TM 9-1440-531-12-1 TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL IMPROVED GUIDED MISSILE ZERO-LENGTH LAUNCHER M192E1 GUIDED MISSILE LOADING AND STORAGE PALLET M1E2 AND IMPROVED GUIDED MISSILE LAUNCHING SECTION CONTROL BOX AN/GSA-132A (X0-1) IMPROVED HAWK AIR DEFENSE GUIDED MISSILE SYSTEM This copy is a reprint which includes current pages from Changes 1 through 16. DEPARTMENT OF THE ARMY SEPTEMBER 1972 1 Google co iclo T™ 9—1440—531—12-1 WARNING RADIATION HAZARD ‘This equipment contains the following radioactive items: Nomenclature NSN Teotope Amount (Microcuries) Electron tube 5787WA 5 960-00-272-8545 Co 60 0.20 Refer to TM 3-261, TM 38-250, and TB 43-0116 for information relative to shipping, storage, handling, ‘and disposal of radioactive material. FIRST AID FOR RADIOACTIVE CONTACT ‘The following first aid procedure for wounds caused by anything coated with a radioactive particle material represent the only reasonable first aid treatment which would possibly be available: @. Stimulation of mild bleeding by normal pressure about the wound and by use of suction cups. Do not suck the wound by mouth. The wound must be washed with soap and flushed with plenty of clear water. ®, If the wound is of the puncture type, or the opening is quite small, an incision should be made to pro- mote free bleeding and to facilitate cleaning and flushing of the wound. ¢. Evacuate patient to a medical facility where monitoring of the wound can be accomplished. All such wounds should be examined by a medical officer. d. For wounds involving the extremities, pending medical attention, place a lightly constricting band (tourniquet) 2 to 4 inches closer to the heart than the site of the wound. The band should be tight enough to halt the flow of blood in superficial blood vessels but not tight enough to stop the pulse (arterial flow). CLEANING SURFACES ON WHICH TUBES HAVE BEEN BROKEN Wet Method. Put on rubber or plastic gloves. Pick up large fragments with forceps then, using a wet cloth, wipe across the area. Make one wipe at a time and fold cloth in half, using the clean side for wiping each time. When cloth becomes too small, discard and start again with a clean piece of cloth. Care must be taken not to rub the radioactive particles into the surface being cleaned by using a back and forth motion. All debris and cloths used for cleaning should be sealed in a container such as a plastic bag, heavy waxed paper, ice cream carton, or glass jar for disposal.T™ 9—1440—531—12 c12 WARNING FOR RADIO-FREQUENCY RADIATION HAZARD | (FOR IHAWK SYSTEMS WITH ICWAR AN/MPQ-55) Radio-frequency (rf) radiation from radar antennas and associated equipment is a potential hazard to personnel. Rf radiation is not cumulative but it can be hazardous. It heats the body tissues, and, if the radiation intensity is sufficiently high, will permanently damage the tissue. This damage is not immediately apparent. Precautions should be taken to insure that personnel are not exposed to rf radiations of hazardous intensity levels. Personnel who must be within the hazardous distances for the below listed radars should be instructed not to place themselves on the radiating side of the antenna, and to never look into a transmitting horn or ‘open waveguide which is connected to an energized transmitter. Personnel are prohibited from entering areas where they may be exposed to levels of rf radiation above 10 milliwatts per square centimeter (10 mw/cm?). This level, though not considered hazardous, is stipulated by AR 40-583 as the maximum permissible exposure level for personnel. A power intensity of at least 10 mw/cm? is present along the axis of each radar’s transmitted beam, for the distances listed below. These distances are based on calculations and actual measurements and may be used as a guide to prevent radio-frequency radiation injury. In each instance, radiation intensity rapidly diminishes as the distance is increased. ANTENNA DISTANCE Improved High-powered Illuminator Radar 111.5 m (36 ft) | Improved Cw Acquisition Radar non-scanning 74m (243 ft) scanning 36 m (118 ft) Improved Pulse Acquisition Radar 15.2 m (50 ft) Improved Range-only Radar 45.1 m (148 ft) ‘The 36m distance for the scanning ICWAR antenna does not mean the system constitutes a hazard to person- nel while the antenna is scanning. It means that those systems capable of producing power densities greater than 100 mw/cm? when the antenna is stationary must be controlled out to the 100 mw/cm? distance in the event the antenna should stop scanning. No radiation hazard exists at radar ground level if the radars are not depressed below zero degrees elevation. When at all possible during maintenance, however, place the antenna at a high elevation. Personnel are restricted from the area atop the radars or other elevated locations in front of the antennas when radiating. Personnel may move in and around the ICWAR to zero range at ground level provided they are below the horizontal center line of the antennas. There is no height restriction to either side or rear of the antennas. Potentially hazardous power density levels do not exist in the radiation field of the improved pulse acquisi- tion radar when scanning. ‘The above information is applicable to typical Hawk sites. The services of the U.S. Army Environmental Hygiene Agency are available, in accordance with the provisions of AR 40-583 for the evaluation of po- tential radio-frequency hazards at sites where unusual operating or site conditions may exist. (16 ™ 9—1440—531—12—1 WARNING FOR RADIO-FREQUENCY RADIATION HAZARD (FOR HAWK SYSTEMS WITH CWAR AN/MPQ-48) Radio-frequency (rf) radiation from radar antennas and associated equipment is a potential hazard to personnel. Rf radiation is not cumulative but it can be hazardous. It heats the body tissues, and, if the radiation intensity is sufficiently high, will permanently damage the tissue. This damage is not immediately apparent. Precautions should be taken to insure that personnel are not exposed to rf radiations of hazardous intensity levels. Personnel who must be within the hazardous distances for the below listed radars should be instructed not to place themselves on the radiating side of the antenna, and to never look into a transmitting horn or ‘open waveguide which is connected to an energized transmitter. Personnel are prohibited from entering areas where they may be exposed to levels of rf radiation above 10 milliwatts per square centimeter (10 mw/cm?). This level, though not considered hazardous, is stipulated by AR 40-583 as the maximum permissible exposure level for personnel. A power intensity of at least 10 mw/cm? is present along the axis of each radar’s transmitted beam, for the distances listed below. These distances are based on calculations and actual measurements and may be used as a guide to prevent radio-frequency radiation injury. In each instance, radiation intensity rapidly diminishes as the distance is increased. ANTENNA DISTANCE High-powered Illuminator Radar 111.5 m (366 ft) Cw Acquisition Radar 20.4 m (67 ft) Pulse Acquisition Radar 15.2 m (50 ft) Range-only Radar 45.1 m (148 ft) No radiation hazard exists at radar ground level if the radars are not depressed below zero degrees elevation. When at all possible during maintenance, however, place the antenna at a high elevation. Personnel are restricted from the area atop the radars or other elevated locations in front of the antennas when radiating. NOTE Potentially hazardous power density levels do not exist in the radiation field of the improved pulse and cw acquisition radars when scanning. ‘The above information is applicable to typical HAWK sites. The services of the U.S. Army Environmental Hygiene Agency are available, in accordance with the provisions of AR 40-588 for the evaluation of po- tential radio-frequency hazards at sites where unusual operating or site conditions may exist.O—$31—12—1 cio WARNING DANGEROUS VOLTAGE is used in the operation of this equipment DEATH ON CONTACT may result if personnel fail to observe safety precautions Never work on electronic equipment unless there is another person nearby who is familiar with the opera- tion and hazards of the equipment and who is competent in administering first aid. When the technician is aided by operators, he must warn them about dangerous areas. Whenever possible, the power supply to the equipment must be shut off before beginning work on the equipment. Take particular care to ground every capacitor likely to hold a dangerous potential. When work- ing inside the equipment, after the power has been tured off, always ground every part before touching it. Use extreme caution when operating equipment protected by interlocks. Insure that interlocks (doors, panels, and drawers) are functioning properly. (TM 9-1425—525—12—4) Be careful not to contact high-voltage connections when installing or operating this equipment. Whenever the nature of the operation permits, keep one hand away from the equipment to reduce the hazard of current flowing through the vital organs of the body. WARNING } Do not be misled by the term “low voltage.” Potentials as low as 50 volts may cause death under adverse conditions. For artificial respiration, refer to FM 21—11.cis ™ 9—1440—531—12-1 MECHANICAL HAZARD When performing maintenance procedures in the vicinity of the ILCHR boom, insure that the correct LAUNCHERS SAFE-OPERATE-ALERT switch for the ILCHR to be checked, located on the improved launching section control box, is set to the LAUNCHERS SAFE position. WARNING EXPLOSIVES Intercept-serial miasile MIM-23B-1 and MIM-23B-2 contains explosives. All applicable safety regulations will be strietly enforced, Explosive components containing electrical wiring murt be protected tt all times from tray voltages or indueed electrical currents, Handling operations should not be performed during electrical storms,eu 1440-531—12—1 WARNING SAFETY MEASURES FOR HANDLING HIGH-PRESSURE AIR SYSTEMS 1, Personnel who handle high-pressure aithoses and components shall be thoroughly trained in the use and maintenance of the equipment, and in the application of safety measures to protect against existing hazards. Proper protective equipment shall be worn as required. 2. The system shall be used only for the purpose for which it was originally designed. 3. Inspect. all systems using high-pressure air before, during, and after use for leaks, defective airhoses, im- properly adjusted valves, malfunctioning regulators and relief valves, the presence of foreign materials in the system; and corrosion. Use only the lubricants that are specified for pneumatic components. Oils and greases can explode when compression heat is present. 4. Clear all airhoses and valves at regular intervals. Release pressure through bleeder valves before discon- necting any lines or hoses or making any repairs. 5. When pressurizing a system, personnel operating the valves shall stand clear of hose connections, and shall turn the valves slowly to prevent shock loading or pressure surges which may damage hoses or components. Close valves manually to prevent overtightening; never tighten with a wrench or tool. NOTE Large volume containers at low pressure have sufficient stored energy to cause death or serious injury. 6. Observe the following precautions pertaining to high-pressure airhoses: a. The minimum bending radius for flexible airhoses shall be: 4 inches for 1/4-inch ID hose; 6 inches for 3/8-inch ID hose; 7 inches for 1/2-inch ID hose; 9-1/4 inches for 3/4-inch ID hose. b. Never coat or paint an airhose, because this impairs the normal breathing tendency of the airhose. ¢. Depressurize and protect airhoses from the sun when not in use. d. Do not kink, twist, strike, walk on, run over, jerk, or otherwise abuse airhoses. e. Allow 2 feet of slack for each 100 feet of airhose to compensate for contraction during pressuri- zation, f. Secure high-pressure aithose at 36-inch intervals. Use equipment straps, ground stakes, or sandbags as necessary. &. 1550 PSIG air pressure is used in the operation of this equipment. NOTE For inspection and test of air and other gas compressors, refer to TB 742—93—1.TM 9—1440—$31—12—1 a WARNING SAFETY MEASURES FOR HANDLING HIGH-PRESSURE HYDRAULIC SYSTEMS 1. Personnel who work with or handle high-pressure hydraulic systems or components shall be thoroughly trained in the use and maintenance of the equipment, and in the application of safety measures to protect against existing hazards. Proper protective equipment shall be worn ax required. 2. The system shall be used only for the purpose for which it was originally designed. 3. Inspect all high-pressure hydraulic systems before, during, and after use for leaks, defective connec- tions and lines, improperly adjusted valves, malfunctioning regulators and relief valves, the presence of foreign materials in the system, and corrosion. 4, Release pressure through bleeder valves before disconnecting lines or components or before making any repairs. Whenever the hydraulic system has been disassembled or opened, perform a fill and bleed exercise to ensure that all possible air contamination or entrapment is removed before operating the system. 5. When pressurizing a system, personnel operating the valves shall stand clear of hose connections, and shall turn the valves slowly to prevent damage to equipment. Ciose valves manually: never tighten them with a wrench or a tool. WARNING Hydraulic pressure in excess of 2000 psi is used in the operation of this equipment.TM9—1440—531—12—1 an WARNING DANGEROUS CHEMICALS are used in the operation of this equipment DEATH may result if personnel to observe safety precautions ‘The following is a list of chemicals used in the operation or maintenance of the equipment in this manual, including proper care and handling procedures and corrective actions (fire and first aid procedures). Corrective Actions Use CO: or dry chemical extin- guisher. Tem (NSNZAPR) Butyl alcohol OC 265 (81348) (Care and Handing Prosedaree Extremely flammable; keep away from open flames and sparks. Can ignite under almost all normal tem- perature conditions. Vapors are toxic and can produce symptoms of intoxication and irri- tation of eyes, nose and throat. Avoid contact with skin. Not toxic but may add to the effect of inhalation. Remove to fresh air and give oxygen if short of breath. Get medical attention. Promptly remove soaked clothing and wash skin thoroughly with water. Induce vomiting if victim is con- scious and alert. If victim is not alert, black coffee and activated charcoal may be given. Never give anything by mouth to a person who is unconscious. Get medical atten- tion. Swallowing causes severe nausea, vomiting, abdominal pain, bleeding and central nervous system damage. Insulation varnish Flammable; keep away from heat, | Use CO, or dry chemical extin- ‘MIL-V-173 5970-00-647-8676 | sparks, and open flames. guisher. Avoid contact with eyes. Flush thoroughly with water. Get medical attention. Avoid prolonged or repeated contact | Wash with mild soap and water and with skin. apply skin cream. Excessive inhalation causes drowsi- | Remove victim to fresh air and get ness, headache, dizziness and irri- | medical attention. Apply artificial tation of eyes, nose and throat. Use | respiration if necessary. If swal- with adequate ventilation. lowed, do not induce vomiting.ce WARNING DANGEROUS CHEMICALS Continued TM 9—1440—531—12—1 Tien WA Cad Hanlin Proto Corte Atos Mineral spirits Flammable. Avoid heat, sparks and | Use CO; or dry chemical extin- (8010-00-242-2089) open flames. When heated, may yield | guisher. carbon monoxide. Excessive in- sett; A halation causes headache, dizziness, | Remove victim to fresh air and get and nausea. Use with adequate venti. | ™edical attention. Apply artificial lation respiration if necessary. Avoid prolonged or repeated contact | Wash with mild soap and water and with skin, apply skin cream. Avoid contact with eyes. Flush thoroughly with water. Get medical attention. Toluene OC265 Flammable; keep away from open | Use COz or dry chemical extin- (6810-00-257-2487) flames. guisher. Vapors harmful. Use in well- ventilated area. Avoid prolonged contact with skin. Avoid contact with eyes. Avoid swallowing. Remove to fresh air. Wash thoroughly with water. Flush with water for at least 15 minutes. Get medical attention. Get medical attention immediately. If swallowed, induce vomiting. Do not induce vomiting in an uncon- scious victim.cu ™ 9—1440—531—12—1 DEPARTMENT OF THE ARMY WASHINGTON, D.C., 1 September 1972 OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL GUIDED-MISSILE ZERO-LENGTH LAUNCHER M192 GUIDED-MISSILE LOADING AND STORAGE PALLET XM1E2 AND GUIDED-MISSILE LAUNCHING SECTION CONTROL BOX AN/GSA-132A (HAWK AIR DEFENSE GUIDED MISSILE SYSTEM) TECHNICAL MANUAL \ HEADQUARTERS, No. 9—1440~531—12—1 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Mail your letter or DA Form 2028 (Recommended Changes to Publications and Blank Forms) direct to: Commander, U.S. Army Missile Command, ATTN: DRSMI-SNPM, Redstone Arsenal, Alabama 25898. A reply will be furnished to you. TABLE OF CONTENTS Paragraph Pane CHAPTER 1._ INTRODUCTION Section General. M IL LOHR description and data .. 12a IIL. LSCB and guided-miasile pallet description and data .. 15 CHAPTER 2 OPERATING INSTRUCTIONS Section 1. Controls and indicators . 24 IL. Operation under usual eo 214 TIL Operation under unusual co 2141 IV. Missile handling. RAT CHAPTER 3. PERIODIC CHECKS AND ADJUSTMENTS Section __I._ Preventive maintenance services. a4 IL. Operational checks. 34.1 TI. HAWK aystem silent mode redeployment checks 3:16, 9.17 3.38 TV. Adjustment illustrations. : 318 338 CHAPTER 4. MAINTENANCE INSTRUCTIONS, Section _L._Repair parts, and special tools and equipment. 41 IL, Service upon receipt - general... a1 TIL Service upon receipt of major item... a2 IV. Lubrication... 47 V. Maintenance servic 47 CHAPTER 5. CORRECTIVE MAINTENANCE Section I. _ General practices for replacement procedures. IL. , Corrective muintenance of the base. IIL. “ Corrective maintenance of the boom. IV. Corrective maintenance of the boom... 'V. Corrective maintenance of additional unit™ 9—1440—531—12—1 cs CHAPTER 6, PREPARATION FOR TRAVEL. Section 1. Genera. 61 IL, Methods of transportat @1 IIL, Preparation for travel for guided-missile Jauncher M192E1 6s IV. Preparation for trave control box AN/GSA1324 .. . ez V. Preparation fr travel for guided: loading and storage pallet MIEB wren a 63 CHAPTER 7. EMPLACEMENT PROCEDURES Sec 1. General TA, nm Il, Emplacement of guided -missile launcher MIS2E1 Ta 18 ” IIL Emplacement of ‘ruided-miasl le loading and storage pallet MIEZ......... teeter 77-710 16 IV. Emplacement of launching section control box. ‘AN/GSA.132A. : TUT 10 CHAPTER 8 ORIENTING AND ALINING Section _1._ Orientation and alinement of the LCHR, 81-87 a1 TE Azimuth mil ing . — se-s10 0 86 LIGHTNING PROTECTION... 91-9. 1 APPENDIX A. REFERENCES. ..o.cous aL B. MAINTENANCE ALLOCATION CHART oes BA ©. NOMENCLATURE AND REFERENCE DESIGNATIONS .. evsnseene CAL D. SERIAL NUMBER EFFECTIVITY CODE Da E. BASIC ISSUE ITEMS LIST ... El F, MINOR ALTERATIONS . Fa Index 1ce TM 9—1440—531—12—1 CHAPTER 1 INTRODUCTION Section L GENERAL 1-1, Scope @ This technical manual (TM) is published for use by organizational maintenance personnel responsible for maintaining guided-missile zero-length launcher ‘M192E1 (LCHR), guided-missile loading and storage pallet and guided-missile launching section control box AN/GSA-182 (XO-1) (LSCB). b. This TM is one of a series of TM’s on operation, assembly and emplacement, organizational mainte- nance, direct and general support maintenance, and depot maintenance of the HAWK air defense guided missile system. ¢ The requirement for nomenclature distinction between “Basic and Improved” HAWK Systems and major items is no longer applicable. Action to delete this distinctive terminology will be taken as the re- spective pages of this manual are changed for other reasons. 1-1.1. Destruction of Materiel to Prevent Enemy Use Destruction of materiel to prevent enemy use will be undertaken by the user upon order of the unit commander. His decision will be based upon orders and policies established by the Army Commander. Procedures for destruction of the LCHR and related materiel are contained in TM 43—-0002—24. 1.2. Travel Preparation, Emplacement, Aline- ment, and Lightning Protection Complete instructions for preparation for travel, emplacement, orientation and alinement, and lightning protection for the LCHR, the guided missile pallet, and the LSCB, are con- tained in chapters 6 through 9. 1-3. Organizational Maintenance Allocation ‘The prescribed organizational maintenance re- sponsibilities will apply as reflected in the main- tenance allocation chart in appendix B. In all cases where the nature of the repair, modification, or adjustment is beyond the scope of the operator or organizational maintenance technician, direct sup- port maintenance units with more specialized tools and equipment are available. 1-4, Forms, Records, and Reports For the forms, records, and reports required of units maintaining this equipment, refer to TM 38-750. 14.1, Reporting Equipment Improvement Recommendations (EIR’S) If your HAWK equipment needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don’t like about your equipment. Let us know why you don’t like the design or performance. Put it on an SF 368 (Quality Deficiency Report). Instructions for preparing EIR’s are provided in TM 38-750, The Army Maintenance Management System (TAMMS). EIR’s should be mailed directly to Commander, US Army Missile Command, ATTN: DRSMI-SNEM, Redstone Arse- nal, Alabama 35898. A reply will be sent directly to you. 1-5. Differences Among Models Differences among models that exist in this equipment are indicated in the text and on di grams by the use of the serial number effectivity code. This code is given in appendix D. 1-6. Modification Work Orders Table 1-1 lists all modification work orders (MWO's) affecting the LCHR, the LSCB, and the guided missile loading and storage pallet. NOTE ‘MWO's are listed in this manual for infor- mation only. This manual is not an authority for requisitioning kits. The published MWO, or ‘a change thereto, is the only authority for requisitioning MWO kits. VtT™ 9—1440—$31—12—| 1-7. Hand Receipt Hand receipts for Components of End Item cn jutant General Publication Center, ATTN: AGDL- (COEI), Basic Issue Items (BII), and Additional Authorization List (AAL) items are published in Hand Receipt manuals TM 9-1425~525—10-HR and TM 9-1425—-1525—-10-HR. These manuals are published to aid in property accountability and are available through: Commander, U.S. Army Ad- OD, 1655 Woodson Road, St. Louis, MO 63114. NOTE MWO's are listed in this manual for information, only. This manual is not an authority for requisitioning kits. The published MWO, or = change thereto, is the only authority for requisition ing MWO kits. Table 1-1. Modification Work Orders wo Deteription [ sttecty 9-1425-525-50-1 9-1440-631-30-1 9-1440-531-30-2 9-1440-581-30-3 9-1440-531-50-4 9-1440-531-50-5 9-1440-831-50-6 9-1440-631-50—7 9-1440-531—50-8 9-1440-531—50-9 9-1440-581—50-10 9-140-531-5011 9-1440-831-50-12 9-1440-531-50-13 9-1440-531—50-14 9-1440-531-50-15 Replaces transistor voltage regulator with 1a zener voltage regulator. ‘Changes relay leads in the relay assembly to correct loading of head follow-up circuits. Replaces switch 82 located on the front Panel of compensation group 10672667. ‘Adds a discharge valve warning note to the flow control box cover. Installs new missile anchoring stud on all ‘missile storage and loading pallets. ‘Adds warning decal to the boom. Replaces headset 10673293 with 10288628. ‘Adds filter to time meter circuits in base distribution box. Replaces CB1 in base distribution box. Replaces lamp lens on the improved Inunching section control box. Redesign of missile retaining stud to re- duce overall height. ‘Adds drain hole to each aft outrigger. Replaces switches S4, 85, $6 on front panel of the improved launching sec- tion control box. ‘Adds relay K7 in base distribution box. ‘Adda drain plug in aft compartment of Inuncher chassis. ‘Adds test jacks J7 and J8 to azimuth control amplifier and elevation con- tol amplifier. ILCHR's with serial numbers 300001 through ‘340024. ILCHR's with serial numbers 275001 through 340000. ILCHR's with serial numbers 275001 through ‘340000. ILCHR's with serial numbers 275001 through 340000. Mimile loading and storage pallets with serial ‘numbers 275001 through 300001. ILCHR’s with serial numbers 275001 through 340000. ILCHR's with serial numbers 275001 through 340143, ILCHR's with serial numbers 275001 through ‘380000. ILCHR’s with serial numbers 275001 through 380000. Improved launching section control boxes with serial numbers 275001 through 380000. ILCHR's with serial numbers 275001 through 380000. ILCHR's with serial numbers 275001 through ‘380000. Improved launching section control boxes with serial numbers 275001 through 430000. ILCHR's with serial numbers 275001 through 400444. ILCHR's with serial numbers 275001 through 276021, 300001 through 300080, 340001 through’ 340143, 380001 through 380265, 400253 through 400444, and 430116 through 430166, Demeter eee] ascot acz Table 1-1. Modification Work Orders — Continued TH 9—1440—531—12—1 wo Description Ettectivity 9-1440—-581—50—16 9-1440—581—50—17 9-1440—581—50—18, 9-1440-531-50-19 Intercom station mounting relocation. Provides field launchers with improved ‘boom shock absorbers. Improves the serviceability of the threaded bushing and reduces the shear pin eyele. Provides additional storage facilities in the boom aupport storage case for for- ILCHR's with 560308, ILCHR's 520423. ILCHR's 520423, with with ILCHR's with 570224. serial serial serial serial numbers 275001 through numbers 275001 through numbers 275001 through numbers 275001 through ‘ward sector spare parts. 9-2300-269-20 pallet to the truck, Provides procedures for loading the Section I. ILCHR DESCRIPTION AND DATA ion NOTE ‘The key numbers shown below in parentheses refer to figure 1-1. 1-8. Physical Descri ‘The ILCHR consists of the zero-length launcher mounted on a trailer base. The major assemblies of the ILCHR are the trailer base (8), the boom (2), and the boom support (3). @, The trailer base assembly consists of the trailer with its leveling system, components of the hydraulic system, and a major portion of the ILCHR electronic equipment. Do not load basic HAWK missiles on the ILCHR. b. The boom supports three improved HAWK missiles. It also contains a thermostatically oper- ated hydraulic fluid heat exchanger. ¢. The boom support contains the boom posi- tioning hydraulic system and a slipring assembly which routes signals between the ILCHR base and the boom. The boom support (hatch) may be raised as shown in figure 1-2 to provide access to the boom hydraulic and electrical components. 1-21Google‘TH 9—1440—531—12—-1 Hydraulic fuld leakage plugs 3-Boom 3-Boom support 4-Ait intake cover ‘5-Lett front leveling cylinder (Support ‘7—Right front leveling cylinder ‘8 Trailer base ‘Umbilical covers 10-Boom saubber (shock absorber) receptacle 15—FIRE UNIT JUNCTION BOX receptacle 16-LOCAL CONTROL 17—Rear leveling cylinder 18—Mounting bracket (launcher control) ‘Figure 1-1. ILCHR ~ assemblies.TM 9—1440—531—12—1 1-Azimuth distribution box ‘2-Elevation cylinder 3—Hydraulic reservoir 4-Hydraulic hatch-raising cylinder 6—Hydraulic fluid leakage indication vial @—Hydraulic pump and motor assembly ‘7-Handnut 8-Hatch support aafety rod 9-Azimuth drive gear 10—Azimuth ring gear Figure 1-2, Hatch raised. 1-9. Functional Description ‘The ILCHR supports and aims from one to three missiles for firing after receiving commands from the improved battery control central (IBCC) and positioning information from the improved high- powered illuminator radar (IHIPIR). After IHIPIR lock is obtained and the FIRE button pressed, the selected ready ILCHR slews to the same azimuth and elevation as the IHIPIR an- tenna. Just before missile launch, the ILCHR repositions to give the missile both superelevation and lead angle and, if necessary, shoot-around or shoot-over corrections. For maintenance and mis- sile loading, the ILCHR can be controlled locally from the launcher control unit (LCU). 1-10, Data Data for the ILCHR is given in table 1-2. Oper- ating data for the ILCHR is provided in TM 9-1425-525. 4 Table 1-2, ILCHR Data Minimum Firing limite Asimuth travel Azimuth fire cutouts Towing speed: Highway 62 to ~82 mils 190-210 to 1280-1250 mila (6400 mils “ in. 900 x 20 60 pei 25 pei 185 kva, 416 vae, 400 Hs 10 degrees 2.90 gal. ‘Not leas than 2400 pei 1350 to 1750 pei 1.62 gal. Hand operation M35/M36—2-1/2-ton ‘truck 50 mph 25 mphSection II 1-11. ILSCB Physical Description The ILSCB (fig. 1-3) is a rectangular metal case mounted on four permanently attached feet. When emplaced and functioning, the ILSCB is, connected between the three ILCHR’s and the IHIPIR with electrical cables. The ILSCB has toggle switches, a communications module, and indicator lamps mounted on the control panel. A compartment for storing the communications station headset and a safety-and-arming (s&a) test set is provided. 1-12. ILSCB Functional Description The ILSCB, under normal operating conditions, receives and distributes command signals from the IBCC and the IHIPIR to all three ILCHR’s. During maintenance or missile loading, the ILSCB isolates control of the ILCHR from the IBC. Data for the ILSCB is given in table 1-3. 1—Cover asembly 4-Case amembly ‘2-Preasure equalizer screw 5—Handles ‘3-Cable connectors €-Snap fasteners Figure 1-3, ISCB ~osemblies TM 9—1440-531-12—1 ILSCB AND GUIDED-MISSILE PALLET DESCRIPTION AND DATA Table 1-3. ILSCB Data Weight & FES seme 1-13, ee Pallet Description (Fig. 1-4 The loading and storage pallet is normally mounted on eithe: trailer XM390C or truck M35 or M36, but may be removed. When dismounted, it can be lifted and transported by the loader, and can be helicopter-lifted with missiles on it. Data for the pallet is given in table 1-4. 2-Missile latch Qui 5—Missile anchoring amembly @-Adapter 7—Quick release pin 8-Skid 2-Quick-release pin 10—Index fitting assembly Figure 1-4. Guided missile loading and storage pallet. Table 1-6. Loading and Storage Pallet DataC 200gle‘TM 9—1440-531—12-1 cz CHAPTER 2 OPERATING INSTRUCTIONS Section L CONTROLS AND INDICATORS 2-1. General 2-2. Controls and Indicators ‘This section describes, locates, and illustrates the The controls and indicators are illustrated in controls and indicators used in the operation of figures 2-1 through 2-14, and described in tables the ILCHR. 2-1 through 2-14. The key numbers in the tabl refer to the callout references in the figures. Plac- arded items are indicated by upper-case letters. , @ | o Reet nen ee an 2 @ ® 10 6 rae 8 = MS 431278 Figure 2-1. LCU — controls and indicators *(AE)'. Refer to appendix D for serial number effectivity. 2TM 9—1440—531—12—1 12 @ @ MI 73799A Figure 2-1.1, LCU — controls and indicators *(AD)". Refer to appendix D for serial number effectivity. = Google12 Table 2-1. LCU — Controls and Indicators (Figs. 2-1 and 2-1.1) ‘MAIN POWER lamp Pressure equalizer valve ELEVATION indicator dial AZIMUTH indicator dial No-obstruction lamp NO OBST CHECK /OPERATE switch ‘Communications station ‘Azimuth handwheel ALIGN switch, HYD PRESS switch LOCAL/REMOTE switch ‘TEST POSITIONED switch Elevation handwheel MAIN POWER switch When illuminated, indicates that generator power is present at the ILCHR and the MAIN POWER switch is in the MAIN POWER position. Protects internal components from pressure differences during air transportation. Indicates in mils the locally commanded boom elevation angle. Indicates in mils the locally commanded boom support azimuth NO OBST CHECK — Provides +28 to enable no-obstruction cireuit check. OPERATE — Normal position, Provides communications between units of the improved HAWK battery. Manually positions the ILCHR boom support in azimuth in local operation. Applies IHIPIX synchro data to the ILCHR servo system in local ‘operation. Activates hydraulic pressure in the ILCHR hydraulic control system in local operation. LOCAL — Switches control of the ILCHR to the LCU. REMOTE — Switches control of the ILCHR to the IBC. Provides'a simulated lead angle command signal to enable shoot ‘around checks. ‘Manually positions the ILCHR boom in elevation in local oper~ ation. Enables the ILCHR power circuits. 2-21GoogleTM 9—1440-531—12—1 Figure 2-2, Base distribution box—controls and indicators. Gooalé* ‘TM 9—1440-531-12—1 Table fc, Base Distribution Boe Controls and tudicators (Fig. 2-2) Ke Cnt or te atime 1 | DISCHARGE switch Removes oil pressure from the hydraulic accumulator. 2 | NORMAL/COLD WKIT switch NORMAL — During remote operation of ILCHR, allows ope ation of heat exchanger and base blower, only when i activate, COLD WKIT — During remote operation of ILCHR, make boom cold weather kit power available when in standby 3 | CBS SERVO REF R2 circuit breaker Protects the servo reference circuits from overload. 4 | cB2 115V PWR circuit breaker Ly outlet and servoamplifier power supply circuit 5 | CBS 28V NO. 1 circuit breaker Protects the 28-vde No. 1 circuits from overload. 6 | CBI2 28V NO. 2cireuit breaker Protects the 28-vde tactical cireuits from overload, 7 | CBB 25V circuit breaker Protects the 25-vde circuits from overload. 8 | CBTMAIN CIRCUIT BREAKER Protects the electrical power unit (epu) power supply from over load, 9 | CBA BLOWERS circuit breaker Protects the chassis and hydraulic oil cooling blower motors from ‘overload, and the boom heater circuit when cold weather kit installed. 10 | CBLHYDRAULIC PUMP circuit breaker Protects the boom-positioning hydraulic pump motor from over load. 1 | PUMP TIME meter Provides a cumulative readout of hydraulic pump operation time. 12 | FILAMENT TIME meter Pr ‘8 cumulative readout of the time power is applied filaments.en TM 9—1440-531-12-1 4 MS430548 Figure 2-3. Base hydraulic control panel — controls and indicators. Table 2-4. Bose Hydraulic Control Panel — Controle and Indicators (Fig. 2-4) Control or ator Fluid level gauge Handpomp Bleed valve (valve location 5) ‘System selector valve (valve location 4) Right-front leveling cylinder valve (valve location 3) Rear leveling cylinder valve (valve location 2 Left-front leveling cylinder valve (valve location 1) Indicates oil level in the base reservoir, when the cylinders are retracted and the hatch is closed. Develops pressure in the hydraulic leveling and hatch-raising system, when operated. Controls flow of fluid from the hydraulic leveling aystem to the reservoir. Controls flow of fuid into hatch-raising cylinders. Controls flow of fuid to right-front leveling cylinder. Controls flow of fuid to rear leveling cylinder. Controls flow of fuid to left-front leveling cylinder. 2-5‘TM 9—1440-531-12-1 a MI 73802A Figure 2-4. Boom support, left side ~ controls and indicators. Table 2-4. Boom Support, Left Side ~ Controls and Indicators (ig. 2-4) Xo Control or weston Femtion 1 | HYD ACCUM AIR FILTER valve Provides means of connecting air fill ine to accumulator. 2 | ACCUMULATOR PRESSURE gage Indicates pressure in the air side of the accuroulator. MANUAL AZIMUTH MOVEMENT VALVE When opened, allows manual azimuth positioning of the ILCHR boom. 2-6TM 9—1440-531-12-1 Table 2-5. Hoom Support, Right Side — Controls and Indicators (Fig. 2-5) ILCHR level Indicates ILCHR base deviation from the horizontal plane. Main reservoir filler cap Allows access to main reservoir for adding hydraulic fluid. Main reservoir level gage ‘Azimuth stow lock ansembly Indicates level of hydraulic fluid in the main system reservoir. Prevents azimuth movement of boom support when locked. Figure 2-8, Azimuth position indicator ~ controls and indicators. Table 2-6, Azimuth Position Indicutur ~ Controle and Indicators (Fig. 28) ‘Azimuth vernier pointer Indlicat relative azimuth position, Azimuth indicator ring Indicates azimuth angle of the hoom relative to the ILCHR base. Hatch lock handnut (8) Secures hatch to base, Figure 2-7. ILCHR boom, right side ~ controle and indicators, 27TM 9—-1440-531-12-1 o Table 2-7. ILCHR Boom, Right Side ~ Controls and Indicators (Fig. 2-7) Elevation fire interrupter lever milk below settings. Elevation fire interrupter scale Applies short Calibration for setting elevation fire interrupter lever. Mi 73806 Figure 2-8. ILCHR boom, left side — controls and indicators. Table £-8. ILCHR Boom, Left Side - Controls and Indicators (Fig. £-8) Releases the umbilical cover for hand engagement of the umbili- cal. Protects components from damage from missile blast. Indicates the elevation angle of the boom. 28en ‘TM 9-1440-531-12-1 MS430549 Figure 2-9. Forward rotating sector — controls and indicators. Table 2-9. Forward Rotating Sector — Controls and Indicators (Fig. 2-9) Forward rotating sector Supports missile and controls downstep switching. Forward sector hook latch Missile latch lever Prevents rebounding of the forward rotating sector. Permits manual operation of the missile latch finger and missile holdback hook Indicates proper position of the missile latch lever to insure Positive latch. Controls the missile in the horizontal plane. Indicator line Mimile latch finger Missile holdback hook Restrains the missile in the vertical plane. 29 aeT™ 9—1440—$31—12—1 a Figure 2.10. ILSCB ~ controls and indicators.on TM 9—1440—531—12-1 Table £-10. ILSCB ~ Controls and Indicators (Fig. 2-10) RING ewiteh Rings remote telephone. VOL control Controls communication volume level. PWR switeh Controls power to communication station. Fuse Protects IHIPIR 28-vde power supply from overload STBY CMD lamp When illuminated, indicates redeipt of ILCHR standby command from the IBCC. ‘MSL COUNT DELAY switch ABOVE 18°C (65°F) — Delays miaile count to IBCC 2.5 ‘minutes after receipt of ILCHR standby command. BELOW 16°C (65°F) — Delays mimile count to IBCC § min- utea after receipt of ILCHR standby command. LAUNCHERS MISSILE READY A, B, C lampe o ‘When illuminated, indicates misaile-ready status for each missile, LAUNCHERS LCHR READY lamp (3) ‘When illuminated, indicates ILCHR is available for assignment. Pane! lampe When PANEL LIGHTS-HPI CABLE IDENT ewitch is on, Provides panel illumination, and indicates that THIPIR data ‘able is connected to J1. LAUNCHERS OPERATE/SAPE ewitch (8) ALERT *(R)! — Energises ILCHR hydraulic pump prior to target engagement by IHIPIR. OPERATE — Permits remote operation of ILCHR. ‘SAFE — Interrupts ILCHR ready signal and disables ILCHR ‘rom remote operation. LAUNCHERS FAILED TO FIRE lamp (8) When illuminated, indicates a hangfire not due to miscile mal- function. LAUNCHERS MSG CMD TEST lamp (8) When illuminated, indicates all message command lines in the aystem are functioning property. LAUNCHERS PREQ CMD TEST lamp (3) ‘When illuminated, indicates all frequency command lines in the aystom are functioning property. LAMP TEST switch ‘Checks operation of all indicator lampe. PREQ/MSG CMD TEST ewitch ‘Sends test command to IHIPIR to initiate frequency and message ‘command test sequence. PANEL LIGHTS-HPI CABLE IDENT ewiteh Applies voltage to panel lamps which will huminate only when THIPIR data cable is connected to J1. Also illuminates panel lamps for night operation. Bomer ‘Telephone signal. External connector for telephone headset. J Refer to appendix D for sevial number effectivity.Dgtizes by Googlecw T™ 9—1440-531-12-1 Mi 73809 Figure 2-11. Shoot-around console—controls and indicators. Table 2-11. Shoot-Around Console — Controls and Indicators (Fig. #-11) Minimum elevation lever Minimum elevation scale Azimuth override elevation scale ‘Azimuth override lever ALIGN/OPERATE switch ALIGN meter FUSE 250V/.5 AMP PRESSURE RELIEF VALVE HUMIDITY INDICATOR Differential generator COARSE ADJUST control ALIGN NULL/COARSE/FINE switch PANEL LIGHTS switch Sets LCHR minimum firing elevation angle as determined by site restrictions. Indicates LCHR minimum elevation firing angle. Indicates elevation angle above which aximuth cutouts are overridden. Sets LCHR asimuth override angle. ALIGN — Permits slinement of HIPIR and LCHR azimuth synchro OPERATE — Normal operating position Indicates null during alinement of LCHR with HIPIR. Protects shoot-around console electronic circuits from overload ‘and provides identification of open fuse. Protects internal components from pressure differences during air transportation, Indicates humidity content of dessicant. Varies LCHR azimuth DG synchro to aline LCHR with HIPIR azimuth. ALIGN NULL — Enables synchro alinement. COARSE — Enables coarse alinement of synchro. FINE — Enables fine alinement of synchro. Controls front pane! illumination. auTM 9—1440-531—12— Figure 2-12, ILCHR boom, forward—controls and indicators, Table 2-12. ILCHR Boom, Forward ~ Controls and Indicators (Fig. 2-12) Contato nator Function ‘Sector release lock (3) Permits manual unlocking of the sector release mechanism for teat and maintenance. | BOOM HEATER switch , energizes the boom heaters for cold weather In the ON posit operation. Cushions boom travel when subjected to full down command. Boom snubbers (2) Figure 2-13, Pallet mile latcher—controle and indeatora | 212cw TM 9—1440-531—12-1 Table 2-18. Pallet Missile Latches Controls and Indicators (Fig. £13) Conta intr Function Missile latch Operates the missile latch mechanism. Quick-release pin Locks the missile latch lever. Missile anchoring assembly Secures the missile. MI 73812 Figure 2-14, Alinement telescope and fire cutout assembly ~ controls and indicators. Table 2-14. Alinement Telescope and Fire Cutout Assembly — Controls and Indicators (Fig. 2-14) Elevation locknut Controls the vertical movement of the telescope. 2 | Obstruction indicator arrow Indiestes the fire cutout switch corresponding to the telescope line-of-sight azimuth. 3. | Fire cutout switeh (64) Each switch controls a horizontal 100-mil fring sector. 4 | Elevation scale Indicates the elevation angle of the telescope optical axis in mils. 5 | Telescope locknut Permits installation or removal of the telescope, and controls vertical alinement. 6 | Telescope ‘Used for optical alinement of the LCHR and HIPIR, determination of fire cutout sectors, minimum elevation and azimuth override angles. 7 Indicates the LCHR zero azimuth line-of-sight. 8 Indicates the horizontal angle of the telescope line- of-sight in mils.TH 9—1440—531—12—1 cw Section Il. OPERATION UNDER USUAL CONDITIONS Do not tow the LCHR with missiles loaded on it. All personnel must be a safe distance from the launcher whenever the hy- draulics are activated. 2-3, Normal Operation a. During tactical operations, the LCHR is re- motely operated by commands originating in the BCC. However, during non-tactical operations (emplacement, checks, and adjustments or non- alert status) and during missile loading, arming, and unloading operations, the LCHR is operated locally from the LCU. The LSCB is emplaced in a location permitting observation of all three LCHR firing areas. The LCU is normally em- placed on the back of the LCHR. However, for safety considerations it is necessary to man- ually hold or emplace it on the tripod at a safe distance from the LCHR during performance of tests or crew drills which require slewing in azimuth or elevation, or when the elevation system. is to be commanded into the limits of boom travel. b, During operations which do not require the LCHR umbilicals to be connected to the missiles and with adequate protection from the weather provided, the LCU may be left emplaced on its tripod. This will maintain a charge on the commu- nications station battery if the LCHR is receiving primary power and the communications station (6.1, fig. 2-1) PWR switch is set to ON. When the ‘LCHR is unattended or is not receiving primary power, the communications station MAIN POWER, switch should be set to OFF to prevent battery discharge. ¢. When the HAWK battery is in a 7.5 minute or higher alert status, the LCU, communications station, and tripod must be stowed. Refer to paragraph 2-12 for procedures for preparing the LCHR for missile firing. 2-4, Tactical Re-leveling If the crew chief determines that an LCHR in the firing section is not available for firing 2-14 because its base level has been excessively eroded by missile blast, he will set the appropriate LAUNCHERS OPERATE/SAFE switch (10, fig 2-10) at the LSCB to SAFE. The crew chief then dispatches LCHR operators to retum the LCHR to service. The following procedures are performed for tactical releveling. a. Open the cover of the LCU and set the MAIN POWER switch to OFF and the LOCAL/REMOTE switch to LOCAL (13 and 10, fig. 2-1). '& Approach the LCHR from the side, and set the missile SAFE/ARM handle (1, fig. 3-5) to SAFE. Dis- connect the umbilical cable and connect the missile umbilical shorting plug. c. Repeat step 6 on the other missiles on the LCHR. When leveling, exercise caution to insure that the leveling cylinders do not pop out of the base plates. d. Inspect the outriggers and blast hole. If onls one outrigger has settled a small amount and the other two outriggers have remained in place, the LCHR may be returned to immediate service by extending the appropriate leveling cylinder until the base is level. ¢. If erosion is too great or other outriggers are not in place, the LCHR must be relocated and re- alined with the HIPIR before being returned to service. Relocating the LCHR requires checking and possibly resetting the azimuth fire cutouts. ‘The crew chief must be advised if the LCHR is relocated. f. Remove the missile umbilical shorting plug from each missile and connect the umbilical cables. Set the missile SAFE/ARM handle to ARM on each missile. g. Set the LOCAL/REMOTE switch on the LCU to REMOTE, and the MAIN POWER switch to MAIN POWER. Secure the LCU cover. h. When the LCHR area is clear, the crew chief sets the appropriate LAUNCHERS OPERATE/ SAFE switch to OPERATE.on ™ 9—1440-$31—12-1 Section IIL OPERATION UNDER UNUSUAL CONDITIONS 2-5. Preparation for High-Velocity Winds When high-velocity winds (75 mph or greater) are forecast, perform the following operations: a. Deenergize the ILCHR (table 3-18). b. Remove and store all extraneous equipment. c. Disarm, unload, and store the missiles in their containers (refer to section IV for disarming and unloading procedures, and TM 9-1410-530-14 for storage procedures). d, Lower the outriggers until the weight of the ULCHR is equally distributed between the outrigger pads and the wheels. e. Place sandbags (or other weights) on top of. ILCHR. outrigger 90 that the weight is over the jack pads (use minimum of 600 pounds per outrig- ger), or tie the four comers of ILCHR securely to five-foot ground anchors. 2-6 Fording Operations a, Water Depth Less Than One Foot. The ILCHR may be forded without special preparations if the depth of the water to be forded does not exceed one foot. aadcu b. Water Depth Exceeds One Foot. Make the following checks: that the drain plugs cover the drain holes located at the bottom of each compart- ment of the ILCHR base; that the forward and rear compartment covers are secured; that the hatch knobs are secured; that the ILCHR base external electrical connector covers are secured; that the sir intake and exhaust covers (4 and 12, fig. 1-1), located outside of the aft compartment of ‘the base cooling assembly, are closed; that the base distribution box mounting bolts, located at the bottom of the aft panel of the ILCHR base, are secured; that the caps for the main reservoir and main reservoir level gage (2 and 8, fig. 2-5) are secured. ¢c. Water Depth Greater Than Three Feet with Low to Medium Stream Velocity (Less Than Two Knots). NOTE ‘The key numbers shown below is parentheses refer to figure 2-15, unless otherwise indicated. (1) Perform the checks in b above. (2) Elevate ILCHR, and remove the two cap- ‘nuts (1) from the wheel. Replace with the two adapters (2), repeating the above sequence for the remaining four capnuts, TM 9—1440-531—12-1 (8) Remove spare wheels with tires from another 2 1/2-ton vehicle and mount them on the ILCHR as duals, using the capnuts (3). (4) Attach a chain or rope (15,000-Ib minimum breaking strength) from the lower forward corn- ers of the ILCHR base to the towing vehicle chassis rear shackles. With the ILCHR connected and in line with the towing vehicle, and on level ground, adjust the chain ‘or rope length to five feet, six inches. 4. Water Depth Greater than Three Feet with High Stream Velocity (Greater Than Two Knots). (1) Perform the checks in b above. (2) Secure an empty watertight 55-gallon drum to each side of the ILCHR base at the spade rack so that the longitudinal center of the drums is in line with the longitudinal center of the spades stored in the racks. NOTE If S6-galon drums are not available, other ‘watertight containers or floatable ma may be used, providing they have » minimum total volume of 16 enbie feet. (8) Perform step c(4) above. MI 73813A ‘Figure -18, ILCHR fording.TM 9—1440—531—12—-1 e. After Fording. (1) Open the forward and rear compartment drain plugs immediately to remove any water which may have seeped in. Clean all parts exposed to the water, and lubricate them in accordance with LO 9-1440-581-12. (2) Elevate the ILCHR, remove the six capnuts (3), and install the outside dual wheels on another 2.1/2-ton vehicle. (3) Remove the two adapters (2) from the inside wheel. Replace and secure with the capnuts (2), repeating the above sequence for the remain- ing four capnuts. 2.7. Extreme Cold Weather Operation Operation in ambients below requires special treatment of missiles. Tt requires the use of a cold weather kit * for heating of the launcher and of launcher emplaced missiles, The cold weather kit provides heating elements in the center compartment of the launcher base, a heater in the !auncher boom, and a heater blanket for each missile on the launcher, For heater blanket installation, refer to. par. Tha. 6. Preparation. Operate the launcher cold weather heaters and missile covers as follows: (1) Remove the launch programmer relay assembly from the electronic rack. (2) Set switch SI (inside the programmer) to WI/COLD KIT and install the programmer on the electronic rack. (3) Disconnect connector P1005 on the base distribution box (base blower). (4) Set switch $1 (NORMAL-COLD/W KIT) on the base distribution box to the COLD/W KIT position. (5) Set all circuit breakers on the base tion box to ON. (8) Set the BOOM HEATER switch on the forward outrigger to ON. dist NOTE In order to supply power to the missile and the haxe heaters for proper cold weather kit ‘operation, the C/WK circuit breaker must be reset, to the ON position each time the hydraulic pump has been activated. c, For further information refer to TM 9-207. 2-8. Extreme Hot Weather Operation Operation in hot humid climates requires vig- 2-16 en ilance to prevent damage from moisture, corrosion, fungus growth, or inadequate lubrication due to the thinning of the lubricants. Damage from moisture, corrosion, or fungus growth can best be prevented by periodic inspection, cleaning, and retouching painted surfaces, and coating un- painted surfaces with proper corrosion preventives, or lubricants. To prevent damage resulting from the thinning of lubricants, it is necessary to change to the proper lubricant grades. Detailed : instructions are contained in LO 9-1440-531- , 12. i Ambient Temperature Variations A significant change in ambient temperature causes servoamplifier imbalance. If a temperature change of greater than 35°F occurs after the servoamplifiers are balanced, the servoamplifiers should be balanced again at the new ambient temperature, Table 3-16, steps 4 and 5, prescribes the procedure for balancing the servoamplifiers. 2-10. Unusual Terrain Oper: a. Mud or Swampland. Operation in mud or swampland requires careful washing, cleaning, dry- ing, and relubrication of all affected surfaces and parts. Maintenance must be performed as soon as possible after exposure of the equipment to those conditions. >. Sand or Dust, Touch up all painted surfaces damaged by sandblasting. Lubricate completely to force out lubricants contaminated by sand or dust. | Air cleaners must be cleaned at least daily. Ex- posed vents should be covered with cloth. Keep oculars protected from etching by sand. ¢. Salt Water Areas. (1) Salt water has a corrosive effect on metals and many metal finishes. Immersion in salt water is particularly harmful. Some metals, such as mag- nesium and aluminum, will be permanently dam- aged by exposure to salt water. Machined mag- nesium parts may have to be replaced if exposed to salt water spray for long periods or totally immersed for shorter periods. (2) Painted surfaces should be inspected for blistering chips, cracks, and corrosion after ex- posure to salt water or salt water spray. Such surfaces should be scraped or cleaned and retouched without delay.10 2-1 TH 9—1440—531—12—1 Section IV. MISSILE HANDLING 1. Loading All personnel must be evacuated from the ILCHR area and other areas con- taining missiles and other explosive com- ponents during severe electrical storms. Matches or other flame- or spark- producing devices (the use of common tools is not prohibited) are not permitted within 60 feet of the ILCHR or loader when missiles are being loaded onto the ILCHR. WARNING If fire develops in the vicinity of the ILCHR, every effort must be made to extinguish the fire before it reaches the missiles. If possible, the missiles should be moved by the loader to a safe dis- tance from the fire. If it appears that the fire will reach the missiles, all per- sonnel must evacuate the area. Missiles and explosive components are not to be roughly handled during load- ing or handling. The possibility of dam- age is increased at low temperatures. Missiles or explosive components that have been dropped or subjected to rough handling will not be used until the serviceability of the items has been determined. NOTE Refer to TM 9—1450-500-10 for procedures for transfer of missiles and loader operation, Personnel guiding the missile during the transfer operations must exercise extreme care to avoid personal injury. When missiles are on the loader and on the launcher without being securely latehed, personnel guiding the missile must at all times insure that their body is positioned in a manner that avoids injury should a missile accidentially fall. Prior to lifting missiles with the con- verted loader, the following precautions are mandatory. (1) Launcher interference. During transfer operations, the missiles are suspended from the loader yoke and are free to swing about the yoke pivot. Missiles normally hang nose down from level. For transfer operations to and from the launcher, it is highly desirable to have the missiles hang at a 5-degree nose-down attitude. Because of the cen- ter of gravity location of the improved HAWK missile and the relationship to the yoke pivot, the missiles (3) hang 2 degrees nose’ down, or less than half the normal angle for standard missiles. If the missiles are allowed to maintain this shallow hang angle throughout the transfer operation, in- terferences of the missile boat tail and umbilical plug with the launcher retain- g stud occur. To avoid this condition, the following procedures are necessary: (a) When transferring missiles to the launcher, as the missile boat tail ap- proaches the launcher retaining stud, exert and hold a light down force (by hand) on the missile radome to prevent contact of the boat tail and umbilical plug with the launcher retaining stud, until the missile(s) is in firm contact with the forward sector and the rear roller. Missile may also require manual guidance from the rear to prevent wing damage. 217TM 9—1440—$31—12—1 cw (6) When removing missiles from the launcher, exert and hold a light WARNING down force on the missile radome until the missile boat tail is safely clear of Make certain that the missile SAFE/ARM the launcher retaining stud. handle (1, fig. 8-5) is set to SAFE. (2) Reduced pressure. Installation c. Open the MANUAL AZIMUTH MOVEMENT of this conversion changes the hydraulic VALVE (3, fig. 2-4) and manually rotate the boom system so that the pressure in the support to the direction from which loading can ‘educed pressure system increases from best be performed. 320 psi to 615 psi. This increase was . a necessary to insure adequate operation d. Make certain that the aft retaining studs (42, with the HAWK missile. Considering that fig. 5-18) are securely mounted on the rear support arm. If missiles are to be loaded after a firing, the f the system is to protect the Purpose of the system is to prot replace the retaining studs and shear pins (2 or 7, missile and equipment against structural overloads produced by the extension cylin- eS 22 1): Spare bard wate tos tees teplaeens nan ieee ta toes tant is tlatmeeaoeed is carried in the storage case (6, fig. 5-17.2) which is pressure will result in less protection located on the side of the boom support. against overloads. Therefore, operators .1, After firing, but before reloading, inspect must exercise greater care while operating the umbilical insert (2, fig. 5-19.2) to insure that the during the reduced pressure mode, particu- pins are straight and free of rocket motor blast larly under the following conditions: deposit. If not, replace the insert. If time permits, inspect the sector release roller (3, fig. 5-23.1) for (a) When removing missiles from freedom of movement and excessive rocket motor the pallet or launcher, avoid inadvertent blast deposit. Replace if necessary. If time permits, retraction of the extension cylinder replace the shear pin (2 or 7, fig. 5-23.1) after each when missiles are latched to both loader firing. and pallet (or launcher). It is of utmost e. Make certain that the aft rollers (88, fig importance to avoid this occurrence 5-18) rotate freely and can be moved laterally on when it results in an unsymmetrical ris cates loading (for example, retracting with | | ; ‘one outboard missile latched to both f. Make certain that any accumulation of paint pallet and loader), on the aft rollers is not excessive. (b) When placing missiles onto the 8. If missiles are to be loaded after a firing, in- pallet or launcher, during final seating spect the outrigger nose fairings (43, fig. 5-18) and of the missile against the retaining associated hardware to insure that they were not studs (pallet or launcher), it is im- damaged by the missile blast, Repair or replace any portant to avoid over-extending the ex- damaged parts as required. tension cylinder, thereby overloading fh. Inspect the tape on the outrigger nose faitings. the structures. Replace, if necessary, using tape 8135-00-926-8941. a i. Check that all forward rotating sectors (1, fig. Meee ea Eee 2.9) are thoroughly cleaned; all missile latch levers isting beam (1450-00-665-8234) is used to ; lift single HAWK missiles, the component (3, fig. 2-9) are released (latch levers up); and all connecting link (2590-00-690-2856, P/N holdbeck fingers and hooks are fully retracted, 9089791) must be installed in hole #6 to i. Direct the loader operator to the proper load- accommodate the different center of grav- ing position. ity in the HAWK missile. k. As the loader operator indexes the loader to the LCHR, insure that both loader index forks are NOTE properly seated on the LCHR index fittings. Tt is not necessary to discharge the LCHR 1. Assist the loader operator by steadying the accumulator before loading misiles, missiles os they are being transferred. During final a. Notify the BCC personnel that the LCHR is ¢xtension of the loader transfer arms, apply to be deenergized. enough downward pressure on the missile radomes | to maintain a slight nose down attitude on the b. Deenergize the LCHR (table 3-13). missiles. This is necessary to prevent damage to the 218C10 ‘missile tailcones and umbilical shorting plugs. In- sure that the body of each missile first contacts the ILCHR at the forward rotating sector rollers, ‘and that the tailcone clears the sensing switch (33, fig. 5-18) and aft retaining stud. ‘m, Direct the loader operator to stop when the missile umbilical brackets are seated against the ILCHR aft retaining studs. Visually insure that a Positive contact is made between the missile umbilical bracket and the ILCHR retaining stud at Avoid overloading the structures by over- extending the cylinder. Over-extension is detectable by noting a vertical rise of the rear portion of the loader yoke assembly. If this occurs, direct the loader operator to slowly retract the extension cylinder until the yoke is again parallel with the missiles. 7. When each missile is seated on the ILCHR, engage the forward hold-back hook, pulling the latch level down until it is alined with the white indicator stripe across the front of the rotating sector assembly. There may be considerable differ- ence in the pull-down force required to obtain a secure latch of each miasile. Insure that a positive latch is made on each missile by checking all of the following latch indications: (1) The hold-back fingers do not bind on the sides of the missile latch pocket and the tapered sides of the hold-back fingers are fully extended into the pocket. (2) The latch is in its over-center position as indicated by the latch lever shank relative to the white stripe on the front of the sector. The top surface of the shank where it enters the slot in the sector must be even with, or below the upper limit of, the white stripe. The missile latch lever should be ightly below, the upper limits of the indicator line on the front of the sector (3) Friction between the rollers on the forward rotating sector and the missile body prevents hand rotation of the rollers. ©. If difficulties are encountered in latching a missile to the ILCHR, proceed as follows: (1) Disengage the missile latch from those mis- tiles that are securely latched to the ILCHR. (2) Retract the missiles. ™ 9—1440—$31—12—1 (3) If a missile failed to latch, inspect the mis- sile forward latch pocket and the missile umbilical bracket for burrs, loose hardware, paint accumu- lation, or any damage that would prevent proper latching of the missile, (4) Inspect the ILCHR forward rotating sector, including the latch mechanism, and the aft missile support arm for burrs, loose hardware, paint accumulation, or any damage that would prevent proper latching of the missile. (8) Repeat paragraphs; through tore-install the missile on the ILCHR. If necessary, use the roll capabilities of the loader to center the hold- back fingers in the missile latch pocket. p. A second operator should verify that the mis- siles are securely latched to the ILCHR. 4g. After verifying that all missiles are properly latched, instruct the loader operator to release the missiles. r Make certain that the MISSILE RELEASED lamps on the loader instrument panel are illumi- nated. During the initial retraction of the loader extension cylinder, frictional loads are applied from the loader support arms to the missiles in the first few inches of travel. This could cause the release of an improperly latched missile. 4. Instruct the loader operator to begin retract- ing the extension cylinder. Stop retraction immedi- ately if any movement of the missile is observed. t. After the loader has been disengaged and backed away from the ILCHR, rotate the boom support back to the setting-of-the-day position. Close the MANUAL AZIMUTH MOVEMENT VALVE. u, It will frequently be necessary to load a single missile on an ILCHR which contains one or two missiles. The procedure is similar to that outlined ‘above, with the following technique added to assist the transfer operation: Be careful not to let the end of the exit nozzle come in contact with the sensing switch or rear stud on the ILCHR. (1) Manually tilt the missile radome up as the missile approaches the halfway point in the transfer. (2) As the missile descends, slowly lower the missile radome. Use caution to insure that the mis- sile elevons do not strike the ILCHR structure. 2-18.1danzeoy Google ecw This attitude must be maintained until the elevons ‘and wings of the missile being loaded have cleared and are interlaced between the wings of the mis- sile(s) on the LCHR. », For the unloading of missiles, logically re- verse the loading procedure as appropriate. w, The use of the suspension lookout during mis- sile transfers is no longer required. x. Perform the SATA checks on the missiles as described in part 1 of TM 9-1410-530—14. NOTE Local operating procedures specify when to perform the checks outlined in paragraph 2-12. 2-12. Safety-and-Arming (S&A) Checks and Missile Arming a Set the LAUNCHERS OPERATE/SAFE switch (10, fig. 2-10) at the LSCB to SAFE for the LCHR to be used. b. Emplace the LCU at a safe distance from the LCHR. ¢. On the LOU (fig. 2-1): (1) Set the MAIN POWER switch (13) to OFF. (2) Set the LOCAL/REMOTE switch (10) to LOCAL. (3) Set the HYD PRESS switch (9) to OFF. 4. Insure that the missile latches (8, 4, fig. 2-9) on the LCHR forward rotating sectors are properly secured (latch levers fully down). NOTE ‘If missile cold weather kits are installed, refer to chapter 6, par. 6-8 for removal of blankets to gain access to the SAFE/ARM handle. ¢. Insure that each missile SAFE/ARM handle is set to SAFE. f, Insure that all LCHR umbilical plugs are disconnected from the missiles, & Inspect the missiles to insure that the missile bodies, radomes, wings, and elevons have not been damaged beyond serviceability criteria in TM 9— 1410-30-14, para. 2-10. h. To check the safety-and-arming test aid (SATA), set and hold the EXT/BTRY switch to BTRY and set the function switch to 1. The SATA lamp illuminates. Release the EXT/BTRY switch. Damaged, nicked, or bent pins on the SATA connector insert (9167513) may cause damage to the LCHR umbilical connector. If the SATA insert pins ex- hibit signs of damage, the SATA con- TM 9—1440—531—12—-1 nector insert must be replaced prior to testing the LCHR umbilicals. Refer to TM 9-1410-530—14 for SATA inspec- tion and replacement procedures. i Connect the SATA to LCHR umbilical A. Set the function switch to 2. Set and hold the EXT/BTRY switch to BTRY. The SATA lamp illuminates. If the lamp does not illuminate, a fault in the initiator circuit is indicated. This fault must be corrected before connecting the LCHR umbil- ical to the missile. i. Release the EXT/BTRY switch. The SATA lamp extinguishes. If the SATA lamp remains illuminated, stray voltage is indicated and must be eliminated before the LCHR umbilical is con- nected to the missile. Observe the SATA lamp continuously throughout steps k through x. Ilumina- tion indicates stray voltage that must be eliminated. hk, Set the REMOTE. LOCAL/REMOTE switch to The LCHR will now be under remcte control when the power switch is set to ON, and personnel must anticipate in- advertent LCHR movement. 1. Set the MAIN POWER switch to ON. m. Set the LAUNCHERS OPERATE/SAFE switch at the LSCB to OPERATE for the LCHR being tested. n, Request the BCC operator to place the LCHR on STANDBY. 0. IftheSATA lamp illuminates at any time dur- ing this procedure, stray voltage is indicated and must be eliminated before the LCHR umbilicel is connected to the missile. P. While observing the SATA lamp request LSCB operator to place the LCHR under test to ALERT. q. After hydraulic activation, position the LCU elevation dial to 50 mils above the setting of the elevation fire interrupter lever (1, fig. 2-7) setting on the boom. 219T™ 91440531121 1. Advise the BCC operator that the LCHR STANDBY command is no longer required at the LCHR. & Set the LAUNCHERS OPERATE/SAFE switch at the LSCB to SAFE for the LCHR being tested. t, Set the LOCAL/REMOTE switch to LOCAL. 4, Position the LCU azimuth dial to approxi- mately indicate the azimuth position of the boom support. », Position the LCU elevation dial indicator to approximately —100 mils. w, While observing the SATA lamp, set the HYD PRESS switch to ON and elevate the boom to 200 mils, If the SATA lamp illuminates at any time during this procedure, stray voltage is indicated and must be eliminated before the LCHR umbilical is connected to the missile. x. Set the HYD PRESS switch to OFF. y. Set the MAIN POWER switch to OFF. z Repeat step h above. If the lamp does not illuminate, stray voltage sufficient to have damaged the lamp must be suspected. Any stray voltage must be eliminated before the LCHR umbilical is connected to the missile. When disconnecting the SATA connector from the LCHR umbilical, pull the con- nector straight out to prevent damage to the contacts. Do not use potted connec- tor as a “handle”. After SATA has been removed from the umbilical, inspect the connectors to in- gure that no contact hoods have been pulled out beyond the face of the SATA connector or remained in the sockets of the LCHR umbilical. NOTE Steps oa and ab need be performed only if the LCHR umbilicals are going to be connectea to the missiles. Otherwise, the LCU and commu- nications stations may remain emplaced on the tripod so that communications can be main- tained with the LCHR crew. aa, Repeat steps i through z with the SATA con- nected to LCHR umbilicals B and C. 2-20 ce NOTE If the missile cold weather kits were removed. to perform the SATA checks, reinstall these kits per chapter 7, par. 7-5a (36). ab. Remove and store the communication station, communication cable, headset and extension cable. ac, Secure all excess equipment, replace the LCU on its mounting bracket on the LCHR base and stow the LCU tripod. Local operating procedures will specify when the LCHR umbilicals will be connected to the missiles. ad. Remove the access cover from the umbilical cover and store it under the spring tension clip on the rear of the umbilical cover. Connect the LCHR umbilicals to the missiles. Local operating procedures will specify when the missiles are to be armed. ae, Arm the missile by setting the SAFE/ARM handle (1, fig. 8-5) to ARM. ‘The missiles are now armed. All unnec- essary personnel must clear the LCHR area. of. On the LCU: (1) Set the LOCAL/REMOTE switch to REMOTE. (2) Set the MAIN POWER switch to MAIN POWER. Insure that the AZIMUTH indicator dial (4, fig. 2-1) is set to the setting of the day.cw (8) Close the LCU cover. ag. Insure that the boom support is positioned to the setting-of-the-day. ah. Set the appropriate LAUNCHERS OPERATE/ SAFE switch at the LSCB to OPERATE. The LCHR is now under control of the BCC and is ready for firing. All person- nel must clear the LCHR area. 2-13. Routine Return to Missile Safe Condition @. Notify BCC personnel that missiles will be retumed to the safe condition. b. Set the LAUNCHERS OPERATE/SAFE switch (10, fig. 2-10) on the LSCB to SAFE for the appropriate LCHR. ¢. On the LCU (fig. 2-1): (1) Set the MAIN POWER switch (13) to OFF. (2) Set the LOCAL/REMOTE switch (10) to LOCAL. (3) Set the ALIGN switch (8) to OFF. (4) Set the HYD PRESS switch (9) to OFF. d. Place the LCU on its tripod at a safe distance from the LCHR. Insure that the LCU ELEVATION indi- cator dial (3, fig. 2-1) is set to zero and that the AZIMUTH indicator dial (4, fig. 2-1) is set to the setting-of-the-day. NOTE If missile cold weather kits are installed, refer to chapter 6, par. 6-8 for removal of blankets to gain ‘access to the SAFE/ARM handle, @ Approach the missile from the side and set the missile SAFE/ARM handle (1, fig. 3-5) to SAFE. Dis- connect the umbilical cable. Connect the missile um- bilical shorting plug. 2-14. Emergency Disarming Procedures a. Firing Delay (Hold). A hold is a temporary suspension in the firing procedures. A hold may be called for a number of reasons, but usually a safety hazard exists. AR385-63 contains the regulations and details for the protection of personnel in vicinity of a firing site. Any person observing a condition which makes firing unsafe will immedi- ately command CEASE FIRING. T™ 91440531121 b. Misfire. A misfire is a complete failure to fire which may be due to faulty electronic or explosive components. Although a misfire is not in itself dangerous, it cannot be immediately distinguished from a hangfire; therefore, it should be considered ahangfire until that possibility has been eliminated. ¢. Hangfire. A hangfire is delay in functioning of either electronic or explosive components. The delay may last a split second or several minutes, thus making it indistinguishable from a misfire. If 8 missile fails to fire, always assume it is due to a hangfire. 4. Disposition in the Event of Hangfire or Mis- fire. When a missile misfires or hangfires, the area around the LCHR becomes a danger area. Necessary safety pre- cautions must be observed. (1) At the LSCB, note whether the LAUN- CHERS FAILED TO FIRE and which LAUN- CHERS MISSILE READY lamps are illuminated. Visually determine which missiles remain on the launcher. Note the missile for which a corres- ponding LAUNCHERS MISSILE READY lamp is, not illuminated; this is the missile that hang- fired or misfired. If the LAUNCHERS FAILED TO. FIRE lamp is not illuminated, the other missiles on the launcher can be fired if urgency dictates; if the LAUNCHERS FAILED TO FIRE lamp is illuminated, set the LAUNCHERS OPERATE/ ALERT/SAFE switch for the affected launcher to SAFE. (2) Following confirmation from the control center that the engagement is terminated: (a) Setthe LAUNCHERS OPERATE/ALERT/ SAFE switches to SAFE, if not already in that, Position. (6) ‘Then set the affected LAUNCHERS OPERATE/ALERT/SAFE switch to OPERATE and note whether the LAUNCHERS MISSILE READY lamp for the missile that hangfired or misfired illuminates. Then set the switch to SAFE. If the lamp did not illuminate, the warhead S&A device may be armed. If so, wait 2 hours before approaching the launcher. In any event wait at least 30 minutes for the missile battery to be expended, beforeapproachingthe launcher contain- ing the missile that hangfired or misfired. 221™ 9—1440—531—12-1 (3) Remove the appropriate launcher power and data cables from the power source and LSCB respectively. (4) Wait the prescribed time, then request that all radars be placed in a no radiate mode until the defective missile is removed. NOTE If missile cold weather kits are installed, refer to ‘chapter 6, par. 6-8 for removal of blankets to gain sccess to the SAFE/ARM handle. (6) Approach the missile from the side and set the missile SAFE/ARM handle (1, fig. 3-5) to SAFE. Disconnect the umbilical cable. Connect the missile umbilical shorting plug. (6) Repeat step (5) on the other missiles re- maining on the LCHR. Set the MAIN POWER switch (13, fig. 2-1) to OFF and the LOCAL/ REMOTE switch (10, fig. 2-1) to LOCAL. Per- form the safety and arming checks in TM 9— 1410-530-14, table 2-4, steps 1, 2a, 2c, and 4. If the checks indicate that the missile is armed, clear all personnel from the LCHR area and request support from an EOD team. (7) If the checks indicate that the missile is safe, reinstall the umbilical shorting plug and re- move the defective missile from the LCHR. (8) Determine the cause of the misfire. If it was accompanied with illumination of the LAUN- CHERS FAILED TO FIRE lamp, the cause is undoubtedly related to ground equipment para- meters or failure; most likely the launcher. Per- form the following as necessary to determine cause: (a) Verify that fire cutout switches, and minimum elevation and azimuth override levers settings are appropriate for the emplacement. (b) Perform launcher checks, tables 3-15 through 3-17. If servo balance check is in excess of +4 vde, the condition can be considered most probable cause. (c) Perform integrated system checks utilizing the launcher arm on which the misfire occurred, If the launcher operates correctly, it can be re- loaded. If not, it must be brought up to opera- tional status before being used. 2-22 cw 2-15, Unloading Suspend all operations during severe electrical storms. Flame or spark- producing devices are not permitted within 60 feet of the LCHR or loader during unloading operations. If fire develops, make every effort to extin- guish it before it reaches the missiles. If it appears that the fire will reach the missile, evacuate all personnel im- mediately. a. Routine Removal. (1) Notify the BCC personnel that the LCHR is to be shut down. (2) Set the LAUNCHERS OPERATE/SAFE switch (10, fig. 2-10) on the LSCB to SAFE for the appropriate LCHR. (3) On the LCU (fig. 2-1): (a) Set the MAIN POWER switch (18) to OFF. () Set the LOCAL/REMOTE switch (10) to LOCAL. Insure that the missileSAFE/ARM handle (1, fig. 3-5) is set to SAFE for all missileson the LCHR. (a) mnnect the LCHR umbilicals and sert the missile umbilical shorting plugs. NOTE Refer to TM 9-1450—500—10 for missile transfer procedures and loader operation. NOTE If missile cold weather kits are installed on missiles to be unloaded, refer to chapter 6, par. 6-8 for cold weather kit removal. (5) Open the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4) and manually rotate the boom support to the direction from | which unloading can be most easily performed,16 (6) Direct the loader operator to the proper missile unloading position. (7) As the loader operator indexes the loader ‘to LCHR, insure that both indexes are properly ‘seated on the LCHR index fittings. (8) Direct loader operator to extend cylinder ‘until missile hoisting beam marker (yoke) line is alined with the seam (space) between the missile ‘warhead shell and the missile rocket motor. (9) Latch missiles as required to yoke assem- bly and verify proper lamp indication on loader console. (10) Release missile latch handle on launcher forward sectors as required. (11) Assist loader operator by steadying missiles to prevent tailcone damage during transfer. (12) When unloading a single missile from a LCHR which contains two or more missiles, it will be necessary to slowly raise the missile radome until the elevons and wings have cleared the remaining missiles. TM 9—1440—531—12—1 (13) Remove the access cover from the rear of the umbilical cover and place it in the top slot of the umbilical cover. b, Defective Missile Removal. (1) Perform the emergency disarming procedure (par. 2-14). (2) Perform the routine missile removal procedures in a above. When removing a defective missile, the area around the missile becomes a danger area. Observe all necessary safety pre- cautions. Insure that the missile SAFE/ ARM handle is set to SAFE for all missiles on the LCHR. ¢. Disposition of Defective Missiles. Dispose of defective missiles in accordance with appropriate directives or as specified by the EOD team. 2-23ce CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS Section |. PREVENTIVE MAINTENANCE SERVICES 3-1, General ‘The purpose of preventive maintenance is to detect the first signs of electrical and mechanical failures, and to insure that appropriate corrective action is taken before expensive and time-consum- ing repairs or replacements are required. This system is based on frequent inspections and ser- vices accomplished by operators or maintenance personnel under active supervision by all comman- ders and supervisors. 3-2. Responsibility Operators and crew chiefs are personally responsible for assigned materiel. Section and pla- toon leaders are charged with supervisory respon- sibility for materiel pertaining to their commands. Unit and organization commanders are required to insure that materiel issued or assigned to their commands is properly maintained. 3-3. Intervals ‘The principal criteria for determining the fre- quency of preventive maintenance services are operating hours and road movement. Since these cannot be accurately predicted, prescribed int vals will be used. Operation under adverse condi- tions such as extreme temperature or inclement weather may require that preventive maintenance services be performed more frequently. Reduce the intervals when environmental conditions indi- cate the need. Do not exceed the intervals unless authorized to do so. 3-4. General Precedures for All Services and Inspections Refer to TM 9—1425—525—12—4 for informa- tion on general procedures for all services and inspections. 3-5. Preventive Maintenance Checks and Ser- vices (Tables 3-1 through 3-3) a. These checks and services are to be per- formed by the organizational maintenance mechanic and the operator. Only those procedures beyond the responsibilities of the operator will be performed by the mechanic. The battery mainte- nance supervisor will determine the specific areas of responsibility. 4. The daily preventive maintenance checks are a systematic inspection of LCHR each day and after each time it is emplaced so that defects may be discovered and corrected before they result in serious damage or failure. c. Daily checks are to be performed before the weekly checks. Daily checks and then weekly checks are to be performed before doing the monthly checks, ete. 4. Ifthe equipment must be kept in continuous operation, check and service only those items that ean be checked and serviced without endangering personnel and without disturbing operation. Make the complete checks and services when the equip- ment can be shut down. ¢. Report any deficiencies using the proper forms (see TM 38—750). Any defects noted that are beyond the scope of the organizational mainte- nance mechanic will be reported immediately to the maintenance supervisor. £. The specific checks and services for the LCHR are listed in table 3-1. The personnel responsible for performing the checks and services at the various intervals are as follows: Interval Responsible Personnel Daily Operator Weekly Operator, organizational Monthly Operator, organizational Quarterly Operator, organizational 120-Day Direct Support Annually Operator, organizational 31TM 9—1440—$31—12—1 10, n BR Mu 3-2 Table $1. LCHR Preventive Maintenance Services D-DAILY W- WEEKLY ‘M- MONTHLY Q- QUARTERLY A- ANNUALLY Check for an accumulation of moisture. Insure that fore and aft ‘access door hinge fittings and access cover fasteners are tight- ‘ened to prevent water leakage. ‘Check deck lip surrounding the rear compartment opening for ‘missing sealing compound at the corners where the deck lip ‘members join. Replace sealing compound if necessary. Refer to paragraph 4-12. ‘Check to insure that the tape covering the nose fairings is in ‘good condition. Replace if necessary. Use tape 8125—00— 925 —8941. (Cheek for eracks or distortion or whenever the LCHR is trans- ported to another site. (Check boom snubbers for signs of leakage. Replace rubber bushings (8,10 fig. 5-191). ‘Boom snubber 1156787, check fllport level in accordance with the procedure in LO 9—1440—581—12. Check soubber support shaft (12, fig. 6-19) to insure that the spring pins are present. Replace if necessary. ‘Boom saubber 9091808, remove anubber from launcher and have direct support unit check fll level prior to replacement. Insure that it is operating properly. Inspect for loose con- ‘nections and defective insulation. Tighten, repair, or replace as required. Refer to TM 9—1425—525—12—4 Remove the drain plugs from the outriggers and the boom housing, and allow all moisture to drain out. If any hydraulic ‘uid is evident, check the hydraulic components for leaks. ‘Check accumulator gage for pressure indication of not lees than +2000 pei, when LCHR hydraulic is off. If necessary, energize LCHR to recharge. Discharge main hydraulic system and check main hydraulic reservoir for indication of proper level (between ADD and FULL marks). Fluid readings apply only when the oil is discharged fromthe hydraulic scumulator the auncher base level, and the ‘boom is in the down position. ‘With main hydraulic system discharged, check accumulator pressure gage for 1850 to 1750 pel. On the shoot-around console front panel, check the humidity Indicator for a blue color. Replace desiccant if the indicator is white or pink. Inspect connector 841 and other electrical components inside the LCU ease for moisture and corrosion. If necessary, clean connector with aleoho! 6810—00—241—4709 or Tolu 6810002812002 and apply a coat of insulation varnish MIL-V-178, 5970-00 —647-8676, to the connector. Inspect gasket between front pane! and panel mounting flange for depressions, kinks or scored areas and replace if necessary. Inspect preformed packing on front panel mounting serews for ‘excessive compression. Replace if necessary. Lubricate IAW LO 9144068112 and figure 4-1. Check fiters to soe that they are socure and free of foreign matter. Refor to TM 9—1425—525—12—4. ‘Cheek for proper operation and leaks.ce 16 RR SF RR LCHR Boom Forward Sector ‘Assefably and Shear Pins LCHR Boresighting ‘and Alinement LCHR Interunit Umbilical Cable Panel Meters ‘Launcher Sector Minsile Guide Rollers ‘Torsion Springs ‘LCHR Missile Retention Rear Outrigger ‘Access Covers Leveling ‘Azimuth Elevation ™ 9—1440—531—12—1 ‘Check for proper fluid level (full) and leaks. Fill and repair as required. Perform the forward rotating sector breakaway adjustment and replace the shear pins. Have direct support unit check as needed, but at least every 360, days. Have direct support perform cable leakage check per TM 91440-58142. Request DS maintenance personnel to perform periodic test procedures on all pane! meters every 960 days. Perform quarterly checks in tables 8-15 through 3-17. ‘Cheek for freedom of movement. If necessary, clean roller and bolt. If free movement is not obtained, have direct support replace rollers. Inspect and replace if necessary (paragraph 5-18). ‘Have direct support unit check as needed, but at least annually per TB 9—1440—581—34—1. (Cheek that the water drain holes are free of foreign material. Cheek leveling. Perform elevation and asimuth servo balance checks as directed in table 3-16, steps 1, 4 and 5. Upon completion of these checks, return the LCHR to REMOTE per table $-14. For readinen reporting, sedy/aralabe it Quarterly checks can- not be successfully performed. 3-2.1TM 9—1440—531—12—1 3.6. Main Hydraulic System @. Static Accumulator Pressure Check. Check the ACCUMULATOR PRESSURE gage (2, fig.2-4) for an indication of not less than 2000 pei. In absence of the hydraulic operation, it is normal for the pressure indication to change due to variation of oil, accumu- lator air temperature, and minor leakage. If, after 12 hoursof non-operation, the pressure drops below 2000 pai, then excessive leakage must be suspected. If this ‘occurs, recharge by energizing the hydraulic pump. ‘Then the following day and/or after 12 hours of non- ‘operation, recheck the pressure for not less than 2000 psi. Occasional recharging is not abnormal. However, if daily observance indicates a need to recharge more ‘than once a week, a leakage problem exists and must be corrected. Fluid level must be checked weekly and filled to the indicated level after the accu- mulator has been discharged. If both accu- mulator and reservoir are full, then dis- charge of the accumulator can cause the reservoir to explode. b Accumulator Discharge Procedure. Discharge the accumulator by holding the DISCHARGE switch (1, fig. 2-2) to DISCHARGE until the ACCUMU- LATOR PRESSURE gage indication drope to a min- ce imum, slowly builds up, and becomes statjonary. Re- lease the DISCHARGE switch. The pressure gage should now indieate the accumulator air pressure of 1850 to 1750 pai. If not, leakage between air and oil chambers in the accumulator is likely. c. Fluid Level Check. Check the hydraulic reser- voir fluid level gage for a reading between ADD and FULL marks. The fluid level indication is only valid when the fluid is discharged from the accumulator (par. b), the LCHR base is level, and the boom is in its FULL down position. @ Accumulator Air Pressure. With the accumu- lator discharged (par. b) the ACCUMULATOR PRES- SURE gage will indicate an accumulator air pressure of 1350 to 1750 pei. If the air pressure is less than the prescribed minimum, it should be recharged in ac- cordance with TM 9—1440—581—84—2, par. 2-2. ‘However, if it is necessary to recharge (air) more than ‘once a month, or for seasonal temperature changes, this indicates excessive leakage. NOTE ‘Any time the aceumalator is discharged, it must be before FULL (reservoir FULL minus finid in the accumu- lator). Paragraphs 3-7 and 3-8 DeletedT™ 9—1440—531—12—1 en Table 3-2. ILSCB Preventive Maintenance Services D- DAILY W- WEEKLY M- MONTHLY Q- QUARTERLY A> ANNUALLY mera | Procedures or readin pontine tem tem to be (Check for and have repaired ‘caulpment isnot e._[DpWyQ]a Inapected ‘oF adjusted as necessary ready available if: Item not reported indivi WARNING dually for readiness report- ing. Do not perform corrective maintenance when ‘equipment is energized unless indicated in operating check. 1. |e} ‘Telephone Head- | Insure that it is operating properly. Inspect for | set connections and defective insulation. Tighten, re- pair, or replace as required. Refer to TM 9-1425— 525-12-4, 2. le} Rubber Sheet | Check for damage. le] Cover seal Check for damage. le] Pressure Insure that it is closed. Quarterly checks cannot be Equalizer Valve successfully performed Table 3-3. Loading and Storage Pallet Preventive Maintenance Services D- DAILY W- WEEKLY M- MONTHLY Q- QUARTERLY ‘A; ANNUALLY Interval Procedures For readiness reporting, " Item to be ‘Check for and have repaired ‘cauipment isnot ae._| ow hudal Inupected or adjusted as necessary Ready available i 1 Missile Latching | Check operation of mechanisms and lever whenever Mechanisms missiles are removed or quarterly as follows: @ Remove ball lockpin from front of cradle. Front | . Front latch handle does latch handle should fall or move freely toaver- | not fall. tical position. b. Observe latch for indications of wear, fracture, | b. Latch fractured or dis- or distorti torted. ¢. Observe rear stop for indications of wear, frac- | c. Rear stop is fractured ture, or distortion. or distorted. d. Rotate rear stop by applying finger pressure |d. Stop does not retum forward and down to tip of stop. Stop should | rapidly tooriginal posi- rotate freely and return rapidly to original posi- | __ tion. tion when pressure is removed. ¢. Raise handle of front latch until it contacts the | ¢ Lock pin cannot be in- cradle; reinsert the ball lockpin to lock the latch. | serted. Observe that the rear stop is also in a locked | Quarterly checks cannot be condition as a result of this action. ‘successfully performed. 3-4en T™ 9—1440—531—12—1 Section IL OPERATIONAL CHECKS 3-9. Preparation for the Checks a. Obtain the test equipment required (table 3-4) for the periodic check to be performed. b, Notify the IBCC that you are beginning the ILCHR checks. Perform the launcher test set operation tests (TM 9-4935-542-12), and then perform the procedures given in table 3-9. 3-10. Shutting Down for Repair When the checks must be interrupted for repair, make a list of the actual position or condition of each control or assembly listed in table 3-10. Then shut down the ILCHR for repair as outlined in Table 3-4, External Test Equipment Required Launcher test et ‘Miniature guided ‘misaile simu- lators (3) Digital multimeter 10177187 "Used in system integrated checks, table 8-10. Keep the list until the checks can be resumed (par. 3-11). 3-11. Starting Up After Repair a, Prepare the ILCHR for resumption of the checks (table 3-11). b. Make sure that all controls and assemblies are at the position or condition indicated on the list made before shutting down for repair (par. 3-10) c. Resume the checks at the point of interrup- tion, 3-12. Energizing Procedures ‘The energizing procedures for the ILCHR are given in table 3-12, When performing the check procedures, table 8-12 may be omitted, as energiz- ing is an integral part of the check procedures. 3-13, Deenergizing Procedures ‘The deenergizing procedures for the ILCHR are contained in table 3-13. 3-14, Returning to Remote Operation Return the ILCHR to the control of the IBCC by performing the procedures in table 3-14. Tables $-5 through 3-8 deleted.Dgtizes by Googlecu TM 9—1440—531—12—1 Table 8-2. Preparation for the Checks ‘Location ‘Control or sammy Poation or condition TLSCB (fig. 2-10) LAUNCHERS OPERATE/SAFE SAFE ‘switch (10) for ILCHR under test ‘LOU (fig. 2-1) ‘Emplace on tripod at safe i from ILCHR. MAIN POWER switch (13) OFF LOCAL/REMOTE ewiteh (10) LOCAL HYD PRESS switch (9) OFF ALIGN switch (8) OFF AZIMUTH dial (4) O mils ELEVATION dial (3) Omils NO OBST CHECK/OPERATE OPERATE switch (6) ‘TEST POSITIONED switch (11) OFF Missile Minsile umbilical shorting plug Installed in missile umbilical receptacle Boom (fig. 2-12) BOOM HEATER ewiteh (2) OFF Boom support TLCHR level (1) Indicates level condition (fig. 255) ‘Azimuth stow lock assembly (4) Disengaged (outboard) (fig. 2-4) MANUAL AZIMUTH MOVEMENT Closed VALVE (3) (fig. 26) Hatch lock handnuts (3) Fingertight Ground rod Emplaced, with ground strap connected Base dietribution Circuit breakers CB1 through 0n (in) box (fig. 2-2) CBS, CBT, CB8, and CB12 (8 through 10) NORMAL/COLD WxIT (2) NORMAL Shootaround Minimum elevation lever (1) Record the setting, console then set to 0 mila, (fig. 2-11) Azimuth override lever (4) Record the setting, Launch Programmer Alinement tele- ‘scope and fire ‘cutout assembly (fig. 214) Forward rotating sector (fig, 2-9) ILCHR (fig. 1-1) ILCHR TLCHR (fig. 1-1) ALIGN/OPERATE switch (5) ALIGN NULL/COARSE/FINE ‘ewiteh (11) NORMALIW COLD KIT Gnsi programmer) Fire cutout ewitches (3) ‘Minile latch lever (2) Launcher control unit, Base airintake and -exhaust covers (4) and (12) Power and data cables Locking sleeves on leveling cylinders (5) and (7) Support jack (6) then set to 0 mile, OPERATE COARSE NORMAL, Record those that are set to the obstruction Position (out), then ‘set to the no-obstruc- ton position (in). Locked (down) On tripod a safe distance to rear of ILCHR Open Connected Secured Pully retracteddanzeoy Google eTM 9—1440-531—12-1 Table 8-10. Preparation for Mid-Check Repair Location Control or assembly Podtion or condition TLSCB (fig. 2-10) LAUNCHERS OPERATE/SAFE SAFE switch (10) for ILCHR under test LOU (fig. 21) MAIN POWER switch (13) OFF LOCAL/REMOTE switch (10) LOCAL ALIGN switch (8) OFF HYD PRESS switch (9) orF NO OBST CHECK/OPERATE OPERATE switch (6) ‘TEST POSITIONED switch (11) orF Base distribution DISCHARGE switch (1) DISCHARGE (until box (fig. 2-2) ‘ACCUMULATOR PRESSURE gage indicates minimum) CBT MAIN CIRCUIT BREAKER (8) oft (out) ILCHR Power and data cables Disconnected Table 3-11. Preparation for Resuming the Checks ‘Location Control or amembly Postion or condition Missiles Installed (TM 9—1425— 525), and shorting plugs connected ILCHR Power and data cables Connected Base distribution CB? MAIN CIRCUIT BREAKER (8) On (in) box (fig. 2-2) LOU (fig. 21) MAIN POWER ewiteh (13) ‘MAIN POWERTM 9-1440-531-12-1 cle Table 3-12. Energizing Procedures 8 It is assumed that three missiles are mounted on the LCHR. When the missiles are emplaced, do not point the boom at any HIPIR which is in radiate. If the HIPIR is in radiate, request the HIPIR operator to position the HIPIR antenna away from the LCHR under test. Insure that each missile rocket motor SAFE/ARM handle is in the SAFE position, each umbilical plug is disconnected from each missile, and that .. shorting plug is installed in each umbilical receptacle. Set the MAIN POWER switch (13, fig. 2-1) to MAIN | ‘The MAIN POWER lamp (1, fig. 2-1) illuminates. POWER. Clear all personnel from the boom radius of rotation. Setting the HYD PRESS switch (9, fig. 2-1) to HYD PRESS will result in immediate LCHR boom movement, pro- vided the MAIN POWER switch has been in the on position for more than 30 seconds. Set the HYD PRESS switch to HYD PRESS. ‘The hydraulic pump motor operates. The sccumulator Pressure gage should indicate not lees than 2400 pai. ‘The LCHR boom slews to the settings of the AZIMUTH and Set the HYD PRESS switch to OFF. ELEVATION dials (4 and 8, fig. 21).cn TM 9—1440-531—12-1 Table 3-13. Deenergizing Procedures rowetre Norma indication ‘Set the LAUNCHERS OPERATE/SAFE switch (10, fg. 2-10) for the ILCHR under test to SAFE. Clear all personnel from the boom radius of rotation, Set the MAIN POWER switch (13, fig. 2-1) to OFF ‘The MAIN POWER lamp (1, fig. 2-1) extinguishes. Place LOCAL/REMOTE switch in LOCAL position. ‘The ILCHR accumulator is under constant hydraulic pressure in excess of 2000 pei. In the event of primary 416-vac power failure, the accumulator pressure cannot be relieved by means of the DISCHARGE switch. The accumulator will remain under normal pressure until this pressure is deliberately relieved. Set and hold the DISCHARGE switch (1, fig. 2-2) to DISCHARGE until the ACCUMULATOR PRESSURE gage (2, fig. 2-4) indicates minimum pressure. Table 3-14. Preparation for Remote Operation Location Control or aemty Postion or condiion IUCHR (fig. 1-1) TORR Emplaced for fing (IM 9-1425~525) Boom (fig. 27) Elevation fire interrupter lever (1) Set as prescribed by site (ig. 212) BOOM HEATER switch (2) OFF unless operating with cold weather Kit Boom support (Sg. 2:5) | Azimuth tow lock assembly (4) Divengased (ig. 24) MANUAL AZIMUTH MOVEMENT VALVE (3) lowed (i 24) ACCUMULATOR PRESSURE gage (2) Indicates not let than 2000 pai Soot around console Minimum elevation lever (1) Set as prescribed by site (hg. 241) ‘Azimuth override lever (4) Set as prescribed by site Aiinement telescope and fire | Fire cutout switches (3) Set as prescribed by site cutout assembly (fig. 2-14) NOTE During non-tectical operations the LCU and communications station need not be stowed, Reter to paragraph 2-3 for instructions. LCU (fig. 21) ‘Communication station and associated cables Removed and stowed ILCHR base (fig. 1-1) Leu Mounted ILCHR base (fig. 1-1) LCU tripod Stowed Base distribution Circuit breaker CBI through CBS, CB7, Goo, and CB12 ‘ON (in) I box (fig. 2-2) ILCHR (fig. 1-1) All hatches and covers Closed and securedT™ 9—1440—531—12. cu Table 3-14. Preparation for Remote Operation—Continued Location ‘Control or assembly Poulton or condition LCHR (fig. 1-1) LOU (fig. 2-1) LOHR base (fi LSCB (fig. 2-10) Leu 3-15 Check Procedures a. Tables 3-15 through 3-17 comprise the procedures for checking the conditionof the LCHR quarterly. In addition, the quarterly checks must be performed when the following conditions exist: (1). The daily integrated system checks indi- cate a failure in this major item area. (2) Maintenance has been performed on the wuncher. 6. The check procedures have been written for orderly progression throughout the entire elec- trieal checkout. When the corrective procedure indicates the performance of another check, such as a fault isolation table, use particular care to make certain that all controls are correctly set for the corrective procedure. c. If a normal indication is not obtained when performing the checks as listed, make certain that the correct procedure is being used, and that the external test equipment is operating correctly before troubleshooting for defective units in the LCHR. If the indicated corrective procedure, if any, does not correct the fault, perform the fault isolation procedures in TM 9-1440-531—12-2. 4, The following sample table explains the use and layout of the check procedure tables. Notice that the operations, normal indications, and cor- rective procedures are alined with their respective headings, as indicated in this sample by the verti- cal arrowed lines. Elevation fire interrupter lever AZIMUTH indicator dial (4) ELEVATION indicator dial (3) MAIN POWER switch (13) LOCAL/REMOTE switch (10) LAUNCHERS OPERATE/SAFE swit for appropriate LCHR Set as prescribed by site Set as prescribed by site by site Set as preset MAIN POWER REMOTE Cover closed OPERATE (a0) ¢. Before starting the checks, perform the applica- ble preventive maintenance checks and services in tables3-1 through 3-4, and the preparation for checks (par. 3-9). f. The checks require organizational main- tenance personnel with assistance from an oper- ator. A minimum of two men is required for safety and convenience when performing checks. During periods of continuous operation, selected checks may be performed more frequently than quarterly to insure that the equipment is operst- ing correctly. &. Upon emplacement of the LCHR, perform all the check procedures contained in tables 3-15 through 3-17. h. Although operational tolerances are specified, in many cases during the checks the operator should attempt to adjust for optimum operation within these tolerances. “Peaking” within tole ances will provide reasonable assurance that equip- ment will operate satisfactorily between mainte nance services. Operator personnel must be able to recognize less-than-optimum performance during normal operation and the performance of operator checks. When the corrective action for this per formance is beyond their capability, they will report it to maintenance personnel. Adjustments are a normal part of the checks and do not neces sarily indicate equipment malfunctions. Table Sample Table firmer rote T t 1. Teheck (Step Name) Sequence and step name of the specific check. a. (OPERATION) Sequential operations required to obtain a normal indication. | NORMAL moyeamion Normal (CORRECTIVE PROCEDURE) applicable. tem oF circuit responses. Adjustment listing if 3-10™ 9—1440-$31-12-1 Table 4-15. Power Distrib step net ition Corective poetare NOTE ‘The key numbers shown below in parentheses refer to figure 8-8, unless otherwise indicated. Insure that the fire cutout switches positions have been recorded as specified in table 3-9 before proceeding with the check procedures, LW Cheek Main Power. It is possible to fire an armed missile with the launcher test set. Before connecting the launcher test set, disconnect all missile umbilicals and install missile umbilical shorting plugs on the missile umbilical connectors, a. Emplace the launcher test set (LTS) (fig. 3-8) at a safe distance from the ILCHR and connect the power cable to a UTILITY receptacle (18, fig. 1-1). b. Connect test data cable 16W2 between connector J2 (16W2) on the LTS and FIRE UNIT JUNCTION BOX receptacle J2 (15, fig. 1-1) on the ILCHR. e. Connect test data cable 17W1 between connector J8 (17W1) on the LTS and connector P8010A (umbilical A). a. Set the following controls to the positions listed, in the sequence listed: Control Position POWER switch (32) OFF LAUNCHER STANDBY switch (4) OFF 7K THRU MEMORY switch (12) OFF ELEVATION FAST TON BLOW switch (34) OFF Penner UP/DOWN switch (35) uP LEAD Ana SET pos NtaH (27) OUT LEAD ANGLE selector switch ELEVATION ALERT switch AR {i 2), OFF AZIMUTH FAST/OFF/SLOW switch (42) OFF AZIMUTH cowjew switch (43) cCcw MESSAGE selector switch om OFF MISSILE PRESENT/READY switch (8) ON FUNCTION SELECTOR switch (36) 28 VDC OPERATE/RESET switch (25) OPERATE LOCAL/RI EMOTE aa'sh ), fig. 2-1) REMOTE AZIMUTH (4, fig. 2-1 O mils ELEVATION dial (3, fig. 21) O mils — Refer to appendix D for serial number effectivity.TM 9—1440-531-12-1 Table $-15. Power Distribution System Check - Continued Neral een Carer proclore ‘Set the MAIN POWER switch (18, fig. 2-1) to MAIN POWER. ‘The MAIN POWER lamp (1, fig. 2-1) ilhuminates. ‘The LAUNCHER READY lamp (1) illuminates. ‘Set the POWER switch (82) to ON. Check Standby. Set the LAUNCHER STANDBY switch (4) to ON. ‘The FUNCTION meter (38) indicates the green area. ‘The LAUNCHER STANDBY lamp (2) ilfuminates. ‘The LAUNCH INDICATION lamp (18) illuminates. ‘The MISSILE PRESENT/READY (6) lamp and SEQUENCE START/STOP (24) lamp illuminate. Set the LEAD ANGLE SET AZ and EL controls (28 and 46) to 0 mils. Set the LAUNCHER STANDBY switch to OFF. Set the MAIN POWER switch (13, fig. 2-1) to OFF. Remove the rear compartment cover from the ILCHR base. Set the POWER switch (82) to OFF. Disconnect test data cable 17W1 from P3010A.TM 9—1440-531—12-1 cs Table 4-16, Boom-Positioning System Check Sup om ermal tention Corrective procetre 1. (Chock Manual Azimuth. a. Open the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4), and manually move the ‘boom support one revolution in each direction. The boom support does not drag or bind. b Close the MANUAL AZIMUTH MOVEMENT VALVE. Clear everyone from the boom field of travel. © Set the LOCAL/REMOTE switch to LOCAL, and the HYD PRESS switch to HYD PRESS (10 and 9, fig. 2-1). a Set the MAIN POWER switch (13, fig. 2-1) to MAIN POWER. After approximately 30 seconds, the hydraulic pump operates. The rear compartment blower operates. The boom elevates to 0 mils elevation and slews to 0 wath. 2 Check Local Azimuth Positioning. Rotate the azimuth handwheel (7, fig. 2-1) clockwise and counterclockwise. The boom smoothly follows the ssimuth indicated on the AZIMUTH dial (4, fig. 2:1) and does not sustain oscillations. Perform step 3 below. Check Local Elevation Positioning. Rotate the elevation handwheel (12, fig. 2-1) clockwise and counterclock wise. The boom smoothly follows the elevation indicated on the ELEVATION dial (3, fig. 2-1) and does not sustain oscillations. 4 Check Elevation Positioning Servo Balance. The boom drifts in azimuth and elevation during these checks. ‘The person using the multimeter must exercise extreme caution. NOTE ‘A minimum of 10 minutes for warmup must be allowed prior to evaluating the need for adjust- ment. a ‘Set the MAIN POWER switch to OFF. 3-13T™ 9—1440—531—12—1 cu Table 3-16. Boom-Positioning System Check — Continued Step Noomalidiettion 6 sreedare NOTE If the multimeter T$505/U is being used, allow for # 10-minute warmup. 4b. Set digital multimeter 10177187 to measure +100 vde. © Insert the INPUT LO test lead of the multimeter into test jack J1 (22, fig. 3-1) and the INPUT HI test lead into test jack J2 (23, fig. 3-1) on the elevation control amplifier. a. Set the MAIN POWER switch to MAIN POWER. Using the elevation handwheel, elevate the boom to 270 mils as indicated on the ELEVATION dial. NOTE Step / eliminates a possible silted condition of the elevation servo valve. f. Rapidly rotate the elevation handwheel approximately 100 mils above and below the 270- mil setting 6 times, and then retum the handwheel to the 270-mil setting from the clockwise direction, then repeat returning to the 270-mil position from the counterclockwise direction. & Adjust balance control R22 (21, fig. 3-1) on the elevation control amplifier until equal plus and minus voltages are indicated on the multimeter. ‘The multimeter indicates —0.5 to 0.5 vde. NOTE It is normal for the balance to change with warmup time, temperature, primary voltage, and dynamic loading. However, if the amplifier is properly balanced and is rechecked at a later time after being turned off, the indication should be within —0.9 to 0.9 vde, provided the check is made under similar conditions. 5. ‘Check Azimuth P joning Servo Balance. The boom drifts during this check. The person using the multimeter must exercise extreme caution. NOTE A minimum of 10 minutes for warmup must be allowed prior to evaluating the need for adjust: ment. Set digital multimeter 10177187 to measure +100 vde. Insert the LO test lead of the multimeter into test jack J1 (14, fig. 3-1), and the HI test led into test jack J2 (15, fig. 3-1) on the azimuth control amplifier. NOTE Before proceeding with the check, read the procedures for steps ¢ through f below. These steps ‘must be performed in sequence with no delay between steps. 31413 Table $-16. Boom-Positioning System Check—Continued Operation a et att Corrective procedure NOTE Step c eliminates a possible silted condition of the azimuth servo valve. Rapidly rotate the azimuth handwheel 100 mils counterclockwise and 100 mils clockwise from the initial setting at least 6 times. ae4.1danzeoy Google <™ 9—1440—531—12—1 Table 4-16. Boom-Positioning System Check — Continued From the clockwise direction, smoothly and slowly return the azimuth handwheel to the original position, and adjust balance control R22 (13, fig. 3-1) on the azimuth control amplifier for 0 vde. Rotate the azimuth handwheel clockwise 100 mils, and then smoothly and slowly return the handwheel to the original position. ‘The multimeter indicates between —0.5 to 0.5 vde. | Rotate the azimuth handwheel counterclockwise 100 mils and then smoothly and slowly return the handwheel to the original position. The multimeter indicates —0.5 to 0.5 vde. NOTE Under certain conditions, the multimeter indication obtained in steps ¢ and f above may not be centered at 0 vde. If this occurs, the azimuth control amplifier may be balanced, using the following procedure: Determine the adjustment of balance control R22 relative to servo dead space, and adjust R22 to obtain approximately equal errors of opposite polarity when approsching the original azimuth ‘from both the ew and cew directions. For example: Approach the original azimuth from the clockwise direction; the meter indication is -0.5 vde. Approach the original asimuth from the counterclockwise direction; the meter indication is 0.1 de. ‘Thos, the servo dead space lies between -0.5 and 0.1 vde. ‘Adjust R22 for a positive indication of approximately 0.25 or 0.80 vde in an effort to shift the center of the dead space to 0 vde. Recheck the balance from both directions; if necessary, readjust and repeat the procedure until the servo dead space is within -0.5 to 0.5 vde. Uf the dead space exceeds 0.6 vde, faulty hydraulic components are indicated. Continue to monitor the indication for approximately one minute to determine that no erratic or excessive drift conditions exist. ‘The multimeter indicates —0.5 to 0.5 vde. NOTE It is normal for the balance to change with warmup time, temperature, primary voltage, and dynamic loading. However, if the amplifier is properly balanced and is rechecked at a later time after having been turned off, the indication sbould be within —0.9 to 0.9 vde, provided the check is made under similar conditions. Using the azimuth handwheel, set the boom support to 0 mils. Disconnect and remove the multimeter. FaryT™ 91440531121 10 Table 3-16. Boom-Positioning System Check — Continued sup Normal indletion Corrective procedure Check Elevation Fail-Safe and Boom Snubber Seating. The LCU must be emplaced on the tripod a safe distance from the ILCHR to prevent personnel from being hit by the launcher boom. Inspect the boom snubbers (10, fig. 1-1) for evidence of hydraulic leakage. A leaking snubber could result in missiles being dropped from the ILCHR. If leakage is observed, replace the snubber (chapter 5). Rotate the elevation handwheel clockwise until an elevation angle of 800 mils is indicated on the ELEVATION dial. Set the MAIN POWER switch to OFF. ‘The boom settles to the lower stops in not less than 3 seconds. Both snubber piston rod-ends seat within the cup of the striking plate. Refer to paragraph 5-51 for adjustment. Set the HYD PRESS switch on the LCU to OFF. Check Remote Azimuth Positioning. Set the POWER switch (32, fig. 3-3) to ON. 6 Unlock the azimuth lock (2, fig. 3-7) and rotate the alinement telescope and fire cutout assembly azimuth scale (8, fig. 2-14) to aline 8200 mils with the zero azimuth reference indicator (7, fig. 2-14), and then lock the azimuth lock. & Using the AZIMUTH FAST/OFF/SLOW and AZIMUTH CCW/CW switches (42 and 43, fig. 3-3), set the AZIMUTH dial (45, fig. 3-3) to 0 mils. a ‘Set and hold the ALIGN/OPERATE switch (5, fig. 2-11) to ALIGN. e Set and hold the ALIGN NULL/COARSE/FINE switch (11, fig. 2-11) to ALIGN NULL. f Rotate the differential generator COARSE ADJUST control (10, fig. 2-11) until the ALIGN meter (6, fig. 2-11) indicates a null of 6 vrms maximum (60-vrms scale). 9. Release the ALIGN NULL/COARSE/FINE switch. 3-16Tm 9—1440—31—12—-1 o Table 4-16. Boom-Positioning System Check — Continued 7 sep Sent tin Th. Rotate the differential generator COARSE ADJUST control clockwise until the ALIGN meter indicates a null of 6 vrms maximum (60-vrms scale). Set and hold the ALIGN NULL/COARSE/FINE switch to FINE. Rotate the differential generator COARSE ADJUST control clockwise or counterclockwise until the ALIGN meter indicates a null of 200 mvrms maximum (6-vrms scale), and release the ALIGN NULL/COARSE/FINE switch. Release the ALIGN/OPERATE switch. Using the AZIMUTH FAST/OFF/SLOW and AZIMUTH CCW/CW switches, position the AZIMUTH dial to 200 mils. Clear everyone from the boom field of travel. Set the MAIN POWER switch to MAIN POWER and allow approximately 30-seconds warmup before proceeding. Set the HYD PRESS switch to HYD PRESS. The boom slews to the azimuth and ele: jon positions indicated on the LCU. Check the elevation setting on the LTS to prevent driving the launcher to its upper limit during this step. Set the ALIGN switch (8, fig. 2-1) to ALIGN. The boom slews to the position indicated by the LTS AZIMUTH and EL- EVATION dials (43 and 30, fg, 3-3). Check Servo Dynamic Performance. NOTE ‘This teat must be performed with one, two, oF three missiles installed on the ILCHR. It is possible to fire an armed missile with the launcher test set. Be sure that all missile umbilicals are disconnected, and that shorting plugs.are installed on the missile umbilical connectors. Set the HYD PRESS and MAIN POWER switches to OFF. Connect test data cable 17W1 between connector J3 (17W1) on the LTS and connector P3010B (umbilical B). Set the MAIN POWER switch to MAIN POWER and allow approximately 30-seconds warmup before proceeding. a7TM 9-1440-531— a Table 3-16. Boom-Positioning System Check—Continued “ _ Soe te ermine pn 80.3, Set the HYD PRESS switch to HYD PRESS. oe Using the ELEVATION FAST/OFF/SLOW switch (34, fig. 3-3), position the boom to exactly —60 mils as indicated on the elevation dial (3, fig. 2-8). © Verify that the LEAD ANGLE selector switch (37, fig. 3-3) is set to ELEVATION. d. Set the LEAD ANGLE SET IN/OUT switch (27, fig. 3-3) to IN. « Adjust the LEAD ANGLE SET EL control (28, fig. 3-3) until the elevation dial on the boom indicates exactly 600 mils, then tighten the knurled knob. f Set the LEAD ANGLE SET IN/OUT switch to OUT. 9 Using the ELEVATION FAST/OFF/SLOW switch, position the boom to exactly 270 mils as indicated on the elevation dial on the boom. A Using the AZIMUTH FAST/OFF/SLOW switch, position the boom support to exactly 700 mils as indierted by the azimuth vernier pointer (1, fig. 2-6). i, Set the LEAD ANGLE selector switeh to AZIMUTH. ii Set the LEAD ANGLE SET IN/OUT switch to IN. k, Adjust the LEAD ANGLE SET AZ control (46, fig. 3-3) until the azimuth vernier (1, fig. 2-6) indicates exactly 1300 mils, then tighten the knurled knob. L Set the ALIGN switch to OFF. m, Set the LEAD ANGLE SET IN/OUT switch to OUT. NOTE Allow time for the ILCHR boom to position to the LCU before performing step x. n, Set the LOCAL/REMOTE switch to REMOTE. 0 Set the following controls on the LTS (fig. 3-3) to the positions listed: Control Position LAUNCHER STANDBY switch (4) ON LOCK THRU MEMORY switch (12) ON INTERNAL POWER switch (16) ON LEAD ANGLE selector switch (37) | BOTH TIMING FUNCTION switch (48) 2 NOTE ‘The indications of steps p and { below are for three missiles and no cold weather kit installed on the ILCHR. If fewer than three missiles and/or a cold weather refer to the table at the end of atep 8 for the normal indict Clear everyone from the boom field of travel. p. Momentarily press the FIRE pushbutton (3, fig. 3-3). I! The installed on the ILCHR, MER dial (49, fig, 3-3) indicates 3.55 seconds maximum.TM 9-1440-531-12-1 Table 3-16. Boom: Positioning System Check—Continued a Navman Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch (25, fig. 3-3) to RESET, then return it to OPERATE. Set the TIMING FUNCTION switch to position 10. Momentarily press the FIRE pushbutton. ‘The TIMER indicates 1.8 seconds maximum. Reset the TIMER. Set the HYD PRESS and MAIN POWER switch to OFF. Disconnect test data cable 17W 1 from P3010B. NOTE Refer to paragraph 2-15 for missle unloading procedures. Remove the missiles from the ILCHR. NOTE Select the normal indication from the table below that corresponds to the number of missiles installed on the ILCHR. Minailes/eotd weather kit ‘natalled Step at ‘Aorc 1.75 max Bonly 1.78 max BrAorC 1.70 max A,ByandC 1.80 max - Cold weather kit Cheek Elevation Fire Interrupter. Set the minimum elevation lever (1, fig. 2-11) on the shoot-around console to 250 mils. Set the azimuth override lever (4, fig. 2-11) on the shoot-around console to 500 mils. Remove the cover from the alinement telescope and fire cutout assembly. Insure that all fire cutout switches are set to the no-obstruction position Clear everyone from the boom field of travel. Set the MAIN POWER switch to MAIN POWER. Set the LOCAL/REMOTE switch to LOCAL. Set the HYD PRESS switch to HYD PRESS, and ws 30 seconds before proceeding. a9TM 9—1*40-531-12-1 Table 4-18. Boom-Positioning System Check ~ Continued Position the boom to 0 mils elevation as indicated on the ELEVATION dial (3, fig. 2-1). Set and hold the NO OBST CHECK /OPERATE switeh (6, fig. 2-1) to NO OBST CHECK. Rotate the boom throucin 6400 mils in azimuth. The no-obstruction lamp (5. fig. 2+1) does not illuminate. Elevate the boom to 275 mils. The no-obstruction lamp illuminates, Rotate the boom through 6400 mils in azimuth. ‘The no-obstruction lamp remains illuminated. Release the NO OBST CHECK /OPERATE switch. ‘Check Azimuth Override. a Set all fire cutout switches to the obstruction position (out). b Set and hold the NO OBST CHECK /OPERATE switch to NO OBST CHECK. Rotate the boom through 6400 mils azimuth. ‘The no-obstruction lamp does not illuminate. a Elevate the boom to 550 mils. The no-obatruction lamp illuminates. e Rotate the boom through 6400 mils in azimuth, ‘The no-obstruction lamp remains illuminated. L Release the NO OBST CHECK/OPERATE switch. o Set all fire cutout switches to the no-obstruction position (in). n. Check Shoot-Around Capability. a Rotate the alinement telescope and fire cutout assembly azimuth scale (8, fig. 2-14) to aline 50 mils with the zero azimuth reference indicator (7, fig. 2-14). b Set the fire cutout switch (3, fig. 2-14) that alines with the obstruction indicator arrow (2, fig. 2-14) to the obstruction position (out). Rotate the azimuth scale to aline 550 mils with the zero azimuth reference indicator. a. Set the fire cutout switch that alines with the obstruction indicator arrow to the obstruction position (out). e Set the four cutout switches between the previously set switches to the obstruction position (out). f Set the minimum elevation lever (1, fig. 2-11) on the shoot-around console to 0 mils. 9. Using the azimuth handwheel (7, fig. 2-1), position the boom to 500 mils, as indicated on the azimuth vernier pointer (1, fig. 2-6). h Using the elevation handwheel (12, fig. 2-1), position the boom to 100 mils.cs TM 9—1440—531—12—1 Table 3-16. Boom-Positioning System Check ~ Continued Corrcine procedure Clear everyone from the boom field of travel during the remainder of this check. The boom slews rapidly each time the setting of the TEST POSITIONED switch (11, fig. 2-1) is changed. Set and hold the TEST POSITIONED switch to TEST POSITIONED. ‘The ILCHR boom slews clockwise and stops at 703 to 737 mils, Release the TEST POSITIONED switch. ‘The ILCHR boom slews counterclockwise to 500 mils. Using the azimuth handwheel, position the boom to 100 mils as indicated on the azimuth vernier. Set and hold the TEST POSITIONED switch to TEST POSITIONED. ‘The ILCHR boom slews counterclockwise and stops at 6263 to 6297 mils. Release the TEST POSITIONED switch. ‘The ILCHR boom slews clockwise to 100 mils. Using the azimuth handwheel, position the boom to 300 mils as indicated on the azimuth vernier. Set and hold the TEST POSITIONED switch to TEST POSITIONED. ‘The ILCHR boom slews in elevation and stops at 303 to 337 mila, Release the TEST POSITIONED switch. The boom depresses to 100 mils elevation. Set the azimuth override lever (4, fig. 2-11) on the shoot-around console to 0 mils. Check Elevation Hydraulic Pressure Reduction. Connect digital multimeter 10177187 to a UTILITY outlet (13, fig. 1-1). Set the multimeter to measure 10 vde. Insert the LO test lead of the multimeter into test jack J1 (22, fig. 8-1) and the HI test lead into test jack J3 (24, fig. 3-1) on the elevation control amplifier. ‘The multimeter indicates 8.0 to 10.0 vde. Rotate the elevation handwheel until the ELEVATION indicator dial indicates —200 mils. Record the multimeter indication for reference. 3-21TM 9— 1440-531- 12-1 Table J-16. Boom-Positioning System Check ~ Continued Operation ep ermal tet Cone procedure 12 Cont. After the boom has been depressed, insure that personnel do not disturb any controls or switch settings other than those specified until this check has been completed; otherwise, injury or death may result to persons pressing the pressure reduction switches. e Press and hold the missile A, B, and C missile sensing switches (33, fig. 5-18) in the sequence listed below, while watching the multimeter. Ref ‘AandB Ref +0.5 to 1.5 ve Aor’ B Ref Aorc BandC Ref +0.6 to 1.6 vde BorC c Ref AorB Cand A Ref +0.5 to 1.5 vde CorA A,B, and Ref +0.8 to 1.5 we ABorc L Set the HYD PRESS switch to OFF. Set the MAIN POWER switch to OFF. 3-22cn T™ 9—1440-531—12-1 Table 4-17. Firing and Control System Check Ops Sree ttn Check Missile Heater Power. . NOTE ‘The key numbers shown below in parentheses refer to figure 3-3, unless otherwise indicated, ‘Connect LTS cable 17W 1 to the ILCHR A arm umbilical connector. Set the MAIN POWER switch (13, fig. 2-1) to MAIN POWER. Set the LOCAL/REMOTE switch (10, fig. 2-1) to REMOTE. Set the LAUNCHER STANDBY switch (4) to ON. Set the POWER switch (32) to ON. Rotate the SSLO HEATER CONTROL (39) fully clockwise. Set the FUNCTION SELECTOR switch (36) to SSLO HEATER. Press and hold the PRESS TO TEST pushbutton (41). The FUNCTION meter (38) indicates the upper red area. Slowly rotate the SSLO HEATER CONTROL fully counterclockwise. The FUNCTION meter indicates the lower red area. Adjust the SSLO HEATER CONTROL until the function meter indicates center scale. Release the PRESS TO TEST pushbutton. Rotate the GYRO HEATER CONTROL (40) fully clockwise. Set the FUNCTION SELECTOR switch to GYRO HEATER. Press and hold the PRESS TO TEST pushbutton. The FUNCTION meter indicates the upper red area. Slowly rotate the GYRO HEATER CONTROL fully counterclockwise. ‘The FUNCTION meter indicates the lower red area. Adjust the GYRO HEATER CONTROL until the FUNCTION meter indicates center scale. Release the PRESS TO TEST pushbutton. Check Missile Message Lines. Rotate the MESSAGE selector switch (26, fig. 3-3) to positions A through E. The LAUNCH COMMAND lam, NATION lamp (23, fig. 3-3) are i Set the MESSAGE selector switch to OFF. (21, fig. 3-3) and REAR SWEEP DESIG- yminated in each position. 3-23TM 9—1440—531—12-1 a Table 4-17. Firing and Control System Check ~ Continued Clear everyone from the boom field of travel. Insure that the LTS is emplaced in a location which provides sufficient slack in test cable 17W1 during movement of the boom. NOTE ‘The key numbers shown below in parentheses refer to figure 3-3, unless otherwise indicated. 3. | Check Firing Sequence. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY switch (4) 10 off for une second ta reset relay in the launch programmer and the LTS. a. Set the MISSILE PRESENT/READY switch (8) to ON. ‘The MISSILE PRESENT/READY lamp (6) illuminates. b Set the LOCK THRU MEMORY switch (12) to ON. ‘The LOCK THRU MEMORY lamp (10) illuminates. ©. Set the INTERNAL POWER switch (16) to ON. ‘The INTERNAL POWER lamp (14) does not illuminate. d. Rotate the elevation handwheel (12, fig. 2-1) until the ELEVATION indicator dial (3, fig. 2-1) indicates 100 mils. e Using the ELEVATION FAST/OFF/SLOW and ELEVATION UP/DOWN switches (34 and 35) set the ELEVATION dial to 100 mils UP. £ Record the setting of the elevation fire interrupter lever (1, fig. 2-7) on the boom and set it to0 mils. Set the minimum elevation lever (1, fig. 2-11) on the shoot-around console to 0 mils. Set all the fire cutout switches (3, fig. 2-14) to the no-obstruction position (in). i. Adjust the LEAD ANGLE SET AZ control (46) for 200 mils CW lead angle and the LEAD ANGLE SET EL control (28) for 150 mils UP lead angle, then tighten the knurled knobs. j Set the LEAD ANGLE selector switch (37) to BOTH. k Set the LEAD ANGLE SET IN/OUT switch (27) to OUT. NOTE Read al of step! before proceeding. L Momentarily press the FIRE pushbutton (3). 3-24TH 9—1440—531—12-1 ‘Table 3-17. Firing and Control System Check — Continued 3h ‘The SEQUENCE START/STOP lamp (24) extinguishes. ‘The base cooling blower operates. The boom slews to the azimuth and elevation indicated by the pointers on the AZIMUTH (45) and ELEVATION (30) dials. ‘The ARM lamp (5) illuminates. ‘The INTERNAL POWER lamp (14) illuminates. ‘The HEAD FU lamp (7) illuminates. ‘The GYRO RUNUP ON lamp (9) illuminates. ‘The GYRO RUNUP OFF lamp (11) illuminates. The ARM OFF lamp (13) illuminates. ‘The AIMED DELAY lamp (29) illuminates. The LEAD ANGLE ON lamp (15) illuminates. ‘The boom slews to the azimuth and elevation lead angle positions. ‘The LAUNCH COMMAND LATCH lamp (17) illuminates. The INITIATE lamp (19) illuminates. The DUD lamp (20) illuminates. The LEAD ANGLE OFF lamp (22) illuminates. ‘The SEQUENCE START/STOP lamp illuminates. The boom slews to the azimuth and elevation indicated by the pointers on the AZIMUTH and ELEVATION dials. The boom slews to the azimuth and elevation indicated by the LCU AZI- MUTH and ELEVATION dials (4 and 3, fig. 2-1). The hydraulics deenergize approximately 15 seconds after the boom slews to the LCU settings. The MISSILE PRESENT/READY (6) lamp extinguishes. m. Set the LAUNCHER STANDBY switch (4, fig. 8-3) to OFF for one second. 31. Check Alert and Alert Firing Sequence. NoTE ‘This step is to be performed only for ILCHR's *(R)! a Set the ALERT switch (46.1, fig. 3-3) to ON. ‘The base cooling blower and hydraulic pump operate. b Record the azimuth and elevation positions of the boom support and the boom. « Rotate the azimuth and elevation handwheels on the LCU. The boom follows in azimuth and elevation. * Refer to appendix D for serial number effectivity.TM 9—1440—531—12—1 an ‘Table 3-17. Firing and Control System Check — Continued Operation Sup Normal indication Corrective procedure 31d, Return the boom support and the boom to the azimuth and elevation positions recorded in step 3.1b. Momentarily press the FIRE pushbutton (3, fig. 3-3). The ILCHR goes through a normal firing sequence as outlined in step 3! except the hydraulics remain energized after the boom slews to the LCU settings. After 30 seconds, verify that the hydraulics remain energized. Set the ALERT switch to OFF. The base cooling blower and hydraulic pump cease to operate. Set the LAUNCHER STANDBY switch to OFF. Check Downstep. NOTE ‘The key numbers shown below in parentheses refer to figure 3-3, unless otherwise indicated. Set the MAIN POWER switch to OFF. Insert a 6/8-inch socket wrench into the sector release lock (1, fig. 2-12) access hole on each forward rotating sector. Release each forward rotating sector by rotating the wrench counterclockwise while pull- ing forward on the sector. | NOTE Do not reengage the sector-locking mechanism. Slowly rotate the sector clockwise until it rests on the locking mechanism. Secure a rope around the A forward rotating sector to permit pulling the sector forward while standing clear of the boom field of travel. Set the MAIN POWER switch to MAIN POWER, and the LAUNCHER STANDBY switch to ON. Clear everyone from the boom field of travel NOTE Read all of steps g and h before proceeding. Momentarily press the FIRE pushbutton (3), and observe the INITIATE lamp (19). Allow sufficient slack in the rope for lead angle insertion. 326T™ 9—1440—531—12—1 Table 3-17. Firing and Control System Check — Continued ermal indication Corrective prosntare NOTE [Lead angle removal and downstep insertion are simultaneous. When the INITIATE lamp illuminates, immediately pull the rope to pull the rotating sector forward. The boom depremes rapidly, approximately 180 mils. Set the LAUNCHER STANDBY switch to OFF for one second., ‘Transfer the rope from the A rotating sector to the B rotating sector, and repeat steps f through h above. ‘Transfer the rope from the B rotating sector to the C rotating sector, and repeat steps f ‘through h above. Remove the rope and rotate all three forward rotating sectors clockwise until they engage the locking mechanism. Check Missile Voltages. NOTE ‘Disregard all lamp indications not specified. NOTE ‘Tue key numbers shown below in parentheses refer to figure 3-8, unless otherwise indicated. NOTE Read all of steps « through c before proceeding. Insure that the LAUNCHER STANDBY switch is set to ON. Set the FUNCTION SELECTOR switch (36) to INITIATE. Momentarily press the FIRE pushbutton (3). The FUNCTION meter (38) momentarily indicates the white area marked INITIATE. When the FUNCTION meter indicates the white area, momentarily press the PRI TEST switch (41). ‘The FUNCTION meter indicator needle deflects to the green area, Toldanzeoy Google —sTM 9—1440—531—12—1 Table 3-17, Firing and Control System Check—Continued ‘Operation When the FUNCTION meter indicates zero, set the LOCAL/REMOTE switch to LOCAL and ff the HYD PRESS switch to HYD PRESS. Set the LOCAL/REMOTE switch to REMOTE and the HYD PRESS switch to OFF. Set the LAUNCHER STANDBY switch (4) to OFF for one second. | ‘The FUNCTION meter indicator needle does not deflect. Set the FUNCTION SELECTOR switch to GYRO RUN UP. Momentarily press the FIRE pushbutton. | ‘The FUNCTION meter momentarily indicates the green area. Set the LAUNCHER STANDBY switch to OFF for one second. Set the FUNCTION SELECTOR switch to ARM. Momentarily press the FIRE pushbutton. ‘The FUNCTION meter indicates the green area for approximately 3 seconds. I When the FUNCTION meter indicates zero, set the LOCAL/REMOTE switch to LOCAL and the HYD PRESS switch to HYD PRESS. ‘The FUNCTION meter indicator needle does not deflect. Set the LOCAL/REMOTE switch to REMOTE and the HYD PRESS switch to OFF. Set the LAUNCHER STANDBY switch to OFF for one second. ‘The FUNCTION meter indicator needle does not deflect. Set the FUNCTION SELECTOR switch to LAUNCH COMMAND LATCH. Momentarily press the FIRE pushbutton. | ‘The FUNCTION meter momentarily indicates the green area. Set the LAUNCHER STANDBY switch to OFF for one second. I 3-27TM 91440531121 ce Table 3-17. Firing and Control System Check — Continued Clear everyoné from the boom field of travel. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY switch to OFF for one second. Set the INTERNAL POWER switch to OFF. NOTE Read all of step b before proceeding. Momentarily press the FIRE pushbutton. ‘The SEQUENCE START/STOP lamp extinguishes. ‘The base cooling blower operates. ‘The boom slews to the azimuth and elevation indicated by the pointers on the AZIMUTH and ELEVATION dials (45 and 30, fig. 3-3). ‘The ARM lamp illuminates. ‘The INTERNAL POWER lamp does not illuminate. ‘The HEAD FU lamp illuminates. The GYRO RUNUP ON lamp illuminates. ‘The GYRO RUNUP OFF lamp illuminates. The ARM OFF lamp illuminates. ‘The AIMED DELAY lamp (J)' illuminates, ‘The HEAD FU GND lamp (H)' does not illuminate. ‘The LEAD ANGLE ON lamp does not illuminate. ‘The LAUNCH COMMAND LATCH lamp does not illuminate. The INITIATE lamp does not illuminate. The DUD lamp illuminates. ‘The LEAD ANGLE OFF lamp docs not illuminate. ‘The SEQUENCE START/STOP lamp illuminates. Set the MAIN POWER switch to OFF. Set the INTERNAL POWER switch to ON. "Refer to appendix D for serial number effectivity. 3-28cu ™ 9—1440—531—12—1 Table 4-17. Firing and Control System Check ~ Continued Step Nomal indeton 7. Check Missile B Arm, - a Remove test data cable 17W1 from umbilical plug A (P3010A) and connect the cable to umbilical cable B (P8010B). b Set the MAIN POWER switch to ON. © Perform steps If through 6, except step 4. 8. ‘Check Missile C Arm. a Set the MAIN POWER switch to OFF. 8 Remove test data cable 17W1 from umbilical plug B (P3010B) and connect the cable to umbilical cable C (P3010C). os Set the MAIN POWER switch to ON. a. Perform steps 1f through 6, except step 4. 9. Check End of Sequence (Umbilical Retraction). Clear everyone from the boom field of travel. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY switch to OFF for ane second. a Set the TIMING FUNCTION switch (48, fig. 3-3) to 6. NOTE Disregard all indications not noted NOTE Read all of steps c and d before proceeding. b Momentarily press the FIRE pushbutton. ¢ When the INITIATE lamp illuminates, immediately set the INTERNAL POWER switch to OFF. The TIMER dial (49, fig. 3-3) indicates 1.5 seconds maximum. da. Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. f Set the INTERNAL POWER switch to ON. 3-29TM 9-1440-531—12-1 a Table 3-17, Firing and Control System Check — Continued Corrective proctre 10. Check Deactivate Timer and Activate Off Time Delays. NOTE net the LAUNCHER STANDBY switch (o OFF for one second NOTE ‘To reset the TIMER dial, momentarily set the OPERATE/RESET switch to RESET. Set the TIMING FUNCTION switch to position 9. It necomary to repeat this step, NOTE Disregard all indieations not noted. Momentarily press the FIRE pushbutton. At the end of the sequence (launcher hydraulics deactivated), immediately press the TIMER MANUAL STOP pushbutton (47, fig. 3-3). Record the time indicated on the TIMER dial (approximately 40 seconds). Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. Momentarily press the FIRE pushbutton. When the boom returns to the azimuth and elevation of the LCU, immediately press the ‘TIMER MANUAL STOP pushbutton. The TIMER dial indicates 22.50 to 27.50 seconds. Record the indication. Calculate the difference between the recorded indications of steps c and g above. Calculate 12,75 to 17.25 seconds, Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. ‘Check Arm Off and Message Latch Timing. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY «witch to OFF for one second. NOTE ‘To reset the TIMER dial, momentarily set the OPERATE/RESET switch to RESET. Set the TIMING FUNCTION switch to position 1. Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 2.79 to 3.57 seconds. Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE.a ‘Tm 9—1440-531— 12-1 Table 8-17. Firing and Control System Check — Continued aan Set the TIMING FUNCTION switch to position 4. t Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 0.85 to 1.15 seconds. o Set the LAUNCHER STANDBY switch to OFF for one second. LS Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. Chock Ignite Enable and Ignite Off Timing. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY snitch to OFF for one second. NOTE ‘To reset the TIMER dial, momentarily set the OPERATE/RESET switch to RESET. * Set the TIMING FUNCTION switch to position 5 and momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 0.15 to 0.25 seconds. b Set the LAUNCHER STANDBY switch to OFF for one second. «. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. a Set the TIMING FUNCTION switch to position 6. « Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 2.10 to 2,58 seconds. £ Set the LAUNCHER STANDBY switch to OFF for one second. o Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. Check End Sequence and Abort Timing. NOTE If necessary to repeat thi step, set the LAUNCHER STANDBY switch to OFF for one second. NOTE ‘To reset the TIMER dial, momentarily set the OPERATE/RESET switch to RESET. ‘Set the TIMING FUNCTION switch to position 7. Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 0.42 to 0.58 seconds Set the LAUNCHER STANDBY switen to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to OPERATE. Set the TIMING FUNCTION switch to position 8. . ET, then return it to 331Ta 9-1440-531- 12-1 a Table 3-17. Firing and Control System Check — Continued’ Set the LOCK THRU MEMORY switch to OFF. Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 12.75 to 17.25 seconds. Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. Check Gyro Settle Time. NOTE If necessary to repeat this step, act the LAUNCHER STANDBY awitch to OFF for one second. Set the LOCK THRU MEMORY switch to ON. Adjust the LEAD ANGLE SET AZ and EL controls to 0 mils, then tighten the knurled knobs. Using the AZIMUTH FAST/OFF/SLOW switch, set the AZIMUTH dial to 0 mils. Rotate the elevation handwheel on the LCU until the ELEVATION dial indicates 0 mils. ‘Set the TIMING FUNCTION switch to position 3. ‘Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 0.12 to 0.22 seconds. Set the LAUNCHER STANDBY switch to OFF for one second. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. ws Roe ° ‘Check Aimed Delay Time. NOTE If ecemary to repeat this step, net the LAUNCHER STANDBY switch to OFF for one second. Position the LCU azimuth handwheel to 0 mils. Position the LCU elevation handwheel to —70 mils. ‘Set the TIMING FUNCTION switch to 2. Position the LTS ELEVATION dial to -70 mils. a & © a. NOTE Before performing step r below, prov the FIRE pushbutton t dicated by the LCU: then place the LAUNCHER STANDI ww the hoom to slew to the position im switch to OFF for one second. Set the CB1 HYDRAULIC PUMP circuit breaker (10, fig. 2-2) to off (out).ry TM 9-1440-531—12—1 Table 3-17. Firing and Control System Check ~ Continued 7 Sey Sarat tin comeing paedre 15 NOTE Cont. If the cold weather kit is installed, perform steps i through i in place of steps f through 4. . Otherwise perform steps / through h and proceed to step |. f Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 0.85 to 1.20 seconds. 9. Set the LAUNCHER STANDBY switch to OFF for one second. h Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE Set the NORMAL-W/COLD KIT switch on the launch programmer to COLD WKIT. Momentarily press the FIRE pushbutton. ‘The TIMER dial indicates 1.44 to 2.03 seconds. Set the NORMAL—W/COLD KIT switch to NORMAL. Set the CB] HYDRAULIC PUMP circuit breaker to on (in). Check Hangfire Due To An Obstruction. NOTE Te necessary to repent this stop, set the LAUNCHER STANDRY switeh tw» OFF for one second. Set the minimum elevation lever (1, fig. 2-11) on the shoot-around console to 0 mils. Set the azimuth override lever (4, fig. 2-11) on the shoot-around console to 700 mils. Rotate the alinement telescope and fire cutout assembly azimuth scale (8, fig. 2-14) to aline 50 mils with the zero azimuth reference indicator (7, fig. 2-14). Set the fire cutout switch (3, fig. 2-14) that alines with the obstruction indicator arrow (2, fig. 2-14) to the obstruction position (out). Rotate the azimuth scale to aline 550 mils with the zero azimuth reference indicator. Set the fire cutout switch that alines with the obstruction indicator arrow to the obstruction Position (out). Set the fire cutout switches between the previously set switches and three additional switches on both sides to the obstruction position (out). Using the AZIMUTH FAST/OFF/SLOW and AZIMUTH CCW/CW switches, set the AZIMUTH dial to 300 mils. Using the ELEVATION FAST/OFF/SLOW and ELEVATION UP/DOWN switches, set the ELEVATION dial to 200 mils. Adjust the LEAD ANGLE SET EL control for 200 mils UP, then tighten the knurled knob. 3-331440-531—12-1 cus Table 3-17. Firing and Control System Check ~ Continued Omen van v6 cone Clear everyone from the boom field of travel. NOTE Read all of step k before proceeding. k Clear the LCHR area and momentarily press the FIRE pushbutton. ‘The SEQUENCE START/STOP lamp extinguishes, ‘The base cooling blower operaten. ‘The boom slews to the azimuth and elevation indicated by the AZIMUTH and ELEVATION dials on the LTS. The ARM lamp The INTERNAL POWER lamp ‘The HEAD FU lamp The GYRO RUNUP ON Lamy ‘The GYRO RUNUP OFF lamp illuminates, The AIMED DELAY lamp illuminates. ‘The LEAD ANGLE ON lamp illuminates, Juminates. ‘The boom elevates to 625 mils, ‘The LAUNCH COMMAND LATCH lamp illuminates, ‘The INITIATE lamp does not illuminate. The DUD lamp illuminates. ‘The LEAD ANGLE OFF lamp illuminates, The boom depresses to 200 mils, ‘The SEQUENCE START/STOP lamp illuminates. L Set the LAUNCHER STANDBY switch to OFF for one second, a. Check Shoot-Over. NOTE If necessary repeat this step, set the LAUNCHER STANDBY switeh tv OFF for one second, a. Set the azimuth override lever (4, fig. 2-11) on the shoot-around console to 500 mils. 334ci T™ 9—1440—$31—12—1 Table 4-17. Firing and Control System Check — Continued Operation Normal indiestion Corrective procedure 17 Cont. Clear everyone from the boom field of travel. NOTE Disregard all indications not specified Clear the LCHR area and momentarily press the FIRE pushbutton. ‘The boom elevates to 625 mils. ‘The INITIATE lamp illuminates. ‘The DUD lamp illuminates, Set the LAUNCHER STANDBY switch to OFF for one second. 18. Check Hangfire Due to Not Being Aimed. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY switch to OFF for one second. Using the ELEVATION FAST/OFF/SLOW and ELEVATION UP/DOWN switches, set the ELEVATION dial to 1100 mils. WARNING } Clear everyone from the boom field of travel. NOTE Disregard all indications not specified. Clear the LCHR area and momentarily press the FIRE pushbutton. The boom elevates to its maximum upper limit. The INITIATE lamp does not illuminate. The DUD lamp illuminates. Reset the TIMER dial by setting the OPERATE/RESET switch to RESET, then return it to OPERATE. Set the MAIN POWER switch to OFF.T™ 9—1440—531—12—1 cu Tabte 3-17. Firing and Control System Check — Continued Normal indiention Corrective procedure neh 3-36 Check Ripple Fire. NOTE If necessary to repeat this step, set the LAUNCHER STANDBY switch to OFF for one second. Remove test data cable 17W1 for umbilical plug C (P3010C) and connect the cable to umbilical cable B (P3010B). Remove two miniature guided missile simulators from the LTS cover and install them on umbilical plugs A (P3010A) and C (P3010C). Set all the fire cutout switches to the no-obstruction position (in). ‘Set the azimuth override lever on the shoot-around console to 0 mils. Set the TIMING FUNCTION switch to position 8. Set the MAIN POWER switch to MAIN POWER. Using ELEVATION FAST/OFF/SLOW and ELEVATION UP/DOWN switches, set the ELEVATION dial to 200 mils. Clear everyone from the boom field of travel. NOTE Disregard all indications not specified, Clear the LCHR area and press and hold the FIRE pushbutton until C-arm has cycled through a normal firing sequence. A-arm miniature guided missile simulator ARM, GYRO RUNUP and INITIATE lamps (1, 2 and 3, fig. 3-4) illuminate during A.arm firing sequence. LTS indicates normal firing sequence for B-arm firing. C-arm miniature guided missile simulator ARM, GYRO RUNUP and INITIATE lamps illuminate during C-arm firing sequence. Launcher hydraulics shut off approximately 15 seconds after C-arm has completed one normal firing sequence. ‘The TIMER continues to run, Set the LAUNCHER STANDBY switch to OFF. Set the MAIN POWER switch to OFF. Disconnect the launcher test set, miniature guided missile simulators, and cables. Set the LOCAL/REMOTE switch to LOCAL. Set the minimum elevation lever (1, fig. 2-11) on the shoot-around console to the setting recorded in table 3-9.cw TM 9-1440—531—12—1 Table J-17. Firing and Control System Cheek — Continued Operon Step Sm cae n. Set the azimuth override lever (4, fig. 2-11) on the shoot-around console to the setting recorded in table 3-9. °. Set the elevation fire interrupter lever (1, fig. 2-7) on the boom to the setting recorded in step 3f. P. Set the appropriate fire cutout switches (3, fig. 2-14) to the obstruction position (out) as recorded in table 3-9. Check Azimuth Mechanical Drive. Do not operate the LCHR with the hatch raised. Raise the hatch (refer to par. 5-3). Measure the clearance between the azimuth drive gear (2, fig. 3-6) and the ring gear (1, fig. 3-6) using two thickness gages (3, fig. 3-6), one on either side of the gear tooth as shown in figure 3-6. The clearance between the azimuth drive gear and the azimuth be 0,005 to 0.007 inch. Inaure that all electrical connectors under the hatch are fingertight. ‘Check Boom-Positioning System Hydraulic Leakage. Visually inspect the hydraulic system for hydraulic fluid leakage. Inspeet the hydraulic pump for signs of excessive hydraulic fluid leakage. The hydraulic pump is dry. and the hydraulic fluid leakage indicator vial (5, fig. 1-2) in empty. If the fluid leakage indicator vial contains clear hydraulic fluid, the pump section of the hydraulic pump assembly may be defective. However, before replacing the hydraulic pump assembly, empty and clean the vial and note the fact on the preventive maintenance form. If the vial is refilled after one hour of hydraulic operation, replace the hydraulic pump assembly using the procedures outlined in chapter 5. If the fluid leakage indicator vial contains dark fluid, the motor section of the hydraulic pump assembly is defective. Replace the hydraulic pump assembly. Close the hatch (refer to chapter 5). Check Elevation Hydraulic Leakage Under Pressure. Remove the blast deflector cover (3, fig. 5-18) and the three boom inspection plates (4, 7, and 8, fig. 5-18). 3136.1cu Table 3-17. Firing and Control System Check — Continued Operation step Nerma ndeton os procter 2la. Cont. With pressure applied, do not rotate the azimuth or elevation handwheels or change the setting of any switches on the LCU, other than those specified, while performing this step. b. Set the MAIN POWER switch to MAIN POWER. ©. Set the HYD PRESS switch HYD PRESS. The hydraulic pump operates; the boom slews to the azimuth indicated on the AZIMUTH dial and to the elevation indicated on the ELEVATION dial on the LCU, d. Visually inspect the elevation hydraulic system for hydraulic fluid leakage. If hydraulic fluid leaks are present, complete steps e and f below before correcting the malfunction. e Set the HYD PRESS switch to OFF. f Set the MAIN POWER switch to OFF. Remove the forward and rear hydraulic fluid leakage plugs (1, fig. 1-1) from the outrigger castings to drain hydraulic fluid which may have collected. Then replace the leakage plugs. h. Replace the three inspection plates and blast deflector cover. 22. Aline ILCHR With IHIPIR. Refer to table 8-1, steps 3, 4, and 5 for this procedure, 23. Load Missiles on ILCHR. Load the missiles on the ILCHR (par. 2-11) but do not arm them. NOTE Inform the IBCC personnel that the checks for the ILCHR have been completed. When requested, place the ILCHR in remote operation per instructions in paragraph 3-14 3-37TM 9—1440-531-12-1 cu | ‘Section Ill. HAWK SYSTEM SILENT MODE REDEPLOYMENT CHECKS 3-16. General 3-17. Preparation This section contains information pertaining to When directed to prepare the LCHR’s for the the HAWK system silent mode redeployment checks. silent mode redeployment checks by the BCC or PCP These checks are performed by the BCC or PCP _ personnel, perform table 3-18. The number of missile personnel following emplacement to establish inte- simulators required per LCHR is as follows: two ‘stem confidence without placing system _ missile simulators for the first LCHR to be tested in the radiate mode. each fire section, and one missile simulator for each of the other two LCHR’s. Only one LCHR is tested at any one time, allowing ample time to transfer one missile from the first LCHR to the third. Table $-18. HAWK System Silent Mode Redeployment Checks Preparation two for first available LCHR, one per available Missile simulators LCHR thereafter. 2 LCHR MAIN POWER switch ON. 13 3. LCHR LOCAL/REMOTE switch LOCAL. 10 4 LSCB LAUNCHERS 1, 2, and 3 OPERATE/SAFE switches .. SAFE. 10 5. LSCB MSL COUNT DELAY switch ABOVE 18°C (65°F) or 6 tactical setting. 6. Report completion of LCHR and LSCB preparation to BCC/PCP personnel and await further instruction. I Section IV. ADJUSTMENT ILLUSTRATIONS order wherever possible, according to the require- section contains illustrations necessary for ments of the check procedures, clarifying the tests operator and organizational maintenance of the and familiarizing the operator with the location of LCHR. The illustrations are presented in logical controls, test points, and adjustments.Byly Bes se TT MI 738148 NOTE: Refer to appendix D for serial number effectivity. Figue 8-1. Blectronic rach, TH 91440531121 aeTM 9—1440-$31-12-1 feo-T-------------- ) SEE NOTE 20 23 1—Launch programmer 2-TP5 (jack J7) 3~TP4 (jack J6) “TPS (jack J5) 5-TP2 (jack Ja) 6—TPI (jack J8) ‘7—Control amplifier power supply |~Test jack J5 )—Test jack J4 10—Teat jack J3, 11—Test jack J2 11.1—Teat jark (37) *( AC) sre note 12--Azimuth control amplifier 13—Balance control R22 13.1—Test jack (38) *(AC) see note 14~Test jack Jt 15—Test jack J2 16—Test jack J3 17—Test jack J4 18—Test jack J5, 18.1—Teat jack J7 (AC) s00 note 19—Teat jack JB 20—Elevation control amplifier 21—Balance control R22 22—Test jack J1 22.1—Teat jack JB *(AC) see note 23—Teat jack J2 24—Teat jack J3 26—Teat jack J4 26~Teat jack J5 27—Teat jack J6 Figure 3-1 — Continued. NOTE: Refer to appendix D for serial number elfectivity,TM 9-1440-531-12-1 or Ee oe f -B- 13 31.30 29 28 27 26 25 24 23 22:21:20 19 «18 17 16 MI 73815 Figure 8-2, Shoot-ardund console (front panel open).242 |440-531—12-1 1-Blevation servo geartrain 2Test jack J7 3~Teat jack J5 4—Test jack J3 5—Test jack J2 @—Test jack Ja ‘TTest jack J6 8Test jack J8 ‘9-Logic chassis 10—Test jack J9 11—Test jack 310 12~Test jack J6 13—Test jack 37 14—Test jack JB 15—Test jack J2 16—Test jack J3 17—Test jack J4 18~Teat jack 35 19Teat jack 314 20~Teat jack 313 21—Test jack 312 22—Test jack J11 23—Azimuth servo geartra 24—Test jack 37 25—Test jack 36 26—Test jack J8 21—Teat jack 39 28—Teat jack 33, 20—Teat jack J2 30—Test jack 35 B1—Test jack 34 '32-Blevation servoamplifier 33Test jack 32 = Continued Figure 34—Test jack J3 35—Teat jack J4 ‘36—Teat jack J5 37—Test jack J6 38—Test jack J7 39-Azimuth servoamplifier 40—Test jack J2 41—Test jack J3 42Test jack Ja 43—Test jack J 44—Teat jack J6 45—Teat jack J7 46—28-Vde power supply 47—Teat jack J2 48—Variable resistor R7 49—Teat jack J3cn 43 42 MOTE. REFER TO APPENDIX D FOR SERIAL NUMBER EFFECTIVITY. 1-LAUNCHER READY lamp 2-LAUNCHER STANDBY lamp ‘3-FIRE pushbutton 4-LAUNCHER STANDBY ewitch 5—ARM lamp 6-MISSILE PRESENT/READY lamp ‘THEAD FU lamp 8-MISSILE PRESENT/READY switch ‘9+GYRO RUNUP ON lamp 10-LOCK THRU MEMORY lamp 11—GYRO RUNUP OFF lamp 12-LOCK THRU MEMORY ewitch 13—ARM OFF lamp |4—INTERNAL POWER lamp 16-LEAD ANGLE ON lamp 16-INTERNAL POWER switch 17-LAUNCH COMMAND LATCH lamp 18-LAUNCH INDICATION lamp 19INITIATE lamp 20—DUD lamp 21—-LAUNCH COMMAND lamp 22-LEAD ANGLE OFF lamp 23-REAR SWEEP DESIGNATION lamp 24~SEQUENCE START/STOP lamp 25—OPERATE/RESET ewitch Figure 3-3. Launcher tea 39 TM 9—1440—531—12—1 Oh 3837 «3635 34 26—MESSAGE selector switch 27-LEAD ANGLE SET IN/OUT switch 28—LEAD ANGLE SET EL control 29-AIMED DELAY lamp 30-ELEVATION dial ‘S1-ELEVATION LEAD ANGLE lamp ‘32-POWER switch ‘33—-POWER lamp ‘34—ELEVATION FAST/OFF/SLOW switch ‘35—ELEVATION UP/DOWN switch ‘36-FUNCTION SELECTOR switch 37-LEAD ANGLE selector switch ‘38-FUNCTION meter 39-SSLO HEATER CONTROL 40-GYRO HEATER CONTROL 41—PRESS TO TEST pushbutton 42-AZIMUTH FAST/OFF /SLOW switch 43—AZIMUTH CCW/CW switch 44—AZIMUTH LEAD ANGLE lamp 45—AZIMUTH dial 45.1—ALERT switch *(R)! 46-LEAD ANGLE SET AZ control 47—TIMER MANUAL STOP pushbutton switch 48—TIMING FUNCTION switch 49—TIMER dial et (LTS). MI 73816A, 3-43» Google _ israry INITIATE SIMULATOR GM MINAT )| [) SER NO PART NO 1067101: Mi 65629 1-ARM lamp 2-GYRO RUNUP lamp S-INITIATE lamp Figure 3-4, Miniature guided-missile simulator. TM 9—1440-531—12-1 MI 73818 1—-SAFE/ARM handle 2_-Motor-safe switch ‘8—Umbilical connector Figure 3-5. Missile safetyand-arming controls.TM 9—1440-531—12-1 a Telescope assembly 2-Azimuth lock Figure 4-7. Alinement telescope and fire cutout ansembly installation. Figure 3-8. Deleted. 1 MI 73819 1-Ring gear 2-Azimuth drive gear 3—Thickness gage Figure 8-6. Azimuth drive gear backlash measurement. 3-46T™ 9—1440—531—12—1 CHAPTER 4 MAINTENANCE INSTRUCTIONS Section | REPAIR PARTS, AND SPECIAL TOOIS AND EQUIPMENT 4-1, Repair Parts Repair parts are supplied to the using orga- nization for replacement of those parts that become worn, damaged, or otherwise unser- viceable, providing that replacement of these parts is within the scope of organizational maintenance. Section Il. 4-3. Scope a. When a new or reconditioned ILCHR, ILSCB or guided missile pallet is first received by the using organization, it is the responsibility of the officer-in-charge to determine whether the material has been properly prepared for service, and to insure that it is in condition to perform its assigned mission when placed in service. For this purpose, # visual ingpection will be made of all major components, assemblies, subassemblies, and accessories to make sure that they ure present, properly assembled, secured, and clean. Equip- ment records will be checked to determine that the major item has been correctly adjusted and lubri- cated. 6. This section presents the services to be per- formed upon receipt of each ILCHR, ILSCB or guided missile pallet. Service upon receipt depends upon the level of preshipment processing, which is explained in paragraph 4-5. 4-4, General Service Procedures a, TM 38~760 lists the applicable forms, records, and reports to be used for inspection. Check the serial number of each major item with the number recorded in the logbook. Examine the logbook for each ILCHR, ILSCB or guided missile pallet to determine the general maintenance background of the material. }. Check all tags attached to the materiel for information pertaining to lubrication required before the adjustment of parts. Check the tags, or other indicators of used or reconditioned equip- ment, for any changes. Immediately transfer to 4-2. Special Tools and Equipment There are no special tools and equipment required for organizational maintenance of the ILCHR. SERVICE UPON RECEIPT — GENERAL the system logbook and appropriate manuals all the information found on such tugs or indicators. ¢. Make certain that all hardware is secure, cubling is not frayed, and cable conductors are not exposed. d. Make sure that ull major component parts are present. Check to insure that leveling jacks are present und in good condition. Look for missing or loose bolts, screws, and rivets. Check the shielding and ground connections. Make sure the nameplates ure present und secured in their proper places. 4 Check ull items of equipment to determine whether they are in good operating condition. Check to determine that all exterior surfaces are intact and properly assembled, noting excessive grease, oil, or foreign matter that might interfere with proper operation. Ff, Visual checks of the equipment give an indication of its condition. Steps (1) through (23) below list these cliecks. Any deficiencies noted should be corrected before operation of the equip- ment. (1) Check the materiel against the accom- panying lubrication orders for proper lubrication. (2) Make sure that sealing is complete on all sealed purts of the equipment. (8) Check all indexes; scales; division and name plates; warning, danger, and caution plates to see thut they are cleur and eusy to read. (4) Look for bare spots or damaged finish to see if uny unprotected metal surfaces are exposed to corrosion or rust. Determine whether a touchup or complete refinishing job should be accomplished. atTH 9—1440—531—12-1 (5) Inspect movable metal parts such as bear- ings, hinges, sliding surfaces, und latches to deter- mine whether they ure cleun, properly lubricated, and free from rust and foreign matter. (6) Look for moisture or rust-producing con- ons. (1) Check the service tugs of fire extinguishers for current servicing. (8) Make sure flammable authorized containers only. (9) Look for excessive or uneven weur, play, or backlash in geurtrains, bearing surfaces, dials, and knobs. (10) Check the contacts of connectors for looseness, corrosion, or dirt. (11) Look for solder filings, stray bite of solder, and cold-solder joints. (12) See that the solder connections are not bulky with excess solder but are neat, smooth and shiny, and couted with anti-fungus varnish. (13) Inspect all the insulation for signs of dis- coloration, carbonization, mildew, or fungus growth. (14) See that there is no chafing, or possibility of chafing, of the insulation. (15) Look for bent, broken, loose, or missing contacts on plug-in components. Muke sure that the contacts are clean. (16) Remove all the dry batteries from equip- ment not in use. (17) Check the capacitors for evidence of heat- ing (discoloration, swelling, cracked, or melted wax), iquids are in Section Il. SERVICE UPON 4.5. Service upon receipt of a major item depends upon whether it hus been processed for overseus, extended storage, or use within 30 days by the using organization. The level at which an item is shipped is clearly marked on it. The main levels of processing for shipment are presented in sub- paragraphs a through c below. a. Level A military package provides preserva- tion and packaging for adequate protection against corrosion, deterioration, and physical damage during shipment, handling, indetermi storage, and world-wide redistribution. General preservation und packaging for adequate protec- tion against corrosion, deterioration, and physical 42 o (18) Check the resistors for discoloration, cracks, breuks, und signs of overheating. (19) Look for indications of burned, pitted, or corroded contacts on switches, relays, and circuit breakers. Check the contacts for cleanliness. sure the switch detents have a positive mechanical ‘action. (20) Ceramic parts should be clean and with- out cracks or breaks. (21) Check the wiring and cabling for proper support where required. Runs should be short and have only enough slack to relieve stress on leads. (22) Examine the wires near terminals for frayed or loose strands that can cause shorts. (28) Visually inspect the lenses, prisms, reti- cles, und windows to make sure that they are free of scratches, pits, dirt, and chips which would interfere with the optical performance of the equipment. Any breakdown or excessive discolora- tion of cement between elements of the compound lenses which affects optical performance in the field is cause for rejection of the instrument. Do not base rejection on the lack of reflection-redue- ing couting for the optical elements of instruments already in the field. There must be no parallax, abnormal, or double vision. If errors cannot be brought into specified tolerances us determined by the system alinement requirements, the optical instrument is considered unserviceable. g. Remove the tape from all glass surfaces, such as meter windows, reflectors, instrument dials, lighta, and windows over eathode-ray tubes. ‘h. Remove the sealing tape from vents, doors, covers, und other tape-sealed areus. RECEIPT OF MAJOR ITEMS damage during multiple domestic shipments, han- dling, und covered storage. ¢ Level C minimum military package prepares for preservation and packaging for adequate pro- tection against corrosion, deterioration, and physi- cal damage during shipment from the supply source to the first receiving activity for immediate use. The supplier's commercial practice will be accepted when such practice meets the require- ments of level C. 4-6. Service Upon Receipt of the Improved Launcher (ILCHR) Refer to paragraphs 4-4 and 4-5 for general ser- vice-uponsreceipt information. In addition, the procedure below must be followed upon receiving the ILCHR.10 a. Remove the front and rear compartment covers (11 and 19, fig. 1-1). b. Visually inspect the interior of the compurt- ‘ments to determine that all assemblies, on-vehicle equipment, and tools are present, in good condi- tion, and properly stowed or mounted. ¢. If the equipment or tools are wrapped and taped, remove the wrapping and tape and stow the tools and equipment in the assigned locations. d. Check the fluid level gage on the base hydraulic system reservoir (1, fig. 2-3), in the front compartment for proper level of the hydraulic fluid. If the base hydraulic system is filled with a preservative, it must be drained and replenished with the proper hydraulic fluid. e. Check the main hydraulic system reservoir level gaye (3. fig. 2-5), on the right side of the boom support base, for the proper hydraulic fluid level. If the main hydraulic system is filled with preservative, it must be drained and replenished with the proper hydraulic fluid. For the specifica tion on proper hydraulic fluid for ILCHR hydraulic systems, refer to figure 4-1. Jf. Check the ILCHR base air vent covers (4.and 12, fig. 1-1) and remove any sealing tape, barrier materiel, and desiccant. g. Check the main hydraulic system heat exchanger intake and exhaust (20, fig. 1-1), and remove any sealing tape and barrier materiel. h. Raise the center compartment hatch cover, and remove the desiccant, sealing tape, and barrier materiel. i Inspect the boom snubber (10, fig. 1-1) for hydraulic leakage. If leakage is observed, replace TH 9—1440—831—12. the snubber. If the part no. of the new snubber is 9091809, return it to direct support for fill level check. If the part no. is 11567877, check the fluid level in accordance with LO 9—1440—531—12 and add fluid if required. Also, if the snubber contains preservative oil, remove and refill in accordance with LO 9—1440—631—12, i. Perform the periodic check procedures con- tained in chapter 3. 4-7. Service Upon Receipt of the Improved Launching Section Control Box (ILSCB) Refer to paragraphs 4-3 und 4-4 for general ser- vice-upon-receipt information. In addition, the following procedure must be followed upon receipt of the ILSCB: @. Check the snap fasteners and switches to see that they are tight and work properly. &. Check the connector receptacles and make sure that they are in good condition. ¢ Check the caps and wire tie ropes; make sure they are secure and in place. d. Open the storage compartment cover and check to see that the sufety and arming test aid and the headset are present and in good condition. ¢. Perform the preventive maintenance checks listed in table 3-2. 4-8. Service Upon Receipt of the Guided- Missile Loading and Storage Pallet Refer to paragraph 4-4 for general service- upon-receipt information. Procedures for service upon receipt of the M390 or M390c trailer and de- scribed in ‘TM 9-2330-235-14. 43TH 9—1440—531—12—1 cre 1—Wheel bearings 4“Leveling cylinder swivel fitting 2-Outrigger swivel fittings 5—Forward support jack fittings ‘3-Sector assembly latch fitting ‘€Elevation cylinder piston rod bearing fitting Figure 4-1. Lubrication points (sheet 1 of 3). a410 TM 9—1440—531—12-1 Mi 74625 ‘7—Blevation actuator trunnion fitting 13-Hatch cylinder fitting 8-Outrigger sway brace attach fitting 14—Azimuth ring gear ‘9~Trunnion sector gear 15—Main system filter element 10—Elevation data bearing fitting 16—Azimuth system filter element 11—Air filter element 17—Aale trailing armfitting 18Handbrake cable 12-Motor pump assembly fill plug Figure 4-1. Lubrication points (sheet 2 of 3). as™ 9—1440—531—12-1 19-Latch bell crank/sector joint 20-Spring cover 21—Spring cover 22—Hook to latch bell crank 23—Hook to finger joint 24—Hook to finger joint 25—Hook to release link joint 26—Spring cover 27—Spring cover 28—Hook to latch bell crank 29-Latch bell erank/sector joint 30—Finger/sector joint 31—Finger/eector joint 32—Release lever/link joint 33—Release lever/sector joint 34—Spring cover/pin point ‘35—Spring cover/pin point 46 10 MS 313462 '36—Spring cover/pin point 37—Spring cover/pin point 38—Releme lever/sector joint 39—Relemse lever/link joint 40—Release lever roller joint 41—Hook/finger surfaces 42-Finger/sector surface 43-Finger/sector surfaces 44—Hook/finger surfaces 45—Release lever roller joint 46—Breakaway adjustment bolt 47—Spring clevis/pin joint 48—Spring clevis/pin joint 49—Breakaway and adjustment bolt 50—Cover 51—Bolt 52-Forward sector cover Figure 4-1. Lubrication points (sheet 3 of 3).c10 TH 9—1440—531—12-1 Section IV. LUBRICATION 4-9. Lubrication Chart ‘The lubrie: 31-12) (fig. 4-1) preser vation pro- cedures, and indicates proper materials, lub! tion points, and service intervals. Views showing locations, of lubrication fittings are provided in figure 4-2. NOTE Refer to TM 9—-2890—235—14 for preventive maintenance checks, service, and lubrication instructions for the trailer. 4-10. General Lubrication and Maintenance Instructions a. Service intervals specified on the lubrication order chart are for normal operation under usual climatic conditions. Intervals should be reduced to compensate for such conditions as the presence of sand or dust, high humidity, or high or low tem- perature extremes. Intervals may be extended during inactive periods, commensurate with ad- equate preservation. ». Clean areas containing contaminated lubricants, using the procedures outlined in TM 9-1425-525-12-4. c. Lubrication Under Unusual Conditions. (1) Extreme cold: Refer to TM 9-207. (2) Dust and sand: Clean and inspect all lubrication points for contaminated lubricants, and relubricate as necessary. d. After Fording Operations. After fording oper- ations in water of a depth of 12 inches or more, all points subject to deterioration from effects of grit, dirt, or water must be lubricated. If the ILCHR has been in deep water for a considerable length of time, or has been submerged beyond fording capabilities, a complete lubrication service must be performed. The hydraulic reservoirs should be drained and checked for the presence of water or sludge. Should such conditons be present, the reservoirs must be flushed, and the filter elements replaced. The reservoirs should be filled with new hydraulic fluid MIL—H—5606. Section V. MAINTENANCE SERVICES 4-11. General For general maintenance procedures, refer to TM 9-1425—525—12-4, 4-12. Sealing Rear Compartment Clean joint and apply sealing compound MIL-$-8802 class B2, NSN 8030-00-616-9167, in the joints (gaps). This compound can be applied with extrusion gun, spatula, or fingers. Contour the compound to conform with lip cross section. 47cmemoncws LO 9-1440-531-12 ZERO LENGTH LAUNCHER (LCHR) HAWK AIR DEFENSE GUIDED MISSILE SYSTEM ‘muna uw bend en perma! operation, Redues o com Naming: Bath th pin thinner sd he dry cleaning stent ‘eset (ST cma puri so sore condo or 9 arma, Kanye rm het nope ae Free te eran, Derg torte erode 70 Clan pare with pnt ther, mineral pts (.TT-2816 conn a camrnenmuraca mith nngeas prion. Gras} er ery Canny sovant (70-000, TY98 1). OY ‘etait after washing o oro ctor hiiening, Curiae doned srw points on both een of tn euipment LUBRICANT © INTERVAL INTERVAL @ LUBRICANT Forward Sector Latch (Main Hydraulic System ‘Fil and Level) {See pote 4 Knobs, hinge, pivots, ete ‘Gee note 3) Leveling Cylinder Swivel — KEY rae Pt GAA-—GREASE, lubr, sutomotive and artillery B | wweekty cnc es 89 | vera aceon ¥5 | come sa ce (EE | ema Lubr, petroleum base (MIL-C-23411) . ‘S—Semi- NSN 8030-00-838-7789 ee GIA—Instrument grease (MIL-G-21164C) Ms 164708F Figure 4-2. Lubrication chart (sheet 1 of 4) cisc13 LUBRICANT ¢ INTERVAL ‘Ale Vent Filter ‘Elemant {See note 5) [Ationeth Systm Filter Element {See note 4) Main System Filter Element (See note 4) Azimuth Ring Gear (Brush coat on Teeth) Hydraulic Pump Motor Hatch Cinder (2 places exch) Brake Master Cylinder (Fi to % inch from top) ave Hydraulic System Reservoir Fill ad Laval {Fill and Level) (Sen note 2) ‘Boom Snubbar 48 TM 9—1440—531—12—1 INTERVAL © LUBRICANT CYLINDER FITTINGS, HATCH IN RAISED POSITION. ELEVATION DATA BEARING FITTINGS Trunnion (See note Eleration (See note Elevation: ‘Sector Gear oT) Data Bearing ” System Filer Elemant (See note: Elevation ‘a Fire Imterrupter Lever Eleration. Trunaion Actuator ‘Axle Telling Arm (2 places sech) Hand Brake Cable Outrigger Pat Socket Stier Outrigger: Sway Brace ‘Attach Fiting, Figure 4-2. Lubrication chart (sheet 2 of 4). MS 164709TH 9—1440—531—12—1 To Balt Stud (See note 10) Half bat joint (See pote 10) @Ouvrigger Arm (See note 10) ourricceR (FORWARD BASE) MS 431887 Figure 4-2. Lubrication chart (sheet 3 of 4). 4-10 cnTM 9—1440—531—12—| — NOTES — 1. TRUNNION SECTOR GEAR AND ELEVATION DATA BEARING — Remove miasite boom cover to (gain sccees to the sector gear and elevation data Deering fittings. Apply a thin coat of GAA to the teeth of the sector gear and lubricate the bearing fetogs. 2. BASE HYDRAULIC SYSTEM RESERVOIR — Check level monthly and add sufficient OHA t0 bring to FULL mark on sight gage. Fluid level readings apply only when leveling cylinders are retracted and hatch ls in the down position. The reservok la accessible when the forward compart: ‘ment cover is emmoved. 3. OIL CAN POINTS — Monthly, lubricate the following points with OAI: the base hydraulic system hand pump plot points, elevaton quadrant hot pin, cover hinges on fush mounted electrical ‘connectors, fie extinguisher pivot points, threaded ‘portion of spede rack retaining bolts and outrigger ‘sway braces, tur table hig locklng screws, support Jack hinge and pad, compartment cover hold-down, knobe, threaded portions of suspension lockout de- vice, aft leveling cylinder hinges, aft outigger sem. binges, left and right hand brake lever lr, boom, ‘support holddown knobe and hinges, aft missile ‘tupport consisting of: cover release mechaniam, ‘umbilical cover hinges, umbilleal retraction ‘mechenism pivot, roller bearings, forward missle ‘support. and shock sbeorber (felt wiper). Coat all ‘bare metal surfaces with alight cout of OA or GAA. ‘se necessary. Wipe surfaces clean before appving. ‘4. MAIN HYDRAULIC SYSTEM — Check reservoir ‘fuld lovel weekty. Fluid readings apply only when the ol le dicherged from the Iydrauke sccumnla- ‘wr, the launcher bese is level, and the boom te a the down position. With the ol dlacharged from the ‘accumulator, have the direct support unit charge the accumulator with aie w the correct pressure. ‘Add OHA through the reservoir fil tubs und the Pointer indicates FULL. Semianrwally, dacharge ol {from the scourulator, drain the main hydraubc ays ‘tem by draining the oll tank and the remaining oll {rom the oil ine atthe bottom of the pump. Refi ‘system with MIL H-5608, Energize the launcher land operate the azimuth and elevation servo ‘systems for 20 minutes. Deenergize the launcher ‘and replace the elevation, azimuth and main system ‘ol iter elements. Energize the launcher hydraulic _aystem briefly, then deenergize the launcher and diacharge oil from the accumulator. Recheck oil level and add OHA if necessary. Energize the launcher and check hydraulic system for leaks. Deenergize the launcher. 5. AIR VENT FILTER HYDRAULIC SYSTEM — Replace aie vent fiter semiannually. Check after {ording, replace if necessary. 6. HYDRAULIC PUMP MOTOR GEAR CASE — Inapect the hydraulle pump motor gear case if 20 ‘equipped quarterty or every 100 hours of operation, whichever occurs first, end fH necessary. 7. TRAILER LUBRICANT — Refer to TM 9_2330—235—1 8. BOOM SNUBBER — Quarter reise the boom tuntit the snubber piston rod Is fully extended. Remove fl port cover and fl to the bottom of the fl port hole with OHA while maintaining the snubber (11667877) body nesr vertical. For snubber ‘9081309, remove the unit from the launcher and. ‘have direct support unit check the fluid leva. ‘9. FORWARD SECTOR — With the missil removed, and with a5/B-inch socket wrench, rotate the bolt (61, fig. 4-1) counterclockwise unt the ‘orward sector cover (60, fig. 4-1) releases. Lubei- ato the points Het in igure 4-1 quartet, o more {frequently # the reeponee to the movement of the rmiaaile latch bell crank Indicates binding and/or rnibing. Lubricate the points with petroleum bese corrosive preventive dry lubricant MIL-C- 23411 NSN 8030-00-838-7789. Exercise all the joints by exercising the missile latch lever. When the forward support cover (50, 4-1) is removed for other maintenance, lubricate the breakaway adjustment bolt and the spring clevis/pin joint on the sector release mechanism. 10. Lubricate the points with petroleum bese corrosive preventive dry lubricant MIL-C- 23411 NSN 8030-00-838-7789, Ms 3134810 Figure 4-2. Lubrication chart (sheet 4 of 4). ce adanzeoy Google <TM 9 1440-531—12-1 CHAPTER 5 CORRECTIVE MAINTENANCE Section L GENERAL PRACTICES FOR REPLACEMENT PROCEDURES 5-1. Safety Instructions a. In all procedures involving work in the im- mediate area of the ILCHR, precautions must be taken to prevent accidental operation of any part of the ILCHR mechanism. If the ILCHR is emplaced, the LOCAL/ REMOTE switch (10, fig. 2-1) must be set to LOCAL, the MAIN POWER switch (18, fig. 2-1) set to OFF, and the three LAUNCHERS OPERATE/SAFE ‘switches (10, fig. 2-10) set to SAFE. Replacement of certain ILCHR assem- lies requires subsequent boresighting and alinement by DS and GS personnel. For a list of these assemblies, refer to paragraph 6-571. 6. The missile umbilical shorting plugs must be installed and the missiles removed before work is performed inside the hatch (par. 2-14). ¢. All electrical cables must be disconnected from the ILCHR before work is performed on electrical components. 4. Hydraulic pressure should be relieved before hydraulic components are removed or opened. If the discharge valve fails to operate, relieve the air pressure in the accum- ulator to 0 psig before rem: replacing hydraulic components. If it is necessary to raise the hatch to perform maintenance, support the hatch and superstructure with a hoist or derrick to prevent accidents during op- erations within the hatch compartment. 5-2. Bulkhead-Type Flareless Tube Fitting Installation Procedures a. Coat the male threads of the fitting (AN or MS), backup ring, and preformed packing with petrolatum, 9150-250-0925 through -0929, or hydraulie fluid. 6. Install the nut on the fitting, then install the backup ring and the preformed packing on the fitting, with the smooth side of the ring toward the preformed packing. Roll the preformed packing carefully over the threads of the fitting to prevent cutting the packing. ¢. Work the ring into the counterbore of the nut, then turn the nut down until the preformed packing is pushed firmly against the lower threaded section of the fitting- 4. Install the fitting into the boss and, at the same time, keep the nut turning with the fitting until the preformed packing contacts the boss, as evidenced by a sudden increase in torque. With the fitting in this position, put a wrench on the nut to prevent its turning and, at the same turn in the fitting 1-1/2 turns. Position the fitting by turning it in not more than one additional turn. ¢. Hold the fitting and turn the nut down against the boss. Slight extrusion of the ring is not detrimental. 5-1TM 9—1440-—531—12—1 5-3. Hatch-Raising Procedure a, Set and hold the DISCHARGE switch (1, fig. 2-2) to DISCHARGE until the ACCUMULATOR PRESSURE gage (2, fig. 2-4) indicates minimum Pressure. 6. Observe safety instructions (par. 5-1). ¢. At the hydraulic epntrol panel, open the MAN- UAL AZIMUTH MOVEMENT VALVE (8, fig. 2-4), and manually rotate the boom support to 0 mils as indicated by the azimuth vernier pointer (1, fig. 2-6). d. Install the azimuth stow lock assembly (4, fig. 2-5) in the lock position. ¢. Release the eight handnuts (3, fig. 2-6) that secure the hatch to the base assembly. Jf. Close all forward rotating sectors (1, fig. 2-9). g. Remove the front compartment cover, and close the three leveling valves (5, 6, and 7, fig. 2-3) counterclockwise. Close the bleed valve (3, fig. 2-3) clockwise on the base hydraulic control panel. ‘h. Open the system selector valve (4, fig. 2-3) clockwise. i. Install the handpump handle so that the hand grip is to the left. Remove the safety rod from the front compartment. Clear all personnel from the boom sup- port area before raising the hatch. J. Operate the handpump (2, fig. 2-8) to fully raise the hatch. k. Install the hateh support safety rod (8, fig. 1.2) and very slowly open the bleed valve counter- clockwise until the safety rod is securely in place. Open the bleed valve so that the weight of the boom support is fully on the safety rod and the two boom support hing: 1. Close the bleed valve clockwise. m. Close the system selector valve counter. clockwise. 5-4, Hatch-Closing Procedure All personnel must be cleared from the ‘boom support area before the hatch is lowered. a, At the base hydraulic control panel, close the three leveling valves counterclockwise. Close the bleed valve clock wise. b. Open the system selector valve clock wise. ¢. Operate the handpump to fully raise the boom support. Remove the safety rod. 4. Check that the handnuts are in the outboard position. Slowly open the bleed valve counter- clockwise, and lower the boom support. ¢. Secure the hatch to the base assembly with the handnuts, Jf Remove the azimuth stow lock assembly from the lock position, and install it in the stow Position. Rotate the boom support to the boresight position and close the MANUAL AZIMUTH MOVEMENT VALVE. g. Open all valves on the base hydraulic contra panel, except the system selector valve, which should be closed. hk, Return the handpump handle and the safety rod to the front compartment, and install the front compartment cover. Section IL CORRECTIVE MAINTENANCE OF THE BASE 5-5. Replacement of the Forward Base Outriggers NOTE ‘The ILCHR must be supported on the wheels tand the front support jack before removal of the front ILCHR outrigger arms, Remove and install the forward ILCHR outrig- ger arms (1 or 2, fig. 5-1). 5-2 5-6 Replacement of the Forward Base Outrigger Swivel Fitting a. Remove the forward base outrigger arm (par. 5-5). b. Remove and install the swivel fitting (7, fig: 5-1). 5-7. Replacement of the Leveling Cylinders NOTE ‘This paragraph covers the replacement of any of the three leveling cylinders.‘TM 9-1440—531—12-1 i 73822 1-Left-front launcher outrigger ‘9-Washer 2-Right-front launcher outrigger 10—Chain assembly ‘3-Front support jack 11-Pin +-Pin 12-Screw 5—Washer 13-Nut 6-Pin 14—Clevis ‘7—Swivel fitting 15—Nut a-Rivet, 16-Brace Figure St, Replacement ofthe forward bse etrgyers ond sy bare webs - 5-3 GoogleTM 9—1440—531—12-1 Open the bleed valve (3, fig. 2-8) on the base hydraulic control panel counter- clockwise. a, Removal and Installation. Remove and install the cylinders as illustrated in figure 5-2. b, Inspection and Teat. (1) Fill the base hydraulic reservoir with hydraulic fluid (9150-252-6883). (2) Generate hydraulic pressure with the handpump, and fully extend the piston of the leveling cylinder assembly. Retract the piston completely. Repeat this operation to purge the cylinder and lines of ai (3) Check for leaks. 5-8. Replacement of the Drawbar Assembly Hold the drawbar when pulling the out- rigger arms away while performing the following procedure. NOTE ‘The key numbers shown below in parentheses refer to figure 5-2. a. Removal. Remove the drawbar lock assembly (27). Hold the drawbar (42) firmly in one hand and, with the other hand, pull the two outrigger arms away, one at a time. jsassembly. (1) Loosen the two hexagon nuts (29) from les of the drawbar and remove the two setscrews (28) with the attached nuts. (2) Remove the two hexagon-socket. setacrews (80) and the serew thread inserts (81). (3) Remove the safety chain (84), the link (35), and the two safety chains (86 and 87). ¢. Assembly. (1) Install and secure the safety chains (37 and 36), the link (35), and the safety chain (84). (2) Install the two screw thread inserts (31) and secure with the two hexagon-socket setacrews (30) and the setacrews (28). 54 cn d. Installation. (1) Engage the balls of the outrigger arms in the sockets of the drawbar (42). Secure the knob of the drawbar lock assembly (27) into the draw- bar, engaging the balls on the top of the outrigger arms into the sockets of the lock assembly. (2) Unscrew the two setscrews (28) until they are seated in the lugs on the inner side of the outrigger arms, and lock the setscrews in place with the two hexagon nuts (29). 5-9. Replacement of the Aft Base Outrigger NOTE ‘The ILCHR must be supported on the wheels and the front support jack before removing the at outrigger arm. Remove and install the aft outrigger arm (49, fig. 5-2). 5-9.1. Replacement of the Compartment ‘Access Cover Fastener Knob Packing NOTE ‘The key numbers shown below in parentheses refer to figure 5-2. Water leakage into the launcher base can occur through the compartment cover fastener shaft holes, if the cover fastener knobs (51) do not provide an adequate seal to the top of the compartment acces cover (50). Corrective action consists of replacing the packing in the base of the cover fastener knobs and insuring that the knob bearing surface ‘on the cover is clean and smooth. a. Removal. (1) With a pin punch drive the pin (52) out from the cover fastener knob and the fastener shaft (54). (2) Remove packing with retainer (53) and clean the groove. ®, Installation. (1) Install new packing with retainer in cover fastener knob. (2) Prior to installing the cover fastener knob, make sure the surface of the cover where the knob seats is clean and smooth. (3) Reinstall the cover fastener knob to the fastener shaft (54) with pin (52).on 5-10. Replacement of the Handbrake Assembly NOTE ‘This paragraph covers the replacement of e- ther of the two handbrake assemblies. NOTE ‘The key numbers shown below in parentheses refer to figure 5-3, a. Removal. (1) Block the wheels. (2) Remove the front. compartment cover. (3) Release the handbrake. T™ 9—1440—531—12—1 (4) Remove the handbrake assembly (1) as illustrated. 6. Installation. (1) Install the handbrake assembly (1) as illustrated. (2) Install the front compartment cover. (8) Remove the blocks from the wheels. ¢. Adjustment of the Handbrake. (1) Set the handbrakes. 2) Rig the ILCHR f chapter 6) (3) When the ILCHR is towed on a smooth, level surface, the wheels should skid and not turn. If the wheels turn, tighten the cable by turning the adjusting knob (1E) until the wheels skid. towing (refer to» Google <TM 9—1440—531—12-1 1-No. 10 hexagon nut 2-No. 10x 2 panhead machine screw 3-Quick-release pin 4-Outrigger brace 5-1/8 x 1-1/4 cotter pin 69/16 slotted hexagon nut ‘79/16 fat washer 8-Byebolt 9-9/16 flat washer 10—Hove assembly 11;Elbow 12*Preformed packing 13—Backup ring 14—Flared tube nut 15—3/4 hexagon safety nut 16-3/4 flat washer 17—8/4 x 1-18/16 hexagon-head machine bolt 18-3/4 flat washer 19-Structure assembly 20-3/4 flat washer 21—Leveling cylinder assembly 22-1/8 x 1-1/2 cotter pin 23-9/16 dotted hexagon nut 24-Flat washer 25—Bolt assembly 26-Link 27—Drawbar lock assembly en 28-6/8 x 2.16 setecrew 29-6/8 hexagon nut 30-1/4 x 7/16 hexagon-socket setecrew 31—Screw thresd insert 82-8/8 hexagon self'locking nut 39~3/8 x 2-21/64 hexagon-head machine bolt 34—Balety chain 35—Link 36—Bafoty chain 37—Gafety chain 38-8/8 hexagon self-locking nut 39-3/8 x 2-21/64 hexagon-head machine bolt 40-Strp 41-Stap 42-Drawbar 43—Spring pin 44—Threaded straight pin 45—Flat washer 46-1/8 x 2-3/4 cotter pin 47—Lubrieation fitting 48-Castellated nut 49-Aft outrigger arm 50—Compartment access covers 51—Cover fastener knob 52-Pin '58—Packing with retainer 54—Fastener shaft Figure 5-2 ~Continued. 5-11. Replacement of the Axle and Brake Assombly NOTE ‘The key numbers shown below in parentheses, refer to figure 5-3. a, Removal. (1) Engage the suspension lockout, and raise the ILCHR off the ground. (2) Remove the wheel from the axle and brake assembly (11). (8) Remove the handbrake assembly (1) (par. 5-10). (4) Remove the cable clip (4) and the hand- brake spacer (2). (5) Remove the brake cable clevis (3) from the brake cable. (6) Remove the cable clip (5) from the support arm (22). (1) Disconnect the hydraulic brake line assem- bly (6). Plug the port and cap the fitting. (8) Cut the locking wire (7) and remove the machine bolts, the flat washers, and the axle thrust washer (8, 9, and 10). (9) Remove the axle and brake assembly (11) from the support arm and remove the square key (12) from the arm. b. Installation. (1) Install the axle and brake assembly (11) ia the eupport. arm (22). (2) Install the axle thrust washer, the four fat washers, and the machine bolts (10, 9, and 8) secure the axle and brake assembly. Safety-tie the four bolts with new locking wire (16). (8) Remove the plug from the port and the a? from the fitting, then connect the hydraulic brake line assembly (6) to the axle and brake assembly. (4) Secure the brake cable to the support arm with the cable clip. (5) Install and secure the brake cable devi (8) on the brake cable. (6) Install the wheel on the axle and brake assembly. NOTE Do not install the handbrake until the brake ‘adjustment and bleeding procedures are com- pleted. ¢. Brake Adjustment and Bleeding Procedures (1) Turn the brake shoe adjusting stud untl the wheel drags. (2) Turn the adjusting stud in the oppesit | direction until the drag is relieved.TM 9—1440-531—12-1 Figure 5-3. Replacement of wheel and brake componente, 57 Google1440—-531—12-1 1-Handbrake assembly ‘A-Spacer B-Cotter C—Washer D-Pin E—Adjusting knob 2-Handbrake spacer 3-Brake cable clevie 4-Cable clip 5—Cable clip 6—Hydraulic brake line assembly ‘7—Locking wire 8-1/4 x 1-1/32 machine bolt 9-1/4 flat washer 10—Acle thrust washer 11—Axle and brake assembly 12-1/2 x 5/16 x 3-1/4 square key eu 13—Bracket 14—Spring lever adjusting nut 15—Gresse fitting 16—Locking wire 17-End thrust cap 18-Seal 19—Bearing 20—Bearing spacer 21—Bearing 22-Support arm - left hand-right hand 23-Seal 24—Washer 25—Axle 26—Bearing retaining locknut 27—Bearing retaining lockwasher 28—Thruat nut spacer 29-Preformed packing Figure 5-4 Continued. (3) Connect the airbrake hoses to a 2-1/2 ton M36 truck, and turn on the air at the truck air- connector shutoff valve. (4) Fill the ILCHR master cylinder with hydraulic brake fluid. (5) Have assistant operator press and hold the truck service brake pedal to engage the ILCHR brakes. (6) Open one of the brake bleed fittings until the fluid starts to flow and then close the fitting. (7) Release the ILCHR brakes by having the assistant operator release the truck service brake pedal. (8) Refill the master cylinder. (9) Repeat steps (5) through (7). (10) Refill the master cylinder and repeat this bleeding process a minimum of three times, or until the line is free of air. (11) Refill the master cylinder. (12) Install and adjust the handbrake assembly (2) (par. 5-10c). 5-12. Replacement of the Axle Support Arm NOTE ‘This paragraph covers the replacement of ei- ther of the two axle support arms. NOTE ‘The key numbers shown below in parentheses refer to figure 5-3. a. Removal, (1) Remove the axle and brake assembly (par. 5-11). (2) Remove the bracket (13) from the suppor. arm (22). (8) Turn the spring lever adjusting nut (14) unload the tension in the torsilastie spring, then, disconnect the spring adjusting link from the support arm. (4) Remove the two grease fittings (15) from the support arm. (5) Cut the locking wire (16) and remove the ‘end thrust cap, seal, bearing, bearing spacer, and bearing (17 through 21); then slide off the support arm. (6) Remove the seal (23) and the washer (24) from the axle (25). 6. Installation. (1) Install the washer (24) on the axle (25) Install the seal (23) in the support arm (22) and slide it into place on the axle. (2) Install the bearing, bearing spacer, bear- ing, the seal and the end thrust cap (21, 20, 19, 18, and 17) and secure. NOTE If necessary, use shim with 9091242 between the axle support arm and the end thrust cap to obtain a 0,002 to 0.010 clearance. (8) Install the two grease fittings (15) in the support arm. (4) Position the spring adjusting link in the support arm and secure. (5) Install the bracket (13) on the support arm. (6) Install the axle and brake assembly (par.| 5-11).cu (7D) Rig the ILCHR for towing (refer to chapter 6). (8) With the ILCHR supported level on the wheels, turn the spring adjusting nut until the top of the tire is one-half inch below, or flush with, the level of the chassis. 5-13. Replacement of the Support Arm Axle NOTE ‘This paragraph covers the replacement of ei- ther of the two support arm axles, NOTE ‘The key numbers shown below in parentheses refer to figure 5-3. a. Removal. (1) Remove the support arm (par. 5-12). (2) Raise the hatch (par. 5-8). (8) Bend up the tabs of the bearing retaining lockwasher (27), and remove the locknut, lockwasher, and thrust nut spacer (26, 27, and 28); then remove the axle (25) and the preformed packing (29) from the axle fitting on the ILCHR base. . &. Installation. (1) Install the new preformed packing (29) on the axle (25), and install the axle in the axle fitting, alining the key in the fitting with the keyway in the axle. Secure with the thrust nut spacer (28), the lockwasher (27), and the bearing retaining locknut (26). Bend the tabs of the bear- ing retaining lockwasher into the slots in the locknut. (2) Close the hatch (par. 5-4). (8) Install the support arm (par. 5-12). 5-14, Replacement of the Air Reservoir Assembly NOTE ‘The key numbers shown below in parentheses refer to figure 54 a. Removal, (1) Remove the forward compartment cover. (2) Open the draincock (6) to discharge the air pressure. (8) Remove the tube assembly (1). TM 9—1440-531—12-1 Tube assembly 2-Square-head machine bolt ‘S~Air Reservoir ‘4-Bracket 5-Elbow €-Draincock Figure 5-4. Replacement of the air reservoir assembly, (4) Remove the square-head machine bolts (2) and withdraw the air reservoir (3) from the brackets (4). (5) Remove the elbow and draineock (5 and 6) from the air reservoir. b. Installation. (1) Install and aline the elbow and draincock (6 and 6). (2) Insert the air reservoir (3) in the brackets (4) and secure with the square-head machine bolts (2). (3) Connect the tube assembly (1). (4) Close the draincock (6) and charge the air reservoir. (5) Install the forward compartment cover. 5-9TM 9—1440-531-12-1 the ILCHR for towing (refer to dl test the brakes for operation. jacement of the Emergency Relay Vv Connecting Valve Assemblies If valve assembly 8016936 requires replacement with 10182413, include the tube assemblies 10292536, 10282587, 10292588, and 10292539 iin replacement-of-parts order. NOTE ‘The key numbers shown below in parentheses refer to figure 5-5, unless otherwise indicated. a, Removal. (1) Remove the forward compartment cover. (2) Open the draincock (6, fig 5-4) to discharge the air pressure. (8) Disconnect the tube assemblies (1 through 4) from the connectors (5) and elbows (6 and 7). (4) Remove the emergency relay valve assem- bly (8). (5) Remove the connectors (5) and elbows (6 and 7). (6) Remove the connecting valve assemblies (9 and 10) from the valve assembly (8). Figure 6-5, Replacement of the emergency relay valve and ‘connecting valve assemblies. 5-10 au 6. Installation. (1) Secure the connecting valve assemblies (9 ‘and 10) to the valve assembly (8). (2) Install and aline the elbows (6 and 7) and connectors (5) in the valve assembly. (8) Seeure the emergency relay valve assem- bly (8). (4) Connect the tube assemblies (1 through 4) to the connectors (5) and elbows (6 and 7). (5) Close the draincock (6, fig. 5-4) and charge the air reservoir. (6) Install the forward compartment cover. (1 Rig the ILCHR for towing (refer to chapter 6) and text the brakes for operation. 5-16, Replacement of the Torsilastic Spring Adjusting Rod and Nut Assembi NOTE ‘This paragraph covers the tof ei- ther of the two torsilastic spring adjusting rod and nut assemblies. NOTE ‘The key numbers shown below in parentheses refer to figure 5-6. a. Removal. (1) Remove the axle and brake assembly (pa 5-11). (2) Unload the tension in the torsilastic spring assembly (22) by turning the spring lever adjor ting nut (3). (8) Disconnect the rod end bearings (1 and §) from the axle support arm and the spring lever arm (19). , Installation. (1) Install the rod and nut assembly on spring lever arm (19) and the axle support arm. NOTE Be sure the adjusting nut is equidistant from the ends of the bearing. (2) Install the axie and brake assembly (p 5-11). (8) Preload the torsilastic spring by rigging ILCHR for towing in accordance with the Po cedures outlined in chapter 6. With the ILO level on the wheels, tum the spring sii ing nut (8, fig. 5-6) until the top of the tire # half inch ‘below, or flush with the level of chassis.TM 9-1440-531—12—1 Figure 5-6. Replacement of suspension ond suspension lockout assemblies a‘Tm 9—1440-531-12-1 1—Rod end bearing o-Washer 2-7/8 jamnut 10-Bushing ‘3-Spring lever adjusting aut 11—Bushing 4-7/8 jamout 12-Bracket ‘5—Rod end bearing 13-Ghock absorber 6-1/4 hexagon safety nut 14—Washer 7-8/4 plain washer 15—Washer o-Washer 16-Bushing 17—Bushing 18-Bhock supporter shaft 19-Spring lever arm 20-Key ‘21—Spring lever cap 22—Torsilastic spring assembly 29-Lockout suspension assembly ‘24—Bumper fitting Figure 5-6 —Continued. 5-17. Replacement of the Torsilastic Spring Lever Arm and Cap NOTE ‘This paragraph covers the replacement of el- ther of the two spring lever arms and caps. NOTE ‘The key numbers shown below in parentheses refer to figure 5-6. a. Removal. (1) Remove the wheel. (2) Loosen the two jamnuts (2 and 4), and turn the spring lever adjusting nut (3) to unload the tension in the torsilastie spring. (8) Disconnect the rod end bearing (1) from the spring lever arm (19). (4) Remove the spring lever arm, the two keys (20), and the spring lever cap (21) from the tor- silastic spring assembly (22). b. Installation, (2) Install the spring lever cap, the two keys, and the spring lever arm (21, 20, and 19) on the torsilastic spring assembly (22). (2) Secure the rod end bearing (1) in the spring lever arm. (8) Install the wheel. (4) Preload the torsilastie spring by rigging the ILCHR for towing in accordance with the pro- cedures outlined in chapter 6. With the ILCHR supported level on the wheels, turn the spring adjusting nut until the top of the tire is one-half inch below. or flush with, the level of the chassis, 5-18 Replacement of the Torsilastic Spring Assemi NOTE ‘This paragraph covers the replacement of ei- ‘ther of the two torslaatic springs. 5:12 NOTE ‘The key numbers shown below in parentheses refer to figure 5-6. a. Torsilastic spring replacement criteria. Visu- ally examine the torsilastic springs (22) to assure that adhesion between the elastomer and the shell and/or inner metal tube still exists. Only separa- tion between these areas is cause for replacement. Crazing or cracks in the elastomer itself, which are considered superficial will not impact performance. Removal. (1) Remove the spring lever arm and cap (par. 5-17). (2) Remove the torsilastic spring assembly (22) from the ILCHR. ¢. Installation. (1) Secure the torsilastic spring assembly (22) on the ILCHR. (2) Replace the spring lever arm and cap (par. 5-17). 5-19. Replacement of the Shock Absorber NOTE ‘Thin paragraph covers the replacement of ei- ther of the two shock absorbers. NOTE ‘The key numbers shown below in parentheses refer to figure 56. 4. Removal. (1) Remove the wheel. (2) Remove the bracket (12) from the axle support arm. (8) Remove the hexagon safety nut (6), and slide the plain washer (7), the washers (8 and 9), and the bushings (10 and 11), with the shock absorber (13), off the shock supporter shaft (18); then lift the shock absorber, with the bracket attached, up through the spring lever arm. (4) Remove the bracket from the shock ab- sorber.o (5) Remove the washers (14 and 15) and the bushings (16 and 17) from the shock absorber. (6) Remove the shock supporter shaft from the fitting on the ILCHR base. b, Installation, (1) Install the shock supporter shaft (18) in the fitting on the ILCHR base. (2) Install the bushings (17 and 16) and the washers (15 and 14) in the lower end of the shock absorber (13). (8) Secure the shock absorber in the bracket (22). (4) Lower the bracket and shock absorber through the spring lever arm (19). Install the washer (9) and the bushing (10) on the shock supporter shaft; then position the shock absorber on the shaft and install the bushing (11), the washer (8), the plain washer (7), and the hexagon safety nut (6). (5) Install and secure the bracket (12) on the axle support arm, (6) Install the wheel. 5-20. Replacement of the Box a, Removal (1) Disconnect the electrical cable at the ILCHR. (2) Remove the rear compartment cover. (3) Remove shoot-around console from aft compartment (See par. 5-22). (4) Disconnect all electrical cables at the base distribution box. (5) Remove the S-hooks and cover assemblies. (6) Disconnect the utility outlet cable from the base distribution box at TB13. (7) Remove the base distribution box (10, fig. 5-7) from the ILCHR base. , Installation. (1) Install_and secure the base distribution box on the ILCHR base. (2) Install the utility outlet cable to the base distribution box at TB13. (8) Install S-hooks and cover assemblies. (4) Install and secure the ground cable to the base distribution box. (5) Connect all electrical cables to the base distribution box. Distribution ™ 9—1440—$31—12—1 (6) Install shoot-round console to the aft compartment. (7) Install the rear compartment cover. (8) Connect all electrical cables to the ILCHR. ¢. Test. Refer to the check procedures (tables 3-16 through 3-17). 5-21. Replacement of the Electronic Equip- ment Rack a. Removal. (1) Observe safety instructions (par. 5-1). (2) Remove the rear compartment cover. (3) Disconnect the electrical cables from the launch programmer. (4) Remove the electronic packages (1), (2), (8) and the launch programmer (4) from the elec- tronic equipment rack (6). (5) Remove the shoot-around console (5): (a) Disconnect P1024 (b) Release the captive screws and raise the cover. (¢) Disconnect P1027 and P1028. (@) Remove J1027 and J1028 from the cabinet. (€) Close the cover. (M Release the cabinet mounting screws ‘and remove the cabinet from the compartment (6) Remove J1019 from its bulkhead mounti bracket_and disconnect PIOI8. from the bese distribution box (10). (1) Remove the captive screws securing the electronic equipment rack to its mounting plate. NOTE If the electronic equipment rack cannot be removed in step (8) perform substeps (8) (a), (bd, and (+ (8)_Lift the electronic equipment rack from the ILCHR, and at the same time disconnect the air hose from the rack plenum and extricate the cables as necessary for rack remo. (a) Remove the screws securing the mount- ing plate to the shock mounts. () Raise the mounting plate (with the elec- tronic equipment rack still mounted) and discon- ect the air hose from the air duct. () Remove the electronic equipment rack and mounting plate from the ILCHR, extricating the cables as necessary for rack removal (9) If necessary, the electronic equipment rack cable can now be removed by removing the screws securing it to the rack bracket and the hard- ware which mounts J301, J401, and J501. s13™ 9—1440-331—12-1 4. Installation. (1) If the electronic equipment rack cable was removed, install it into the electronic equip- ment rack (6). NOTE If unable to snake cables under the mounting plate during the installation of the electronic ‘Gquipment rack, remove the mounting plate from the ILCHR hase and install the electronic equip- ment rack on it, Remove the ait hose from the duct and connect it to the plenum. While in- Stalling the mounting plate, pass the aif howe une der the air duct and connect it to the air duct (2) Set the electronic equipment rack (6) in position on the ILCHR base. (8) Raise the electronic rack and connect the air hose to the plenum. Tighten down the elec- tronic equipment rack. (4) Connect P1018 to the base distribution ox (10) and install J1019 on its bulkhead mounting bracket. (5) Install the shoot-around console (5). (a) Install the cabinet into the com- partment and secure the cabinet with the mount ing serews. (b) Release the captive screws and open the cover. (e) Install 51027 and 31028 in the cabinet. (a) Connect P1027 and P1028. (e) Close the cover and secure the captive screws. Connect P1024. (6) Install the electronic packages (1), (2), (3) and the launch programmer (4) in the electronic equipment rack (6). (1) Connect the electrical launch programmer. (8) Install the rear compartment cover. . Test. Refer to the check procedures (tables 3-15 through 3-17). cables to. the 5-22. Replacement of the Shoot-Around Console NOTE ‘The Key numbers shown below in parentheses refer to igure 5-7. a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Remove the rear compartment cover. (3) Disconnect the electrical cables from the shootaround console (5). 4 (4) Remove the shootaround console from the ILCHR base. Installation. (1) Install the shoot-around console on the ILCHR base, and secure. (2) Connect. the electrical cables to the base distribution box (10). (8) Install the alinement telescope and fire cutout assembly (8). (4) Connect the electrical cables to the alinement telescope and fire cutout assembly. (5) Install the rear compartment cover. ¢. Test. Refer to the check procedures (tables 8-16 through 3-17). 5-23. Replacement of the Electrical Power Unit (EPU) Power Supply a. Removal and Installation. Remove and install the EPU power supply (9, fig. 5-7) as illustrated in figure 5-7. 2. Test, Refer to the check procedures (tables 8-15 through 3-17). 5-23.1 Replacement of the Alinement Telescope and Fire Cutout Assembly @. Removal and Installation. Removal and instal- lation of the alinement telescope and fire cutout assembly (8, fig. 5-7) is obvious by illustration. bd, Test. (1) Upon replacement of the alinement tele- scope and fire cutout assembly, its M109 telescope or mounting tube 10182918, have DS and GS maintenance perform the alinement telescope and fire cutout assembly alinement procedures con- tained in TM 9-1440-531—34—2. (2) Perform check procedures per paragraph 3-16 of this manual. 5-24, Replacement of the Filter Housing Assemblie: Remove and install the filter housing assembly (9 or 59, fig. 5-8) as illustrated in figure 5-8.a ‘5-25, Replacement of the Blower Assembly NOTE ‘The key numbers shown below in parentheses refer to figure 5-8. a. Removal, (1) Remove the electronic equipment rack (par. 5-21). (2) Remove the alinement telescope and fire cutout assembly mounting plate from the ILCHR. base, (8) Disconnect the electrical cable and the bonding jumper at the blower assembly. (4) Disconnect the blower assembly (23) from the plenum (14). (5) Remove the clamps (20 and 21) and the connector (22) that secure the blower assembly to the intermediate duct (43). b. Installation. (1) Install the gasket (16) and the blower assembly (23) on the plenum (14). Tm 91440531121 (2) Install the connector (22) between the intermediate duct (43) and the blower assembly. (8) Connect the bonding jumper and the elee- trical cable to the blower assembly. (4) Install the electronic equipment rack (par. 21). (6) Install the rear compartment cover. (6) Connect all electrical cables to the ILCHR. ¢. Test. Refer to the chéck procedures (tables 3-16 through 3-17). 5-26. Replacement of th Assembly NOTE ‘The key numbers shown below in parentheses refer to figure 5-9. 5-141T 9—1440—S31—12-1 Mi 73828 1-Asimath electronic control amplifier 6 Electronic equipment rack 2-Blevation electronic control amplifier ‘Bonding jumper Control amplifier power supply ‘S—Alinement telescope and fire cutout assembly “Launch programmer ‘9 -Electrical power unit (epu) power supply 10—Base distribution bor 5-Shoot-around console Figure 5-7. Replacement of base electrical components, 515TM 9—1440-531-12—1 Figure 5-8. Disassembly of the base cooling system.TM 9—1440-531—12-1 1—Cover assembly 21—Clamp 42-Connector 2-Beal 22-Connector 43—-Duet ‘S$—Retalning ring 23—Blower assembly 44-No, 10 salflocking nut 4-Filter 24-No, 10 self-locking nut 45—No, 10 flat washer 5—No. 10 safety nut @—No. 10 fiat washer T-No. 10x 1-1/4 bolt ‘25—No. 10 flat washer ‘26-No. 10x 5/8 panhead machine screw 27—No, 10 flat washer 46—No. 1 x 1-1/2 panhesd machine screw 47-No. 10 self-locking nut 48—No. 10 flat washer ‘8-No. 10 flat washer 28-Clamp 49-No, 10:x 6/8 panhesd machine screw 9—Filter housing assembly 29-Clamp 50-Bnd duet 10—Preformed packing 30—Howe 51—Cover amembly 11—No. 8x 3/4 panbead machine screw 31—No. 10 safety nut Sed 12-No. 8 split lockwasher 32-No. 10 flat washer ‘53-Retaining ring 13—No. 8 flat washer 39-No. 10 flat washer Sa-Fllter 14—Plenum 84—No, 10x 6/8 panhead machine screw 55—No. 10 safety nut 15—Preformed packing 35—Clamp 5€—No, 10 fat washer 16—Gasket 36-Hlose S7-No. 10x 1-1/4 bolt 17—No. 10 selflocking nut 19-No. 10 flat washer 20-Clamp eee 41-Clamp 87—No. 10 salfdocking aut 38-No. 10 flat washer 18—No. 10x 8/4 panhead machine screw 9070 15 x 8/4 panhead machine screw 58—No, 10 flat washer 59—Filter housing esserably 60—Preformed packing 61—Blectronie equipment rack Figure 5-8 -Continued a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Open the bleed valve counterclockwise to relieve the pressure. (8) Disconnect the tube assemblies (1, 2, and 3). (4) Remove the nuts, washers, and screws (12, 13, and 14) that secure the bleed valve assembly (22) to the bracket (18). (5) Remove the nut (21) and withdraw the bleed valve assembly. b, Installation. (1) Install and secure the bleed valve assembly (22) to the bracket (18). (2) Secure the bleed valve assembly with the nut, handle, and the nut (21, 20, and 19). (8) Connect the tube assemblies (1, 2, and 3). (4) Close the bleed valve clockwise and replen- ish the hydranlie fluid. (5) Connect all electrical cables to the ILCHR. c. Test. Refer to the check procedures (table 3-16). 5-27. Replacement of the Leveling Cylinder Valves NOTE ‘The key numbers shown below in parentheses refer to figure 5-9. a, Removal. (1) Observe the safety instructions (par. 5-1). (2) Open the bleed valve counterclockwise to relieve the pressure, (8) Remove the following valve assemblies as applicable: (a) For the rear leveling cylinder valve (98), disconnect the tube assemblies (51 and 85). (b) For the left-front leveling cylinder valve (95), disconnect the tube assemblies (52 and 78). (c) For the right-front leveling cylinder valve (94), disconnect the tube assemblies (58 and 19). (4) Remove the nuts, washers, and screws (90, 91, and 92) and withdraw the leveling cylinder valves (98, 94, or 95). b. Installation. (1) Install and secure the leveling cylinder valves (93, 94, or 95). (2) Install and secure the related tube assem- blies (51 and 85, 52 and 78, or 58 and 79) to the respective leveling cylinder valves. (3) Close the bleed valve clockwise and replen- ish the hydraulic fluid. (4) Connect all electrical cables to the ILCHR. Test, Refer to Level ILCHR. Par 7-6a(19). $17TM 9-1440-531-12-1 Mi 73830 Figure 5-9. Replacement of the base hydraulic control panel components 5-18TM 9-1440-531—12-1 1—Tube assembly 50—Preformed packing 2-Tube assembly 51—Tube assembly 3—Tube assembly 52—Tube assembly 4-Reducer 53~Tube amembly 5-Preformed packing 54—Union 6Tee 55—Preformed packing ‘Preformed packing 56—Check valve 8-Backup ring '57—Preformed packing %Locknut 58—Union 10-Reducer 59-Preformed packing 11—Preformed packing 60-Union 12-No. 6 safety nut 61—Preformed packing 19-No, 6 flat washer 62—Union 14—No. 6 x 1-1/4 panhead screw 63—Preformed packing 15—No. 10 safety nut 64—Union 16—No. 10 flat washer 65—Preformed packing 17-No. 10x 1/2 panhead serew 66—Union 18—Bracket 61—Preformed packing 19-Nat 68-No. 10 safety nut 20-Handle 69-No. 10 flat washer 21—Nut 70-No. 10x 2-1/4 panhead screw 22—Bleed valve assembly 71—Manifold 25—Tee 12-Reducer 24—Preformed packing 13—Tube assembly 25—Backup ring 74—-Union 26—Locknut 15—Preformed packing 27—Bushing 76—Union 28—Preformed packing 71—Preformed packing 29—Locknut 78—Reducer 30-7/16 flat washer 19—Tube assembly 31—Union 80-Union 32—Preformed packing £81—Preformed packing 33—Thermal relief valve 82-Union 34—Tube assembly 83-Preformed packing 35-No, 10 safety nut 84—Reducer 36—No. 10 flat washer 85—Tube amembly 37—No. 10 x 1-8/4 panhead screw 86—Union 38-Screw 87—Preformed packing 39—Handle 88—Union 40-System selector valve ‘89-Preformed packing 41-Elbow 80-No. 10 safety nut 42-Preformed packing 91-No, 10 flat washer 43—Backup ring 92-No. 10 x 6/8 panhesd screw 44—Locknut 93—Rear leveling cylinder valve assembly 45—Elbow ‘94—Right front leveling cylinder valve assembly 46—Preformed packing 95—Left front leveling eylinder valve assembly 47—Backup ring 96—Panel 48-Locknut 97—Hose 49-Reducer 98—Hose Figure 5-%.~Continied, 5-28. Replacement of the System Selector Valve (2) Open the bleed valve counterclockwise. NOTE (3) Disconnect the hose (97) and tube assem- ‘The key numbers shown below in parentheses bly (34). refer to figure 5-9. (4) Remove the nuts, washers, and screws (35, NOTE 36, and 37) that secure the system selector valve ‘The leveling cylinders should he in the (40) to the bracket. retracted position. a. Removal. (5) Remove the screw and handle (38 and 39) and withdraw the system selector valve (40). (1) Observe the safety instructions (par. 5-1).TM 9 1440-531-.12-1 b. Installation. (1) Install and secure the system selector valve (40) to the bracket. (2) Install and secure the screw and handle (88 and 89). (8) Connect the hose (97) and tube assembly (84). (4) Close the bleed valve clockwise and replen- ish the hydraulic fluid. (5) Connect all electrical cables to the ILCHR. ¢. Test, Refer to Level ILCHR Par.7-5a(19). 5-29. Replacement of the Base Hydraulic Panel Check Valve NOTE ‘The key numbers shown below in parentheses refer to figure 5-9. @. Removal. (1) Observe the safety instructions (par. 5-1). (2) Open the bleed valve counterclockwise to relieve the pressure. (8) Disconnect the hose (98) (4) Remove the check valve (56) from the manifold (71). b. Installation, (1) Install and secure the cheek valve (56) in the manifold (71). (2) Connect the hose (98). (8) Close the bleed valve clockwise and replen- ish the hydraulic fluid. (4) Connect all electrical cables to the ILCHR. ¢. Test. Refer to the check procedures (table $16). 5-30. Replacement of the Base Hydraulic Panel Manifold NOTE ‘The key numbers shown below in parentheses refer to figure 5-9. . Removal. (2) Observe the safety instructions (par. 5-1). (2) Open the bleed valve counterclockwise to relieve the pressure. (3) Disconnect the hose (98) and tube assem- bles (2, 34, 61, 52, and 63). 5-20 @ (4) Remove the nuts, washers and screws (68, 69, and 70) and withdraw the manifold (71). 6, Installation, (1) Install and secure the manifold (71). (2) Connect the hose (98) and the tube assem- blies (2, 84, 51, 52, and 58). (8) Close the bleed valve clockwise and replen- ish the hydraulic fluid. (4) Connect all electrical cables to the ILCHR. ¢. Test. Refer to the check procedures (table 3-16). 5-31. Replacement of the Synchro Control ransformer NOTE ‘The key numbers shown below in parentheses refer to figure 5-10, a. Removal. (1) Remove the synchro control transformer (2). (2) Disconnect all electrical connections to the synchro assembly and tag the leada. 6, Installation, (1) Conneet the electrical connections to the synchro and remove the tags from the leads. (2) Install the synchro control transformer (2) 5-32. Replacement of Additional Units ‘The repair or replacement of the following units is obvious by illustration. Refer to TM 9-1440-531-24P for the appropriate illustration. Insure that the equipment is deenergized before performing maintenance. For the appropriate test after installation, refer to the table given in parentheses after each unit. For those units with no table reference, refer to the fault isolation pro- cedures in TM 9-1440-531-12-2, Azimuth electronic control amplifier 10672158 (table 8-16) .T™ 9—1440—531—12—1 c10 Ss a 2 = 5—Elevation servoamplifier Azimuth servoamplifier ‘7—Azimuth servo geartrain 8-28-Vde power supply Figure §-10. Replacement of unite in the shoot-around console.TM 9-1440-531— 12-1 Azimuth servo geartrain 10179086 (table 3-16) Azimuth servo amplifier 10179081 (table 3-16) Brace assembly, sway 9091289 Brace assembly, towing 9089281 Cable assembly 9089519 Cable assembly 9089817 Chain assembly 9194225 Chain assembly 9194226 Communications station 10288848 *(Y)', 10291990 *(T)' , 10288711 *(L)', or 10677377 *(K)'. Control amplifier power supply 10183644 (table 3-16) cn Cover assembly 9080929 Cover assembly 10669397 Elevation electronic control amplifier 10672134 (table 3-16) Elevation servo geartrain 10182104 (table 3-16) Elevation servo amplifier 10179081 (table 3-16) Jack assembly 9091940 (table 3-17) Logic chassis 10179078 (table 3-17) 28-Vde power supply 10179084 (table 3-15) Hydraulic control panel 9089710 (table 3-16) Section II CORRECTIVE MAINTENANCE OF THE BOOM SUPPORT 5-33. Replacement of the Azimuth Distribution Box NOTE ‘The key numbers shown below in parentheses refer to figure 5-11. @, Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (8) Disconnect the electrical cables from the azimuth distribution box (12). (4) Remove the azimuth distribution box from the boom support base assembly (16). b. Installation. (1) Install the azimuth distribution box (12) on the boom support base assembly (16). (2) Torque the capscrews (11) to 108 —132 Ib-in, (8) Connect the electrical cable to the azimuth distribution box. (4) Close the hatch (par. 5-4). (5) Connect the cables to the rear of the ILCHR base and remove the tags. NOTE ‘The key numbers shown below in parentheses refer to figure 5-12. a. Removal. (1) Observe the safety instructions (par. 5-1). “TRster to appendix D for serial number effectivity. 5-22 (2) Raise the hateh (par. 5-3). (3) Drain the hydraulic fluid reservoir (12). (4) Remove the air vent filter (8). 6. Installation. (1) Install the air vent filter (8). (2) Lower the hatch (par. 5-4). (8) Fill the hydraulic fluid reservoir (12). (4) Connect all electrical cables to the rear of the ILCHR base. lacement of the Main Reservoir static Switch Assembly NOTE ‘The key numbers shown below in parentheses sefer to figure 5-12 a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). 5-35. R 1 (3) Drain the hydraulic fluid reservoir (12). (4) Remove the thermostatic switch assembly (13). b. Installation, (1) Install the thermostatic switch assembly (13). (2) Lower the hatch (par. 5-4). (3) Fill the hydraulic fluid reservoir (12). (4) Connect all electrical cables to the rear of the ILCHR base.eu 5-36. Replacement of the Main Hydraulic System Check Valves a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Remove the check valves (12, fig. 5-13 or 11, fig. 5-14). b. Installation. Before installing the check valve observe the flow direction indicated on the valve. ‘The valve must be installed with the free flow indicator pointing away from the pump. 1™ 9—1440—31—12—1 (1) Install and secure the check valves (12, fig. 5-13 or 11, fig. 5-14). (2) Lower the hatch (par. 5-4). (8) Fill the hydraulic fluid reservoir. (4) Connect all electrical cables to the ILCHR. ¢. Test. Refer to the check procedures (table 3-16). 5-224T™ 9 1440-531—12-1 1-1/2 safety nut 10—Distribution box support 9-1/2 fat washer 116/16 x 3/4 hexagon-head capecrew 3-5/16 eafety nut 12—Asimuth distribution box 4-5/16 flat washer 13-5/16 safety out 56/16 x 1 bexagon-heed capecrew 1476/16 flat washer 6-1/2 x 2-19/32 eyebolt 15-5/16 x 3 hexagon-head capecrew ‘7-1/8 flat washer 16—Boom support base assembly 8-1/4 x 25/32 bexagon-head bolt 17—Boom support 9-1/4 flat washer Figure 6-11, Replacement of the azimuth distribution borTM 9—1440-531-12-1 Sap 17/16 hexagon plug 9Tube assembly 2-Preformed packing 10-Union 3-No. 10 hexagon safety nut 11—Preformed packing 4-No. 10x 3/4 panhead machine screw 12-Hydraulic fluid reservoir 5—Tube assembly 13~Thermontatic ewitch assembly 6-6/8 clamp 114—Preformed packing 1-1-15/16 clamp 16—Boom support ‘8—Air vent filter 16-No, 10x 3/4 panhead machine screw Figure 5-12. Replacement of the main hydraulic system componente. 5-24ao 17-1x 1/8 clamp S-Ring 1o-Hteee H—Buing 20-1/4 hexagon safety nut 85—Preformed packing Boast: 3877/16 hexagon nut 22—1/4 x 1-8/8 hexagon-head capecrew om ot 23-Pump amembly 38-Preformed 24—Union 2e-Bing prere cuee oeee 41—1/4 x 1-1/8 hezagonhead capecrew 26-1-1/16 hexagon nut eat eee 43-1/4 x 21/32 spacer pa 44—Reallent washer 29-Elbow 45~6/16 fat washer 30-8/4 hexagon mut e 31—Preformed packing i Figure 5-18 ~Continwed. 5-37. Replacement of the Pump Assembly (4) Disconnect the electrical connector from the pump assembly (23). NOTE (5) Remove the pump assembly from the ler igure S12 Pevoinowee bracket (46). Pp », Installation. * 1) Install and the pump assembly (23) imetructi in secure (1) Obeerve the safety instructions (par. 5-1). ae eee ae Oe eens erage, (2) Connect the electrical connector to the (8) Drain the main hydraulic fluid reservoir. pump assembly. lamp 5-1/4 x 2.1/2 bexagomhead capecrew 6-1/4 fat washer ‘7—Berew and boltspacer 8-Support bracket 9-Blevation presmure control vaive 10—Tube reducer 11-Preformed pecking 12-Check valve 19-Preformed packing 14—Tube reducer 15—Preformed packing Figure 5-18. Replacement of hydraulic components in support bracket. 5-25TM 9—1440-531— 12-1 1—Tube assembly, 2~Tube assembly 3-Hose ‘4-Tube amembly 5-1/4x 8 hexagon-head capecrew @-1/4x 3/4 spacer ‘7-1/4 flat washer 22-21 24) Lf? ° sUaloa 10-Preformed pecking Figure 6-14. Replacement of the accumulator, fter, ond valves. THcu 11—Cheek valve 12-Preformed packing 19-Union 14-Preformed packing 15—Elbow 16-Preformed packing 17—8/4 hexagon nut 18—Preformed packing 19-Ring 20-Union 21-8/4 hexagon nut 22-Preformed packing 23-Union 24-Elbow 25—Tube assembly 26—Tube assembly 21-No. 10 x 2-1/2 panhead machine screw 28-No. 10 flat washer 29-Bracket 30-Main system relief valve 31—Preformed packing 32-Ring 33-Ebow 34—3/4 hexagon nut 35—Nut 36—Washer 31—Tee 38—Tube assembly 39Tubs amembly 40-1/4 x 2-1/2 hexagomhead capecrew 41-1/4 flat washer 42-Azimuth system filter ‘A-Filter case B-Element (C—Backup ring D-Preformed pecking E-Head 43-Reducer 44—Preformed packing 45—Union 46—Preformed packing 47—Restrictor assembly 48—Preformed packing 49-Reducer TM 9—1440-531—12-1 50—Preformed packing 51-Elbow 52-Preformed packing 5-3/4 hexagon nut 54—Preformed packing 55—Ring 56—Union 57—Tube assembly 58—Tube assembly 59-1/4 x 2 hexagon-head capscrew 60-1/4 flat washer |ILCHR pressure valve }2—Union 63—Preformed packing 64—Tee @5—Preformed packing (€6-1-1/16 hexagon nut 67—Preformed packing 68—Ring 69—Union 70-1-1/16 hexagon nut 71—Preformed packing 72-Ring 13-Elbow ‘14-Reducer ‘76—Preformed packing 76-1/4 x 1/2 hexagon-head capecrew ‘77-1/4 flat washer 18—Bracket 19-Valve 80—Packing 81—Nut 82—Reducer 83—Packing ‘84—Union 85—Cross ‘86—Union 87-Elbow ‘88—-Nut 89—Tee 90—Union 91-Elbow 92-Valve Figure 515 ~Continved. (3) Add fluid to the reservoir until the indicator is at the full level. (4) Perform the following as applicable: (a) For the Weatherhead pump, disconnect the system return hose (19) from the pump, and disconnect the pump check valve to allow fluid to flow through the pump. Secure the check valve and the hose after fluid has appeared at the exposed port, (b) For the New York air brake pump, dis- conneet the suction hose (47) from the pump to allow fluid to flow freely. When the hose has filled with fiuid, reconnect the hose to the pump. (5) Close the hatch (par. 5-4). 5-38. Replacement of the Main Hydraulic System Filter NOTE ‘The key numbers shown below in parentheses refer to figure 5-14. a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Disconnect the tube assemblies (1, 2, 4) and the hose (3). (5) Remove the main system filter (8). 5-27TM 9-1440—531-12-1 b. Installation. © (1) Install and secure the main system filter ). (2) Install and secure the tube assemblies (1, 2, and 4) and the hose (3). (8) Lower the hatch (par. 5-4). (4) Fill the hydraulic fluid reservoir. (5) Connect all electrical cables to the ILCHR. c. Test. Refer to the check procedures (table 3-16). 5-39. Replacement of Relief Valve e Main Hydraulic NOTE ‘The key numbers shown below in parentheses refer to figure 5-14. a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Disconnect the tube assemblies (2 and 26). (5) Remove the main system relief valve (30). b. Installation. (1) Install and secure the main system relief valve (30). (2) Install and secure the tube assemblies (2 and 26), (8) Lower the hatch (par. 5-4). (4) Fill the hydraulic fluid reservoir. (5) Connect all electrical cables to the ILCHR. c. Test. Refer to the check procedures (table 3-16). 5-40. Replacement of the Azimuth System Filter NOTE ‘The key numbers shown below in parentheses refer to figure 5-14. a, Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (8) Drain the hydraulic fluid reservoir. (4) Disconnect the tube assemblies (38 and 39). cn (5) Remove the azimuth system filter (42). b. Installation. (1) Install and secure the azimuth system filter (42). (2) Install and secure the tube assemblies (38 and 39). (3) Lower the hatch (par. 5-4). (4) Fill the hydraulic fluid reservoir. (5) Connect all electrical cables to the ILCHR c. Test. Refer to the check procedures (table 3-16). 5-41. Replacement of the Pressure Valve NOTE ‘The key numbers shown below in parentheses refer to figure 5-14. a. Removal. (1) Observe the safety instructions (par. 5-1) (2) Raise the hatch (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Disconnect the electrical connector at the ILCHR pressure valve (61). (5) Disconnect the tube assemblies (25, 39, and 58). (6) Remove the pressure valve. b, Installation. (1) Install the ILCHR pressure valve (61). (2) Install and secure the tube assemblies (25 39, and 58. (3) Secure the electrical connector to the pres sure valve. (4) Lower the hatch (par. 5-4). (5) Fill the hydraulic fluid reservoir. (6) Connect all electrical cables to the ILCHR ¢. Test. Refer to the check procedures (table 8-16). 5-42. Replacement of the Rest Assembly tor NOTE ‘The key numbers shown below in parentheses refer to figure 5-14.cn a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hateh (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Disconnect the tube assembly (38) from the restrictor assembly (47). (5) Remove the restrictor assembly. b. Installation. (1) Install the restrictor assembly (47). (2) Connect the tube assembly (38). (3) Lower the hatch (par. 5-4), (4) Fill the hydraulic fluid reservoir. (5) Connect all electrical cables to the ILCHR. c. Test. Refer to the check procedures (table 3-16). 5-43. Replacement of the Manual Azimuth Movement Valve NOTE ‘The key numbers shown below in parentheses refer to figure 5-15, a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Remove the cover (3). (3) Disconnect the tube assemblies (10 and 1D. * (4) Remove the manual azimuth movement valve (14). b. Installation. (1) Install and secure the manual azimuth movement valve (14). (2) Install and secure the tube assemblies (10 and 11) in accordance with paragraph 5-2, (8) Install and secure the cover (8). (4) Connect all electrical leads to the ILCHR. ¢. Test. Refer to the check procedures (table 3-16). 5-44, Replacement of the Accumulator Air Filler Valve NOTE ‘The key numbers shown below in parentheses refer to figure 5-15. TM 9-1440-531--12-1 a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Remove the cover (3). (3) Have direct support maintenance person- nel discharge the accumulator. (4) Disconnect the tube assembly (7). (5) Remove the accumulator air filler valve (6). b, Installation. (1) Install and secure the tube assembly (7) in accordance with paragraph 5-2. (2) Install and secure the accumulator air filler valve (6). (3) Install and secure the cover (3). (4) Have direct support maintenance person- nel charge the accumulator. (5) Connect alll electrical cables to the ILCHR. c. Test. Refer to the check procedures (table 3-15). 5-45. Replacement of the Azimuth Drive and Data Assembly Components NOTE ‘The key numbers shown below in parentheses refer to figure 5-16. a. Removal. (1) Observe the safety instructions (par. 5-1). (2) Raise the hatch (par. 5-3). (3) Drain the hydraulic fluid reservoir. (4) Remove the electrical connectors from the valve assembly (17) and the transducer (11). (5) Disconnect the tube assemblies (2, 3, and 4). (6) Remove the overload relief valve, trans- ducer, manifold, and the valve assembly (6, 11, 13, and 17). b. Installation, (1) Install and secure the overload relief valve, transducer, manifold, and the valve assembly (6, 11, 18, and 17). (2) Connect the tube assemblies (2, 3, and 4). 5-29TM 9- 1440-531 12-1 on MI 73898 1—Panhead machine screw 8-Union 15—Flat washer 2-Flat washer 9-Preformed packing 16—Union 3Cover 10—Tube assembly 17—Preformed packing 4-Bracket 11—Tube assembly 18—Union 5—Bracket 12-Panhead machine screw packing @—Accumulator air filler valve 13-Bpacer 20-Union ‘7Tube assembly 14—Manual azimuth movement valve Figure 5-16. Replacement of the valve assemblies. (8) Install the electrical connectors on the valve assembly (17) and the transducer (11). (4) Lower the hatch (par. 5-4). (5) Fill the hydraulic fluid reservoir. (6) Connect all electrical cables ta the ILCHR. ae t. Refer to the check procedures (table 5-45. Replacement of the Boom Support NOTE ‘The key numbers shown below in parentheses refer to figure 5-16. @ Removal. Remove the boom support lev! from the level mounting plate (35).TM 9—1440~531—12-1 MI 73837A ‘Figure 5-16. Replacement of the asimuth drive and data assembly components.T™ 9—1440—531—12—1 A-Azimuth drive assembly 2Tube amembly 3~Tube assembly 4—Tube amembly 5-6/16 x 6/8 fillister-head machine screw 6—Overload relief valve assembly ‘7—Preformed packing 8—Preformed packing ‘9-No, 10 x 2-17/32 hexagor-head machine screw 10-No. 10 flat washer 11—Transducer 12-Preformed packing 18-Manifold 14—Lockwire 15—No. 10 x 8/4 socket-head capecrew 16-No, 10 lockwasher 17—Valve assembly 18--Preformed packing 19-Berew 20—Washer 21-Nut 22-Case 23-8/8-inch self-locking nut 24—No. 10 flat washer 26—Cap 26—Level cover 27—Preformed packing 28—Window 29-Ring guket 30—Gasket 81—No. 6 safety nut ‘92—Round spirit level 83-No. 6 safety nut ‘84—Shouldered stud ‘86—Level mounting plate Figure 5-16.—Continued. b. Installation. (1) Install the level (32) on the level mounting Plate (35). (2) Insure that the launcher is emplaced on a solid surface and level it in accordance with pro- cedures outlined in par 7-5a(19). (3) Rotate the turntable 90 degrees and ob- serve the level. If necessary, adjust the level using the safety nuts (33 and 31) until the bubble is approximately halfway from the edge to the center of the level; then again level the launcher. (4) Repeat step (3) above as many times as necessary until the tumtable can be rotated through ‘360 degrees of travel with the bubble of the level remaining centered. (5) Cement the gasket (30) on the level, and install the ring gasket, the window, the new pre- formed packings (29, 28, and 27), and the level cover (26) on the level. Install the cap (25). 5-46. Replacement of the Hatch-Raising Cylinder NOTE The key numbers shown below in parentheses refer to figure 5-17, NOTE ‘Thin procedure covers the replacement of ei ther the left or right hatch-raising cylinder. a. Removal. NOTE It may be necessary to raise the hatch using hoist or derrick. (1) Raise the hatch (par. 5-3). (2) Open the bleed valve (1) counterclockwise to relieve the hydraulic pressure. (8) Disconnect the hose assembly (27). Cap the hose and plug the port. (4) Remove the hatch-raising cylinder (37). b, Installation. (1) Install and secure the hatch-raising eylin- der (37). (2) Remove the plug from the port and the esp from the hose assembly. Connect the hose assem- bly (27) to the cylinder. (8) Close the bleed valve (1) clockwise. (4) Check that the handnuts are in the out- board position. (8) Close the hatch (par. 5-4). 5-47. Replacement of the Handpump Assembly NOTE ‘The key numbers shown below in parentheses refer to figure 6-17. l a. Removal, (1) Observe the safety instructions (par. 5-1) (2) Open the bleed valve (1) counterclockwise to relieve the pressure. (8) Remove the drain plug (5) and drain the reservoir (4).1—Bleed valve ‘2-No, 10 x 21/32 hexagon-head bolt 3-Flat washer 4 -Reservoir 5—Drain plug Washer ‘T—Hoee assembly 8-Elbow 9-Preformed packing 10—Washer ‘11—Tube assembly 12-Elhow 13-Preformed packing 14—Washer 18-3/4 hexagon nut 16-3/4 flat washer V7-Spacer 18-Handpump assembly 19~1/4 x 3-17/32 hexagon-head bolt TM 9—1440-531-12-1 20-No. 10 safety nut 21-No. 10 flat washer 22-No. 10 hexagon-head bolt 23-No. 10 flat washer 24—No. 10 x 21/32 hexagon-head bolt 25—No. 10 flat washer ‘26—Base hydraulic control panel 27—Hose assembly 28—Reducer 29-Preformed packing 30-8/8 castellated nut 31—8/8 flat washer ‘92~3/8 x 1-81/64 shear bolt ‘33-8/8 hexagon nut 34—8/8 flat washer 85—3/8 x 1-16/32 hexagon-head bolt 36-3/8 flat washer 87—Hatch-raising cylinder Figure 5-17. Replacement of the base hydraulic componentsTM 9—1440—531—12—1 (4) Disconnect the hose and tube assemblies (7 and 11). Cap the hose and tube assemblies and plug the ports. (5) Remove the handpump assembly (18) from the handpump bracket. b. Installation. (1) Install and secure the handpump assembly (18) in the handpump bracket. (2) Remove the plugs and uncap the hose and tube assemblies. Install and secure the hose and tube assemblies (7 and 11). (8) Close the bleed valve (1) clockwise. (4) Install and secure the drain plug (5) and fill the reservoir (4). (5) Connect all electrical cables to the ILCHR. 5-34 10 5-48. Replacement of Additional Units The repair or replacement of the following units is obvious by illustration. Refer to the appropriate illustration. Insure that the ILCHR is deenergized before performing maintenance. For the appropri- ate test after installation, refer to the fault isola- tion procedures in TM 9-1440- 531 The shaded area in figure 5-17.2 indicates the repaira- ble or replaceable unit. Cable assembly 9089392 (1, fig. 5-17.1) Cable assembly 10292806 (2, fig. 6-17.1) Cable assembly 10292805 (3, fig. 5-17.1) Cable assembly 10288760 (5, fig. 5-17.1) Cable assembly 10288761 (4, fig. 5-17.1) Cable assembly 9194239 (6, fig. 5-17.1) Cable assembly 9089859 (7, fig. 5-17.1) Cable assembly 10672230 (9, fig. 5-17.1) Cable assembly 9089381 (8, fig. 5-17.1) Case assembly 10109490 (6, fig. 5-17.2)clo T™ 9—1440—531—12-1 1—Cuble assembly 90H9:192 ‘assem naan 1 Cable sembly MANS a -mbly 1028876) extembly 1028760 Figure 5-17.1. Boom support electrical system (10672231) (sheet 1 of 2) 5-34)MS 164687A Boom support electrical system (10672231) (aheat 2 of 2). Figure 5-171T™ 9—1440—531—12—-1 MS 164688 6—Cuse assembly 10109490 Figure 5-172. Boom support (10183106). $34.3TM 9—1440—531—12—1 cs Section IV. CORRECTIVE MAINTENANCE OF THE BOOM Replacement of the entire boom, specific subassemblies of the boom, or piece parts of the specific subassemblies requires subsequent alining and boresighting by DS and GS personnel. For a list of assemblies which require subsequent alining and boresighting, refer to paragraph 6-57.1. 5-49. Replacement of the Igniter Relay istribution Box a, Remove and install the igniter relay dis- tribution box (15, fig. 5-18). b. Refer to table 3-17 for test procedure. 5-50. Replacement of the Missile Sensing Switch a, Remove and install the missile sensing switch (83, fig. 5-18). b. Refer to table 3-16 for the test procedure. 5-50.1. Replai and Fi ent of the Nose Fairings ing Plates NOTE Perform only those steps necessary to remove and replace the hardware, nose fairing, fairing plate or plates that have been found to be defective. NOTE ‘The key numbers shown below in parentheses refer to figure 5-18. a, Removal of the Nose Fairings. (1) Remove the five screws securing the nose fairing (43) to the fairing plate (44). (2) Remove the four screws securing the nose fairing (43) to the fairing plate (46). (3) Remove the nose fairing (43) from the fairing assembly (46). b. Removal of the Fairing Plates. (1) Remove the fairing assembly (46). (2) Perform the appropriate steps in subpara- graph a above. (3) Remove the fairing plate (44) from the fairing assembly (46). 534.4 (4) Remove the fairing plate (45) from the fairing assembly (46). c. Installation. (1) Assembly and installation of the now fairing (43), fairing plates (44 and 45) and fairing assembly (46) is obvious by illustration. If when installing the fairing assembly (46) a new roller (38) and/or shaft (37) is installed in the LCHR, have DS and GS personnel perform appropriate bore- sight and alinement procedures. (2) Apply tape 7510-926-8939, as required, to cover the forward edge of the nose fairing (43). 5-51. Replacement of the Boom Snubber (Shock Absorber) NOTE Boom snubbers should be replaced in pain ‘with each snubber having the same part number. NOTE ‘The key numbers shown below in parentheses refer to figures 6-19 and 5-19.1. a. Elevate the boom 180 mils. b, Remove the boom snubber (9) from mounting hardware (6) through (10) and spring (4) from support shaft (12). ¢. Inspect the rubber bushings (8) and (10) for deterioration. Replace if necessary. d. If the boom snubber is to be replaced, veri the oil level (para. 4-6i) in the replacement unit ¢. Install the boom snubber (9)and hardware(4), and (6) through (11). Jf Lower the boom until the snubber is fully settled into the compressed state. 9. Check that the snubber piston rod end sas within the striking plate cup as the boom depress. Tf not, adjust the screw (3).cw 5-52. Replacement of the Hydraulic Oil Cooler a. Disconnect all electrical cables from the rear of the LCHR base. >. Remove, disassemble, assemble, and install the hydraulic oil cooler in accordance with figure 5-20. c. Insure that the main hydraulic oil reservoir is full. d. Connect all electrical cables to the base. e. Cycle the LCHR hydraulic system to insure operation of the oil cooler. LCHR 5-53. Replacement of the Actuator Power Control Assem! NOTE ‘The key numbers shown below in parentheses refer to figure 5-21. a. Removal, (1) Disconnect the electrical cables at the LCHR. (2) Install the azimuth lock assembly in the lock position. (8) Remove the locking wire (18). (4) Remove the valve assembly (4 through 8 or 20), or the transducer (16). NOTE The valve assembly (4 through 8) is recessed into the manifold and requires a thin-walled socket wrench for removal. b. Installation, (1) Install the valve assembly (4 through 8, or 20), or the transducer (16) and torque the bolts to 29-82 Ib-in. (2) Install the locking wire (18). (8) Install the azimuth lock assembly in the stow position. (4) Connect the electrical cables to the rear of the LOHR base. ¢. Test, Refer to the check procedures (tables 3-16 and 3-17). 5-54. Replacement of the Elevation Fluid Filter or the Elevation Pressure Flow Regulator NOTE ‘The key numbers shown below in parentheses refer to figure 2-1, unless otherwise indicated. 1 9—1440—531—12—1 a. Preliminary Removal Procedure, (1) Remove the missile from the launcher per paragraph 2-11». (2) Relieve the pressure in the elevation hydraulic system as follows: (a)_ Place the LOCAL/REMOTE switch (10) to LOCAL (@) Set the ALIGN switch (8) to OFF. opr, © Pisee the HYD PRESS switch () to (@)_Set the MAIN POWER switch (13) to ON. Wait approximately 45 seconds for the amplifiers to warm up. (@) Place the HYD PRESS switch (9) to ON. With the elevation handwheel (12), elevate the boom to the maximum up position. G) Set the MAIN POWER switch (13) to OFF and wait for the boom tosettle to the maximum down position. (h) Place the HYD PRESS switch (9) to OFF. 1. Adjust the elevation handwheel (12) until the elevation indicator dial (3) indicates zero. 2 Pull out the knob of the CB7 MAIN CIRCUIT BREAKER (8, fig. 2-2). $. Remove the blast deflector assembly and the cover plates (3, 4, and 6, fig. 5-22). 4. Disconnect three hose assemblies (35, 36, fig. 5-22), and (16, fig. 5-22.1) from the trunnion shaft (44, fig. 5-22). 5. Cap lines and ports to prevent contami- nation and fluid loss. 6. Removal of the Elevation Fluid Filter Ele- ‘ment. NOTE Removal of the elevation fluid filter is not required for replacement of the filter element. NOTE ‘The key numbers shown below in parentheses. refer to figure 6-22, unless otherwise indicated. (1) Remove the lockwire between the case (43) and the head (25). (2) Rotate the case (43) and remove it from the head (25). (3) Remove and replace the old filter element (40) and packing (41). ¢. Installation. (1) Replace filter element (40) and packing (an. (2) Reassemble the case (43) to the filter head (25). (3) Install the lockwire between the case (43) and the head (25). (4) Push in the knob of the CB7 MAIN CIR- CUIT BREAKER (8, fig. 2-2). 5-35TM 9—1440-531-12-1 MI 73839B 1-1/4 x 1-9/82 hexagomhead bolt ‘T—Cover plate 2-1/4 flat washer 8—Cover plate ‘3-Blast deflector cover 9-1/4 self-locking nut 4—Cover plate 10—1/4 x 1-5/32 hexagon-head bolt 5-1/4 x 1-9/82 hexagon-head bolt 11—Flat washer 6-1/4 flat washer 12-Cover plate Figure 5-18. Replacement of the missile boom components — forward. 5-36cio T™ 9—1440—531. 19-No, 10x 29/32 hexagon-head bolt 30—Outrigger support 14-No. 10 flat washer 31—No. 10x 3/4 panhead screw 15—Igniter relay distribution box 32-No, 10 flat washer 16-No, 10 selflocking nut 33—Missile sensing switch 17-No. 10x 3/4 panhead screw 34~Connector 18-Cover 35—Cable assembly 19-1/4 x 3/4 panhead screw 36—Pin 20-1/4 internal-tooth lockwasher 37—Bhaft 21—Cover 38-Roller 2-1/2 seltlocking nut 39-Pin 23-1/2 x 9-11/32 hexagon-head bolt 40—Washer 24—1/2 Oat washer 41Fin 25—1/2 selfocking nut 42—Retaining stud 26—-1/2 x 3-11/32 hexagon-head bolt 43—Nove fairing ‘27-1/2 flat washer 44—Fairing plate (upper) 28—Bracket 45—Fairing plate (lower) 29-Outrigger amembiy 46—Fairing assembly Figure 5-18—Continued. 1-1/4 hexagon jamnut 2-1/4 hexagon jamnut 3-1/4 x 2 panhead machine screw 4-Hielical compression spring ‘5—Spring retainer 6-3/4 hexagon safety nut ‘7—Retaining washer 8-Bushing ‘9-Bhock absorber 10—Bushing 11—Retaining washer 12-Support shaft 13-No, 10 hexagon safety nut 14-10 x 8/4 panhead machine screw 15—No, 10 flat washer 16—Angee bracket 17—Boom Figure 19. Replacement of the boom snubber (9091308). 5-37™ 9—1440—531—12—1 d. Test. (1) Test for leaks as follows (@)_ Press any two missile sensing switches (83, fig. 5-18) by wedging the actuating arm of the switeh with a screwdriver. (6) Set the MAIN POWERswitch (13, fig. 2- 1) to on and wait approximately 45 seconds before proceeding to the next step. (©)_ Place the HYD PRESS switch (9, fig. 2- 1) to HYD PRESS. a 1% hexagon jamnut 2% hexagon jamnut 3—¥ panhead machine screw 4—Helical compression spring a retainer 6% hexagon safety nut ‘7—Retaining washer 8-Bushing 9—Shock absorber 10—Bushing 11—Retaining washer 12—Support shaft 18—Hexagon safety nut 14—Panhead machine screw 15—Flat washer 18—Preformed packing 19—Fillport plug. Figure 5-191. Replacement of the boom anubber (11567877). 5-38 (2) After approximately one minute of hydraulic activation, set the HYD PRESS switch to OFF and inspect for leaks. (@) Correct any leaks and recheck for leaks. (f)_ Set the MAIN POWER switch (13, fig. 2- 1) to OFF. (g) Remove the screwdriver wedge (step (a) above) from the sensing switches. (4) Re-install the cover plates (4) and (5)and the blast deflector assembly (8). ¢. Removal of the Fluid Pressure Filter Assembly or the Elevation Flow Regulator Valve. NOTE ‘The key numbers shown below in parentheses refer to figure 5-22, unless otherwise indicated. (1) Disconnect the tube assemblies (21) and “@)_ Cap lines and ports to prevent contamina- tion and fluid loss. NOTE During removal of the regulator valve observe that the end closure does not rotate with respect to the regulator body. (8) Remove the capscrew, washer and nut (23), (24), and (10). (4) Remove the tee (29), the head (25), elbow (83) and elevation pressure flow regulator valve (32) assembled as a unit. (8) Disassemble either the head (25) or the elevation pressure flow regulator valve (32). f Installation of the Fluid Pressure Filter Assembly or the Elevation Flow Regulator Valve. (1) _Install the tee (29), the head (25), the elbow (83), and the elevation flow regulator valve (32) asan mana ‘Remove the caps from the tube assembly en (ea) (3) _ Install the assembly (29), (25), (33) and (82) into the launcher and secure with the capecrew (23), the washer (24), and the nut (10). NOTE During replacement of the regulator valve, ‘observe that the end closure does not rotate with respect to the regulator body. (4) Reconnect tube assembly (21) to the tee (29), and the tube assembly (22) to the elevation pressure flow regulator valve (32). (6) Remove caps from trunnion shaft hydrau- lie ports and hoses (35), (36) and (16, fig. 5-22.1),ce (6) Reconnect the hoses to the trunnion shaft. Assure that the hoses marked PRESSURE and RETURN are connected to the trunnion shaft ports marked “P” and “R” respectively. (1) Push in the knob of the CB7 MAIN CIRCUIT BREAKER (8, fig. 2-1). go. Test. (1) Repeat subparagraphs d(1)(a) through (h) to test for leaks. (2) Re-install the cover plates (4) and (5) and the blast deflector assembly (3). 5-54.1. Replacement of the Elevation Return Flow Regulator Valve NOTE ‘The key numbers shown below in parentheses refer tofigure 5-22.1, unlessotherwise indicated. a, Preliminary Removal Procedure. Perform the preliminary removal procedures in paragraph 5- 54a. b. Removal. (1) Label hose assemblies (35 and 36), fig. 5-22. Then disconnect the hoses from the trunnion shaft (44). (2) Disconnect the small return hose (16) and the tube assembly (14) from the tube union (5). (8) Cap the bottom of hose (16) and tube assem- bly (14) to prevent contamination and fluid loss. (4) Disconnect the tube assembly (14) from the elbow (18) and cap the tube. (6) Disconnect the clamps (8). (6) Remove the return flow regulator valve (10), with the tube union (5), the elbow (13) and the clamp (8) attached, from the launcher. (1) Remove the clamps (3) from the return flow regulator valve (10). (8) Remove the elbow (13), the locknut (17), the washer (12) and the preformed packing (6) from the return flow regulator valve (10). T™ 9—1440—531—12—-1 (9) Using an open end wrench to maintain the relative position of the return flow regulator valveend closure with respect to the body, remove the tube union (5), the nipple (18) and the preformed packing (6) from the regulator body. ¢. Preliminary Installation. NOTE During installation, do not permit the flow regulator end closure to turn with respect to its body. (1) With an open wrench, maintain the relative position of the flow regulator end closure with respect to the body and connect the nipple (18) and tube union (5) with the preformed packing (6)to the return flow regulator valve (10). (2) Slip clamps (8) onto the regulator body. (8) Assemble the elbow (13), the locknut (17), the washer (12), and the preformed packing (6) to the regulator body. Leave the locknut (17) loose to permit orienting of the elbow during launcher installation. d, Installation. (1) In the launcher, remove the caps from the bottom of the small return hose (16) and tube assembly (14). (2) Place the flow regulator valve in the launcher and connect the small return hose (16) and tube as- sembly (14) to the tube union (5). (8) Using a screw (1), spacer (2), and nut (4), fasten the flow regulator valve to the boom. (4) Connect the tube assembly (14) to elbow (18) and tighten the locknut (17). (5) Reconnect hose assembly (35 and 36, fig. 5-22) to trunnion shaft (44). (6) Complete reassembling and test for leaks per paragraph 5-54d(a) through (h). e. Test. Have DSU personnel verify that the elevation return line flow regulator is operating within limits by performing step 3 of Table 2in TB 9—1440—531—34—1.T™ 9—1440—531—12—1ca. 1—Tube assembly ‘2~Tube assembly ‘3—Cable assembly 4-Strap assembly ‘A-Strap assembly bolt B-Strap assembly washer (C—Strap assembly spacer sleeve D-Strap assembly 5—Hydraulic oil cooler assembly ‘A-Coupling clamp nut B-Coupling clamp sector T™ 9—1440—531—12—1 ‘C—Coupling clamp sector D-Cooler assembly E-Ghell assembly @Union ‘7-Preformed packing 8-Elbow ‘9-Preformed packing 10—Backup ring 11-Nut Figure 5-20—Continued. 5-55. Deleted 5-56. Replacement of the Temperature Control Unit NOTE shown below in parentheses 1 to figure 5-23. a. Removal. (1) Remove the serews and washers (1 and 2). (2) Remove the cover plate, gasket, and tem- perature control unit (3, 5, and 6). (3) Disconnect the cable assemblies from J1 and J2. (4) Remove the four screws (4) to remove the gasket from the temperature control unit, b, Installation (1) Install the four serews (4) into the cover plate (3), through the gasket (5), into the temper- ature control unit (6). (2) Connect the cable assemblies to J1 and J2. (3) Install the ten screws and washers (1 and 2) to the aft outrigger. 5-56.1. Replacement of the Sector Release Shear Pin . NOTI ‘The key numbers shown belo refer to figure 6-23.1. a. Removal, (1) Remove two threaded bushings (1 or 4). (2). Slide shear pin (2, or 6, 7)from the roller (3) through the hole in the mount and remove theroller. (8) If the shear pin is in two parts (6, 7) separate the two. (4) Remove O-rings (5) from bushings (4) if necessary. 6. Inapection. NOTE Shear pin must be replaced annually as part of the annual boresighting procedure. (1) Inspect threaded bushings (1 or 4) and replace any that are worn or have damaged threads. Insert the end of a new shear pin (2 or 7 as appli- cable) in the hole in both threaded bushings (1 or 4), Observe that the new shear pin fits snugly with the same clearance all around. If it does not, replace the bushing. 5-39TM 9—1440-531-12-1 Figure 5-21. Disassembly of the actuator power control assembliesca TM 9—1440—531—12—1 1—No, 8 x 1/4 panhead screw 12-Flared tube nut 2—No. & lockwasher 13—Locking wire ‘3—Valve assembly shield 14—0,359 x 1-25/32 aircraft machine bolt 4—Reliet valve 15—No, 10 flat washer 5—Backup ring 16~Transducer 6—Preformed packing 17—Preformed packing ‘7—Beckup ring 18-1/4 x 2-3/4 hexagon sockethead capecrew ‘8—Preformed packing 19-1/4 lockwasher 9-Elbow 20-Valve assembly 10—Preformed packing 21—Preformed packing 11—Backup ring 22-Cylinder manifold Figure 5-21—Continued. Figure 6-21.1. Deleted. S-41T™ 9—1440—531—12—1 Figure 5-22, Replacement of the boom hydraulic components. 5-42 . Google - BIC +a 1—Flat washer 2—Hexagon-head capscrew 3—Blast deflector assembly 4—Cover plate 5—Cover plate 6—Tube assembly 7—Tube assembly 8—Hose 9 Hose 10—Self locking nut 11—Hexagon-head capscrew 12—Elevation pressure flow regulator valve 18—Tee 14—Preformed packing 15—Preformed packing 16—Hexagon nut 17—Reducer 18-Ring 19—-Union 20—Elbow 21—Tube assembly 22—Tube assembly T™ 91440531121 23—Hexagon-head capscrew 24—Flat washer 25—Head 26—Reducer 21—Preformed packing 28—Pressure seal cap 29—Tee 30—Hexagon nut 31—Ring 82—Elevation pressure flow regulator valve 83—Elbow 34—Union 35—Hose assembly '36—Hose assembly 37—Cam 38—Hexagon capscrew 39—Cam control 40—Filter element 43—Case ‘44—Trunnion shaft Figure 5-22-Continued. (2) In units 11567873*(AG)' check that shear pin (7) fits in bushing (6) and observe that bushing (6) fits in roller (3) without any interfer- ence. If an abnormal condition exists, replace the shear pin and/or bushing. (8) If the pin (2 or 7) shears during firing, re- move the sector cover and inspect the bottom of the housing for foreign debris, roller and/or shear pin material. Remove all debris from the bottom of the housing. (4) In units 11567873*(AG)', visually in- spect the O-rings (5) for deterioration. Replace if necessary. Installation. (1) Re-install the bushings, shear pin, and roller. (2) Tighten the bushings with an Allen head ¥/4-inch key NSN 5120-00-827-2967 or screwdriver a8 applicable until metal-to-metal contact is made with the mount. Continue tightening a fraction of a turn beyond this point. (8) Insure that there is no gap between the bushing head and the mount as shown in figure 5- 2. d. Inspection After Assembly (Fig. 5-23.2) (1) Inspect the legs of the mount. If a leg is bent outward, higher stress on the shear pin will ‘secur. If the dimension across the outside of the mount is greater than 1-13/32 inches, replace the mount. ‘Rater vo appendix D for serial number effectivity. (2) Inspect the inside surface of the mount for evidence of interference between the mount inner surface and the corner of the arm. Any interference could result in an improper latch and should be correctly adjusted. Look for foreign objects between stop and ari loose screw could create a sector false lateh condition where the sector would appear latched but will take less than 500 pounds to release. (3) Inspect the roller for freedom of move- ment. If interference is observed, notify direct support unit. (4) Relatch the sector. Push and pull the sector. by hand to assure that there is a small amount of play in the direction of rotation, but no excessive play or rattle. If there is no play, the sector is preloaded and direct support personnel must be notified to readjust the sector. NOTE Ifa preload condition exists, donot load a missile ‘on the launcher arm before adjustment by the direet support unit. (5) If the sector release roller (3, fig. 5-23.1) has been replaced, and time is available before missile reloading, notify the DSU personnel to check the clearance between the roller and the release arm when the sector is latched. The clearance should be 0.004 to 0.008 inch. 5-43cio T™ 91440531121 1—Serew 7—Outlet end 2-Spacer 8—End closure 14—Tube assembly 3Clamp 9am nut. 15—Hard lines aout 10—Return flow regulator valve 16—Small return hose ‘5—Tube union 11—Inlet end 17—Loeknut 6—Preformed packing 12—Washer 18—Nipple Figure 5-#8.1. Replacement of the boom hydraulics components,c10 T™ 91440531121 1Serew 3-Cover plate 5-Gasket 4-Berew 2-Washer @ Temperature control unit Figure 5-88. Replacement of the temperature control unit 5-441Figure 5-23.1. Replacement of the sector release shear pin.cio saecaL To METAL INTERFERENCE toripannort coven poner tonne T00 taney musi not Preis snes 7 ue GREATER THAN sma ronoxtese eonnet FOREIGN OBJECT STOP NOT CORRECTLY FABRICATED MS 313430 Figure 5-28.2 Release inspection parameters. 5-56.2. Replacement of the Umbilical Insert NOTE ‘Tue key numbers shown below in parentheses refer to figure 6-23.3 The launcher umbilical connector which mates with the missile umbilical connector must be freeof rocket motor blast deposit. The pins must be straight and the rim gasket must be pliable so as to provide a water barrier when it bears against the ‘missile. If not, replace the umbilical insert. @ Removal. (1) Open the cap (1). (2) With a 3/8 inch nutdriver unscrew the center pin (5) on insert (2) until the insert is jacked out of the connector shell (4). (8) If the rim gasket (7), a part of the insert, adheres to the connector shell, forcibly extract the insert. TM 9—1440—531—12—1 b. Installation. NOTE Insure that the inside surface of the connector ‘hell where the insert rim gasket seats is clean ‘and void of any pieces of gasket. NOTE When cleaning the shell, take precautions to revent material from falling into the connector sockets, NOTE If, in removal, the gasket adhered to the shell, lubricate the’ shell and the gasket of the replacement with silicone compound (non- conductive) NSN 16850-00-880-7616. Remove any excess lubricant, (1) Open the cap (1). (2) Re-install the insert (2) so that the center pin (5) and the guide pin (6)mate with the connector socket (3). (3) With a 3/8 inch nutdriver, tighten the center pin (5) on the insert (2) until the insert pulled down and mates with the connector socket @. 5-57. Replacement of Additional Units ‘The repair or replacement of the following units is obvious by illustration. Refer to TM 9-1440— 581-24P for the appropriate illustration. Insure that the ILCHR is deenergized before performing maintenance. Center arm blast deflector 10112858 Roller assembly 10183636 5-57.1. Replacement of Assemblies Requiring Boresight and/or Alinement The following is a list of ILCHR assemblies, which upon replacement, require boresight and/or alinement. However, it is not intended to indicate that only the replacement of the items listed necessitates subsequent boresighting and/or aline- ment. The replacement of some of the components which are part of these assemblies would also re- quire that DS and GS personnel perform specific oresight and/or alinement procedures. This listing is merely intended to alert battery personnel that should maintenance be performed on any of these assemblies, boresight and/or alinement may be necessary. Therefore, DS and GS personnel should be notified to determine if the actual maintenance 5-44.3TM 9—1440—531—12—1 cio Performed necessitates boresighting and/or aline- Forward support assembly 10674181 ment. Rear support assembly 10670470 Boom 10674175 Boom electrical installation 10869091 Elevation actuator assembly 10673199 Alinement telescope and fire cutout Loader index fitting assembly 9089273 assembly 10179415 MS 313431 Figure 6-23.38, Umbilical insert. 5-444TM 9—1440-531—12-1 Section V. CORRECTIVE MAINTENANCE OF ADDITIONAL UNITS ‘5-58. Replacement of the Missile Pallet mponents NOTE ‘The key numbers shown below in parentheses refer to figure 5-24. a. Disassembly. (1) Remove the missile anchoring plate (1) with attached components. (2) Remove the spring pin, headless pin (6), locking nut (37), round nut (7), self-adjusting washer (8), and the missile anchoring stud (10). NOTE Use 10-inch adjustable wrench 5120-449- ‘8088 to hold the flat portion of the missile anchoring stud while replacing the locking it. . (8) Remove the retainer (3) and the eyebolt (4) Repeat steps (1) through (8) above to remove the opposite assembly. (5) Remove the cotter pin and clevis pin (12 and 18). Do not remove the locking clevis (14) from the slotted clevis (23). (6) Remove the quick-release pin (15), the spacer (16), and the sash chain (17), (7) Remove the grooved headed pin (20), and withdraw the missile latch with the slotted clevis the cradle of the pallet (8) Remove the cotter pin (12), from the clevis pin (21), from the slotted clevis (28), and from the missile lateh (22). Do not remove the slotted clevis (28) from the locking clevis (14). (9) Remove the spring pin (24). (10) Remove the pin (26), the missile stop (27), and the spring (28) from the spring pin (29) and the missile stop. (11) Remove the spring pin (29). (12) Repeat steps (1) through (11) above for disassembly of the outboard cradles. 6. Assembly. (1) Install the spring pin (29). (2) Install the pin (26) into the hole in the missile stop (27), and over the spring pin (24). (8) Install the missile stop (27), aline it with the pin, and secure it with the retaining ring (25). (4) Pull the missile stop lever to the left, and the spring pin (29) with the slot opposite the contact area of the lever. (5) Install the spacer on the pin and secure the chain. (6) Install the slotted clevis (28) on the missile latch (22) with the clevis pin (21). (7) Install the missile latch with the slotted clevis attached into the cradle of the pallet frame, and secure it with the grooved headed pin (20), sleeve spacer (19), and the retaining ring (18). (8) Install the locking clevis (14) to the slotted clevis (23) and insert the pin under the missile” latch with the latch in the upward position. (9) Install the locking clevis (14) on the mis- sile stop (27), aline it with the clevis pin (13), then secure it with the cotter pin (12). (10) Install and secure the eyebolt (4) to the missile anchoring plate (1), allowing a 0.005- to 0.015-inch gap. (11) Install and secure the retainer (3) to the eyebolt (4), allowing a 0.400-inch minimum gap. (12) Install and secure the panhead screw (2) to protrude 0.940 to 0.009 inch from the external surface of the plate. Insure that the locking nut (37) is backed off to provide full thread engage- ment with the ex: threaded wing bolt. The round nut (7) may be loosened by tapping with a small hammer or any tool to break the initial friction, the locking nut can then bé backed off several turns to provide thread engage- ment with the missile, (13) Install the missile anchoring stud (10), flat washer (11), self-adjusting washer (8), round nut (7), locking nut (37) and the spring pin (9). NOTE ‘The spring pin (9) should be centrally located within 0.060 inch in the missile anchoring stud (9, (14) Install and secure the missile anchoring plate (1) with attached components to the eradle. 5-45‘TM 9—1440-531-12-1 1—Miasle anchoring plate 25—Retaining ring 2-Panhead serew 26—Pin ‘3-Retainer (27—Missile stop’ 4-Eyebolt 28—-Spring S~Spring pin 29-Spring pin 6—Straight headless pin ‘30—Adapter 7Plain round nut 31—Bolt 8—Self-adjusting washer (32—Nut Spring pin 33-Fin 10-Minsile anchoring stud 34—Index housing T—Flat washer '35~Shim 12-Cotter pin 24—Spring pin 36-Spacer 37—Locking nut Figure 5-24. Replacement of the missile pallet components. 5-46ce (15) Repeat steps (11) through (14) to assemble the opposite clamp assembly. (16) Repeat steps (1) through (15) to assemble the two outboard cradles, except the quick-release pin (15), and the attached components will be installed to the outside of the outboard cradles. 5-59. Replacement of the Index Housing NOTE ‘The key numbers shown below in parentheses refer to figure 5-24. a, Disassembly. (1) Remove the two bolts and nuts (31 and 32). (2) Remove the pin (33). (3) Remove the index housing, shim, and spacer (34, 35, and 36) from the frame assembly. 6. Assembly. (1) Install the spacer (36), shim (35), and index housing (34) on the frame assembiy. (2) Install the pin (33). (3) Install the two bolts (31) and attach with the two nuts (32) to secure the index housing to the frame. T™ 9-1440-531-12-1 5-60. Removal of the Loading and Storage Pallet from the Trailer NOTE ‘The key numbers shown below in parentheses refer to figure 5-25. a. Disassembly. (1) Remove the four screws and nuts (1 and 2) and the washers (3 and 4). (2) Remove the frame pallet (5) from the chassis (6). b, Assembly. (1) Install the frame pallet (5) on the chassis (6). (2) Install the four screws (1), washers (3 and 4) and nuts (2) and secure them to the chassis. 5-61. Replacement of the ILSCB Circuit Cards Remove and replace the cireuit cards as shown on figure 5-26. 5-47cis T™ 9—1440—531—12—1 Figure 5-25, Removal of the loading and storage pallet from the trailer. Google i 5-48TM 91440531121 CHAPTER 6 Section I. 6-1 Scope Preparation for travel of the improved launcher (ILCHR), pallet XMIE2, and ILSCB js presented in this chapter. Paragraphs 6-4 and 6-5 contain general information of the transportation of the equipment by truck (prime mover), cargo aireraft, and helicopter. Paragraphs the preparation for travel 6-2. Explanation of Procedures The preparation for travel procedures describe Section Il. 6.4 Transportation by Truck Usually the ILCHR, guided-missile pallet and the ILSCB are transported by the M36 truck (prime mover) to the battery site. 6-5. a. Helicopter. ‘The small items of the improved HAWK system, such as the ILSCB are transported inside a helicopter. The ILCHR and guided-missile pallet are helicopter-lifted by means of a suspension sling assembly. This assem- bly is shown in figure 6-1 and table 6-1. The storage bag (7, fig. 6-1) is used to stow the remaining eomponents when not in use. The grounding device assembly (1, fig. 6-1) is used to ground the helicopter lifting hook (2, fig. 6-18) before hookup of the ILCHR or guided-missile pallet_and is fabricated locally. Refer to sub- Paragraph 6 below for fabrication procedures for this device. The spreader bar assembly (fig. 6-4) is used to prevent the suspension sling assembly legs from bearing against sharp edges, fragile or lightly constructed parts of the equipment being lifted, and is fabricated locally. Refer to sub- paragraph ¢ below for fabrication procedures of this assembly. The suspension sling assembly (fig. 6-2) required to lift the improved HAWK system major items consists of four nylon web and chain legs connected to a 30.5 cm (1 ft) diameter nylon Transportation by Air IEPARATION FOR TRAVEL GENERAL the most efficient method of converting the improved HAWK system from a completely emplaced battery into a mobile unit. 6-3. Trailers ‘The zero-length launcher is mounted on its own trailer, consisting of the trailer leveling system, the components of the hydraulic system, and a major portion of the ILCHR electronics system. ‘The quided-missile pallet can be mounted on either the 390 or the 390C trailer without modification. ‘The ILSCB is stowed on the prime mover. METHODS OF TRANSPORTATION MS 156058 ce asnembly 'm (15 00) tiedown wtrap Suspension sling assembly wage bax, Figure 6-1. Helicopter lifting components.Tm 9—1440—531—12—1 Table 6-1. Description of Helicopter Lifting Components Tew Tienticaon namber Description ‘Suspension ling assembly (2) | 1670-00-902-3080 Nylon and chain leg cargo sling. 7 m (23 (0) long, 15,000 the capacity Nylon cord MIL-C.5040, Type Tor IT | Nylon cord 3.18 mm 1/8-inch diameter + Protective pudding 8135-00-559-1831 Cellulose wadding, cushioning material ‘Webstrap (2) 1670-00-360-0540 Nylon webbing. 4.57 em (15 £0 long. 1 ply Load binder (2) Eccentric takeup, wilever Strap fastener (2) 1670-00-360-0340 Quick-fit buckle ‘Adhesive tupe 8135-00-266-5016 Pressure sensitive, 5.08 em (2 in) wide 54.9 m (60 yds) long Storage bag $8480-00-245-6603 Cotton duck, OD w/tipper Grounding device ursembly | Fubricuted locally Refer to paragraph 6-6b for fabrication instructions Spreader bur assembly Fabricated locally Refer to paragraph 6-5e for fabrication instructions Nain 10d oF 164 104: 7.62 cm (3 in), 14: &.89.em (9% ind MS 156059 120.5 em (1 10 web ring 2-457 m (15 (0) nylon web ring 3—Grab link 4-24 m (8 MD) chain leg Figure 6-8. Helicopter euspension sling — t, pial a2 web ring. Each leg is 7 m (23 ft) long and consists of a 4.57 m (15 ft) nylon web leg with a 2.4 m (8 ft) chain assembly bolted to the end of the nylon web leg. The sling lege can be adjusted in length to compensate for the center of gravity or constru tion of the item to be lifted. Figure 6-3 show: typical chain leg hookup of the suspension sling as- sembly. Instructions for sling preparation for each major item are given in the Preparation for Travel sections of this chapter. 4. Grounding Device Assembly. The ground- ing device assembly (1, fig. 6-1) must be fabri- cated locally. Detailed procedures for fabricating this device are as follows. NOTE ‘The letters, und key numbers shown below in parentheses, refer to figure 6-5. (1) Obtain a 60.9 cm (2 fe) section of 1-inch copper tubing (1) or other suitable material and fabricate as shown in A. (2) Obtain a 2.54 em (1-inch) strip of copper material (4) or other suitable material 25.4 em (10 in) long and fabricate as shown in B. (8) Attach the copper strip (4) to the copper tubing (1) with two self-threading screws. (4) Obtain a piece of copper braid (2) or other suitable material, which has a minimum length of 7.92 m-(26 ft) and fabricate as shown in C. (6) Attach one end of the copper braid (2) to the copper tubing (1) with a %-inch bolt, lock- washer, and nut.MS 156060 1—Grab link 2—Tie point 3—Taped excess chain Figure 6-3. Suspension sling assembly-typical chain log hookxp, TH 91440531121 (6) Obtain a 30.5 em (1 ft) copper rod (3) or other suitable material, and fabricate as shown in D. (D Attach the remaining end of the copper braid (2) to the copper rod (8) with a 4-ineh bolt, lockwasher, and nut. (8) Insulate one-half of the copper tubing (1) with an insulating tape as shown in A. ¢. Spreader Bar Assembly. The spreader bar assembly (fig. 6-4) is fabricated locally. Detailed procedures for fabricating this assembly are as follows: NOTE ‘The letters shown below in parentheses, refer to figure 6-4, (1) Obtain the required number of lengths of 2x 4-inch lumber or other suitable material. (2) Obtain the required nails for construction of the spreader bar assembly (table 6-1). (8) Cut the ends of two pieces of lumber as shown in (A). (4) Nail the pieces of lumber together us shown in (B). 4. Cargo Aircraft. When the ILCHR, guided- missile pallet and ILSCB are transported by cargo aircraft, the preparation for travel procedure is the same procedure that is used with the prime mover. o3‘Tm 9—1440—S31—12—1 MS 164645 Figure 6-6. Spreader bar assembly. 64‘TH 91440531121 SSS Ep sa A rte ier —_0, HOLE, 1.27em (17Mie.) OUAMETER ko Ber eco SS Eg ——s MS 164644 Figure 6-5. Grounding device assembly. Section III. PREPARATION FOR TRAVEL FOR THE IMPROVED GUIDED-MISSILE LAUNCHER M192E1 6-6. General NOTE This section describes the preparation for travel procedures for the ILCHR by the prime mover (par. 6-8) und by helicopter (par. 6-9). 6-7. Tools The only tool required to prepare the ILCHR. for travel is a%-inch open-end wrench. It is in the General mechanics’ tool kit. 6-8. Preparation for Travel Procedures — Prime Mo a. The detailed procedures for preparing the ILCHR for travel by the prime mover ure as follows. (D Deenergize the ILCHR (Table 3-18). Ifthe battery is operating in cold-weuther condi- tions, prior to removing the missiles from the ILCHR, set the buse distribution box switch S1 to NORMAL (2. fig. 2-2) und remove the heater covers, us stated in (2) below. (2) Remove the cold-weather kit heater covers from the missiles as follows: NOTE For the following removal procedures, two men and 4 0.91 m (if stand or stepladder are NOTE Unless otherwine specified, the key numbers shown in parentheses below refer to figure 6-6, osT™™ 9—1440—$31—12—1 ¢ NOTE 23 REFER TO APPENDIX FOR SERIAL NUMBER EFFECTIVITY 20 cry 1423508 Z | Aa a GGA 11—Top heater cover (no mo! tunnel cut-out) Ewa phatiey 14—Taileone insulating cover 8 156—Bottom side insulating cover ” igure 6-6. Removal of cold-weather kit heater covers. osce (a) Disconnect the cable assemblies (6) from the receptacles on the distribution box. (b) Pull both ball-lock pins (18) of the bot- tom center insulating covers (17 and 19) from the holes in the sides of the fairing and center blast deflector. (c) Release and remove the strap restrain- ing the side heater covers on each missile (fig. 6-8, (d) Release each side cover lower strap (8) from the buckle (20) of the bottom side cover Release the tabs of the tailcone cover from the pile on the bottom and side covers. Pull the bottom side cover loose from the wing surface and the launcher. (e) Release the lower strap (8) of each side heater cover (5) from the pile of the bottom side insulating covers (15 and 21) and pull the bottom covers loose from the missile (P Release the fastening tape (23) from the pile on the bottom of each outboard cover and release each bottom side cover (15 and 21) from the center cover. (g) Separate the bottom center cover (17 or 19) from the supporting step (16) of each out- board cover and move the center cover forward until it releases from the launcher fairing. (h) Release the lower strap (8) of each side cover from the buckle (20) of each outboard cover. Remove both bottom side covers (15 and 21) from between the lower wings of the missile. (@) Remove the bottom center cover (17 or 19) from between the two lower wings of the missile. () Release the top strap (7) of each side cover from the buckles (12) of the top cover. (k) Release the tubs (13) from the pile on the rear edges of the top and side covers, (D Pull the tailcone insulating cover (14) from against the rear edges of the top and side covers, Remove the cover from the taileone of the missile (m) Dis nect_ the breakaway connection 3). Release the forward section of each cover by removing the two strap assemblies (2 and 27) from around each of the two strap roves. (n) Remove the bottom front insulating cover (25) from the missile. (o) Release the top heater cover from the side heater cover by releasing the side heater strap (4) from the pile (10) of the top heater cover. Remove one side heater cover (5). (p) Remove the remaining side cover as de- scribed in step n above. (q) Remove the top heater cover (11). Tm 91440531121 Prior to removing the missiles from the LCHR, set the SAFE/ARM handle (1, fig. 3-5) on each missile to the SAFE position and install shorting plugs on the missile umbilical connector (3, fig. 3-5). Utilize all safety precautions in ‘removing the mis- siles from the LCHR. Prior to lifting missiles with the loader, the following precautions are mandato- ry. Launcher Interference. During transfer operations, the missiles are sus- pended from the loader yoke and are free to swing about the yoke pivot. Missiles normally hang nose-down from level. For transfer operations from the launcher, it is highly desirable to have the missiles hang at a 5-degree nose- down attitude. Because of the center gravity location of the missile and the relationship to the yoke pivot, the missiles hang 2 degrees nose down. If the missiles are allowed to maintain this shallow hang angle throughout the transfer operation, interferences of the missile bout tail and umbilical plug with the launcher rear hook occur. To avoid this condition, the following procedu necessary. When removing missiles from the launcher exert, and hold a light down force on the missile radome until the missile boat tail is safely clear of the launcher rear hook. b, Reduced Pressure. The hydra system in the reduced pressure mode is 615 psi. This mode protects the missile and equipment against structural overloads produced by the extension cylinder. ‘Because higher reduced pressure can result in leas protection against overloads, great care must be exercised while operating the hydraulic system in the reduced pressure mode. (D) When removing missiles from the launcher, avoid retraction of the ex- tension cylinder when missiles are latchedT™ 9—1440—531—12—-1 to both loader and launcher. It is of ut- most importance to avoid this occur- rence as it may result in equipment damage. (2) When placing missiles onto the launcher, during final seating of the missile against the rear hooks, it is important to avoid over-extending the extension cylinder, thereby overloading the structure. c. Hoisting beam. When the XM15 hoisting beam, 1450-00. 34 is used issile, the component connect ing link, 2590-00-690-2856, P/N 9089791, must be installed in hole 6 t accommodate the center of gravity in the missile. (3) Remove the missiles from the ILCHR (para. 2-15) (4) Open and remove the front compartment cover 5) Remove the outrigger pad retaining bars and plate from the front compartment. NOTE Unless otherwise indicated, the key numbers shown in parentheses in steps 5) through (15) refer to figure 69. Prior to handling a system power cable, the generator main circuit breaker must be turned OFF. Never attempt to handle cables which may be carrying 416- or 208-vae power with- out first assuring that the power to the cable is removed. (6) Disconnect all the control, power, and data cables (5 and 6), and cap the connectors and receptacles. (7) Disconnect the ground rod cable (4) from the ground rod cable attach point (A2) and from the ground rod (3). (8) Remove the ground rod from the ground as described in (a) through (g) below and stow it in the front compartment of the ILCHR. NOTE Unless otherwise indicated, the key numbers shown in parentheses below refer to figure 6-7. cio (a) Position the tripod (D) so that the pulley (6) is directly over the ground rod. () Drive the prime mover toward the tripod and hook the retrieving cable (2) to a tow- ing point on the front of the vehicle. (c) Place the ground rod grip (3) on the ground rod (4) and secure the lateh. (d) Attach the cable yoke to the eye of the grip. (e) Insure that the other tripod pad is directly under the retrieving cable (P Back off the prime mover, stopping when the cable yoke has run to the cable restrain- ing pin (5). (g) If the ground rod has not pulled free, and cannot be removed by hand, unlateh the grip. drive the truck forward, attach the grip of the ground rod, and back off the vehicle once more. (9) Close the air vent covers (Al. fig. (one each side of the launcher). 9) NOTE Unless otherwise indicated, sshuwn in parentheses below he key numbers fer to figure 69. 3° MI-70504 1—Tripod 2 Retrieving cable Ground red rip 4—Ground rod Cable restraining pin 6—Pulley Figure 6-7. Removal of ground rod.(10) Engage the azimuth stow lock (C2) as de- scribed below. (a) Open the control panel door, and open the MANUAL AZIMUTH MOVEMENT VALVE (B2) on the boom support hydraulic con- trol panel (B3) by turning the valve handle coun- terclockwise. Manually move the boom support 80 that the azimuth vernier indicator points to 3200 on the azimuth mil ring (C3). (®) Unscrew the finger grip knobs (C1) on the azimuth stow lock (C2). Lift and turn the azimuth stow lock 180 degrees. Enguge the lug in the slot on the boom support and secure the finger grip knobs. (c) Close the MANUAL AZIMUTH MOVEMENT VALVE by turning the valve han- dle clockwise, and close panel door. (11) Remove the headset and extension cable from the launcher control (LC) (7) and (D1) and stow them in the ILCHR front compartment (8). (12) Disconnect the communication cable (D3) and stow it in the LC cover. (13) Remove the communication station and NOTE: I l | | ' | ' | Sr Cy (aay See NOTE I | ! I I 1 | I TM 9—1440—531—12-1 bracket assembly (D2) and stow it in the ILCHR, front compartment. (14) Remove the LC (7) from the front of the ILCHR. | WARNING } Check to insure that the front support Jack (E3) is locked in the down position and that the jack pad (E4) is just clear of the ground. (15) Emplace the ILCHR on its wheels and the front support jack as outlined in (a) through (e) below. (a) At the base hydraulic panel, close the bleed valve (F5) and the hatch-raising valve (F6), and leave the left-front, right-front, and rear eylinder leveling valves (F7, F8, and F9) in the ‘open position. () Remove the handpump handle (F3) from the forward compartment and insert it into the handpump (F4). Move the handpump handle REFER TO APPENDIX D FOR SERIAL NUMBER EFFECTIVITY MI 142351B Figure 6-8 Heater covers on the missile.TM 9—1440—531—12-1 = Leveling evlinder — Outrigger pad — Power and data cables Launcher 7—Launeher X— Front comps A 1 Air vent covers 2—Ground rad cable attach paint B 1—Control panel door MANUAL AZIMUTH MOVEMENT VALVE }— Boum support hydraulic control panel a 1—Finger grip knob(2) 2—Azimuth stow lock 3 Azimuth mil ring. D 1—Launcher control 2—Communications station and bracket assembly: 3—Communication eable Figure 6-9. ILCHR—preparation for travel and emplacement. Quick-diseonnect pin Front support jack a 1—Protective cap 2—Bulls-eye level 3—Hundpump handle 4—Handpump 5—Bleed valve 6—Hatch-raining valve 7—Left-front cylinder leveling valve 8—Right-front cylinder leveling valve 9—Rear eylinder leveling valve G 1—Outrigger pad socket slide 2—Socket spring 3—Outrigger pad 4 1—Axle support arm 2—Lobe 3—Suspension lockout handle (2)o back and forth until all three locking sleeves (Fl, fig. 6-10) loosen from their piston collar (F2, fig. 6-10). Unscrew the locking sleeves as fur us possi- ble. (c) Slowly open the bleed valve to retract, the leveling cylinders until the weight of the ILCHR rests on the wheels and the front support Jack. (@) Disengage each suspension lockout system by rotating the suspension lockout handle (H3) to the downward position. NOTE Unless otherwise specified, the key numbers ‘ahown in parentheses in nteps (16) through (19) below refer to figure 6-10, (16) Disengage the left-front outrigger as de- seribed below. (a) Lift the outrigger (G4) so that the out- rigger socket (F3) is forced uguinst the piston col- lar (F2), forcing the retraction of the leveling eylinder (1, fig. 6-9). Close the left-front cylinder leveling valve (F7, fig. 6-9). (@) While supporting the left leveling cylinder, lower the outrigger. Lower the leveling cylinder and allow it to rest against the ILCHR base. (©) Disconnect the quick-disconnect pin i AID that secures the outrigger sway brace (A2) tu the sway brace locking bracket (A3). (@) Stow the sway brace in the storage compartment. (17) Attach the left-front towing brace as de- scribed in (a) through (c) below. (a) Remove the towing brace (B5) from the front compartment. Screw the T-handle ball ‘ac *ket end into the socket on the left-front outrig- ger. () Raise and swing the outrigger into the towing position. (©) Attach and secure the-clevis end of the towing brace to the towing brace bracket on the upper left-front corner of the ILCHR base with the quick-disconnect pin, (18) Disengage the right-front outrigger as described below. (a) Lift the outrigger (B12) so that the outrigger socket is forced against the piston collar forcing retraction of the leveling cylinder. Close the right-cylinder leveling valve (F8, fig. 6-9). (®) While supporting the leveling cylinder. lower the outrigger. Lower the leveling cylinder and allow it jnct che 'TLCHR base. T 9—1440—$31—12—1 (c) Disconnect the quick-disconnect pin that secures the outrigger sway brace to the lock- ing bracket. (d) Stow the sway brace in the storage compurtment. (19) Attach the right-front towing brace as described below. (a) Remove the towing brace (B2) from the front compartment. Screw the T-handle bull socket end into the socket on the right-front out- rigger. (b) Raise and swing the outrigger into the towing position. (@) Attach and secure the clevis end of the towing brace to the towing brace bracket on the upper right-front corner of the ILCHR base with the quick-disconnect pin. (20) Remove the lunette from the front. com- partment. Position it eo that the luge on each side of the lunette fit into the slots on the inside of the front outriggers and that the lunette cross bars engage the ball projections on the top and bottom of the outriggers. Press the detent (B10) und tighten the finger grip knob (B11). (21) Raise the rear outrigger into the travel position us described below. (a) Lift the outrigger (C3) so that the out- rigger socket is forced against the piston collar, forcing retraction of the leveling cylinder (2). (&) While supporting the leveling cylinder, lower the outrigger to the outrigger pad. Lower the leveling cylinder until it rests against the ILCHR base. (c) Raise the outrigger and lay it against the ILCHR base. Raise the leveling cylinder. aline the fitting on the leveling cylinder with the clevis fitting (C1) on the under side of the outrigger and secure with the quick-disconnect pin (C4). NOTE It may be necessary to adjust the leveli cylinder locking sleeve to uline the leveling ceylinder to the clevis fitting. NOTE In batteries equipped with the stake puller kit. omit step (22) und perform step (23). (22) Remove the spades (G2) from the out- rigger pad (G3) as described below.TH 9—1440—531—12—1 1—Launcher control 2—Rear leveling cylinder |—Rear outrigger |— Outrigger und socket 5—Luuncher control cover A 1—Quick-disconneet pin 2—Left-front outrigger sway brace 3—Sway bruce locking bracket 4—Quick-disconnect pin B 1—Intervehicle electrical cable connector 2—Right-front towing brace 3—T-handle ball socket end 4—Brake huse fitting (2) 5—Left-front towing brace 6—Quick-disconnect pin 7—Towing brace bracket B—Left-front outrigger 9—Lunette 10—Detent 11—Finger grip knob 12—Right-front outrigger c 1—Clevis fitting, 2—Rear leveling cylinder 3—Rear outrigger 4—Quick-disconneet pin D Protective cover (2) 2—Index boom 3—Chain 4—Outrigger pad 5—Safety hook 6—Spades E 1—Protective cover (2) 2—Hook (2) Chain (2) ‘Safety hook F 1 —Locking sleeve (leveling cylinder) 2—Piaton collar 3—Outrigger socket G —Storage rack 2—Spudes Outrigger pad 4—Left-front outrigger Figure 6-10, ILCHR outriggers—preparation for travel and emplacement,To prevent damage to the index boom, insure that the protective covers are placed around the index boom. (a) Place the two chains (E3) with the pro- tective covers (El) of the cable stay over the index boom (D2), and engage the two hooks on their respective chains (D3) as close to the index boom as possible. (b) Insert the safety hook (D5) into the hole of the spade (D6). (c) Raise the boom assembly on the toader- transporter and pull the spade from the outrigger pad (D4) and the ground. (a) Repeat steps (b) and (c) above for the remaining spades, securing all three outrigger (23) To remove the ILCHR spades using the stake puller kit (fig. 6-11) perform the following steps. (a) Position the tripod (2, fig. 6-12) so that the pulley (1, fig. 6-12) is directly over the spade to be removed. (b) Place the cable yoke (3, fig. 6-12) on the spade and insert the pin through the yoke and ILCHR spade hole. NOTE All eight spades can be removed without chang ing the approuch angle of the prime mover. The spudes nearest the vehicle should be removed first to insure that the tripod will straddle and clear the pad when removing the spades on the far edge of the pad. Ifthe spades on the sides of the pad ure removed, either forward leg of the tripod can bear on the pad when positioning the pulley over the spade to be removed (fig. 6-13) (c) Drive the prime mover toward the. tripod and hook the retrieving cable (4, fig. 6-12) to a towing point on the front of the vehicle. NOTE ‘The cuble must be hooked to the prime mover ut a height less than 106.7 em (42 in) from the ground. If the cuble is pulled upward from a higher point, the tripod assembly could rotate backward #0 that a tension load could not be applied to the cable. (a) Insure that the rear tripod pad is directly under the cable. TM 9—1440—831—12-1 1—Ground rod grip 2—Straight jawed grip Retrieving cable 4—Pulley 5—Tripod (disassembled) Figure 6-11. Stake puller kit Insure that personnel are standing for- ward and clear of the tripod before per- forming the following step. (e) Back off the prime mover, stopping when the spade has been pulled free. @) Drive the prime mover forward approximately 1 m (3 ft) to slacken the cable for the next operation. ) Position the tripod so that the pulley is directly above another spade and attach the cable yoke to the spade. (h) Repeat steps (d) through (9) above until all eight spades have been removed. (24) Stow the spades (4, fig. 6-14) in the storage racks. (25) Remove the intervehicular electrical cable from the front compartment and connect it to the receptacle (BI). (26) Remove the handpump handle. (27) Close the air tank bleed valve. (28) Insure the LC pressure equalizer valve is closed during travel.™™ 9—1440—531—12 Mal 70581 1—Pulley Tripod B—Cable yoke 4—Retrieving cable Figure 6-12, Removal of the ILCHR front and rear spades. (29) Stow the following items in the front com- partment: (a) Ground rod (®) Ground rod cable (©) Tripod (@) Launcher control (e) Launcher control cable (P Handpump handle (30) Visually inspect the front compartment to insure that all the necessary equipment is present and properly stowed. (81) Close the ILCHR chassis drain valves. (82) Install and secure the front compartment cover. (83) Stow the outrigger pads (3, fig. 6-14) above the stowed spades. (34) Secure the two front leveling cylinders (1, fig. 6-14) in their stow brackets on top of the ILCHR base by inserting the quick-disconnect pins (2, fig. 6-14) through the brackets and the eyes on the leveling cylinder locking sleeves. ony NOTE Te may be necessary to adjust the leveling cylinder locking sleeves to aline the eye and bracket. (35) Open the pintle hook on the prime mover by removing the pintle hook locking pin (1, fig. 6-15), and lift the spring-loaded T-bar latch (2, fig. 6-15) (36) Position the prime mover to the ILCHR lunette so that the pintle hook (3, fig. 6-15) is directly below the lunette (4, fig. 6-15). (37) Engage the lunette onto the open pintle hook by retracting the front support jack (E3, fig. 6-9). ) Close the pintle hook and insert the lock- ing pin. (39) Connect the safety chains as described below. (a) Hook the safety chains (8, fig. 6-14) to the appropriate loops at the rear of the prime mover. (b) Insert the outrigger safety chain (9, fig. 6-14) through the left-and-right+forward out- riggers (7, fig. 6-14) and hook it to the loop pro- vided on the lunette. (40) Retract the front support jack (E3, fig. 6-9) with the crank (El, fig. 6-9). MI 70552 Figure 6-18. Removal of the ILCHR spades (side view).aTH 91440531121 (41) Remove the quick-disconnect pins (E2 and E5, fig. 6-9) and swing the jack to a horizontal position with the jack pad (E4, fig. 6-9) on top. (42) Replace the quick-disconnect pins removed in (40) above. (43) Extend the jack with the crank until the hooks on the jack pad rest on the cross bars on the lunette. (44) Connect the intervehicular electrical cable to the receptacle at the rear of the prime mover. (45) Connect the two airbrake hoses (6, fig. 6-14) to the air hose connections at the rear of the prime mover, and open the service coupling shutoff cocks. (46) Release the ILCHR brakes by moving the handbrake levers (5, fig. 6-14) on euch side of the ILCHR base to a vertical position. b. Make the following checks befure leaving the area: (1) All cable receptacle connectors are cap- ped. (2) The ground rod cable and ground rod are disconnected. Figure 6-15. Connecting trailer to prime mover. 6-16 (3)- The air vent covers are closed. (4) The azimuth stow lock is engaged. (5) The LC is removed and stowed. (6) The suspension lockout mechanism is dis- engaged. (1D The towing braces are properly secured to the front outriggers and to the ILCHR base. (8) The lunette is properly secured to the front outriggers. (9) The rear outrigger is properly secured. (10) The alinement telescope and the fire cutout assembly and support are properly stowed. (11) The spades and the outrigger pads are properly stowed. (12) ‘The intervehicular electrical cable is pro- perly secured and the lights are working. (13) The front support jack is properly stowed. (14) The front and rear compartment covers are properly secured. (15) The front leveling cylinders «re properly stowed. (16) The ILCHR is properly connected to the prime mover. (17) The handbrakes are released. (18) The trailer brakes are working (move prime mover a short distance and then stop). Travel Procedures — a. The helicopter lifting kit (fig. 6-1) is provided for each major item in the improved HAWK system. The kit contains the items necessary to form the suspension sling assembly for each major item. The suspension sling assembly required to lift the ILCHR consists of four nylon web and chain legs connected to a one-foot diameter nylon web ring. Each leg is 7 m (23 ft) long and is made up of a 4.57 m (15 ft) nylon web leg with an eight- foot chain assembly bolted to the nylon leg. For detailed procedures, refer to ¢ below. b. Prepare the ILCHR for helicopter lift us de- scribed below. (1) Perform the procedures outlined in paragraph 6-84 (1) through (9). (2) Engage the azimuth stow lock as de- scribed in (a) through (c) below. (a) Open the control panel door (Bl, fig. 6-9), and open the MANUAL AZIMUTH MOVE- MENT VALVE (B2, fig. 6-9) on the boom supporthydraulic control panel. Manually move the boom support so that the azimuth vemnier indicator points to 0 mils on the azimuth mil ring. (b) Unscrew the finger grip knobs (C1, fig. 6-9) on the azimuth stow lock 180 degrees. Engage the lug in the slot on the boom support, and secure the finger grip knobs. (c) Insure that LC pressure equalizer valve is open for all air transportation. (@) Close the MANUAL AZIMUTH MOVEMENT VALVE and close the control panel door. (3) Perform the procedures outlined in paragraph 6-82 (11) through (24), and (26) through (33). (4) Engage the ILCHR brakes by moving the handbrake levers (5, fig. 6-14) on euch side of the ILCHR base to a horizontal position. (5) Position the TLCHR lunette (B9, fig. 6-10) downwind. (6) Retract the front support until the front of the ILCHR is lower than the rear. (1) Perform the checks outlined in paragraph 6-86 (1) through (1D, (14), (17), (18), and (20). ¢. Prepare the ILCHR suspension sling as sembly as described below. Inspect web legs before use, for defects (burns, cut edges or broken threads) to prevent personnel injury or equipment damage. (1) Lay the lifting kit on top of the ILCHR boom with each of the legs hanging down between the center and outer booms, and adjacent to the lift points (3 through 5, fig. 6-17). NOTE Due to the uneven distribution of weight in the ILCHR an unequal number of chain links wre used to attach the chain ley to the front and rear lifting points. In the following steps the correct chain link in determined by counting from the end ink of the chain lex. (2) Attach each of the two sling legs to the front lifting eyes by passing one chain leg through each eye und fastening link 25 to its grab link. TM 9—1440—531—12—1 (3) Attach each of two sling legs to the rear lifting eyes by passing one chain leg through each eye und fustening link nineteen to its grab link. (4) Remove one chain leg from a second sling set by removing the grab link bolt and spacet. This extra chain leg will be connected between the two front lift chains us shown in figure 6-16 to prevent the two rear sling legs from interfering with the two outer booms during helicopter lift. (5) Connect the grab link device of the extra chain leg to the grab link device of a sling leg con- nected to a front lift point (fig. 6-16). Tighten bolt with 1-1/16-inch wrenches. (6) Insert the free end of the extra chain leg through the wide part of the grab link of the adja- cent front chain leg and fasten a link of the extra chain leg into its grab link. Pull the two front sling legs taut to insure that the extra restraining chain (fig. 6-16) is not twisted and that it will restrain the two chain legs during helicopter lift. (1) Fasten loose chain encls with tape to pre- vent fouling (fig. 6-3). (8) To prevent fouling of the slings before hookup, coil all four sling legs together at the top of the center boom, fold and wrap with tape so that it will break away during lift. Insure that the sling legs ure positioned so that they will not hang up during helicopter lift. The extra chain leg rests over the indexing points as shown in fig. 6-17. (9) Drive the ground rod of the grounding device ussembly into the ground next to the ILCHR. (10) Place the grounding device (1, fig. 6-17) with the taped suspension slings on top of the center boom. . Prior to helicopter lift of the ILCHR, per- form the following checks. (1) The ILCHR is prepared for travel. (2) The turntable is rotated so that the azi- muth vernier indicator points to 0 mils on the azimuth mil ring indicator, and the azimuth stow lock is engaged. (3) The front of the ILCHR base is lower than the rear. (4) The lunette is facing downwind. (5) ‘The suspension sling assembly is taped for helicopter pickup. (6) The brakes are engaged, ¢. The using organization may be required to perform the following helicopter hookup pro- cedures. 617T™ 9—1440—531—12—1 MS 156072 Figure 6-18, ILCHR — suspension aling assembly restraining chain. Failure to perform step (1) may result in injury to personnel. (1) The hookup crew must wear protective devices consisting of helmet liners, shell, and gog- gles for protection against flying sand, dirt, dust, and debris. ‘The hovering helicopter develops high static voltages in excess of 20,000 volts on the helicopter lifting hook (2, fig. 6-18). Failure to perform steps (2) through (8) below in the exact sequence given may result in injury to personnel. (2) The hookup crew takes a position on the major item so that the opening of the helicopter lifting hook is to their left. This permits the hook to be grounded from its right side and the nylon assembly to be placed on the hook from the left side. Failure to perform step (3) may result in injury to personnel. (3) Ground the helicopter lifting hook using the grounding device assembly (1, fig. 6-1). Main- tain the contact between the grounding device and the lifting hook throughout the hookup procedure. If the ground is disconnected before the hookup is, completed, the hook must be grounded again before attempting to hook up the sling assembly.a TH 9—1440—531—12—1 (4) Grasp the hook by hand and slip the nylon web ring of the suspension sling onto the hook. (5) Make certain that the helicopter lifting hook latch (3, fig. 6-18) has locked the ring into Fuilure to perform step (7) may result place. in injury to personnel. = (6) Muke certain that all hands are clear of the helicopter lifting hook and then remove the (7) The hookup crew must leave the major grounding device from the hook. item to the right of the line-of-flight of the heli- copter (fig. 6-19) after completion of the hookup. MS 156073 1—Grounding device 4—Left-front lift point 2—Suspension sling assembly 5—Right-front lit point 3—Left-rear lift point Figure 6-17. ILCHR — euspension sling assembly secured for helicopter pickwp. onTH 9—1440—531—12—1 MS 156064 1—One-foot nylon web ring Helicopter lifting hook 3—Helicopter lifting hook latch Figure 6-18. Hookup of euspension sling assembly to helicopter lifting hook. ‘The hookup crew must stay clear of the major item until it is airborne (fig. 6-19), (8) Retrieve the grounding device assembly and return it to the storage bag.TM 9—1440—$31—12—1 wookun crew Part “> im 200d TO Bn 908 DURING HOOK-UP DURING APPROACH, RELEASE AND TAKEOFF mamoency mamowecy & revconen moves ter [ALL GROUND PERSONNEL MOVE RIGHT => MI 705078 Figure 6-19. Position diagram.Tm 91440531121 Section IV. PREPARATION FOR TRAVEL FOR THE IMPROVED LAUNCHING. SECTION CONTROL BOX AN/GSA-132A 6-10. General This section describes the preparation for travel procedures for the ILSCB by prime mover (par. 6-11) and by helicopter (par. 6-12). 6-11. Preparation for Travel Procedures Prime Mover a. The detailed procedures for preparing the ILSCB (fig. 6-20) for travel are us follows. (1) Set the LAUNCHERS OPERATE/ SAFE switches (5, fig. 6-20) to SAFE. 2) Disconnect all cables , and install all pro- tective caps on their respective connectors and receptacles. (3) Disconnect the headset from the com- munication station (3, fig. 6-20) and stow it in the storage compartment (2, fig. 6-20) (4) Close and secure the cover (1, fig. 6-20) on the ILSCB. (5) Disconnect the ground rod cable from the ground rod cable attach point on the ILSCB and the ground rod. NOTE Refer to paragraph 6-8a(Q(a)-(y) for the removal of the ground rod using the stake puller kit. (6) Remove the ground rod. (2) Stow the ground rod and ground rod cable on the IHIPIR. (8) Place the ILSCB on the IHIPIR prime mover. (9) Center the ILSCB laterally on the prime mover as shown in figure 6-21. (10) Tie down the ILSCB with two web strap ‘assemblies (1 and 3, fig. 6-21). (11) Insure that the ILSCB pressure equalizer valve is closed for all surface transportation. 4, Before leaving the area, make the following checks: _ (D The protective cups are installed on all connectors and receptacles. (2) The ground rod and ground rod cable are disconnected and properly stowed on the IHIPIR. (8) The ILSCB is properly tied down. 6-22 bar 70867 1-ILSCB cover 2—Storaye compartment 3—Communication station 4—MSL COUNT DELAY awitch 5—LAUNCHERS OPERATEISAFE switch (2) Figure 6-20. ILSCB. 6-12. Preparation for Travel Procedures Heli- copter a. Prepare the ILSCB for helicopter transpor- tation as described in paragraph 6-114 (1) through mM. », Insure the ILSCB pressure equalizer valve is open for all air transportation. ¢ Place the ILSCB in the helicopter and Fequest the helicopter crew to tie it down in the prescribed manner.C16 TM 9—1440—$31—12. 1-Web strap assembly 2-Stake pocket 3-Web strap assembly LSCB-tied down on the prime mover. PREPARATION FOR TRAVEL FOR GUIDED-MISSILE LOADING AND STORAGE PALLET M1E2 1 2 3 Ne MI 70568 Figure 6-21. Section V. 6-13. General This section describes the preparation for travel procedures for the guided-missile loading and storage pallet (missile pallet) and its supporting trailer by the prime mover (par. 6-15) and by heli- copter (par. 6-16). The missile pallet can be mounted on either the M390 or the M390C trailer (fig. 6-30 and 6-21) without modification. The difference between the M390 and M390C trailers is that the M390 trailer has four leveling jacks and the M390C trailer has three. The M390C leveling jacks are physically and functionally the same as those of the M390. For the preparation for travel procedures of the M390 trailer, or the M390C trailer, refer to paragraph 6-15e. 6-14, Tools The only tools required to prepare the missile pallet for travel are two%4-inch open-end wrenches and one 14-inch open-end wrench. 6-15. Preparation for Travel Move ocedures Prime When the missiles are to be transported the SAFE/ARM handle (1, fig. 3-5) must be set to the SAFE position for each missile. a. For loading the missile pallet on the trailer, refer to TM 9-1450-500-10. Secure the missile pallet to the trailer with the attaching hardware (6, fig. 6-30). b. Remove and retain the plug from the missile anchoring stud (fig. 6-22).TH 9—1440—531—12— ¢. For loading the missiles on the pallet, refer to Prior to lifting the missiles with the loader, the following precautions are mandatory. a. Interference. During transfer opera- tions, the missiles are suspended from the loader yoke and are free to swing about the yoke pivot. Missiles normally hang nose-down from level. For transfer operations it is highly desirable to have the missiles hang at a 5-degree nose-down attitude. Because of the center of gravity location of the missile and the relation- ship to the yoke pivot, the missiles hang 2 degrees nose down. b, Reduced Pressure. The hydraulic system in the reduced pressure mode is 615 psi. This mode protects the missile and equipment against structural over- loads produced by the extension cylin- der. Because higher reduced pressure can result in less protection against overloads great care must be exercised while opera- ting the hydraulic system in the reduced pressure mode. (1) When removing missiles from the pallet, avoid inadvertent retraction of the extension cylinder when missiles are latched to both loader and pallet. It is of utmost importance to avoid this occur- rence when it results in an unsymmetrical loading (for example, retracting with one outboard missile latched to both pallet and loader). (2) When placing missiles onto the pallet during final seating of the missiles against the pallet rear hooks it is impor- tant to avoid over-extending the exten- sion cylinder, thereby overloading the structure. . © Hoisting Beam. When the XMI5 hoisting beam (1450-00-665-3234) is used to lift a missile, the component connecting Tink (2590-00-690-2856, P/N 9089791) must be installed in hole 6 to accommodate the center of gravity in the missile. ‘TM 9-1450-500-10. 6-24 If the missiles are to remain on the cis pallet during transport, each missile must be properly secured to the pallet to prevent injury to personnel or damage to the equipment. Make certain that the SAFE/ARM handle (1, fig. 3-5) is set to the SAFE position. d. Secure the missile to the pallet as described below. When installing the missile anchoring stud in step (3) below do not tighten the stud using a wrench on the recessed area of the stud, The recessed area is pro- vided only to hold the stud when replac- ing the self-locking nut. (1) Place the missile latch in the up position secure with the quick-disconneet pin (2, fig. ). Failure to perform step (2) below. may result in damage to the threaded wing nut or dropping of the missile due to insufficient engagement of the missile anchoring stud in step (3). (2) Fully retract both the self-locking nut (5. fig. 6-24) and the plain round nut (4, fig. 6-24) by turning them counterclockwise. (3) Secure the missile anchoring stud (6, fig. 6-24) to the threaded wingnut (1. fig. 6-24) by turning the missile anchoring stud clockwise. 1 Plug 2—Missile anchoring stud Figure 6-22, Missile anchoring stud — stowed.1—Minaile latch 2—Quick-disconnect pin Figure 6-23. Missile latch. Failure to perform the following step may result in stripping of the threaded wingnut. (4) Firmly hundtighten the plain round nut until the self-adjusting washer (3, fig. 6-24) is tight against the missile anchoring plate (2, fig. 6-24). (5) Firmly tighten the self-locking nut (5, fig. 6-24) until it is secured tightly against the plain round nut. (6) Rotate the nut handle retainer (2, fig. 6-25) over the plain round nut pin. (2) Using a wrench, tighten the self-locking nut to insure that the nut handle retainer clasps the plain round put pin up to the next serration to keep the missile anchoring stud secured tightly. (8) Place the nut handle retainer into the detent on the missile anchoring plate und secure it with the wingnut (1, fig. 6-25). (9) Repeat steps (2) through (8) above for securing the five missile anchoring studs. 4 The missile pallet can be transported by prime mover on either the M390 or the M390C trailer. The detailed procedures for preparing the M390 trailer, which supports the pallet for travel, are as follows. Disregurd step (3) for the M390C, since this trailer does not have front corner level- ing jacks. TH 91440531121 Insure that the front support jack (E3, fig. 6-26) is locked in the down position and that the wheels are resting firmly on the ground. NOTE Unless otherwise indicated, the key numbers shown in steps (1) through (6) below refer to figure 6-28. (1) Remove the leveling jack cranks from their stow brackets (center reur of trailer) and position them on the crankshufts (F1) of the two rear leveling jucks (F5). 4 anchoring plate adjusting washer round nut ‘king nut 6—Mimnile anchoring stud Figure 6-24. Missile anchoring stud — plain round nut retracted. 6-25TM 9—1440—531—12-1 (2) Retract the rear leveling jacks with the cranks until they are clear of the ground. (3) Stow each of the front corner leveling jacks (1) as described below. (a) Remove the leveling jack erank (A6) from its stow bracket on A frame (A5), and posi- tion it on the jack crankshaft (2). (b) Retract the jack with the crank. (c) Remove and stow the jack erank. (d) Pull up and hold the front leveling jack vertical lock (3), fe) Swing the jack upward until it is horizontal. Release the leveling jack vertical lock. (4) Stow the center leveling jack (5) as de- scribed below. Be careful not to damage the trailer airbrake line when lowering the front center leveling jack. (q@) Attach the jack crankshaft and retract the jack. (b) Remove and stow the jack crank. (c) Pull up and hold the jack verticul lock. (d) Swing the jack sideways and upward to ‘@ horizontal position. Release the jack vertical lock. tank to the (e) Pull up und hold the jack horizontal lock (4). 1—Wingnut jut handle retainer Pluin round nut pin Figure 6-25, Mi ‘anchoring atud secured in missile. (f) Swing the juck beneath the trailer. Release the juck horizontal lock. (5) Connect the trailer to the prime mover as described below. (a) Open the pintle hook (D3) on the prime mover by removing the pintle hook locking pin (D1) and lifting the spring-loaded T-bar latch (D2. (b) Back the prime mover up to the trailer so that the pintle hook is directly under the lunette (D4). (c) Disengage the front support jack erank (E5) from its stowage clip. (d) Engage the lunette on the open pintle hook by retracting the front support jack (E3). (e) Close the pintle hook and insert the locking pin. () Remove the trailer airbrake hose (A2) from the dummy coupling (A1). Connect the hose to the service coupling at the rear of the prime mover, and open the service coupling shutoff cock, permitting the operation of the trailer brakes from the prime mover (g) Remove the intervehicular cable (A3) from the stowage clip. Open the cover on the cable connector. and plug the cable into the receptacle on the reur of the prime mover to provide power for the trailer lights. th) Hook the safety chains (C2) to the appropriate loops at the rear of the prime mover. (6) Stow the front support jack (E3) as de- scribed below. (a) Fully retract the jack with the crank. (b) Place the jack crank in the stowage clip. (c) Pull the spring-loaded frame handle (ED) und, using the jack handle (E4), rotate the jack rearward and upward until the frame handle engages the holes in the top of the lunette mount- ing bracket (A7), thus locking the jack in the stowed position. (7) Stow each of the two rear leveling jacks (5) as described below. (@) Fully retract the jack with the crank. (b) Remove and stow the jack crank. (c) Pull up and hold the vertical lock (F2). (d) Swing the ground pad (F4) rearward and upward until it is in a horizontal position, release the vertical lock (F3). (e) Pull upand hold the horizontal lock (F3). (A) Swing the jack horizontally until itis be- neath the trailer. Release the horizontal lock. (8) Release the handbrake levers (E2), on each tide of the A-frame.ce T™ 9—1440—$31—12—1 t corner leveling jack wck crankshaft nt leveling jack vertical lack enter leveling jack. horizontal lock —Center leveling jack my coupling brake hose cular exble 1 jack crank 7—Lunette mounting bracket 1 2-Ground pad 4—Support wheels ‘hook locking pin ded Tebar lateh wok Spring-lowded frame handle wage clip |— Front support jack | Jack handle — Front xupport ja 7—Bracket and spindle assembly 1 Crankshaft — Rear leveling juck vertical lock — Rear leveling jack horizontal lock |—Ground pad 3—Rear leveling jack (2) Figure 6-26. M390 trailer—preparation for travel and emplacement. f The missile pallet can also be transported 6-27) are installed on the truck bed and used to secure directly in the bed of the M35 or M36 prime the pallet to the truck per TM 9—1440—531—34—2 movers. When these prime movers are used to — Theproceduresfor loading and mounting the pallet on transport missiles, tapered mounting skids (fig. the truck are described in steps (1) through (7) below. 6:271440—$31—12—1 a3 MI 705744 Figure 6-27. Pallet mounting akida installed on M36C prime mover. (1) Index the loader to the pallet and insert the pallet lift pins. (2) Raise the pallet to maximum height and approach the rear of the truck, stopping when the rear end of the pallet is near the tailgate. If necessary, lift the pallet by hand so that the skids will clear the back edge of the truck. NOTE ‘The missile pallet can be loaded on an M25 truck without interference problems, provided the if the MAGC truck is, truck is level. Hower ed, the back ed ick up a slight rine as shaven, vring the back end of the truck p approximately 15 29). This ramp can be constructed using. sxandbaygs or other equipment available tthe battery. 6-28 (3) Slide the pallet forward onto the taperel skids, slightly lifting the pallet by hand to clear the front edge of the skids. (4) Lower the pallet onto the skids, remove the pallet lift pins, and store them on the pallet. (5) Raise the boom and back off the loader. (6) Slide the pallet by hand so that all four mounting holes are alined. (D Install the mounting bolts and washers and tighten the bolts. NOTE ‘Transfer of missiles to or from the pallet is accomplished using procedures contained in TM 9-14650-500-10,16 When transporting missiles on trucks, radome interference with some trailer loads exist. Do not tow the PAR, the HIPIR, or missiles on trailers. It is possible to cause radome interference when making a sharp turn up a steep slope. This is expecially true when tow- ing a LCHR or generator, Adequate caution should be taken by the truck driver during extreme maneuvers of this type. Under normal conditions adequate clearance when towing the following trailer loads with 5 trucks carrying missile load () LCHR's (2) Generators. cy CWAR (4) ROR dock pedestal with ing aft, hk. When missiles are ca there: sufficient r loads. ular dish fac vied on an M36C truck, ome clearance ler i. Prior to leaving the area, make the following. cheeks. (1) All missiles are properly secured to the mis- sile pallet, and the SAFE/ARM handle is in the SAFE position. (2) The missile pallet is properly secured to the skid. (3) The front support jack is properly stowed, (4) All leveling jacks are properly stowed and secured. (5) The trailer is properly connected to the prime mover. (6) ‘The trailer lights are working properly. (7) The handbrakes are released. (8) The trailer brakes are working (move prime mover a short distance and then stop). 6-16. Preparation for Travel Procedures — Helicopter 4, The helicopter lifting kit (fix. 6-1) is provided for each major item. The kit contains the items necessary to form the suspension sling assembly for each major item. The suspension sling assem- bly required to lift the trailer-mounted missile pallet and the missile pallet by helicopter consists of four nylon web and chain legs connected to a T™ 9—1440—531—12—1 one-foot diameter nylon web ring. Each leg is 7m (23 {0 long and is made up of a 4.57 m (15 ft) nylon web le with 2.43 m (8 0) chain assembly bolted to the nylon leg. The detailed procedures for lifting the trailer-mounted missile pallet are con- tained in ¢ through f below. The detailed pro- cedures for lifting the missile pallet are contained in g through j below. 6. Prepare the trailer-mounted missile pallet for helicopter lift as described in paragraph 6-15 @ through e. ¢ Prepare the spreader bar as described in d. Prepare the suspension sling assembly as de- ‘ibed below. Inspect web legs before use for defects (burns, cut edges, or broken threads) to prevent personnel injury or equipment damage. (D Prep spreader bar with an overall length of 3.61 m (142 inches) (center section) and a distance of 3.2 m (126 in) between sling-points (two outer sections) (2 Tape padding along the spreader bar center or along the edges of the top wings of the center missile. This padding is required to prevent the spreader bar from resting directly on the wings, (3) Lay the suspension sling assembly on the xround at the forward end of the trailer. Select two legs and insert the spreader bar between the legs aproximately 86.3 em (34 in) above the grab link bolts of each leg: Tie with nylon cord and tape. (4) Place the spreader bar on top of the center missile, carefully resting it on the wings. Center the spreader bar on the missile (fig. 6-33). (5) Place the web loop on top of the center missile warhead section (fig. 6-38), Pass the remaining two sling legs between the center and ‘outer missiles so that the chain legs fall adjacent to the trailer rear lifting eyes. NOTE Due to the uneven distribution of weight in the ited! missile pallet an unequal number scare used to attach the chain legs to lifting points. In the following steps the correct chitin link i determined by counting from the end link of the chain le. 6-29TM 9—1440—531—12—1 Figure 6-28 Indexing the louder to the prime mover using terrain advantage. Figure 6-29, Indexing the loader to the prime mover using the ramp. MI T0875A,a (6) Attach the two sling legs which are attached to the spreader bar to the front trailer lifting: eyes by passing one chain through each eye, and fastening link 9 of each chain into its grab link. (7) Attach the two remaining sling legs to the two rear trailer eves (3 and 4, fig. 6-32) by passing each chain leg through each eye and fastening link 24 of each chain in its grab link. (8) Remove one chain leg from # second sling set by removing the grab link bolt and spacer. This extra chain leg will be connected between the two rear lift chains as a restraining chain (2, fig. 6-32) to prevent the two rear sling legs from interfering with the outer two missiles during helicopter lift. (9) Connect the grab link device of the extra chain leg to the grab link device of the sling leg 3B—Quick-diseonnect pin (1) 4—Brake handle Figure 6-30. Missile pallet — TM 91440531121 connected to the trailer rear left lifting eye. Con- nect as shown in figure 6-32 and tighten with two 1-1/16-inch wrenches, (10) Insert the free end of the extra chain through the wide part of the grab link on the sling leg connected to the right rear eye, and fasten link 9 of the extra chain leg into its grab link. Pull the two rear sling legs taut to insure that the extra restraining chain is not twisted and that it will restrain the two chain legs during helicopter lift. (LD Fasten loose chain ends with tape to pre- vent fouling (fig. . (12) To prevent fouling of the slings before hookup. coil all four slings together at the top of the center missile and wrap with several turns of tape. Insure that the sling legs are positioned and MI_70577A 5—M290C: trailer fi Attaching hardware 7—Rigght helicopter lift arm mounted on M390C trailer — front view. 6:31TM 9—1440—531—12—1 taped so that they will not hang up during helicop- ter lift. The extra chain leg rests on the trailer (13) device trailer, (14) Place the grounding device (1. fig. 6-33) with the taped suspension slings on top of the center missile. e. Prior to helicopter lift, perform the following check: ive the ground rod of the grounding sembly into the ground next to the (1) The trailer has been prepared for travel, and the handbrakes have been set. All jacks have been retracted and are in the vertical position, (3) The front support jack is ret in the vertical position, (4) All missiles are secured to the pallet and the SAFE/ARM handle is in the SAFE position. (5) The spreader bar is resting on the wings of the center mis: wcted and is J. To attach the suspensi the helicopter hook 9. Prepare the missile pallet for helicopter lit as described below. (1D) For preparation for travel procedures of the missile pallet, refer to paragraph 6-15e, f and he NOTE ied, the Figure references loss otherwise xp steps (2) thru sa, (2) Remove the four quick-disconnect pins (2) that secure the helicopter lift arms (Land 7) tv the helicopter lift arm support tube (2). CH Place the right helicopter lift arm (7) into the support tube and secure it with the two quick- disconnect pins. the spreader bar as described in Se. A. Prepart paragraph MI_70578A me (2 dligconnect pin hole disconnect pin (2) A= Left rear pallet brace Figure 6-31. Missile pallet — mounted on M390C trailer — rear view. 6-32a ™ 91440531121 MS 156076 1—Grab link 2—Reatraining chain 3—Right rear lift point (eye) 4—Left rear lift point (eyed Figure 6-32. Missile pallet — suspension sling assembly secured for helicopter pickup — rear view. i. Prepare the suspension sling assembly as de- seribed below. , NOTE ‘The suspension aling assembly can be used to transport one. two or three missiles on the insile pallet. If one missile ix to be lifted, it should be placed in the center position and if two missiles are to be lifted they should be placed on Inspect web legs before use for defects the wutaide positions, (ourns, cut edges, or broken threads) to prevent personnel injury or equipment (1) Prepare # spreuder bar with un overall damage. length of 3.25 m (128 in) (center section) and aTm 91440531121 distance of 2.84 m (112 in) between sling-points (two outer sections). (2) Tape padding along the spreader bar center or along the edges of the top wings of the center missile. This padding is required to prevent the spreader bar from resting directly on the wings. (3) Lay the suspension sling sissembly on the ground at the forward end of the trailer or at the exhaust end of the missiles if the pallet is off the trailer. Select two legs und insert the spreader bar between the legs approximately 86.4 cm (34 in) above the grab link bolts of euch leg. Tie with nylon cord and tupe. (4) Place the spreader bar on top of the center missile, carefully resting it on the wings. Center the spreader bur on the missile (fig. 6-33) so that the sling legs full adjacent to the helicopter lift arm eyes. a (5) Place the web loop and sling assembly on top of the center missile or center arm with the remaining two sling legs hanging forward over the loader indexing points to the pallet skids. NOTE Due to the uneven distribution of weight in the missile pallet an unequal number of chain links ‘are used to uttach the chain lege to the front and rear lifting points. In the following steps the cor- rect chain link is determined by counting from the end link of the chain leg. (6) Attach each of the two rear sling legs to the rear lifting points (fig. 6-34, front view) by passing one chain leg through each eye and fasten- ing link 26 of each chain in its grab link. (7) Attach each of the two forward sling legs to the pallet skids by passing one chain leg through SoS heres D 1—Grounding device 2—Suapension sling assembly ‘3—Spreader bar assembly Figure 6-83. 34 ‘MS 156077 4—Left front lif point Trailer-mounted misvile pallet — suspension sling assembly secured for helicopter pickup — front view, (T™ 9—1440—531—12 the hole in the skid and fastening link 50 of euch chain in its grab link, (8) Fasten loose chain ends with tape (fig. 6-3) to prevent fouling. (9) To prevent fouling of the sling legs before hookup, coil all four sling legs together on top of the center missile or center arm and wrap with tape so that it will break away during lift (fig. 6-34, rear view). Insure that the sling legs are positioned and taped so that they will not hang up during lift. (10) Drive the ground rod of the grounding device assembly (1, fig. 6-1) into the ground next to the major item. (11 Place the grounding device (1. fig. 6-33) with the taped suspension sling assembly on top of, the center missile. NOTE ‘The missile pallet attaching hardware must remain with the trailer j. Prior to helicopter lift, perform the following cheeks: (1) The hi secured in place. opter lift arms are extended and (2) The suspension slings are properly attached. cs (3) The suspension slings are taped for heli copter pickup. (4) The missiles, if less than three. are placed on the pallet correctly. (5) All areas where the suspension sling eould contact sharp edges are properly taped. (6) The missile pallet is f (7) The missiles are latched properly on the pal- let, the anchor bolts are tightened securely and locked, and the SAFE/ARM handle is in the SAFE position. ing downwind. ‘The hovering helicopter develops high static voltages in excess of 20,000 volts n the helicopter lifting hook (2. fig. -18). Failure to perform steps () through (6) in paragraph 6-9e in the exact sequence given may result in in- Jury to personnel. tw k. To attach the suspension sling assembly the helicopter hook. refer to paragraph 6-9. (10 CHAPTER 7 EMPLACEMENT PROCEDURES Section |. 7-1. Scope The detailed emplacement procedures for the ILCHR and guided missile pallet are presented in this chapter. Refer to TM 9-1425-525-1 for infor- mation concerning site selection and evaluation. Section II. 7-3. General This section describes the emplacement pro- cedures for the ILCHR (fig. 1-1). The procedures begin with the arrival of this major item at the battery site by either prime mover (par. 7-5) or helicopter (par. 7-6). 7-4, Tools The only tools, required are a %-inch open-end wrench and a sledge hammer. 7-5. Emplacement Procedures — Prime Mover a. The detailed procedures for emplacing the ILCHR by prime mover are us follows. (1) Engage the ILCHR brakes by placing the handbrake levers (1, fig. 7-1) on each side of the ILCHR base to the horizontal position. (2) Close the service coupling shutoff cocks, disconnect the two airbrake hoses (2, fig. 7-1) from the rear of the prime mover, and stow them in the brake hose fittings (B4, fig. 6-10) on the front of the ILCHR base. GENERAL 7-2, Explanation of Procedures The procedures for emplucing the ILCHR de- scribe a typical method of setting up a completely emplaced ILCHR from a mobile unit. These pro- cedures cover arrival by prime mover or helicop- ter. They continue in sequence until all the major items are ready for orientation and alinement. Procedures for orientation and alinement are de- scribed in chapter 8. EMPLACEMENT OF THE IMPROVED GUIDED-MISSILE LAUNCHER M192E1 Prior to handling a system power cable, the generator main circuit breaker must be turned OFF. Never attempt to handle cables which may be carrying 416- or 208-vac power with- out first assuring that the power to the cable is removed. (3) Disconnect the intervehicular electrical cable from the receptacle at the rear of the prime mover. (4) Hold the front support jack (E3, fig. 6-9) and turn the crank counterclockwise until the jack pad is free of the lunette cross bar. (5) Rotate the jack downward to a vertical position and secure it to the ILCHR base with the quick-disconnect pin (E2, Fig. 6-9). (6) Remove the quick-disconnect pin (E5, fig. 6-9) and rotate the jack pad to « horizontal posi- tion. mHTH 9—1440—531—12—-1 (D Secure the jack pad in the horizontal posi- tion with the quick-disconnect pin. (8) Adjust the jack until the jack pad rests firmly on the ground. (9) Disconnect the safety chains as described in (a) and (6) below. (a) Disconnect the outrigger safety chain (6, fig. 7-1) and remove it from the forward out- riggers(3, fig. 7-1). (®) Disconnect the sufety chain (4, fig. 7-1) from the rear of the prime mover. (10) Remove the pintle hook locking pin (D1, fig. 6-26) from the pintle hook (D3, fig. 6-26) on the prime mover. 19, (11) Release the spring-loaded T-bar latch (D2, fig. 6-26) and open the pintle hook. (12) Adjust the front support jack until the lunette (D4, fig. 6-26) is free of the pintle hook. Move the prime mover forward, close the pintle hook, and insert the locking pin. (13) Disconnect the intervehicular electrical cable from the receptacle (B1, fig. 6-10) on the ILCHR base. (14) Remove the quick-disconnect pins (BS, fig. 6-10) which secure the front leveling cylinders in their stow brackets. Lower the leveling cylin ders clear of the front compartment cover. Replace the quick-disconnect pins in the stow brackets. 1 Handbrake lever rake hove Forward outriggers MS 166313A 4-Sufety chain 5—Outrigger safety chain Figure 7-1. ILCHR — emplacement. 7-2cio (15) Remove the front compartment cover. NOTE ‘The figure numbers shown below in parentheses refer to figure 6-10, unless otherwise indicated. (16) Depress the detent (B10) and turn the finger grip knob (B11) counterclockwise. Remove the lunette (B9) from the front outriggers (B8 and BI2). (17) Emplace the left front and right front outriggers as described below. (a) Support the outer end of the outrigger (B8), withdraw the quick-disconnect pin (B6), and remove the towing brace (B5) from the bracket on the upper left (B7) corner of the ILCHR base. (b) Remove the towing brace from the out- rigger by unscrewing the T-handle ball socket end (B3) from the outrigger. (c) Obtain the sway brace (A2) from the storage compartment. (d) Swing the outrigger around, and secure the sway brace to the outrigger and the locking bracket (A3) on the ILCHR base with the quick- disconnect pins (Al and Ad). (e) Remove the outrigger pad retaining bars and plate. (P Remove an outrigger pad (G3, fig. 6-9) from its stow position above the spade storage rack (G1), place it on the ground with the socket, spring (G2, fig. 6-9) toward the ILCHR side under the outer end of the outrigger, and insert the outer end into the outrigger pad socket slide (G1, fig. 6-9). (g) Remove the handpump handle (F3, fig. 6-9) from the front compartment, and connect it to the handpump (F'4, fig. 6-9). (h) Open the left front or right front cylinder leveling valve (F7 or F8, fig. 6-9) and close all other valves on the base hydraulic panel to allow manual operation of the appropriate leveling cylinder. Before performing step i insure that the conditions in figure 7-11 are sat- isfied. (@) Aline the leveling cylinder (F1) with the outrigger socket (F3). @) Actuate the handpump to extend the Piston collar (F2) until it engages the outrigger socket. (k) Close the leveling valve. T™ 9—1440—531—12—1 1LcHR: BASE LINK ‘THE LINK MUST 3} REST FLUSH AGAINST THE LeveL BASE 9 MS 312407 Figure 7:1.1. Leveling Cylinder. (18) Emplace the rear outrigger as described below. (a) Support the rear leveling cylinder (C2), and remove the quick-disconnect pin (C4) that secures the cylinder to the clevis fitting (C1) on the underside of the outrigger. (b) Support the outrigger, lower the level- ing cylinder, and then lower the outrigger. (c) Remove an outrigger pad from its stow position above the spade storage rack, place it on the ground with the socket spring toward the rear of the ILCHR under the outer end of the rear out- rigger. and insert the outer end into the outrigger pad socket slide. (@) Open the rear cylinder leveling valve (F9, fig. 6-9). (e) Aline the rear leveling cylinder (C2) with the rear outrigger socket. () Actuate the handpump to extend the piston collar until it engages the rear outrigger socket. () Close the leveling valve. When leveling, exercise caution to insure that the outrigger arms do not pop out of the outrigger pad socket slide. ca(19) Level the LCHR as described below. (a) Lock each wheel suspension system out by rotating the suspension lockout handles (H3 fig. 6-9) to an upright position, so that the spring- loaded detents are engaged. (b) Open the front cylinder leveling valves (F7 and F8, fig. 6-9). Actuate the handpump until the LCHR wheels are one inch off the ground. Close the cylinder valves. (c) Open the rear cylinder leveling valve (F9, fig. 6-9). Actuate the handpump until the LCHR base appears level. (d) Remove the protective cap on the bulls- eye level (F2, fig. 6-9). (e) View the bulls-eye level and determine if the LCHR is level. If necessary to level the LCHR, open the leveling valves one at a time, and actuate the handpump to extend the associated leveling cylinder. NOTE Close the opened leveling valve before opening. the second one. (P Ifnecessary, with the required leveling valve in the open position, open the bleed valve to retract the associated leveling cylinder. (1) Check the three outrigger pads for the following: 1. Pad socket slide must be in line with the outrigger arm and the pad must be oriented so that the side which contains the slide spring is facing the launcher. 2 The socket slide must not be at the extremities of its travel range in the pad “V” groove. 3. There must be free movement of the slide to prevent the possibility of the outrigger arm extremity from being forced out of the socket slide by the launcher bouncing forees which are imposed during operation. 4, The groove should be lubricated with grease (LC 9—1440—531—12) especially if the pads are staked to the ground. (g) When the LCHR is level, screw the locking sleeves on the three leveling cylinders down against the piston collars. (h) Open all the leveling valves on the base hydraulic panel. (@ Recheck the bulls-eye level to insure the LCHR remains level. @) Remove and stow the handpump han- dle. (%) Turn the front support jack crank clockwise until the jack pad is just clear of the ground. 14 cs (20) Open the LCHR chassis drain valves. (21) Remove the tripod and launcher control (LC) (7, fig. 6-9) from the front compartment and emplace the LC on the tripod. If necessary, close the LC equalizer pressure valve. (22) Open the LC cover, set the REMOTE- LOCAL switch to LOCAL, and place the remain- ing switches in the OFF (down) position. (23) Remove the communications station and bracket assembly (D2, fig. 6-9) from the LCHR forward compartment and install it on the LC (D1, fig. 6-9) (24) Remove the communications cable (D3, fig. 6-9) stowed in the LC cover and connect it bet- ween J2 on the LC and J1 on the communications station. Extension cable 10288606 must be used with the single ear headset 10288628 at all times in order to prevent damage to the LCHR communications circuits. (25) Remove the headset and extension cable from the LCHR forward compartment and con- nect them to the communications station. (26) Remove the LC cable (6, fig. 6-9) from the front compartment. Connect it between the LOCAL CONTROL cable receptacle at the base of the LCHR base and connector J1 on the LC. (27) Remove the ground rod and ground rod cable from the front compartment. (28) Emplace the ground rod and connect the cable between the rod and the ground rod cable attach point (A2, fig. 6-9). (28.1) Insure that the resistance to ground of the ground rod is 25 ohms or less. NOTE Refer to TM 9~1425~525—1, Appendix 1, for detailed instructions for measuring the resistance of the ground rod. It may be necessary to use additional ground rods and/or buried wire to achieve 25 ohms or less resistance to wound. (29) Open the air tank bleed valve. (30) Stow the lunette, intervehicular electrical cable, outrigger pad retaining bars and plate, and towing braces in the front compartment. (81) Close the pressure relief valve (2.1, fig 5-10) on the compensation group cabinet and storage case (6, fig. 4-17.2). Close and secure the front and rear compartment covers.cs T™™ 9—1440—531—12—1 shallow hang angle throughout the transfer operation, interferences of the missile boat tail and umbilical plug with (32) Release the azimuth STOW lock (C2, fig. 6-9) by releasing the grip knobs (Cl, fig. 6-9) and rotating the STOW lock 180 degrees. Secure the grip knobs. (33) Pull open the air vent covers (Al, fig. 6-9) on each side of the LCHR base. (34) Remove the spades (G2) from the storage rack (G1) and emplace the outrigger pads (G3) by driving the spades through the slots provided on the pads. Prior to lifting missiles with the loader, the following precautions are mandato- ry. @. Launcher Interference. During transfer operations, the missiles are sus- pended from the loader yoke and are free to swing about the yoke pivot. Missiles normally hang nose down from level. For transfer operations to the launcher, it is highly desirable to have the missiles hang at a 5-degree nose- down attitude. Because of the center of gravity location of the missile and the ionship to the yoke pivot, the les hung 2 degrees nose down. If the missiles are allowed to maintain this rela the launcher rear hook occur. To avoid this condition, the following procedure is necessary. When transferring missiles to the launcher, as the missile boat tail approaches the launcher rear hook, exert and hold a light down foree (by hand) on the missile radome (to prevent contact of the boat tail and umbilical plug with the launcher hook), until the missile(s) is in firm contact with the for- ward sector and the rear roller. b. Reduced Pressure. The loader hy- draulic system in the reduced pressure mode is 616 psi. This mode protects the missile and equipment against structural overloads produced by the extension cylinder. Because higher reduced pressure can result in less protection against over- loads, great care must be exercised while operating the hydraulic system in the reduced pressure mode. Avoid inadver- tent retraction of the extension cylinder when missiles are latched to both loader and launcher. It is very important to avoid this occurrence when it results in an unsymmetrical loading (for example, retracting with one outboard missile latched to both launcher and loader). 724.1¢. Hoisting beam. When the XM15 hoisting beam, 1450-00-665-3434, is used to lift a missile, the component con- necting link, 2590-00-690-2856, P/N 9089791, must be installed in hole 6 to accommodate the center of gravity in the missile. (35) Load the missiles on the ILCHR (par. 21D, NOTE Ir the battery is operating. in cold weather condi tions, install the cold-weather kit heater covert as stated in C5) below and energize the cold- weather heater cavers (paragraph 2-7b), (36) Install the cold-weather kit heater covers on the missiles, as follows: NOTE For the following removal procedures, two men and a 0.91 m (3 0 stand or atepladder are required. NOTE Unless otherwise specified, the key numbers shown in parentheses below refer to figure 6-6, (a) Install the top heater cover (11) with the strap grooves (26) forward on the missile as shown on figure 6-6. Aline the rear edge of the heater cover with the reur edge of the elevons. (b) Install one side heater cover (5). Aline the strup grooves (1) with those of the top heater cover. Secure the top heater cover, with the side heater strap (4) to the pile (10) of the top heater cover. (c) Install the remaining side heater cover as described in (b) above. (@) Install strap around missile at the side heater strap (fig. 6-8) locations. Adjust the strap for a snug fit to hold the heater straps in place. (e) Install the bottom front insulating cover (25) to the missile. Aline the strap grooves (24) with those of the side heater covers. P Secure the forward section of each cwer with the two strap assemblies (2 and 27) with the breakaway connection (3) at the top. (g) Install the taileune insulating cover (1d), pushing it tight against the rear edges of the top and side covers. (h) Fasten the tabs (13) to the pile on the rear edges of the top and side covers. (@) Pasten the top straps (7) of each side cover to the buckles (12) of the top cover. ™ 9—1440—531—12—1 @) Insert the bottom center insulating covers (17 or 19) between the lower wings. NOTE ‘The cover (17) ix used in the outbourd positions ‘of the launcher. the cover (19) is used in the center position (k) Insert. bottom side insulating covers (15 and 21) between the wings of the missile, alin- ing the rear edge of each cover with the rear edge of each elevon. Fasten the lower strap (8) of each side cover to the buckle (20) of each outboard cover. (1) Move the bottom center insulating cover (17 or 19) aft until it seals with the launcher fairing, and mates with the supporting step (16) of each outboard cover. (m) Squeeze bottom side covers (15 and 21) together with the center cover, and secure the fastening tape (23) to the pile on the bottom of, each outboard cover. NOTE It ix important that step n be accomplished pro- perly xo that the center insulating cover (IT oF 19) will lie against the surface of the missile, (x) Push the bottom cover assembly against the missile, and fasten the lower strap (8) of side heater covers (5) to the pile of bottom side insulating covers (15 and 21). Take up the slack of the missile blanket heater cables so that no part of the cable will strike when the boom is elevated. Secure the slack of the cables through the lower straps. (0) Push each bottom side cover tightly against the wing surface and the launcher. Fasten the tabs of the tailcone cover to the pile on the bot- tom und side covers. Secure each side cover lower strap (8) to the buckle (20) of the bottom side cover. (p) Insert ball-lock pins (18) of bottom center covers (17 and 19) into holes provided in the sides of the fairing and center blast deflector. (q) Connect the cable assemblies (6) to the receptacles on the distribution box.TM 9—1440—531—12—1 Observe all missile handling precautions contained in TM. 9-1410-530-14 prior to energizing the LCHR. 6. Prior to energizing the LCHR, make the following checks. (1) The missiles are properly latched and the SAFE/ARM handle is in the SAFE position. (2) The handbrakes are engaged. (3) The airbrake hoses are properly stowed. (4) The lunette, outrigger retaining bars and plate and intervehicular electrical cable are pro- perly stowed in the front compartment. (5) All three outriggers are properly emplaced. (6) The sway braces are properly emplaced. (D The wheel suspension system is locked out, (8) The LCHR is level. (9) The front support jack pad is just clear of the ground. (10) The azimuth STOW lock is unlocked and properly stowed. (1) The LC is properly emplaced. (12) The REMOTE-LOCAL switch on the LC. is in the LOCAL position and all other switches are in the OFF (down) position. Section 7-7. General This section describes the emplacement pro- cedures for the guided-missile loading and storage pallet (guided-missile pallet) and its supporting trailer by prime mover (par. 7-9) and by helicop- ter (par. 7-10). The missile pallet can be mounted on either the or the M390C trailer. The differences in emplacement of the M390 und M390C are the number of leveling jacks and the 7-6 cle (13) The headset is properly connected to the Le. (14) The launcher control cable is_ properly connected between the LC and the LCHR base. (15) The air vent covers are opened. (16) The ground rod and ground rod cable are properly emplaced. When emplacing the LCHR cables, lay the cables on the ground at right angles (90 deg) from the LCHR to the Primary ‘Target Line (PTL). Leave slack for a dis- tance of up to 6.08 m (20 ft.) utilizing a lazy-S shape. Power and data cables are to be separated from each other by 0.254 m (10 in.) minimum. If available, sand- bags should be placed over the cables from the LCHR out to 3.04 m (10 ft.). (17) The power and data cables are properly connected. (18) The front and rear compartment. covers are secured. (19) All remaining equipment is stowed. 7-6. Emplacement Procedures — Helicopter a. Remoye and disassemble the suspension slings. b. Stow the helicopter lifting kit in the storage bag and stow the bag. c. The LCHR is emplaced as described in paragraphs 7-5a (1), (14) through (35), and 7-56. EMPLACEMENT OF GUIDED-MISSILE LOADING AND STORAGE PALLET M1E2 physical location of these jacks. The M390 has five leveling jacks, and the M390C has three. ‘The M390C leveling jacks are functionally the same as those of the M390 trailer. Emplacement of the M390 trailer by prime mover is described in para- graph 7-9a(1) through (10) and emplacement of the M390C trailer by prime mover is described in Paragraphs 7-9a(1) through (6) and 7-9e(1) through 6).C16 7 Tools The only tools required are two%-inch open-end wrenches, a 1-7/16-inch open-end wrench, and a small hammer. 7-9. Emplacement Procedu Mover a. The detailed procedures for emplacing the M390 or trailer are as follows. NOTE Unless otherwise indicated, the key numbers in parentheses shawn below refer to figure 1 9—1440—531—12-1 (1) Set the trailer handbrake with the handbrake levers (4, fig. 7-3), one on each side of the A-frame. (2) Emplace each rear leveling jack (5) as de- scribed below. (a) Pull up and hold the rear leveling jack horizontal lock (3). (b) Turn the jack horizontally until the ground pad (4) is at the rear of the trailer, Release the horizontal lock. (c) Pull up and hold the rear leveling jack vertical lock (6). (d) Rotate the jack to the vertical position with the ground pad down. Release the vertical lock. 7-61TM 9—1440—531—12—1 leveling jack crank car leveling jack horizontal lock round pad MS 164690 Rear leveling Rear leveling jack vertical lock 7—Crankshatt Figure 7-2, Trailer emplacement — left rear view. (e) Remove a rear leveling jack crank (2) from the stow bracket (1) on the rear center of the trailer and place it on the crankshaft (7). (P Adjust the jack until the ground pad is Just clear of the ground. (3) Lower the front support jack as described below. (a) While supporting the front support jack (3, fig. 7-4) with the ground pad handle (4, fig. 7-4), pull upward on the spring-loaded frame handle (1, fig. 7-4). (b) Lower the jack to the down position. Insure that the ends of the spring-loaded frame handle engage the holes in the bracket and spindle assembly (7, fig. 7-4). (c) Disengage the front support jack crank (6, fig. 7-4), and turn it clockwise until the support wheels (5, fig. 7-4) rest firmly on the ground, (4) Release the trailer from the prime mover as described below. (a) Disconnect the safety chains and secure them with the turnbuckler () Remove the intervehicular cable a sembly (4. fig. 7-5) from the receptacle on the prime mover and place it in the stowage clip (5, fig. 7-5). (©) Close the service coupling shutoff cock at the rear of the prime mover. Disconnect the trailer uirbrake hose from the service coupling and place it on the dummy coupling (2, fig. 7-5). (d) Remove the locking pin from the pintle hook (3, fig. 6-15) on the prime mover. (e) Release the spring-loaded T-bar latch (2, fig. 6-15) and open the pintle hook. (P Turn the front support jack crank clockwise until the lunette (4, fig. 6-15) is free of the pintle hook. (@) Move the prime mover forward, close the pintle hook, and insert the locking pin, (5) Lower the center leveling jack (7, fig. 7-3) us described below. Ceaser) Be careful not to damage the trailer airbrake line when lowering the front center leveling jack. (a) Pull up and hold the horizontal lock. (6) Turn the jack until the ground pad is clear of the trailer. Release the horizontal lock. () Pull up and hold the center leveling Jack vertical lock (8, fig. 7-3). (@) Rotate the jack to the vertical position with the ground pad down. Release the vertical lock. edTM 9—1440—531—12-1 fe) Remove the leveling jack crank (6. fig. 7-3) from the stow bracket (6. fig. 7-3) on the A- frame. and place it on the jack erank-shaft (1. fig. 73) (f) Adjust the jack until the ground pad is just clear of the ground. (6) Lower each of the front leveling jacks (2. fig. 7-3) as described below. (a) Pull up and hold the front leveling jack vertical lock (3, fig. 7-3) (b) Rotate the jack to the vertical position with the ground pad down. Release the vertical lock. (c) Obtain a crank and engage it on the front leveling jack crankshaft, (d) Adjust the jack until the ground pad is, just clear of the ground. (7) Adjust the jacks until the trailer wheels are at least one (1) inch off the ground and the trailer ‘Appears level. (8) Stow the jack cranks. (9) Adjust the front support jack until the sup- port wheels are resting firmly on the ground. (10) Stow the jack crank in its storage clip. b. Release the missiles from the pallet by per forming steps (1) through (4) below. (1) Release the wing nut (1, fig. 3-80) and re- move the nut handle retainer (2, fig. 3-80) from the plain round nut pin (3, fig. 3-80). (2) Using a wrench, if necessary, release the missile anchoring stud assembly from the threaded wingnut (1, fig. 3-79) by tuming it counterclock- wise. (3) Loosen the plain round nut with a small hammer to break it loose from the self-adjusting ‘washer (3, fig. 3-79). (4) Release the quick-disconnect pin (2, fig. 3-78) and place the missile latch (1, fig. 3-78) in the down position. Prior to lifting missiles with the loader the following precautions are mandatory. a. Interference. During transfer operations, the missiles are suspended from the loader yoke and ‘are free to swing around the yoke pivot. Missiles normally hang nose down from level. For trans- fer operations, it is highly desirable to have the missiles hang at a B-degree nose-down altitude. Because of the center of gravity location of the mimile and the relationship to the yoke pivot, the missiles hang 2 degrees nose down. 7. o b. Reduced Pressure. The hydraulic system pressure in the reduced pressure mode is 615 psi. ‘The purpose of the mode is to protect the missile and equipment against structural overloads pro- duced by the extension cylinder. Because higher reduced pressure can result in less protection against overloads, great care must be exercised while opera- ting the hydraulic system in the reduced pressure mode. (1) When removing missiles from the pallet or launcher, avoid inadvertent retraction of the extension cylinder when missiles are latched to both loader and pallet. It is of utmost importance to avoid this occurrence when it results in an un- symmetrical loading (for example, retracting with ‘one outboard missile latched to both pallet and loader). (2) When placing mimiles on to the pallet dur- {ng final seating of the missile against the rear hooks (pallet), it is important to avoid over-extending the extension cylinder, thereby overloading the struc- ture, ¢. For removing the missile pallet from the trailer or missiles from the pallet, refer to TM 9-1450— 500-10. d. The detailed procedures for emplacing the M390C trailer are as follows: (1) Perform the procedures outlined in para- graph 7-9a(1) through (6). (2) Adjust the jacks until the trailer wheels ‘are at least one (1) inch off the ground and the trailer appears level. (3). Stow the jack cranks. (4) Adjust the support jack crank until the support wheels are resting firmly on the ground. (5) Store the jack crank in its storage clip. ¢. Release the missile from the pallet as scribed in steps b(1) through (3) above. (Observe the CAUTION preceding paragraph 7-9¢ abore. f. To remove the missiles from the pallet or the the missile pallet from the trailer, refer to TM 9— 1450-500-10. 7-10. Emplacement Procedures — Helicopter a. Remove, disassemble, and stow the suspen- sion sling assembly in the helicopter lifting kit bag. Stow the bag. b, Emplace the M390 or M390C trailer as de- scribed in paragraph 7-9,¢. For loading the missile pallet on the trailer, or loading the missiles on the pallet. refer to TM 9-1450-500-10. Ceaunon} Prior to lifting missiles with the loader the following precautions ure mandato- ry. a. Interference. During transfer operations. the missiles are suspended from the loader yoke and are free to swing about the yoke pivot. Missiles normally hang nose down from level. For transfer operations. it is highly desirable to have the missiles hang at S-degree nose-down attitude. Because of the center of gravity location of the issile and the relationship to the yoke pivot. the missiles hang 2 degrees nose down, 4, Reduced pressure. The hydraulic system pressure in the reduced pressure mode is 615 psi. The purpose of the mode is to protect the missile and equipment against structural overloads produced by the extension cylinder. Because high- er reduced pressure can result in less protection against overloads, great care must be exercised while operating the hydraulic system in the reduced pres- sure mode. () Avoid inadvertent retraction of the extension cylinder when miseiles. are lutched to both loader und pallet. It in of ‘utmost importance to avoid this occurrence when it reaults in an unaymmetrical loading. ™ 9—1440—$31—12—1 ides MI 150668 1—Jack erankshatt 2 Front leveling jack 3—Fromt leveling jack vertical back 44— Handbrake lever 3—Stw bracket S8— Leveling jack crank F—Center leveling jack 8=Center leveling jack vertical bck Figure 7-3. M300 trailer forward leveling jacke — preparation for tracel and emplacewrent {for example, retracting with une wutboard missile latched to both pallet and loader.) (2) When placing missiles onto the pallet during final seating of the m against the rear hooks (pallet). it is important to avoid over-extending the extension cylinder. thereby overloading the structure. 4. For loading the missiles on the pallet, refer to TM 9-1450-500-10.MI 705124 1—Spring-loaded frame handle Stowage cli — Front support Bracket and spindle assembly Figure 7-4. M390 trailer front support jack — preparation ‘for travel and emplacement. TM 9—1440—$31—12—-1 ‘MI 150669 1—Lunette mounting bracket 2—Dummy coupling 3—Airbrake hose 4—Intervehicular cuble ussembly ba 6—Safety chain Figure 7-5. M390 trailer A-frame — preparation for travel and emplacement. radT™ 9—1440—$31—12—1 Section IV. EMPLACEMENT OF THE IMPROVED LAUNCHING SECTION CONTROL BOX AN/GSA-132 7A. This section describes the emplacement pro- cedures for the improved launching section control box (ILSCB). The procedures begin with the arrival of the major item at the buttery site by either prime mover or helicopter. 7-12, Tools ‘The only tool required is a sledge hammer. 7-13. Emplacement Procedures — Prime Mover or Helicopter The ILSCB must be emplaced at least 60.9 m (200 ft) from the nearest ILCHR, und with a suitable barricade to protect it and operating personnel from the missile rocket motor blast. NOTE During inclement weuther. or under blackout tions, the ILSCB hall be emplaced and ‘operated under x protective shelter. a. Remove the ILSCB from the prime mover or helicopter. b. Remove the ground rod and cable stowed on the IHIPIR und emplace the ground rod. 7-10 ¢. Connect the ground rod cable between the ground rod und the ground rod cable attach point ‘on the ILSCB. d.. Place the LAUNCHERS OPERATE/SAFE switches (5, fig. 6-20) to SAFE. @ Set the MSL COUNT DELAY switch (4, fig. 6-20) us appropriate for the existing temperature ‘as stamped on the ILSCB. f. Perform the procedures described below at the ILSCB. (1) Request the IHIPIR personnel to ener- ize the radars. (2) Set the HPI CABLE IDENT/OFF switch to HPI CABLE IDENT. Connect each data cable, in tum, to connector J1 on the ILSCB until the panel lights on the ILSCB illuminate. (8) Connect the data cable that causes the panel lamps to illuminate to connector J1 on the (This is the THIPIR data cable). (4) Determine which ILCHR’s are to be designated 1, 2, and 3. (8) Connect the data cables from ILCHR's 1, 2, and 8 to connectors J2, J3, and J4, respec- tively, on the ILSCB. (8) _ Repeat steps (2) through (6) above for the other firing section. g. Remove the headset from the storage com- partment (2, fig. 6-20) and connect it to the com- munications station (3, fig. 6-20).cu T™ 9—1440—531—12—1 CHAPTER 8 ORIENTING AND ALINING Section I. 8-1. Purpose a. Accurate target firing data and successful target engagement largely depend on alinement of the HAWK system major items. If the proper procedures for the radars are not carefully followed, misleading target information will be displayed on the major item scope, and effective target engage- ment will be degraded. In addition, if the LCHR is, not accurately alined with its associated HIPIR, probability of intercept may also be adversely affect- ‘ed. This is because one of the most vital functions performed by the LCHR is to point the missile directly along, the HIPIR tracking line of sight, during the missile initiate and gyro runup phase of the launch sequence. This provides proper missile head gyro orientation in relation to target position. Therefore, this initial gyro runup position, along with LCHR lead angle and superelevation informa- tion serve to optimize the probability of intercept, once a missile has been fired. 8-2. Methods of Orienting and Alining a LCHR There are two methods of orienting and alining the LCHR: a primary and an alternate. Subpara- graphs a and b below give a general description of the two methods. a, Primary Method. When the LCHR is em- placed so that line of sight with the HIPIR exists, the primary method of orienting and alining is used. Once the HIPIR antenna is oriented and its antenna synchro is properly nulled, alinement of the LCHR is accomplished as follows. The HIPIR antenna aline- ment telescope and the LCHR alinement telescope on the alinement telescope and fire cutout assembly mounted to the LCHR chassis are alined with one another. The LCHR telescope is secured in this position. This mechanical setting provides a refer- ence relative to LCHR chassis orientation. Upon installation of the alinement telescope and fire cutout assembly into the LCHR front compartment this mechanical reference is used to provide an ORIENTATION AND ALINEMENT OF THE LCHR electrical reference by which the LCHR boom positioning circuits position the boom in response to synchro information received from the HIPIR. b, Alternate Method. When the LCHR is em- placed so that line of sight to the HIPIR does not exist the alternate method of alinement is used. In this method the M2 aiming circle is used, by the HIPIR personnel, to determine the position at which the LCHR alinement telescope is set. Essentially the ‘M2 aiming circle is used to relay the HIPIR antenna azimuth angle around the line of sight obstruction to the LCHR alinement.telescope. The alternate non- line of sight alinement procedures are included in table 8-1. 8-3. LCHR—HIPIR Azimuth Alinement Verifi- cation 4. Azimuth alinement is verified after the LCHR and HIPIR have been alined to insure that the LCHR arms are parallel to the HIPIR line-of-sight. This parallel condition is necessary for the missile to lock on target. Table 8-1, step 4 contains detailed alinement verification procedures. Paragraphs 0, c, and ¢ below contain a brief description of these procedures. b, If line-of-sight exists between the LCHR and the HIPIR and there are no missiles on the LCHR, azimuth alinement is verified by sighting both the front reference point (1, fig. 8-6) and the rear reference point (3, fig. 8-6) on the HIPIR alinement telescope vertical crosshair. This line-of-sight verifi- cation is made on the LCHR arm closest to the LCHR alinement telescope. If both reference points cannot be alined on the vertical crosshair of the HIPIR telescope, a sighting target and support are used as described in paragraph d below. Construc- tion of the sighting target is described in paragraph d below. ¢. The sighting target and support (fig. 8-0.1) are used to verify the LCHR and HIPIR alinement under the following conditions.TM 9—1440—531—12—1 (1) Alinement cannot be verified using the pro- cedure described in paragraph above. (2) Line-of-sight exists between the ILCHR and THIPIR and there are missiles on the ILCHR. (3) Line-of-sight between the ILCHR and the IHIPIR does not exist (refer to par. f below). d. The sighting target support should be con- structed using a yard or meter stick, or a straight stick or rod marked in 1-cm or 0.5-inch intervals. One of the following two targets should be made and mounted on the target support so that the tar- get can be moved along the support. If the ILCHR, and IHIPIR are separated by less than 90 m (300 ft) or if the distance between the missile or ILCHR reference points (4 and 7, or 1 and 3, fig. 8-6) and the ILCHR alinement telescope line-of-sight is less than 15 cm (6 inches), a black band should be used for a target (fig. 8-0.1a). The band should be made from a strip of heavy black paper 1.7 cm (0.5 inch) wide. It should be long enough so that the two ends can be taped together and the band can be placed around the target support as shown on figure 8-0.1a. Otherwise, a cardboard or a thin board circle at least 15 cm (6 inches) in diameter should be made and painted with two colors which contrast with the terrain, as shown on figure 8.0.16. This target should then be mounted on the support using two brackets, wire loops, or paper clips (fig. 8-0.1¢). e. The sighting target support is placed on the front reference point (1 or 4, fig. 8-6), and the sighting target is moved along the support until it is alined with the vertical crosshair of the IHIPIR alinement telescope. The distance x (fig. 8-7) be- tween the front reference point and the IHIPIR. alinement telescope line-of-sight is measured and recorded. The same measurement is taken of the distance y (fig. 8-7) at the rear reference point (8 or 7, fig. 8-6). The difference between these two measurements should be 3.8 cm (1.5 inches) or less. If the difference in measurement exceeds 3.8 cm (1.5 inches), it indicates improper alinement, boresighting, incorrect adjustment of the servo balance, or broken or bent connector pins in the compensation group cabinet. f. If the line-of-sight between the ILCHR and IHIPIR does not exist, aline the sighting target with the vertical crosshair of the M2 aiming circle telescope exactly as done with the IHIPIR aline- ment telescope in par. e above. au rc) 150M (6 IN) MINIMUM cc) 'MS430552 1—Black band sighting target 2Sighting target support ‘3-Circular sighting target 4-Sighting target support 5—Brackets, wire loops, or paper clips Figure 8-0.1. Sighting target and support.cu 8-4. Sequence of Alinement Operations ‘The overall system alinement operation is con- trolled from the BCC or PCP. Personnel in these major items will initiate, monitor, and coordinate the alinement operations for all major items. Figure 8-1 illustrates the sequence of alinement operations for the LCHR as it is alined with the HIPIR. Only the steps pertinent to LCHR aline- ment are shown (unshaded portion). It should be understood that the HIPIR must complete its alinement procedures prior to LCHR aline- ment. 8-5. Orientation and Alinement During Blackout Conditions During blackout conditions, either of the two methods discussed in paragraph 8-2 above may be employed with the assistance of an M53-E1 instru- ment light, stored in the forward compartment. The M109 alinement telescope and fire cutout as- sembly are stored in the forward compartment and the telescope mounting tube is stored in the rear compartment. NOTE The key numbers al refer to figure 8:3, wn below in parentheses The M53-E1 instrument light (5) is used in con- junction with the M109 alinement telescope (1). The M53-E1 contains a battery power lead (6), and a lead with a pen light (2) on the end. This light fits into a bracket (3) which is mounted on the alinement telescope (1). The lamps are illumi- nated by means of a control switch (4). During TH 9—1440—531—12—1 alinement at night, the telescopes on the radars and the LCHR's are sighted on the pen lights. 8-6. Preliminary Procedures Prior to orientation und ulinement of the LCHR, perform steps a through ¢ below. Then perform orientation and alinement procedures in table 8-1. LCHR as described in a, Emplace the paragraph 7-3 through 7- 6. Energize the power generators in with the instructions posted on the inside of the generator panel, and set the output of the genera- tors for 425 vac, Extension cable 10288606 must be used with the single ear headset 10288628 at all times in order to prevent damage to the LCHR communications circuits. ¢. Establish interunit communications in accor- dance with detailed emplacement instructions in paragraph 7-5. 8-7. Synchro Control System Detailed functional schematics of the synchro control system for the HAWK major items are con- tained in TM 9-1425-525-12-2, together with syn- chro alinement procedures. 8-3ca ™ 9—1440—531—12—1 ‘ALINEMENT SEQuence MPR LcHR's sou HetBearion | Y #1 Sreucron cara LOHR/HIPIR i 1 Lene FRONTSIGHT SIGHT ON, ON UCHR iia TeeScore. TELESCOPE ’ secune AzimurH Loex on Fin ebfout ASSEMBLY + RE-INSTALL ALINEMENT, TELESCOPE AND Fine curour ASSEMBLY INTO Cene FRONT COMPARTMENT Y NULL SYNCHRO + BOOM SLEWS TO AZIMUTH AND ELEVATION OF HIPIR ANTENNA WHEN ENERGIZED VERIFICATION = ee FRONTSIGHT Pearonm outa Connective FRonT AND SROCEDURSS as REAM ae Ceence Regu 19 omnes INsUHe Rober ASNEMENT Figure 8-1. Sequence of LCHR alinement operations. MS 432472 Figure 8: Deleted.T™ 9—1440—S31—12—1 MS 164696 1—Alinement telescope 2-Pen light 3-Bracket 4—Control switeh 5—M53-E1 instrument light 6—Battery powered leadcu T™ 9—1440—531—12—1 Table 8-1. Orientation and Alinement Procedure With the IHIPIR Opraton sep Normal indication Corretive procedure NOTE ‘The following procedures are coordinated from the IBCC or IPCP. 1 Preparation. Perform the following procedures in the exact sequence given to prevent injury to personnel. a Direct the ILSCB personnel to set the ILSCB LAUNCHERS OPERATE/SAFE switches (10, fig. 2-10) for the ILCHR being alined to SAFE. 6 On the LC, set the LOCAL-REMOTE switch (10, fig. 2-1) to LOCAL and the MAIN POWER switch (13, fig. 2-1) to OFF. ¢ Install the LC on its tripod 3 m (9.75 ft) or more from the ILCHR. a Insure that the ILCHR is level (refer to par. 7-5a(19)). @ Obtain the telescope support bar (2, fig. 8-4) from its storage location in the ILCHR rear compartment. f Install the telescope support bar in the bracket (3, fig. 8-4) provided on the rear of the ILCHR chassis, on the side away from the IHIPIR. Secure the telescope support bur lock (4, fig. 8-4). o. Remove the alinement telescope and fire cutout assembly (1, fig. 8-4) from the ILCHR for- ward compartment. A Install the alinement telescope and fire cutout assembly on the telescope support bar (2, fig. 8-4). Secure the alinement telescope and fire cutout assembly lock (6, fig. 8-5). Remove the cutout assembly cover und loosen the telescope locks. 2, Obstruction Cutout Switches. NOTE Ignore obstructions at ranges xreater than 2 kilometers a Using the alinement telescope und fire cutout ussembly telescope, scan the horizon and determine the elevation angle of the highest obstruction by reading the elevation indicator (7. fig. 8-5) & Transfer the alinement telescope and fire cutout assembly and support bar to the opposite side of the ILCHR and repeat step a. above. « Set the azimuth override lever (4, fig. 2-11) to the detent which is between 100 und 150 mils above the highest obstruction noted in steps a und b above. a. Adjust the telescope to an elevation of 90 mils. 891 9—1440—531—12—-1 ce Table 8-1, Orientation and Alinement Procedure With the IHIPIR — Continued arma indivation Corrective procure | 26. Scan the horizon and determine if there is an obstruction greater than four switches wide (400 mils). Repeat from the other side of the LCHR. () | Ifthe obstruction sector is not greater than four switches wide, set the minimum elevation lever (1, fig. 2-11) and the elevation fire interrupter lever (1, fig. 2-7) to 150 mils. (2) | Ifthe obstructiva sector exceeds four switches and the azimuth override lever (4, fig. 2-11) is set at or below 600 mils, set the minimum elevation lever (1, fig. 2-ID and the elevation fire interrupter lever (1, fig. 2-7) to 200 mils below the setting of the azimuth override lever (4, fig. 2-1D selected in step ¢ above. () | Ifthe obstruction sector exceeds four switches and the azimuth override lever (4, fig. 2-11 is set above 600 mils, scan the horizon to determine the lowest elevation angle at which no obstruction is more than four switches, then set the minimum elevation lever (1, fig. 2-11) and the elevation fire interrupter lever (1, fig. 2-7) to 60 mils above that angle ‘The minimum elevation lever and the fire interrupter lever shall never be set below 150 mils. NOTE ‘The minimum elevation lever should under no circumstances be set to greater than 400 mils. If the minimum elevation lever setting in step ¢ exceeds 400 mils, relocate the LCHR or set the minimum elevation lever to 200 mils and accept high probability of misfire. f Adjust the alinement telescope to an elevation of 60 mils below the setting of the minimum elevation lever. Sean the horizon and set all azimuth cutouts by setting the appropriate fire cutout switches (4, fig. 8-5). 3. Alinement with the HIPI Antenna. a Direct the HIPIR personnel (1) | Position the HIPIR antenna to 0 mils elevation and engage the elevation STOW lock. Direct the HIPIR personnel not to set the minimum elevation control to less than 190 mils in step @ (2) below. (2) | Insure that the minimum elevation control of the stowed synchro is set to 40 mils above the highest fire interrupter setting of any LCHR of that firing section. b If a line-of-sight exists between the LCHR and HIPIR, proceed directly to step i below. Ifa line-of-sight does not exist, proceed to step c for alternate alinement procedures using the M2 aiming circle. Also refer to the note below.a ™ 9—1440—531—12—1 Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued Operation so Nereis corrective rendre NOTE %. 5 Cont. ‘When performing the alternate alinement procedures, the reference point must be located at least 905 m (1000 ft) from the ILCHR and IHIPIR. The M2 aiming circle must be located at this point and must be visible to both the ILCHR and the HIPIR. © If line-of-sight does not exist, direct the IHIPIR personnel to emplace the M2 aiming circle, and level it using the circular and tubular levels. a When the M2 aiming circle is emplaced: qa Direct the IHIPIR personnel to frontsight the IHIPIR antenna until the vertical crosshair of the IHIPIR alinement telescope is centered on the aiming circle telescope. (2) | Sight the ILCHR alinement telescope (1, fig. 8-5) until the vertical crosshair of the telescope is centered on the aiming circle telescope. e Direct the IHIPIR personnel to: a) Prevent the IHIPIR antenna from moving in azimuth. (2) Record the IHIPIR azimuth mil ring indication. (3) | Adjust the aiming circle azimuth recording knob until the azimuth micrometer indicates 0 mils, (4) | Unlock (fast motion) the azimuth recording knob and rotate the aiming cirele until the azimuth mil ring upper scale indicates approximately 3200 mils. Lock (slow motion) the azimuth recording knob. (5) | Rotate the azimuth recording knob until the azimuth mil ring upper scale indicates 3200 mils. (6) | Unlock (fast motion) the azimuth non-recording orienting knob and frontsight the aiming circle on the IHIPIR telescope. Lock (slow motion) the azimuth nonrecording orienting knob and then adjust the knob for a fine frontsight. £ Direct the IHIPIR personnel to sight the aiming circle on the ILCHR alinement telescope using both the fast and slow motion of the azimuth recording knob. Simultaneously sight the ILCHR alinement telescope on the aiming circle telescope and then record the azimuth angle determined at the M2 aiming. 0 Calculate and adjust for proper azimuth angle as follows: (1) | Subtract the aiming circle azimuth from the ILCHR alinement telescope azimuth. However, if the ILCHR alinement telescope azimuth is less than the aiming circle azimuth, add 6400 mils and then subtract the M2 aiming circle azimuth. (2) Rotate the ILCHR alinement telescope directly to the azimuth value calculated above, and then lock it in position by tightening the azimuth lock (6, fig. 8-4). A Proceed to step j. i If line-of-sight exists, proceed as follows: a Direct the IHIPIR personnel to frontsight the IHIPIR until the vertical crosshair of the IHIPIR alinement telescope is centered on the ILCHR alinement telescope (1, fig. 8-5). (2) Simultaneously sight the ILCHR alinement telescope on the IHIPIR until the vertical crosshair is centered on the IHIPIR alinement telescope. (3) | Lock the ILCHR alinement telescope in position by tightening the azimuth lock (5, fig. 8-4). (4) Direct IHIPIR personnel to record the IHIPIR azimuth mil ring indication.TM 9—1440—531—12—1 cn Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued Sup Operation ermal niin Corrective procedure 35. a) (2) (3) (a) (5) (6) m (8) 9) (ao) a (2) (3) 8-12 ILCHR adjustments are as follows: Remove the ILCHR alinement telescope and fire cutout assembly (1, fig. 8-4) from the telescope support bar (2, fig. 8-4) and install it in the ILCHR front compartment. Connect P9 to J2 and P10 to JI on the fire cutout assembly. Remove and stow the telescope support bar in the ILCHR rear compartment. Unlock the differential generator COARSE ADJUST control (10, fig. 2-11) and set and hold the ALIGN/OPERATE switch (5, fig. 2-11) to ALIGN. NOTE If the ALIGN meter (6, fig. -11) does not indicate as specified in step j (5) below, insure that the cable ‘connections made in step j(1) above have been made correctly. Set and hold the ALIGN NULL/COARSE/FINE switch (11, fig. 2-11) to ALIGN NULL and rotate the differential generator COARSE ADJUST control (10, fig. 2-11) until a null (less than volts) is indicated on the ALIGN meter. Release the ALIGN NULL/COARSE/FINE switch (COARSE) and rotate the differential generator COARSE ADJUST control clockwise only (see note) until another null is indicated on the ALIGN meter. NOTE ‘The indication on the ALIGN meter increases slightly before null is obtained. Set and hold the ALIGN NULL/COARSE/FINE switch to FINE and carefully rotate the differential generator COARSE ADJUST control a small amount in either direction until a fine null is obtained. Release the ALIGN NULL/COARSE/FINE switch. Release the ALIGN/OPERATE switch. Lock the differential generator COARSE ADJUST control. Direct the IHIPIR personnel to position the antenna to 200 mils elevation. ‘The ILCHR boom is subject to movement while the HYD PRESS s HYD PRESS position. Failure to perform step [(1) below may cause injury to personnel. ILCHR servo cheek: Clear the boom radius of rotation before performing the next operation. Set the MAIN POWER switch (13, fig. 2-1) to MAIN POWER, and set the HYD PRESS switch (9, fig. 2-1) to HYD PRESS. Set the ALIGN switch (8, fig. 2-1) to ALIGN. ‘The launcher boom slews in response to the IHIPIR position commands. Position accuracy is checked by alinement verification procedure (step 4).au TM 9—1440—531—12—1 Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued met teem corre posers a) @) @) Alinement Verification. Before performing the alinement verification, direct the IHIPIR personnel to i that the IHIPIR is in false radiate and the LOCAL/REMOTE switeh i LOCAL position. If line-of-sight does not exist between the ILCHR and IHIPIR, proceed directly to step d below. If line-of-sight exists and missiles are emplaced on the ILCHR, proceed to step c below. If line-of-sight exists and there are no missiles on the ILCHR, proceed to step b. Uf line-of-sight exists and there are no missiles on the ILCHR: Place the missile latch levers (2, fig. 2-9) in the latched (down) position. The ILCHR boom will slew during the following steps. Clear the boom radius of rotation. NOTE For certain emplacements, the ILCHR missile holdback hook (1, fig. 8-6) or the missile retaining stud (3, fig. 8-6) may be masked when viewed through the IHIPIR alinement telescope in step &(2) below. In this case, direct the IHIPIR personnel to raise or lower the antenna until the missile holdback hook and the ‘missile retaining stud can be viewed through the IHIPIR alinement telescope. NOTE ‘The missile holdback hook and the missile retaining stud used in step b{2) below are located on the ILCHR arm closest to the ILCHR alinement telescope position (3, fig. &-7). Direct the IHIPIR personnel to rotate the IHIPIR antenna until the vertical crosshair of the IHIPIR alinement telescope is alined with the missile holdback hook and the missile retaining stud. ‘The telescope crosshair is sighted on some portion of both the missile holdback hook and the missile retaining stud. Rotate the IHIPIR antenna to the azimuth value recorded in step 3i(4); proceed to step (1) below for alternate alinement verification procedure. Proceed to step 5.TM 9—1440—531—121 cu Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued era inns Corre procedure a (2) (3) (4) (5) (6) @ (8) () 8-12.2 Uf line-of-sight exists and there are missiles on the ILCHR: ‘The ILCHR boom will slew during the following steps. Clear the boom radius of rotation. Direct the IHIPIR personnel to insure that the IHIPIR antenna is at the azimuth mil ring indication recorded in step 3i(4). Record the ILCHR azimuth mil ring (2, fig. 8-6) indication. Set the HYD PRESS switch (9, fig. 2-1) to OFF. ‘The hoom support does not move in azimuth. Open the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4) and manually position the ILCHR boom to the azimuth valve recorded in step c(2) above. NOTE ‘The measurements in step c(4) through (9) below are made from the front and rear of the ILCHR arm closest to the ILCHR alinement telescope position. If there are no missiles on the ILCHR, the front reference point is the missile holdback hook (1, fig. 6) and the rear reference point is the missile retaining stud (3, fig. 8-6). If there are mistiles on the ILCHR, the front reference point (4 fig. 8-6) is on the tunnel (6, fig. £6), approximately 2.5 cm (1 inch) back from the missile holdback hook; the rear reference point (7, fig. £-6) is on the tunnel immediately behind the elevon (6, fig. 8-6). NOTE Refer to par. 8-3 for construction of sighting target used in steps ¢ (4) through (9) below. Direct the IHIPIR personnel to view through the IHIPIR alinement telescope. Simultaneously place the sighting target support (1, fig. 8-7) at the front reference point. ‘Move the sighting target (2, fig 8-7) along the support until the IHIPIR personnel signals that the sighting target is alined with the vertical crosshair of the IHIPIR alinement telescope. If the IHIPIR personnel cannot see the target in alinement telescope, see note below. NOTE For certain emplacements, the sighting target may be masked when viewed through the IHIPIR ‘alinement telescope. In this case, direct the IHIPIR personnel to raise or lower the antenna until the sighting target can be viewed through the telescope. Measure and record the distance = (fig. 8-7) between the front reference point and the IHIPIR alinement telescope line-of-sight. Move the sighting-target support to the rear reference point. Repeat step (5) above, measuring and recording the distance y (fig. 8-7) between the rear reference point and the IHIPIR alinement telescope line-of-sight. Determine the difference between the distances recorded in steps o(6) and (8) above. ‘The difference is 3.8 em (1.5 inches) or less. Recheck orientation and alinement with the IHIPIR (step 3). Check azimuth positioning servo balance (table 3-16, step 5), servo dynamic performance (table 3-16, steps 8a through k). Check for broken or bent pins in the compensation group cabinet.on TM 9—1440—531—12-1 Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued ‘Operation w= Nee pers 4e. Cont. (10) | If the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4) was opened in step c(3) above, close the valve. ‘The ILCHR boom is subject to movement while the HYD PRESS switch is in the HYD PRESS position. Clear the boom radius of rotation. (11) | Set the HYD PRESS switch (9, fig. 2-1) to HYD PRESS. (12) | Proceed to step 5. a If line-of-sight does not exist. ‘The ILCHR boom will slew during the following steps. Clear the boom radius of rotation. q@) Direct the IHIPIR personnel to: (a) Rotate the IHIPIR antenna to the azimuth mil reading in step 3i(4). (b) Add the aiming cirele azimuth value reeorded in step 9f to the IHIPIR azimuth value recorded in step 3e(2). If the sum exceeds 6400, subtract 6400 from the sum. (c) Rotate the IHIPIR antenna to the azimuth value caleulated above. ‘The ILCHR boom slews ia response to the IHIPIR position commands. (2) Record the ILCHR azimuth mil ring (2, fig. 8-6) indication. (3) Set the HYD PRESS switch (9, fig. 2-1) to OFF. The hoom support does not move in azimuth. Open the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4) and manually position the ILCHR boom to the azimuth value recorded in step d(2) above. NOTE ‘The measurements in steps d(4) through (8) below are made from the front and the rear of the ILCHR ‘arm closest to the ILCHR alinement telescope position. If there are no missiles on the ILCHER, the front reference point is the missile holdback hook (I, fig. 8-6), and rear reference point is the missile retaining stud (3, fig. 8-6). If there are mussiles on the ILCHR, the front reference point (4 fg. 8-6) is on the tunnel (6, fig. 8-6), approximately 25 em (1 inch) back from the missile holdback hook. The rear reference point (fig. 86) ison the tunnel immediately behind the elevon (6, fig. 8-6). 8-12.3TM 9—1440—531—12—1 cn Table 8-1. Orientation and Alinement Procedure With the IHIPIR — Continued Operation Corrie prosedre 4d(4) ©) 6) m (8) (9) (10) (qn) 8-12.4 NOTE Refer to par. 8-3 for construction of the sighting target used in steps d(4) through (8) below. Direct the IHIPIR personnel to view through the M2 aiming circle telescope. Simultaneously, place the sighting target support (1, fig. 8-7) at the front reference point. Move the sighting target (2, fig. 8-7) along the support until the IHIPIR personnel signals that the sighting target is alined with the vertical crosshair of the M2 aiming circle telescope. If the THIPIR personnel cannot see the target in the M2 aiming circle telescope, see note below. NOTE For certain emplacements, the sighting target may be masked when viewed through the M2 aiming circle ‘telescope. In this case, direct the IHIPIR personnel to raise or lower the aiming circle telescope until the sighting target can be viewed through the telescope. Measure and record the distance x (fig. 8-7) between the front reference point and the M2 aiming circle telescope line-of-sight. Move the sighting target support to the rear reference point. Repeat step (5) above, measuring and recording the distance y (fig. 8-7) between the rear reference point and the M2 aiming circle telescope line-of-sight. Determine the difference between the distances recorded in steps (6) and (8) above. The difference is 3.8 em (1.5 inches) or less. Recheck orientation and alinement with the IHIPIR (step 3). Check the azimuth positioning servo balance (table 3-16, step 5), and servo dynamic performance (table 3-16, step 8a through 4). Check for broken or bent pins in the compensation group cabinet, If the MANUAL AZIMUTH MOVEMENT VALVE (3, fig. 2-4) was opened in step d(3) above, close the valve. ‘The launcher boom is subject to movement while the HYD PRESS switch (9, fig. 2-1) is in the HYD PRESS position. Clear the boom radius of rotation. Set the HYD PRESS switch (9, fig. 2-1) to HYD PRESS. Launcher Orientation. Direct the IHIPIR personnel to rotate the IHIPIR antenna to the center of the fire section sector, or to the desired stow azimuth of the ILCHR. Observe that the ILCHR slewed to the IHIPIR stowed azimuth and note the mil indication below the red indicator on the ILCHR azimuth mil ring (2, fig. 8-6). Rotate the azimuth handwheel (7, fig. 2-1) until the azimuth indicator dial (4, fig. 2-1) indicates the same azimuth value as step b above. This is the stow azimuth of the ILCHR. ‘Set the ALIGN switch to OFF (8, fig. 2-1). Direct the IHIPIR personnel to rotate the antenna to 0 mils azimuth.an TM 9—1440—531—12—1 Table &-1. Orientation and Alinement Procedure With the IHIPIR — Continued Operation ermal anion qa) (2) (3) The ILCHR boom will slew during steps g and j below. Clear the boom radius of rotation. Ingure that the ILCHR is cleared. Set the ALIGN switch to ALIGN (8, fig. 2-1). Record the mil indication below the red indicator on the azimuth mil ring. This value will be used in ILCHR alignment checks (TM 9—1430—526—12—1, TM 9—1430—535—12—1, TM 9—1430—1526—12—1, or TM 9—1430—1535—12—1). Observe the elevation dial (3, fig. 2-8) located on the side of the elevation actuator trunnion. The elevation dial indicates 175 to 225 mils. Set the ALIGN switch (8, fig. 2-1) to OFF. ‘The ILCHR slews to the stow azimuth of the LCU azimuth indicator dial. Direct the ILCHR and IHIPIR personnel to repeat steps 3 and 4 for the remaining ILCHR’s. Direct the IHIPIR personnel to insure that the LOCAL-REMOTE switch is set to LOCAL. Insure that the LCU controls and indicators (fig. 2-1) are set as follows: ALIGN switeh .. OFF. HYD PRESS switch OFF. MAIN POWER switch OFF. LOCAL-REMOTE switch LOCAL. e125—Alinement telescope and fire cutout assembly —Telexenpe support bar 3—Teleseupee support bar bracket 4—Teleseupee support bat lock Azimuth lock Figure 8-4. Alinement telescope and fire cutout ‘assem bly-mounted. Figure 8-5. TM 91440531121 1—Telereope -—Telexcope lockout |— Elevation lockout 4—Fire cutout switches — Azimuth lock — Axsembly lock 7—Elevation indicator Alinement telescope and fire cutout assembly. 8-13cn TM 9—1440—531—12-1 oD |—Miasile holdback hook (ILCHR front reference point) ‘7—Rear reference point (missile) Figure 8-6. ILCHR and missile reference points. ‘6-Elevon a-14a TM 9—1440—$31—12—1 8430551, 1 Sighting target support 2-Sighting target ‘3~Launcher alinement telescope Figure 8-7. Azimuth alinement verification using sighting target.TM 9—1440—531—12—1 Section I. 8-8. Introduction This section explains how to read the azimuth mil ring and the vernier scale. Part A of figure 8-8 illustrates the vernier scale, while part B illustrates the azimuth mil ring. These two items provide LCHR boom position data. The azimuth mil ring is read to provide accurate data to within 50 mils, while the vernier scale is used to provide accurate data to within 10 mils. The azimuth mil ring data, together with the vernier scale data, provides the LCHR boom azimuth mil ring reading. 8-9. Description of the Azimuth Mil Ring @. Azimuth Mil Ring. When the LCHR boom is oriented and alined, the azimuth mil ring, lined up with the zero (0) mark on the vernier scale can be read to obtain the LCHR boom position in mils. The azimuth mil ring contains 128 equally-spaced marks which divide the azimuth mil ring into 50-mil sections equalling 6400 mils. These marks are all the same length, Every other mark has a number, begin- ning with zero (0) (6, fig. 8-8). The zero (0) mark has ‘a value of zero mils or 6400 mils. These numbers continue with 100 (6, fig. 8-8), which has a value of 100 mils, and 200 which has a value of 200 mils. This is followed by 300, which has a value of 300 mils, and 0 on, through 6300 (4, fig. 8-8), which has a value of 6300 mils, and finally to zero with a value of 6400 mils. The marks located between numbered marks divide that area into two 50-mil sections. The azimuth mil ring is fixed and cannot be adjusted. b. Vernier Scale, The vernier scale is so mounted that it can be used to aid in reading the azimuth mil ring. The value of the azimuth mil ring is always read at a point exactly opposite the zero (0) mark on the vernier scale. There are 11 marks that divide the vernier scale into 10 equal sections. The first, mid- dle, and last marks are numbered 50, zero (0), and 50 (1,2, and 3, fig. 8-8). The short marks between 50 and zero (0), and between zero (0) and 50, are not numbered, but have a value of 10 mils each. The vernier scale is divided into two groups. These are zero (0) to 50 going in a cw direction, and zero (0) to 50 going in a cew direction. The cw group is used to read the azimuth mil ring setting between zero (0) and 3200 mils. The ccw group is used to read the azimuth mil ring setting between 6400 mils and 3200 mils. The position of the vernier scale is fixed and cannot be adjusted. 8-16 ca AZIMUTH MIL RING 8-10. How to Read the Azimuth Mil Ring Using the Vernier Scale (Fig. 8-9) The azimuth mil ring reading when used with the vernier scale indicates the boom azimuth position in mils. The azimuth mil ring reading is always taken opposite the zero (0) mark on the vernier scale. Part A of figure 8-9 shows the vernier scale zero mark lined up with the 50-mil mark on the azimuth mil ring. This value is read cw. In this example, the azimuth mil ring reading simply reads 50 mils. Part C of figure 8-9 shows the vernier scale zero (0) mark lined up with the 6350-mil mark on the azimuth mil ring. This value is read cew. But a simple mil ring reading is not always possible. Often, the azimuth mil ring must be read, using the vernier as shown in part B of figure 8-9. In this situation, notice that the vernier scale zero mark is not lined up with an azimuth mil ring mark. Instead, the zero mark is somewhere between 50 mils and 100 mils and in acw direction. This means that the reading is at least 50 mils, but less than 100 mils. The vernier scale now must be used to indicate the number of mils between 50 and 100. This number is more than zero but less than 50. When located, this number is added to 50 to complete the azimuth mil ring reading. This is how the vernier seale is read. Observe the location of the azimuth mil ring 50-mil mark with respect to the vernier scale. Notice that this mark lies between the 20- and 30-mil markson the vernier scale. Added to 50 mils, the azimuth mil ring reading is now placed between 70 and 80 mils. A second and closer look at the vernier scale is needed to determine the number of mils between 20 and 30. The azimuth mil ring 50-mil mark appears to divide this are equal sections of five mils each. The vernier scale reading is approximately 25 mils. The azimuth mil ring reading of 50 mils plus the vernier scale reading of 25 mils totals 75 mils. The azimuth mil ring reading then is approximately 75 mils. In part D of figure 8-9, the vernier scale zero (0) mark is between the azimuth mil marks of 6300 and 6350 mils. This means that the azimuth mil ring reading is more than 6300 but less than 6350 mils. To obtain the total reading, add the azimuth mil ring reading to the vernier scale reading. Observe the location of the azimuth mil ring 6350-mil mark with respect to the vernier scale. Notice that it lies between the 20-and 30-mil marks on the vernier scale, Added to 6300 mils,theazimuth mil ring reading is placed between 6330 and 6320 mils. A second and closer look at thevernier scale is needed to determine the number of mils between 30 and 20. The azimuth mil ringcue ™ 9—1440—531—12—1 6300-mil mark appears to divide this area into two ring reading of 6300 mils plus the verier scale equal sections of five mils each. The vernier scale reading of 25 mils totals 6325 mils. The azimuth reading is approximately 26 mils. The azimuth mil _mil ring reading then is approximately 6325 mils. 2 7 ~— an 100 ° 6300 6200 (PAT © AZIMUTH MK Re Ws 432873 5-0 (zero) mile 6-100 (100 mils) Figure 8-8, Azimuth mil ring/vernier sale. (ART C4980 mis (Cow? ‘VERNIEN SCALE 30 eis 50 0 6300 AZIMUTH ML RIN, PART 0-4308 MILB (CCW) ) PART 0-75 wns (ew) MS 432474 Figure 8-8, How to read the azimuth mil ring.12 ™ 9—1440—531—12—1 CHAPTER 9 LIGHTNING PROTECTION 9-1. Scope a. This chapter contains instructions for protect- ing the ILCHR from direct and indirect lightning strikes. Standard battery and platoon emplacement procedures require equipment grounding. However, lightning protection is also required in areas where the battery site is higher than the surrounding terrain and in areas where severe electrical storms are experienced. b. Individual site requirements may dictate changes in the procedures described in this chapter. Changes are permissible as long as equivalent pro- tection is provided for the system. 9-2. Lightning Red Design and Construction @, General. The procedures contained in this paragraph are used to design, construct, and em- place a lightning rod for the ILCHR. Once emplaced, the lightning rod is connected to the ILCHR light- ning protection ground system. The presence of a well-grounded lightning rod for the ILCHR protects the ILCHR from direct lightning strikes and light- ning-induced current surges. . Cone of Protection. The “cone of protection” concept is used in the following procedures to protect the ILCHR. A cone of protection starts at the high- est point of a vertical shielding conductor, and extends conically downward. The shielding conduc- ‘tor provides lightning protection for all items or structures completely enelosed by the cone. The radi- 1s of the circular base of the cone defines the ground area protected by the vertical shielding conductor. This radius is equal to twice the height of the vertical shielding conductor (fig. 9-1). c. Design and Construction. Fabricate a light- ning protection assembly for each ILCHR in accordance with figures 9-2 and 9-3. Refer to table $1 for a list of materials required. NOTE ‘Secure the clamp and bracket on the wooden post 30 ‘that the mast may be lowered away from the ILCHR whenever missiles are left on the ILCHR (or on another nearby ILCHR) in the ARMED position, 9-3. Lightning Red Emplacement Procedures The following are the detailed procedures for emplacing the vertical shielding conductor and mast assemblies fabricated according to paragraph 9-2c. Do not connect the equipment ground system to the lightning protection ground system. To do so will result in serious damage to electronic equipment in the event of a lightning strike. a. Emplace the shielding conductor mast with vertical shielding conduetor 1.8 m (6 ft) from the equipment being protected. NOTE: THE RADIUS OF THE COME ISEQUAL TO Twice ITS HEIGHT WeIGNT OF COME _t___¢ MI 70656 Figure 9-1, Cone of protection concept.™ 9—1440—531—12—1 12 CAUTION | DO NOT CONNECT THE EQUIPMENT GROUND ROD TO THE SHIELDING CONDUCTOR GROUND ROD. 5.9m 4.9m “tise tig ———— er (19.4) NO.6 COPPER WIRE 1.83 (6ft.) iy MIN BONDING CONDUCTOR : + BONDING CONDUCTOR EQUIPMENT. GROUND ROD SHIELDING. CONDUCTOR GROUND ROD (MAXIMUM DISTANCE Pt VERTICAL SHIELDING. SHIELDING _ CONDUCTOR CONDUCTOR GROUND ROD MAST EQUIPMENT, GROUND ROD MI 70657E Figure 9-2, ILCHR lightning protection layout.2 NOTE ‘The above distance is measured fr ‘conductor mast to the tip of the mi the shielding radome. 0. If the shielding conductor mast must be em- placed more than 1.8 m (6 ft) from the equipment, inerease the height of the mast by one-half the added distance. This keeps the equipment within the cone of protection. NOTE If the equipment is located on a mound or tower, increase the height of the shielding conductor mast by an amount equal to the height of the mound or tower. ¢. Extend the shielding conductor 60 cm (2 ft) above the top of the mast. This provides an air terminal to intercept the electrical discharge at a safe distance above vulnerable and flammable parts or structures. d. Use a 1.8 m (6 ft) length of hollowed wood molding to protect the shielding conductor from mechanical damage at ground level. e. If a lightning protection ground rod is not emplaced for the equipment being protected, em- place a 1.8 m (6 ft) shielding conductor ground rod at least 1.8 m (6 ft) beyond the mast (at least 3.6 m (12 {t) from the equipment being protected). The T™ 9—1440—531—12-1 distance between the shielding conductor ground rod and the equipment ground rod should be as large as possible. NOTE If bedrock prevents driving the shielding conductor ground rod 1.8 m (6 ft) deep, dig a radial trench 36 1m long by 0.914 m deep (12 ft by 3 ft) from the base of the mast and away from the equipment being protected. Connect No. 2 copper wire to the vertical ‘shielding conductor, and bury the wire in the trench. Ff. Drive the shielding conductor ground rod at least flush with the ground. If possible, drive the ground rod 30 cm (1 ft) below the soil surface. NOTE Refer to TM 914251525, appendix F, for detailed instructions for measuring the resistance of the tning protection ground rod or buried wire. If the measured resistance is more than 10 ohms, use the procedures contained in TM 91425 1525, appendix F, to reduce the resistance to 10 ohms or less. 9. Connect a bonding conductor of No. 2 AWG copper wire between the base of the shielding conductor and the ground rod using silver epoxy material. Bury the bonding conductor at least 60 em (2 ft) underground. The soil above the buried wire should be compressed to increase soil contact. Table 9-1. Materials Required for each ILCHR ATOMatioal Deseriton ‘Stock No Mast, wooden, 10.2 em X 102 em X 805 m (4 in. X 4in. X 10 ft) Rod, ground, 1.83 m X 1.59 em (6 ft X 5/8 in) '5975-00-206-0762, Wire, copper, No. 2, 27 m (88.6 ft) Staples, 254 em X 0.95 em (1 in. X 9/8 in.) 5315-00-161-9862 Mast sections 977 m X 1.11 em (8 ft 219/32 in. X 7/16 in.) '5820-00-199-8842 099 m X 1.21 em (8 ft 8-7/82 in. X 1/2 in.) '5820-00-155-8151 (0.998 m X 1.43 em (8 ft $-19/64 in. x 9/16 in.) '5820-00-1565-8190 1.008 m X 1.59 em (8 ft 1/2 in. X 5/8 in.) $5820-00-155-8129 11.006 m % 1.75 em (8 ft 889/64 in. X 11/16 in.) '5820-00-166-1055 Clamp & Bracket as in figure 9-3, 1 set. ‘Molding, Ranier wood, ground wire, No. RGM-2, 1.83 m (6 ft) ‘Staples, 7.62 em (3 in.) long, 0.95 cm (3/8 in.) di.TM 9—1440—531—12—1 WOODEN POST 4 PO Sem (3/4in.) 1.8¢m (IV/Iéin,) DIA, 0.6cm STEEL ROD THREADED BOTH ENDS 1/4~ 20 NC 1.9m (3/4in.) V2 lem (4-9/4in.) CONNECT BONDING CONDUCTOR HERE MI 70658B Figure 9-8. Bracket assembly for attaching the mast to the post. cyTM 9—1440—531— 12-1 APPENDIX A REFERENCES Refer to TM 9-1425-525-L for a list of other publications pertinent to this material and associated equipment. ra)TM 9—1440—531—12—1 APPENDIX B MAINTENANCE ALLOCATION CHART B-1. General ‘This appendix provides a summary of the main- ‘tenance operations covered in the equipment man- uals. It authorizes categories of maintenance for specific maintenance functions on repairable items and components, and the tools and equipment required to perform each function. This appendix may be used as an aid in planning maintenance operations. 8-2. Explanation of Format for MAC Page a. Group Number. The numbers in this column identify components, assemblies, and modules within the next higher assembly. b, Functional Group. This column lists the item names of component units, assemblies, subassemb- ies, and modules on which maintenance is au- thorized. ¢. Component/Assembly. This column indicates the maintenance category at which performance of the specific maintenance function is authorized. Authorization to perform a function at any cate- gory also includes authorization to perform that function at higner categories. Maintenance functions will be limited to and defined as follows: (1) Inapect. To determine serviceability of an item by comparing its physical, mechanical, and electrical characteristics with established stand- ards. (2) Test. To verify serviceability and to detect. electrical or mechanical failure by use of test ‘equipment. (8) Service. To clean, preserve, to char to add fuel, lubricants, cooling agents, and ai (A) Adjust. To rectify to the extent necessary to bring into proper operating range. (5) Aline, To adjust specified variable el- ements of an item to bring to optimum perfor- mance. . (6) Calibrate. To determine the corrections to be made in the readings of instruments of test equipment used in precise measurement. Consists of the comparison of two instruments, one of and which is a certified standard of known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared with the cer- tified standard. (7) Install. To set up for use in an operational environment such as an emplacement site or vehiele. (8) Replace. To replace unserviceable items with serviceable assemblies, subassemblies, or parts. (9) Repair. To restore an item to serviceable condition. This includes, but is not limited to, inspection, cleaning, preserving, adjusting, replac- ing, welding, riveting, and strengthening. (10) Overhaul. To restore an item to a com- pletely serviceable condition as prescribed by maintenance serviceability standards using the Inspect and Repair Only as Necessary (IROAN) technique. d, Maintenance Category. The codes used represent the various maintenance categories as follows: Code Maintenance category C ——Operator/crew © Organizational maintenance F _ Direct support maintenance H General support maintenance D _ Depot maintenance ‘The figures in the columns represent the manhours required to perform the function. @. Tools and Equipment. The numbers appear- ing in this column refer to specific tools and equip- ment which are identified by these numbers in the tools required page. 8-3. Explanation of Format for Tools Required Pages a. Tools or Test Equipment Reference Code. ‘The numbers in this column correspond to the numbers used in the tool required column of the MAC. The numbers indicate the applicable tool for the maintenance function. erTm 91440531121 b. Maintenance Category. The codes in this col- umn indicate the maintenance category normally allocated the facility. ¢. Nomenclature. This column lists tools, test kits, test and maintenance equipment required to perform the maintenance functions. a2 a d. National/NATO Stock Number. This column lists the National/NATO stock number. €. Tool Number. This column lists the part number.a T 91440531121 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 o a o “ ts) GROUP ‘yom COMPONENT/ASSEMBLY _| MAINTENANCE FUNCTION 0100 | Guided Missile Launcher, | Inspect [0.4 ¥i92z1 Test 40 Service {1.0 Adjust 1. Align 6. Calibrate Install [0.5 Replace [0.5 Repair 3.0 Overhaul 999 0900 | Intercommunication Inspect | 0. Bracket Inst. Service 0. Repair 0.2 1000 | Communication Station Inspect 0.1 Test 0.2 Service 0.1 Adjust 0,2 Replace 0.2 Repair 0.4 Overhaul 20.0 1010 Cover Assembly Inspect Replace Repair 0 1020 Wiring Harness Inspect 0. Test 0. Replace 0 Repair 0. 1030 Wiring Harness Inspect 0, Test 0. Replace 0. Repair 0. "© opeaterferem © orpanisnionat F - direct mppert HH gerarl mppert D - depot a3TM 9—1440—531—12—-1 o ‘NUM. BER MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 2 COMPONENT/ASSEMBLY 1066, 1070 1090 2000 3000 3100 3110 Cable Assembly, Intervehicular Tripod Assembly Plate, Base Cable Assembly, LC U Mechanism Installation Instrument Assembly, Elevation Gear Assembly Inspect Service Replace Repair Inspect Test Service Replace Repair Inspect Test Service Adjust Replace Repair Overhaul Inspect Service Adjust Replace Repair Inspect Replace Repair 0.1 0.2 0.3 2,3,6 °C opsrtorierew 0 - erpunisations! F - rect support H.- ganaral sport - dopat a4rar) ™ 91440531121 MAINTENANCE ALLOCATION CHART for mre GUIDED MISSILE, real CHART NUMBER 10674109 o “ 8 coro [mens eee Boom, Launcher Inspect Test Service 0.5 Adjust Align Replace Repair Overhaul 16.0 4100 Switch Assembly, Inspect |0.2 Missile Sensing Test 0.2 Service |0.4 Replace 1.3 6 Repair 1.3 Overhaul 4.0 4200 Hydraulic Installation | Inspect | 0. Service |0 Repair ll 4210 Cooler, Hydraulic 011 | Inspect | 0.1 Test 0.2 Service 0.2 Replace 0.5 6,10 Repair 0.7 4215 Cooler Assembly Inspect 0.2 Replace LS 6,10 Repair 1.5 Pan Assembly Inspect 0.3 Replace 0.9 6,10 Repair 1.5) 4225 4230 | Fan, Axial Inspect 0. Test 0. Replace 0. Repair 0. Valve Assembly Inspect 0.2 Test Service Replace Repair 4235 6,10 *C- operetorerew © - orpniaational F - divct support Hi - ganarl wipport D - depot ‘Sa FOFR 1134, 1 FEB 75 PREVIOUS EDITION 1S OBSOLETE as™ 9—1440—531—12—1 cn MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 pu aa C “ s ‘GROUP wae COMPONENT/ASSEMBLY 4240 Filter Assembly, Elevation Inspect Test Replace Repair 4260 Shock Absorber Inspect Replace Repair Overhaul 4300 Bracket Assembly, Hydraulic O11 Inspect Replace Repair 4400 Support Assembly, Rear | Inspect Service Adjust Inspect Service Replace Repair 4480 Housing Assembly, Downstep Switch Inspect Test Service Adjust Align Repla Repair Overhaul 4500 Support Assembly, Missile, Forward 6,10 + C- operatorierew © - rganiertionsl Greet support Hl ganarl support - depot ‘Sal FORM 1134, 1 FEB 75 PREVIOUS EDITION 18 OBSOLETECd ™ 91440831121 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 Shock Absorber 6,10 4520 Service Adjust . Replace \ Repair 4530 Sector Assembly, Inspect Support Service 0.2 Adjust 0.5 Align 0.6 Replace 0.3 Repair 0.6 Inspect Replace Repair 4540 Finger Assembly Crank Assembly Inspect Replace Repair 4550 8600 Interrupter Installa- | Inspect tion Test 0.2 Service 0.2 Replace 0.3 Repatr 0.5 Overhaul 12.0 Inspect O21 Replace 0.2 Repair 0.3 4605 Turnbuckle Assembly Inspect Test Service Replace Repair Overhaul 4610 Interrupter Assembly "© eperstorerew © - crpanizationsl F Greet support Hi genarl support - depot aTH 9—1440—531—12-1 o MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 @ COMPONENT/ASSEMBLY Wiring Harness Lever Assembly Arm Assembly Electrical Installation| Control Unit, ‘Temperature Control Unit Distribution Box, Igniter © opaatereren 0 = orpmisetionel Fret mepport MH - gear! nepport OD - depot™ 9—1440—531—12-1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILZ, M192E1, CHART NUMBER 10674109 o 2 COMPONENT/ASBEMBLY Supporter, Loader, Indes, R. H. (Cont'd) 4797 Supporter, Loader Index, L. H. ' 0.6 Replace 0.5 Repair 0.6 4798 Outrigger Assembly, | Inspect | 0.1 Front Service | 0.2 Align 0.5 Replace 0.6 Repair 0.8 4799 Outrigger Assembly, | Inspect | 0.1 Rear Service | 0.2 Align 0.5 Replace 0.6 Repair 0.8 4800 Support Assembly, Inspect | 0.1 Outriggers Service | 0.1 Replace 0.3 Repair 0.4 5000 Actuator Installation] Inspect | 0.1 Test 0.2 Service 0.2 Repair 12 5100 Traneducer, Elevation | Inspect 0.21 Test 0.2 Service O.1 Replace 1.2 6 Repair 1.2 Overhaul 4.0 5200 Valve Assembly Inspect. 0.1 Test 0.2 Service On Replace 5 C epersterierew © - orgaiztionsl F - dect support - ger wwpport 0 - depot woTH 9—1440—531—12—1 a MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, waszEl, CHART NUMBER 10674109 o. “ » Lae ae peTot+ [«Te| Valve Assembly (cont) Repair Overhaul (CONT) 5300 | Cylinder Assembly Inspect Test Service Replace Repair Overhaul 5400 | Valve Assembly Inspect Test Service Replace 1S 5500 | Bearing Unit Inspect {0. Service 0. Replace 0. Repair 0. 6000 | Support Assembly, Boom Inspect Service Replace 3.0 Repair 6100 | Hydraulic Installation | Inspect Service Repair Replace Repair Valve Assembly Inspect Test Replace Repair Inspect Replace 6102 3 0. 0. oO 6101 | Filter Assembly Inspect 0. 0, 0, 0, 0, 6103 | Valve Assembly Switch Assembly *C- eperatorfren © - expenizndonat F + Greet mppert H- penral mappert 0 - depot w10a T™ 9—1440—531—12—-1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART WUMBER 10676109 Valve Assembly Inspect Replace Valve Assembly Inspect Test Replace Valve Assembly Inspect Replace ‘ Valve Assembly Inspect Test Service Valve Assembly Valve Assembly Filter Assembly, Azimuth Valve Assembly Filter Assembly, Main System 0 - eperaterorew © - erpunianlonal F = dest euppert H.- general suppert © - depot onTa 9—1440—$31—12—1 a MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 m am “ Accumulator Hydraulic Pump, Motor Assembly Electrical Installation Contact Assembly Azimuth Dist. Box Installation wa9 T™ 91440-53112. 1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 o " @ ow s Azimuth Drive & Data Installation 6410 Drive & Data Assembly 6415 Drive Assembly, Power Control 80.0 5100 ‘Transducer Assembly, Azimuth 0.2 0.5 I 1S 8.0 6420 Manifold Assembly 0.2 1.0 6430 Valve, Overload Relief 0.3 6 1.8 7.0 Motor, Hydraulic + © epuotrirew © = erginndonsl = dreet mopert H- pearl wepert D = dapatTH 9—1440—531—12-1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 o wm ta “ » MAINTENANCE FUNCTION. [—¢ COMPONENT/ASSEMBLY 6450 Valve, Solenoid Inspect Test Service Replace Repair Overhaul 6465 Drive Assembly, Data | Inspect Service Adjust Replace Repair Overhaul 6470 Gear Assembly, Synchrq Inspect Replace Repair 6475 Cover Assembly Inspect Replace Repair 6480 Box, Stowage Inspect Replace Repair 6485 Clamp Assembly Inspect Replace Repair 6490 Ring Support Inspect Replace Repair 6500 Support Assembly Inspect Replace Repair Base, Launcher Inspect Service « | Repair 7000 Hydraulic Installation ae™ 9—1440—531—12—1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 o 2 a w GROUP ‘NUM. BER COMPONENT/ASSEMBLY 7105 Pump Assembly, Hand | Inspect Test Service Replace 1.2 6 Repair 0.8 7110 Cylinder Assembly Inspect | 0.1 Test 0.2 Service | 0.3 Replace 0.5 6 Repair 1.2 Overhaul hho.0 7120 Cylinder Assembly Inspect | 0.3 Test 0.2 Service | 0.5 Replace 0.9 6 Repair Overhaul 7130 Panel Assembly Inspect 0.3 Replace 1.3 7135 Valve Assembly Inspect | 0.8 Test 0.3 Service ° Replace 1 Repair La. 7145 Valve Assembly Inspect | 0.8 Replace 0.7 6 6103 Assembly Inepect | 0.8 0.3 Repair LS 7165 Valve Assembly Inspect | 0.8 ‘Gal FORM 1194, 1 FEB 78 PREVIOUS EDITION 16 OBSOLETE as™ 9. 440531121 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 2 GROUP ‘NUM. BER 7175 7200 7205 7325 7330 7340 7345 * C operttorierew © - erpanizational F direct support H- gener weport 0 COMPONENT/ASSEMBLY Valve Assembly Electrical Installa~ tion, Base Stop Light Assembly Power Supply, E.P.U. Sight, Launcher Emplacement Distribution Box, Base Wiring Harness MAINTENANCE FUNCTION Inspect Test Service Replace Repair Inspect Service Repair Inspect Test Replace Repair Inspect Test Service Replace Repair Overhaul Inspect Test Service Adjust Align Replace Repair Overhaul Inspect Test Service Replace Repair Overhaul Inspect Test Replace Repair e°°o BOL 0.2 0.5 ‘941 FORM 1194, 1 FEB 75 PREVIOUS EDITION IS OBSOLETE B16 eo bn ecco @ubn 0.2 2.0 0.4 0.4 0.5 8.0 30.0 3.0 3.0 14.0 cn7355 7360 7361 7363 7365 7370 7375 7377 7378 7380 7385 C- epersterferen © - erpeiaalonal direct vupport Hi. mere eppert D - dopet MAINTENANCE ALLOCATION CHART for T™ 9—1440—531—12—1 ee GUIDED MISSILE, waszEl, CHART NUMBER 10674109 Wiring Harness Relay Assembly Terminal Board ‘Assembly Terminal Board Assembly Cover Assembly Terminal Board Assembly Relay, Transformer ‘Assembly Terminal Board ‘Assembly Terminal Board ‘Assembly Corrector Group Wiring Harness Inspect Test Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Replace Repair Inspect Service, Repair Inspect Test Service a7™ 9—1440—31. 7415 7425 7430 7445 7455 ec. ere. MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 cy i a MAINTENANCE FUNCTION COMPONENT/ASSEMBLY Wiring Harness (cont)} Replace Repair Power Supply, 28 VOC | Inspect Test 0.3 Service 0.2 Replace 0.7 Repair 0.2 Overhaul 9.0 Amplifier, Inst. Inspect | 0.2 Servo Test 0.3 Service 0.2 Replace 0.7 Repair 0.4 Overhaul 8.0 Compensator Firing | Inspect | 0.2 Test 0. Service 0. Adjust 0. Replace 0. Repair 0.3 Overhaul 30.0 Wiring Harness Inspect 0.3 Test 0.3 Service 0.4 Replace al Repair al Servomechanism, Inspect | 0.3 Azimuth Test 0. Service 0. Adjust 0, Replace 1 Repair 0.4 Overhaul 26.0 Servomechanisn, Inspect | 0,3 Elevation Test 0.3) Service 0.4] 0.6) 1 Adjust Replace cpetereren © - epnlantonal F< dhect moper H- genera! support - dapatcn MAINTENANCE ALLOCATION CHART for LAUNCHER, | GUIDED MISSILE, M192E1, CHART NUMBER 1067; w o Servomechanism, Elevation (cont) (cont)| Repair Overhaul 7456 | Cover Assembly Inspect Replace Repair 7495 | Dessicant Container | Inspect Replace Repair 7510 | Power Supply, Servo Inspect Test Service Replace Repair Overhaul 7525 | Power Supply, Sub- Assembly Inspect 7530 | Relay Assembly, Programmer Inspect Test Service Replace Repair Overhaul 7535 | Wiring Harness Inspect Test Replace Repair 7540 | Cover Assembly Inspect Replace Repair 7545 | Chassis, Relay Assembly Inspect Replace *C- operatorerew © - oryaniational F - direct support H.- general support D - depot ‘Sil FORM 1134, 1 FEB 75 PREVIOUS EDITION 18 OBSOLETE component wamrenance]| MAINTENANCE caTeconY> [FOOLS ano JENT/ASSEMBLY 01S A remem fre To Te Te [eo | wer 26.0 9.0 22.0 TM 9—1440—531—12—1 4109 sTM 9—1440—531—12—1 w ‘GROUP ‘NUM. BER cy MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 2 COMPONENT/ASSEMBLY a w os MAINTENANCE CATEGORY* [TOOLS AND. Equip. w |] o | Men MAINTENANCE FUNCTION 7550 7570 7600 7610 7700 7710 771s Amplifier, Elec. Control, Azimuth Amplifier, Elec. Control, Elevation Blower Installation Fan Assembly Wheel Installation, L.H. Axle Assembly, L.H. Brake Assembly Inspect Test Service Adjust 22.0 Inspect Test 0 Service 0. Adjust 0. Replace 0. Repair 0.4 Overhaul 23.0 Inspect l. Test 0.2 Service [0.5 Repair Inspect Test 0. Service 1. Replace 2. Repair 0.9 Overhaul 8.0 Inspect Service Adjust Repair Inspect Service Replace Repair Overhaul 20.0 Inspect 0.5 Replace 1.5 Repair 1.8 + © operatorierew © - organizational F< ect wppert H- poneral support 0 - depot ‘941 FORM 1134, 1 FEB 75 PREVIOUS EDITION IS OBSOLETE 8-20a: TH 9—1440—531—12—1 MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 Cylinder Asseably 6,12 7725 | Lockout Assembly 6 6,12. 7800 | Wheel Installation, R.H. 7810 | Axle Assembly, R. H. 6 6,11 20.0 7815 | Brake Assembly 6 7820 | Cylinder Assembly 6 6,11 7725 | Lockout Assembly ‘ 6,11 7900 | Brake Installation 7905 | Filter Assembi; * 7 546,10 Valve Assembly + C eperntoreren 0 - erpninilonal FF - direct mppert = general eppert 0D - depotTM 91440531121 ao MAINTENANCE ALLOCATION CHART for LAUNCHER, GUIDED MISSILE, M192E1, CHART NUMBER 10674109 o a a “ o 7925 Stroke Indicator Inspect ‘Assembly Replace 7935 Master Cylinder Inspect ‘Assembly Replace 7945 Air Cylinder Assembly] Inspect Replace 8100 Brace Assembly, Inspect Towing Service Replace 6 Repair 8110 Outrigger Assembly, | Inspect Front, R.H. Replace 6 8120 Outrigger Assembly, | Inspect Front, L.H. Replace 6 8130 Outrigger Assembly, | Inspect Age Replace 6 8140 Cover, Stowage Com- | Inspect partment, Front Replace Repair 546 8150 Cover, Stowage Com- | Inspect partment, Aft Replace Repair 5,6 8160 Tube Assembly, Tele~| Inspect scoping Replace 8200 Bracket Installation | Inspect Replace Repair *C- operatorforew 0 - orpniznional F + direct support M - poral muppert OD - dopet o22cy T™ 9—1440—S31—12—1 MAINTENANCE ALLOCATION CHART for eee GUIDED MISSILE, aroun CHART NUMBER 10674109 | __ MAINTENANCE CATEGORY [TOOLS AND COMPONENT/ASSEMBLY Equip. Chassis, Launcher Replace Repair Overhaul Latch Assembly, Tie-down | Inspect Replace Repair Control, Launcher Inspect Test Service Adjust Replace Repair Inspect Service Replace Repair Inspect Service Replace Repair © epernterforew 0 - oxganisetonal F - direct sport Hi - general support 0 - depot ‘Sa FOF 1194, 1 FEB 75 PREVIOUS EDITION 18 OBSOLETE 8-23TH 9—1440—531—12—1 o MISSILE, M192E1, CHART NUMBER 10674109 TOOL AND TEST EQUIPMENT REQUIREMENTS 1 0 Launcher Test Set 4935-00-133-9770 | 10668801 2 ° Multimeter 6625-00-688-9507 | AN/PSH-6B 3 ° Oscilloscope 6625-00-532-4288 | AN/USH-SOB 4 ° Multimeter 6625-00-376-4937 | TS 505 D/U 5 0 Tool Kit, Guided Missile: 4935-00-724-9093 | w40265 Field Maint, Electro-Mech, HAWK (403) 6 0 Tool Kit, Guided Missile: 5180-00-231-7690 | 285647 Org. Maint. (A60) 7 0 Tool Kit, Guided Missile: 5180-00-231-7689 | 285648 Maint, Org, Adj & Align (as9) 8 0, F, G] Tool Kit, Guided Missile: 4935-00-724-9098 | W40539 Field Maint, Hydraulic, HAWK (A04) ( 9 0 Vacuum Cleaner 7910-00-530-6260 | 33768 10 0 Screwdriver, Flat Tip, 7/16" | 5120-00-236-2092 Tip so 0 Wrench Set, Open End, Midget | 5140-00-708-3431 _|_ | {91 FORM 11341, 1 FEB 75 PREVIOUS EDITION IS OBBOLETE ( om7 ™ 9—1440—531—12—1 MAINTENANCE ALLOCATION CHART for pes AND STORAGE, ra CHART NUMBER 10288330 w w oo [_waiwrenance catecony= | Pete Try] | tur Pallet, Loading and Storage Inspect | 0.1 Service | 0.4 Adjust Install | 0.3 Repair 2.0 Overhaul 0200 | Adapter, Hoisting Pallet | Inspect | 0.1 Service 0.2 Replace 0.3 Repair 0300 | Frame, Pallet Inspect Service Replace Repair 0400 | Housing Assembly, Index | Inspect Service Replace Repair + C- operatorerew © - oryanizational F direct wpport 1 - gnarl mepport 0D - depot eas™ 440531121 END ITEM: PALLET, LOADING AND STORAGE, MIE2, CHART NUMBER 10288330 TOOL AND TEST EQUIPMENT REQUIREMENTS Tool Kit, GUIDED MISSILE, Org.| 4180-00-231-7690 | 285647 Maint. (A60) o26a T™ 91440531121 MAINTENANCE ALLOCATION CHART for COMTROL BOK, GM, Lamecaitng SECTION, AN/GSA-13 4 , CHART NUMBER 10668870 & 10291991 7 wy Oy SOT /ASaUBUY MAINTENANCE, MAINTENANCE CATEGORY® roous ano remeron Te To Te Te [oo | men 0100 Control Box, GM, Inspect Launching Section | Test 1 Service 2 Adjust Install 0105 Cover Assembly, Test | Inspect Set & Headset Replace 0.2 3 Repair 0.3 0110 Cover Assembly, Coumo| Inspect | 0.1 Station Replace 0.2 3 Repair 0.3 0115, Clamp Assembly, Card | Inspect 0.3 ‘Assembly Replace 0.7 Repair 0.7 116 Circuit Card Assembly} Inspect 0.2 Replace 0.2 3 Repair 2.0 0117 Semiconductor Device | Inspect 0.2 Assembly, Diode Replace 0.2 3 Repair 2.0 o118 Resistor Assembly Inspect 0.2 Replace 0.2 3 Repair 2.0 0120 Clamp Assembly, S & 4 Inspect Test Device Replace Repair 1000 Wiring Harness Inspect Test Replace Repair 1500 Plate Assembly Inspect Replace Repair 7 © opmratorferew © - organisational F - direct wppert Ml genet woport D - depot 027T™ 9—1440—531—12—1 2500 3005 3100 3200 MAINTENANCE ALLOCATION CHART for CONTROL BOX, GM, LAUNCHING SECTION, AN/GSA-13A, CHART NUMBER 10668870 & 10291991 ow @ ao “ Case Assembly Headset Assembly Communication Station Cover Assembly Wiring Harnes Wiring Harness Test Set, S&A Device 7 C- opermerferew © - orpanizational F - divest woppert H.- general mppert D - depot arsTH 9144053112 Multimeter 6625-00-957-4376 Oiler, Hand, 16 Ounce 4930-00-262-8868 Tool Kit, Guided Missile, 5180-00-231-7690 Maint: Organizational (A60)} Hammer, Ball Peen, 1/2 Pound | 5120-00-242-9299 AN/PSM-6B 029o 1 9—1440—531—12-1 APPENDIX C NOMENCLATURE AND REFERENCE DESIGNATIONS a 1M veeulatre a nate ato TAL Improved launching section control | Control Box, Gi 10291991 box Launching Se (x04) TAIAI3 Communication station Intercommunication Station 10288848 *(¥)! 10291990 *(T)! 10288711 *(L}! 10677377 *(K)! 9 Improved launcher Launcher, Zero-Length, Guided Mis- | 10674109 sile: M192E1 Actuator bearing assembly Bearing Unit 9089159 Boom elevation actuator cylinder Cylinder, Actuating, Boom Elevation | 9089601 Boom elevation actuator group Actuating Installation, Boom El- vation 9089180 ‘Cam adjusting lever Lever, Adjusting Cam 9096640 Cradle Cradle, Guided Missile 9183050 Elevation data assembly Instrument Assembly, Elevation Data | 10111609 Cam, Elevation Data Assembly 9096641 Mechanism, installation Elevation Data 10112195 Blevation main drive sector Sector, Main Drive Elevation 9099454 Guided missile pallet Pallet Loading and Storage, Guided Missile MIEL 9196208 Helicopter lift hoisting adapter Adapter, Hoisting Pallet 9196164 Index housing assembly Housing Assembly 9189016 Launcher outrigger jack pad Plate, Base, Missile 9089635, j Pallet frame Frame, Pallet 9196206 Spade Spade 10674113, oat Base ‘Trailer, Launcher, Guided Missile 10674176 Aft outrigger Outrigger, Aft 9098881 Base electrical system Base, Bletrical Installation 10674179 Base hydraulic system Hydraulic Installation 10669314 Brake system Brake System Installation 9099626 Chassis structure assembly Structure, Chassis Assembly 10669515 Forward base outrigger Outrigger, Forward Base 9088365, Forward base outrigger Outrigger, Forward Base 9091285, Front compartment cover Cover, Front Compartment 9080829 Left wheel group Wheel Installation, LH. 9191200 Rear compartment cover Cover, Access, Electrical Components | 10669897 Right wheel group Wheel Installation, R.H. 9091706 Support jack Jack, Leveling Support 9091940 SA1AL Electronic equipment rack Rack, Electrical Equipment 10673977 SALAIAL Launch programmer Relay Assembly, LCH Programmer | 10288750 *(M)! SAIAIAL Launch programmer Relay Assembly, LCH Programmer | 10287906 *(E)' SAIAIAL Launch programmer Relay Assembly, LCH Programmer | 10674737 *(D)' SA1ALA2 Control amplifier power su Power Supply, Control Amplifier 10189644 SAIAIAS Bevaton entra ampiier Amplifier, Blectronie Control (El- | 11566288 *(AC) ? evation) 10672134 *(AB)* SAIAIAG Azimuth control amplifier Amplifier, Electronic Control (Az- | 11566284 *(AC) imuth) 10672153 *(AB)* SA1A2 Base distribution box Distribution Box 10288676 *(P)! SAIAz Base distribution box Distribution Box 10674996 *(N)! SAIAS Shoot-around console Correction Group Launcher Em- placement 10672667 SAIASAL Azimuth servo geartrain Servo Mechanism, Azimuth Correction | 10179086 SALASA2 ‘Azimuth servo amplifier ‘Amplifier, Electronic Control 10179081 TRefer to appendix D for serial number effectivity.TM 9—1440—S531—12—1 clo canes oe a een ram — TaIARAT Bevaton sere geartain Serve Mechaniom, Blevation Corver ‘ion hoxszi04 earasas Bevaion servo amplifer ‘Amplifier, Elevation Control fore OATASAS Tole chee Compensction, Fring Obstruction, tauneher horrors oaiasns Synchro contra transformer synchro Contra Tranaformer Assembly 909144002 oaiasat 2 Vée porer uppiy Power Supply. 28, rorree8a SALAS Epu power supply Power Supply 19167693 oats ‘linemen telescope and fire cutout wey Sight, Launcher Emplacement sores ona Baw support Support Boom rorssiee oazat Contact ing asembiy Contact Ascembly rorsit28 oak ‘Aimuth diatiton box Distbution Box Asimuth rors ‘Azimuth drive eawembiy [aimuth Drive and Data Toatalation —_ |poo040 Azimuth ring gear and bearing ase- | Ring Gea, Asimuth Drive ossoon ‘my ao suport lctrcleystem trical instalation osreza1 ‘Boom support hydraulic system ‘Support, Hydraulic System Boom 10672291 ons Boom Boom, Launcher, Guided Mise rosters Boom electric instalation tial Inataliaton, Boom rosee0ot Blast detector Detection Section, Blast rovrzase Boom electrical system Electrical Installation, Boom 19098907 Boom forward ouigget Outrigger Asemby rooras83 Boom hyarelc ystems Hydrhe Instalton sossass. Bom rear outrigger Outrigger Assembly posses Boom trunnion shaft Shaft Trunan Boom osoise Front mile sopprt sembly ee 100 Index ting esumbly osrezs Index fing ancemBty Fitting Asembly ossers Mal outrtager support Support Minne Outrigger soo Rear minal suppor sasembly Support, Mil roero4To sasat Elevation fre ntrropter Intrrpte, Elevation Fire oscats pasa Iniator rely dstrbtion box Distribution Box, lgniter Relay rorsaee4 BABAR, AG Temperature contra nit, Temperature Conte Unit Awembly [10182671 9A4 Launcher control unit Control, Launcher 11568602" (AE) fosro4Te (AD)! AS Communication station Intercommunication Station 10288848 *(¥)! 10291990 *(T) 10288711 *(L} 10677377 *{K} 9ASAL AF amplifier Audio Frequency Amplifier (Headset) 10675622 9ASA3 AGC amplifier Amplifier, AGC Squelch 10676770 asad Power suply Power Surly Interonnection Board | 16rTast Extension imp Light, Extension esse Fire extinguisher Extinguisher, Fire 8192081 Ground rl fod, Ground s0ssa04 Hatch safety support Support, Turntable Safety ooss4i6 Headset Headset, Microphone Launcher control unit tripod. ‘Tripod, Control, Launcher Seley and arming tnt Safety and Arming Spotem Test Set ‘i Refer to appendix D for serial number effectivity. C212 APPENDIX D SERIAL NUMBER EFFECTIVITY CODE D-1. General The serial number effectivity code is an al- phabetical code to indicate differences among models. D-2. Symbols Used Alphabetical symbols are used in the code. The symbol represents the serialization of the major assembly. An asterisk preceding the symbol ii dicates that the serialization is not of the major assembly, but instead is of the major item in which the assembly is normally located. D-3. Symbols Not Used To avoid possible confusion with classification markings, numerals, and certain units of equip- ment, the symbols (A), (B), (C), (I), (0), (S), and (U) are not used. D-4. Serial Number Effectivity Code The following is a list of code symbols used in this manual: *(D) 275001 through 340000 provided MWO 9-1440—831—30—1 has not been applied. '*(B) 275001 through 340000 provided MWO 9~1440—531—30—1 has been applied and 340001 through 380000. *(F) 275001 through 340000 provided MWO 9-1440-531—30—3 has not been applied. *(G) 275001 through 340000 provided MWO 9-1440-531—30-3 has been applied and 340001 and up. (H) Launcher test sets with serial numbers 275001 through 300000 provided MWO $-4900-525—50-8 has not been applied. (D) Launcher test sets with serial numbers 275001 through 300000 provided MWO 9—4900-525—50-8 has been applied and 300001 and up. ‘*(K) 300001 through 340024 provided MWO 9-1425—525—50—1 has not been applied. 7) *(M) *(N) *(P) @ (R) (T) Ww) cw) *(X) “Y) *(Z) (Aa) *(AB) *(AC) 300001 through 340024 provided MWO 9—-1425—525—50-1 has been applied and 380001 and up. 380001 and up. 275001 through 380000 provided MWO 9~1440—531—50—7 has not been applied. 275001 through 380000 provided MWO 9-1440-531—50-7 has been applied and 380001 and up. Improved launching section control boxes with serial numbers 275001 through 430000, and improved launchers 275001 through 400444 provided MWO 9-1440— 531—18 has not been applied. Improved launching section control boxes with serial numbers 275001 through 430000, and improved launchers 275001 through’ 400444, provided MWO 9—1440— 531—13 has been applied and 430001 and up. Communication stations 10291990 pro- vided MWO 9—1425—525—50—2 has been applied. Safety and arming test aid set with serial numbers 275001 through 415017 provided MWO 9-4935-542-50-3 has not been applied. Safety and arming test aid set with serial numbers 275001 through 415017 provided MWO 9-4! -3 has been upplied and 430001 and up. Superseded by (Y) on an exhaust of spares basis in ILCHRs 275001 through 5002 500287 and up, 275001 through 410000. 410001 and up. 275001 through 520423 provided MWO 9-1440-631—50—15 has not been applied. 275001 through 520423 provided MWO 9—1440-631—50—15 has been applied and 430234 and up.T™ 9—1440—531—12—1 *(AD) 275001 through 660308 provided MWO 9-1440-531—50—16 has not been applied. *(AE) 275001 through 660308 provided MWO 9—-1440-531—50—16 has been applied and 560309 and up. C16 *(AF) 275001 through 530000 provided MWO 9-1440—531—50—18 has not been applied. *(AG) 275001 through 530000 provided MWO 9-1440-531--50—18 has been applied and 530001 and up.TM 9-1440-531-12-1 APPENDIX E BASIC ISSUE ITEMS LIST Ex. Scope ‘This appendix lists basic iasue items and items troop-installed or authorized required by the crew/ ‘operator for operation of improved guided-missile zero-llength launcher M192E1 (ILCHR), guided- missile loading and storage pallet M1E1, and im- proved guided-missile launching section control box AN/GSA-182 (XO-1) (ILSCB). £-2. General This appendix is divided into the following sections: a. Basic Issue Items List - Section II. A list, in alphabetical sequence, of items which are furnished with, and which must be tumed in with, the end item. b. Items Troop-Installed or Authorized List - Sec- tion III. Not applicable. ¢. Illustrations - Section IV. Not applicable. d, Indexes - Section V. Not applicable. e. Abbreviations. Not applicable. E-3. Explanation of Columns ‘The following provides an explanation of col- umns in the tabular list of Basic Issue Items, Sec- tion II. @. Source, Maintenance, Codes (SMR), Column 1. (1) The source code indicates the selection status and source for the listed item. The source code is: Code Explanation P _Repair parts which are stocked in or supplied from the GSA/DSA or Army supply system, and author- ized for use at indicated mainte- nance categories. (2) The maintenance code indicates the low- est category of maintenance authorized to install the listed item. The maintenance level code is: and Recoverability Code Explanation c Crew/operator (3) The recoverability code indicates whether unserviceable items should be returned for recovery or salvage. Items not coded are expendable. The recoverability codes are: Code Explanation R _Repair parts assemblies and compo- nents) which are considered eco- nomically reparable at direct and general support maintenance levels. ‘When the maintenance capability to repair these items does not exist, they are normally disposed of at the GS level. When supply considera- tions dictate, some of these repair parts may be listed for automatic return to supply for depot level re- pair as set forth in AR 710-50. When 80 listed, they will be replaced by supply on an exchange basis. S Repair parts and assemblies which are economically reparable at DSU and GSU activities and which nor- mally are furnished by supply on an exchange basis. When items are determined by a GSU to be uneco- nomically reparable, they will be evacuated to a depot for evaluation and analysia before final disposition. T High dollar value recoverable repair parts which are subject to special handling and are issued on an ex- change basis. Such repair parts nor- mally are repaired or overhauled at depot maintenance activities. U _ Repair parts specifically selected for salvage by reclamation units be- cause of precious metal content, critical materials, or high dollar value reusable casings and castings. b. Federal Stock Number, Column 2. This num- ber indicates the Federal stock number assigned to e1TM 91440531121 the item and will be used for requisitioning pur- poses. The Federal stock number shown in paren- theses identifies the old Federal stock number. ¢. Description, Column 3. This column indicates the Federal item name and any additional descrip- tion of the item required. The abbreviation “w/e”, when used as a part of the nomenclature, indicates that the Federal stock number includes all arma- ment, equipment, accessories, and repair parts issued with the item. A part number or other refer- ence number is followed by the applicable 6-digit Federal supply code for manufacturers in paren- theses. Repair parts quantities included in the kits, sets, and assemblies are shown in front of the re- pair part name. If there have been previous part part numbers assigned to the item, these are shown immediately preceding the primary number which is the last one shown. The code (R), which is shown as the first engry on the second line of the item in the description field, where applicable, indicates the item contains radioactive material. Refer to TM 3— 261, TM 38-250, and TB 750-237 for shipping, storage, handling, and disposal of radioactive material: d. Unit of Measure (U/M), Column 4. A 2- character alphabetic abbreviation indicating the amount of quantity of the item upon which the allowances are based, e.g., ft, ea, pr, etc. ce €. Quantity Furnished with Equipment, Column 5. This column indicates the quantity of the item furnished with the equipment. f. Mlustration, Column 6. Not applicable. E-4. Special Information For inventory of those loose components and parts which are included in improved guided-missile zero-length launcher M192E1 (ILCHR) and im- proved guided-missile launching section control box AN/GSA-132 (XO-1) (ILSCB) refer to TM ‘740-525 appendix C. E-5. Federal Supply Codes tor Manufacturers Code 81337 Manufacturer Army Natick Laboratories Quality Assurance Office Natick, Mass., 01760 96906 Military Standards promulgated by Standard- ization Division Directorate of Logistic Services DSA Section Il. BASIC ISSUE ITEMS LIST Launcher, zero-length, Not applicable. 10668870 (18876) Not applicable. P-C | 8340-064-5050 | Cover, HAWK missile 5-4-832 (81337) P-C | 5310-763-8921 | Nut, plain, hexagon MS51967-23 (96906) P| 5305-051-0634 | Screw, cap, hexagon head MS90725-201 (96906) P-C | 5310-809-8536 | Washer, flat MS27183-24 (96906) P-C | 5310-584-7888 | Washer, lock MS35338-51 (96906) [=| - ££ ‘M192E1 10674109 ‘ise76) Control box, guided-missile launching section AN/GSA-132 (XO-1) Pallet, guided-missile loading and storage, M1E1 9196208 (18876) a. ontrcs ™ 9—1440—531—12—1 APPENDIX F MINOR ALTERATIONS F-1. General ‘This appendix contains instructions for perform- ing authorized minor alterations to guided-missile zero-length launcher XM192E1. The paragraphs below describe the alterations and provide detailed procedures for performing the alterations. F-2. Alteration of Wiring and Adjustment of Retaining Plate on Launcher Gearcase Motor 9176715 a. Deficiency. Some of the motors manufactured by Vernitron Company do not operate properly in the launcher. There are two basic problems. One is the gear retaining plate in the gearhead may loosen and rotate slightly. This causes output speed reduction. The problem is incorrect phasing in units below serial number 505. ’. Modification Application. The phasing prob- lem is corrected by reversing the normal connection of the white and yellow wires on Vernitron units below serial number 505. Output speed reduction is corrected by loosening all of the retaining plate screws, repositioning the plate, and retightening the screws. ¢. Recording and Reporting. The minor alter- ations will be recorded as routine maintenance ac- tions in accordance with TM 38—750.ca TM 9—1440—531—12-1 INDEX Paragraph Pare Adjustment illustrations General . . oe 318 Azimuth mil ring Description : 86 Introduction : ut 8.16 Reading : IIIT so 816 B Base, corrective maintenance of the ‘Additional unite, replacement of... : 5.32 5:20 ‘Att base outrigger, replacement of |». : 50 54 Air reservoir assembly, replacement of ..... . 5-14 59 ‘Alinement telescope and fire cutout assembly, replacement of 5231 514 Axle and brake assembly, replacement of . 5-11 56 ‘Axle support arm, replacement of... 5.12 58 Base distribution box, replacement of 5-20 513, Base hydraulic panel Check valve, replacement of . 5.29 5:20 Manifold, replacement of 5-30 5:20 Bleed valve assembly, replacement o 5.26 sada Blower assembly, replacement of 5-25 54. Drawbar aazembly, replacement of |. : 58 54 Electrical power unit (epu) power supply, replacement of 5:23, 514 Blectronie equipment rack, replacement of 5-21 5:13 Emergency relay valve and connecting valve amemblies, replacement of 5.15 510 Filter housing assemblies, replacement of viens 5:24 514 Forward base outrigger, replacement of : 55 52 Forward base outrigger swivel fitting, replacement ‘of . 56 5-2 Handbrake assembly, replacement of...» 510 541 Leveling cylinders, replacement of |... 57 52 Leveling cylinder valver, replacement of. - oe 5:27 5:17 Shock absorber, replacement of Mh 519 512 Shoot around console, replacement of | : 5-22 54 Support arm axle, replacement of. -- : 5.13 58 Synchro control transformer, replacement of : 531 5-20 ‘System selector valve, replacement of . 5-28 5-19 Torsilastie spring: Adjusting rod and nut assembly, eee of 5-16 5-10 ‘Assembly, replacement of 5.18, 512 Lever arm and cap, replacement of 517 saz Boom, corrective maintenance of the: ‘Actuator power control assemblies, replacement of... 5.53 5-35 ‘Additional units, replacement of . : 557 544.3 Boor snubber (shock absorber), replacement of 551 5-344 Fluid pressure filter or the regulator valve, replacement of 5-54 5.35 Hydraulic oil cooler, replacement of a 5-52 5.35 Igniter relay distribution box, replacement of 549 54 Mintle sensing switch, replacement of 5-50 5.344 Pressure regulating valve, replacement of 5-55 5-38.1 ‘Temperature control unit, replacement of 556 5:39 Boom support, corrective maintenance of: ‘Accumulator air filter valve, replacement of... 5-44 5.29 ‘Additional unite, replacement of»... + 548 534 Assemblies requiring boresight and/or alinement, | replacement. of 6-67.1 544.3 Azimuth distribution box, replacement of . 5-83 5-22 ‘Azimuth drive and data assembly componenia, replacement of : 545 5.29 Azimuth system filter, replacement of . . . 5-40 5-28 Handpump assembly, replacement of . : 547 5-32 Index-1T™ 9—1440—531—12—-1 cs Paragraph Page BContinued Hatch-raising cylinder, replacement of 6-32 Level, replacement of... 5-80 Main hydraulic system: Check valves, replacement of . . 5-221 Filter, replacement of . . ee Relief valve, replacement of . 5-28 Main reservoir: Air vent filter, replacement of... . 5-22 ‘Thermostatic switch assembly, replacement of | 5-22 Manual azimuth movement valve, replacement of . 5-29 Nose fairings and fairing plates, replacement of . . 534.4 Pressure valve, replacement of |... . . 5-28 Pump assembly, replacement of 5-25 Restrictor assembly, replacement of 5-28 c Check procedures (See Tables for specific items)... .. 8:10 Controls and indicators (See also Tables for specific items) 21 Corrective maintenance (See specific items) D Description and data: LCHR: Data ........... 2110 14 Functional description 218 14 Physical description . ... 18 12. LSCB and guided-missile pale: LSCB functional description . 142 16 LSCB physical description 1a 15 Guided-miasile pallet description . +143 16 Destruction of materiel to prevent enemy use -aaa a Differences among models 16 a gE Emplacement procedures Guida mise losding and storage pallet MIEI Prime mover... 78 16 Helicopter 710 18 LSCB Prime mover . 118 a Helicopter .. vee 16 16 Prime mover ot helicopter ++ 713. 116 Energizing procedures ... . 73-12 38 External test equipment required . 13-4 34.1 F Figures ‘Alinement telescope and fire cutout assembly... 2.040 + FBS ‘Alinement telescope and fire cutout assembly — controls and indicators . + Fal Alinement telescope and fire cutout assembly installation ....... 2 FBT Alinement telescope and fire cutout assembly — mounted 8-4 Azimuth alinement verification using sighting target . Azimuth drive gear backlash measurement Azimuth mil ring/vernier scale... . ‘Azimuth position indicator — controls and indiestore, Base distribution box — controls and indicators Base hydraulic control panel - controls and indicators i. FRB Boom support (10183106) ; + F672 Boom support electrical system (10672281)... + F671 Boom support, left side —controls and indicators... 2 R24 Index-2ca ™ 9—1440—S31—12—1 F—Continued Fang Feoe Boom support, right side — controls and indicators... . . F286 Bracket amembly for attaching the mast to the pot ««- 2 F938 Gone of protection concept ...... 2 Fe Connecting trailer to prime mover... + F615 Disassembly of the actuator power control. 2 F521 Disassembly of the base cooling system... 2 P58 Electronic rack... . Peeeree 2 FBa Forward rotating sector ~ controls and indicators 1 Fr. Grounding devices amembly . 2 FBS Guided missile loading and storage pallet | Fit Hatch raised 5... se 5 2 PLZ Heater covers on the missile’ | | + F68 Helicopter lifting components + P61 Helicopter suspension sling-typical |. 2 62 Hookup of suspension sling assembly to helicopter lifting hook - F618 How to read the azimuth mil ring. : : FB9 Indexing the loader to the prime mover using the ramp... - | F629 Indexing the loader to the prime mover using terrain advantage... 2 F628 LCHR — assemblies... oo : a LCHR boom, forward — controls and indicators + Faiz LCHR boom, left side — controls and indicators 1 Fae LCHR boom, right side — controls and indicators . + F297 LCHR fording ...... 5 5 + F246 UCHR lightning protection layout . J! pea LCHR and missile reference points - + FBS LCHR — emplacement. . ; 2 FT LHR — preparation for travel. F614 LHR — preparation for travel and emplacement . + F69 LGHR outriggers — preparation for travel and emplacement F610 LCHR — suspension sling assembly restraining chain ..... 0... + F616 LUGHR — suspension sling asembly secured for helicopier Pickup + F617 LSCB .... F6-20 LSCB ~ assem : PLS LSCB — controls and indicators. : F210 LSCB tied down on prime mover. : Fe-21 Launcher test set (LTS) ; . E38 LOU — controls and indicators : Dra Lubrication chart 2 Pea Labriction points : 2 Fat ture guided missile simulator ||. 2 F384 Mine anchoring stad plain round nui ftrcied + F6-24 Minsile anchoring stud secured in mile... . . : F625 Missle anchoring stud — stowed . 5 » F622 Missile latch 2 F623 Missile pallet — mounted on M390C trailer — front view F6-30 Missle pallet ~ mounted on M380C trailer — rear view. > F631 Missile pallet ri icopter pickup — front view... 2 F634 Missle pallet — suspension sling assembly secured for helicopter pickup — rear view. 2 F632 Missile safety-and-arming controls . . - : 1 FSS M390 trailer A frame — preparation for travel and emplacement. sae : ETS 1M390 trailer front support jack — preparation for travel and emplacement. 5 2 FT (M390 trailer and forward leveling jacks — preparation for travel and emplacement 5 + ETS M390 trailer — preparation for travel and emplacement 1! r626 Mounting the M53 instrument light... . : » F883 Pallet missile latches — controls and indicators | ; F243 Pallet mounting skids installed on M36C prime mover . . F627 Position diagram F619 Removal of cold weather kit heater covers + F66 Removal of ground rod. : : P67 Removal of the LCHR front and rear spades : F612 Removal of the LCHR spades (side view). . 5 F613 Removal of the loading and storage pallet from the taller. | 5-25 Replacement of base electrical components are F567 Replacement of hydraulic components in support bracket ||... F513, Replacement of LCHR base components peneee F562TM 9—1440—531—12—1 F — Continued Replacement of suspension and suspension lockout assemblies. Replacement of the accumulator, filter, and valves ....... Replacement of the air reservoir assembly ...... Replacement of the azimuth distribution box - Replacement of the azimuth drive data assembly components Replacement of the base hydraulic control panel components Replacement of the base hydraulic components... ... Replacement of the boom hydraulic components Replacement of the boom snubber Replacement of the emergency relay valve and connecting vaive sssembii Replacement of the forward base outriggers and sway brace assemblies aoe Replacement of the hydraulic oil cooler ......2.2.0e0esecerecsevsreceseer eres F520 Replacement of the LSCB circuit cards... . : : Replacement of the main hydraulic aystem components Replacement of the missile boom components forward Replacement of the missile pallet components . Replacement of the pressure regulating valve . .. Replacement of the sector release shear pin... Replacement of the temperature control unit Replacement of the valve assem Replacement of units in the shoot-around console. Replacement of wheel and brake components . Sequence of LCHR alinement operations Shoot-around console (front panel open)... . Shoot-around console — controls and indicators Sighting target and support . Spreader bar assembly Stake puller kit Suspension sling assembly — typical chain leg hookup ‘Trailer mounted missile pallet —suspension Hing awemtiy ‘secured for hel copier pickup — front view . ‘Trailer preparation for emplacement — left rear view Forms, records, and reports. Hand receipt . Pee HAWK system silent mode redeployment checks, preparation for . How to read the azimuth mil ring using the vernier scale ...... LCHR-HIPIR azimuth alinement verification 83 LSCB circuit cards, replacement of the . + 5-61 Index housing, replacement of the . oon + 559 L Lightning protection General lightning protection emplacement instructions . . . . a se O82 Lightning protection fabrication for LCHR's .......- 0.00.0 cececcccesecss sees OB Loading and storage pallet, removal from the trailer. . + 5-60 Lubrication: General lubrication and maintenance instructions - 410 Lubrication chart ..........20seseee5 42 4d cee Bad 241 : te 248 Safety and-erring checks and mise arming « + 2a Unloading + 246 Index-4 cs S41 5-26 59 5-28 5-81 518 5-83 5-44 5:87 5:10 58 5.38.2 5-49 5-24 5-36 5-46 5-41 544.2 544.1 81 5-47 547 o1 98 5-47 48 47 Fa 221 247 221 219 2-22cu TM 9—1440—531—12-1 M—Continued Perneaph Pee Missile pallet components, replacement of 545 Modification work orders Beane aa ° Operational checks (See Tables for spect item): ‘Check procedures... 310 Deenergizing procedures. - 341 Energizing procedures . 34.1 Preparation for the checks 341 Returning to remote operation - 341 Shutting down for repair . . 341 Starting up after repair 341 Operation under unusual conditions: ‘Ambient temperature variations 216 Extreme cold weather operation 216 Extreme hot weather operation 216 Fording operations . . . : 2141 Preparation for high-velocity winds’. 2144 Unusual terrain operation ..... 216 Operation under usual conditions: Normal 2a4 Tactical re-leveling 214 Organizational maintenance allocation 1 Orientation and alinement LCHR-HIPIR azimuth alinement verification . a1 Methods of orienting and alining a LCHR : 84 Orientation and alinement during blackout conditions. 83 Preliminary procedures... an 33 Sequence of alinement operations. 83 P Preparation for checks + 73-8 36 Preparation for mid-check repair 2.731000 8-7 Preparation for remote operation 17814 88 Preparation for resuming the checks Dai 37 Preparation for travel Guided missile loading and storage pallet MIE Preparation for travel procedures — helicopter... . 629 Preparation for travel procedures — prime mover. _ 6-23 LOHR Preparation for travel procedures — helicopter .......... Bee eee 616 reparation for travel procedures ~ prime mover « «+. Trailers. : ‘Transportation by air i : 61 LscB Preparation for travel procedures — helicopter ez o-22 Preparation for travel procedures — prime mover 2 61 6-22 Preventive maintenance servies (See alao Tables fr specific itera) Daily... - 36 84 General procedures for all services and inspections ; a4 Intervals. 133 General 281 a Monthly | 236 34 Quarterly || 36 a1 Responsibility . 32 a4 Weekly 35 aa Index-5TM 9—1440—531—12—1 R Redeployment checks, silent mode, HAWK system, preparation for .. . Replacement of the compartment access cover fastener_knob packing Replacement procedures, general practices for: Bulkhead-type flareless tube fitti Hatch-closing procedures... . . Hatch-raising procedures. . Safety instructions . installation procedures Reporting equipment improvement recommendations (EIR's) 8 Scope . Peer : Sequence of alinement operations... - Service upon receipt and emplacement... . . Silent mode redeployment checks, HAWK system, Drepartion for... Special tools and equipment . .. .. : T Tables: ‘Alinement telescope and fire cutout assembly — controls and indicators .. .. ‘Azimuth position indicator ~ controls and indicators . Base distribution box — controls and indicators... Base hydraulic control panel — control and indicators . ‘Boom-positioning system check : Boom support, let side — controls and indicators. Boom support, right side — controls and indicators Deenergizing procedures ..... Energizing procedures 5 Firing and control system check. Forward rotating sector — controls and indicators. HAWK system silent mode redeployment checks preparation . LCHR boom, forward — controls and indicators........... CHR boom, left side — controls and indicators LCHR boom, ight side — controls and indicators . LCHR preventive maintenance services LGHR data. . ; CHR monthly preventive maintenance services LGHR quarterly preventive maintenance services LCHR weekly preventive maintenance services LCU—controls and indicators . .. LSCB— controls and indicators. . |. LSCB preventive maintenance services USCBdata....... 600 Loading and storage pallet data Loading and storage pallet preventive maintenance services Materials required for each LCHR Modification work orders... . Orientation and alinement procedure with the HIPIR . Pallet missile latches — controls and indicators. . Power distribution system check ..... ; Preparation for checks ..........- Preparation for mid-check repair... Preparation for remote operation. Preparation for resuming the checks Shoot-around console — controls and indicators Vernier seale: Description . Reading . Index-6 cu Paragraph Page 3a7 338 50.1 54 52 5a 54 52 53 52 51 51 a a 141 Va 1a aa 84 83 13 1 3a7 3.38 42 “a T2144 248 126 27 122 26 123 25 T3160 28 T24 26 125 27 131339 T3412 38 T3170 3-28 729 29 7318 3.38 T2120 aaa 128 28 727 28 73.1 32 Ta 14 73.1 32 73.1 32 73.1 32 T2100 2101 73.2 a4 T13 16 TR 22 m4 16 133 a Te1 93 T14 12 78.1 39 T2130 243 73150 3.1 139 36 73100087 3-14 311 rst 89 816 810816TM 9-1440-531-12-1 cus By Order of the Secretary of the Army: E.C. MEYER General, United States Army Chief of Staff Official: ROBERT M. JOYCE Major General, United States Army The Adjutant General Distribution: To be distributed in accordance with DA Form 12-32, Section II, Organizational Maintenance requirements for HAWK Missile System.Google i