer to paragraph 5-199)

Drawbar Visually inspect for cracks and corrosion

Weld cracks or treat corrosion as required (Refer to paragraph 5-17) or replace drawbar (Refer to paragraph 5-346)

Drawbar Visually inspect drain holes for obstruction

Unclog and clean drain holes as required

5-4

Table 5-2. Lubrication Requirements

Component Frequency Lubricant

Support pads As required (No. 7, Table 2-3)

Load cell pads Prior to use (No. 8, Table 2-3)

Towbar surge brake actuator Prior to use (No. 1, Table 2-3)

Hydraulic reservoir Prior to use (No. 4, Table 2-3)

Gear reducer Every 180 days (No. 5, Table 2-3)

Cam surfaces and storage legs Every 180 days (No. 8, Table 2-3)

Long slot with delron wiper Every 180 days (No. 8, Table 2-3)

Idle bearing and roller pad Every 180 days (No. 8, Table 2-3)

Trailer and jib crane winch Every 180 days (No. 46, 47, Table 2-3)

I-beam rails bushings Every 180 days (No. 46, Table 2-3)

Tie rods Every 180 days (No. 7, Table 2-3)

King pin Every 180 days (No. 7, Table 2-3)

Center axle pin Every 180 days (No. 7, Table 2-3)

Locking strut assembly Every 180 days (No. 7, Table 2-3)

Hydraulic actuator gear head Every 180 days (No. 7, Table 2-3)

Drive screw threads Every 180 days (No. 8, Table 2-3)

Lateral actuator worm gear shaft Every 365 days (No. 7, Table 2-3)

Gear reducer Every 365 days (No. 5, Table 2-3)

Transmission chains Every 365 days (No. 7, Table 2-3)

Transmission sprockets Every 365 days (No. 7, Table 2-3)

Hydraulic maintenance platform Every 180 days (No. 7, Table 2-3)

Wheel bearings Every 2 years (No. 7, Table 2-3)

5-19. PREVENTIVE MAINTENANCE.

5-20. Periodic maintenance and service tasks required to maintain lift trailer in good working order are listed in Table 5-3.

CHANGE 2 5-5

Table 5-3. Preventive Maintenance

Prior to use:

Load cell pads Service fitting with grease Lubricate load cell pads (Refer to paragraph 5-198)

Drawbar Visually inspect for cracks and corrosion

Repair or replace drawbar (Refer to paragraph 5-23 or 5-346)

Drawbar Visually inspect drain holes for obstruction

Unclog and clean drain holes as required

Drawbar surge brake actuator Check drawbar surge brake actua-tor for full service

Service drawbar surge actuator (Refer to paragraph 5-350)

Tires Check tires for 70-80 PSI and general condition

Repair or replace tire (Refer to paragraph 5-353 and

TO 36-1-191)

Grounding reels Visually inspect for security of mounting and evidence of cor-rosion or damage. Frayed or nicked cables will not exceed 25% of original diameter

Repair or replace (Refer to paragraph 5-343)

Hydraulic reservoir Check hydraulic system filter “indicator” for by-pass condi-tion while the hydraulic system is under loaded condition with pendant actuated for left or right movement

Service hydraulic reservoir (Refer to Table 5-2)

Hydraulic system filter Check hydraulic system filter for by-pass condition

Replace hydraulic system filter (Refer to paragraph 5-227)

Gear reducer Visually inspect gear reducer for leakage

Repair or replace (Refer to paragraph 5-257)

Cam surfaces and storage legs

Dirty grease or no grease on cam surfaces/storage legs

Lubricate cam surfaces and stor-age legs (Refer to Table 5-2)

Long slot with delron wiper Dirty grease or no grease on long slot with delron wiper

Lubricate long slot with delron wiper (Refer to Table 5-2)

Idle bearing and roller pad Dirty grease or no grease on idle bearing and roller pad

Lubricate idle bearing and roller pad (Refer to Table 5-2)

Brakes Check brakes for proper adjustment

Adjust brakes as required.

Lift trailer Check for general condition Repaint and treat for corrosion (Refer to paragraph 5-17)

5-6

Table 5-3. Preventive Maintenance - Continued

Every 180 days:

Drawbar Visually inspect drain holes for obstruction

Unclog and clean drain holes as required

Load cell pads Check torque, lubricate, and clean Torque puck screws (Refer to paragraph 5-198)

Trailer and jib crane winch Check trailer and jib crane winch for full service

Service trailer and jib crane winch (Refer to Table 5-2)

Tie rods Dirty grease or no grease on tie rods

Lubricate tie rod grease fittings with one stroke of grease (Refer to Table 5-2)

King pins Dirty grease or no grease on king pin

Lubricate king pin grease fittings with one stroke of grease (Refer to Table 5-2)

Center axle pin Dirty grease or no grease on cen-ter axle pin

Lubricate center axle pin grease fittings with one stroke of grease (Refer to Table 5-2)

Locking strut assembly Dirty grease or no grease on lock-ing strut assembly

Lubricate locking strut assembly grease fittings with one stroke of grease (Refer to Table 5-2)

Main electrical relays Corrosion or wear Replace main electrical relays (Refer to paragraph 5-275 or 5-277)

Electrical conduits Stretching, binding, or crushing on electrical conduits

Replace damaged electrical conduits

Electrical and hydraulic clamps

Worn, loose, or saturated electrical and hydraulic clamps

Replace clamps

Main power supply circuit breaker

Proper operation of main power supply circuit breaker

Replace main power supply circuit breaker (Refer to TO 1-1A-15)

Main power connector Proper operation of main power connector

Replace main power harness as-sembly (Refer to paragraph 5-335)

Electrical receptacles Bent, broken, loose, or corroded electrical receptacles

Replace electrical receptacles (Refer to Chapter 6)

Main and remote pendant cable

Frayed or faulty wires on main or remote pendants

Replace control pendant (Refer to paragraph 5-81)

Hydraulic components Leaking hydraulic components Replace hydraulic components

I-beam rails Nicks, dents, gouges or obvious defects on I-beam rails

Replace I-beam rails

5-7

Every 180 days: - continued

I-beam rails - continued Check bushings (82, Figure 7-13, Sheet 2) for residue buildup on the inside surface of the bush-ing

Clean inside surface of the bush-ing with isopropyl alcohol (No.

37, Table 2-3). Lubricate bush-ing (Refer to Table 5-2). Repair or replace as required. (Refer to paragraph 5-397)

Check alignment of brackets (8 and 9, Figure 7-13, Sheet 2) for proper insertion of lock pin

Repair or replace as required. (Re-fer to paragraph 5-397)

Grounding reels Check for corrosion and ensure resistance between cable and trailer is less than 10 ohms

Repair or replace (Refer to para-graph 5-343)

Load cell calibration Ensure proper values of load cells (T0001-T0004)

Adjust as necessary (Refer to paragraph 5-459)

Drive screw assemblies Dirty grease or no grease on drive screw threads

Lubricate threads as required with grease as required (Refer to Table 5-2)

Hydraulic maintenance plat-form

Dirty grease or no grease on sup-port brackets, adjusters, eyebolts or hydraulic cylinders

Lubricate grease fittings (Refer to table 5-2)

Every 365 days:

Pintle hook General condition, bent, broken or missing pins on pintle hook

Replace pintle hook (Refer to paragraph 5-345)

Tie rod ends General condition or looseness on tie rod ends

Replace tie rod ends (Refer to paragraph 5-365 or 5-367)

Gear reducer Drain oil and inspect for contami-nates

Reservice (1 1/2 quarts); repair or replace (Refer to paragraph 5-257)

Lateral actuator worm gear shafts

No grease on lateral actuator worm gear shafts

Lubricate lateral actuator gear shaft with one stroke of grease on both sides of nut (Refer to Table 5-2)

Actuator piston rods Scratches, wear or corrosion on actuator piston rods

Replace actuator (Refer to para-graph 5-189 or 5-193)

Transmission chain tensioners Loose transmission chains Adjust transmission chain tension-ers (Refer to paragraph 5-245)

Transmission chains Visually inspect for unusual wear, excessive stretch, or damage

Replace transmission chains (Refer to paragraph 5-247)

Dirty grease or no grease on trans-mission chains

Lubricate transmission chains (Refer to Table 5-2)

5-8

Every 365 days: - continued

Transmission sprockets Dirty grease or no grease on trans-mission sprockets

Lubricate transmission sprockets (Refer to Table 5-2)

Central Processing Unit (CPU) (A23A1) battery

Battery Low (Bat Low) Indicator Illuminated

Replace CPU (A23A1) battery (ensure electrical power is ap-plied before replacing battery) (Refer to paragraph 5-333)

Periodic Load Test Inspect for proper operation of trailer

For periodic load test (Refer to paragraph 5-473)

CPU (A23A1) ready run lights

CPU (A23A1) ready run lights are on

Replace CPU controller (A23A1) (Refer to Chapter 6 and TO 00-25-234) (Refer to paragraph 5-299)

CPU (A23A1) memory pro-tect switch

Memory protect switch is in up position on CPU (A23A1)

Set CPU (A23A1) memory protect switch to up position (Refer to paragraph 5-299)

CPU (A23A1) communica-tion switch

Communication switch is in DEF position on CPU (A23A1)

Set CPU (A23A1) communication switch to DEF position (Refer to paragraph 5-299)

Electrical wiring Frayed, broken, loose, or corroded electrical wiring

Replace electrical wiring (Refer to Chapter 6 and TO 1-1A-14)

Relay Board (A1) LED’s LED’s are on Replace relay board (A1) (Refer to Chapter 6 and TO 1-1A-14)

Forward and reverse relays Corrosion or worn forward or re-verse relay

Replace forward or reverse relay (Refer to paragraph 5-275 or 5-277)

Lateral actuator bearing track

Dirty grease or no grease in lateral actuator bearing track

Lubricate track with delron wiper as required (Refer to Table 5-2)

Lower (soft) limits Ensure proper values of lower limits (T0005-T0008)

Adjust as necessary (Refer to paragraph 5-461)

Upper (soft) limits Ensure proper values of upper limits (T0005, T0006, T0009, and T0010)

Adjust as necessary (Refer to paragraph 5-363)

Off-center (soft) limits Ensure proper values of off-center limits (T0013 and T0014)

Adjust as necessary (Refer to paragraph 5-465)

Lower limit switches Ensure proper operation of switches

Adjust as necessary (Refer to paragraph 5-475)

Upper limit switches Ensure proper operation of switches

Adjust as necessary (Refer to paragraph 5-477)

5-9

Every 365 days: - continued

Axis limit switches Ensure proper operation of switches

Adjust as necessary (Refer to paragraph 5-479))

Aft limit switches Ensure proper operation of switches

Adjust as necessary (Refer to paragraph 5-481)

Lift motor brushes Motor brushes worn below 1/4 inch

Remove an accessible brush in-spection plug(s). If brush is less than 1/4 inch, remove motor for repair or replacement (Refer to paragraph 5-255).

Note: A Minimum of five full turns are required to install the plug. Ensure 3-4 threads are visible on the plug when seated.

Turning the plug in too far will result in an electrical short be-tween the plug and the brush holder.

Every 2 years:

Brake shoes Linings worn with less than 1/8 inch remaining on brake shoes

Replace brake shoes (Refer to paragraph 5-361)

Brakes Check brakes for proper adjust-ment

Adjust brakes

Wheel bearings Dirty grease or no grease on wheel bearings

Repack or replace wheel bearings (Refer to paragraph 5-355)

Hydraulic system filter Check hydraulic system filter for general condition or contami-nants

Clean and/or replace as needed (Refer to paragraph 5-227)

Check hydraulic system inlet filter for general condition or con-taminants

Clean and/or replace as needed (Refer to paragraph 5-221)

5-21. FAULT ISOLATION.

5-22. The fault isolation table identifies the failure in the table title, the step column gives the sequence to fault isolate, the instruction column identifies the test points, the indication column gives the result, the yes and no columns answers the indication column results and follows a se-quence of events to fault isolate to replace a failed compo-nent. Prepare lift trailer for fault isolation. Refer to para-graph 4-83.

NOTE

When following the fault isolation procedures all voltage readings will be taken with power applied and continuity readings with power off.

5-10

2. Remove winch clamp assembly (3, Figure 4-6, con-tinued) from aft right lateral end work platform assembly (2).

3. Slide winch clamp assembly (3) onto the fwd left I-beam (4).

4. Install handle (5) securing winch clamp assembly (3) to fwd left I-beam (4).

5. Remove handle (5) securing winch clamp assembly

(3) to fwd left I-beam (4).

6. Remove winch clamp assembly (3) from the fwd left I-beam (4).

7. Position winch clamp assembly (3) on aft left lateral end work platform assembly (2).

8. Install knob (1) securing winch clamp assembly to aft right lateral end work platform assembly (2).

4-95. The following procedure describes setup and posi-tioning of the work platform assembly following lift trailer being positioned near the engine for repair. There are two work platform assemblies. The following procedure de-scribes setup and positioning of one work platform:

1. Remove three pins (1, Figure 4-7) securing work platform assembly (2) in closed position.

2. Holding guard rail (3) pull work platform assembly

(2) up and away from longitudinal work platform assembly (4).

3. Install three pins (1) securing work platform assembly

(2) in position.

4. Remove three pins (1) securing work platform assem-bly (2) in position.

5. Holding guard rail (3) push work platform assembly

(2) back in storage position on the longitudinal work platform assembly (4).

6. Install three pins (1) securing work platform assembly

(2) in closed position.

4-21

ICN−88277−8AA00451−004−01

LEGEND

1. GROUNDING CONNECTOR REEL

2. JUNCTION BOX

3. PIN

4.

5. LATERAL END WORK PLATFORM ASSEMBLIES

6. POWERED WORK PLATFORM ASSEMBLY

7. SIDE EXTENSION PLATFORMS

EXTENSION LOCKBAR

Figure 4-5. Powered Work Platform Setup and Positioning

4-22 CHANGE 4

ICN−88277−8AA00461−002−01

1.

2.

3.

4.

KNOB

5.

I−BEAM

LATERAL END WORK

PLATFORM ASSEMBLY

HANDLE

ASSEMBLY

WINCH CLAMP

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

CHANGE 4 4-23

ICN−88277−8AA00471−002−01

1. PIN

2. WORK PLATFORM

3. GUARD RAIL

4. LONGITUDINAL WORK PLATFORM

ASSEMBLY

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

4-24 CHANGE 4

ICN−88277−8AA04101−001−01

UP UP

DOWNDOWN

LH LH RHRH

AXIAL/ROLL

FWD

CW CCW

AFT

MAIN REMOTE

LOW GUARD

HIGH

SPEED

PLATFORM

UP

RESET C.G. LOAD

NULL PLATFORM

DOWN

FWD AFTEND END

EMERGENCYSTOP

BUILT IN TEST

CONTROLSELECT

LOAD LIMIT

TRAILER TRAILER

LCD

DISPLAY

LED

DISPLAY

Figure 4-10. Control Pendant

4-38 CHANGE 4

3. Install four bolts (25, Figure 7-17, Sheet 1), four washers (26), and four nuts (27) securing pintle assembly (24) on lower frame assembly (75, Figure 7-1, Sheet 1).

5-346. DRAWBAR ASSEMBLY. There is one draw-bar assembly located at the fwd end of the lift trailer. The following procedure describes replacement of the drawbar assembly.

5-347. Drawbar assembly replacement for PN PT90-F- 507 is as follows:

NOTE

Three people are required to perform this proce-dure.

1. Engage four handbrake levers (2, 70, Figure 7-26, Sheet 2, 4).

2. Remove spring coil (36, Figure 7-17, Sheet 1) from shackle (35).

3. Disconnect brake line at male connector (72, Figure 7-24, Sheet 1).

4. Remove two rings (32, Figure 7-26, Sheet 1) from pin (34).

5. Remove pin (34) and drawbar assembly (32, Figure 7-17, Sheet 1) to center arm assembly (37, Figure 7-26, Sheet 1).

6. Position replacement drawbar assembly (32, Figure 7-17, Sheet 1) on center arm assembly (37, Figure 7-26, Sheet 1).

7. Install pin (34) securing drawbar assembly (32, Figure 7-17, Sheet 1) to center arm assembly (37, Figure 7-26, Sheet 1).

8. Install two rings (32) on pin (34).

9. Apply grease (No. 7, Table 2-3) to lube fitting (25) until grease is visible around pin (34).

10. Connect brake line at male connector (72, Figure 7-24, Sheet 1).

11. Install spring coil (36, Figure 7-17, Sheet 1) on shackle (35).

12. Release four handbrake levers (2, 70, Figure 7-26, Sheet 2, 4).

13. Perform surge actuator bleed. Refer to paragraph 5-423.

5-348. Drawbar assembly replacement for PN PT90-F- 509 is as follows:

NOTE

Three people are required to perform this proce-dure.

1. Engage four handbrake levers (2, 70, Figure 7-26, Sheet 2, 4).

2. Disconnect brake line at male connector (39, Figure 7-25, Sheet 3).

3. Remove two rings (32, Figure 7-26, Sheet 1) from pin (34).

4. Remove pin (34) and drawbar assembly (33, Figure 7-17, Sheet 1) to center arm assembly (44, Figure 7-26, Sheet 3).

5. Position replacement drawbar assembly (53, Figure 7-25, Sheet 1) on center arm assembly (44, Figure 7-26, Sheet 3).

6. Install pin (34) securing drawbar assembly (53, Figure 7-25, Sheet 1) to center arm assembly (44, Figure 7-26, Sheet 3).

7. Install two rings (32, Sheet 1) on pin (34).

8. Apply grease (No. 7, Table 2-3) to lube fitting (25) until grease is visible around pin (34).

9. Connect brake line at male connector (39, Figure 7-25, Sheet 3).

10. Release four handbrake levers (2, 70, Figure 7-26, Sheet 2, 4).

11. Perform surge actuator bleed. Refer to paragraph 5-423.

5-349. SURGE ACTUATOR. Surge actuator is located at the fwd end of the drawbar assembly. The following procedure describes replacement of the surge actuator.

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wheels and tire assemblies on the lift trailer. The following procedure describes replacement of one wheel and tire assembly, but applies to all four.

5-353. Wheel/tire assembly replacement is as follows:

w Tire may contain pneumatic pressure. Release pressure completely before attempting to remove tire or dislodge tire beads, lock-rings or split flange rings for performing maintenance on the tire.

Failure to comply may result in injury to personnel and damage to equipment.

NOTE

• The tire does not need to be deflated if it is being removed to facilitate maintenance task other than on the tire itself.

• Ensure trailer is supported by external jack prior to removing wheel.

1. Loosen six nuts slightly (42, Figure 7-17, Sheet 1).

2. Using control pendant raise lift trailer until just enough clearance exists between the wheel and tire assembly and the ground to facilitate removal and installation of the wheel and tire assembly.

3. Remove six nuts (42) from wheel and tire assembly (37).

4. Remove wheel and tire assembly (37) from hub (2, Figure 7-27).

5. If necessary repair tire IAW TO 36-1-191.

w Tire shall be taken to tire shop to be inflated in the tire cage. Failure to comply may result in injury to personnel and damage to equipment.

6. Install wheel and tire assembly (37, Figure 7-17, Sheet

1) on hub (2, Figure 7-27).

7. Install six nuts (42, Figure 7-17, Sheet 1) securing wheel and tire assembly (37) to hub (2, Figure 7-27).

8. Using control pendant lower lift trailer until wheel and tire assembly (37, Figure 7-17, Sheet 1) just touch the ground.

9. Torque six nuts (158) to 199 ± 16 ft-lb.

10. Perform lift trailer functional test. Refer to paragraph 5-431.

5-354. HUB. There are four hubs on the lift trailer. The following procedure describes replacement of one hub but applies to all four.

5-355. Hub replacement is as follows:

1. Remove wheel/tire assembly. Refer to paragraph 5-352.

2. Remove four screws (6, Figure 7-27), four washers (5), cap (4), and gasket ( 7) from hub (2).

3. Remove pin (8, 76, Figure 7-26, Sheet 2, 4), nut (9, 77), and washer (10, 78) from hub (2, Figure 7-27).

4. Remove six bolts (12), six washers (13), six nuts (14), and hub (2) from brake drum (11, 79, Figure 7-26, Sheet 2, 4).

5. Remove bearing (8, Figure 7-27) from hub (2).

6. Clean and pack bearing (8) using grease (No. 7, Table

2-3) IAW TO 1-1A-15.

7. Remove bearing (9) and seal (10) from hub (2).

8. Clean and pack bearing (9) using grease (No. 7, Table

2-3) IAW TO 1-1A-15.

9. Install bearing (9) and seal (10) in replacement hub (2).

10. Install bearing (8) in hub (2).

11. Position hub (2) on brake drum (11).

12. Install six bolts (12), six washers (13), and six nuts

(14) securing hub (2) on brake drum (11).

13. Install washer (10, 78), Figure 7-26, Sheet 2, 4) nut (9, 77), and pin (8, 76) on hub (2, Figure 7-27).

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14. Install gasket (7, Figure 7-27, continued), cap (4), four washers (5), and four screws (6) securing cap (4) to hub (2).

15. Install wheel/tire assembly. Refer to paragraph 5-352.

5-356. LEFT BRAKE ASSEMBLY. The following procedures cover replacement of the front and rear left brake assembly.

5-357. Left brake assembly replacement is as follows:

1. Remove hub. Refer to paragraph 5-354.

2. Remove hose assembly (37, Figure 7-23, Sheet 2) from LH wheel cylinder (24, Figure 7-27).

3. Install protective cap plug (No. 20, Table 2-3) in hose assembly (37, Figure 7-23, Sheet 2).

4. Install protective plug (No. 21, Table 2-3) on wheel cylinder (24, Figure 7-27).

5. Hold handbrake lever (2, 70, Figure 7-26 Sheet 2, 4) toward cable (7, 75).

6. Work cable (7, 75) barrel out of handbrake lever (2, 70).

7. Remove four screws (12, 80 Figure 7-27), four wash-ers (13, 81), and brake assembly (21) from spindle and knuckle (23, 84) allowing cable (7, 75) to pull through brake assembly (21, 82).

8. Position replacement brake assembly (21, 82) on spindle and knuckle (23, 84) feeding cable (7, 75) through brake assembly (21, 82).

9. Install four screws (12, 80) and four washers (13, 81) securing brake assembly (11, 79) to spindle and knuckle (23, 84, Figure 7-26, Sheet 2, 4).

10. Pull handbrake lever (2, 70) towards cable (7, 75) working cable (7, 75) into handbrake lever (2, 70).

11. Remove protective cap plug (No. 21, Table 2-3) from wheel cylinder (24, Figure 7-27).

12. Remove protective cap plug (No. 20, Table 2-3) from hose assembly (37, Figure 7-23, Sheet 2).

13. Install hose assembly (37) on wheel cylinder (24 Figure 7-27).

14. Install hub. Refer to paragraph 5-354.

15. Bleed hydraulic brake system. Refer to paragraph 5-420.

16. Perform brake burnishing. Refer to paragraph 5-467.

5-358. RIGHT BRAKE ASSEMBLY. The following procedures cover replacement of the front and rear right brake assembly.

5-359. Right brake assembly replacement is as follows:

1. Remove hub. Refer to paragraph 5-354.

2. Remove hose assembly (37, Figure 7-23, Sheet 2) from RH wheel cylinder (26, Figure 7-26).

3. Install protective cap plug (No. 20, Table 2-3) in hose assembly (37, Figure 7-23, Sheet 2).

4. Install protective plug (No. 21, Table 2-3) on wheel cylinder (26, Figure 7-27).

5. Hold handbrake lever (2, 70, Figure 7-26, Sheet 2, 4) toward cable (7, 75).

6. Work cable (7, 75) barrel out of handbrake lever (2, 70).

7. Remove four screws (12, 80), four washers (13, 81), and brake assembly (22, 83) from spindle and knuckle (24, 85) allowing cable (7, 75) to pull through brake assembly (22, 83).

8. Position replacement brake assembly (22, 83) on spindle and knuckle (24, 85) feeding cable (7, 75) through brake assembly (22, 83).

9. Install four screws (12, 80) and four washers (13, 81) securing brake assembly (24, 85) to spindle and knuckle (24, 85).

10. Pull handbrake lever (2, 70) towards cable (7, 75) working cable (7, 75) into handbrake lever (2, 70).

11. Remove protective cap plug (No. 21, Table 2-3) from wheel cylinder (26, Figure 7-27).

12. Remove protective cap plug (No. 20, Table 2-3) from hose assembly (37, Figure 7-23, Sheet 2).

13. Install hose assembly (37) on wheel cylinder (26, Figure 7-27).

14. Install hub. Refer to paragraph 5-354.

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15. Bleed hydraulic brake system. Refer to paragraph 5-421.

16. Perform brake burnishing. Refer to paragraph 5-467.

5-360. BRAKES. There is one set of brake located in each hub and drum assembly. The following procedure describes replacement of one set of brake but applies to all four.

5-361. Brake replacement is as follows:

1. Remove hub. Refer to paragraph 5-354.

2. Loosen LH adjuster nut (34, Figure 7-27) to relieve pressure.

3. Remove end of cable and fitting (46) from LH auto adjuster lever (38).

4. Remove LH auto adjuster spring (36) and LH auto adjuster lever (38).

5. Remove shoe to shoe springs (32, 33).

6. Remove two shoe hold down springs (31) and brake shoe set (21).

7. For the PT90-F-507, remove nut (45), bushing, cable and fitting (46), camplate, LH lever (40), spring (43), washer (44), and anchor bolt (42).

8. For the PT90-F-509, remove nut (45), cam link (48), circle clip pin (50), cable and fitting (46), camplate, LH lever (40), spring (43), washer (44), and anchor bolt (42).

9. Disconnect brake cable (7, 75, Figure 7-26Sheet 2, 4).

10. Remove hose assembly (37, Figure 7-23, Sheet 2) from wheel cylinder (24, 25, Figure 7-27).

11. Install protective cap plug (No. 20, Table 2-3) in hose assembly (37, Figure 7-23, Sheet 2).

12. Install protective cap plug (No. 21, Table 2-3) on wheel cylinder (24, 25, Figure 7-27).

13. Remove screws (28) and wheel cylinder (24, 25).

14. Install wheel cylinder (24, 25) and secure with screws (28).

15. Remove protective cap plug (No. 21, Table 2-3) from wheel cylinder (24, 25).

16. Remove protective cap plug (No. 20, Table 2-3) from hose assembly (37, Figure 7-23, Sheet 2).

17. Install hose assembly (37) on wheel cylinder (24, 25, Figure 7-27).

18. For the PT90-F-507, install washer (44), spring (43), LH lever (40), camplate, cable and fitting (46), and bushing on anchor bolt (42). Ensure spring (43) fits over end of bushing.

19. For the PT90-F-509, install washer (44), spring (43), LH lever (40), cable and fitting (46), cam link (48), circle clip pin (50) on anchor bolt (42). Ensure spring

(43) fits over end of circle clip pin (50).

20. Connect brake cable (7, 75, Figure 7-26, Sheet 2, 4).

21. Install anchor bolt (42, Figure 7-27) through back plate (17).

22. Install nut (45).

23. Install brake shoe set (21) and secure with two shoe hold down springs (31).

24. Install LH auto adjuster lever (38) and LH auto adjuster spring (36).

25. Ensure cable and fitting (46) is resting in cable guide

(22) and attach end of cable and fitting (46) to LH auto adjuster lever (38).

26. Install LH adjuster nut (34).

27. Install shoe to shoe springs (32, 33) to secure brake shoe set.

28. Install hub. Refer to paragraph 5-354.

29. Perform brake burnishing. Refer to paragraph 5-467.

5-362. HANDBRAKE LEVER. There are four hand-brake levers on the lift trailer. The following procedure describes replacement of one handbrake lever but applies to all four.

5-363. Handbrake lever replacement is as follows:

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3. Remove fitting (25, Figure 7-26, Sheet 1) from pin (34).

4. For PN PT90-F-507, remove two rings (32), pin (34), and center arm assembly (37) from axle assembly (51).

5. For PN PT90-F-509, remove two rings (32), pin (34), and center arm assembly (44) from axle assembly (51).

6. For PN PT90-F-507, position replacement center arm assembly (37) in axle assembly (51).

7. For PN PT90-F-509, position replacement center arm assembly (44) in axle assembly (51).

8. For PN PT90-F-507, install pin (34) securing center arm assembly (37) to axle assembly (51).

9. For PN PT90-F-509, install pin (34) securing center arm assembly (44) to axle assembly (51).

10. Install two rings (32) securing pin (34) in position.

11. Install fitting (25) in pin (34).

12. Apply grease (No. 7, Table 2-3) to fitting (25) until grease is visible extruding around the pin (34).

13. Install two forward tie rod assemblies. Refer to para-graph 5-364.

14. Install drawbar assembly. Refer to paragraph 5-346.

5-372. LOCKING STRUT ASSEMBLY. There is one locking strut assembly located on the rear axle of the lift trailer. The following procedure describes replacement of the locking strut assembly.

5-373. Locking strut assembly replacement is as follows:

1. Engage four handbrake levers (2, 70, Figure 7-26, Sheet 2, 4).

2. Remove pin (109, Sheet 3) securing locking strut assembly (114) in bracket (112).

3. Remove pin (113), nut and locking strut assembly

(114) from center arm (98).

4. Position replacement locking strut assembly (114) in bracket (112) and center arm (98).

5. Install nut securing locking strut assembly (114) to center arm (98). Torque nut to 60 ± 5 ft-lb.

6. Install pin (113) on to nut.

7. Apply grease (No. 7, Table 2-3) to fittings (115, Sheet

4) until grease is visible extruding around the ball joint (116).

8. Install pin (109, Sheet 3) securing locking strut assem-bly (114) in bracket (112).

5-374. AFT CENTER ARM. The following procedure describes replacement of the aft center arm on the lift trailer.

5-375. Aft center arm replacement is as follows:

NOTE

Two people are required to perform this procedure.

1. Remove two aft tie rod assemblies. Refer to paragraph 5-366.

2. Remove steering bar (87, Figure 7-2, Sheet 7) from aft center arm (98, Figure 7-26, Sheet 3).

3. Remove locking strut assembly. Refer to paragraph 5-372.

4. Remove fitting (86) from pin (95).

5. Remove two rings (93), pin (95), and aft center arm

(98) from axle assembly (125).

6. Position replacement aft center arm (98) on axle assembly (125).

7. Install pin (95) securing aft center arm (98) to axle assembly (125).

8. Install two rings (93) securing pin (95) in position.

9. Install fitting (86) in pin (95).

10. Apply grease (No. 7, Table 2-3) to fitting (86) until grease is visible extruding around the pin (95).

CHANGE 1 5-175

ICN−88277−8AA70001−003−01

L

Figure 7-2. Maintenance Platform Installation, Lift Trailer (Sheet 7)

7-28 CHANGE 4

Figure 7-17. Aircraft Engine Installation Lift Trailer Axle (Sheet 1 of 2)

7-140 CHANGE 4

Figure 7-25. Drawbar Assembly Engine Lift Trailer (Sheet 1 of 3)

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Figure 7-25. Drawbar Assembly Engine Lift Trailer (Sheet 2)

CHANGE 4 7-235

Figure 7-25. Drawbar Assembly Engine Lift Trailer (Sheet 3)

7-236 CHANGE 4

Figure 7-26. Front and Rear Axle Assemblies (Sheet 1 of 4)

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Figure 7-26. Front and Rear Axle Assemblies (Sheet 2)

CHANGE 4 7-241

Figure 7-26. Front and Rear Axle Assemblies (Sheet 3)

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Figure 7-26. Front and Rear Axle Assemblies (Sheet 4)

CHANGE 4 7-243/(7-244 blank)

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

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5-350