Technical Manual - Overhaul Instructions_MAAS.pdf

TO 35E8-2-10-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

DEPOT LEVELS

ARRESTING SYSTEM, AIRCRAFT, MOBILE

MODEL NO. A/M 32A-96

PN 52-D-8013-101

ADVANCED DEVELOPMENT AND ENGINEERING CENTER (ADEC)

FSCM 21439

F33657-85-C-0092

This manual supersedes TO 35E8-2-10-3 dated 10 September 1996, Change 4 dated 7 April 2013.

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) (10 September 1986). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning 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 SEPTEMBER 2019

Dates of issue for original and changed pages are:

Original. . . . . . . .0 . . .17 September 2019

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 64, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - v vi Blank vii - ix x Blank xi xii Blank 1-1 - 1-3 1-4 Blank 2-1 2-2 Blank 3-1 - 3-16 4-1 - 4-2 5-1 - 5-4 6-1 - 6-9 6-10 Blank 7-1 - 7-5 7-6 Blank 8-1 - 8-3 8-4 Blank A-1 - A-2

TO 35E8-2-10-3

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 USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi

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

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1.1 Item Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.1.2 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 CONSUMABLE MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.3 MAIN FEATURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.1 Energy Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.2 Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3 Trailer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3.1 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3.2 Coolant Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3.3 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3.4 Emergency Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3.3.5 Parking Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3.3.6 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3.3.7 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3.3.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

2 SPECIAL TOOLS AND TEST EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 SPECIAL SERVICE TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1.1 Special Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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

3.1 ENERGY ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 HYDRAULIC POWER UNIT (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1 Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1.1 Hydraulic Reservoir Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1.2 Oil Filler Cap and Air Filter Unit Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1.3 Hydraulic Oil Filter/Suction Gauge Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.4 High Temperature Ignition Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.6 Two-Way Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1.7 Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.2 HPU Hydraulics Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.3 Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.3 TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.1 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.1.1 Trailer Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.1.2 Trailer Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.3.2 Hydraulic Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.3.3 Coolant Reservoir Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.3.4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 i

3.3.4.1 Service Brake Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3.3.4.2 Emergency Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.3.4.3 Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3.3.5 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.3.5.1 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3.3.5.2 Rear Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.3.6 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

3.3.6.1 Front Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3.3.6.2 Rear Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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

4.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 SPECIAL CLEANING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.1 Bearings (Wheels and Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.2 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 TOUCH UP PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3.1 Polyurethane Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3.2 Enamel Paint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5 INSPECTION, REPAIR, AND REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

5.2 BAK-12 ENERGY ABSORBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3 HYDRAULIC POWER UNIT (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1 Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1.1 Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1.2 Oil Filler Cap and Air Filter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1.3 Hydraulic Oil Filter/Suction Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1.4 High Temperature Ignition Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.3.1.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.1.6 Two-Way Valve (Gas Shutoff Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.1.7 Hydraulic Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.2 HPU Hydraulics Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3.3 Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.1 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.2 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.3 Coolant Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.4.1 Service Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.4.2 Bearing Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4.4.3 Brake Drum Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.4.4 Wheel Cylinders (Service Brakes). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.4.5 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.5.1 Front Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.5.2 Rear Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.6 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4.7 Item Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

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

6.1 ENERGY ABSORBER (BAK-12) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Hydraulic Power Unit (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1 Miscellaneous Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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TABLE OF CONTENTS - CONTINUED

ii

6.2.1.1 Hydraulic Reservoir Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1.2 Oil Filler Cap and Air Filter Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1.3 Hydraulic Oil Filter/Suction Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1.4 High Temperature Ignition Cutout Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2.1.5 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1.6 Two-Way Valve (Gas Shutoff Valve) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1.7 Diverter Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.2 HPU Hydraulics Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.3 Kohler Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3.1 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3.1.1 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3.1.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.2 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.3 Coolant Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.4 Service Brake Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6.3.4.1 Cable Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.5 Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.6 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.6.1 Front Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6.3.6.2 Rear Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

7 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 ENERGY ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 HYDRAULIC POWER UNIT (HPU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3 TRAILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.1 Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.2 Coolant Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.3 Service Brakes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.3.1 Service Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.3.2 Service Brakes (Bleeding) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.3.3.3 Final Cheek. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3.4 Emergency Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3.5 Parking Brake Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7.3.5.1 Adjustment (After Cable Replacement) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3.6 Winch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3.7 Axle Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

7.3.8 Hydraulic Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

8 TABLE OF LIMITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.2 LIMITING VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.3 LUBRICATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.4 FIT OF NEW AND OVERSIZE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.5 FIT OF INSERTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.6 DISPOSITION OF REJECTED PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

8.7 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2

APPENDIX A ITEM UNIQUE IDENTIFICATION (IUID) SUPPORTING INFORMATION . . . . . . . . . A-1

A.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

TO 35E8-2-10-3

iii

A.2 APPLICATION OF IUID LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

TO 35E8-2-10-3

iv

LIST OF ILLUSTRATIONS

Number PageTitle

3-1 Hydraulic Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-2 Sheave Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 3-3 Sheave Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 3-4 MAAS Trailer Wheel Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 3-5 Wheel Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 3-6 Trailer/Body Axle Support Frame Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 3-7 Rear/Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 3-8 Hydraulic Cylinder Port Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 3-9 Hydraulic Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 6-1 Coolant Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6-2 Piston Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 7-1 Manual Operation of Surge Actuator (Brake System Bleeding) . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 A-1 IUID Identifier, PN 52D6299-1 (Not to Scale) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

LIST OF TABLES

Number PageTitle

1-1 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 Consumable Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 2-1 Special Service Tools and Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2 Special Service Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 7-1 Troubleshooting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5 8-1 Trailer Table of Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 8-2 Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 8-3 Tightening Torques (Hexagonal Head and Socket Head Cap Screws - Cadmium Plates) . . . . . . . . . 8-3 8-4 Tightening Torques (Nut-Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 A-1 IUID Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 v/(vi blank)

INTRODUCTION

1 PURPOSE.

This Technical Order (TO) contains overhaul instructions for Arresting System, Aircraft, Mobile, A/M 32A-96 manufactured by Advanced Development and Engineering Center (ADEC). For Illustrated Parts Breakdown refer to TO 35E8-2-10-4.

2 SCOPE.

The instructions provided are depot level procedures which include disassembly, cleaning, inspection, repair, assembly, and test for the components affected by this TO. BAK-12 energy absorbers are repair coded for depot level repair (T) and will be removed and forwarded to depot/contractor facilities in accordance with TO 35E8-2-5-3 as directed. Other items coded “T” will be handled similarly. This manual consist of the following chapters:

Chapter 1 General Information Chapter 2 Special Tools and Test Equipment Chapter 3 Disassembly Chapter 4 Cleaning Chapter 5 Inspection, Repair, and Replacement Chapter 6 Assembly Chapter 7 Testing Chapter 8 Table of Limits

3 COMMON PROCEDURES.

Common procedures not included in this TO should be accomplished by the appropriate general technical orders, standards, and specifications such as TO 11N-35-51, MIL-STD-2073-1, and MIL-STD-129D.

4 TERMS.

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

1. Front of Mobile Aircraft Arresting System (MAAS) unit: end to which the trailer tow bar is attached.

2. Rear of MAAS unit: end from which the tape issues.

3. Hydraulic side: that side having the BAK-12 hydraulic stand, instrument panel, etc.

4. Rewind side: that side having the BAK-12 rewind chain/sprocket, the gear reducer, fluid coupling, etc.

5. Right side: on observer’s right when standing on the runway approach end, facing down the runway.

In addition to the above, Chapter 5 contains other special terms (which are used during inspections). Definition of those terms are contained in Chapter 5. (See Paragraph 5.4.)

5 ABBREVIATIONS.

All abbreviations used in this manual are shown in the list of abbreviations below. Standard abbreviations are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents.

°F Degrees Fahrenheit ADEC Advanced Development and Engineering Center AF Air Force AFTO Air Force Technical Order AR As Required CD Compact Disk vii

DLA Defense Logistics Agency DoD Department of Defense ESDS Electrostatic Discharge Sensitive ETIMS Enhanced Technical Information Management System GPM Gallons Per Minute HCI Hardness Critical Items HPU Hydraulic Power Unit IUID Item Unique Identification MAAS Mobile Aircraft Arresting System MPH Miles Per Hour PN Part Number PSI Pound-force per Square, Inch RPM Revolution Per Minute TCTO Time Compliance Technical Order TO Technical Order TOMA Technical Order Management Agency UID Unique Identification UNC Unified Coarse UPA Units Per Assembly

6 RELATED PUBLICATIONS.

NOTE

When searching Technical Order (TO) numbers in the Enhanced Technical Information Management System (ETIMS) catalog, please use the wildcard (*) after typing in the TO number. Many TOs are not available in paper format, (i.e., digital (WA-1) or Compact Disk (CD-1)). This ensures TOs in all media formats will populate the search.

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 DODI 5330.03_AFI 33-395 Defense Logistics Agency (DLA) Document Services TO 00-5-1 AF Technical Order System TO 00-25-234 General Shop Practice Requirements for the Repair, Maintenance, and Test of Electri-cal Equipment TO 00-25-260 Methods and Procedures for Asset Marking and Tracking Item Unique Identification

(IUID) Marking Procedures TO 1-1A-15 General Maintenance Instructions for Support Equipment TO 11N3551 General Instructions Applicable to Nuclear Weapons, IAW AFI 21204 TO 35E8-2-10-1 Operation and Maintenance Instructions, Arresting System, Aircraft, Mobile, A/M

32A-96 TO 35E8-2-10-4 Illustrated Parts Breakdown, Arresting System, Aircraft, Mobile, A/M 32 A-96 TO 35E8-2-5-3 Technical Manual Overhaul Instructions, Aircraft Arresting Barrier TO 36C36-11-3 Repair Manual - Power Unit (Wacker) TO 38G2-120-11 Operation and Service Manual - Single Cylinder Engine (Kohler) TO 42C-1-20 Air Force Maintenance Operations, Chemical Cleaning MIL-HDBK-808 Finish, Protective and Codes for Finishing Schemes for Ground and Ground Support and Equipment MIL-STD-129 Military Marking for Shipment and Storage MIL-STD-2073-1 Methods of Preservation viii

7 RECORD OF APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS (TCTOS).

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

None

8 HARDNESS CRITICAL ITEMS (HCI).

The HCI symbol ( ) establishes special requirements limiting changes and substitutions and that the specific parts listed must be used to ensure hardness is not degraded.

If included, items with nuclear survivability requirements are marked with the HCI symbol ( ). All changes to, or proposed substitutions of, HCIs must be approved by the acquiring activity.

9 ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) ITEMS.

All ESDS parts shall be handled in accordance with the ESDS device handling procedures in TO 00-25-234.

If included, items containing ESDS parts are marked with the ESDS symbol ( ).

10 CHANGE RECOMMENDATIONS.

Recommendations proposing changes to this technical order shall be submitted through the Enhanced Technical Information Management System (ETIMS). Refer to TO 00-5-1.

ix/(x blank)

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, CAUTIONs, and NOTEs included in that task shall be reviewed and under-stood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, condi-tions, or statements which are considered essential to protection of personnel (WARNING) or equipment (CAUTION).

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. Failure to comply could result in injury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

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

xi/(xii blank)

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL.

This chapter contains brief descriptions of the major components of Mobile Aircraft Arresting System (MAAS) A/M 32A- 96, along with the leading particulars of the system. This Technical Order (TO) is intended to provide overhaul instructions for those items of equipment not included in other manuals and to interface assembly/disassembly instructions and checkout of the systems after overhaul.

1.1.1 Item Description. The arresting system is a rotary friction-type energy absorber consisting of identical units in-stalled on each side of the runway. It is designed around special nylon tape which is used as the purchase or drive member.

1.1.2 Leading Particulars. Leading particulars, capabilities, and limitations of this arresting system are shown in Table 1-1.

Table 1-1. Leading Particulars

Item Characteristics Gross Weight per Trailer 17,700 pounds maximum (configuration for air shipment) with 65 gal-lon water MAAS Unit Dimensions:

Length 20 feet -11 inches Width 8 feet Height RAISED 7 feet 8 inches

LOWERED 6 feet 8 inches Energy absorber 40 x 106 foot-pounds Aircraft weight (nominal) 40,000 pounds Aircraft runout (nominal) 990 feet Aircraft weight/runout selection method Fixed cam Ambient temperature operating range -40 Degrees Fahrenheit (°F) to +125 °F Maximum allowable engaging velocity 150 kiloton Rewind system type Gasoline engine (Wisconsin)

Fuel -ASTM D4814 or ASTM D910 Lubricant MIL-L-2104 grade 30

Hydraulic fluid MIL-PRF-87257 or MIL-H-83282 Capacity (Energy Absorber) 4-1/2 gallons (per side)

Coolant, brakes Water coolant Capacity 65 gallons. (total per side)

Rewind time (990 feet runout) 106 seconds Purchase tape ultimate strength 105,000 pounds minimum Purchase tape construction 8-1/2 x .225 inches nylon Runway hook cable construction 1-1/4 inches diameter (12 x 6)/(6 x 30) nonrotating wire rope Runway hook cable length 90 feet service and 153 feet spare Engagement direction Unidirectional

1.2 CONSUMABLE MATERIALS.

The only consumable hardware designed into the system are the anchor nuts used with the bolts for the concrete anchor system. Twenty-four nuts are consumed on each concrete installation. (An additional box of 20 is supplied on each mobile unit providing 40 spares per system.) Other consumables depend on operating conditions. The items most susceptible to

1-1 damage, wear or consumption are listed in Table 1-2.

Table 1-2. Consumable Materials

Nomenclature/Material Specification/Government Standard Number

(No.) Part No.

10 Grade Oil MIL-L-2104 30 or 50 Grade Oil MIL-L-2104 90 Grade Oil SAE J2360 Sub-Zero Grade Oil MIL-PRF-46167 Grease MIL-G-81322 Mobile Gargoyle BRB Drycleaning Solvent MIL-PRF-680 Type II or III Epoxy Primer MIL-P-23377, Type I, Class 2 Water Borne Epoxy Primer MIL-P-85582, Type I, Class 2 Polyurethane Top Coat MIL-PRF-85285 or MIL-C-85285 In Accordance with MIL-HDBK-808 Organic Zinc Primer MIL-P-26915 Hydraulic Fluid MIL-PRF-87257 or MIL-H-83282 Silicon Base Brake Fluid MIL-B-46176 Aqueous Cleaner MIL-C-87937

1.3 MAIN FEATURES.

1.3.1 Energy Absorber. The energy absorber is a BAK-12 aircraft arresting barrier with a friction brake absorber.

Overhaul of the BAK-12 is covered in TO 35E8-2-5-3.

1.3.2 Hydraulic Power Unit (HPU). The HPU is a portable unit contained within a tubular steel frame. The HPU is equipped with wheels which allow it to be rolled about when it is removed from its stowed position on the Mobile Aircraft Arresting System (MAAS). There is one HPU stowed on each side of a MAAS trailer, i.e. four HPU’s per MAAS system.

The HPU is equipped with a gear-type hydraulic pump rated at 3,000 Pound-force per Square, Inch (PSI) with a 4 Gallons Per Minute (GPM) flow rate at 2,550 Revolution Per Minute (RPM). The HPU is equipped with a diverter valve which allows selection of either of the units two operating modes: breaker or ancillary. In the breaker mode, hydraulic power is supplied to the 50 ft long transmission hoses. These hoses consist of one high pressure (input) and one low pressure (return) hose and weigh approximately 45 pounds.

1.3.3 Trailer.

1.3.3.1 Sheaves. The sheaves are located within the trailer body so that a positive wrap is achieved by the tape, thus creating a reliable tracking system for the tape during payout.

1.3.3.2 Coolant Reservoir. If utilized the optional external portable coolant bladder increases water capacity to 100 gallons. The portable bladder is a fully self-supporting pillow style tank, constructed of a light weight durable nylon reinforced urethane. It is equipped with a filler neck and cap, outlet connection tube, weighing less than three pounds with a nominal size of 50” x 46” x 12” when completely full. It is highly resistant to W and ozone factors, with a life expectancy in excess of 10 years. Operation of the onboard coolant pump and its components remains the same when the portable bladder is utilized.

1.3.3.3 Service Brakes. During deceleration of the tow vehicle, the 20,000 pounds rated surge actuator, which consists of a master cylinder and a built-in reservoir, develops pressure which is applied to a preloaded coil spring inside the housing.

The preload in the spring serves as a “hold-off” to prevent braking snubs which could be caused by uneven road surfaces.

The deceleration forces of the tow vehicle transmit a compressive force to the actuator mechanism. When this force exceeds the resistant force of the “hold-off” spring, the compressive stroke initiates the application of the four hydraulic wheel brakes.

1.3.3.4 Emergency Brake System. An emergency breakaway lever with a cable and fasteners for attachment to the towing vehicle is provided. In the event of accidental vehicle separation, the cable puts the lever forward causing the hydraulic brakes to be applied to stop the MAAS.

1-2

1.3.3.5 Parking Brake System. The parking brake feature of the rear wheel brakes is actuated by a single lever via steel cables.

1.3.3.6 Winch. The hydraulic cable winch, employed to load the MAAS onto an aircraft, is powered by the hydraulic power unit via the 50 feet transmission hoses. The winch system is comprised of four major parts: the winch, the cable, the manual four-way valve, and the hoist hook.

1.3.3.7 Axle Assemblies.

1.3.3.7.1 Front Axle Assembly. (Figure 3-4). Suspended from the front axle support frame by two leaf spring sets is a steerable front axle, rated at 10,000 pounds at 55 Miles Per Hour (MPH). Located at each end are left and right handed yokes respectively, to which hydraulic, 15 x 3 shoe-type, service brakes are mounted. Each yoke is connected to the tongue by a. tie rod assembly, and the tongue is centered on the axle, with a pivot bolt set. Mounted directly to the axle and behind the tongue are two axle stop assemblies, which are set to provide a maximum cramp angle of 40 degrees. Attached to the tongue is the tow bar, which has a surge actuator assembly. The surge actuator provides the self-contained hydraulic braking for the trailer. Also mounted to the tow bar is a double lock-pin swivel jack and mounting bracket. The jack, when not in use to support the tow bar, or when the trailer is being towed, can be swung and locked into a parallel position with the tow bar.

When the jack is in use to support the tow bar, its caster is in contact with the floor or ground, and depending on the condition will roll when the tow bar is pulled right or left for alignment and connection to a tow vehicle. This arrangement is also used when the trailer is being loaded for air shipment. By pulling on either a left or right 8 feet nylon guide strap, the trailer can be kept in a straight line to facilitate aircraft loading and eliminate the need for personnel to be directly behind the trailer while on the aircraft ramp. Tow point connection is a standard 3 inches lunette eye.

1.3.3.7.2 Rear Axle Assembly. (Figure 3-4). The rear axle assembly is a fixed weldment, rated at 12,000 pounds at 55 MPH, and having 15 x 3 hydraulic brakes, and mechanically operated parking brakes at each wheel. The axle is suspended from the rear axle frame by two leaf springs sets.

1.3.3.8 Hydraulic Cylinders. The raise/lower circuit of the trailer is comprised of a front jack, a rear jack, and two manual four-way valves. The front and rear jacks are heavy-duty cylinders rated for a nominal pressure of 3,000 PSI and nonshock capacity of 5,000 PSI. A hydraulic ram cylinder is also used for removal of earth anchor stakes and moil points.

1-3/(1-4 blank)

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2.1 SPECIAL SERVICE TOOLS.

(Table 2-1). Special service tools required for overhaul of the trailer section are listed in the following paragraphs and referenced figures. These tools are not provided with the Mobile Aircraft Arresting System (MAAS).

Table 2-1. Special Service Tools and Test Equipment

Manufacturer Tool/Equip-ment Number (No.) Figure No. Nomenclature Use and Application

Mueller None Jumper Wires (at least 14 ameri-can Wire Gage with “booted” alli-gator clips)

Check for continuity or electrical shorts

8A6

AN/USM-311 None Multimeter Measure electrical system currents and voltages

Mateo None Torque Wrench To apply an accurate amount of torque - and to tighten wheel nutsTWD F600

G.E. None 10,000 pounds Hoist To lift BAK-12 from trailer 1C5602601 Parker None Spanner Wrench Hydraulic cylinder disassembly 0117030000 0110770000 Ametek None Phototachometer Read HPU engine rpm

2.1.1 Special Service Kits. (Table 2-2. The brake bleed kit contains a length of TYGON clear tubing, a hose fitting for attachment to the brake bleed fitting and a wrench to open and close the brake bleed fitting. Air in the fluid can be readily observed in the clear tubing with the fluid being drained into a container at ground level or back into the reservoir. When all air is bled from the system the fluid will appear as a solid red stream in the tube.

Table 2-2. Special Service Kits

Kit/Component No. Figure No. Nomenclature Use and Application 52-C-1247-1 None Brake Bleed Kit Bleeding brakes Consists of:

52-C-1247-2 Open End Wrench 52-C-1247-3 Tubing, Clear 52-C-1247-4 Hose Fitting

2-1/(2-2 blank)

CHAPTER 3

DISASSEMBLY

3.1 ENERGY ABSORBER.

The energy absorber BAK-12 unit is designed to be removed from the trailer body. See Technical Order (TO) 35E8-2-10-1.

3.2 HYDRAULIC POWER UNIT (HPU).

The HPU is divided into three categories: miscellaneous items are covered in the first section, while the hydraulics and the gasoline engine are incorporated in the remaining sections.

3.2.1 Miscellaneous Items. The following procedures should be substituted for/added to those contained in the refer-enced TO’s (Paragraph 3.2.2 and Paragraph 3.2.3).

3.2.1.1 Hydraulic Reservoir Removal. (Figure 3-1)

Hydraulic fluids often contain additives which may affect skin, eyes, and respiratory tract. These additives can be readily absorbed through the skin. Use in a well ventilated area and avoid breathing of vapors. Neoprene gloves and safety goggles/faceshield shall be worn. Keep away from sparks and flames. Failure to comply could result in injury to, or death of, personnel or long term health hazards.

a. Drain hydraulic fluid from reservoir by removing pipe plug at base of tank.

b. Replace pipe plug when tank is empty.

c. Remove coiled hose assembly.

d. Disconnect hydraulic hose connections at base of tank.

e. Remove four hex head cap screws and lock washers to remove reservoir.

3.2.1.2 Oil Filler Cap and Air Filter Unit Removal. (Figure 3-1)

a. Drain hydraulic fluid from reservoir by removing pipe plug at base of tank.

b. Remove six screws connecting top of reservoir with filter unit.

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Figure 3-1. Hydraulic Power Unit

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3.2.1.3 Hydraulic Oil Filter/Suction Gauge Removal. (Figure 3-1)

a. Drain hydraulic fluid from reservoir by removing pipe plug at base of tank.

b. Remove oil filter by loosening by hand. If oil filter is the only piece to be changed, stop here. If entire unit is to be replaced continue with Step c and Step d.

c. Disconnect two hydraulic hose connections and one hydraulic tube connection.

d. Disconnect unit by removing two screws and lock washers through spacer.

3.2.1.4 High Temperature Ignition Cutout Switch. (Figure 3-1)

a. Disconnect electrical connection at switch, located at a bolt on the cylinder head.

b. Loosen bolt on the cylinder head and remove switch.

c. Disconnect electrical connection at condenser.

d. Note which bolt on cylinder head contained switch for assembly.

3.2.1.5 Fuel Filter. (Figure 3-1)

a. Drain gasoline from tank into an approved Safety Container by removing cap nut at tank base.

b. Disconnect fuel filter by loosening hose clamps.

3.2.1.6 Two-Way Valve. (Figure 3-1)

a. Drain gasoline from tank into an approved Safety Container by removing cap nut at tank base.

b. Loosen hose clamps at inlet and outlet of the two-way valve. Disconnect hoses.

c. Remove two-way valve by removing self-tapping hex head bolt at the top of the valve.

d. Remove the 90 degree elbow from the valve.

e. Remove the female connector, and then the female-to-female adapter from the valve body.

f. Retain the elbow and connectors for reassembly.

3.2.1.7 Diverter Valve.

a. Drain hydraulic fluid from reservoir by removing pipe plug at base of tank.

b. Replace pipe plug when tank is empty.

c. Disconnect 50 feet hose assembly and adjoining hardware by removing two Allen head screws.

d. Disconnect diverter valve by removing the remaining two Allen head screws.

3.2.2 HPU Hydraulics Section. The remainder of the hydraulic components are covered in TO 36C36-11-3, Repair Manual - Power Unit (Wacker).

3.2.3 Kohler Engine. Disassembly of the engine for the hydraulic power unit is covered in TO 38G2-120-11, Operation and Service Manual - Single Cylinder Engine (Kohler). Removal of the engine from the HPU is contained in TO 36C36- 11-3, Repair Manual - Power Unit (Wacker).

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3.3 TRAILER.

3.3.1 Sheaves. Refer to Figure 3-2 for sheave locations in the Mobile Aircraft Arresting System (MAAS) unit.

3.3.1.1 Trailer Removal. The following removal procedures are typical for any of the sheave assemblies. Refer to Figure 3-3.

a. Place support blocks under the front of trailer, and then raise the wheels (refer to TO 35E8-2-10-1) to provide access to the top and bottom of the front turnaround sheave. Remove all sheave covers.

b. Remove the winch.

c. Remove two bolts (9) and two lock washers (10).

d. Detach end plate (1) by removing three bolts (11) and three lock washers (10).

e. Remove the shaft (6) from the sheave.

f. With a wood block tap the shaft sleeve (2) out.

g. Remove the phenolic pads by removing the retaining screws.

h. Remove sheave assembly from mount.

3.3.1.2 Trailer Disassembly. All sheaves are disassembled in the following manner (Figure 3-3).

Figure 3-2. Sheave Location

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Exercise care when removing seals. The inner race and bearing cage are retained by the seals and may slide out when the seals are removed.

a. Remove both seals (3) from sheave (5).

b. Remove both inner race and bearing cages from sheave (5).

Leather gloves should be worn when handling cable to guard against possible injury to personnel.

c. With a wood block, tap the outer bearing race from the sheave.

NOTE

The relatively infrequent use of the winch and the anticipated low failure rate of the hydraulic motor and low generation of repairable assets invalidates the effort and expense required to establish tooling, test equipment, training, and manning for overhaul facilities for the hydraulic motor. Overhaul of the winch consists of the following:

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Figure 3-3. Sheave Assembly

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3.3.2 Hydraulic Winch. Winch cable removal.

a. Disengage the dog clutch enclosed in the end housing of the winch.

b. Manually unwind (pull) the cable from the spool.

c. Remove the last wrap of cable from the spool by loosening the set screw which clamps the cable to the spool.

3.3.3 Coolant Reservoir Removal. If the optional portable coolant bladder is utilized the existing trailer mounted reservoir need not be removed from the trailer. Removal of the trailer mounted reservoir can be accomplished during the programmed 10 year overhaul or at such time as the BAK-12 energy absorber is removed from the trailer. For access to the coolant reservoir the energy absorber (BAK-12) must be removed from the trailer body (Paragraph 3.1). To remove the reservoir proceed as follows (Figure 6-1):

NOTE

• When the BAK-12 is in place its coolant pump can be used for this operation. Otherwise use hand pump or other approved means.

• By raising the front axle assembly the tank will slope to drain coolant to stand pipe.

a. Remove as much brake coolant as possible from the reservoir.

b. Remove the hose clamps from stand pipe and disconnect the upper hose.

c. Remove stand pipe from tank assembly.

NOTE

Using a marking pencil, match mark filler and breather unit mounting screws to the trailer body.

d. Remove six screws from filler and breather unit.

e. Push both stand pipe and filler linings below the top of the trailer body.

f. Remove 12 hex head cap screws and washers from the tank straps which secure the tank to trailer body.

g. Compress tank and work free from trailer body.

3.3.4 Brakes.

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3.3.4.1 Service Brake Removal.

NOTE

All brakes, front and back, are the same on the trailer. The rear axle assembly has the parking brake components connected.

a. Lower the trailer (refer to TO 35E8-2-10-1) until the weight is off the tire for removal of the wheel bearing, hub, and brake drum, as outlined below.

(1) Ensure that the parking brake is released (rear wheels).

(2) Using a 5/8 inches wrench, back off the primary and secondary brake shoe adjusters. Adjusters are opposed to each other (Figure 3-4).

(3) Referring to Figure 3-5 remove grease cap (1).

(4) Remove cotter pin (2) from spindle (3).

(5) Loosen the castellated nut (4) and back off until it is flush with the end of the spindle. Do not remove at this time.

NOTE

If the wheel and tire assembly does not move readily, it may be necessary to provide additional clearance between the brake shoes and drum by turning the adjusters.

(6) Pull wheel and tire assembly (5) outwards and then push it back on the spindle. This should leave the outer wheel bearing exposed against the castellated nut and washer.

(7) Remove the castellated nut (4), flat washer (6), and outer wheel…