TECHNICAL EXHIBIT 10 - MAFFS Trailer Manual.pdf

15 APRIL 2016

ASD2244 CARGO HANDLING

TRAILER 113449 MAINTENANCE AND

OPERATION MANUAL WITH ILLUSTRATED

PARTS LIST

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the information or illustrations contained in this publication is not permitted without specific approval of the Assistant Director, Fire Operations U.S. Forest Service

D14 - Technical Exhibit 10 - MAFFS Trailer Manual

A 15 APRIL 2016i

Dates of issue for original and changed pages are:

Pages affected by change are as follows

Page No.

*Change No.

Change

• * Zero in this column indicates original

Original 0 15 APRIL 2016

15 APRIL 2016 i

Table of Contents

CHAPTER 1 INTRODUCTION ..................................................................................................................................1-1

1.1. Trailer Configuration Description: .............................................................................................................. 1-1 CHAPTER 2 DESCRIPTION AND OPERATION......................................................................................................2-1

2.1. GENERAL LOADING DATA...................................................................................................................... 2-1

2.1.1. DIMENSIONS: ........................................................................................................................................ 2-1

2.2. TRAILER LOADING ONTO AIRCRAFT.................................................................................................... 2-3

2.3. CARGO LOADING PROCEDURES FROM TRAILER TO AIRCRAFT..................................................... 2-5

2.4. OFF LOADING PROCEDURE FROM AIRCRAFT TO TRAILER: .......................................................... 2-10

2.5. TRAILER EXTENSIONS.......................................................................................................................... 2-16

2.5.1. Forward Extension Assembly: .............................................................................................................. 2-16

2.5.2. Aft Extension Assembly........................................................................................................................ 2-16

2.6. POWER ................................................................................................................................................... 2-16

2.7. HYDRAULIC OPERATION...................................................................................................................... 2-18

2.8. TONGUE REMOVAL & INSTALLATION................................................................................................. 2-19 CHAPTER 3 TESTING AND FAULT ISOLATION....................................................................................................3-1

3.1. FUNCTIONAL TEST.................................................................................................................................. 3-1 CHAPTER 4 MAINTENANCE AND INSPECTION ...................................................................................................4-1

4.1. HYDRAULIC LINES................................................................................................................................... 4-1

4.2. TRAILER LIFT HYDRAULIC SYSTEM...................................................................................................... 4-1

4.3. ELECTRICAL SYSTEM............................................................................................................................. 4-2

4.4. TIRES......................................................................................................................................................... 4-2

4.5. WHEEL BEARINGS................................................................................................................................... 4-2

4.6. CASTERS .................................................................................................................................................. 4-2

4.7. ROLLERS .................................................................................................................................................. 4-2

4.8. TRAILER SYSTEM MAINTENANCE PROGRAM..................................................................................... 4-2

4.9. SYSTEM MAINTENANCE PROGRAM CHECKLIST................................................................................ 4-3 CHAPTER 5 ILLUSTRATED PARTS LIST...............................................................................................................5-1

5.1. INTRODUCTION ....................................................................................................................................... 5-1

5.2. TRAILER DETAILED PARTS LIST ........................................................................................................... 5-2

5.3. HYDRAULIC INSTALLATION DETAILED PARTS LIST........................................................................... 5-4

5.4. ELECTRICAL INSTALLATION DETAILED PARTS LIST.......................................................................... 5-8

5.5. DETAILED PARTS LIST FOR EXTENSIONS (OPTIONAL) ................................................................... 5-10

5.6. DETAILED PARTS LIST NUMERICAL BY ITEM NO. ............................................................................ 5-12

APPENDIX A TITAN 13” X 2-1/2 BRAKE INSTALLATION INSTRUCTIONS

APPENDIX B RELIABLE H-60-880F HUB AND SPINDLE PARTS LIST

APPENDIX C TORQUE OF HYDRAULIC & PNEUMATIC FITTINGS

APPENDIX D WARN Winch XD-9000 Operation Manual ii 15 APRIL 2016

List of Figures

Fig. 2-1 Overall Trailer Dimensions........................................................................................................................... 2-1 Fig. 2-2 Trailer Tongue.............................................................................................................................................. 2-3 Fig. 2-3 Hydraulic Control Box ................................................................................................................................... 2-4 Fig. 2-4 Electrical Power Box ..................................................................................................................................... 2-4 Fig. 2-5 Tongue Details............................................................................................................................................. 2-5 Fig. 2-6 Jack Pads ..................................................................................................................................................... 2-6 Fig. 2-7 Parking Break Lever ..................................................................................................................................... 2-6 Fig. 2-8 Pallet Bumper Stops ..................................................................................................................................... 2-7 Fig. 2-9 Storage Box .................................................................................................................................................. 2-8 Fig. 2-10 Hydraulic Controls....................................................................................................................................... 2-9 Fig. 2-11 Tongue in Position for Aircraft/Trailer Alignment ...................................................................................... 2-10 Fig. 2-12 Pallet Stops............................................................................................................................................... 2-11 Fig. 2-13 Tongue Jack Details ................................................................................................................................. 2-11 Fig. 2-14 Jack Pad Detail ......................................................................................................................................... 2-12 Fig. 2-15 Parking Break ........................................................................................................................................... 2-13 Fig. 2-16 Hydraulic Control Box ............................................................................................................................... 2-14 Fig. 2-17 Winch and Winch Remote ........................................................................................................................ 2-15 Fig. 2-18 Electrical Power Box ................................................................................................................................. 2-17 Fig. 2-19 Hydraulic Control Box ............................................................................................................................... 2-18 Fig. 2-20 Tongue Hydraulic Disconnect................................................................................................................... 2-19 Fig. 2-21 Tongue Jack Details ................................................................................................................................. 2-19 Fig. 2-22 Tongue Details.......................................................................................................................................... 2-20 Fig. 3-1 Winch Detail .................................................................................................................................................. 3-2 Fig. 3-2 Trailer Electrical System Schematic (113439).............................................................................................. 3-3 Fig. 3-3 Trailer Hydraulic System Block Diagram (113436)....................................................................................... 3-5 Fig. 5-1 Trailer & Caster details ................................................................................................................................. 5-2 Fig. 5-2 Hydraulic Line Details ................................................................................................................................... 5-4 Fig. 5-3 Hydraulic Solenoid Plumbing Details............................................................................................................ 5-6 Fig. 5-4 Electrical Component Details........................................................................................................................ 5-8 Fig. 5-5 Extension Details (OPTIONAL) .................................................................................................................. 5-10

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CHAPTER 1 INTRODUCTION

The instructions in this manual provide descriptive information necessary for repair of the Trailer. Subjects covered include Description and Operation, Disassembly, Cleaning, Check, Repair, Assembly, Illustrated Parts List, and Wire Diagram.

NOTICE: Reproduction for non-military or non US government use of the information or illustrations contained in this publication is not permitted. The policy for military reproduction is established for the Army in AR 38-4, for the Navy and Marine Corps in OPNAVINST 5510.1, and for the Air Force in AFPD 34-1.

NOTICE: Occupational Safety and Health Act (OSHA) Users of this manual shall be in compliance with OSHA regulations.

1.1. Trailer Configuration Description:

All trailer configurations are identical, except where noted. For more information see AUC Drawing Number 113455 Trailer Mechanical Interface.

Table 1-1 Trailer Configuration

113449-301 Paint Color: Forest Service Green Included Optional Equipment:

113441-301 Trailer Extension, Aft Qty 1 113433-301 Trailer Extension, Forward Qty 1 113449-303 Paint Color: Field Green Included Optional Equipment: N/A

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CHAPTER 2 DESCRIPTION AND OPERATION

2.1. GENERAL LOADING DATA

The Trailer is utilized for loading and unloading cargo aboard cargo aircraft. The Trailer is designed to be transported in a C-130 or similar cargo aircraft.

2.1.1. DIMENSIONS:

For overall trailer dimensions, see Fig. 2-1.

Fig. 2-1 Overall Trailer Dimensions

WEIGHT (NOMINAL):

Trailer: 9800 lbs. (10,000 Maximum) Optional Trailer Extension, Fwd: 260 lbs.

Optional Trailer Extension, Aft: 375 lbs.

Total Trailer weight with Extensions installed: 10435 lbs.

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REQUIRED PERSONNEL:

A minimum of 3 crew members are required. One crew member will operate the winch, one shall operate the Hydraulic Control Box to steer the casters, and one shall assist at the base of the ground loading ramp to check line up and clearances.

REQUIRED EQUIPMENT & MATERIALS:

Cargo Winch (aircraft) Forklift or aircraft tug

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2.2. TRAILER LOADING ONTO AIRCRAFT

The Trailer is designed to load onto a C-130 or similar cargo aircraft. The Trailer Tongue has a specific position for this purpose. (See Fig. 2-2 and Fig. 2-11)

Fig. 2-2 Trailer Tongue

Hydraulic actuators on the left forward and left aft casters allow the Trailer to be steered for aligning the trailer to the aircraft while winching into an aircraft cargo area. The casters steering is controlled via the Hydraulic Control Box.

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NOTE

Both the Electrical Power Switch and the Hydraulic Control Box Power Switch must be in the “ON” position for the Hydraulic Control Box to function.

Fig. 2-3 Hydraulic Control Box

Fig. 2-4 Electrical Power Box

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2.3. CARGO LOADING PROCEDURES FROM TRAILER TO AIRCRAFT

1. Loading crew shall be briefed and specific duties assigned.

2. Coordinate all loading and/or unloading activities with the aircraft loadmaster

3. Verify the Hydraulic Control Box, P/N 113402-301, is connected

4. Verify any item located on the trailer are secured

5. Align the tug (or forklift) to the Trailer and connect to Tongue.

NOTE

Remove the Tongue Retaining Pin, as needed to connect tongue to tug. The Tongue Jack can be used to help position the Tongue for connection to tug.

6. Raise the Tongue Jack Pad by rotating the handle counter clockwise.

7. Pull the Tongue Jack Retaining Pin, rotate the Tongue Jack 90 degrees and replace the Tongue Jack Retaining Pin.

Fig. 2-5 Tongue Details

CAUTION

When pulling jack pad retaining pin keep hands and feet clear. The jack pad may fall when the pin is removed

8. Raise all four Jack Pads:

9. Insert the Jack Hand Crank and rotate to raise the Jacks fully.

10. Pull the Jack Pad Retaining Pins by rotating them 90 degrees and pulling outward.

11. Once the pins have been pulled, raise the Jack Pads by lifting the Jack Pads vertically.

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Fig. 2-6 Jack Pads

12. Release Parking Brake:

Fig. 2-7 Parking Break Lever

13. Push the Trailer with the tug to the aircraft ramp and align Trailer with aircraft

The left side casters can be used to steer the Trailer, as needed, by using the Hydraulic Control Box.

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Both the Electrical Power Switch and the Hydraulic Control Box Power Switch must be in the “ON” position for the Hydraulic Control Box to function.

WARNING

During movement of the Trailer and/or cargo a crushing hazard will exist. Maintain a safety corridor between trailer and cargo ramp. If caught between the Trailer and cargo ramp serious injury or death may occur.

14. Remove tug from Trailer Tongue, as needed.

15. Remove the Forward Pallet Bumper Stops.

NOTE

Bumper Stops can be stored in Storage Box located on the left side of the Trailer

Fig. 2-8 Pallet Bumper Stops

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Fig. 2-9 Storage Box

16. Chock both sides of road tires to prevent Trailer movement during raise operations.

17. Apply power to the Trailer’s hydraulic system by placing the Electrical Power Switch in the “ON” position. See Fig.

2-4.

18. Using the forward and aft left and right hydraulic controls adjust height of Trailer so it matches the height of the cargo ramp.

The Trailer Deck will not tilt beyond 7 degrees in any direction to prevent rollover.

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Fig. 2-10 Hydraulic Controls

19. Chock both sides of the left front and right rear castor wheels.

20. When the Trailer has been positioned level with the cargo ramp secure the Trailer as follows:

A. Lower the Jack Stands to the ground.

B. Insert the Jack Retaining Pin in each Jack Stand in the hole that most closely places the base plate on the ground.

C. Secure Jack Stand on ground by turning the Jack Hand Crank clockwise until the base plate contacts the ground and supports the weight of the Trailer.

D. Perform steps A. through C. for each Jack Stand.

21. Position the Electrical Power Switch to “OFF”.

22. Remove any tie downs securing cargo to the Trailer.

23. Remove forward Pallet Bumper Stops.

NOTE

Pallet Bumper Stops can be stored in Storage Box located on the side of the Trailer

24. Load cargo onto aircraft per aircraft loadmaster’s instructions. An aircraft cargo winch may be used to transport cargo from the Trailer to the aircraft.

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2.4. OFF LOADING PROCEDURE FROM AIRCRAFT TO TRAILER:

1. Loading crew shall be briefed and specific duties assigned.

2. Coordinate all loading and/or unloading activities with the aircraft loadmaster

3. Verify the Hydraulic Control Box, P/N 113402-301, is connected

4. Verify any item located on the trailer are secured

5. Align the tug (or forklift) to the trailer and connect to tongue.

NOTE

Remove the Tongue Retaining Pin, as needed to connect Tongue to tug. The Tongue Jack can be used to help position the Tongue for connection to tug.

6. Remove forward Pallet Bumper Stops.

NOTE

Pallet Bumper Stops can be stored in the Storage Box located on the left side of the Trailer.

Fig. 2-11 Tongue in Position for Aircraft/Trailer Alignment

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Fig. 2-12 Pallet Stops

7. Raise the Tongue Jack by rotating the handle counter clockwise

8. Once the Tongue Jack Pad has been raised, remove Tongue Jack Retaining Pin and rotate the jack 90 degrees to the horizontal position.

9. Replace Tongue Jack Retaining Pin:

Fig. 2-13 Tongue Jack Details

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10. Raise all four Jack Pads.

11. Insert the Jack Hand Crank.

12. Pull the Jack Retaining Pins by rotating them 90 degrees and pulling outward.

13. Once the pins have been pulled, raise the Jack Pads by lifting the Jack Pads vertically.

Fig. 2-14 Jack Pad Detail

14. Release Parking Brake:

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Fig. 2-15 Parking Break

15. Push the Trailer with the tug to the aircraft ramp and align Trailer with aircraft

16. The left side casters can be used to steer the trailer, as needed, by using the Hydraulic Control Box.

NOTE

Both the Electrical Power Switch and the Hydraulic Control Box Power Switch must be in the ON position for the Hydraulic Control Box to function.

WARNING

17. During movement of the Trailer and/or cargo a crushing hazard will exist. Maintain a safety corridor between Trailer and cargo ramp. If caught between the Trailer and cargo ramp serious injury or death may occur.

18. Remove tug from Trailer Tongue, as needed.

19. Chock both sides of road tires to prevent Trailer movement during raise operations.

20. Apply power to the Trailer’s hydraulic system by placing the Electrical Power Switch in the “ON” position.

21. Using the forward and aft left and right hydraulic controls adjust height of Trailer so it matches the height of the cargo ramp.

The Trailer Deck will not tilt beyond 7 degrees in any direction to prevent rollover.

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Fig. 2-16 Hydraulic Control Box

22. Chock both sides of the left front and right rear castor wheels.

23. When the Trailer has been positioned level with the cargo ramp secure the Trailer as follows:

24. Lower the Jack Stands to the ground.

25. Insert the Jack Retaining Pin in each Jack Stand in the hole that most closely places the base plate on the ground.

26. Secure Jack Stand on ground by turning the Jack Hand Crankuntil the base plate contacts the ground and supports the weight of the Trailer.

27. Perform steps A. through C. for each Jack Stand.

28. Position Electrical Power Switch to “OFF”.

29. Remove any tie downs securing cargo to the aircraft.

30. Connect the Trailer Winch to the cargo to be off loaded per the loadmaster’s instructions.

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Fig. 2-17 Winch and Winch Remote

WARNING

Care should be taken when operating the Trailer Winch to prevent property damage, personal injury, and/or death. Operate winch per manufacturer’s instructions (see Appendix D).

31. Pull cargo from aircraft to trailer using Trailer Winch per winch manufacturer’s instructions.

NOTE

A remote control for the winch is provided with the Trailer.

32. Disconnect winch from cargo.

33. Secure cargo onto trailer, as needed.

34. Reinstall forward Pallet Bumper Stops. See Fig. 2-12.

35. Using the hydraulic Control Box, lower the casters to take weight off the jack stands.

36. Raise Jack Stands by removing Jack Retaining Pins and rotating the Jack Hand Crank counter clockwise. See Fig. 2-14.

37. Using the Hydraulic Control Box, fully raise the casters. See Fig. 2-16

38. Connect Tongue to tug, as required.

39. Release Parking Brake (See Fig. 2-15) and move cargo away from aircraft

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2.5. TRAILER EXTENSIONS

The -301 configuration of the Trailer is equipped with Extensions, which mount to the forward and aft sections.

2.5.1. Forward Extension Assembly:

1. Remove the front Pallet Bumper Stops and retain the hardware for reuse. Storage is provided onboard the Trailer.

2. Lift the Forward Trailer Extension into place with the aid of a forklift or equivalent.

3. Guide the extension support channels forward, aligned with the Trailer Frame.

4. There are three bolt holes on each side of the trailer.

5. Mate the extension bolt holes to the Trailer bolt holes.

6. Insert the bolts through the mated holes and secure with the nuts.

7. Tighten fasteners to 240 to 290 in-lbs. See IPL Fig. 31.

2.5.2. Aft Extension Assembly

1. Lift the Aft Extension into place with the aid of a forklift or equivalent.

2. Locate the extension bolt holes to the trailer frame bolt holes.

3. Insert the bolts through the mated holes and secure with the nut.

4. Tighten fasteners to 240 to 290 in-lbs. See IPL Fig. 31.

2.6. POWER

Connect a 28 Volt DC power supply to the Trailer and turn on the Electrical Power Switch. See Fig. 2-18

The Trailer is equipped with a set of two 12 Volt batteries connected in series (24 Volt total) and can be operated if no power supply is available.

For best performance, the batteries need periodic recharging, depending on usage.

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Fig. 2-18 Electrical Power Box

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2.7. HYDRAULIC OPERATION

The hydraulic system is used to control the lifting/leveling of the Trailer, as well as steering of the Trailer to align it with the aircraft. The hydraulic system is controlled by Hydraulic Control Box, P/N 113402-301, which is located next to the enclosure containing the Electrical Power Switch and 28 VDC Power Receptacle. In order for the Hydraulic Control Box to operate, both the Electrical Power Switch and the Hydraulic Control Box Power Switch must be the “ON” position.

Fig. 2-19 Hydraulic Control Box

To prevent rollover, the Trailer Deck is able to tilt no more than 7 degrees in any direction.

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2.8. TONGUE REMOVAL & INSTALLATION

Removal:

1. Disconnect Tongue Hydraulic Line from Trailer at coupling (item 1 Fig. 2-20):

Fig. 2-20 Tongue Hydraulic Disconnect

2. Rotate Tongue Jack to the horizontal position as shown:

Fig. 2-21 Tongue Jack Details

3. Remove the nut and bolt (item 3) connecting Tongue to Trailer. Retain all hardware.

4. Remove Tongue Retaining Pin (item 4)

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5. Lower Tongue.

NOTE

Tongue assembly weighs approximately 230 lbs. Use adequate personnel and support Tongue as needed to prevent damage to Tongue or injury to personnel.

Installation:

1. Raise Tongue to mounting position.

2. Install Tongue Retaining Pin (item 4)

3. Install the nut and bolt attaching tongue to trailer (item 3).

4. Torque bolt connecting Tongue to Trailer to 100 to 120 ft-lbs.

5. Rotate Tongue Jack to the vertical position as shown in Fig. 2-22.

6. Connect hydraulic line (item 1) from Trailer to Tongue

Fig. 2-22 Tongue Details

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CHAPTER 3 TESTING AND FAULT ISOLATION

See Fig. 3-2 for Trailer Electrical System Schematic.

See Fig. 3-3 for Trailer Hydraulic System Block Diagram.

3.1. FUNCTIONAL TEST

1. Using a multimeter, verify Trailer batteries are charged to full capacity (at least 24 VDC). Test voltage at ground power receptacle on the electrical control box (Fig. 2-18)

2. Open the Hydraulic Controls Storage Assembly (P/N 113404) and remove Hydraulic Controls Assembly (P/N 113402). See Fig. 2-19.

3. Turn on the System Power Switch located on the Electrical Control Box.

4. Turn on the Power Switch located on the Hydraulic Controls Assembly.

5. Verify the POWER indicator illuminates.

NOTE

Keep hands, clothing, etc. away from moving parts. Verify the Trailer is properly secured to prevent it from rolling (i.e. chock blocks, etc.).

6. Move the LEFT FRONT STEERING Switch to the RIGHT position.

7. Verify the left front steering cylinder extends.

8. Release the LEFT FRONT STEERING Switch.

9. Move the LEFT FRONT STEERING Switch to the LEFT position.

10. Verify the left front steering cylinder retracts.

11. Release the LEFT FRONT STEERING Switch.

12. Move the LEFT REAR STEERING Switch to the LEFT position.

13. Verify the left rear steering cylinder retracts.

14. Release the LEFT REAR STEERING Switch.

15. Move the LEFT REAR STEERING Switch to the RIGHT position.

16. Verify the left rear steering cylinder extends.

17. Release the LEFT REAR STEERING Switch.

NOTE

In the following sections, the operator’s estimation of “level” is sufficient. No measurements are required.

NOTE

Trailer should be cargo free to prevent falling items.

18. Raise the left side of the trailer by moving the AFT LEFT and FORWARD LEFT switches to the UP position, keeping the fore/aft angle as flat as possible, until the LEFT/RIGHT TILT LIMIT light illuminates.

19. Verify that the following switch positions do NOT move the trailer: AFT LEFT UP, FORWARD LEFT UP, FORWARD RIGHT DOWN, and AFT RIGHT DOWN.

20. Lower the left side of the trailer by moving the AFT LEFT and FORWARD LEFT switches to the DOWN position until the trailer is level.

21. Raise the right side of the trailer by moving the AFT RIGHT and FORWARD RIGHT switches to the UP position, keeping the fore/aft angle as flat as possible, until the LEFT/RIGHT TILT LIMIT light illuminates.

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22. Verify that the following switch positions do NOT move the trailer: AFT RIGHT UP, FORWARD RIGHT UP, FORWARD LEFT DOWN, and AFT LEFT DOWN.

23. Lower the right side of the trailer by moving the AFT RIGHT and FORWARD RIGHT switches to the DOWN position until the trailer is level.

24. Verify winch operation:

NOTE

Observe all winch safety precautions & operation instructions per winch manufacturer (see Appendix D).

Failure to do so may result in severe injury or death.

Fig. 3-1 Winch Detail

25. Verify power is connected to winch.

E. Verify the winch clutch is engaged.

F. Using the winch remote control switch, spool out approximately 3 feet of winch cable (line out button).

G. Using the winch remote control switch, spool in winch cable(line button) and secure.

END OF TEST PROCEDURE.

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Fig. 3-2 Trailer Electrical System Schematic (113439)

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Fig. 3-3 Trailer Hydraulic System Block Diagram (113436)

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CHAPTER 4 MAINTENANCE AND INSPECTION

4.1. HYDRAULIC LINES

1. Hydraulic system tubing maintenance can be proactive in the sense that routine inspections for evidence of weeping and leakage can be done visually or by wiping exposed surfaces with a clean, white rag to determine if fluid is present.

2. Tube clamping points should be examined visually for evidence of looseness and possible chafing against the tubes they are clamping.

3. Loose or damaged clamps or clamps whose protective elastomer padding is worn or damaged should be replaced. Tubes should be examined visually for evidence of scratches, nicks, dents, or any other malformations or defects that could cause failure points.

4. Tubing should also be free from excessive accumulations of other fluids such as cleaning fluids and other foreign substances that might eventually lead to corrosive damage to the tube.

5. Tubing should not be in direct contact with airframe structure, other tubes and/or hose or other accessories that might lead to chafing.

6. Check the tube fittings and nut connections to ensure they are properly torqued (See Appendix C for details).

7. When inspection does reveal any of these problems, replacing the entire tube assembly or sections thereof may be required.

NOTE

See Appendix C for hydraulic fitting torque specifications.

4.2. TRAILER LIFT HYDRAULIC SYSTEM

1. Visually inspect all hydraulic equipment for signs of fluid leakage. Tighten or replace any malfunctioning parts.

2. At least once a year, or after a repair has been performed to the hydraulic system, fill the hydraulic reservoir to the top level. Use AW46 hydraulic fluid only.

3. Replace the hydraulic filter and fluid if:

A. Contamination of the hydraulic fluid is suspected or

H. Every five years under normal conditions.

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4.3. ELECTRICAL SYSTEM

1. Visually inspect all wires and electrical connections for signs of damage.

2. Replace any cracked or worn harnesses or wires as needed.

4.4. TIRES

1. Visually check the tires for signs of low pressure

2. Use a standard tire pressure gauge and fill tires to correct tire pressure.

3. Maintain 125 PSI of pressure.

4.5. WHEEL BEARINGS

1. The first symptom of wheel bearing trouble is usually noise. If you suspect a wheel bearing is making unusual noise, remove the wheel and brake drum and inspect the wheel bearing.

2. With bearings removed, clean all old grease and then inspect.

3. Any bearing that has pitted rollers or races, or any bearing that functions with slack, should be replaced.

4. Spinning the tires by hand is another way to check for bearing problems. Some brake drag is normal, but any noise from the bearings or roughness calls for further inspection.

5. Bearings must be dry before they're repacked with grease. A quality high temperature wheel bearing grease (a #2 NLGI lithium-based grease, for example) or a synthetic wheel bearing grease should be used.

NOTE

Use a dry, lint free cloth to dry bearings. Do not dry bearings using compressed air, as damage may result.

6. Unless a problem is suspected, inspect wheel bearings at time of brake replacement.

NOTE

See Appendix B for more hub/spindle information

4.6. CASTERS

Lubricate casters at least once a year using high grade graphite grease.

4.7. ROLLERS

The roller assemblies are sealed and do not require lubrication.

4.8. TRAILER SYSTEM MAINTENANCE PROGRAM

The purpose of this Inspection chart is to assist the operator in developing and revising a scheduled maintenance program. The maintenance program should be accomplished in intervals to retain the Trailer in serviceable condition by systematical inspection, detection and replacement of worn parts, adjustment, calibration and cleaning.

To provide a maintenance record, the person responsible for each periodic inspection should be recorded in the Trailer Maintenance Log.

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4.9. SYSTEM MAINTENANCE PROGRAM CHECKLIST

Table 4-1 Periodic System Maintenance Checklist

Schedule Interval

Description

Periodic US Battery USAMG 31 12V BATTERY Insure batteries are fully charged.

Periodic TIRE 245/70R17.5 Inspect for physical flaws and low pressure

Periodic HYDRAULIC BRAKE RESERVOIR Visually inspect the fluid level.

Add fluid as needed.

Table 4-2 Annual System Maintenance Checklist

Schedule Interval

Description

Annual ROLLER ASSEMBLY 113444-301 Roller Assemblies are manufactured with a sealed bearing. Functional check only.

Annual Warn 265012 WINCH test operation

Annual ACTUATOR CSC (Thomas Welding) Inspect for fluid leaks. Check cylinder rams for wear such as pitting.

Annual ACTUATOR HF025012-1.125 ORB (Hyforce) Inspect for fluid leaks. Check cylinder rams for wear such as pitting.

Annual PUMP/MOTOR S-326 (Monarch) Inspect for fluid leaks

Annual HOSE ASSEMBLY FAX0106160808C13 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX 3706060606C13 Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX 3701060806C50 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606060606C13 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0601060806C50 (Parker) Inspect for fluid leaks and worn or cracked lines

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Schedule Interval

Description

Annual HOSE ASSEMBLY FAX637060606C40 (Parker)Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606040604C54 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606040604C59 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX3701060606C49 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606080808C40 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606080808C38 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0639040404C14 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual HOSE ASSEMBLY FAX0606060606C18 (Parker) Inspect for fluid leaks and worn or cracked lines

Annual SOLENOID 44F3648 Check external condition. Listen for clicking noise.

Annual FUSE 70635K31 (McMaster Carr) Check for cracked or disconnected wires

Annual VALVE SVW1BA1-S24Q (Prince) Check for external leakage

Annual VALVE SVW1BAT24H (Prince) Check for external leakage

Annual JACK 182400H (BULLDOG PRODUCTS) Remove assembly from trailer. Lubricate through top hatch.

Annual HYDRAULIC RESERVOIR Visually inspect the fluid level. Add fluid as needed.

Annual PARKING BRAKE ADJUSTMENT Adjust parking brake with the threaded link attached to the aft handle

Annual CASTERS Inspect caster wear surface for pitting Lubricate caster axle

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Schedule Interval

Description

Annual RUB STRIPS Inspect rub strips for wear, specifically on leading edge (fwd edge)

Annual RUBBER BUMPER

Annual GREASE HYDRAULIC CONTROL ARMS Move the control arms fully from side to side. Lubricate arms where contact is made to brackets.

Table 4-3 System Maintenance Checklist

Schedule Interval

Description

5 years Remove wheel, hub, and brake drum. Visually inspect shoes for excessive wear. Replace as needed (See appendix A).

5 years FILTER 51551 (Wix) Drain system, replace filter, refill reservoir to correct level

5 years BRAKES AND WHEEL BEARINGS Inspect for unusual wear, rust and corrosion, and fluid leaks

5 years GREASE FITTINGS Fill with grease as needed Inspect for damage

4-6 15 APRIL 2016

15 APRIL 2016 5-1

CHAPTER 5 ILLUSTRATED PARTS LIST

5.1. INTRODUCTION

PURPOSE

This Illustrated Parts List is intended for use in requisitioning, storing, and issuing the replacement parts for the trailer.

The detailed parts list consists of illustrations and a breakdown of component part numbers and nomenclature. The numerical index lists all parts that make up the replaceable parts of the trailer.

HOW TO USE THE ILLUSTRATED PARTS LIST

When the part number is unknown, locate the part on the illustration and note its item number. Use this item number to locate the part number in the detailed parts list.

When the part number is known but its location on the illustration is not known, find the part number in the Part Number column of the Detailed Parts List (page 55 & 56) and note the Fig. and item numbers. If the detailed parts list indicates that the part is illustrated, locate the part on the Fig. number illustration by its item number.

FIG. / ITEM COLUMN

The numeral listed under Fig. No. at the top of each page of listed parts is the Fig. number of the illustration in which the listed parts can be found. The numerals in the ITEM column correspond to the part in the illustration.

A hyphen (-) in the item number column indicates that the part is not illustrated.

A letter designation is used with the item number (e.g., 15, 15A) when a variety of similar parts is used in the same location but on different models.

PART NUMBER COLUMN

The part number by which a part may be ordered or procured is listed in the Part Number column. Parts that cannot be purchased are also listed in order to complete a parts breakdown and to show the relationship of these parts to other parts of a matched set or a part that is permanently bonded or riveted to another part.

NOMENCLATURE COLUMN

Part names are given in the NOMENCLATURE column. A bold dot at the top left-hand side of this column indicates that indentions are used to show the relationship of one part to another, and identifies the next assembly level. An item with greater indentation will always be a part of a preceding item with one less indent dot. This system provides rapid determination of the parts comprising an assembly, or the next higher assembly for any particular part.

5-2 15 APRIL 2016

5.2. TRAILER DETAILED PARTS LIST

Fig. 5-1 Trailer & Caster details

15 APRIL 2016 5-3

Fig. & Item No.

Part Number Nomenclature Eff.

Code

Qty. per

Assy

Fig. 5-1 113449 TRAILER REF

20 113458-301 • BUMPER ASSEMBLY 1

21 113458-302 • BUMPER ASSEMBLY 1

- 113437-101 • ROLLER INSTALLATION 1

30 113444-301 • • ROLLER ASSEMBLY 184

- 113440

• BRAKE, TOOLBOX, BUMPER, WINCH

AND JACK STORAGE INSTALLATION

40 265012 • • WINCH (WARN) 1

- 113431-301 • WHEEL & AXLE ASSEMBLY 1

50 0965100

• • BRAKE ASSEMBLY, RIGHT HAND

(TITAN)

51 0965200

• • BRAKE ASSEMBLY, LEFT HAND

(TITAN)

74 245/70R17.5 • • TIRE 4

- 113465-101 • SIDE RAIL INSTALLATION 1

320 113447-003 • • Rub strip (LH) ` 2

330 113447-004 • • Rub strip (RH) 2

340 113447-009 • • Rub strip 4

341 113447-010 • • Rub strip 4

350 113447-013 • • Rub strip 2

351 113447-014 • • Rub strip 2

- 113464-101 • CASTER INSTALLATION 1

360 113432-301 • • CASTER LIFT ASSEMBLY (LH) 2

380 AS15001-1P • • • FITTING, GREASE 2

381 AS15001-3P • • • FITTING, GREASE 2

370 113432-302 • • CASTER LIFT ASSEMBLY (RH) 2

380 AS15001-1P • • • FITTING, GREASE 2

381 AS15001-3P • • • FITTING, GREASE 2

5-4 15 APRIL 2016

5.3. HYDRAULIC INSTALLATION DETAILED PARTS LIST

Fig. 5-2 Hydraulic Line Details

15 APRIL 2016 5-5

No.

Part Number Nomenclature Eff.

Code

Qty. per Assy

Fig. 5-2 113435-101 • HYDRAULIC INSTALLATION 1

37 51551 • • FILTER (WIX) 1

55 FAX0601060806C50 • • HOSE ASSEMBLY 4

56 FAX0606060606C13 • • HOSE ASSEMBLY 8

57 FAX0606040604C54 • • HOSE ASSEMBLY 2

58 FAX0606040604C59 • • HOSE ASSEMBLY 2

59 FAX0606060606C18 • • HOSE ASSEMBLY 4

60 FAX0606080808C38 • • HOSE ASSEMBLY 1

61 FAX0606080808C40 • • HOSE ASSEMBLY 1

64 FAX3701060606C49 • • HOSE ASSEMBLY 4

65 FAX3701060806C50 • • HOSE ASSEMBLY 4

66 FAX3706060606C13 • • HOSE ASSEMBLY 4

67 SVW1BAT24H • • VALVE (PRINCE HYDRAULICS) 6

68 SVW1BA1-S24Q

• • VALVE BODY (PRINCE

HYDRAULICS)

- 113464-101 • CASTER INSTALLATION REF

73 CSC

• • ACTUATOR (THOMAS

WELDING )

360 113432-301 • • CASTER ASSEMBLY 2

72 HF02512-1.125 ORB • • • ACTUATOR (LIFT) (HYFORCE) 8

- 113438-101 • ELECTRICAL INSTALLATION 1

290 70635K31 • • FUSE (MCMASTER CARR) 2

5-6 15 APRIL 2016

Fig. 5-3 Hydraulic Solenoid Plumbing Details

15 APRIL 2016 5-7

No.

Part Number Nomenclature Eff.

Code

Qty. per Assy

Fig. 5-3 113435-101 • HYDRAULIC INSTALLATION 1

54 FAX0106160808C13 • • HOSE ASSEMBLY 1

60 FAX0606080808C38 • • HOSE ASSEMBLY 1

61 FAX0606080808C40 • • HOSE ASSEMBLY 1

62 FAX0637060606C40 • • HOSE ASSEMBLY 8

63 FAX0639040404C14 • • HOSE ASSEMBLY 1

64 FAX3701060606C49 • • HOSE ASSEMBLY 4

69 SV115

• • INLET MANIFOLD (PRINCE

HYDRAULICS)

70 S-326 • • PUMP/MOTOR (MONARCH) 1

5-8 15 APRIL 2016

5.4. ELECTRICAL INSTALLATION DETAILED PARTS LIST

Fig. 5-4 Electrical Component Details

15 APRIL 2016 5-9

No.

Part Number Nomenclature Eff.

Code

Qty. per Assy

Fig. 5-4- 113438-101 • ELECTRICAL INSTALLATION 1

10 US AMG 31 • • 12V BATTERY (US BATTERY) 2

280 35M1914 • • SOLENOID (NEWARK) 1

290 70635K31 • • FUSE (MCMASTER CARR) 2

5-10 15 APRIL 2016

5.5. DETAILED PARTS LIST FOR EXTENSIONS (OPTIONAL)

Fig. 5-5 Extension Details (OPTIONAL)

15 APRIL 2016 5-11

Fig. & Item No. Part Number

Nomenclature

Eff.

Code

Qty.

per Assy

Fig. 5-5 113449 Trailer Assembly REF

10 113441-301 • Trailer Extension (Aft) 1

20 113444-301 • • Roller Assembly 20

30 91257A810 • • Cap Screw (V3A054) 4

40 90715A185 • • Nut (V3A054) 4

50 113433-301 • Trailer Extension (Fwd) 1

60 113444-301 • • Roller Assembly 24

70 91257A728 • • Cap Screw (V3A054) 6

80 90715A165 • • Nut (V3A054) 6

5-12 15 APRIL 2016

5.6. DETAILED PARTS LIST NUMERICAL BY ITEM NO.

Fig. Item No. Part Number Nomenclature Eff.

Code

Qty. per Assy

Fig. 5-4 10 US AMG 31 • • 12V BATTERY (US BATTERY) 2

Fig. 5-5 10 113441-301 • Trailer Extension (Aft) 1

Fig. 5-1 20 113458-301 • BUMPER ASSEMBLY 1

Fig. 5-5 20 113444-301 • • Roller Assembly 20

Fig. 5-1 21 113458-302 • BUMPER ASSEMBLY 1

Fig. 5-1 30 113444-301 • • ROLLER ASSEMBLY 184

Fig. 5-5 30 91257A810 • • Cap Screw (V3A054) 4

Fig. 5-2 37 51551 • • FILTER (WIX) 1

Fig. 5-1 40 265012 • • WINCH (WARN) 1

Fig. 5-5 40 90715A185 • • Nut (V3A054) 4

Fig. 5-1 50 965100 • • BRAKE ASSEMBLY, RIGHT HAND (TITAN) 1

Fig. 5-5 50 113433-301 • Trailer Extension (Fwd) 1

Fig. 5-1 51 965200 • • BRAKE ASSEMBLY, LEFT HAND (TITAN) 1

Fig. 5-3 54 FAX0106160808C13 • • HOSE ASSEMBLY 1

Fig. 5-2 55 FAX0601060806C50 • • HOSE ASSEMBLY 4

Fig. 5-2 56 FAX0606060606C13 • • HOSE ASSEMBLY 8

Fig. 5-2 57 FAX0606040604C54 • • HOSE ASSEMBLY 2

Fig. 5-2 58 FAX0606040604C59 • • HOSE ASSEMBLY 2

Fig. 5-2 59 FAX0606060606C18 • • HOSE ASSEMBLY 4

Fig. 5-2 60 FAX0606080808C38 • • HOSE ASSEMBLY 1

Fig. 5-3 60 FAX0606080808C38 • • HOSE ASSEMBLY 1

Fig. 5-5 60 113444-301 • • Roller Assembly 24

Fig. 5-2 61 FAX0606080808C40 • • HOSE ASSEMBLY 1

Fig. 5-3 61 FAX0606080808C40 • • HOSE ASSEMBLY 1

Fig. 5-3 62 FAX0637060606C40 • • HOSE ASSEMBLY 8

Fig. 5-3 63 FAX0639040404C14 • • HOSE ASSEMBLY 1

Fig. 5-2 64 FAX3701060606C49 • • HOSE ASSEMBLY 4

Fig. 5-3 64 FAX3701060606C49 • • HOSE ASSEMBLY 4

Fig. 5-2 65 FAX3701060806C50 • • HOSE ASSEMBLY 4

Fig. 5-2 66 FAX3706060606C13 • • HOSE ASSEMBLY 4

Fig. 5-2 67 SVW1BAT24H • • VALVE (PRINCE HYDRAULICS) 6

Fig. 5-2 68 SVW1BA1-S24Q • • VALVE BODY (PRINCE HYDRAULICS) 1

Fig. 5-3 69 SV115 • • INLET MANIFOLD (PRINCE HYDRAULICS) 1

Fig. 5-3 70 S-326 • • PUMP/MOTOR (MONARCH) 1

Fig. 5-5 70 91257A728 • • Cap Screw (V3A054) 6

Fig. 5-2 72 HF02512-1.125 ORB • • • ACTUATOR (LIFT) (HYFORCE) 8

Fig. 5-2 73 CSC • • ACTUATOR (THOMAS WELDING ) 2

Fig. 5-1 74 245/70R17.5 • • TIRE 4

Fig. 5-5 80 90715A165 • • Nut (V3A054) 6

Fig. 5-4 280 35M1914 • • SOLENOID (NEWARK) 1

Fig. 5-2 290 70635K31 • • FUSE (MCMASTER CARR) 2

15 APRIL 2016 5-13

Fig. 5-4 290 70635K31 • • FUSE (MCMASTER CARR) 2

Fig. 5-1 320 113447-003 • • Rub strip (LH) ` 2

Fig. 5-1 330 113447-004 • • Rub strip (RH) 2

Fig. 5-1 340 113447-009 • • Rub strip 4

Fig. 5-1 341 113447-010 • • Rub strip 4

Fig. 5-1 350 113447-013 • • Rub strip 2

Fig. 5-1 351 113447-014 • • Rub strip 2

Fig. 5-1 360 113432-301 • • CASTER LIFT ASSEMBLY (LH) 2

Fig. 5-2 360 113432-301 • • CASTER ASSEMBLY 2

Fig. 5-1 370 113432-302 • • CASTER LIFT ASSEMBLY (RH) 2

Fig. 5-1 380 AS15001-1P • • • FITTING, GREASE 2

Fig. 5-1 380 AS15001-1P • • • FITTING, GREASE 2

Fig. 5-1 381 AS15001-3P • • • FITTING, GREASE 2

Fig. 5-1 381 AS15001-3P • • • FITTING, GREASE 2

Fig. 5-1 - 113437-101 • ROLLER INSTALLATION 1

Fig. 5-1 - 113440

• BRAKE, TOOLBOX, BUMPER, WINCH AND JACK

STORAGE INSTALLATION 1

Fig. 5-1 - 113431-301 • WHEEL & AXLE ASSEMBLY 1

Fig. 5-1 - 113465-101 • SIDE RAIL INSTALLATION 1

Fig. 5-1 - 113464-101 • CASTER INSTALLATION 1

Fig. 5-2 - 113464-101 • CASTER INSTALLATION REF

Fig. 5-2 - 113438-101 • ELECTRICAL INSTALLATION 1

Fig. 5-1 - 113449 TRAILER REF

Fig. 5-2 - 113435-101 • HYDRAULIC INSTALLATION 1

Fig. 5-3 - 113435-101 • HYDRAULIC INSTALLATION 1

Fig. 5-4 - 113438-101 • ELECTRICAL INSTALLATION 1

Fig. 5-5 - 113449 Trailer Assembly REF

5-14 15 APRIL 2016

APPENDIX A

MAFFS

TITAN 13” X 2-1/2” BRAKE INSTALLATION

INSTRUCTIONS

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the information or illustrations contained in this publication is not permitted without

15 APRIL 2016 A

Contents APPENDIX A. TITAN 13” X 2-1/2” BRAKE .........................................................................................................A-1

A.1. Istaallation..................................................................................................................................................A-1 A.2. Parts Diagram ............................................................................................................................................A-5 A.3. Limited Warranty........................................................................................................................................A-7

B 15 APRIL 2016

15 APRIL 2016 A-1

APPENDIX A. TITAN 13” X 2-1/2” BRAKE

A.1. Istaallation

A-2 15 APRIL 2016

A-3

A-4 15 APRIL 2016

A-5

A.2. Parts Diagram

A-6 15 APRIL 2016

A-7

A.3. Limited Warranty

A-8 15 APRIL 2016

Revised 15 APRIL 2016

APPENDIX B

MAFFS

RELIABLE H-60-880F HUB AND SPINDLE

PARTS LIST

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the

14 APRIL 2016 B-1

APPENDIX B RELIABLE H-60-880F HUB AND SPINDLE

B-2 14 APRIL 2016

APPENDIX C

MAFFS

TORQUE OF HYDRAULIC & PNEUMATIC

FITTINGS

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the

APPENDIX C. TORQUE OF HYDRAULIC & PNEUMATIC FITTINGS................................................................C-1

C.1. Purpose and Scope ...................................................................................................................................C-1 C.2. Requirements.............................................................................................................................................C-1 C.3. Procedure ..................................................................................................................................................C-1 TABLE C-1. TORQUE VALUES ..............................................................................................................................C-1

FIGURE C-1 TORQUE WRENCH WITH VARIOUS ADAPTERS ...........................................................................C-2

15 APRIL 2016 C-1

APPENDIX C. TORQUE OF HYDRAULIC & PNEUMATIC FITTINGS

C.1. Purpose and Scope

To specify the accepted torques for tightening “AN type” fittings when assembling hydraulic and pneumatic systems.

C.2. Requirements

Calibrated torque wrench and crawfoot wrench of the appropriate size.

C.3. Procedure

Caution

Over tightening will damage the tube or fitting, which may cause a failure. Under-tightening may cause leakage which could result in a system failure.

After assembly, use an open faced wrench of the appropriate size to hold the fitting, then tighten nut using a calibrated torque wrench and adapter of the appropriate size. Tighten the nut to the final values listed in Table I. When using an adapter, always correct the torque values listed in Table I, in accordance with Figure C1, to get the corrected torque reading.

Table C-1. Torque Values

C-2 15 APRIL 2016

Figure C-1 Torque Wrench with Various Adapters

APPENDIX D

MAFFS

WARN WINCH XD-9000 OPERATION MANUAL

Notice: Reproduction of the information or illustrations contained in this manual is not permitted without specific approval of the Assistant Director, Fire Operations, U.S. Forest Service

NOTICE: Reproduction for non-military or non US government use of the

APPENDIX D. WARN WINCH XD-9000 OPERATION MANUAL ........................................................................D-1

D.1. General Safety Precautions.......................................................................................................................D-1 D.2. Installation Instructions ..............................................................................................................................D-2 D.3. Operation Instructions................................................................................................................................D-3

APPENDIX D. WARN WINCH XD

D.1. General Safety Precautions

D-1

WARN WINCH XD-9000 OPERATION MANUAL

D-2

D.2. Installation Instructions

D.3. Operation Instructions

D-3

D-4 15 APRIL 2016