PD08WRGBGBEB16B.pdf

PD08WRGBGBEB16B

Comments, suggestions, or questions on this document should be addressed to:

AFLCMC/WNZEC, Robins AFB GA 31098-1813.

AMSC N/A

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

INCH-POUND

CAGE 98752

10 June 2013

PURCHASE DESCRIPTION

AIRCRAFT AND MISSILE ENGINE LIFT TRAILERS

1. SCOPE

1.1 Scope. This specification covers aircraft and missile engine lift trailers, designated ETU-8/E (T4000) and ETU-9/E (T4100). This specification consolidates the requirements of both aircraft and missile trailers into one universal trailer with two different types.

1.2 Classification. Engine trailers are one of the following types as specified (see 6.2).

Type 1 – ETU-8/E, (T4000), 8000 pound capacity

Type 2 – ETU-9/E, (T4100), 10000 pound capacity

These requirements are generally the same, and the differences are tabulated in Table II as specified herein.

1.3 Part or Identifying Number (PIN). The following PIN procedure is for Government purposes and does not constitute a requirement for the contractor. The PINs to be used for these Aircraft and Missile Engine Lift Trailers acquired to this specification are created as follows:

Specification number:

2. APPLICABLE DOCUMENTS

Type: 1 - ETU-8/E, 8000 pound capacity Type: 2 - ETU-9/E, 10000 pound capacity

XXXXXX-X

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this specification. This section does not include documents cited in other sections of this specification or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this specification, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks of the exact revision listed below form a part of this specification to the extent specified herein.

FEDERAL STANDARDS

FED-STD-595C/26173 Ocean Gray, NAVSEA FED-STD-595C/31136 Lusterless Red FED-STD-595C/37038 Lusterless Black

COMMERCIAL ITEM DESCRIPTIONS

A-A-52464B Coupler, Drawbar, Ring; Light Duty, 60,000 Lb GVW;

Offset (Taper Shank), 60,000 Lb GVW; and Heavy Duty 120,000 Lb GVW

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-DTL-5541F Chemical Conversion Coatings on Aluminum and

Aluminum Alloys MIL-PRF-23377J(2) Primer Coatings: Epoxy, High-Solids MIL-T-26310A(1) Notice

Trailer, Lift, Aircraft – Missile Engine ETU-9/E

MIL-PRF-26915D(2) Primer Coating, for Steel Surfaces MIL-DTL-53030C Primer Coating, Epoxy, Water Reducible, Lead and

Chromate Free MIL-DTL-81706B(1) Chemical Conversion Materials for Coating Aluminum and Aluminum Alloys MIL-PRF-85285D(3) Coating: Polyurethane, Aircraft and Support Equipment

DEPARTMENT OF DEFENSE STANDARDS

MIL-STD-130N Identification Marking of U.S. Military Property MIL-STD-810G Environmental Engineering Considerations and

Laboratory Tests MIL-STD-882E System Safety MIL-STD-889B(3) Dissimilar Metals

MIL-STD-1366E Interface Standard for Transportability Criteria MIL-STD-1472G Human Engineering MIL-STD-1791A Designing for Internal Aerial Delivery in Fixed Wing

Aircraft

(Copies of these documents are available online at https://assist.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia PA 19111-5094.))

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

AIR FORCE INSTRUCTION (AFI)

AFI 32-7086 Hazardous Materials Management, dated 1 November

(Copies of this document are available online at http://www.e-publishing.af.mil/.)

TEST OPERATIONS PROCEDURE (TOP)

TOP 2-2-800 Center of Gravity, dated 26 September 2006

(Copies of this document can be obtained from https://vdls.atc.army.mil/.)

2.3 Non-Government publications. The following documents of the exact revision listed below form a part of this document to the extent specified herein.

AMERICAN WELDING SOCIETY (AWS)

D1.1/D1.1M:2006 Structural Welding Code–Steel–20th Edition D1.2/D1.2M:2003 Structural Welding Code–Aluminum–Fourth Edition

(Application for copies should be addressed to American Welding Society, 550 N.W. LeJeune Road, Miami FL 33126.)

SOCIETY OF AUTOMOTIVE ENGINEERS (SAE)

AS8090 Mobility, Towed Aerospace Ground Equipment, General Specification For

(Application for copies should be addressed to SAE, Inc., 400 Commonwealth Drive, Warrendale PA 15096.)

TIRE AND RIM ASSOCIATION

2012 Year Book

(Application for copies should be addressed to The Tire and Rim Association, Inc., 175 Montrose West Ave., Suite 150, Copley OH 44321.)

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein (except for related specification sheets), the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. REQUIREMENTS

3.1 First article. When specified (see 6.2), one sample of each type (as applicable) shall be subjected to first article inspection in accordance with 4.2.

3.2 Engine trailers description. The engine trailer is a mobile, hydraulically self-supporting trailer, which is made up of a set of rails connected to an elevating main frame by a hydraulically controlled linkage system. A towbar forward and a pintle hook aft provide means of transporting the trailers individually or in groups.

3.3 Design and construction. The trailers shall be designed and constructed in accordance with all applicable European Union (EU) requirements in order to have the “CE” marking affixed (see 3.3.3.1). They shall be designed and constructed so that no parts will work loose in service, and to withstand the strains, jars, vibrations, and other conditions incident to shipping, storage, installation, and service. They shall be weatherproof and designed to prevent the intrusion of water, sand, and dust into critical operating components.

3.3.1 Materials, protective coatings, and finish.

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

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

Fasteners, handles, and fittings used in the assembly of the item shall also be primed and painted.

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

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

3.3.1.2.2.1 Ferrous surfaces. Ferrous structures and surfaces shall be primed with a water reducible zinc rich primer in accordance with MIL-PRF-26915, Type II, Class B; this shall be followed, within four hours, by a coat of MIL-DTL-53030 intermediate primer in a wet-to-wet primer application. This two part primer system shall yield a dry-film thickness of 2.0-2.5 mils for the zinc primer and 0.9 to 1.1 mils for the intermediate primer. The two-primer system shall be allowed to dry and fully cure in accordance with the primer manufacturer's directions prior to top coating.

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

0.6 to 0.8 mils.

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

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

3.3.1.4 Finish. The exterior finish color of the engine trailer shall be Gray, Color Number 26173 of FED-STD-595.

3.3.1.5 Exclusion of water. The design of the trailer shall be such as to prevent water leaking into, or being driven into, any part of the trailer interior when either in an operating or travelling configuration. All windows, doors, panels, covers, etc., shall be provided with sealing arrangements such that the entry of water is minimized when these items are correctly closed.

Particular care shall be taken to prevent wetting of equipment, insulation, and sound proofing materials. Sharp corners and recesses shall be avoided so that moisture and solid matter cannot accumulate to initiate localized attack. Sealed floors with suitable drainage shall be provided for storage compartments, engine compartments, and other areas in the trailer that could collect and retain water.

3.3.1.5.1 Fluid traps and faying surfaces. There shall be no fluid traps on the engine trailer.

Faying surfaces of all structural joints, except welded joints, shall be sealed to preclude fluid intrusion.

3.3.1.5.2 Ventilation. Ventilation shall be sufficient to prevent moisture retention and buildup.

3.3.1.5.3 Drainage. Drain holes shall be provided to prevent collection or entrapment of water or other unwanted fluid in areas where exclusion is impractical. All designs shall include considerations for the prevention of water or fluid entrapment and ensure that drain holes are located to effect maximum drainage of accumulated fluids. The number and location of drain holes shall be sufficient to permit drainage of all fluids when the unit is in a 10 degree incline in any plane. The minimum size of the drain holes shall be 0.25 inch.

3.3.2 Markings. All external devices which require an operational or maintenance interface shall be marked in accordance with MIL-STD-130. Markings shall be applied with decals and shall be 1-inch high block letters unless prohibited by the available space. In such cases, the markings shall be the largest size possible, but shall not be less than ½-inch high. Markings, Information/Caution shall be Lusterless Black, Color Number 37038 of FED-STD-595, and Markings, Warning/Danger shall be Lusterless Red, Color Number 31136 of FED-STD-595.

The center of gravity of the trailer shall be stenciled on the unit within 1.0 inch of the calculated center of gravity.

3.3.3 Identification and information plates.

3.3.3.1 Identification plate. An identification plate in accordance with MIL-STD-130 shall be securely attached to the engine trailer in a readily accessible location. The identification plate shall contain the following information: nomenclature, part number, serial number, date of manufacture, manufacturer’s name, Commercial and Government Entity (CAGE) code, date of warranty expiration, and National Stock Number (NSN). The engine trailer and any of its components for which the Government’s unit cost is more than $5,000, is serially managed, or the procuring agency determines is mission essential, shall have Unique Identification (UID) (also known as Item Unique Identification (IUID)) information permanently affixed on or near the respective identification plate(s), marked in accordance with MIL-STD-130. UID information shall be included as both a bar code and human readable markings. The “CE” marking shall be affixed in accordance with EU requirements on or adjacent to the identification plate.

3.3.3.2 Transportation data plate. A transportation data plate shall be securely attached to the engine trailer in a readily accessible location. The plate shall contain at least the following information:

a. Side and rear silhouette views of the engine trailer.

b. Horizontal and vertical location of the center of gravity of the engine trailer in air transportable configuration, marked on the silhouette views.

c. Shipping weight.

d. Loading cubage.

e. Overall height, width, and length.

f. Front and rear axle loads.

g. Tie down information.

3.3.4 Miscellaneous design requirements.

3.3.4.1 Commercial parts. Commercially available components shall be utilized throughout the design of the trailer. Commercially available components shall be defined as components that can be obtained from more than one manufacturer with standard interface and dimension characteristics. For utility components such as screws, bolts, nuts, and cotter pins it is required that standard parts (MS or AN) be utilized to the maximum extent possible.

3.3.4.2 Specially manufactured components.

3.3.4.2.1 Cast components. Cast components are permitted in the design of the trailer. Impact loading, toughness, fatigue resistance, and wear resistance are some examples of properties to consider in the casting component design.

3.3.4.3 Interchangeability. Fabrication and assembly processes and techniques shall be such as to support, without degradation, the interchangeability requirements of the design. Like units, assemblies, subassemblies, and parts shall be physically and functionally interchangeable without modification of such items or of the equipment.

3.3.5 Maintainability. The engine trailers shall be designed for maintainability in accordance with 5.9 through 5.9.18 of MIL-STD-1472; forces shall not exceed those specified for both males and females.

3.3.6 Operators. The trailers shall be designed such that a maximum number of three operators are needed, which are two pumpers and one spotter. The desired number of operators is one pumper and one spotter.

3.3.7 Service life. The trailers shall be designed for a minimum service life of 25 years.

3.3.8 Safety.

3.3.8.1 Environment, Safety, and Occupational Health (ESOH).

3.3.8.1.1 System safety. The design of the engine trailer shall not contain any system safety mishap risk categories greater than medium as defined in Table III of MIL-STD-882.

3.3.8.1.2 Hazardous material. The design shall minimize and control hazards associated with the inclusion or use of hazardous or toxic materials (including hexavalent chromium) and the generation of toxic or noxious gases. The engine trailer shall not generate or use Class I or Class II Ozone Depleting Substances (ODS) during operation, maintenance, or disposal. For the purposes of this requirement, the Class I ODS and controlled substances identified in Chapter 4 of AFI 32-7086 shall not be used in any system, component, or process.

3.3.8.2 Component protection. All space in which work is performed during operation, service, and maintenance shall be free of hazardous protrusions, sharp edges, or other features which may cause injury to personnel. All rotating and reciprocating parts and all parts subject to high operational temperatures or subject to being electrically energized, that are of such nature or so located as to be hazardous to personnel, shall be guarded or insulated to eliminate the hazard.

All wires, cables, tubes, and hoses shall be supported and protected to minimize chafing and abrasion and shall be located so as to provide adequate clearance from moving parts and high operational temperatures. Grommets shall be provided wherever wires, cables, tubes, or hoses pass through bulkheads, partitions, or structural members.

3.3.8.3 Foolproofness. Where improper installation of an item causes a malfunction, an asymmetric mounting system shall be provided, where practical, to ensure proper mounting of the item.

3.3.8.4 Foreign object damage (FOD). All loose metal parts, such as pins or connector covers, shall be securely attached to the engine trailer with wire ropes or chains. "Dog tag" style beaded chains shall not be provided. Removable panels, if provided, shall be attached with captive fasteners. Tire valve stem caps shall be made of plastic.

3.3.9 Human engineering. The engine trailers shall be designed in accordance with MIL-STD-1472 for ease of operation, inspection, and maintenance, including the use of arctic mittens and Mission-Oriented Protective Posture (MOPP) Level 4 Chemical Warfare Gear.

3.3.10 Fastening devices. All screws, bolts, nuts, pins, and other fastening devices shall be properly designed, manufactured, and installed with adequate means of preventing loss of torque or adjustment. Cotter pins, lock washers, or nylon patches shall not be used for this purpose, except for the attachment of trim items or as provided in commercial components. Tapped threads shall have a minimum thread engagement in accordance with Table I.

TABLE I. Minimum thread engagement.

Material

Minimum Thread Engagement

Steel 1.0 times the nominal fastener diameter Cast iron, brass, or bronze 1.5 times the nominal fastener diameter Aluminum, zinc, or plastic 2.0 times the nominal fastener diameter

3.4 Environmental conditions.

3.4.1 Operating temperature range. The engine trailer shall be capable of operating in ambient temperatures ranging from -65 degrees Fahrenheit F to +140 degrees Fahrenheit.

3.4.2 Storage temperature range. The engine trailer shall be capable of being stored in ambient temperatures ranging from -65 degrees Fahrenheit F to +140 degrees Fahrenheit.

3.4.3 Precipitation.

3.4.3.1 Rain. The engine trailer shall be capable of storage and operation during rainfall of 5-inches per hour for three consecutive hours and 10 inches per hour for 10 consecutive minutes, with winds of up to 35 knots; and with 6 inches of rain per hour impinging on the engine trailer at angles from vertical to 45°.

3.4.3.2 Snow. The engine trailer shall be capable of storage and operation during accretion of wet snow up to 2 inches per hour for at least 12 hours on exposed horizontal surfaces.

3.4.3.3 Ice. The engine trailer shall be capable of storage and operation with ice accretion up to

1.5 inches on exposed horizontal surfaces. An operator may use an ice scraper for five minutes during the start-up process.

3.4.4 Solar radiation. The engine trailer shall not be adversely affected by full time exposure to solar radiation, such as those conditions encountered in desert environments and high altitudes.

3.4.5 Fungus. All materials used in the engine trailer shall be fungus resistant or shall be suitably treated to resist fungus. Materials treated for fungus resistance shall retain their original electronic and physical properties, shall not present toxic hazards, and treatment shall last for the entire service life of the part. The engine trailer shall be suitable for operation and storage in conditions encountered in a tropical environment.

3.4.6 Salt fog. The engine trailer shall be capable of storage and operation in high temperature, high humidity, salt laden, and sea coast environments without damage or deterioration of performance.

3.4.7 Sand and dust. The engine trailer shall be capable of storage and operation during exposure to wind-blown sand or dust without damage or deterioration of performance.

3.4.8 Humidity. Relative humidity up to 100 percent, including conditions wherein condensation takes place in the form of water, frost, and ice.

3.5 Weight, dimensions, and capacities. Overall weight, dimensions, and capacities in air transport configuration shall be in accordance with Table II.

TABLE II. Weights, dimensions, and capacities.

Requirement

Type 1 Type 2

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

18 29

Minimum height without spacers (inches)

29 29

Maximum height without spacers (inches)

79 105

Maximum weight 2760 3170 Rail length (inches) 152 ± 0.25 174 ± 0.25 Wheelbase (inches) 126 148 Overall width (inches) 80 80 Tread (inches) 72±1.0 72±1.0 Minimum curb-to-curb turning radius (feet)

14 22.5

3.6 Performance.

3.6.1 Rated load. The trailers shall be capable of transporting a component that weighs its maximum rated load in accordance with Table II. The trailers shall be designed for a minimum safety factor of 3.0 based on the rated load as specified in Table II and minimum material properties.

3.6.1.1 Tension load. When subjected to the rated load as specified in Table II placed on one end of the trailer, the loaded end of the rails shall not deflect more than 4-inches and the opposite end of the rails shall not deflect more than 5-inches when measured from the top of the rail to the top of the main frame.

3.6.2 Proof load. Each trailer type shall be capable of withstanding the respective proof load as specified in Table II. The center of gravity of the load shall be placed at the height specified for each trailer type in Table II. The load for the Type 1 and Type 2 trailers shall be applied to two points 30 ±2 inches either side of center (60 inches apart). The trailers shall be capable of being raised to their maximum height with spacer and lowered to the low position while subjected to the proof load. The wheel lift cylinders shall also be subjected to this proof load and shall operate through their entire range.

3.6.3 Endurance. The trailers shall be capable of withstanding repeated operations as specified in 4.5.8

3.6.4 Mobility. The trailer with rated load in low position shall be designed and constructed to meet the general requirements of SAE AS8090 and those specified for Type II mobility with the following additional requirements and limitations. The low position is defined as the trailer with its wheels in maximum height position and the rails in lowest position with the spacers in place.

Reflectors are not required.

3.6.4.1 Terrain.

3.6.4.1.1 Paved surfaces. The engine trailer shall be towable at speeds up to 20.0 miles per hour (mph) over paved surfaces.

3.6.4.1.2 Graded gravel. The engine trailer shall be towable at speeds up to 10.0 mph over graded gravel.

3.6.4.1.3 Belgian block. The engine trailer shall be towable at speeds up to 8.0 mph over Belgian block.

3.6.4.2 Towing force. The towing force shall be in accordance with 3.3.4 of SAE AS8090.

3.6.4.3 Minimum curb-to-curb turning radius. Each trailer size shall have a minimum curb-to-curb turning radius as specified in Table II.

3.7 Chassis. Type 1 and Type 2 trailers shall have foot assemblies, one each at the four corners of the main frame. The foot assemblies shall have at least 12 inches of adjustment using pull pins and a series of holes at 2 inch increments. For the Type 2 trailer only, extendable stabilizers shall be provided one each at the four corners of the main frame to increase the stability of the trailer. The stabilizers shall extend at least 18 inches from the side of the chassis and incorporate manual screw-type jacks capable of at least 12 inches of adjustment. The stabilizers shall retract and stow securely when not in use.

3.7.1 Tires and wheels. The tires shall be in accordance with the Tire and Wheel Association requirements for this application, 7.50-10 NHS, 10 ply rating, or larger. The wheels shall be retractable by hydraulic lifts, with the two front wheels interconnected and steerable. The wheels shall turn 90º from the forward position and lock for side movement.

3.7.2 Wheel cylinders. The wheel cylinders shall be equipped with mechanical positive locks in case of hydraulic failure. The wheel cylinder assemblies shall be capable of raising or lowering the rated load.

3.7.3 Clearances. Ground clearance, ramp break over angle, and angles of approach and departure shall be in accordance with 3.3.9 of SAE AS8090.

3.7.4 Suspension. The engine trailer shall have a suspension system in accordance with 3.4.1.2 of SAE AS8090.

3.7.5 Steering. The engine trailer shall have a steering system in accordance with 3.5.1.1 of SAE

AS8090.

3.7.6 Brakes.

3.7.6.1 Parking brakes. The engine trailer shall have parking brakes in accordance with 3.6.1 of

SAE AS8090.

3.7.6.2 Service brakes. The engine trailer shall have service brakes in accordance with 3.6.2 of

SAE AS8090.

3.7.7 Bumper. The engine trailer shall have a rear bumper in accordance with 3.7 of SAE

AS8090.

3.7.8 Fenders. The engine trailer shall have fenders in accordance with 3.9 of SAE AS8090.

3.7.9 Mudflaps. The engine trailer shall have mud flaps in accordance with 3.12 of SAE

AS8090.

3.7.10 Pintle hook. A pintle hook shall be mounted on the rear of the engine trailer in accordance with SAE AS8090.

3.7.11 Towbar. A telescoping tow bar 44.5 to 72 inches long shall be provided with the engine trailers. All towing operations shall be performed with the base frame at a maximum ground clearance and with the lift frame fully collapsed with all locks engaged. The towbar shall be in accordance with 3.17.1 of SAE AS8090. It shall have a lunette eye in accordance with A-A-52464 and accommodate any pintle hook height from 22 through 30 inches. When in operation or storage (that is, not being towed), the towbar shall be stowed upright, secured, and not hinder visibility, operation, or maintenance.

3.8 Hydraulic system. The hydraulic lift shall be provided with hydraulic cylinders. Each cylinder shall be equipped with a mechanical position-locking device to prevent lowering or tipping in the event of hydraulic line failure. A visual indicator shall indicate when the position-locking device is engaged or disengaged. The position-locking device shall be manually disengaged. The hydraulic lift shall raise the rails in a vertical direction with a variance of not more than 0.5-inch on either side of the true vertical.

3.8.1 Lift mechanism. The lift mechanism shall be designed to permit the center of gravity of the rated load to be transferred to either end and to prevent tipping. Once the rated load is transferred to either end, the center of gravity, either side of center, shall not exceed 38 inches for the Type 1 or 49 inches for the Type 2. The lift mechanism shall be capable of adjusting the height of the rails from a low position without spacers to a maximum height with spacers under the rails. These maximum and minimum heights for each trailer type are specified in Table II.

The trailer shall be designed to raise or lower the loads to any position within these limits.

Figure 1 illustrates the elevation range for the Type 2 trailer.

FIGURE 1. Elevation range example for Type 2.

3.8.2 Lift controls. The hydraulic lift provisions for the rails and wheels shall be located at one operator’s position on the left side of the trailer. They shall be designed to enable one operator to raise the rails or the main frame, maintaining a level height of the rails and frame. The provisions shall also enable one operator to control one end of the rail or frame.

3.8.3 Secondary locking mechanism. A secondary mechanical locking mechanism shall be incorporated into the design. This secondary locking mechanism shall be external from the hydraulic system. This secondary locking mechanism shall enable maintainers to service the unloaded trailer and replace cylinders while the rails are in a lifted position.

3.8.4 Pumping force. The force on the handle required to pump the hydraulic cylinders shall not exceed 75 pounds.

3.8.5 Cylinder settling rate. After the endurance test, the cylinder settling rate shall not exceed

0.0625 inches per hour.

3.9 Rails. Each trailer type shall have parallel rails with a rail length as specified in Table II.

The rail gage shall be 48 ± 0.12 inches along the entire length of the rail. The rail shall have a

3.33 ± 0.125 inch working face on each rail. The working face or flange of each rail shall have a minimum clearance of 0.90 inch on the inside and a minimum clearance of 0.55 inch on the outside. These clearances shall extend 3 inches below the face of the rail as specified in Figure

2. The end of each rail shall be square within +30, -0 minutes to ensure contact on the top of the rails. The ends of the parallel rails shall be in the same plane within 0.0625 inches. The top face of the rails shall be in the same plane within 0.0625 inches.

110 INCHES:

MAX RAIL

WITH SPACER

29 INCHES:

MIN RAIL W/O

SPACER

3.9.1 Adjustments. The rails shall be joined together to obtain the following minimum adjustments as shown in Figure 2 through Figure 5 below with any load from no load and the proof load:

a. Yaw 2.25º each direction from the centerline

b. Roll 10º each side of the horizontal centerline

c. Lateral 3 inches in each direction from the vertical centerline of the trailer

d. Tilt 10º from the horizontal at each end of the rails

FIGURE 2. Yaw adjustment.

FIGURE 3. Roll adjustment range.

2.25°

2.25°

FIGURE 4. Lateral adjustment range.

FIGURE 5. Tilt adjustment range.

3.9.1.1 Control mechanisms. The mechanism for yaw, roll, and lateral adjustments shall be of the mechanical-type drive. The tilt adjustment shall be obtained by actuating the main hydraulic lift cylinders on each end of the trailer. The adjusting mechanisms shall be operable by hand while the respective size trailer is under its rated load as specified in Table II. The controls shall be located on the left side. A minimum clearance radius of 21.5 inches, with spacers installed (see 3.8.1), shall be provided between the rails and structure for mounting required components.

3.9.1.2 Spacers. Removable spacers shall be provided between the rails and lift structure.

Removing the spacers shall permit the rails to be lowered 5.0 inches.

3.9.1.3 Control knobs. Control knobs shall have a 1/2-inch square drive for use with a 1/2-inch male wrench.

3.9.2 Overload. The trailer shall be so designed that the adjustments specified in 3.9.1 can be accomplished with standard 1/2-inch drive wrenches when each trailer is under its respective proof load as specified in Table II. While under its proof load, the trailer shall not tip or overturn when a 1,000 pound side load is applied at the side of the rails and the rails are raised to their maximum height with spacers installed (see 3.9.1.2).

3.9.3 Couplings. Each rail shall be equipped with a male and female coupling. The mating dimensions of the couplings shall be in accordance with Figure 2 of MIL-T-26310. The female coupling shall be provided with a quick-release, positive-lock-type pin. The pin shall be 3/4-inch in diameter, and permanently attached to the coupler by a steel cable. The pin shall have a double shear value in excess of 70,000 pounds.

3.9.4 Rail guides. Each rail shall be provided with rail guides for aligning two rails together when two trailers are connected together. The rail guides shall be in accordance with Figure 3 and Figure 4 of MIL-T-26310.

3.9.5 Rail stops. A positive, mechanical-type stop shall be provided near the extreme ends of each rail. In the event of failure to lock a roller adapter to the rails, the stops shall be designed to hold a component (weighing the rated load of Table II) from rolling off the rails. The stops shall be spring-loaded and manually retractable to permit a roller adapter to pass or roll along the rails to another trailer or into the aircraft. The rail stops shall be hand-operated and shall extend 0.5-inch above the face of the rails when fully extended. The rail stops shall engage the vertical face of the roller adapter.

FIGURE 6. Rail clearances.

3.10 Winch. RESERVED.

3.11 Transportability.

3.11.1 Surface transportability. The engine trailers shall be transportable via all modes of surface shipment (highway, rail, and water) in accordance with MIL-STD-1366, and shall be capable of withstanding the mechanical shock and vibration characteristics of highway, rail, and water transport, except that design for rail impact testing (see 5.2.5 of MIL-STD-1366) is not required.

3.11.2 Air transportability. The trailers shall be transportable on C-130, C-17, and C-5 aircraft in accordance with MIL-STD-1791. In all air transport configurations, the trailers shall be capable of being restrained and withstanding, without loss of serviceability, 2.0 G up and 4.5 G down accelerations, and shall be capable of being restrained and withstanding, without loss of structural integrity, 3.0 G forward, 1.5 G aft, and 1.5 G lateral accelerations. The trailers shall be equipped with pressure relief devices or configured for air transport to prevent any part from becoming a projectile in the event of catastrophic loss of aircraft cabin pressure. The trailers shall roll on and off the aircraft, negotiating the required maximum ramp angles without shoring.

3.11.2.1 Shoring. The engine trailer shall be air transportable without shoring.

3.11.2.2 Tire pressure. Tire pressure shall not exceed 100 pounds per square inch (psi) and shall not be reduced for air transport.

3.11.2.3 Winch points. Winch points shall be provided at the front and rear of the engine trailer for aircraft loading using the aircraft’s winch.

3.11.2.4 Equipment removal and reconfiguration. Preparation for air transport shall take no more than 15 minutes and restoration to operating configuration shall take no more than 15 minutes for two persons using common hand tools (see 6.3.1). The only item that may be removed is the tow bar; if removed, it shall be stored on the engine trailer.

3.11.3 Tie downs. The trailers shall be symmetrically restrained during air and ground transport with tie down rings. Tie down points shall be rated at a minimum of 10,000 pounds, marked for capacity, with a clear opening compatible with the appropriate devices. Each end of each tie down device shall terminate at a tie down point and not pass through any other tie down point.

There shall be no interference between tie down devices and the trailers.

3.11.4 Welders and welding. All welders shall be certified to weld in accordance with AWS D1.1 and AWS D1.2. The contractor shall make available to the Government certifications for all welders being utilized on the trailers. Welding procedures and all welding on the trailers shall be in accordance with AWS D1.1 and AWS D1.2. The surface parts to be welded shall be free from rust, scale, paint, grease, and other foreign matter. Welds shall be of sufficient size and shape to develop the full strength of the welded parts. Welds shall transmit stress without cracking or permanent distortion when the parts connected by the welds are subjected to test, proof, and service loadings.

3.12 Workmanship. The engine trailer including all parts and accessories, shall be constructed and finished in a thoroughly workmanlike manner. Workmanship objectives shall include freedom from blemishes, defects, burrs and sharp corners and edges; accuracy of dimensions, surface finish, and radii of fillets; thoroughness of welding, painting, and riveting; marking of parts and assemblies; and proper alignment of parts and tightness of assembly fasteners.

3.12.1 Bolted connections. Bolt holes shall be accurately punched or drilled and shall be deburred. Threaded fasteners shall be tight and shall not work loose during testing or service usage.

3.12.2 Riveted connections. Rivet holes shall be accurately punched or drilled and shall be deburred. Rivets shall be driven with pressure tools and shall completely fill the holes. Rivet heads shall be full, neatly made, concentric with the rivet holes and in full contact with the surface of the component.

3.12.3 Gear and lever assemblies. Gear and lever assemblies shall be properly aligned and meshed and shall be operable without interference, tight spots, loose spots, or other irregularities.

Where required for accurate adjustment, gear assemblies shall be free of excessive backlash.

3.12.4 Cleaning. The engine trailer shall be thoroughly cleaned. Loose, spattered, or excess solder; welding slag; stray bolts, nuts, and washers; rust; metal particles; pipe compound; and other foreign matter shall be removed during and after final assembly.

4. VERIFICATION

4.1 Classification of inspections. The inspection requirements specified herein are classified as follows:

a. First article inspection (see 4.2).

b. Conformance inspection (see 4.3)

Requirements shall be verified in accordance with Table III.

TABLE III. Requirement verification matrix.

Section 3 Requirement Verification

Method

Section 4 Verification

3.1 First article

Not Applicable

(N/A)

3.2 Engine trailer description. N/A

3.3 Design and construction. Examination 4.5.1 Examination of product.

3.3.1 Materials, protective coatings, and finish.

N/A

3.3.1.1 Recycled, recovered, or

environmentally preferable materials.

Examination 4.5.1 Examination of product.

3.3.1.2 Protective coatings. Examination 4.5.1 Examination of product.

3.3.1.2.1 Surface preparation and

pretreatment.

Examination 4.5.1 Examination of product.

3.3.1.2.2 Primer. Examination 4.5.1 Examination of product.

3.3.1.2.2.1 Ferrous surfaces. Examination 4.5.1 Examination of product.

3.3.1.2.2.2 Aluminum and mixed

aluminum and ferrous surfaces.

Examination 4.5.1 Examination of product.

3.3.1.2.3 Topcoat. Examination 4.5.1 Examination of product.

3.3.1.3 Dissimilar metals. Examination 4.5.1 Examination of product.

3.3.1.4 Finish. Examination 4.5.1 Examination of product.

3.3.1.5 Exclusion of water. Examination 4.5.1 Examination of product.

3.3.1.5.1 Fluid traps and faying

surfaces.

Examination 4.5.1 Examination of product.

3.3.1.5.2 Ventilation. Examination 4.5.1 Examination of product.

3.3.1.5.3 Drainage. Examination 4.5.1 Examination of product.

3.3.2 Markings. Examination 4.5.1 Examination of product.

3.3.3 Identification and information

plates.

N/A

3.3.3.1 Identification plate. Examination 4.5.1 Examination of product.

3.3.3.2 Transportation data plate. Examination 4.5.1 Examination of product.

Section 3 Requirement

3.3.5 Maintainability. Examination 4.5.1 Examination of product.

3.3.6 Operators. Examination 4.5.1 Examination of product.

3.3.7 Service life. Analysis 4.5.3 Service life analysis.

3.3.8 Safety. N/A

3.3.8.1 Environment, Safety, and

Occupational Health (ESOH).

N/A

3.3.8.1.1 System safety. Analysis

4.5.2 System safety hazard

analysis.

3.3.8.1.2 Hazardous materials. Examination 4.5.1 Examination of product.

3.3.8.2 Component protection. Examination 4.5.1 Examination of product.

3.3.8.3 Foolproofness. Examination 4.5.1 Examination of product.

3.3.8.4 Foreign object damage

(FOD).

Examination 4.5.1 Examination of product.

3.3.9 Human engineering. Examination 4.5.1 Examination of product.

3.3.10 Fastening devices. Examination 4.5.1 Examination of product.

3.4 Environmental conditions. N/A

3.4.1 Operating temperature range. Test

4.5.4.1 High temperature storage

and operation test.

4.5.4.2 Low temperature storage

and operation test.

3.4.2 Storage temperature range. Test

4.5.4.1 High temperature storage

and operation test.

4.5.4.2 Low temperature storage

and operation test.

3.4.3 Precipitation. N/A

3.4.3.1 Rain. Test 4.5.4.5 Rain test.

3.4.3.2 Snow. Analysis 4.5.4.6 Snow load analysis.

3.4.3.3 Ice. Test

4.5.4.7 Ice accretion test

3.4.4 Solar radiation. Examination 4.5.1 Examination of product.

3.4.5 Fungus. Examination 4.5.1 Examination of product.

3.4.6 Salt fog. Test 4.5.4.4 Salt fog test.

3.4.7 Sand and dust. Test 4.5.4.8 Sand and dust test.

3.4.8 Humidity Test 4.5.4.3 Humidity test

3.5 Weight, dimensions, and

capacities.

Test

4.5.5 Weight and dimension tests.

4.5.5.1 Weight and center of

gravity test.

4.5.5.2 Dimension measurement.

3.6 Performance. N/A

3.6.1 Rated load.

Test 4.5.7 Rated load test.

Analysis 4.5.7.1 Structural analysis.

3.6.1.1 Tension load. Test 4.5.7.2 Tension load test.

Section 3 Requirement

3.6.2 Proof load. Test 4.5.7.3 Proof load test.

3.6.3 Endurance. Test 4.5.8 Endurance tests.

3.6.4 Mobility. Test

4.5.11 Mobility tests.

4.5.11.1 Towing test.

3.6.4.1 Terrain. N/A

3.6.4.1.1 Paved surfaces. Test

4.5.11 Mobility tests.

4.5.11.1 Towing test.

3.6.4.1.2 Graded gravel. Test

4.5.11 Mobility tests.

4.5.11.1 Towing test.

3.6.4.1.3 Belgian block. Test

4.5.11 Mobility tests

4.5.11.1 Towing test..

3.6.4.2 Towing force. Test 4.5.11.1 Towing test.

3.6.4.3 Minimum curb-to-curb

turning radius.

Test 4.5.11.2 Turning radius test.

3.7 Chassis. Examination 4.5.1 Examination of product.

3.7.1 Tires and wheels. Examination 4.5.1 Examination of product.

3.7.2 Wheel cylinders. Test 4.5.12 Wheel cylinder tests.

3.7.3 Clearances. Test 4.5.5.2 Dimension measurement.

3.7.4 Suspension.

Examination 4.5.1 Examination of product.

Test 4.5.11 Mobility tests.

3.7.5 Steering.

Examination 4.5.1 Examination of product.

Test 4.5.11 Mobility tests.

3.7.6 Brakes. N/A 4.5.20 Brake tests.

3.7.6.1 Parking brakes. Test 4.5.20.1 Parking brake test.

3.7.6.2 Service brakes. Test 4.5.20.2 Service brake test.

3.7.7 Bumper. Examination 4.5.1 Examination of product.

3.7.8 Fenders. Examination 4.5.1 Examination of product.

3.7.9 Mudflaps. Examination 4.5.1 Examination of product.

3.7.10 Pintle hook. Examination 4.5.1 Examination of product.

3.7.11 Towbar. Examination 4.5.1 Examination of product.

3.8 Hydraulic system. Examination 4.5.1 Examination of product.

3.8.1 Lift mechanism. Examination 4.5.1 Examination of product.

3.8.2 Lift controls. Examination 4.5.1 Examination of product.

3.8.3 Secondary locking

mechanism.

Examination 4.5.1 Examination of product.

3.8.4 Pumping force. Test 4.5.9 Pumping force test.

3.8.5 Cylinder settling rate. Test 4.5.10 Cylinder settling rate test.

3.9 Rails. Examination 4.5.1 Examination of product.

3.9.1 Adjustments. Test 4.5.13 Adjustment controls.

3.9.1.1 Control mechanisms. Examination 4.5.1 Examination of product.

3.9.1.2 Spacers. Examination 4.5.1 Examination of product.

3.9.1.3 Control knobs. Examination 4.5.1 Examination of product.

Section 3 Requirement

3.9.2 Overload. Test 4.5.14 Overload tests.

3.9.3 Couplings. Examination 4.5.1 Examination of product.

3.9.4 Rail guides. Examination 4.5.1 Examination of product.

3.9.5 Rail stops. Test 4.5.15 Rail stops test.

3.10 Winch. N/A

3.11 Transportability. N/A

3.11.1 Surface transportability. Analysis

4.5.6.1.1 Surface transportability

analysis.

3.11.2 Air transportability. Analysis 4.5.17 Air transportability analysis.

3.11.2.1 Shoring. Analysis 4.5.17 Air transportability analysis.

3.11.2.2 Tire pressure. Examination 4.5.1 Examination of product.

3.11.2.3 Winch points. Analysis 4.5.16 Winch test.

3.11.2.4 Equipment removal and

reconfiguration.

Demonstration

4.5.18 Equipment removal and

reconfiguration demonstration.

3.11.3 Tie downs.

Analysis

4.5.19.1 Tie down provision

analysis.

Test 4.5.19.2 Tie down provision test.

3.11.4 Welders and welding. Examination 4.5.1 Examination of product.

3.12 Workmanship. Examination 4.5.1 Examination of product.

3.12.1 Bolted connections. Examination 4.5.1 Examination of product.

3.12.2 Riveted connections. Examination 4.5.1 Examination of product.

3.12.3 Gear and lever assemblies. Examination 4.5.1 Examination of product.

3.12.4 Cleaning. Examination 4.5.1 Examination of product.

4.2 First article inspection. The first article trailers shall be subjected to the analyses, demonstrations, examinations, and tests described in 4.5.1 through 4.5.20. The contractor shall provide or arrange for all test equipment and facilities. Upon completion of the first article requirements, the first article trailers are to be shipped to a location as specified in contract. The compatibility test described in 4.5.21 will be carried out under supervision of WR-ALC. Unless otherwise approved by the procuring activity, all first article trailers shall be in the same configuration at all times and configuration changes shall not be made during the first article inspection.

4.3 Conformance inspection. Each production engine trailer shall be subjected to the examination and tests described in 4.5.1.

4.4 Inspection requirements.

4.4.1 General inspection requirements. Apparatus used in conjunction with the inspections specified herein shall be laboratory precision type, calibrated at proper intervals to ensure laboratory accuracy.

4.4.2 Data. During all testing specified herein, at least the following data, unless not applicable, shall be recorded at intervals not to exceed 30 minutes. Additional data and/or shorter intervals shall be provided as appropriate for any specific test.

a. Date.

b. Time started.

c. Time finished.

d. Ambient temperature.

e. Ambient humidity.

4.4.3 Test rejection criteria. Throughout all tests specified herein, the engine trailers shall be closely observed for the following conditions, which shall be cause for rejection.

a. Failure to conform to design or performance requirements specified herein or in the contractor's technical proposal.

b. Any spillage or leakage of any liquid, including lubricant, or hydraulic fluid, under any condition, except as allowed herein.

c. Structural failure of any component, including permanent deformation, or evidence of impending failure.

d. Evidence of excessive wear. If excessive wear is suspected, the original equipment manufacturer’s (OEM’s) specifications or tolerances shall be utilized for making a determination.

e. Evidence of corrosion or deterioration.

f. Misalignment of components.

g. Conditions that present a safety hazard to personnel during operation, servicing, or maintenance.

h. Interference between the engine trailer components or between the engine trailers the ground, and all required obstacles, with the exception of normal contact by the tires.

i. Evidence of undesirable mobility characteristics, including instability in handling during cornering, braking, and while traversing all required terrain.

4.4.4 Failure reporting, analysis, and corrective action system (FRACAS). A closed loop system shall be used to collect data, analyze, and record timely corrective action for all potential failures that occur during the first article. The contractor's existing FRACAS shall be utilized with the minimum changes necessary to conform to this specification. The system shall cover all test samples, interfaces between test samples, test instrumentation, test facilities, test procedures, test personnel, and the handling and operating instructions. The contractor shall establish and maintain a FRACAS database; all information shall be entered into the database. Authorized procuring activity personnel shall have read-only access to the FRACAS database.

4.4.4.1 Problem and failure action. At the occurrence of a problem or potential failure that affects satisfactory operation of a test sample, entries shall be made in the appropriate data logs and the failed test sample shall be removed from test, with minimum interruption to the other test samples continuing on test.

4.4.4.1.1 Problem and failure reporting. A failure report shall be initiated at the occurrence of each problem or potential failure of the contractor hardware. The report shall contain the information required to permit determination of the origin and correction of the failure. The contractor’s existing failure report form may be used with minimum changes necessary to conform to the requirements of this specification. The failure report form shall include the information specified in a through c:

a. Descriptions of failure symptoms, conditions surrounding the failure, failed hardware identification, and operating time (or cycles) at the time of failure.

b. Information on each independent and dependent failure and the extent of confirmation of the failure symptoms, the identification of failure modes, and a description of all repair actions taken to return the test sample to operational readiness.

c. Information describing the results of the investigation, the analysis of all part failures, an analysis of the system design, and the corrective action taken to prevent failure recurrence. If no corrective action is taken, the rationale for this decision shall be recorded.

4.4.4.1.2 Identification and control of failed items. A failure tag shall be affixed to the failed part immediately upon the detection of any failure or suspected failure. The failure tag shall provide space for the failure report serial number and for other pertinent entries from the test sample failure record. All failed parts shall be marked conspicuously or tagged and controlled to ensure disposal in accordance with contract requirements. Failed parts shall not be handled in any manner which may obliterate facts which might be pertinent to the analysis. Failed parts shall be stored pending disposition by the authorized approval agency of the failure analysis.

4.4.4.1.3 Problem and failure investigations. An investigation and analysis of each reported failure shall be performed. Investigation and analysis shall be conducted to the level of hardware or software necessary to identify causes, mechanisms, and potential effects of the failure. Any applicable method (for example, test, microscopic analysis, applications study, dissection, X-ray analysis, spectrographic analysis) of investigation and analysis which may be needed to determine failure cause shall be used.