Technical_Order_43E17-3-4-3.pdf

TECHNICAL MANUAL

T.O. 43E17-3-4-3

OVERHAUL INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

TOWREEL ASSEMBLY

PN 53896-1

Southwest Aerospace Contract Number: F42630-91-D-0937

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

DISTRIBUTION STATEMENT: Distribution authorized to U.S. Government agencies and their contractors, administrative or operational use, April 1988. Other requests for this document shall be referred to OO-ALC/TIED, Hill AFB, Utah 84056- 5820.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751 et e.g._q) or the Export Administration Act of 1979, as amended (Title 50, U.S.C., App 2401 s_e_t_q). Viola-tions of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of AFI 61-204.

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

Published under authority of the Secretary of the Air Force.

1 APRIL 1990

CHANGE 4 15 JANUARY 1997

marylyn.aldana basic changes

T.O.43E17-3-4-3

INSERT LATESTCHANGED PAGES. DESTROY SUPERSEDED PAGES.

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

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original 0 1 April 1990 Change 1 11 August, 1992 Change 2 1 June 1995 Change 3 24 August, 1995 Change 4 15 January 1997

Total number of pages in this publication is 220 consisting of the following:

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Page No.

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A Change 4

USAF

TO 43E17-3-4-3

III

IV

V

VI

VII

VIII

IX

TABLE OF CONTENTS

INTRODUCTION

GENERAL INFORMATION

1-1 Description

SPECIAL TOOLS AND TEST EQUIPMENT

2-1 General 2-3 Fabricated Special Tools 2-5 Safety Equipment

DISASSEMBLY

3-1 General 3-6 Unpacking 3-8 Disassembly Procedure

CLEANING

4-1 General 4-3 Cleaning Procedures

INSPECTION, REPAIR, AND REPLACEMENT

5-1 5-4 5-10 5-11 5-20 5-54

General Inspection Repair and Replacement Repair Replacement Preservation

ASSEMBLY

6-1 General 6-5 Consumable Materials 6-11 Assembly Procedure 6-12 Preparation for Shipment

TESTING

7-1 General 7-3 Test Conditions 7-4 Test Procedures 7-5 Troubleshooting

TABLE

8-1 8-3 8-5

OF LIMITS

General Table of Limits Torque Limits

MAINTENANCE PARTS LIST

9-1 Introduction vii

1-1 1-1

2-1 2-1 2-1 2-1

3-1 3-1 3-1 3-3

4-1 4-1 4-1

5-1 5-1 5-1 5-5 5-5

5-32 5-71

6-1 6-1 6-1

6-15 6-19

7-1 7-1 7-1 7-1 7-8

8-1 8-1 8-1 8-1

9-1 9-1

Change 2

1-1 1-2 1-3 1-4 1-5 1-6 1-7 2-1 2-2 2-3 2-4 3-1 3-2 3-3 3-4 3-5 5-1 5-2 5-3 5-4 5-5 5-6 5-7 5-8 5-9 5-10 5-11 5-12 5-13 5-14 5-15 5-16 5-17 5-18 5-19 5-20 5-21 5-22 5-23 5-24 6-1 6-2 6-3

LIST OF ILLUSTRATIONS

Title

Towreel Assembty, P/N 53896-1 Towreel Assembly, P/N 53896-1 Towreel Assembly Sections Towreel Schematic Transmission Drive Sequence Hydro-Pneumatic Schematic Interconnection Diagram Towreel Biock Diagram Peculiar Support Equipment Cockpit Control Display Panel Pin Wrench Pin Wrench Towreel Shipping Container Towline Service Stand Towreel Maintenance Stand and Towreel Arrangement Towline Unloading Setup Routing ,Towline Through Towreel Sheaves Tachometer Repair Turbine Brake Disc and Bushing Belleville Spring Installation Servo Repair and Wiring Diagram Belleville Spring Installation Intensifier and Air Cylinder Adjustment Solenoid Overhaul Solenoid Diode Installation Manifold Assembly Manifold Wiring Diagram Sprocket and Bushing Location of Sprocket and Bushing Press Holes Spool End Play Adjustment Levelwind Sprocket Alignment Support Equipment Setup Levelwind End-Play Adjustment Inspect and Modify Spring Clips Pry Spring Clips Inspect Spring Clips Ball Reverser Installation Dual Cutter Body Alignment Tension Sheave Eccentric Shaft Adjustment Guide Sheave, Exit Sheave and Latch Mechanism Piping Diagram Pressurizing Brake System Towline Service Stand and Towreel Alignment Towline Loading Setup vii 1-2 1-2 1-5 1-7 1-9

1-13 1-17 2-3 2-4 2-5 2-6 3-2 3-4 3-6 3-7 3-8 5-7 5-9

5-12 5-15 5-18 5-23 5-26 5-27 5-29 5-3O 5-33 5-38 5-42 5-44 5-45 5-47 5-50 5-51 5-51 5-52 5-54 5-57 5-59 5-65 6-4 6-5 6-5

6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 7-1 7-2 7-3 8-1 8-2 8-3 8-4 8-5 9-1 9-2 9-3 9-4 9-5 9-6 9-7 9-8 9-9 9-10 9-11 9-12 9-13 9-14 9-15 9-16 9-17 9-18 9-19 9-20 9-21 9-22

Title

Towline Service Stand Turbine Drive Assembly and Shaft Extension Shop Test Set Routing Towline Through Towreel Sheaves Roll Dies. Feed Adapter and Guide Mechanism Starting Positions for Swaging Operation Towline Terminal Installation Termial End Gauge GA-S26 Tow Adapter Installation Towreel Electrical System Interconnector Diagram Release of Tow Adapter Latch Tension Indicator Calibration Set-Up Typical Sprocket Alignment Spool End Play Limits Levelwind Shaft End Play Limits Intensifier/Air Cylinder Limits Latch Switch Limits Towreel Assembly, RMK-35 Cable Assembly W4 Processor/Receiver Kit Assembly Towreel Assembly Tachometer Assembly Wiring Harness Assembly, W6 Wiring Harness Assembly, W3 Wiring Harness Assembly, Wl Center Section Assembly Turbine Brake Caliper Assembly Servo Motor Assembly Spool Brake Caliper Assembly Follower Assembly Structural Frame Assembly Strongback Assembly Afterbody Section Assembly Air Control Manifold Assembly Launcher Assembly Tension Mechanism Assembly Sensor Assembly Exit Sheave Assembly Latch Mechanism Assembly

6-6 6-7 6-8 6-9

6-12 6-13 6-13 6-15 6-16 7-2 7-5 7-7 8-2 8-3 8-4 8-4 8-5 9-5 9-7 9-8

9-10 9-17 9-19 9-21 9-22 9-24 9-30 9-32 9-33 9-35 9-37 9-39 9-41 9-47 9-50 9-56 9-58 9-59 9-60 iii

TO43E17-34,3,

Table

1.1 2-1 2-2 2-3 5-1 6-1 7-1 8-1 8-2

LIST OF TABLES

Title

Non.standard Abbreviations Leading:Particulars Special; Tools and Test Equipment List Fabricated Special Tools List Safety Equipment List.

Inspection Data Consumable Materials List Troubleshooting Guide Table of Limits Table of Torque Values.

viii 1-3 2-1 2-4 2-6 5-2 6-1 7-8 8-1 8-5 iv

SAFETY SUMMARY

DEFINITIONS

The words "shall" or "will" are used in this manual to indicate mandatory requirements. The word "should" indicates a nonmandatory desire or a preferred method of accomplishment. The word "may" indicates an acceptable or suggested means of accomplishment.

WARNINGS, CAUTIONS, AND NOTES

The following definitions apply to WARNINGS, CAUTIONS, and NOTES used in this technical manual.

WARNING

WARNING

An operation or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in injury to or death of personnel.

An operating or maintenance procedure, practice, statement, etc., which, if not strictly observed, could result in damage or destruction of equipment, or loss of mission effectiveness.

NOTE

An essential operating or maintenance procedure, condition, or statement which must be highlighted.

GENERAL PRECAUTIONS

The following general safety precautions are not related to any specific procedure. For this reason, they may not appear elsewhere in this technical manual. These are precautions that personnel must understand and apply during equipment operation and maintenance.

Potentially lethal voltages may be present in equipment used to test the service stand. Serious shock hazards from high voltages may exist in exposed electrical connectors and test panels.

Observe the following precautions during testing:

Use the buddy system any time work involving electrical testing is being done.

Turn off electrical power before making or breaking any electrical connections.

Regard any exposed electrical connector or test panel as a possible shock hazard.

Be familiar with modern methods of resuscitation. Do not wear jewelry (rings, bracelets, metal watches or watchbands, neck chains, etc.) while working on ex-posed electrical equipment.

Exercise care when using sharp-pointed tools to prevent injury to personnel.

When an item cannot be lifted with ease, use two or more people, and auxiliary lifting equipment (forklift, crane, etc.) to prevent personnel injuries.

Observe the following precautions when working with pneumatic equipment and air pressure supplies:

Wear safety goggles or a face shield when anywhere near pressurized test equipment, units under test, or air pressure systems.

V

Keep loose objects away from all air flow passages. At pressures above 200 psi, all equipment (test equipment, unit under test, etc..) shall be shielded from personnel with barrier material or .shall be placed in a test chamber.

Do not disconnect any instrumentation or attempt any repairs (parts removals, disassembly, major movement) other than specified adjustments while the unit under test is under pressure.

Allow adequate time for pressure to bleed off before making any disconnections or new connections to the unit under test.

Keep hands, hair, clothing, etc., clear of moving parts.

CLEANING, INSPECTION, AND REPAIR OF

COMPONENTS

Personnel involved in cleaning, inspection, or repair of components must comply with all appropriate safety .precautions. All maintenance personnel must wear rubber gloves, protective clothing, and eye protection when using caustic cleaning materials;

chlorinated, emulsion-type, or petroleum solvents;

vapor blasting equipment; ultrasonic cleaning equipment; and degreasing solutions. All such cleaning must be accomplished in a well-ventilated area.

Protective clothing and equipment shall be main-tained in a sanitary and reliable condition when not being used.

ELECTROSTATIC DISCHARGE (ESD)

The equipment described herein contains parts sensitive to damage by electrostatic discharge

(ESD).

This warning label indicates that this equipment has been manufactured under strict static control condi-tions to prevent damage to the static sensitive parts contained therein. These static sensitive parts can also be damaged if proper static control procedures are not followed during servicing and handling of equipment. Personnel must be properly grounded before touching any ESD sensitive equipment and should follow provisions of T.O. 00-25-234, Chapter

7. Operation and maintenance procedures involving the handling of ESD sensitive components are identified by the ESD symbol preceding written instruction.

SOLDERING IRONS

The risk of receiving painful and dangerous burns is always present .during soldering operations. Review safety operations in paragraph 3-6 of T.O. 00-25-234 prior to performing a solder operation. Exercise caution when using a soldering iron.

RESUSCITATION

Personnel working with or near high voltages should be familiar with modern methods of resuscitation.

vi

INTRODUCTION

PURPOSE AND SCOPE LIST OF COMPLIANCE TECHNICAL ORDERS

This manual provides depot level instructions for the Towreel Assembly, RMK-35, part number 53896-1, hereinafter referred to as towreel. The towreel is manufactured by Southwest Aerospace, Tustin, California 92680. The towreel is shown in figure 1.

The towreel is the primary component of the aircraft-mounted A/A37U-36 Aerial Gunnery Target Set

(AGTS36).

This technical order includes atl changes, additions, and deletions required by the following time com-pliance technical orders:

T.O. NO. DATE TITLE

IMPROVEMENT REPORTS ABBREVIATIONS AND SYMBOLS

Suggestions for changes or improvements to this technical order shall be in accordance with TO 00-5-1, Section VI.

Abbreviations used in this manual are in accordance with MIL-STD-12. Abbreviations used, together with their definitions, are as shown in Table 1.

Figure 1. Towreel Assembly, P/N 53896-1

Change 2 vii

Table 1. Non-Standard

Abbreviation Definition amp

(AP)

assy

BK

COML

C/D dc

DPL

ESD

F fig.

CAGE

ft. Ibs.

g lAW in.

in. Ibs.

IPB

Ibs

LCH

MLCM

ampere(s) Attaching Part (in MPL) assembly Brake Commercial (Non-Standard) Control Display direct current Deploy Electrostatic Discharge Fahrenheit figure Commercial and Government Entity foot pounds Gravity (acceleration) in accordance with inch inch pounds Illustrated Parts Breakdown pounds Latch Microprocessor Logic Control Module

Abbreviations

Abbreviation Definition

MPL

NHA

psi P/R

PN

RCVR

Ref

REL

rf

RFS

SCD

SMR

SRU

STS

TMS

T.O.

TSS

Vdc v

Maintenance Parts List Next Higher Assembly pounds per square inch Process Receiver Part Number Receiver Refer Release radio frequency Radio Frequency Scorer Source (or Specification) Control Drawing Source, Maintenance, and Recoverability Shop Replaceable Unit Shop Test Set Towreel Maintenance Stand Technical Order Towline Service Stand Volts, direct current Volts Plus or Minus viii Change 2

SECTION

GENERAL INFORMATION

1-1. DESCRIPTION.

1-2. The towreel (figure 1-1) is the primary component of the aircraft-mounted A/A37U-36 Aerial Gunnery target Set (AGTS36) and is designed to provide reliable and accurate aerial gunnery training.

1-3. The towreel is a semi-automatic, ram-air, turbine-driven reeling machine designed to reel out, stop, reel in and recover a TDK-39/A37U-36 Aerial Towed Target attached to the towreel by a standard .177/.182 in. diameter armored-strand aerial towline.

The towline is stored on a spool and is controlled and guided during reel-in and reel-out procedures by a levelwind assembly and a system of sheaves.

Reeling speeds, target recovery, and visual augmenter deploy/release are automatically controlled by the system logic of the towreel electrical system. The towreel electrical system executes the commands (IN, OUT, STOP, LENGTH/TENSION) from a cockpit control/display panel and generates function and status information signals from towreel sensors. A pneumatic system uses stored compressed gas controlled by a manifold assembly to operate the target visual augmenter deploy and release mechanism, the target release latch, and a fail-safe hydraulic disc brake system that prevents turbine and towline spool rotation when the towreel is not in the reeling mode. A redundant towline cutting system employs impulse cartridges to sever the towline if an emergency cut is required. The sections of the towreel along with their component assemblies and units are described in the following paragraphs (refer to figure 1-2). A list of leading particulars for the towreel are listed in table 1-1.

1-4. Turbine/Air-vent Section. The turbine/air-vent section contains the ram-air turbine power unit, the air vent system and the tachometer.

The turbine enclosure consists of a 0.12 in. thick cylindrical aluminum housing and cast aluminum vent doors. The cylindrical housing contains two internal-forged aluminum rings. The forward ring, which is part of the stator assembly, is connected to a tubular central hub by the 12 stator blades. This assembly also provides for the interface attachment, at the forward end, for a nacelle and a stator nose.

The aft ring provides for the attachment of the supporting frames and the air vent doors.

ao Ram Air Turbine. The ram air turbine is a 17-inch diameter, single stage, fixed-blade, impulse turbine consisting of a stator and a rotor. The rotor is the only moving part of the ram air turbine and can rotate in both a clockwise and counterclockwise direction. The rotor provides the necessary mechanical power for the reeling in of the towline and serves as a power dissipater during reel-out. The rotor blades are aluminum extruded and are bolted to a bearing supported shaft.

The curved, equally spaced, stator blades are placed to direct the incoming ram air against the rotor blades in such a way that the rotor will be impelled to turn in a (when viewed from the forward end) clockwise direction. The stator blades are formed from 6061-T6 aluminum sheet and are welded to the forward ring and the central tubular hub.

Air Vent System. The turbine is shrouded by the nacelle and stator nose to direct ram air into and through the stator and rotor blades. The speed of the turbine, during reel-in and reel-out, can be varied by the volume of ram air that passes through the turbine, and that volume of air is controlled by the microprocessor logic control module through the use of the air vent system’s, six servomotor-actuated, vent doors. During reel-in the vent doors are open and ram air entering the forward end of the turbine is free to pass through the stator and react against the rotor blades, this causing the rotor to rotate and providing the torque necessary to reel in the towed target. When the vent doors are closed by the MLCM, ram airflow is stopped and turbine torque production ceases. I

Change 2 1-1

STRONGBACK AFTERBODY

FAIRING

TURBINE/

AIR VENT

I LAUNCHER

Figure 1-1. Towreel Assembly, PIN 53896-1

CHAIN REAR AFT

FRONT BRAKE TRANSMISSION BRAKE B,ULKHEAD

CENTERSODY SECTION

TURBINE/AIR VENT SECTION

BULNEAD

Figure 1-2. Towreel Assembly Sections

1-2 Change 2

Table 1-1. Leading Particulars

Length 112 inches

Diameter:

Air vents (open) 19.4 inches

Turbine 17.3 inches

Centerbody 16.0 inches

Height (vents closed) 20.2 inches

Center of gravity (less towline) 52.5 inches

Weight (without towline):

Without RFS units and cables 430 + 20 pounds

Without RFS units and cables 480 + 20 pounds

Performance:

Reel-out speed 800 feet per minute

Reel-in speeds:

High 800 feet per minute

Low 150 feet per minute

Turbine:

Diameter 17 inches

Power rating 30 horsepower

Speed Nominal, 3500 rpm

Electrical:

Operating voltage 28 Vdc

Tension Mechanism circuit 12 Vc

Sensor Assembly circuit 5 Vdc

Current (maximum during reeling) 10 Amperes Pneumatic System:

Unregulated pressure Nominal 1300 to 1500 psi

Regulated pressure ..: Nominal 110 to 130 psi

Hydraulic System:

Pressure needed to release brakes 1750 psi

Change 2 1-3

The vent doors are opened and closed by an electrically-powered servomotor mounted on the forward bulkhead. The motor is a dc-permanent magnet type which is shielded and filtered to reduce EMI emissions. The motor bearings are permanently lubricated to withstand a -55 to +85 fahrenheit temperature environment. The servomotor actuates the vent doors through a crank, a link, a rotating disc and six actuating rods. Two limit switches in the air vent section limit the travel of the vent doors. One switch opens the current path to the servomotor at the maximum limit of air vent door travel and the other switch at the minimum limit of vent door travel (closed position) (refer to figure 1-3).

An internal air detlector covers the air vent actuating mechanism and provides a smooth exit duct for directing the ram air from the turbine out through the vent doors.

Co Tachometer. The tachometer is mounted on the forward bulkhead. As the tachometer is mechanically coupled to the idler shaft, which is driven by chain and sprockets by the turbine output shaft, tachometer output signals reflect a proportional rate of the turbine rotation.

The tachometer output provides voltage feedback through the logic control module and the limit switches to the air vent servomotor for turbine speed control during reel-out procedures (refer to figure 1-3).

1-5. Center Section. The center section, located between the forward and aft bulkheads, contains the servomotor, transmission, towline supply spool, levelwind mechanism and the turbine and spool brake caliper assemblies. The center section is covered and enclosed by the three piece, hinged, removable centerbody fairing fabricated from 6061-T6 aluminum. The bottom section of the fairing is screwed to the forward, center and afl bulkheads, carries the compression and tension loads between the 3 bulkheads and provides the necessary structure for cradling the towreel during ground transport. The upper, hinged, portions of the lairing are attached to the strongback with 14 "dzus" type fasteners and allow quick access to the cenerbody section from either side of the towreel.

Transmission. The transmission, located between the forward and center bulkheads, transmits the torque of the turbine from the turbine shaft to the towline spool and levelwind mechanism through a series of roller-chain driven sprockets attached to the idler, spool and levelwind shafts (refer to figure 1-4). The transmission drive sequence is as follows:

(1) The turbine output shaft drives the idler shaft through the turbine chain.

(2) The idler shaft drives the spool through the spool chain.

(3) The spool drives the levelwind shaft through the levelwind chain.

Towline Spool and Levelwind Mechanism.

The towline spool and levelwind mecha-nism provide for the orderly storage and transfer of the towline as it is reeled in and out of the towreel. The spool is a welded assembly that consists ot a tubular drum and two circular flanges. Support shafts are bolted to the forward and aft end of the spool and the spool/shaft assembly is supported by an adapter (,at the rear) and two flanged bearing assemblies mounted in the center and aft bulkheads. The spool sprocket and levelwind drive sprocket are attached to the forward spool support in the transmission area. The spool brake disc is attached to the aft support shaft between the aft spool flange and the aft bulkhead.

1-4

Figure i-3. Towreel Schematic

Change 2 1-5/(1-6 Blank)

TURBINE

SHAFT

IDLER

SHAFT

LEVELWIND

DRIVE

SPROCKET

Figure 1-4. Transmission Drive Sequence

The levelwind mechanism consists of a diamond-threaded shaft with a ball-reverser unit, a follower assembly with a feed sheave, and a guide rod. The levelwind shaft is supported by flanged bearing assemblies in the center and aft bulkheads.

The levelwind driven sprocket is.attached to the forward end of the levelwind shaft in the transmission area and is driven by a chain from the levelwind drive sprocket on the spool support shaft. The follower assembly is driven by the threads of the shaft as the shaft turns and guides the towline to and from the towline spool during reel in and reel out, providing an even towline wind as the follower traverses the length of the spool. The follower assembly is supported by the levelwind shaft and a guide rod.

Turbine and Spool Brake Calipers. The turbine and spool brake calipers are of the fail-safe type, that is, they are actuated by internal springs and released by hydraulic pressure. The turbine brake caliper is attached to the forward bulkhead and acts against a brake disc attached to the turbine output shaft. The spool brake caliper is attached to the aft bulkhead and acts against the brake disc attached to the aft spool support shaft.

1-6. Afterbody Section. The afterbody section, to the rear of the aft bulkhead, contains the shock absorltion mechanism, manifold assembly, cylinder/intensifier, brake reservoir, towline cutter(s) and the microprocessor logic control module. Also included in the afterbody section is the receiver/processor kit which are components of the radio frequency scoring system. The afterbody

Change 2 1-7 section is enclosed by a one piece, conical aluminum fairing attached to the aft bulkhead by two press-to-release, over-center latches (one on each side). The fairing is removed by releasing the latches and moving it aft.

ao Shock Absorption Mechanism. The shock absorption mechanism consists of a sheave mounted between two pivoted swing arms, over which the towline passes, controlled by two shock absorbers. The purpose of the mechanism is to minimize the effects on the towline reeling system caused by sudden stops and starts during reeling procedures.

bo Manifold Assembly. The manifold assembly is mounted on the right side of the aft bulkhead. All pneumatic components other than the intensifier, actuating cylinders, latch cylinder and connecting tubing are installed as components of the manifold assembly.

The manifold assembly contains the storage bottle, fill valve, air regulator, high and low pressure gauges, solenoid valves, electrical connector (J1), low-air switch and a rupture disc (refer to figure 1-5).

The storage bottle is installed beneath the manifold assembly and contains the pressurized air supply, nominally 1500 psi, used to operate the various components of the pneumatic system.

The bottle is filled through the fill valve on the right side of the manifold assembly.

Storage bottle air pressure is monitored by the high pressure gauge, the low air switch and the rupture disc, all installed on top of the manifold assembly. When the bottle pressure falls below 425 + 50 psi the low air switch closes and sends a signal through the microprocessor logic control module to the air warning light on the cockpit control/display panel (refer to figure 1-3). The rupture disc is designed to burst at a nominal 1900 psi to

Co prevent overpressurizing the storage bottle.

The air regulator is installed on top of the manifold assembly and regulates the 1500 psi air pressure from the storage bottle down to the 100-140 psi required to operate the pneumatic system components. Regulated air pressure is monitored by the low pressure gauge.

The solenoid valves are installed on the left side of the manifold assembly and receive electrical signals from the control display via the microprocessor logic control module through electrical connector (J1) to direct the regulated pressurized air to operate the brake intensifier, latch cylinder and the release and deploy actuating cylinders (refer to figure 1-3).

Cylinder and Intensifier. The cylinder assembly is mated to the intensifier by means of an attached adapter and both are mounted, in conjunction, on the right side of the aft bulkhead by means of a large ring nut. The cylinder assembly is a component of the pneumatic system and is essentially a brake booster. The intensifier is a component of the hydraulic system and serves as a master cylinder to the towreel brakes. When the command IN or OUT is selected on the control/ display, the command is routed through the microprocessor logic control module to a manifold assembly solenoid (refer to figure 1-3). The solenoid vents compressed air into the cylinder where it acts against an internal piston rod that, in turn, acts against the internal piston of the intensifier, pressurizing the hydraulic system and releasing the brakes (refer to figure 1-5).

The intensifier is supplied with hydraulic fluid by a reservoir mounted on the left side of the aft bulkhead.

1-8 Change 2

TURBINE

BRAKE

SPO0 L

BRAKE RESERVOIR

INTENSIFIER

UNLATCH

CYLINDER

RELEASE

CYLINDER

OEPLOY

CYLINOER

DEPLOY’]’

MANIFOLD,

LP SIDE

ANIFOLD ASSY

RUPTURE

DISC FILL

Figure 1-5. Hydro-Pnuematic Schematic

1-9/( 1-10 blank) do eo

Towline Cutter(s). The single towline cutter with its attendant cutter holder has been superseded by a redundant dual cable cutter system. However the single cutter system may still be in use in some towreels. The towline cutter(s) are mounted in the path of the towline on a holder attached to the shock absorption swing arms.

The cutter(s) contain an electrically detonated cartridge that propels a ram against a fixed anvil to sever the towline in emergency situations. The single cut system circuit, and the primary cut circuit of the dual system, runs from the CUT switch on the cockpit control display, through the interface unit and microprocessor logic control module, and connects to a cutter through wiring harness W6 (refer to figure 1-6). The redundant cut circuit of the dual system runs from an "arm system/fire" switch on a cockpit control joystick directly to the cutter through an interface cable and wiring harness Wl (refer to figure 1-6).

The microprocessor logic control module and processor/receiver are the electronic control and information processing components of the towreel. The processor/receiver is attached to shock-isolated mounting plates bolted to the upper channel of the launcher. The microprocessor logic control module is mounted aft of the processor/receiver on a mounting plate attached to the launcher upper channel and is not shock isolated. The electronic components operate off an aircraft-supplied 28 Vdc.

The microprocessor logic control module contains the towreel system circuitry, as well as the major, connector interfaces. The microprocessor logic control module is contained in an EMI-shielded container mounted at the very aft end of the towreel.

The microprocessor logic control module receives commands from the control/display and transmits towreel function and status information through discrete lines. The microprocessor logic control module distributes power to the air vent system servo, manifold assembly solenoids, and towline cutters and receives and processes signals from the tachometer, in-lock switch, tension sensor, length counter, and low-air switch (refer to figure 1-3). To protect the turbine in the event of a servo failure, the microprocessor logic control module also contains an overspeed sensor circuit which places the towreel in the STOP mode with the brakes set whenever the turbine speed in either direction exceeds a set rpm. The microprocessor logic control module contains a 12V power supply for the tension sensor and a 5V power supply for the towline length sensor. Wiring harnesses W2, W3 and W6 connect the microprocessor logic control module with the appropriate towreel components.

1-7. Launcher Assembly. The launcher is located on the centerline beneath the aft end of the towreel. Its primary function is to hold the towed target captive during flight and to guide the initial launch and final recovery of the target to and from the towreel. Other functions include deployment and release of the visual augmenter and monitoring of towline length and tension.

The basic launcher structure consists of two parallel aluminum sideplates bolted to an upper and lower channel and attached to the aft bulkhead by a support block. The latch mechanism; tension, guide and exit sheaves; deploy and release cylinders and various stiffeners are installed between the plates. The tension mechanism, sensor assembly are installed externally. The assembly provides hard points for the aft end of the towreel and is designed to accept and/or transfer all of the dynamic and inertial loads to the target during captive carriage and reel in and reel out.

Change 2 1-11/(1-12 blank)

A

RECE VER

PEN

LIMIT j ’IP3

_0SED

W3

LOW AIR

w!

PROC.2T_.SSOR

V4.

A5

MAN FOLD

ASF_MLY

CUT

NILOGX _,2-

COL,TE

TENSION

AI

A2

AICROPROCESSOR

LOGIC

CONTROL

MODULE

Figure 1-6. Intetconnection Diagram

Chanle 2 1-13/(1-14 Blank)

Two removable sets of swaybraces are attached to the bottom side of the launcher to hold the target in place. A streamlined fairing closes off the forward end of the structure.

Towline Sheaves, Tension Mechanism and Sensor Assembly. The three towline sheaves installed in the launcher receive the towline from the spool, the levelwind and the shock absorption sheave and route it to the latch mechanism and the towed target. The tension mechanism provides information on towline tension to the logic control module (refer to figure 1-3). The sensor assembly measures the length of towline reeled in or out.

The tension sheave is the topmost of the sheaves in the launcher and operates in conjunction with the tension mechanism to provide information on towline tension.

The sheave turns on a hub which is installed on an eccentric shaft. The reaction of cable tension on the sheave tends to rotate this hub about the eccentric pivot. This motion is reflected in a spring-loaded lever arm attached to the eccentric shaft which is much longer than the eccentricity of the hub and thus amplifies the movement of the displacement of the hub about its pivot.

Cable tension information is indicated by a linear potentiometer attached near the end of the lever arm and is reported to the logic control module (refer to figure 1-3).

The voltage of the potentiometer is approximately a linear function of tension.

The exit sheave is installed between the plates of the launcher and is mounted on an externally lubricated ball bearing. The exit sheave serves as the upper guide for the target tow adapter during launch, recovery and captive carriage and, along with the sensor assembly measures the length of towline reeled in or out. The towline length is measured by counting the number of revolutions of the sheave.

The revolution counting is accomplished by a permanent magnet mounted on the side of the sheave and the stationary

TO 43E17-3-4-3

sensor assembly mounted opposite the magnet on the left sideplate. As the sheave rotates, the magnet on the sheave passes the sensor pickup and the sensor sends an electric pulse to the logic control module.

The guide sheave, installed between the sideplates at the very bottom of the launcher, acts as the final cable guide during towing and reeling and is the lower guide for the target towline adapter during launch, recovery and captive carriage.

Latch Assembly and Latch Switch. The latch assembly is installed between the plates of the launcher just beneath the tension sheave. The latch assembly ensures that the target remains attached to the towreel during captive carriage if there should be a towline failure or inadvertent release of the towreel brakes.

The spring-loaded latch bar of the latch mechanism engages a notch in the tow adapter when the adapter is fully seated in its innermost position. The latch mechanism has a self-actuating characteristic which tends to prevent release of the target when the target weight bears on the latch bar. It is necessary, therefore, that the towline be under tension to release the load from the latch bar for reliable target deployment.

To release the target from the launcher, the manifold assembly, on command from the control/display, directs compressed air to the air cylinder of the latch mechanism (refer to figure 1-5) which pushes the spring-loaded latch bar out and away from the machined groove in the towline adapter.

The latch switch, mounted to the left launcher sideplate, is closed by the latch mechanism actuator block whenever the tow adapter is in its innermost position in the launcher. The closed switch illuminates the green IN/LOCK lamp on the control/display to indicate that the target is in the in position (refer to figure 1-3).

1-15

Deploy and Release Cylinders. The deploy and release cylinders are mounted between the launcher sideplates at the very rear of the launcher. These cylinders are actuated by compressed air from the manifold assembly (refer to figure 1-5) and are essentially pneumatic solenoids.

With the target in the captive position, the pistons of the cylinders extend upon command from the logic control module and operate against mechanical levers in the towed target which deploy the visual augmenter (VA) just prior to target launch and release the VA from the target on recovery.

Telemetry Antenna. The telemetry antenna is mounted externally on a bracket at the very aft end of the launcher and is a component of the radio frequency scoring system. The antenna receives radio signals from the towed target and relays the signals to the processor/receiver through cable W5 (refer to figure 1-6).

1-8. The basic operational modes of the towreel are outlined in the following paragraphs (refer to figure 1-7). For detailed explanations of specific towreel components or systems see paragraph 1-3.

1-9o Stowed. The towed target is stowed and locked in the towreel launcher by the towline adapter latch mechanism. The turbine vent doors are closed, the turbine rotor is stopped, and the brake system is set. On the control/display panel, the master power switch is in the ON position and the towline length is displayed.

1-10. Launch. Placing the function control switch on the ontrol/display to the OUT position causes the VA to deploy and, following a 2 second delay, the target towline adapter to disengage from the towreel latch mechanism, and the towreel brake system to release. The towed target is released from the launcher and the green IN/LOCK lamp on the control/display goes out. The drag of the towed target through the airstream initiates towline reel-out.

1-11. Reel-out. The turbine rotor, functioning as a compressor, controls the rate at which the towline is reeled out. The rotational speed of the turbine is controlled by the turbine vent system, and a steady-state reel-out velocity is achieved automatically. Towline length is displayed on a digital read-out on the control/display. Reel-out is automatically terminated when 2,000 feet of towline have reeled out, or by placing the function control switch in the STOP position. At this time, the brake system is activated and the turbine vent doors close.

1-12. Towed. The target is out to the desired towline length, the brake system is set and the turbine vent doors are closed. A digital read-out on the control/display displays towline tension.

1-13. Reel-in. Placing the function control switch on the control/display in the IN position initiates automatic reel-in. The brake, system releases and the turbine vent doors open permitting turbine rotation. Towline reel-in speed is limited to 800 feet per minute by a feedback control that regulates turbine vent opening to control turbine speed. At a distance of 300 feet from the towreel, the reel-in speed automatically reduces to 100 feet per minute for final target recovery.

1-14. Recovery. The forebody of the towed target mates with the launcher swaybraces, and the towline adapter engages the latch mechanism.

Simultaneously, towreel brakes are applied, the turbine vent doors close, the green IN/LOCK lamp on the control/display illuminates, and the target visual augmenter is automatically released from the forebody.

1-16

SECTION II

SPECIAL TOOLS AND TEST EQUIPMENT

2-1. GENERAL. 2-3. FABRICATED SPECIAL TOOLS.

2-2. The special tools and test equipment required to accomplish overhaul and testing of the towreel are shown in table 2-1 and in figures 2-1 and 2-2.

Equivalent tools or equipment may be used in place of those listed.

NOTE

All test equipment shall function properly, and be calibrated in accordance with

MIL-STD-45662.

2-4. Table 2-2 lists locally manufactured special tools and provides fabrication instructions for each tool. Locally manufactured special tools are shown in figures 2-3 and 2-4.

2-5. SAFETY EQUIPMENT.

2-6. Table 2-3 provides a list of safety equipment to be used during cleaning and repair of the towreel.

Table 2-1. Special Tools and Test Equipment List

Tool/Equipment Figure Number/ Number Nomenclature Use and Application

40850-1 2-1 Turbine Extension Shaft

Item

40855-1

40840-1

40800-1

40865-1

26924-1

26870-1

2-1

2--1

2-1

Turbine Drive Assembly

Towreel Maintenance Stand

Towline Service Stand, 100

Lambda LES-EE 04-OV

Tektronix Model 2213

Lambda LPD-422A-FM

Continental Specialty Model 2001

2-1

2-1

2-2

Towreel Cradle

Shop Test Set

Cockpit Control Display Panel

Power Supply, 28 VDC, 9 Amp

Oscilloscope

Power Supply, Variable with Isolated Ground (0 to >- 100 Ma)

Variable Square Wave Oscillator

Assembly extension and testing

Assembly and testing

Repair

Repair

Repair

Disassembly, assembly, repair

Repair

Testing

Testing

Testing

Testing

2-1

Table 2-1. Special Tools and Test Equipment List (Continued)

Tool/Equipment Figure Number/ Number Nomenclature Use and Application

Testing

Item

Beckman Tech 310 or equiv.

Strobotac 1531-AB or equiv.

Mitsutoyo or equiv.

M1

M8196914-02

M8196914-03

M22520/1-01

M22520/1-02

M22520/HD

MS 90387-1

Digital Volt-ohm Meter

(DVOM)

Tachometer

Dial Indicator

Repair

Repair

Swaging Tool, Portable

Pin Extractor, 20 Gauge

Pin Extractor, 16 Gauge

Pin Crimp Tool

Pin Crimp Tool.

Pin Crimp Tool

Tie Wrap Pliers

Assembly

Repair

Repair

Repair

Repair

Repair

Repair

2-2

Eo [] oO000ll

SHOP TEST SET

TURBINE DRIVE

ASSEMBLY

"c_,._z-._-- ’--TII-

TOWREEL II

MAINTENANCE II

TOWLINE

SERVICE

TURBINE SHAFT

EXTENSION

Figure 2-1. Peculiar Support Equipment

2-3

TO 43E17o3-4-3

SCORE

POWER

RESET TOWLINE

F OUT L

O

L...- IN TNSN

IN/LOCK

CUT (

Figure 2-2. Cockpit Control Display Panel

Table 2-2. Fabricated Special Tools List

Tool

Quantity Nomenclature

Pin Wrench

Pin Wrench

Fabrication Instructions

Refer to figure 2-3

Refer to figure 2-4

2-4

Figure 2-3. Pin Wrench

2-5

4.2 IN.

1.5 IN.’--------"

Figure 2-4. Pin wrench

Table 2-3. Safety Equipment List

Tool/Equipment Number Nomenclature Use and Application

MIL-STD-1434 Goggles, Chemical

MIL-STD-1202

MIL-G-87066

MIL-G-29409A

GGG-M-125

Faceshield

Gloves, Neoprene

Gloves, Leather

Respirator

Eye protection while using solvents and strippers.

Eye protection while using solvents and strippers and cutting steel bands.

Skin protection while using solvents, strippers and lubricating oil.

Hand protection while cutting steel bands.

Lung protection while using solvents and strippers.

2-6

SECTION III

DISASSEMBLY

3-1. GENERAL.

3-2. Special Procedures. This section presents, by text and illustrations, any special procedures preliminary to inspection, repair, and replacement of parts. These procedures consist of removal from shipping container and dismantling into major assemblies, subassemblies and component parts.

The text is keyed to the index numbers of figures 9-1 through 9-22. Necessary data is included to enable depot activities to determine when components, assemblies, and subassemblies require maintenance or repairs, or when they shall be completely overhauled.

3-3. Extent of Disassembly. Although this section provides extensive disassembly instructions pertaining to the repair and replacement of parts, disassembly should only be performed to the extent necessary for completion of required repair.

3-4. ESD Warning. All procedural steps marked with label indicate that there may be damage by electrostatic sensitive discharge (ESD) and that the use of special handling procedures is required to avoid such discharges during the procedure.

3-5. Parts Not Covered. Due to the nature of the towreel, some parts are not covered in this section.

Parts not covered in this section will be covered in Section V, INSPECTION, REPAIR, AND

REPLACEMENT.

3-6. UNPACKING.

3-7. Packing Container. The towreel is usually packed in a plywood packing container (refer to figure 3-1) consisting of load-bearing bases;

cushioned saddles; and metal banding. The towreel is held to the base of the packing container with quick-release tiedown straps. All deliverable hardware items will be preserved, packaged and packed lAW Level A/A of MIL-STD-794, in conformance with AFLC Form 872. The packing container will be marked/bar code labeled lAW MIL-STD-129. To remove towreel from packing container, proceed as follows:

Steel banding, cut under tension, can snap free and cause injuries.

Leather gloves and a faceshield are required when cutting steel bands.

a. Cut and remove banding straps from packing container.

b. Remove top of packing container from base by removing the lag bolts.

NOTE

Do not destroy or discard compo-nents of packing container. The packing container may be reused for storage or reshipment of towreel.

Remove control display assembly, towline adapters and towline end fittings from their containers in packing container and place them in storage.

d. Carefully remove restraining straps and barrier bag from around towreel.

Install towreel onto towreel maintenance stand (refer to table 2-1, item 3). All towreel maintenance procedures will be performed with towreel installed on towreel maintenance stand. Proceed as follows:

3-1

TO 43E’t.7-3-4-3

REBONDED RUBBER

lb. DENSITY

+ + 4-

FORWARD SADDLE ASSEMBLY

3/4 IN. THK

PLYWOOD

FRAME

REBONDED RUBBER

t" 8 lb. DENSITY, 6 IN. WIDE

"t- -t- -’t- + "

AFT SADDLE ASSEMBLY

3/4 IN. THK

PLYWOOD

FRAME

38.00 IN.

IN.

28.00 IN.----*

Figure 3-1. Towreel Shipping Container

3-2

(i) Connect a hoist with a 1000 lb. lifting capacity to towreel suspension lugs (55, figure 9-4), lift towreel from packing container and place it on towreel cradle (refer to table 2-1, item 5) so that cradle bars just extend under aft bulkhead (27, figure.9-14). Remove hoist and strap towreel to towreel lifting cradle.

(2) Using a fork lift or jammer, raise towreel lifting cradle so that towreel suspension lugs (55, figure 9-4) fit up into lug blocks on towreel maintenance stand and install lug pins through suspension lugs and lug blocks. Remove towreel lifting cradle from towreel.

(3) Run jack screws on towreel maintenance stand down against towreel swaybraces (10, figure 9-15) until jackscrew pads hold towreel firmly in place.

Install launcher saddles (75, figure 9-18) onto towreel. (Refer to Section VI, ASSEMBLY).

3-8. DISASSEMBLY PROCEDURE.

3-9. Open and Close the Turbine Vent Doors. It will be necessary during disassembly and several repair, replacement and testing procedures to open and close the turbine vent doors. Proceed as follows:

’ a. Disconnect connector P2 of cable W2 from logic control module connector Jl.

Using a 28 Vdc power supply (refer to Table 2-1, item 8), apply +28 vdc power to LCM pins Jl-m and Jl-d and ground to Jl-r.

Open turbine vent doors by applying ground to IN control pin J1-G.

d. Close turbine vent doors by removing ground from pin J1-G.

Remove the 28 Vdc power from LCM connector J1. Connect connector P2 of cable W2 to LCM connector J1.

Close the turbine vent doors by powering up shop test set and setting IN/STOP/OUT switch on shop test set control/display panel to STOP.

g. Reverse procedural steps a. through e. to remove shop test set from towreel.

3-10. Release and/or Set Towreel Brakes. Itwill be necessary during several repair, replacement and testing procedures to release and set towreel brakes. The towreel brakes are of a fail-safe design, that is, they release upon application of hydraulic pressure and are set upon removal of hydraulic pressure. Proceed as follows:

Ensure that fluid level in reservoir (8, figure 9-16) is correct, that hydraulic system is bled, and that pneumatic system is properly charged. To service and purge and towreel pneumatic system refer to Section VI, ASSEMBLY.

bo Set towline service stand (refer to table 2-1, item 4) to power towreel (refer to figure 3-2) as follows:

(1) Connect 115 Vac electrical power to towline service stand at connector J3.

(2) Disconnect wiring harness W6 (92, figure 9-4) from manifold connector J1 (22, figure 9-17).

(3) Connect brake release cable W8 (supplied with towline service stand) between towline service stand connector J2 and manifold con-nector J1 (22).

3-3

TO 43E17;3"4-3

POWER

SWITCH

TOWLINE

DIRECTION

SWITCH

TOWLINE

TENSION

GAUGE

PRESSUR E

REGULATOR

ACCESS COVERS

END}

LEVELWIND

ASSEMBLY

RIGHT

BULKHEAD

SPOOL

SPINDLE

FRAME

TIE DOWN

FEET

TOWLINE SUPPLY

SPOOL

(TOWLINE SUPPLY

SPOOL PROCURED

SEPARATELY)

o@

AIR SUPPLY INLET

(120 PSI)

RIGHT

BULKHEAD

/-t.

ELECTRICAL SUPPLY,

_/ BRAKE

..- ELECTRICAL SUPPLY,

ELECTRICAL SUPPLY

OUTLET

Figure 3-2. Towline Service Stand

3-4

Release towreel brakes by setting TOWLINE DIRECTION SWITCH on towline service stand to TO TOWREEL.

do Set towreel brakes by setting TOWLINE DIRECTION SWITCH on towline service stand to STOP.

Reverse procedures in procedural steps b. or

c. to remove power and support equipment from towreel.

3-11. Remove Towline from Towreel. It will be necessary during several repair, replacement and testing procedures to remove towline from towreel.

Proceed as follows:

Position towreel, mounted on towreel maintenance stand (refer to table 2-1, item 3), not more than fifteen feet (maxi-mum) in front of towline service stand (refer to table 2-1, item 4). Align the centerlines of both towreel and towline service stand within 10 degrees. (Refer to figure 3-3).

bo Lock the casters of towreel maintenance stand and tighten swaybraces to prevent movement during the transfer of towline.

c. Disconnect cable W6 (92, figure 9-4) from manifold connector J1 (22, figure 9-17).

Connect brake release cable W8 (supplied with towline service stand) between towline service stand outlet J2 (TOWREEL BRAKE) and manifold connector J1 (22). (Refer to figure 3-4).

If target tow adaptor is attached to towline, remove it by cutting towline. Cut towline as close to the target tow adapter as possible.

fo Connect shop pressurized air (maximum 120 psi) to AIR IN valve on towline service stand. Connect 115 Vac electrical power to towline service stand at J3 (POWER IN). (Refer to figures 3-2, 3-4).

ho

Set towline service stand TOWLINE TENSION to read 0 psi at PRESSURE GAUGE on control panel (refer to figure 3-2). Set TOWLINE DIRECTION switch to STOP and push ON/OFF POWER SWITCH on (the green switch lamp will come on).

Set towline service stand TOWLINE DIRECTION switch (refer to figure 3-2) to TO TOWREEL to unlock towreel brakes.

Inspect towreel to ensure that towline is properly muted over towreel sheaves.

(Refer to figure 3-5).

Pull approximately twenty-five feet of towline from towreel and mute it through towline guides on towline service stand levelwind arm and attach towline to supply spool.

Set towline service stand TOWLINE DIRECTION switch to STOP to apply towreel brakes, turn towline service stand ON/OFF POWER SWITCH off to release towline service stand brake and rotate towline service stand supply spool manually to take slack out of towline.

Never leave towline service stand unmanned while loading and unload-ing towline. The towline service stand and turbine drive motor can cause maintenance stand to tip over if towline jams.

Remove towline from towreel by turning towline service stand ON/OFF POWER SWITCH on, and setting TOWLINE DIRECTION switch to TO SERV STAND.

Manually operate towline service stand levelwind arm from side to side to produce and even…