Amendment1.pdf

TO 35E8-2-5-3

TECHNICAL MANUAL

OVERHAUL MAINTENANCE WITH

ILLUSTRATED PARTS BREAKDOWN

AIRCRAFT ARRESTING BARRIER

MODEL BAK-12/E32A

ADVANCED DEVELOPMENT ENGINEERING CENTER

A UNIT OF WICKES COMPANIES, INC.

F41608-90-D-1819

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without 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 provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (15 January 2007). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concern-ing technical content shall be referred to AFLCMC/WNZEC.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

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

17 JUNE 2011 CHANGE 3 - 21 JANUARY 2015

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0 . . . . . . . 17 June 2011 Change . . . . . . . . 1 . . . . . 30 August 2012

Change . . . . . . . . 2 . . . . . . . 21 May 2014 Change . . . . . . . . 3. . . . .21 January 2015

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 258, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

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Title A i - iii iv - v vi - vii viii Blank ix x - xiii xiv Blank 1-1 - 1-25 1-26 Blank 2-1 - 2-5 2-6 Blank 3-1 - 3-58 4-1 - 4-2 5-1 - 5-17 5-18 5-19 - 5-24 5-25 5-26 - 5-42 6-1 - 6-39 6-40 Blank 7-1 7-2 Blank 8-1 8-2 Blank 9-1 - 9-5 9-6 Blank 10-1 - 10-7 10-8 Blank 11-1 11-2 Blank 11-3 - 11-9 11-10 Blank 11-11 - 11-18 A-1 - A-8 B-1 - B-5 B-6 Blank C-1 - C-10 D-1 - D-2

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TO 35E8-2-5-3

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

A Change 3 USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . vi

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . vii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . ix

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xiii

1 GENERAL INFORMATION . . . . . . . . . . . . 1-1

1.1 SCOPE. . . . . . . . . . . . . . . . . . . . 1-1

1.2 PURPOSE. . . . . . . . . . . . . . . . . . 1-1

1.3 INSTALLATIONS . . . . . . . . . . . . 1-1

1.4 EXPEDITIONARY INSTALLA-

TION (STANDARD SPLIT

TYPE) . . . . . . . . . . . . . . . . . . 1-1

1.5 SEMI-PERMANENT

INSTALLATION . . . . . . . . . . . 1-1

1.6 CONCRETE PIT PERMANENT

INSTALLATION . . . . . . . . . . . 1-4

1.7 MAAS INSTALLATION. . . . . . . . 1-4

1.8 GENERAL SPECIFICATIONS. . . . 1-4

1.9 CONSUMABLE SUPPLIES . . . . . 1-4

1.10 MAIN FEATURES OF MAJOR

COMPONENTS. . . . . . . . . . . . 1-5

1.11 BASE. . . . . . . . . . . . . . . . . . . . . 1-5

1.12 REEL ASSEMBLY. . . . . . . . . . . . 1-5

1.13 PILLOWBLOCKS . . . . . . . . . . . . 1-5

1.14 HYDRAULIC STAND . . . . . . . . . 1-6

1.15 REEL SUPPORTS . . . . . . . . . . . . 1-6

1.16 RESERVOIR. . . . . . . . . . . . . . . . 1-6

1.17 ACTUATOR . . . . . . . . . . . . . . . . 1-6

1.18 REWIND ENGINE . . . . . . . . . . . 1-6

1.19 REWIND ENGINE (52-W-2291-801

Wisconsin) . . . . . . . . . . . . . . . 1-6

1.20 REWIND DRIVE. . . . . . . . . . . . . 1-6

1.21 BATTERY . . . . . . . . . . . . . . . . . 1-7

1.22 FUEL TANK. . . . . . . . . . . . . . . . 1-7

1.23 INSTRUMENT PANEL . . . . . . . . 1-7

1.24 BRAKE WATER COOLING . . . . . 1-7

1.25 REEL BRAKE. . . . . . . . . . . . . . . 1-7

1.26 REWIND CLUTCH . . . . . . . . . . . 1-7

1.27 SYNCHRONIZING DRIVE . . . . . 1-7

1.28 LEAD-OFF SHEAVE

ASSEMBLY . . . . . . . . . . . . . . 1-7

1.29 GUARDS . . . . . . . . . . . . . . . . . . 1-7

1.30 MAIN FEATURES OF MAJOR

SYSTEMS . . . . . . . . . . . . . . . 1-7

1.31 HYDRAULIC SYSTEM . . . . . . . . 1-8

1.32 REWIND SYSTEM . . . . . . . . . . . 1-8

1.33 SYNCHRONIZING SYSTEM . . . . 1-8

1.34 REEL TACHOMETER

SYSTEM . . . . . . . . . . . . . . . . 1-8

Chapter Page

1.35 BRAKE PRESSURE GAGE

SYSTEM . . . . . . . . . . . . . . . . 1-8

1.36 ELECTRICAL SYSTEM. . . . . . . . 1-8

1.37 WATER COOLED BRAKE

SYSTEM . . . . . . . . . . . . . . . . 1-8

1.38 LUBRICATION SYSTEM. . . . . . . 1-9

2 SPECIAL TOOLS AND TEST

EQUIPMENT . . . . . . . . . . . . . . . . . . . . 2-1

2.1 SCOPE. . . . . . . . . . . . . . . . . . . . 2-1

2.2 SPECIAL TOOLS . . . . . . . . . . . . 2-1

2.2.1 Bearing Puller Tool . . . . . . . . . . . 2-1

2.2.2 Bearing Retaining Nut Tool . . . . . . 2-1

2.2.3 Bearing Driver Tool . . . . . . . . . . . 2-1

2.3 SPECIAL KITS . . . . . . . . . . . . . . 2-5

2.3.1 Accumulator Charging Kit . . . . . . . 2-5

2.3.2 Brake Bleed Kit . . . . . . . . . . . . . . 2-5

2.3.3 Synchronizing Calibration Kit . . . . 2-5

2.4 SPECIAL TEST EQUIPMENT . . . 2-5

3 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 3-1

3.1 SCOPE. . . . . . . . . . . . . . . . . . . . 3-1

3.2 BASE. . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1 The Modification . . . . . . . . . . . . . 3-37

3.3 REEL ASSEMBLY. . . . . . . . . . . . 3-37

3.4 HYDRAULIC STAND . . . . . . . . . 3-43

3.5 INSTRUMENT PANEL . . . . . . . . 3-44

3.6 HYDRAULIC CONTROL

VALVE. . . . . . . . . . . . . . . . . . 3-44

3.7 RELIEF VALVE . . . . . . . . . . . . . 3-45

3.8 GEAR REDUCER . . . . . . . . . . . . 3-48

3.9 BATTERY . . . . . . . . . . . . . . . . . 3-49

3.10 SELECTOR VALVE. . . . . . . . . . . 3-51

3.11 HAND PUMP . . . . . . . . . . . . . . . 3-51

3.12 ACTUATOR . . . . . . . . . . . . . . . . 3-51

3.13 RESERVOIR. . . . . . . . . . . . . . . . 3-51

3.14 ACCUMULATOR . . . . . . . . . . . . 3-52

3.15 REEL TACHOMETER . . . . . . . . . 3-52

3.16 FLUID COUPLING-TWIN

DISC . . . . . . . . . . . . . . . . . . . 3-52

3.17 ADEC FLUID COUPLING . . . . . . 3-53

3.18 WATER PUMP AND MOTOR. . . . 3-53

3.19 HELICOID GAGE . . . . . . . . . . . . 3-53

3.20 GASOLINE TANK . . . . . . . . . . . 3-57

3.21 CHAIN TENSIONERS . . . . . . . . . 3-57

3.22 BARCO SWIVEL JOINT . . . . . . . 3-57

3.23 DEUBLIN SWIVEL JOINT. . . . . . 3-57

3.24 BRAKE ASSEMBLY . . . . . . . . . . 3-57

4 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 4-1

i

4.1 SCOPE. . . . . . . . . . . . . . . . . . . . 4-1

4.2 BEARINGS. . . . . . . . . . . . . . . . . 4-1

4.3 RESERVOIR. . . . . . . . . . . . . . . . 4-1

4.4 ACCUMULATOR . . . . . . . . . . . . 4-2

4.5 BRAKE CLUTCH

ASSEMBLY . . . . . . . . . . . . . . 4-2

5 INSPECTION, REPAIR, AND

REPLACEMENT . . . . . . . . . . . . . . . . . . 5-1

5.1 SCOPE. . . . . . . . . . . . . . . . . . . . 5-1

5.2 TERMS . . . . . . . . . . . . . . . . . . . 5-1

5.3 HYDRAULIC CONTROL

VALVE. . . . . . . . . . . . . . . . . . 5-1

5.4 RELIEF VALVE . . . . . . . . . . . . . 5-1

5.5 REWIND GEAR REDUCER . . . . . 5-1

5.6 SELECTOR VALVE. . . . . . . . . . . 5-2

5.7 BARCO UNIT. . . . . . . . . . . . . . . 5-2

5.8 DEUBUN ROTARY JOINT. . . . . . 5-2

5.9 HAND PUMP . . . . . . . . . . . . . . . 5-2

5.10 ACTUATOR . . . . . . . . . . . . . . . . 5-2

5.11 RESERVOIR. . . . . . . . . . . . . . . . 5-2

5.12 ACCUMULATOR . . . . . . . . . . . . 5-3

5.13 REEL TACHOMETER . . . . . . . . . 5-3

5.14 NEEDLE VALVE. . . . . . . . . . . . . 5-3

5.15 FLUID COUPLING (TWIN

DISC) . . . . . . . . . . . . . . . . . . 5-3

5.16 RIGHT ANGLE DRIVE . . . . . . . . 5-3

5.17 CHAIN TENSIONERS . . . . . . . . . 5-3

5.18 BRAKE ASSEMBLIES. . . . . . . . . 5-4

5.18.1 General. . . . . . . . . . . . . . . . . . . . 5-4

5.18.2 Brake Wear . . . . . . . . . . . . . . . . . 5-4

5.18.3 Carrier Assemblies . . . . . . . . . . . . 5-4

5.18.4 Rotating Discs . . . . . . . . . . . . . . . 5-4

5.18.5 Backing Plate Assembly . . . . . . . . 5-4

5.18.6 Stator Assembly . . . . . . . . . . . . . . 5-4

5.18.7 Pressure Plate Assembly . . . . . . . . 5-5

5.18.8 Brake Adjusting Pins . . . . . . . . . . 5-5

5.18.9 Return Spring Cup . . . . . . . . . . . . 5-5

5.18.10 Torque Tube . . . . . . . . . . . . . . . . 5-5

5.18.11 Heat Shields . . . . . . . . . . . . . . . . 5-5

5.18.12 Pistons . . . . . . . . . . . . . . . . . . . . 5-5

5.18.13 Piston Seals (O-Rings) . . . . . . . . . 5-5

5.18.14 Piston Backup Rings. . . . . . . . . . . 5-5

5.18.15 Piston Wiper . . . . . . . . . . . . . . . . 5-5

5.18.16 Carrier . . . . . . . . . . . . . . . . . . . . 5-5

5.19 REWIND TAPE SHEAVE

ASSEMBLY . . . . . . . . . . . . . . 5-6

5.20 REEL ASSEMBLY - TAPE REEL

SHAFT. . . . . . . . . . . . . . . . . . 5-8

5.20.1 Primary NDI Procedure Magnetic

Particle . . . . . . . . . . . . . . . . . . 5-8

5.20.1.1 Keyway Area and Area A . . . . . . . 5-8

Chapter Page

5.20.1.2 Threaded Keyway Area and Area

B . . . . . . . . . . . . . . . . . . . . . . 5-9

5.20.1.3 Area C . . . . . . . . . . . . . . . . . . . . 5-9

5.20.1.4 Keyway Area and Area D . . . . . . . 5-10

5.20.1.5 Area E. (Spline) . . . . . . . . . . . . . . 5-10

5.21 BASE. . . . . . . . . . . . . . . . . . . . . 5-17

5.22 REEL ASSEMBLY. . . . . . . . . . . . 5-17

5.23 REEL ASSEMBLY - TAPE DRUM

RING . . . . . . . . . . . . . . . . . . . 5-17

5.23.1 Primary NDI Procedure - Eddy

Current: . . . . . . . . . . . . . . . . . 5-17

5.24 REEL ASSEMBLY - BRAKE

DRUM . . . . . . . . . . . . . . . . . . 5-18

5.24.1 Primary NDI Procedure - Eddy

Current: . . . . . . . . . . . . . . . . . 5-18

5.25 REEL ASSY - TAPE REEL BOLT,

MAGNETIC PARTICLE IN-

SPECTION (MPI) FOR

DEFECTS. . . . . . . . . . . . . . . . 5-20

5.25.1 Part Description . . . . . . . . . . . . . . 5-20

5.25.2 Defect or Condition

Description . . . . . . . . . . . . . . . 5-20

5.25.3 Primary NDI Procedure - Fluores-

cent Magnetic Particle Inspection . . . . . . . . . . . . . . . . 5-20

5.25.4 Access . . . . . . . . . . . . . . . . . . . . 5-20

5.25.5 Preparation of Part . . . . . . . . . . . . 5-20

5.25.6 Stationary Equipment NDI Equip-

ment Settings/Standardization/Setup 5-21

5.25.7 Inspection - Circular Magnetism

Utilizing Equipment Stationary . . . . . . . . . . . . . . . . 5-21

5.25.8 Stationary Equipment NDI Equip-

ment Settings/Standardization/Setup 5-21

5.25.9 Inspection - Longitudinal Magnetism

Utilizing Stationary Equipment. . . . . . . . . . . . . . . . 5-21

5.25.10 Demagnetize the part: AC Demagne-

tization Using Stationary Equipment. . . . . . . . . . . . . . . . 5-22

5.25.11 Clean Residual Inspection Materials

from Reel Bolt. . . . . . . . . . . . . 5-22

5.26 Backup NDI Procedure - Fluores-

cent Penetrant Inspection . . . . . . 5-22

5.26.1 NDI Materials and Equipment . . . . 5-22

5.26.2 Preparation of Part . . . . . . . . . . . . 5-22

5.26.3 NDI Equipment

Settings/Standardization/Setup 5-22

5.26.4 Inspection . . . . . . . . . . . . . . . . . . 5-22

5.27 SYSTEM SECURING . . . . . . . . . 5-24

5.28 HYDRAULIC STAND . . . . . . . . . 5-25

TO 35E8-2-5-3

TABLE OF CONTENTS - CONTINUED

ii

5.29 REPAIR AND

REPLACEMENT. . . . . . . . . . . 5-25

5.30 BAK-12 FAIRLEAD BEAM AN-

CHOR BOLT

INSPECTIONS . . . . . . . . . . . . 5-25

5.31 DESCRIPTION . . . . . . . . . . . . . . 5-25

5.32 CRITICAL DEFECTS . . . . . . . . . 5-25

5.33 PRIMARY NDI PROCEDURE -

ULTRASONIC . . . . . . . . . . . . 5-26

5.34 NDI EQUIPMENT AND

MATERIALS . . . . . . . . . . . . . 5-26

5.34.1 Safety Precautions . . . . . . . . . . . . 5-26

5.35 PREPARATION OF BOLTS FOR

INSPECTION . . . . . . . . . . . . . 5-26

5.36 ACCESS. . . . . . . . . . . . . . . . . . . 5-26

5.37 INSTRUMENT

SETTINGS/CALIBRATION . . . 5-26

5.37.1 Marking and Recording of Inspec-

tion Results . . . . . . . . . . . . . . . 5-27

5.38 BACKUP NDI PROCEDURE . . . . 5-27

5.39 SYSTEM SECURING . . . . . . . . . 5-27

5.40 BAK-12 ANCHOR ROD RE-

PLACEMENT METHOD . . . . . 5-32

5.41 FAIRLEAD BEAM

UPGRADE . . . . . . . . . . . . . . . 5-34

6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 SCOPE. . . . . . . . . . . . . . . . . . . . 6-1

6.2 BASE. . . . . . . . . . . . . . . . . . . . . 6-2

6.3 REEL ASSEMBLY. . . . . . . . . . . . 6-18

6.4 HYDRAULIC STAND . . . . . . . . . 6-20

6.5 INSTRUMENT PANEL . . . . . . . . 6-20

6.6 REEL ASSEMBLY. . . . . . . . . . . . 6-20

6.6.1 Sheave Shaft . . . . . . . . . . . . . . . . 6-21

6.7 HYDRAULIC CONTROL

VALVE. . . . . . . . . . . . . . . . . . 6-23

6.8 RELIEF VALVE . . . . . . . . . . . . . 6-23

6.9 GEAR REDUCER . . . . . . . . . . . . 6-25

6.10 BATTERY . . . . . . . . . . . . . . . . . 6-28

6.11 SELECTOR VALVE. . . . . . . . . . . 6-28

6.12 ACTUATOR . . . . . . . . . . . . . . . . 6-28

6.13 RESERVOIR. . . . . . . . . . . . . . . . 6-29

6.14 ACCUMULATOR . . . . . . . . . . . . 6-29

6.15 REEL TACHOMETER . . . . . . . . . 6-33

6.16 NEEDLE VALVE. . . . . . . . . . . . . 6-33

6.17 TWIN DISC FLUID

COUPLING . . . . . . . . . . . . . . 6-33

6.18 ADEC FLUID COUPLING . . . . . . 6-34

6.19 WATER PUMP AND MOTOR. . . . 6-34

6.20 HELICOID GAGE DIAL . . . . . . . 6-34

6.21 GASOLINE TANK . . . . . . . . . . . 6-35

6.22 CHAIN TENSIONERS . . . . . . . . . 6-35

6.23 BARCO SWIVEL JOINT . . . . . . . 6-35

6.24 DEUBLIN SWIVEL JOINT. . . . . . 6-35

Chapter Page

6.25 BRAKE ASSEMBLY . . . . . . . . . . 6-36

6.26 FLARELESS TYPE TUBE

FITTINGS . . . . . . . . . . . . . . . 6-36

6.27 FLEXIBLE HYDRAULIC HOSE

SYSTEM . . . . . . . . . . . . . . . . 6-39

7 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 ACCESSORIES . . . . . . . . . . . . . . 7-1

8 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 SCOPE. . . . . . . . . . . . . . . . . . . . 8-1

8.2 INITIAL TESTING AFTER

OVERHAUL. . . . . . . . . . . . . . 8-1

8.3 PROOF TEST OF HYDRAULIC

SYSTEM . . . . . . . . . . . . . . . . 8-1

8.4 SYSTEM CHECKOUT

PROCEDURE . . . . . . . . . . . . . 8-1

9 TABLE OF LIMITS . . . . . . . . . . . . . . . . . . 9-1

9.1 SCOPE. . . . . . . . . . . . . . . . . . . . 9-1

9.2 LIMITING VALUES . . . . . . . . . . 9-1

9.3 FIT OF NEW AND OVERSIZE

PARTS . . . . . . . . . . . . . . . . . . 9-3

9.4 FIT OF INSERTS . . . . . . . . . . . . 9-3

9.5 DISPOSITION OF REJECTED

PARTS . . . . . . . . . . . . . . . . . . 9-3

9.6 TIGHTENING TORQUES . . . . . . 9-3

10 ILLUSTRATED PARTS BREAKDOWN . . . . 10-1

SECTION I FOREWORD . . . . . . . . . . . . . . 10-1

10.1 INTRODUCTION . . . . . . . . . . . . 10-1

10.2 MODELS COVERED. . . . . . . . . . 10-1

10.3 FINDING PART NUMBERS, IL-

LUSTRATION,

DESCRIPTION . . . . . . . . . . . . 10-1

10.4 SIMILAR ASSEMBLIES . . . . . . . 10-1

10.5 SHEET NUMBER

EXPLANATION . . . . . . . . . . . 10-1

10.6 USABLE ON CODES . . . . . . . . . 10-1

10.7 SOURCE, MAINTENANCE, AND

RECOVERABILITY (SMR)

CODES . . . . . . . . . . . . . . . . . 10-1

10.8 PARTS STANDARDIZATION . . . . 10-1

10.9 MANUFACTURER’S LIST. . . . . . 10-1

10.10 MAINTENANCE PARTS LIST

(MPL) . . . . . . . . . . . . . . . . . . 10-1

10.10.1 Figure and Index Number

Column . . . . . . . . . . . . . . . . . 10-2

10.10.2 Part Number Column . . . . . . . . . . 10-2

TO 35E8-2-5-3

iii

10.10.2.1 Commercial Hardware . . . . . . . . . 10-2

10.10.2.2 Parts Not Illustrated . . . . . . . . . . . 10-2

10.10.2.3 Markings . . . . . . . . . . . . . . . . . . 10-2

10.10.2.4 Government Furnished Equipment

(GFE) and Contractor Furnished Equipment (CFE) Covered by Separate Manuals . . . . . . . . . . . 10-2

10.10.2.5 Alternate Part . . . . . . . . . . . . . . . 10-2

10.10.3 CAGE Column . . . . . . . . . . . . . . 10-2

10.10.4 Description Column . . . . . . . . . . . 10-2

10.10.4.1 Indentation . . . . . . . . . . . . . . . . . 10-2

10.10.5 Units Per Assembly Column . . . . . 10-2

10.10.6 Usable on Code Column . . . . . . . . 10-2

10.10.7 Source, Maintenance, and Recover-

ability (SMR) Code Column . . . 10-2

SECTION II MAINTENANCE PARTS

LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

11 DIFFERENCE DATA SHEETS . . . . . . . . . . 11-1

11.1 DIFFERENCE DATA SHEETS . . . 11-1

11.2 DIFFERENCE DATA SHEETS . . . 11-1

APPENDIX A CHECKOUT PROCEDURES,

PROCESS SPECIFICATIONS, AND

KLOZURE SEAL INSTALLATION

DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A.1 CHECKOUT PROCEDURES . . . . A-1

A.2 EQUIPMENT REQUIRED . . . . . . A-2

A.3 PRELIMINARY CHECKOUT . . . . A-3

A.4 HYDRAULIC CONTROL

SYSTEM . . . . . . . . . . . . . . . . A-3

A.5 ELECTRICAL ASSEMBLY

CHECKOUT . . . . . . . . . . . . . . A-4

A.6 REWIND SYSTEM

CHECKOUT . . . . . . . . . . . . . . A-4

A.6.1 Bleed Hydraulic Line . . . . . . . . . . A-4 A.6.2 Pin Rewind System . . . . . . . . . . . A-5 A.6.3 Rewind Engine Checkout . . . . . . . A-5

A.7 SYNCHRONIZATION

PROCEDURE . . . . . . . . . . . . . A-5

A.8 MAXIMUM PRESSURE

TEST . . . . . . . . . . . . . . . . . . . A-6

A.9 SHUTTLE VALVE CHECK . . . . . A-6

A.10 COOLING SYSTEM . . . . . . . . . . A-7

A.11 FINAL CHECK . . . . . . . . . . . . . . A-7

APPENDIX B BRAKE CHECKOUT

PROCEDURE . . . . . . . . . . . . . . . . . . . . . B-1

B.1 CARRIER ASSEMBLY . . . . . . . . B-3

B.2 BRAKE ASSEMBLY . . . . . . . . . . B-3

Chapter Page

APPENDIX C PROCESS SPECIFICATION

PS100. . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

100-1 (ALUMINUM PARTS) . . . . . . . . . C-1

100-2 (STEEL PARTS) . . . . . . . . . . . . . C-1

100-3 (STEEL PARTS) . . . . . . . . . . . . . C-1

100-4 (STEEL PARTS) . . . . . . . . . . . . . C-2

100-5 (ALUMINUM PARTS) . . . . . . . . . C-2

106-6 (STEEL PARTS) . . . . . . . . . . . . . C-2

100-7 (ALUMINUM PARTS) . . . . . . . . . C-2

100-8 (FERROUS MATERIALS) . . . . . . C-2

100-9 (ALUMINUM PARTS) . . . . . . . . . C-2

100-10 (STEEL PARTS) . . . . . . . . . . . . . C-2

100-11 (ALUMINUM PARTS) . . . . . . . . . C-3

100-12 (STEEL PARTS) . . . . . . . . . . . . . C-3

100-13 (STEEL PARTS) . . . . . . . . . . . . . C-3

100-14 (ALUMINUM PARTS) . . . . . . . . . C-3

100-15 (STEEL PARTS) . . . . . . . . . . . . . C-3

100-16 (FERROUS CASTINGS). . . . . . . . C-3

100-17 (FERROUS PARTS) . . . . . . . . . . . C-3

100-18 (PLATED FERROUS PARTS) . . . . C-3

100-19 (ALUMINUM PARTS) . . . . . . . . . C-3

100-20 (STEEL PARTS) . . . . . . . . . . . . . C-3

100-21 (ALUMINUM PARTS) . . . . . . . . . C-4

100-22 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-23 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-24 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-25 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-26 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-27 (STEEL, ALUMINUM, BRONZE

PARTS) . . . . . . . . . . . . . . . . . C-4

100-28 (STEEL PARTS - IF USED UNDER

PAINT). . . . . . . . . . . . . . . . . . C-4

100-29 (STEEL PARTS) . . . . . . . . . . . . . C-4

100-30 (STEEL PARTS) . . . . . . . . . . . . . C-5

100-31 (STAINLESS STEEL PARTS) . . . . C-5

100-32 (FOR ASSEMBLED

MACHINES). . . . . . . . . . . . . . C-5

100-33 (STEEL PARTS) . . . . . . . . . . . . . C-5

100-34 (STEEL AND ALUMINUM

PARTS) . . . . . . . . . . . . . . . . . C-5

100-35 (STEEL PARTS - OIL RESISTANT

PRIMER) . . . . . . . . . . . . . . . . C-5

100-36 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-5

100-37 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-5

100-38 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-6

100-39 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-6

100-40 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-6

100-41 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-6

TO 35E8-2-5-3

iv Change 3

100-42 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-6

100-43 (FERROUS PARTS) . . . . . . . . . . . C-7

100-44 (FERROUS PARTS) . . . . . . . . . . . C-7

100-45 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-7

100-46 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-7

100-47 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-7

100-48 (FERROUS PARTS) . . . . . . . . . . . C-7

100-49 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-7

100-50 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-8

100-51 (STEEL PARTS) . . . . . . . . . . . . . C-8

100-52 (FERROUS PARTS, OTHER THAN

STAINLESS, GALVANIZED

AND PLATED STEEL) . . . . . . C-8

100-53 (ELECTRICAL CABINETS AND

ENCLOSURES). . . . . . . . . . . . C-8

100-54 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-8

100-55 (STEEL PARTS) . . . . . . . . . . . . . C-9

100-56 (ENCLOSED STEEL

WELDMENT) . . . . . . . . . . . . . C-9

100-57 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-9

Chapter Page

100-58 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-9

100-59 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-9

100-60 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-9

100-61 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-9

100-62 (STEEL PARTS) . . . . . . . . . . . . . C-10

100-63 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-10

100-64 (STEEL AND ALUMINUM PARTS

AND CASTINGS) . . . . . . . . . . C-10

100-65 (ALUMINUM PARTS) . . . . . . . . . C-10

100-66 (STEEL HYDRAULIC TUBING,

CLAMPS, AND

FITTINGS) . . . . . . . . . . . . . . . C-10

APPENDIX D KLOZURE SEAL INSTALLA-

TION DATA . . . . . . . . . . . . . . . . . . . . . . D-1

D.1 INSTALLATION

RECOMMENDATIONS . . . . . . D-1

D.2 AFTER INSTALLATION . . . . . . . D-1

TO 35E8-2-5-3

Change 3 v

LIST OF ILLUSTRATIONS

Number PageTitle

1-1 Aircraft Arresting Absorber Model BAK- 12/E32A-Expeditionary Installation. . . . . . . . . . . . . . . . . . . . 1-10

1-2 Aircraft Arresting Absorber Model BAK- 12/E32A-Semi-Permanent Installation (With Runway Edge Sheaves). . . . . . . 1-11

1-3 Aircraft Arresting Absorber Model BAK- 12/E32A-Semi-Permanent Installation (With Fairleads) . . . . . . . . . . . . . . . . 1-12

1-4 Aircraft Arresting Absorber Model BAK- 12/E32A-Concrete Pit Permanent Instal-lation (With Runway Edge Sheaves) . . . . . . . . . . . . . . . . . . . . . 1-13

1-5 Aircraft Arresting Absorber Model BAK- 12/E32A-Concrete Pit Permanent Instal-lation (With Fairleads). . . . . . . . . . . . 1-14

1-6 Arresting System, Aircraft, Mobile, A/M 32A-96 . . . . . . . . . . . . . . . . . . . . . . 1-15

1-7 Synchronizing Drive-Exploded View (52- W-2291 Wisconsin Rewind Engine) . . . . . . . . . . . . . . . . . . . . . . 1-16

1-8 Synchronizing Drive-Exploded View (52- W-2220 Wisconsin Rewind Engine) . . . . . . . . . . . . . . . . . . . . . . 1-17

1-9 Synchronizing Drive-Exploded View (52- W-1765 Packette Rewind Engine) . . . . 1-18

1-10 Control Valve Linkage (52-W-1765 Pack-ette/52-W-2220 Wisconsin Rewind Engines) . . . . . . . . . . . . . . . . . . . . . 1-19

1-11 Control Valve Adjustment (52-W-2291 Wisconsin Rewind Engine) . . . . . . . . 1-20

1-12 Brake Water Cooling System (52-W- 2291-1, 52-W-2291-2 Wisconsin Re-wind Engines) . . . . . . . . . . . . . . . . . 1-21

1-13 Electrical Diagram (52-W-2291-801 Wis-consin Rewind Engine) . . . . . . . . . . . 1-23

1-14 Reel Assembly . . . . . . . . . . . . . . . . . . . 1-24 2-1 Bearing Puller Tool. . . . . . . . . . . . . . . . 2-1 2-2 Bearing Retaining Nut Tool . . . . . . . . . . 2-3 2-3 Bearing Driver Tool . . . . . . . . . . . . . . . 2-4 3-1 Aircraft Arresting Absorber Model BAK-

12/E32A Standard (Expeditionary) Installation. . . . . . . . . . . . . . . . . . . . 3-3

3-2 Reel Assembly . . . . . . . . . . . . . . . . . . . 3-5 3-3 Rewind Engine-Packette Rewind

Engine . . . . . . . . . . . . . . . . . . . . . . 3-7 3-4 Engine Rewind-Wisconsin Type

MVG4D . . . . . . . . . . . . . . . . . . . . . 3-9

3-5 Engine Rewind-Wisconsin Type

V-465D. . . . . . . . . . . . . . . . . . . . . . 3-11 3-6 Structural Steel Base Equipment

Arrangement . . . . . . . . . . . . . . . . . . 3-13 3-7 Arresting Engine Assembly . . . . . . . . . . 3-14

Number PageTitle

3-8 Hydraulic System . . . . . . . . . . . . . . . . . 3-18 3-9 Rewind Clutch Control-Packette Rewind

Engine . . . . . . . . . . . . . . . . . . . . . . 3-22 3-10 Rewind Clutch Control-Wisconsin Rewind

Engine . . . . . . . . . . . . . . . . . . . . . . 3-24 3-11 Control Valve Linkage. . . . . . . . . . . . . . 3-28 3-12 Control Valve Linkage (2291

Wisconsin) . . . . . . . . . . . . . . . . . . . 3-30 3-13 Twin Disc Coupling Dowel Pin

Removal . . . . . . . . . . . . . . . . . . . . . 3-31 3-14 Brake Water Cooling System (1765 Pack-ette/2220 Wisconsin) . . . . . . . . . . . . . 3-33 3-15 Brake Water Cooling System (2291

Wisconsin) . . . . . . . . . . . . . . . . . . . 3-36 3-16 Sheave Assembly-Tape . . . . . . . . . . . . . 3-38 3-17 Reel Support Fixture . . . . . . . . . . . . . . . 3-40 3-18 Pin Rewind Assembly . . . . . . . . . . . . . . 3-42 3-19 Modified Yoke . . . . . . . . . . . . . . . . . . . 3-46 3-20 Valve Gland Assembly . . . . . . . . . . . . . 3-47 3-21 Relief Valve. . . . . . . . . . . . . . . . . . . . . 3-48 3-22 Selector Valve . . . . . . . . . . . . . . . . . . . 3-50 3-23 Fluid Coupling-Twin Disc . . . . . . . . . . . 3-54 3-24 ADEC Fluid Coupling. . . . . . . . . . . . . . 3-55 3-25 Helicoid Gage . . . . . . . . . . . . . . . . . . . 3-56 3-26 Plane Swivel . . . . . . . . . . . . . . . . . . . . 3-58 3-27 Deublin Union . . . . . . . . . . . . . . . . . . . 3-58 5-1 Sheave Assembly Inspection - Top

View . . . . . . . . . . . . . . . . . . . . . . . 5-7 5-2 Sheave Assembly Inspection - Side

View . . . . . . . . . . . . . . . . . . . . . . . 5-7 5-3 Tape Reel Shaft, PN 52-D-341, showing

Key Way Areas and reference Areas; A through E . . . . . . . . . . . . . . . . . . . . 5-12

5-4 Tape Drum Ring. . . . . . . . . . . . . . . . . . 5-18 5-5 Brake Drum - Outside View. . . . . . . . . . 5-19 5-6 Brake Drum - Inside View . . . . . . . . . . . 5-20 5-7 Tape Reel Bolt . . . . . . . . . . . . . . . . . . . 5-24 5-8 Tape Reel Direct Contact Technique (Cir-cular Magnetism) . . . . . . . . . . . . . . . 5-24 5-9 Tape Reel Bolt Coil Technique (Longitudi-nal Magnetism) . . . . . . . . . . . . . . . . 5-25 5-10 Inspection Area Locations . . . . . . . . . . . 5-28 5-11 Position No. 1 and No. 2 for Calibration

Locations . . . . . . . . . . . . . . . . . . . . 5-28 5-12 Screen Display 1, Position 1 Initial Cali-bration (5.0 MHz). . . . . . . . . . . . . . . 5-29 5-13 Screen Display 2, Position 1 Initial Cali-bration (2.25 MHz) . . . . . . . . . . . . . . 5-29 5-14 Screen Display 3, Position 2 Initial Cali-bration (2.25 MHz) . . . . . . . . . . . . . . 5-30 5-15 Fairlead Beam Anchor Rod Repair . . . . . 5-30 5-16 BAK-12 Anchor Rod Replacement (X-

Anchor) Method . . . . . . . . . . . . . . . . 5-33 vi

Number PageTitle

5-17 Modified Fairlead Beam, Assembled (not showing bolt/washers/nuts). . . . . . . . . 5-35

5-18 Hand Hole Cover Assembly (Detail-1 per Figure 5-17, sheet 1). . . . . . . . . . . . . 5-37

5-19 FLB Top Plate Upgrade Drawings. . . . . . 5-38 5-20 FLB Side Plate Gusset Upgrade Drawing.

Twelve Required per FLB unit . . . . . . 5-41 5-21 Basic Drawing for Final FLB D-Ring

Weldment/Locations . . . . . . . . . . . . . 5-42 6-1 Rewind Pin Installation-Configuration

52-W-2291-801 . . . . . . . . . . . . . . . . 6-4 6-2 Brake Water Cooling System (52-W-2291

Wisconsin Rewind Engine) . . . . . . . . 6-5 6-3 Wisconsin Rewind Engine and Hydraulic

Synchronizing Installation . . . . . . . . . 6-7 6-4 Rewind Clutch Control-Wisconsin Rewind

Engine . . . . . . . . . . . . . . . . . . . . . . 6-12 6-5 Fluid Coupling Orientation For #2

Fill . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 6-6 Wisconsin Rewind Engine . . . . . . . . . . . 6-17 6-7 Control Valve Linkage (52-W-2291 Wis-consin Rewind Engine) . . . . . . . . . . . 6-22

Number PageTitle

6-8 Relief Valve. . . . . . . . . . . . . . . . . . . . . 6-24 6-9 Shim Determination . . . . . . . . . . . . . . . 6-26 6-10 Gear Reducer. . . . . . . . . . . . . . . . . . . . 6-27 6-11 Pressure Gage . . . . . . . . . . . . . . . . . . . 6-29 6-12 Installation/Exploded View of Various

Bak-12 Component and Assemblies . . . . . . . . . . . . . . . . . . . 6-30

6-13 Standard Reinforcing Pad. . . . . . . . . . . . 6-31 6-14 Reservoir. . . . . . . . . . . . . . . . . . . . . . . 6-32 6-15 Needle Valve . . . . . . . . . . . . . . . . . . . . 6-33 6-16 Barco Swivel Joint . . . . . . . . . . . . . . . . 6-35 6-17 Deublin Swivel Joint . . . . . . . . . . . . . . . 6-36 6-18 Ferulset Tool . . . . . . . . . . . . . . . . . . . . 6-37 6-19 Nut and Ferrule on Tube . . . . . . . . . . . . 6-37 6-20 Fitting Body . . . . . . . . . . . . . . . . . . . . 6-38 6-21 Inspection After Presetting . . . . . . . . . . . 6-38 10-1 BAK-12 Hydraulic System (I Beam Base)

Flexible Hydraulic Hose/Fittings . . . . . 10-6 FO-1 Base Modernization Assembly . . . . . . . . FP-1

LIST OF TABLES

Number PageTitle

1-1 Energy Absorbers and Accessories Utilized. . . . . . . . . . . . . . . . . . . . . . 1-2

1-2 Leading Particulars for

BAK-12/E32A . . . . . . . . . . . . . . . . . 1-4

2-1 Special Tool List . . . . . . . . . . . . . . . . . 2-2 2-2 Special Kits . . . . . . . . . . . . . . . . . . . . . 2-5 5-1 Initial Calibration 1 (5MHz). . . . . . . . . . 5-27 5-2 Initial Calibration 2 (2.25 MHz) . . . . . . . 5-27

Number PageTitle

6-1 Base Conversion. . . . . . . . . . . . . . . . . . 6-1 6-2 Hydraulic Hose Lengths . . . . . . . . . . . . 6-39 9-1 Table of Limits . . . . . . . . . . . . . . . . . . 9-1 9-2 Tightening Torques (Hexagonal Head and

Socket Head Cap Screws-Cadmium Plates) . . . . . . . . . . . . . . . . . . . . . . 9-4

9-3 Tightening Torques (Nut Type) . . . . . . . . 9-5

TO 35E8-2-5-3

LIST OF ILLUSTRATIONS - CONTINUED

vii/(viii blank)

FOREWORD

1 PURPOSE.

This technical manual contains overhaul instructions for Air-craft Arresting Absorber Model BAK-12/E32A, manufac-tured by the Advanced Development and Engineering Center of Folcroft, Pennsylvania. The major items of equipment in various types of installations are shown in figures 1-1 through 1-6.

2 SCOPE.

The instructions provided are depot level procedures which include disassembly, cleaning, inspection, repair, assembly, and testing.

3 SYMBOLS.

- A dash (-) before an index number denotes a part which is not illustrated.

* An asterisk (*) flush right of the part number denotes a marking that is to be requisitioned in accordance with DODI 5330.03_AFI 33- 395.

# A number sign (#) flush right of a part number indicates that detail parts are listed in a sepa-rate manual.

= Alternate Part F The letter “F” before the figure number means

“follows” and is used when an assembly or part has not been assigned an index number, and the figure and index number of the pre-ceding part has been used.

4 OVERVIEW OF OVERHAUL PROCEDURES.

The following tasks generally comprise standardized ten-year overhaul. These tasks do not represent step-by-step proce-dures, and are only intended to define standard 10-year over-haul requirements.

a. Remove reel assembly, disassemble, inspect 100%, re-place worn/damaged components and reassemble us-ing new hardware. Remove and replace reel bolts of reel assembly with new hardware.

b. Strip all paint from hubs and inspect brake hubs and keys for cracks and/or flaws. Dye penetrant test or magnaflux of brake hubs will be performed at bolt hole areas and at brake key locations. Prime and repaint hubs.

c. Visually inspect reel side plates for warping and pit-ting. Replace if any warping exists and if pitting ex-ceeds a depth of 1/32” in any area. Small imperfec-tions on side plate surfaces may be filled with liquid metal.

d. Remove and replace brake key bolts, washers, and lock wire.

e. Perform NDI test of shaft assembly and shaft threads checking for wear, distortion, and cracks. Inspect all bearing and mounting locations for proper fit and tol-erance

f. Remove and inspect main shaft bearings. Clean bear-ings thoroughly prior to inspection for the following conditions: spalling, smearing, corrosion, cracks, scor-ing, discoloration, brinelling and abrasing. If any defi-ciencies are found, replace bearing.

g. Replace or overhaul Bliss brake components per Para-graph 5.18 of this document.

h. Replace tactair shuttle valve with new valve on mani-fold assembly or have shuttle valve refurbished from an approved source. (Presently only R&R Industries of Sioux City, Iowa and ESCO-ZA of Aston, PA are ap-proved to refurbished shuttle valves.) During proof testing of the system, inspect for leakage at the O-ring between the shuttle valve and manifold.

i. Remove main hydraulic pump and replace with a new pump.

j. Remove and visually inspect valve gland assembly.

Gland assembly should be removed from manifold and thoroughly inspected for scored, scratched, or bent components. Replace gland valve seals and defective components. Clean thoroughly prior to reassembly.

k. Install new 40-2 ASA Main Hydraulic Pump Drive Chain and adjust properly.

l. Install new 35 ASA CAM Drive Chain and adjust properly.

m. Replace or recondition and test reservoir and accumu-lator as per Paragraph 5.11 and Paragraph 5.12, re-spectively.

Change 2 ix

n. Replace pillow block mounting bolts and nuts 100% new hardware.

o. Replace brake to pillow block screws and washers with 100% new hardware.

p. Remove lead-off sheave and disassemble. Remove and inspect bearings as per conditions in paragraph g above.

Replace bearing as required. Replace all sheave seals with new parts. Repack bearing cavity with approved grease.

NOTE

Check part number (PN) or size of bearing. PN should be ML 5214 or the bearing should measure

4.30 inches in diameter. If the bearing is not this part number or required diameter, the bearing must be replaced.

q. Remove, disassemble, inspect, and repair rewind gear reducer. Install new shaft seals. Inspect bearings per conditions listed in paragraph g above. Replace bear-ings as required. Reassemble gear box with new shims per paragraph 6.9 to provide proper end play of rewind gear box bearings.

r. Remove, disassemble, inspect, and repair cam gear re-ducer. Thoroughly clean and inspect internal mecha-nism. Inspect shaft for trueness, replace as necessary.

Seal should be replaced 100%, shaft and bearings as necessary.

s. Perform tune-up of rewind engine in accordance with applicable manufacturer’s manual

t. Visually inspect weldment base and pillow block for stress-cracks, corrosion, and any signs of failure. All corrosion shall be removed and the surfaces refinished.

Any welds in areas of corrosion shall be examined. If welding repairs are necessary, the weld repairs shall be in accordance with AWS D1.1 (General Welding Pro-cedures). Any material (Base Plates) that are cracked shall be removed and replaced if possible; otherwise, the absorber base shall be replaced.

u. It shall be standard practice to replace all hydraulic seals regardless of date installed and/or condition.

(1) The arresting gear shall be subjected to a compre-hensive preliminary visual, electrical, operational, and mechanical inspection to assist in pinpointing general areas that will require particular attention.

(2) The following steps are recommended for over-haul of the arresting system components based on results of preliminary inspection.

(a) Disassembly.

(b) Cleaning.

(c) Inspection.

(d) Disposition (Repair of replacement criteria).

(e) Lubrication.

(f) Reassembly.

(g) Test (Major system components).

(3) Finish requirements for Arresting Gear Fairlead Beam, Deck Sheaves, and runway edge sheaves:

(a) Finish in accordance with Air Force drawing number 7545352.

(b) Abrasive blast to a near white blast cleaned surface finish per Steel Structures Paint Council SSPC-SP 10-85.

(c) Prime with an organic zinc rich primer. Ap-proved primers are listed in Air Force draw-ing number 7545352. The dry film thickness of the primer coating shall be 2.0 to 3.0 mils.

(d) Topcoat with MIL-PRF-85285 polyurethane.

Refer to QPL-C-85285 for approved coat-ings. Color shall be color number 24057 per

FED-STD-595C.

5 CHAPTER ARRANGEMENT.

Chapter 1 contains general information for maintenance per-sonnel to further understand the equipment. Chapter 2 iden-tifies special tools, special kits, and test equipment required to perform overhaul. Chapter 3 provides procedures to dis-assemble assemblies/subassemblies to replace faulty parts.

Chapter 4 contains special cleaning procedures. Chapter 5 contains procedures for inspection, repair, and replacement of parts. Chapter 6 provides procedures for assembly of vari-ous subassemblies/assemblies after they have been repaired.

Testing of components after repair is covered in Chapter 8. It may not be necessary to perform all of the disassembly, as-sembly, and testing procedures. Testing of the entire system after repair and process specifications is contained in Appen-dix A.

6 COMMON PROCEDURES.

Common procedures such as cleaning, preservation, packag-ing, and identification marking of depot repaired items for storage or shipment to the field are not included in this manual. The procedures should be performed in accordance with the applicable portions of TO 11N-35-51, MIL-P-116J, and MIL-STD-129P.

x

7 TERMS .

The nomenclatures and abbreviations used throughout this manual conform to Military Standard MIL-STD-12 with the following exceptions:

a. Front of energy ab-sorber:

End from which purchase tape is-sues.

b. Rear of energy ab-sorber:

End on which rewind engine mounts.

c. Hydraulic side:

That having the hydraulic stand.

d. Rewind side:

That having the rewind sprocket.

e. Right side: On observers right when standing at rear of and facing energy absorber.

f. Top: Highest part.

In addition, Chapter 5 contains other special terms

(which are used during inspections). Definition of those terms are contained in Chapter 5 (see Para-graph 5.2).

8 ABBREVIATIONS.

All abbreviations used in this manual are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents.

AF Air Force AFTO Air Force Technical Order ASSY Assembly DoD Department of Defense GFE Government Furnished Equipment PN Part Number PSI Pound-Force Per Square Inch REF Reference

9 RELATED PUBLICATIONS.

The following publications contain information in support of this technical manual.

List of Related Publications

Number Title ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents

CA55 (Manufacturer’s Document)

Overhaul, Cone Drive Speed Reducer

List of Related Publications - Continued

Number Title DODI 5330.03_AFI 33-395 Document Automation and

Production Service

(DAPS)

FED-STD-595C Colors Used in Government Procurement

MIL-P-116 Methods of Preservation MIL-PRF-85285D Coating: Polyurethane, Air-craft and Support Equip-ment

MIL-STD-129P Military Marking for Ship-ment and Storage

MM-288-A (Manufacturer’s Document)

Wisconsin Engines, Instruc-tion Book and Parts List

(MVG4D)

No Number (Manufacturer’s Document)

37X Pump Service Manual

TCD2011 Operations Manual - Deutz Diesel Engine

TO 00-5-1-WA-1 Air Force Technical Order System

TO 00-25-195-WA-1 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Sys-tems, and Equipment

TO 00-25-234-WA-1 General Shop Practice Re-quirements for the Repair, Maintenance, and Test of Electrical Equipment

TO 1-1A-15 General Maintenance In-structions for Support Equipment

TO 4B1-4-133 Overhaul with Illustrated Parts Breakdown, Brake Assembly, 24 x 16 5/16-4 Rotor

TO 33B-1-1 Magnetic Particle Inspection Safety

TO 35E8-2-5-1 Operation and Maintenance Instructions, Aircraft Ar-resting Barrier, Model

BAK- 12/E32A

TO 35E8-2-5-4 Illustrated Parts Breakdown, Aircraft Arresting Barrier, Model BAK-12/E32A

TO 38G2-30-73 Overhaul, Gasoline Engine, Model No. MVG4D

10 RECORD OF APPLICABLE TIME COMPLIANCE

TECHNICAL ORDERS (TCTOS).

xi

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

None

11 HARDNESS CRITICAL ITEMS (HCI).

If included, items with nuclear survivability requirements are marked with the HCI symbol ( ) and a CAUTION im-mediately preceding the item’s description. The HCI symbol ( ) and CAUTION establish special requirements limit-ing changes and substitutions and that the specific parts listed must be used to ensure hardness is not degraded. All changes to, or proposed substitutions of, HCIs must be approved by the acquiring activity.

12 ELECTROSTATIC DISCHARGE SENSITIVE

(ESDS) ITEMS.

If included, items containing ESDS parts are marked with the ESDS symbol ( ) and a CAUTION. Items so marked shall be handled in accordance with the ESDS device han-dling procedures in TO 00-25-234-WA-1.

13 CHANGE RECOMMENDATIONS.

Recommendations proposing changes to this technical order shall be submitted on AFTO Form 22 in accordance with TO 00-5-1-WA-1. Forward completed AFTO Form 22 to the Technical Order Management Agency (TOMA) at:

robins.ce.afto22@robins.af.mil.

xii

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and/or chemical processes which may cause injury or death to personnel, or damage to equipment, if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any specific task, the WARNINGs, CAU- TIONs, and NOTEs included in that task shall be reviewed and understood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are considered essential to protection of personnel (WARNING) or equipment (CAU- TION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, CAUTION, or icon), a statement of the hazard, minimum precautions, and possible results if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are not essential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending upon the information to be highlighted. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in in-jury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in dam-age to, or destruction of, equipment or loss of mis-sion effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

3 GENERAL.

• Procedures contained in this manual shall be per-formed only by qualified personnel under supervi-sion.

• All test equipment shall be grounded.

• When an abnormal condition is noted and pertinent procedures contained herein do not specifically re-late to the noted irregularity, work will be stopped and technically qualified guidance will be obtained before continuing the operation.

• It is not always feasible or convenient to follow procedures in the sequence provided in this manual.

For instance, maintenance may require disassembly for access to only one component for replacement or reassembly although the manual provides a more extensive sequence. The following rule applies: The using organization may change the sequence of pro-cedures to facilitate operations if no required tests are omitted, no inspection tests invalidated, and no safety features violated.

• Ensure that waste material is disposed of properly.

4 CABLE CARE.

Handle cables and wiring carefully; avoid pulling, twisting, bending or tugging on cables or wiring. Ensure that cables and wiring are retained within clamping area prior to secur-ing clamp. Avoid snugness over protrusions.

5 BATTERY.

• Batteries contain electrolyte which is poisonous and extremely corrosive. When handling battery wear protective gloves.

• Batteries recently charged, may explode.

6 FIRE PREVENTION.

Do not permit sparks, open flames, or other sources of igni-tion to be present in area where flammable material is used.

7 TOXIC OR VOLATILE CLEANING AGENTS.

Use toxic or volatile agents sparingly and only in well-ven-tilated areas. Wear protective clothing and safety equipment and wash hands and other exposed skin areas thoroughly with soap and water after using toxic or volatile agent. Keep containers closed except when in actual use.

xiii/(xiv blank)

CHAPTER 1

GENERAL INFORMATION

1.1 SCOPE.

This chapter contains brief descriptions of the various instal-lations of Aircraft Arresting Barrier Model BAK-12/E32A, along with the leading particulars of the system. Physical descriptions of the main features of the major components and operating details of the major systems are also covered.

1.2 PURPOSE.

The Aircraft Arresting Barrier Model BAK-12/E32A is a ro-tary friction brake-type energy absorber. Consisting of two identical units with one installed on each side of the runway, the system uses a special nylon tape as the drive member.

Arrestment of landing aircraft is accomplished by engage-ment of the aircraft’s arresting hook with a pendant assem-bly stretched across the runway. The energy of the arrested aircraft is absorbed in the rotary friction brakes during the tape payout. The system can also be used as the energy ab-sorber in installations equipped with various combinations of engaging devices designed to arrest aircraft that are not equipped with arresting hooks.

1.3 INSTALLATIONS.

The system can be installed as an expeditionary, semi-per-manent, or permanent runway facility (see Figure 1-1 through Figure 1-5) or may be used in conjunction with other engag-ing devices. Several types of engines (called rewind engines) and accessories are utilized for the various installations and are listed in Table 1-1. At overhaul, however, all rewind en-gines are reconfigured, if necessary, so that they conform to model 52-W-2291-801. Figure 1-7 through Figure 1-14, are provided to illustrate the major components and to provide data as to their overall operation. Refer to List of Related Manuals for figures and details of the rewind engines.

1.4 EXPEDITIONARY INSTALLATION (STANDARD

SPLIT TYPE).

For standard on-grade expeditionary installation (see Figure 1-1), the tape is reeved from the storage reel around the lead-off sheave in the engine base, and through the fairlead tubing, to the fairlead beam assembly. The tape enters the fairlead beam through the lead-on sheave assembly and is then reeved around the runway edge sheave to the tape con-nector.

1.5 SEMI-PERMANENT INSTALLATION.

The installation at ground level with concrete bases for the engines and runway edge sheave assemblies, is designated as a semi-permanent installation (see Figure 1-2). Reeving of the tape is from the storage reel, around the lead-off sheave in the engine base, and through the fairlead tube to the run-way edge sheave assembly. The tape enters the runway edge sheave assembly through a vertical slot in the back and is then reeved around the runway edge sheaves to the tape con-nector. The use of fairlead beams in lieu of runway edge sheave assemblies in an alternate arrangement (see Figure 1-3). This unit is then reeved in the same manner as the split type expeditionary installation.

1-1

Ta bl e 1-

1.

E ne rg y A bs or be rs an d

A cc es so ri es

U ti liz ed

It em

-W

-1 w ith Pa ck et te R ew in d E ng in e (6 in ch R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-2

1-w ith

W is co ns in R ew in d E ng in e (6 in ch R ee l)

(1

Pa ck et te

(2

W is co n-si n)

(2

0-

W is co n-si n)

(2

0-

W is co n-si n)

(2

1-

W is co n-si n)

-9

1.

R ew in d E ng in e

D es ig n

C on tin en ta l

G L

U -1

U (P

C

-7

W is co ns in M

V G

4D W is co ns in

M V

G 4D

W is co ns in M

V G

4D W is co ns in

V -4

D

Fi gu re R ef er en ce (R ef er to L is t of R el at e M an ua ls

2.

In st ru m en t Pa ne l

D es ig n

-W

-1

9-

-W

-2

9-

-W

-2

9-

-W

-2

9-

-E

-9

-1

Fi gu re R ef er en ce (R ef er to L is t of R el at e M an ua ls

3.

Sy nc hr on iz in g

D ri ve A rr an ge m en t

D es ig n

N o

N um be r

N o

N um be r

N o

N um be r

N o

N um be r

N o

N um be r

Fi gu re R ef er en ce 1-

1-

1-

1-

1-

4.

H yd ra ul ic

C on tr ol

Sy st em

D es ig n

N o

N um be r

N o

N um be r

N o

N um be r

N o

N um be r

N o

N um be r

Fi gu re R ef er en ce 1-

1-

1-

1-

1-

5.

R ew in d C lu tc h C on tr ol

D es ig n

-W

-1

7-

-W

-2

1-

-W

-2

3-

-W

-2

3-

-W

-2

3-

Fi gu re R ef er en ce

6.

B ra ke

W at er C oo l-in g

Sy st em

D es ig n

-W

-1

7-

-W

-2

1-

-W

-2

3-

-W

-2

3-

N ot

A pp lic ab le Fi gu re

R ef er en ce

1-

1-

N ot

A pp lic ab le

7.

Pu m p

D ri ve Sp ro ck et

D es ig n

2-

A -7

-1

2- A

-7

-1

R ep la ce d by st ra ig ht sp ro ck et

R ep la ce d by st ra ig ht sp ro ck et

R ep la ce d by st ra ig ht sp ro ck et

Fi gu re R ef er en ce Fi gu re

1-

8.

Fa ir le ad B ea m

A ss y

D es ig n

-W

-1

7-

-W

-1

7-

-W

-2

5-

-W

-2

5-

-W

-2

5-

Fi gu re

R ef er en ce

1-th ro ug h

1-

1-th ro ug h

1-

1-th ro ug h

1-

1-th ro ug h

1-

1-th ro ug h

1-

9.

E le ct ri ca l Sy st em

D es ig n

-W

-1

-D -5

-D -5

-D -5

-D -5

Fi gu re

R ef er en ce

1-

1-2 e 1-

1.

E ne rg y A bs or be rs an d

A cc es so ri es

U ti liz ed

C on ti nu ed

It em

-W

-1 w ith Pa ck et te R ew in d E ng in e (6 in ch R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-W

-2 w ith W is co ns in

R ew in d

E ng in e

(6 in ch

R ee l)

-2

1-w ith

W is co ns in R ew in d E ng in e (6 in ch R ee l)

(1

Pa ck et te

(2

W is co n-si n)

(2

0-

W is co n-si n)

(2

0-

W is co n-si n)

(2

1-

W is co n-si n)

-9

R ew in d

D ri ve D es ig n

-W -1

5-

-W -2

-W

-2

8-

-W

-2

8-

-W

-2

8-

Fi gu re R ef er en ce

R ep la ce d by m od el

-W

-2

1-at ov er ha ul

T hi s te rm is us ed th ro ug ho ut th e m an ua l to id en tif y a pa rt ic ul ar ar re st in g en gi ne de si gn

* Se e C ha pt er

D iff er en ce of

D at a Sh ee ts fo r

-W

-2

1-

C on fig ur at io n.

1-3

1.6 CONCRETE PIT PERMANENT INSTALLATION.

The installation of the energy absorber in a concrete pit be-low the ground surface is…