Caylym Technologies International

www.Caylym.com

Guardian
Containerized Aerial Fire Fighting System

Assembly Guide

October 7, 2019
Version 3.7

For current version visit ​www.Caylym.com/Guardian/Guide

AUTHORIZED USE ONLY

 Guardian Containerized Aerial Firefighting System Assembly Guide

Version Control:
This Assembly Guide is version 3.7, released October 7, 2019. To check for the most current
version of the Assembly Guide, visit ​www.Caylym.com/Guardian/Guide​ or scan the QR code.

Scope of this Assembly Guide:

The scope of this guide is limited to the assembly and use of the Caylym Guardian Containerized Aerial
Firefighting System ​in conjunction​ with a Caylym officiated training program. Use of this guide without
Caylym authorized training does not constitute a guarantee of product performance.

Authorized Use & Distribution:

Use and distribution of this document, the content and images it contains, in part or whole, is limited
exclusively to persons or parties authorized by Caylym. For questions regarding authorized use and
distribution, contact Caylym at ​[email protected]​ or call +1 (209) 322-9596.

This document and its contents protected by Copyright 2019 © Caylym Technologies International.
Products depicted in this document protected by one or more US/International patents.
All Rights Reserved.

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Guardian Containerized Aerial Firefighting System
Assembly Guide & Appendices v3.7

Table of Contents
Components & Terms 4

Additional Guardian Setup Tools 6

Assembly Steps:
1. Box Setup and Positioning 7

2. Cassette Setup and Positioning 1​1

3. Unit Filling 15

4. Cap Rigging and Prep for Loading 22

Appendix A: Guardian Assembly Checklist 2​7

Appendix B: Limited Storage & Reuse of Filled Guardian Units 2​8

Appendix C: Draining a Guardian Unit 2​9

Appendix D: Recommended Pre-Engine Start Checklist for Guardian CDS Load Inspection 3​1

Appendix E: Product Catalog 3​4

Glossary & Index 3​6

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 Caylym Guardian System
Components & Terms

CDS Skid

Guardian Box Terms: Enclosures & Cutouts

Buffer Block Load Retention Block (LRB)

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 Inverted Guardian Cap, Cassette,
2 LRBs (Load Retention Blocks), 2 Buffer Blocks

Cassette (Closed) Cassette (Open) with Bag & Bag Strap

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 Additional Guardian Setup Tools

Assembly Deck

Grabber Squaring Device

Fill Arm Pump (Optional Equipment)

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 Assembly Steps
1. Box Setup and Positioning
1.1. Stage assembly deck. White marks will be forward on the aircraft. ​(Figure 1)

Figure 1

1.2. Place CDS skid on assembly deck. Align white marks on skid and pallet.
(Figure 2)

Figure 2

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 1.3. Separate Vertical Retention Straps (VRS) from tape and place to the sides
and center of the skid. (​Figure 3)

Figure 3

1.4. Open box on skid. Align white marks on assembly deck, skid and box.
Note: White mark on box is at the top. ​(Figure 4 & 5)

Figure 4 Figure 5

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 1.5. Insert squaring device into box. (​Figure 6)​

Figure 6

1.6. Tilt box, thread VRS up through cutouts in the bottom box enclosure. ​(Figure 7)

Figure 7

1.7. Lift VRS with grabber. ​(Figure 8, 9 & 10)

Figure 8 Figure 9 Figure 10

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 1.8. Thread VRS through top enclosure cutout (​Figure 11)​ . Tighten & connect hook
and loop across the edge of the box. Repeat on opposite side of box.
(Figure 12)

Figure 11 Figure 12

1.9. Tilt box, pull rubber band from the bottom of the skid and stretch over top edge
of box. The bottom of the rubber band will remain stretched over the bottom
edge of the box. ​(Figure 13, 14, & 15)

Figure 13 Figure 14 Figure 15

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2. Cassette Setup and Positioning
2.1. Open cassette by breaking or peeling tape with finger.​ (Figure 16)
Do not use knife to open cassette.

Figure 16

2.2. Lay cassette on top of box. Remove bag strap from cassette ​(Figure 17)​ and insert
into VRS outside box to stage for future use. ​(Figure 18)

Figure 17 Figure 18

2.3. Remove squaring device. ​(Figure 19)

Figure 19

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 2.4. Fold cassette and place into bottom of box. ​(Figure 20, 21 & 22)

Figure 20

Figure 21 Figure 22

2.5. Push cassette into bottom of box with load retention block (LRB).
(Figure 23 & 24)

Figure 23 Figure 24

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 2.6. Lift bag with grabber. ​(Figure 25)

Figure 25

2.7. Pull bag over sides of box. ​(Figure 26 & 27)

Figure 26 Figure 27

2.8. Open bag in box and align seams into the two corners without enclosures.
Lay bag over enclosures of other corners.​ ​(Figure 28 & 29)

Figure 28 Figure 29

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 2.9. Place hook and loop ends of both box straps outside box. ​(Figure 30)

Figure 30

2.10. Center box on skid using white mark for alignment​ (Figure 31 & 32)​ Unit is
now ready to fill.
Note: Weight of contents will prevent adjustment after fill.​

Figure 31

Correct Incorrect Incorrect

Figure 32

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3. Unit Filling
3.1. Slowly open valve and begin filling. Direct flow into bottom center of bag.
(Figure 33)​. Recheck step 2.10 during fill and maintain box position.
Note: Keep fill nozzle below surface if contents foams. (Figure 34)

Figure 33 Figure 34

3.2. Fill unit to maximum fill line indicated inside box unless a decreased fill is
indicated by appropriate aircraft and mission requirements. ​(Figure 35)

Figure 35

3.3. After fill completes, begin closing procedure by lifting edges of bag up.
(Figure 36)

Figure 36

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 3.4. Beginning at a corner of the bag, lift up the edge of the bag near the corner,
and pull into the corner to form a bundle. ​(Figure 37 & 38)

Figure 37 Figure 38

3.5. Repeat lifting a portion of the edge of the bag and pulling into the bundle until
the entire edge of the bag has been lifted and bundled. ​(Figure 39 & 40)

Figure 39 Figure 40

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 3.6. Eliminate air from bag by pressing bag down on the bag surface and driving
any air bubbles from the edges of the unit to the center to escape the bag.
Keep bundled bag portion level with the surface of the contents to prevent air
from re-entering. ​(Figure 41, 42 & 43)

Figure 41 Figure 42

Figure 43

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 3.7. Tightly fold twisted bundle of bag into horseshoe (inverted U) shape and
compress. ​(Figure 44, 45)

Figure 44

Figure 45

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 3.8. Tightly wrap center hook and loop portion of bag strap around compressed
bag bundle. Keep all edges of the bag opening pulled through strap. Connect
hook and loop to seal bag shut. ​(Figure 46, 47)

Figure 46

Figure 47

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 3.9. Lift the rubber bands up from the top edges of the box and allow to lie loose
on each side of the skid next to the box until step 4.8. ​(Figure 48, 49 & 50)

Figure 48 Figure 49 Figure 50

3.10. Feed one end of bag strap under enclosure and through one corner of box.
Feed other end of bag strap through opposite corner​. (Figure 51)

Figure 51

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4. Cap Rigging and Prep for Loading
4.1. Place squaring device across the top of the box next to straps as shown.
(Figure 52)

Figure 52

4.2. Place cap on box while allowing squaring device to raise the corner near the
straps. Align white mark on cap with white marks on box, skid, and assembly
deck. ​(Figure 53)

Figure 53

4.3. Pull the two white cap straps and two black cap straps loose and position at
corner near box straps. ​(Figure 54)

Figure 54

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 4.4. Thread white cap strap followed by grey bag strap followed by other white cap
strap onto one box strap. (​Figure 55 & 56)

Figure 55 Figure 56

4.5. COMPRESS FIRMLY hook and loop fasteners on ends of box straps into a
loop enclosing two cap straps and one bag strap. (​Figure 57, 58 & 59)

Figure 57

Figure 58
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 Figure 59

4.6. Repeat steps 4.4 and 4.5 with black cap straps and other bag strap on other
box strap. ​(Figure 60)

Figure 60

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 4.7. Place all straps under cap and remove Squaring Device. ​(Figure 61)

Figure 61

4.8. Lift rubber bands up over cap. (​Figure 62, 63)

Figure 62 Figure 63

4.9. Place the two LRBs and two Buffer Blocks under rubber bands.
(Figure 64 & 65)
Note: Aircraft Loadmaster will affix LRBs and Buffer Blocks for aircraft
rigging

Figure 64 Figure 65

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 4.10. Complete Guardian Assembly Checklist ​(Appendix A)
4.11. Guardian unit is ready for transport to aircraft
Note: Units may be stored in accordance with Appendix B or emptied in
accordance with Appendix C
4.12. Load & rig the Guardian IAW applicable aircraft technical order
4.13. Recommend Pre-Engine Start Checklist for Guardian CAFFS Load Inspection
(Appendix D)

* * * End of Assembly Steps * * *

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 Guardian Containerized Aerial Firefighting System​ Assembly Guide
​

Appendices

Appendix A: Guardian Assembly Checklist 2​7

Appendix B: Limited Storage & Reuse of Filled Guardian Units 2​8

Appendix C: Draining a Guardian Unit 2​9

Appendix D: Recommended Pre-Engine Start Checklist for Guardian CDS Load Inspection 3​1

Appendix E: Product Catalog 3​4

Glossary & Index 36

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 Guardian Containerized Aerial Firefighting System​ Assembly Guide
​

Appendix A: Guardian Assembly Checklist

In accordance with Guardian CAFFS Assembly Guide v3.7.

Inspect each Guardian unit to confirm:

❏ Vertical restraint straps are tight and hook & loop is affixed inside box (step 1.8)

❏ Box is Centered on skid (step 2.10)

❏ Bag is filled at or below the max fill line (step 3.2)

❏ Bag is secured with a bag strap and no leaks are visible (step 3.8)

❏ Straps are rigged in Black-Gray-Black and White-Gray-White pattern (step 4.4,

4.5 & 4.6)

❏ All white marks on Skid, Box, and Cap are oriented in the same direction (step
1.2, 1.4 & 4.2)

❏ Elastic bands are properly installed: over cap and between skid board and box
(step 1.9 & 4.8)

❏ Two (2) Load Retention Blocks (LRBs) placed on top of unit (step 4.9)

❏ Two (2) Buffer Blocks placed on top of unit (step 4.9)

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 Guardian Containerized Aerial Firefighting System​ Assembly Guide
​

Appendix B: Limited Storage & Reuse of Filled

Guardian Units
Guardian units assembled and filled in accordance with
Guardian CAFFS Assembly Guide v3.7:

Recommended storage duration

Contents Recommended Duration Conditions

Water 30 Days or less As listed below

US Forest Service approved

14 Days or less As listed below
fire fighting agents

Conditions:
Guardian units should be stored in a clean, dry, sunlight-protected location and in
temperatures above 40 degrees Fahrenheit (4.4 degrees Celsius).

Limited Reuse:

Guardians may be reused after flight if inspected and cleared for reuse by qualified
Caylym personnel.

Guardians may be reused after being filled and drained if inspected and cleared for
reuse by qualified Caylym personnel.

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 Guardian Containerized Aerial Firefighting System Assembly Guide

Appendix C: Draining a Guardian Unit

Components

Drain Wand High Volume Pump & Suction Hoses

(Optional Equipment - See Appx E: Catalog)
Drain Instructions
1. Insert and lock Drain Wand into suction pump hose or appropriate liquid suction
apparatus for specific unit contents. ​(Figures 1 & 2)

Figure 1 Figure 2

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2. Use Drain Wand to suction contents from Guardian Unit. ​(Figure 3)

Figure 3

3. Draw bag towards Drain Wand to drain all contents from Unit. ​(Figure 4)

Figure 4

4. Dispose of bag in accordance with any instructions from the ​Material Safety Data
Sheet​ (​MSDS)​ of the contents, if any.

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 Guardian Containerized Aerial Firefighting System Assembly Guide

Appendix D: Recommended Pre-Engine Start

Checklist for Guardian CDS Load Inspection
1. These recommended procedures are intended to support and where appropriate, augment
the currently required procedures adopted by the user. The procedures outlined below are
not intended in any way to conflict, countermand or replace the approved and authorized
Final Load Inspection Procedures published by the users organization, technical order, or
the requisite equipment manufacturer. Such orders will take priority over recommendations
made in this document.

RECOMMENDED FINAL INSPECTION FOR GUARDIAN LOADS

2. Each Guardian unit will be inspected using the Guardian Assembly Checklist (Appendix A)
prior to the unit being loaded on the aircraft. After Guardian units are loaded on the aircraft
the rigged load must be given a complete and final inspection by a qualified person. The
loadmaster or designated aircrew member should inspect the Guardian containers. The load
inspection should include the following at a minimum:

2.1. Verify serviceability of load securing webbing, straps, hooks and covers.

2.2. Verify Guardian containers are rigged in accordance with applicable technical orders
and flight manuals.

2.3. Inspect forward restraint for correct installation and positioning on the first Guardian
unit (forward) in each row.

2.4. Affix two Buffer Blocks to rear/aft facing box wall of each box except the last box (aft
most) in the stick. Place each of the two Buffer Blocks on the corner of the top edge of
the bottom flap on the aft side of the unit ​(Figure 1)​ to fill the space between adjacent
Guardian units.

Figure 1

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3. If using a Buffer Stop Assembly (BSA) forward restraint and strap rear restraint:

3.1. Affix one Load Retention Block (LRB) to the front side of the forward most box for each
Guardian unit in the stick. Example: for a stick of eight (8) units, use eight LRBs.
(Figure 2 & 3)​ Invert the LRBs so the larger side of the LRB is the same height as the
BSA restraint surface.

Figure 2 Figure 3

3.2. Affix one Load Retention Block (LRB) to the rear side of aft most box for each Guardian
unit in the stick. ​(Figure 4).​ Example: for a stick of eight (8) units, use eight LRBs. For a
stick of four (4) use four LRBs.

Figure 4

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4. If using strap or chain forward and rear restraint:

Affix one Load Retention Block (LRB) to the restraint facing side of the aft most and the
forward most box for each Guardian unit in the stick. ​(Figures 5 & 6).​ Example: for a
stick of eight (8) units, use eight; for a stick of six (6) use six.

Figure 5

Figure 6

RELEASE GATE

5. Install aft release gate in accordance with applicable technical order for Container Delivery
System (CDS) for aircraft.

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 Guardian Containerized Aerial Firefighting System Assembly Guide

Appendix E: Product Catalog

* Catalog pictures are representative only. Actual product may differ or change without notice.
For additional information or to order products contact ​[email protected]​ or call +1 (209) 322-9596.
Item / Product Description/Components Product Image(s)
Part # Name
G01 Guardian G01 - Guardian – Container Delivery System G01 Assembled Filled and Rigged

(CDS) Aerial Firefighting unit.

(Black plastic AC Deck not included) Box
Assembly w/ straps, Cap Assembly w/ straps,
Cassette w/Bag and Rigging Strap, SKD01
(48”X48” Plywood deck w/2” radius Corners),
Load Retention Blocks (LRB), Buffer Blocks, AC
Bands
The Guardian is shipped and stored as two ​
Pallet -16 Box Assemblies​ Pallet - 8 Cap Assemblies
types of palletized and wrapped set of & CDS Skids

components – The Box Assemblies = (16 on a

pallet) and the Cap Assemblies with CDS Skids
= (8 on a pallet) These pallets include all
components to assemble, fill and rig for loading
the 1000-liter (264 US Gal) unit.

BOX01 Box Assembly 1000 Liter, Guardian Container, pre-threaded Box Assembly set up with squaring device

straps with load orientation marking

CAP01 Cap Assembly Guardian Cap assembly with black and white Cap Assembly - Straps, LRBs, Buffer Blocks AC-Band, Bag
Cassette
straps, load orientation marking. Placed in the
Cap for shipment are 2 LRB’s, 2 Buffer Blocks,
2 rubber unit-securing bands and 1 1,000-liter
bag cassette with bag strap.

SKD01 CDS Skid Standard 1” plywood CDS skid with radial CDS Skid with Vertical Retention Straps

corners. Can be used on almost any cargo

aircraft with a roller floor and rear ramp 48"x 48"
1" CDS Skid with Vertical Retention Straps (pre
threaded) and Load Orientation Marking
FIL-0001 Assembly Deck Assembly Deck provides a stable base for G01 Assembly Deck

to be assembled, filled & rigged for loading. 48”

X 40” Plastic Pallet platform with non-skid tape
stability points. The Assembly Deck allows four
(4) direction fork lift access.

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FIL-0002 Assembly / Guardian Filling System Arm & Support FIL-0002 Assembled
Filling System Package. Modular Filling Arm with Ball Valves, (Lower Left) Disassembled & Packed
(Lower Right) Crate for Transport
Hose, Frame, Squaring Device, Strap/Bag
Grabbers, Draining Wand and Connector. With
Transport/Shipping Crate

FIL-0015 3 in. Ball 3 inch ball valve, threaded

Valve
Threaded
3 in. Ball Valve

FIL-0004 ERHV 3” Extended Run High Volume Pump, 3in. Port,

Pump self-priming, 15,000 US Gallon per Hour /
50,000 Liters per Hour fill rate. With wheel &
handling kit.

Extended Run High Volume 3’ Pump

FIL-0005 SSFS 4000 SSFS-4000 US Gallon / 15,000 Liter, Self
Tank Supporting Portable Tank with 3"
FIL-0006 intake-dispense ports (Male NPT). With
protective ground tarp. NPT to CAM fitting SSFS-4,000 US Gal / 15,000 Liter Tank
included.

FIL-0007 Y-Manifold Station Distribution Manifold - Wye 1 into 2

2.5 inch threaded single side
2 inch threaded double side

1 into 2 Wye Manifold

FIL-0016 2 in. Pressure 2 inch dispense (pressure) hose, Length: 50
Hose Line Feet (standard), Couplings: Aluminum (Male x
Female), CAM fitting.
2 in. Dispense Line
FIL-0017 2.5 in. 2.5 inch dispense (pressure) hose, Length: 50
Pressure Feet (standard), Couplings: Aluminum (Male x
Hose Line Female), Thread: NH / NST (Fire Hose Thread).
2,5 in. Dispense Line
FIL-0018 3 in. Pressure Red Feed Line 76 MM, Length: 50 Feet
Hose Line (standard), Couplings: Aluminum (Male x
Female), Thread: NH / NST (Fire Hose Thread).
3 in. Dispense Line
FIL-0011 3 in. Suction Rigid suction hose, 2 inch diameter. Length 10
Hose Line feet. Cam male/female fittings.
3 in. Rigid Suction Line

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 Guardian Containerized Aerial Firefighting System Assembly Guide

Glossary & Index

Underlined terms​ below are defined in this glossary.

Term Definition Page Reference

Assembly Deck Black plastic platform (inverted pallet) used to allow easy 6, 7
assembly and handling of each unit.

Bag Bladder used to line each unit and hold liquid contents. Packed 5, 13, 15, 16, 17,
inside ​Cassette​. 18, 19

Bag Strap Single gray strap with ​Hook & Loop​. Packed inside ​Cassette​. 5, 10, 11, 19, 20,
21, 22, 23, 24

Box Thick walled cardboard (corrugated) box. 4, 8, 9, 10, 11, 12,

13, 14, 15, 17, 20,
21, 30, 31, 32, 33

Box Straps Two (2) gray straps with ​Hook & Loop taped in one corner of 4, 14, 21, 22, 23,
each ​Box​. 24

BSA See ​Buffer Stop Assembly

Buffer Block Rectangular stiff block with adhesive tape on one side and 4, 5, 24, 31
without notches. Used to occupy the the void space between
units in the aircraft. Packed inside ​Cap​.

Buffer Stop A fixed cargo restraint device installed in the forward section of
Assembly some aircraft.

Cap Stiff, thick, 48 inch square top for each unit. Contains ​Cap 5, 21, 22, 24
Straps​.
Cap Strap White or black strap connected to each ​Cap​. 5, 21, 22, 23, 24

Cassette Triangular cardboard (corrugated) component containing the 5, 11, 12

Bag​ and ​Bag Strap​ for each unit. Packed in ​Cap​.

CDS Skid Container delivery system standard A22 wooden skid (48” x 48” 4, 7, 8, 10, 14, 20
x 1”). The base of each unit.

Cutout Opening in each ​Enclosure allowing ​VRS and ​Bag Straps to 4, 9, 10

pass through

Drain Wand Pipe fitting used to drain a filled unit when affixed to a hose and 29, 30
pump.

Enclosure Thin cardboard (corrugated) portion on the top and bottom of 4, 9, 10, 13, 20
each ​Box​ through which ​VRS​ and ​Bag Straps​ are threaded

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 Grabber Extended grabbing device to allow easy reach of straps and unit 6, 9, 13
parts inside the ​Box​. Packed with additional Guardian setup
tools.
Hook See ​Hook & Loop

Hook & Loop Commonly called Velcro​TM​. Comprised of a rough ‘hook’ 10, 14, 19, 22
material that binds mechanically to a felt-like ‘loop’ material.
Used to connect pieces of strap during the rigging process.
Load Retention Rectangular stiff block with adhesive tape on one side and a 4, 5, 12, 24, 32,
Block (LRB) notch on the other side. Used to hold units in place in the 33
aircraft and allow securing straps to be placed inside notches.
Packed inside ​Cap​.
Loop See ​Hook & Loop

LRB See ​Load Retention Block

Rubber Band Black elastic rubber bands used to hold ​Cap​, ​LRBs​, & ​Buffer 4, 10, 20, 24
Blocks on top of each unit during handling and transport.
Packed around ​CDS Skid​.

Squaring Device Long plastic pipe tool used to hold each unit open during initial 6, 9, 11, 21
unit assembly. Packed with additional Guardian setup tools.

Vertical Retaining Straps with ​Hook & Loop securing the ​Box to the ​CDS Skid​. 4, 8, 9, 10, 11
Straps Packed pre-threaded through ​CDS Skid​.

VRS See ​Vertical Retaining Straps

White Mark White direction indicator on the ​Assembly Deck​, ​CDS Skid​, ​Box​, 4, 7, 8, 14
and ​Cap​. Indicates the forward side of the unit relative to the
forward face of the aircraft.

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