CSTO XX21M-AIM9M-2
CSTO XX21M-AIM9M-2
TECHNICAL MANUAL
MAINTENANCE
WITH
ILLUSTRATED PARTS BREAKDOWN
FIELD LEVEL
MISSILE
AIM-9M
(SIDEWINDER)
DISCLOSURE STATEMENT - This information is furnished on the conditions that it will not be released to
another nation without the specific authorization of the Department of the Air Force of the United States; it will
be used for military purposes only; individual or corporate rights originating in the information, whether
patented or not, will be respected; the recipient will report promptly to the United States any known or
suspected compromise; and the information will be provided substantially the same degree of security afforded
it by the Department of Defense of the United States. Also, regardless of any other markings on the document,
it will not be downgraded or declassified without the written approval of the originating U.S. agency. Any
request for this document should be referred to the Tactical Missile Technical Coordination Group (TMTCG),
AFLCMC/EBHAMF, 235 Byron Street, Suite 19A, Robins AFB, GA 31098-1813.
HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method
that will prevent disclosure of contents or reconstruction of the document.
1 MARCH 2002
CHANGE 2 22 AUGUST 2012
1 of 12
CSTO XX21M-AIM9M-2
INSERT LATEST CHANGED PAGES DESTROY SUPERSEDED PAGES.
LIST OF EFFECTIVE PAGES
NOTE:
The portion of the text affected by the changes is indicated by a
vertical line in the margins of the page. Changes to illustrations are
indicated by miniature pointing hands. Changes to wiring diagrams
are indicated by shaded areas.
NOTE:
Work Packages/Subordinate Work Packages (WP/SWP) are listed
in the Numerical Index of Effective Work Packages/Subordinate
Work Packages. This index will reflect the WP/SWP assigned to
this manual and the latest change of each.
Dates of issue for original and changed pages are:
Original ...................... 0..............................1 MARCH 2002
Change ...................... 1..............................14 SEPTEMBER 2007
Change ...................... 2..............................22 AUGUST 2012
TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 948 CONSISTING OF THE FOLLOWING:
Page
No.
*Change
No.
Title ...................................... 2
A - C .................................... 2
D added ............................... 2
E Blank added ..................... 2
i - ii ....................................... 1
iii - vi .................................... 2
WP 001 00
1 - 10 ................................... 1
11 ......................................... 0
12 - 19 ................................. 1
20 Blank............................... 0
WP 002 00
1 - 2 ..................................... 2
3 - 7 ..................................... 1
8........................................... 0
9........................................... 2
10 - 13 ................................. 0
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16.1 added........................... 2
16.2 Blank............................ 2
17 - 19 ................................. 1
20 Blank............................... 1
WP 003 00
1 - 2 ..................................... 1
3 - 4 ..................................... 0
5........................................... 1
6 - 7 ..................................... 0
8........................................... 1
9 - 11.................................... 0
12......................................... 1
13 - 14 ................................. 0
15 - 18 ................................. 1
Page
No.
*Change
No.
SWP 003 01
1 .......................................... 2
2 - 3 ..................................... 1
4 .......................................... 2
5 - 10 ................................... 1
WP 004 00
1 - 2 ..................................... 2
3 .......................................... 0
4 - 5 ..................................... 1
6 - 7 ..................................... 2
8 .......................................... 0
9 - 10 ................................... 2
11 - 13 ................................. 0
14 ........................................ 2
15 - 16 ................................. 0
17 - 18 ................................. 2
19 - 22 ................................. 1
23 ........................................ 0
24 - 26 ................................. 1
27 ........................................ 0
28 - 31 ................................. 1
32 - 33 ................................. 2
34 ........................................ 1
WP 005 00
1 - 2 ..................................... 2
3 .......................................... 1
4 .......................................... 2
5 - 12 ................................... 1
WP 006 00
1 - 3 ..................................... 2
4 - 5 ..................................... 1
6 .......................................... 2
Page
No.
*Change
No.
6.1 added .............................1
6.2 Blank added ...................1
7 - 8......................................1
9 - 11 ....................................2
12 .........................................0
13 - 15 ..................................1
16 .........................................2
17 .........................................1
18 .........................................2
19 - 24 ..................................1
24.1 added ...........................1
24.2 Blank added .................1
25 - 34 ..................................1
34.1 - 34.2 added .................1
35 - 37 ..................................0
38 - 40 ..................................2
41 - 42 ..................................0
43 - 45 ..................................1
46 .........................................2
47 .........................................1
48 .........................................2
49 - 58 ..................................1
SWP 006 01
1 ...........................................2
2 - 3......................................1
4 ...........................................2
5 - 8......................................1
9 ...........................................0
10 - 14 ..................................1
15 .........................................0
16 .........................................1
17 .........................................2
18 .........................................1
19 - 21 ..................................2
* Zero in this column indicates an original page
2
A
Change 2
USAF
CSTO XX21M-AIM9M-2
LIST OF EFFECTIVE PAGES
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*Change
No.
22 - 23 ..................................0
24 - 28 ..................................1
29 - 30 ..................................0
31 - 33 ..................................1
34 Blank ...............................0
SWP 006 02
1 - 4 ......................................2
5 ...........................................1
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9 - 10 ....................................1
11..........................................2
12 .........................................1
13 - 16 ..................................2
17 .........................................1
18 Blank ...............................1
SWP 006 03
1 - 6 ......................................1
7 ...........................................0
8 ...........................................1
SWP 006 04
1 - 7 ......................................1
8 Blank .................................0
SWP 006 05
1 - 4 ......................................2
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13 .........................................2
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15 .........................................2
16 - 22 ..................................1
23 - 26 ..................................2
27 - 28 ..................................1
29 - 30 ..................................2
31 - 34 ..................................1
SWP 006 06
1 - 10 ....................................1
11..........................................0
12 .........................................1
Page
No.
*Change
No.
SWP 006 07
1 - 6......................................1
SWP 006 08
1 - 11 ....................................1
12 Blank ...............................1
WP 007 00
1 ...........................................2
2 - 6......................................1
6.1 - 6.2 added.....................1
7 ...........................................1
8 ...........................................2
9 ...........................................1
10 - 11 ..................................2
12 .........................................1
13 .........................................2
14 .........................................1
15 .........................................0
16 - 17..................................1
18 .........................................2
18.1 added ...........................1
18.2 added blank .................1
19 - 21..................................0
22 - 24..................................2
25 - 28..................................1
29 .........................................0
30 - 31..................................1
32 .........................................0
32.1 added ...........................1
32.2 added blank .................1
33 .........................................0
34 - 36..................................2
37- 39...................................1
40 .........................................0
41 - 42..................................2
42.1 added ...........................1
42.2 added blank .................1
43 - 45..................................2
46 .........................................0
47 .........................................1
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52 .........................................2
53 - 54..................................0
55 - 56..................................1
Page
No.
*Change
No.
56.1 added........................... 1
56.2 added blank ................. 1
57......................................... 0
58 - 61.................................. 1
62......................................... 2
63......................................... 0
64......................................... 1
65 - 68.................................. 0
69......................................... 2
70 - 72.................................. 0
73 - 75.................................. 2
76 - 78.................................. 1
79......................................... 0
80......................................... 1
81......................................... 2
82......................................... 0
83......................................... 1
84 - 86.................................. 0
87 - 90.................................. 2
91 - 92.................................. 1
93......................................... 0
94 - 95.................................. 1
96......................................... 0
97......................................... 1
98......................................... 0
99 - 102................................ 1
103 - 104.............................. 2
105....................................... 1
106....................................... 2
107....................................... 1
108....................................... 0
109 - 110.............................. 1
111 - 114 .............................. 2
114.1 added ......................... 1
114.2 added blank ............... 1
115 - 116 .............................. 2
117 ....................................... 0
118 ....................................... 1
119 ....................................... 2
120....................................... 1
121....................................... 0
122 - 123.............................. 1
124....................................... 0
125....................................... 2
126....................................... 0
127....................................... 2
128 - 130.............................. 1
130.1 added......................... 1
* Zero in this column indicates an original page
Change 2
B3
CSTO XX21M-AIM9M-2
LIST OF EFFECTIVE PAGES
Page
No.
*Change
No.
130.2 added blank............... 1
131 ...................................... 1
132 - 134 ............................. 0
135 - 136 ............................. 1
SWP 007 01
1 - 8 ..................................... 1
9 .......................................... 0
10 - 12 ................................. 1
13 ........................................ 0
14 - 15 ................................. 1
16 ........................................ 0
17 - 19 ................................. 1
20 ........................................ 0
21 - 23 ................................. 1
24 - 27 ................................. 0
28 - 30 ................................. 1
SWP 007 02
1 .......................................... 2
2 .......................................... 1
3 - 6 ..................................... 2
7 - 10 ................................... 1
SWP 007 03
1 - 4 ..................................... 1
5 .......................................... 0
6 .......................................... 1
SWP 007 04
1 .......................................... 2
2 .......................................... 1
3 .......................................... 2
4 .......................................... 1
5 - 6 ..................................... 0
7 .......................................... 1
8 - 9 ..................................... 2
10 - 12 ................................. 1
12.1 added .......................... 1
12.2 added Blank ................ 1
13 ........................................ 1
14 ........................................ 0
15 - 16 ................................. 1
SWP 007 05
1 - 9 ..................................... 2
10 Blank .............................. 0
Page
No.
*Change
No.
SWP 007 06
1 - 2......................................2
3 ...........................................1
4 ...........................................2
5 ...........................................0
6 - 8......................................2
9 ...........................................0
10 .........................................1
10.1 added ...........................1
10.2 added Blank .................1
11 .........................................0
12 - 13..................................2
14 - 15..................................1
16 .........................................2
16.1 added ...........................2
16.2 added Blank .................2
17 .........................................2
18 - 24..................................0
WP 008 00
1 - 4......................................2
5 ...........................................1
6 - 8......................................0
9 - 11 ....................................1
12 - 13..................................0
14 .........................................1
15 .........................................0
16 - 28..................................1
SWP 008 01
1 - 5......................................2
6 - 7......................................1
8 ...........................................2
9 - 14....................................1
15 - 17..................................2
18 - 19..................................1
20 - 21..................................2
22 - 27..................................1
28 - 29..................................2
30 .........................................1
SWP 008 02
1 - 5......................................1
6 ...........................................0
7 - 11 ....................................1
12 Blank ...............................1
* Zero in this column indicates an original page
4
C
Change 2
Page
No.
*Change
No.
SWP 008 03
1 - 3...................................... 1
4 - 6...................................... 0
SWP 008 04
1 - 3...................................... 1
4........................................... 0
5........................................... 1
6........................................... 0
SWP 008 05
1 - 3...................................... 2
4........................................... 1
5 - 7...................................... 2
8 - 21.................................... 1
22......................................... 2
23 - 27.................................. 1
28......................................... 2
29......................................... 1
30 - 31.................................. 2
32 Blank............................... 2
33 - 34.................................. 2
35......................................... 1
36 - 37.................................. 2
38 - 50.................................. 1
SWP 008 06
1 - 4...................................... 1
5 - 6...................................... 0
7 - 9...................................... 1
10......................................... 0
11 ......................................... 1
12......................................... 0
13 - 16.................................. 1
SWP 008 07
1 - 4...................................... 1
5........................................... 0
6 Blank................................. 0
SWP 008 08
1 - 2...................................... 2
3 - 5...................................... 1
6........................................... 2
7........................................... 1
8 Blank................................. 1
LIST OF EFFECTIVE PAGES
Page
No.
*Change
No.
Page
No.
*Change
No.
WP 009 00
1 - 4 ..................................... 2
5 .......................................... 1
6 .......................................... 0
7 .......................................... 2
8 - 10 ................................... 1
11 - 22 ................................. 0
23 ........................................ 2
24 - 26 ................................. 0
27 - 28 ................................. 2
29 ........................................ 1
30 Blank .............................. 0
6 ...........................................0
7 - 8......................................1
9 - 21....................................0
22 .........................................2
22.1 added ...........................2
22.2 added Blank .................2
23 .........................................0
24 .........................................1
25 - 29..................................0
30 .........................................1
31 - 35..................................0
36 .........................................1
SWP 009 01
1 - 5 ..................................... 2
6 - 8 ..................................... 1
8.1 added ............................ 1
8.2 added Blank .................. 1
9 .......................................... 1
10 ........................................ 2
11 - 12 ................................. 1
12.1 - 12.1 added ................ 1
13 ........................................ 0
14 - 16 ................................. 2
17 - 19 ................................. 0
20 ........................................ 2
21 - 28 ................................. 1
SWP 009 05
1 - 5......................................2
6 ...........................................0
7 ...........................................1
8 ...........................................0
9 - 10....................................2
11 - 14 ..................................0
15 - 17..................................2
18 - 19..................................0
20 .........................................2
SWP 009 02
1 - 2 ..................................... 2
3 - 6 ..................................... 1
7 .......................................... 2
8 .......................................... 0
9 .......................................... 1
10 - 14 ................................. 0
SWP 009 03
1 .......................................... 1
2 .......................................... 0
3 .......................................... 1
4 - 5 ..................................... 0
6 Blank ................................ 0
SWP 009 04
1 - 4 ..................................... 2
4.1 added ............................ 2
4.2 added Blank .................. 2
5 .......................................... 2
Page
No.
*Change
No.
WP 012 00 - Deleted
SWP 009 06
1 - 2......................................1
3 ...........................................0
4 - 5......................................1
6 ...........................................0
7 ...........................................1
8 - 32....................................0
WP 010 00
1 ...........................................2
2 ...........................................1
3 ...........................................2
4 - 9......................................1
10 Blank ...............................0
WP 011 00
1 - 2......................................2
3 ...........................................1
4 - 6......................................2
7 ...........................................1
8 - 10....................................0
11 - 13 ..................................2
14 - 25..................................0
26 Blank ...............................0
* Zero in this column indicates an original page
Change 2
D/(E blank)
CSTO XX21M-AIM9M-2
NUMERICAL INDEX OF EFFECTIVE
WORK PACKAGES/SUBORDINATE WORK PACKAGES
NOTE
Only those work packages and subordinate work packages assigned to this manual are listed in this index, therefore, WP/
SWP numbers may not be sequential.
WP/SWP No.
Title
*Change No.
001 00
Foreword
1
002 00
Safety Summary and Accident Prevention
1
003 00
Description of Tactical AUR
1
Description of Training AUR
1
004 00
Master List of Special Tools, Equipment, and Consumables
1
005 00
Storage and Inspection Requirements
1
006 00
Unpacking, Packaging, Inspection, and Ground Handling AIM-9M Tactical Missile
1
006 01
Unpacking, Packaging, Inspection, and Test, Guidance Control Section, WGU-4A/B
1
006 02
Unpacking, Packaging, Inspection and Test, Target Detector, DSU-15/B, DSU-15A/B,
and DSU-15B/B
1
006 03
Unpacking, Packaging, and Inspection, Safety-Arming Device, Mk 13 Mod 2
1
006 04
Unpacking, Packaging, and Inspection, Warhead, WDU-17/B
1
006 05
Unpacking, Packaging, and Inspection, Rocket Motor, Mk 36 Mod 7, Mk 36 Mod 8,
Mk 36 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11
1
006 06
Unpacking, Packaging, and Inspection, Wing Assembly, Guided Missile, Mk 1 Mod 1
and Mk 1 Mod 2
1
006 07
Unpacking, Packaging, and Inspection, Fins, BSU-32/B
1
006 08
Unpacking, Packaging, Inspection, Test and Servicing,
Coolant Pressure Tank, TMU-72/B, TMU-72A/B and TMU-72B/B
1
Unpacking, Packaging, Inspection, and Ground Handling, CATM-9M and DATM
Missile, Training Missile CATM-9M and DATM
1
007 01
Unpacking, Packaging, Inspection and Test, Guidance Control Section,
WGU-4A(T-2)/B and AN/DSQ-29-T1
1
007 02
Unpacking, Packaging and Inspection, Target Detector, DSU-15(T-1)/B and
DSU-15(T-1)A/B
1
007 03
Unpacking, Packaging and Inspection, Warhead, Mk 70 Mod 1
1
007 04
Unpacking, Packaging and Inspection, Rocket Motor, Mk 57 Mod 1, Mk 57 Mod 2,
Mk 57 Mod 3
1
003 01
007 00
Change 1
7i
CSTO XX21M-AIM9M-2
WP/SWP No.
Title
*Change No.
007 05
Unpacking, Packaging and Inspection, Missile Body Assembly
1
007 06
Unpacking, Packaging and Inspection, Dummy Body Section, MDU-27/A and
MDU-27A/A
1
Maintenance, Assembly and Disassembly with Illustrated Parts Breakdown,
AIM-9M Tactical Missile
1
008 01
Maintenance with Illustrated Parts Breakdown, Guidance Control Section,
WGU-4A/B
1
008 02
Maintenance with Illustrated Parts Breakdown, Target Detector, DSU-15/B,
DSU-15A/B, and DSU-15B/B
1
008 03
Maintenance with Illustrated Parts Breakdown, Safety-Arming Device, Mk 13 Mod 2
1
008 04
Maintenance with Illustrated Parts Breakdown, Warhead, WDU-17/B
1
008 05
Maintenance with Illustrated Parts Breakdown, Rocket Motor, Mk 36 Mod 7,
Mk 36 Mod 8, Mk 36 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11
1
008 06
Maintenance with Illustrated Parts Breakdown, Wing Assembly, Guided Missile,
Mk 1 Mod 1 and Mk 1 Mod 2
1
008 07
Maintenance with Illustrated Parts Breakdown, Fins, BSU-32/B
1
008 08
Maintenance with Illustrated Parts Breakdown, Coolant Pressure Tank, TMU-72/B,
TMU-72A/B and TMU-72B/B
1
Maintenance, Assembly and Disassembly with Illustrated Parts Breakdown,
CATM-9M and DATM Training Missile
1
009 01
Maintenance with Illustrated Parts Breakdown, Guidance Control Section,
WGU-4A(T-2)/B and AN/DSQ-29-T1
1
009 02
Maintenance with Illustrated Parts Breakdown, Target Detector, DSU-15(T-1)/B and
DSU-15(T-1)A/B
1
009 03
Maintenance with Illustrated Parts Breakdown, Warhead, Mk 70 Mod 1
1
009 04
Maintenance with Illustrated Parts Breakdown, Rocket Motor, Mk 57 Mod 1,
Mk 57 Mod 2, Mk 57 Mod 3
1
009 05
Maintenance with Illustrated Parts Breakdown, Missile Body Assembly
1
009 06
Maintenance with Illustrated Parts Breakdown, Dummy Body Section, MDU-27/A
and MDU-27A/A
1
010 00
Contingency Procedures, Guided Missile AIM-9M
1
011 00
Weapon System Evaluation Program Telemetry Configured AIM-9M Missiles
1
012 00
Deleted
008 00
009 00
ii
8
Change 1
CSTO XX21M-AIM9M-2
LIST OF RELATED PUBLICATIONS
Number
Title
AFI 21-201........................... Ammunition Management and Maintenance Objectives (AMMO)
AFI 91-204........................... Safety Investigations and Reports
AFI 91-301........................... Air Force Occupational and Environmental Safety, Fire Prevention, and Health (AFOSH)
Program
AFI 91-302........................... Air Force Occupational and Environmental Safety, Fire Protection and Health (AFOSH)
Standards
AFJMAN 24-204 ................. Preparing Hazardous Materials for Military Air Shipments
AFMAN 23-110................... USAF Supply Manual
AFMAN 91-201................... Explosives Safety Standards
ASME Y14.38M .................. Abbreviations and Acronyms
CSTO XX33D9-20-13-1...... PTS-15 Portable Test Set, Part Number 02400081
CSTO XX35D18-6-2 ........... Digital Hygrometer, TTU-546/E, Part Numbers 639AS9334-1 and 639AS9334-2
DODD 5330.3/AF SUPP ..... Defense Automated Publishing Service
DODD 6055.9-STD ............. DOD Ammunition and Explosives Safety Standards
FED-STD-595...................... Colors Used in Government Procurement
FMS TS3860 Series ............. Operation and Maintenance Instructions with IPB, Test Set, Guidance Control Section
(TS-3860A)
MIL-HDBK-129 .................. Military Marking
MIL-STD-129 ...................... Standard Practice for Military Marking
MIL-STD-398 ...................... Shields, Operational for Ammunition Operations, Criteria for Design and Test for
Acceptance
NAVAIR 01-lA-75 ............... Airborne Weapons and Associated Equipment Consumable Material Applications and
Hazardous Material Authorized Use List
NAVAIR 11-75-64 ............... Sidewinder/Sidearm Missile System Shipping and Storage Containers All Mks and Mods
PPP-B-621D......................... Federal Specification, Box, Wood, Nailed and Lock - Corner dated 21 Dec 1984
PPP-B-585C......................... Federal Specification, Box, Wood, Wirebound, dated 16 Nov 1978
T.O. 00-20-1......................... Preventive Maintenance Program, General Requirements and Procedures
T.O. 00-20-14 ...................... Air Force Metrology and Calibration Program
T.O. 00-25-234..................... General Shop Practice Requirements for the Repair, Maintenance, and Test of Electrical
Equipment
T.O. 00-5-19......................... Security Assistance Technical Order Program
T.O. 1-1-691......................... Aircraft Weapons Systems Cleaning and Corrosion Control
T.O. 1-1-8............................. Application and Removal of Organic Coatings, Aerospace and Non-Aerospace Equipment
T.O. 1-1A-8 .......................... Aircraft and Missile Repair, Structural Hardware
T.O. 11A-1-10 ...................... Air Force Munitions Surveillance Program and Serviceability Procedures
T.O. 11A-1-46 ...................... Fire Fighting Guidance, Transportation, and Storage Management Data
T.O. 11A-1-60 ...................... General Instructions, Inspection of Reusable Munitions Containers and Scrap Material
Generated from Items Exposed to, or Containing Explosives
T.O. 11-l-38.......................... Positioning and Tie-down Procedures, Nonnuclear Munitions
T.O. 21M-1-101 ................... Reliability Asset Monitoring System
T.O. 32-1-2........................... Use of Hand Tools
T.O. 32-1-101....................... Use and Care of Hand Tools and Measuring Tools
T.O. 33B-1-1 ........................ Nondestructive Inspection Methods
T.O. 32B14-3-1-101............. Operation and Service Instructions Torque Indicating Devices
T.O. 33D5-14-52-1............... Operation/Maintenance Manual, Amptec Research Model 620A-4 FailSafe Digital
Ohmmeter/Igniter Circuit Tester, NSN 6625-01-460-1499AQ
T.O. 33D9-1-432 .................. Service Instructions with Illustrated Parts Breakdown, AIM-9 Missile Field Support Tools
and Equipment (AGE)
T.O. 35-1-12......................... Compounds and Procedures for Cleaning Support Equipment
T.O. 35D18-4-1 .................... Operation and Maintenance Instructions with IPB, Recharging Unit Assembly GCU-26A/E
PN 639AS10030
Change 2
iii
9
CSTO XX21M-AIM9M-2
LIST OF RELATED PUBLICATIONS (Continued)
Number
Title
T.O. 35D18-5-1.....................Operation and Maintenance Instructions with Illustrated Parts Breakdown, Guided Missile
Coolant Recharging Unit GCU-30/E PN 8431336
T.O. 35E20-2-31-2................Organizational, Intermediate Maintenance, and Depot Overhaul Instructions with Illustrated
Parts Breakdown, Shipping and Storage Containers AIM-9 Series Missiles
T.O. 42B5-1-2.......................Use, Handling, and Maintenance Instructions - Storage Type Gas Cylinders
T.O. 44H1-1-117...................General Installation of Heli-Coil Inserts
T.O. XX11A-1-1...................Conventional Munitions, Suspended or Restricted
T.O. XX 33D9-54-67-1 ........Operation and Maintenance Instructions with Illustrated Parts Breakdown, Guidance
Control Section Test Set TS-4044/D PN 757300-10
iv
10
Change 2
CSTO XX21M-AIM9M-2
List of Applicable Time Compliance Technical Orders
TCTO No.
TCTO
XX21M-AIM9M-6001
Date
Title
1 Nov 2003
Installation of a Safety Relief Valve in the
Guidance Control Section of the AIM-9M-( )
Sidewinder Missile
TO 21M-AIM9L-501
15 September 1980
TO 21M-AIM9L-502
Not published
TO 11A15-1-594
Inspection and Marking of Coupling Ring
Threaded Pin PN 639AS693, AIM-9L
Missile.
Rescission
Date
31 August 2005
15 September 1982
1 December 1982
Mod of Rocket Motors Mk 36 Mod 8, PN
1204AS100, Mk 36 Mod 9, PN 639AS4600,
and Mk 57 Mod 2, PN 639AS4765.
1 December 1988
TO 21M-AIM9L-503
30 November 1987
Mod and Marking of Mk 1 Mod 1 Wing Assy,
PN 639AS2836, AIM-9L.
30 November 1992
TO 21M-AIM9L-504
25 April 1985
Inspection of AIM-9M Missile Coupling Ring
Threaded Pin, PN 639AS693.
25 April 1986
TO 21M-AIM9L-505
12 June 1986
Inspection of Refurbished Coolant Pressure
Tank, TMU-72/B, PN 639AS1505, HTL PN
4000100, AIM-9L/M Missiles.
12 June 1988
TO 21M-AIM9L-506
1 September 1987
Mod of AIM-9L/M Inert Body Section, PN
8241297-10.
1 August 1991
TO 21M-AIM9L-507
15 July 1988
Inspection of AIM-9L/M Missile Coupling
Ring Screw, PN 639AS1599 Rev K.
1 January 1989
TO 21M-AIM9L-508
Not published
TO 21M-AIM9L-509
19 July 1990
Inspection/Replacement of Coupling Ring
Screws.
19 July 1992
TO 21M-AIM9L-510
Message Only
Inspection of the forward mating flange of
Inert Mk 57 Rocket Motor
2 March 1992
TO 21M-AIM9L-511
3 November 1992
Inspect for coupling rings manufactured by
00784 dated 1-90 through 12-90
3 November 1993
TO 21M-AIM9M-501
Not published
TO 21M-AIM9M-503
1 January 2002
Installation of Relief Valve in the Guidance
and Control Section of the AIM-9M
Sidewinder Missile
1 January 2006
TO 21M-AIM9M-504
24 October 2001
One-Time Inspection of In-Use AIM-9M
Missile Coupling Ring Screws
24 October 2002
TO 21M-AIM9M-505
10 February 2010
Inspection of the AIM-9L/M, CATM-9L/M,
DATM-9L/M Missile, Coupling Rings (PN
639AS672 and 639AS2725)
28 February 2011
Change 2
v
11
List of Applicable Time Compliance Technical Orders (Continued)
TCTO No.
TO 21M-AIM9M-506
vi
Change 2
Date
28 February 2011
Title
Removal of the Safe and Arm Assembly on
the CATM-9L/M and the Missile Body
Assembly (MBA)
Rescission
Date
28 February 2012
CSTO XX21M-AIM9M-2
WP 001 00
WORK PACKAGE
FOREWORD
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M, CATM-9M AND DATM
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 20
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-10 . . . . . . . . . . . . . . . . . . . . . . 1
20 blank . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
11 . . . . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
12-19. . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Abbreviations and Acronyms ...................................................................................................................... ASME Y14.38M
AF Technical Order System Source, Maintenance, and Recoverability Coding of Air Force
Weapons, Systems, and Equipment ................................................................................................................ TO 00-25-195
Airmunition Serviceability and Location Record ........................................................................................... AFTO Form 15
Ammunition Management and Maintenance Objectives (AMMO) ..................................................................... AFI 21-201
Defense Automated Printing Service...............................................................................................DODD 5330.3/AF SUPP
Security Assistance Technical Order Program ..................................................................................................... TO 00-5-19
Installation of Heli-Coil Inserts ..................................................................................................................... TO 44H1-1-117
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Storage and Inspection Requirements.................................................................................................................... WP 005 00
USAF Supply Manual................................................................................................................................... AFMAN 23-110
Table of Contents
Title
Page
Acronyms............................................................................................................................................................................... 6
Definitions ............................................................................................................................................................................. 4
Disposition of Rejected Items................................................................................................................................................ 3
How to Use this Technical Order........................................................................................................................................... 2
Manual Structure.................................................................................................................................................................. 2
Numerical Index .................................................................................................................................................................. 2
Reference Methods .............................................................................................................................................................. 2
Work Package ...................................................................................................................................................................... 2
Illustrated Parts Breakdown (IPB) ......................................................................................................................................... 7
Commercial and Government Entity (CAGE) Code Column ............................................................................................. 7
Description Column ........................................................................................................................................................... 10
General................................................................................................................................................................................. 7
How to Use the IPBs.......................................................................................................................................................... 10
Illustrated Parts Breakdown Figure and Index Number Column ........................................................................................ 7
Illustrated Parts Breakdown Part Number Column ............................................................................................................. 7
Requisitioning Decals .......................................................................................................................................................... 7
Source, Maintenance, and Recoverability (SMR) Code Column ...................................................................................... 10
Change 1
1 of 20
CSTO XX21M-AIM9M-2
WP 001 00
Table of Contents (Continued)
Title
Page
Symbols and Abbreviations............................................................................................................................................... 10
Units Per Assembly Column ............................................................................................................................................. 10
Usable On Code Column................................................................................................................................................... 10
Improvement Reports ............................................................................................................................................................ 3
Maintenance Concept ............................................................................................................................................................ 3
Inspection Tables ................................................................................................................................................................. 3
Missile Maintenance Activities ........................................................................................................................................... 3
Storage and Inspection......................................................................................................................................................... 3
Maintenance Instructions....................................................................................................................................................... 3
Numerical Index of Part Numbers......................................................................................................................................... 6
Figure and Index Number Column...................................................................................................................................... 7
Part Number Column........................................................................................................................................................... 7
Purpose of Technical Order ................................................................................................................................................... 2
Record of Applicable Time Compliance Technical Orders................................................................................................... 6
Reference Publications .......................................................................................................................................................... 3
Repair Restrictions ................................................................................................................................................................ 3
Repairing/Replacing Components and Parts ......................................................................................................................... 3
Scope of Technical Order ...................................................................................................................................................... 2
Use of Words ......................................................................................................................................................................... 3
List of Tables
Title
Page
Numerical Index .................................................................................................................................................................. 12
SMR Coding Matrix .............................................................................................................................................................11
1.
PURPOSE OF TECHNICAL ORDER.
2. This technical order (TO) describes the operations and
maintenance requirements for the AIM-9M (tactical), and
CATM-9M (captive air training), and DATM-9M (dummy
air training) missiles. This TO is to be used by authorized
personnel whose duties require detailed knowledge of the
weapon system.
3.
SCOPE OF TECHNICAL ORDER.
NOTE
Illustrations are intended for clarity only and use
is mandatory only where noted.
4. This TO contains information necessary for ground
handling, inspection, disassembly, assembly, maintenance,
storage, and emergency procedures of the training and
tactical missile at maintenance activities.
5.
2
HOW TO USE THIS TECHNICAL ORDER.
Change 1
6. MANUAL STRUCTURE. Data is presented in
Work Package (WP)/Subordinate Work Package (SWP)
format. This WP/SWP TO is a self-contained, independent
set of procedures to support significant operation and
maintenance tasks. A WP is subdivided into SWPs when
one division by WP is not sufficient to maintain a logical
sequence of data, for clarity, or to isolate specific
maintenance level requirements.
7. WORK PACKAGE. WP numbers are identified by
arabic numerals beginning with the number 001 00. The
last two digits of the WP numbers are used to identify the
SWPs. The SWPs are numbered 01 through 99.
8. NUMERICAL INDEX. The numerical index (front
matter) lists subdivisions of data and directs the user to a
specific WP/SWP. A table of contents in alphabetical
order at the beginning of each WP/SWP further directs the
user to a specific page within the WP/SWP.
9. REFERENCE METHODS. Reference to a
paragraph within the same WP/SWP is by paragraph
number. References to a WP/SWP within this manual is by
CSTO XX21M-AIM9M-2
WP 001 00
the WP/SWP number. References to a different manual is
by manual number.
10. REFERENCE PUBLICATIONS.
11. Reference publications are listed in each WP/SWP
and in the List of Related Publications in the front matter
of this TO.
Defect Classification column describes the category of
nonconformance. The Corrective Action column contains
a brief description of the action required. At times the
required action will include changing the condition code
of an item. TO 11A-1-10 defines and identifies munitions
condition codes used by field activities.
20. MAINTENANCE INSTRUCTIONS.
12. IMPROVEMENT REPORTS.
13. Suggested improvements to this TO shall be reported
in accordance with TO 00-5-19 to Warner Robins Air
Logistics Center, 575 CBSS/GBIA, 460 Richard Ray
Blvd, Ste 200, Robins AFB, GA 31098-1813.
14. USE OF WORDS.
15. The words SHALL or WILL are used in this technical
order to indicate mandatory requirements. The word
SHOULD indicates a non-mandatory desire or a preferred
method of accomplishment. The word MAY indicates an
acceptable or suggested means of accomplishment.
16. MAINTENANCE CONCEPT.
17. MISSILE MAINTENANCE ACTIVITIES. Units
are limited to repairing or replacing defective components
and parts as listed in this TO and identified in WP/SWP
IPBs. The maintenance procedures (except those requiring
loosening of coupling ring joints) may be performed at any
approved location provided all safety and missile
grounding procedures are observed. Cleaning, painting,
preservation, and lubrication in support of the replacement
operations are authorized. Explosive components with
defects not authorized for field repair shall be reported and
processed in accordance with AFI 21-201. Rocket motors
equipped with Safe-Arm selector must be in SAFE
position.
18. STORAGE AND INSPECTION. Maintaining the
stock pile in a serviceable condition requires that items be
stored so that their shelf life/service life are not adversely
affected. Storage requirements are contained in WP 005 00
of this manual. Additionally, periodic/sample inspections
must be accomplished to ensure that the stock pile is
serviceable/usable for its intended purpose. These
inspections are accomplished through the use of visual
inspection tables (Paragraph 19) and are found in the
applicable WP/SWP covering the item.
21. The work sequence given in this TO is provided as a
guide in performing maintenance of the missile
components. Production techniques involving preparation
of more than one missile may require deviations from the
work sequence. Several procedures may be performed
simultaneously, and in different work areas, providing the
preceding and subsequent tasks are not invalidated or
interfered with and that all safety and reliability
requirements are observed.
22. REPAIRING/REPLACING COMPONENTS
AND PARTS.
23. Disassembly of missile sections is not authorized
unless specified procedures for such an operation are
given in this TO. Authorized repair and replacement
procedures are provided in this manual.
24. All screws and bolts shall be inspected and retained
for use if not damaged, unless otherwise specified. Screws
and bolts with damage to the head recess or threads shall
be discarded. Clean screw and female threads and allow to
air dry. Apply screw thread sealant to screw threads only,
unless otherwise specified. Torque screws as required in
accordance with applicable tables. Replace damaged or
missing screws with screws of the same dimension and
type. Replace damaged helical coil inserts in accordance
with TO 44H1-1-117, except that replacement which
requires drilling of holes that are open to the internal areas
of missile components is not authorized.
25. REPAIR RESTRICTIONS.
26. The Base Level Repair Restrictions shall be in
accordance with the Source, Maintenance, and
Recoverability Code assigned in the Illustrated Parts
Breakdown section. For maintenance data collection
purposes NRTS (not repairable this station) Code 1 will be
used based on the maintenance procedures in this TO.
27. DISPOSITION OF REJECTED ITEMS.
19. INSPECTION TABLES. Inspection tables identify
inspection requirements by step, inspection, defect
classification and corrective action. The Inspection
column describes the inspection to be performed. The
28. Disposition of rejected items shall be as specified in
this manual. Disposition of rejected repairable items not
addressed in this TO shall be processed in accordance with
Change 1
3
CSTO XX21M-AIM9M-2
WP 001 00
(2) Etching. Damage where the surface is
marked with lines, but no pits visible to the
naked eye.
AFI 21-201 or as directed by Warner Robins Air Logistics
Center, 575 CBSS/GBIA, 460 Richard Ray Blvd, Ste 200,
Robins AFB, GA 31098-1813. Requests for disposition of
rocket motors, warheads, and safe-arm devices will be sent
to Warner Robins Air Logistics Center 575 CBSS/GBIA,
Robins AFB, GA 31098-1813.
(3) Pitting. Damage beyond minor corrosion
discoloration or etching stage. Pits are
present and visible to the naked eye.
29. DEFINITIONS.
a.
Acceptance Number. A number indicating
quantity of defectives by class permissible in a
sample.
b.
AFTO Form 15. AFTO Form 15, Airmunition
Serviceability and Location Record, is a record of
inspection, suspensions, and restrictions of a
particular lot/item.
c.
All-Up-Round (AUR). An AUR is a complete
assembled missile with wings, fins and coolant
tank installed.
(4) Developed Rust. Damage where the surface
is covered with rust and pitting. Rust patches
do not appear to be caked.
(5) Caked Rust. Damage which projects beyond
the surface in such a compact growth it
presents a caked appearance and pits are
readily visible to the naked eye.
g.
d.
Ammunition Lot Number. A code number
systematically assigned to each ammunition lot at
the time of manufacture, assembly, or
modification that uniquely identifies the
particular ammunition lot. Each lot is assembled
under uniform conditions and is expected to
function in a uniform manner.
Damage Criteria Terms. The damage criteria is
described as follows:
(1) Bend. A distortion of the material caused by
a blow or contact pressure.
(2) Burr. Displaced, raised material.
(3) Casting Marks. Small irregularities in the
surface of the material caused by the
manufacturing process.
(4) Crack. A narrow break in the material.
e.
f.
4
Barrier Sealed Container. A barrier sealed
container is a barrier paper bag sealed by heat to
exclude air and is leakproof under normal
temperatures and atmospheric conditions.
(5) Dent. A depression in the surface of the
material caused by a blow or contact
pressure.
Corrosion Damage. Corrosion is the
deterioration of metal from reaction to its
environment. Corrosion occurs because of the
tendency of most metals to return to a natural
state. The following types of corrosion are listed
in order from the least to the most serious
condition.
(6) Fretting Corrosion. Surface scaling and pits
which result from two very hard materials
contacting each other.
(1) Minor Corrosion. Appears as a gray, black,
or reddish film or surface rust on ferrous
metals and in various color formations on
non-ferrous metals (blue-green or copper,
brass, and bronze and is white powder on
aluminum). It is readily removable and does
not project beyond the surface. Etching or
pitting has not occurred.
(8) Manufacturing Porosity. Small pits in the
surface of the material caused by the
manufacturing process.
Change 1
(7) Gouge. A line or area abrasion penetrating
the surface coating and displacing the
underlying material.
(9) Pit. A small indention in the surface of the
material.
(10) Puncture. A hole which penetrates through
the material.
CSTO XX21M-AIM9M-2
WP 001 00
(11) Scratch. A line or area abrasion penetrating
the surface coating and exposing, but not
displacing, the underlying material. The term
scratch is not applicable to uncoated
surfaces.
prior to use, e.g., missing DOT name in the
item packing.
j.
Defective Item. A defective item is an item
which contains one or more defects. A defective
item shall be used in determining serviceability
of a lot rather than accepting or rejecting a lot
based on a count of individual defects.
k.
Lite Box/Container. A box or container
containing less items than the standard pack for
the specific item.
l.
Lot Size. The number of units in a lot in storage.
(12) Split. A tear in the material.
(13) Waviness. Viewing along the leading and
trailing edges of the wings and fins, the sideto-side variance of the edge caused by the
manufacturing process.
h.
i.
Date of Manufacture (DOM). Unless
specifically identified on the item, or by this
manual, the DOM shall be extracted from the lot
number. If a MIL STD lot number is not assigned
to the item, contact WR-ALC, 575 CBSS/GBIA,
460 Richard Ray Blvd, Ste 200, Robins AFB, GA
31098-1813 for instructions.
Defect. A defect is any non-conformance with
specified requirements of an item, packaging
used, or marking required. Defects will be
classified critical, major, or minor in this TO. An
item may be scratched in any number of places,
however, the defect will be counted once rather
than counting each scratch as a separate defect.
Several spots of rust may be observed, but all will
be classed as one defect. If both scratches and
rust appear, then the item contains two defects.
(1) Critical Defect. A defect that may result in a
hazardous or unsafe condition for
individuals using, transporting, handling, or
maintaining the munition. For markings, a
condition where the marking can result in
hazardous or unsafe conditions for persons
using or maintaining the item, e.g., HE
warhead with practice marking.
(2) Major Defect. A defect other than critical,
that is likely to result in failure in tactical use
or which precludes or reduces materially the
usability of the item for its intended purpose.
For markings, a condition where the marking
can cause misuse or failure, e.g., incorrect
model or type, HE instead of HEAT, etc.
(3) Minor Defect. A defect which is a deviation
from established requirements but does not
affect use or operation of the munition. For
markings, a condition other than critical or
major which normally should be corrected
m. Missile. A missile consists of assembled
components minus wings, fins, and coolant tank.
n.
Operational Test. A test in which an item is
operated under controlled conditions to
determine if the item performs as required.
o.
Periodic Inspection. Inspections required at
specific intervals as prescribed in this TO.
p.
Pre-Issue Inspection. Inspections required to
assure serviceability of an item prior to issue for
operational use.
q.
Receiving Inspection. An inspection performed
upon receipt of a shipment of munitions to
establish condition and confirm that the material
is the same as described on the shipping
document.
r.
Rejection Number. A number indicating the
quantity of defectives by class which exceeds the
permissible acceptance number in a sample and is
cause for rejection of the entire lot or batch.
s.
Sample. One or more items drawn from a lot or
batch for inspection and/or test.
t.
Sample Inspection Container. A package which
has been opened for inspection, resealed, and
identified in accordance with WP 005 00 of this
TO.
u.
Sample Size. The number of items selected for
inspection or test as outlined in this TO.
v.
Shelf Life. The length of time an item can remain
in storage under prescribed packaging and
storage conditions. The expiration date for shelf
Change 1
5
CSTO XX21M-AIM9M-2
WP 001 00
life on items with month and year listed is the last
day of month.
w. Service Life. The length of time an item can
remain installed in an operating configuration or
in actual usage.
x.
Shipping Inspection. An inspection performed
on an item or container to verify condition,
proper markings, and adequacy of the container
for shipment.
y.
Special Inspection. An inspection required by
higher authority, in accordance with specific
instructions from that authority or instructions
specified in this TO to determine or change the
serviceability or specific condition of a munition.
z.
Standard Packs. Standard packs for munitions
vary in accordance with the item and there may
be a number of packs considered standard for
each item. Standard pack(s) will therefore be that
listed in the DOD Consolidated Ammunitions
Catalog, Volume II and/or this TO.
aa. Storage Monitoring Inspection (SMI). A
storage monitoring inspection is an inspection
performed on items in storage in accordance with
procedures and at intervals specified in this TO.
bb. Witness Mark. A reference mark applied to a
properly torqued screw/bolt head and the
adjacent surface. If the screw/bolt loosens
(rotates) the two parts of the reference mark will
no longer be aligned providing a clear visual
indication the screw/bolt is loose. Witness marks
eliminate the need to verify torque during
inspection.
30. ACRONYMS.
ABF
AOTD
AUR
°C
CAGE
CATM
CCM
CLP
CPC
DATM
EOD
°F
GCS
6
-
Annular Blast Fragmentation
Active Optical Target Detector
All-Up-Round
Degree Celsius
Commercial and Government Entity
Captive Air Training Missile
Counter-Countermeasure
Cleaner Lubricant Preservative
Corrosion Preventive Compound
Dummy Air Training Missile
Explosive Ordnance Disposal
Degree Fahrenheit
Guidance Control Section
Change 1
HERO
- Hazards of Electromagnetic Radiation
to Ordnance
IAW
- In Accordance With
ID
- Identification
IPB
- Illustrated Parts Breakdown
IR
- Infrared
LOS
- Line-of-Sight
MAJCOM - Major Command
MSDS
- Material Safety Data Sheet
NRTS
- Not Repairable This Station
OSHA
- Occupational Safety and Health
Administration
PMEL
- Precision Measurement Equipment
Laboratory
PN
- Part Number
psig
- Pounds Per Square Inch Gage
PWR
- Power
RDU
- Refrigerated Detector Unit
RIF
- Radio Interference Filter
RTV
- Room Temperature Vulcanizing
S-A
- Safety-Arming
SWP
- Subordinate Work Package
TD
- Target Detector
TDD
- Target Detecting Device
TM
- Telemetry
TMDE
- Test Measurement Diagnostic
Equipment
TO
- Technical Order
VOC
- Volatile Organic Compound
WP
- Work Package
31. RECORD OF APPLICABLE TIME
COMPLIANCE TECHNICAL ORDERS.
32. Time Compliance Technical Orders (TCTO’s) are
listed in the front matter of this TO.
33. NUMERICAL INDEX OF PART NUMBERS.
34. The Numerical Index of Part Numbers is an index of
all part numbers contained in this manual. It is compiled in
accordance with the alphanumerical listing system
described below.
a.
The order of precedence beginning at the extreme
left-hand position in the part number arrangement
is as follows:
Letters A through Z
Numbers 0 through 9
(Alphabetic Os are considered as numeric zeros.)
b.
The order of precedence in continuing the part
number arrangement in the second and
CSTO XX21M-AIM9M-2
WP 001 00
succeeding positions of the part number, from left
to right, is as follows:
Space (blank column)
Diagonal (slant)/
Point (period).
Dash (-)
Letters A through Z
Numerals 0 through 9
35. PART NUMBER COLUMN. Part numbers are used
exclusively to identify parts. They are selected in
accordance with the following order of importance:
government standard, original manufacturer, commercial
source, and prime design manufacturer. This column lists
one of the following:
a.
The vendor’s part number for purchased parts.
b.
A government standard or a specification part
number such as AN, MS or RC.
36. FIGURE AND INDEX NUMBER COLUMN. This
column identifies the figure that illustrates each listed
item, and the index number(s) that identifies the item on
the illustration. Assemblies or parts that have not been
assigned an index number will have the figure number and
index number of the preceding part shown, with the letter
"F" before the figure number. Example: F008 01/11/09.
The letter "F" indicates this part does not have an index
number assigned, and is listed on the Maintenance Parts
List, SWP 008 01, in Figure 11 after the item indexed as
number 09.
37. ILLUSTRATED PARTS BREAKDOWN (IPB).
38. GENERAL. Each maintenance WP/SWP has an IPB
that consists of a breakdown of the complete equipment
into assemblies, subassemblies, detailed parts, and
attaching parts. Each assembly is listed in order of
disassembly and is followed immediately by its
component parts properly indented below it to show their
relationship to the assembly. Attaching parts are listed
immediately following the parts which they attach. Items
which are obtained from bulk stock such as grease, sealing
compounds, cement, insulating material, paints, etc., are
not included.
39. ILLUSTRATED PARTS BREAKDOWN FIGURE
AND INDEX NUMBER COLUMN. In this column, the
first two numbers represent the figures in the Maintenance
Parts List of which the assembly or part is illustrated and
the third number is the index number of the assembly or
part. Parts shown for reference purposes only are not given
index numbers. The index numbers are numerically
arranged in the listing and are used to key the assemblies
and parts to the figure. The index numbers are also used to
locate a part in the Maintenance Parts List after it has been
found in the Numerical Index. Any items not given a
separate index number are located at the location of the
last index number listed.
40. ILLUSTRATED PARTS BREAKDOWN PART
NUMBER COLUMN. The numbers in the part number
column are either the Government assigned numbers,
Government standard numbers (AN, MS, etc.), or vendor
part numbers. Part numbers are used exclusively to
identify parts.
41. REQUISITIONING DECALS. Obtain decals
identified in this manual from the managing Air Logistics
Center for the item requiring the decal (DODD 5330.3/AF
SUPP). The request must include the IPB figure and index
number, the quantity required, and a shipping address
where you can receive the decals. For the Rocket Motor,
Warhead, and Missile Body Assembly decals may be
obtained from 00-ALC/LIW Hill AFB, UT 84056-5819.
42. COMMERCIAL AND GOVERNMENT ENTITY
(CAGE) CODE COLUMN. The CAGE code identifies
the manufacturer or Government entity whose number
appears in the part number column. The list of names and
addresses of vendors and their codes were obtained from
the H4/H8 Commercial and Government Entity
Publication. The following is a listing of those used in this
TO.
Cage
Name and Address
0FEP9
SNAP-ON TOOLS CORP
Gardena, CA 90247
0ZDS4
CHEMENCE INC
6425 Industrial Way
Alpharetta, GA 30201
01359
FAIRCHILD CONTROLS CORP
540 Highland St.
Frederick, MD 21701-5716
01556
EMHART INDUSTRIES / HELICOIL
510 River Rd.
Shelton, CT 06484
02101
HTL ELECTRO KINETICS
Sub of HTL Industries Inc.
4-2 E. Gutierrez
P.O. Box 1500
Santa Barbara, CA 93105
Change 1
7
CSTO XX21M-AIM9M-2
WP 001 00
NAVAL SURFACE WARFARE CENTER
INDIAN HEAD DIV
101 Strauss Ave.
Indian Head, MD 20640-5035
14439
FLAMEMASTER CORP.
CHEMICAL SEAL DIV.
11120 Sherman Way
Sun Valley CA 91352
16151
GULTON INDUSTRIES INC
Connector Div.
Buena Park, CA 90620
18876
U S ARMY AVIATION AND MISSILE
COMMAND
AMSAM-RD-SE-TD-SA-M
Redstone Arsenal
Huntsville, AL 35898-5000
24655
GENRAD CORP.
300 Baker Ave.
Concord, MA 01742
26512
NORTHROP GRUMMAN CORP
S. Oyster Bay Rd.
Bethpage, NY 11714
30003
NAVAL AIR SYSTEMS COMMAND
Washington, D.C. 20360
34222
HI REL CONNECTORS INC.
748 E. Alosta Ave.
Glendora, CA 91740
38597
LOCKHEED MARTIN CORP
LOCKHEED MARTIN
NE. and SS. Baltimore MP E-5
2323 Eastern Blvd.
Baltimore, MD 21220-4207
46859
CHATILLON JOHN AND SONS INC
83-30 Kew Gardens Rd.
Jamaica, NY 11415
FORD AEROSPACE AND
COMMUNICATION CORPORATION
Willow Grove, PA 18975
49956
NAVAL AIR WARFARE CENTER
WEAPONS DIV
1 Administration Circle
Ridgecrest, CA 93555
RAYTHEON CO.
141 Spring St.
Lexington, MA 02173
50568
APCOM INC
324 Meadowlane Dr.
Franklin, TN 37064
DEXTER CORP
THE DEXTER ELCTRONIC
MATERIALS DIV
211 Franklin St.
Olean, NY 14760-1297
04820
HERMATIC SEAL CORP.
4232 Temple City Blvd.
Rosemead, CA 91770
52152
MINNESOTA MINING AND MFG CO
INDUSTRIAL TAPE AND
SPECIALTIES DIV
3M CTR
Saint Paul, MN 55144-1000
05972
LOCTITE CORPORATION
1001 Trout Brook Xing
Rocky HilL, CT 06067-3582
08718
ITT CANNON ELECTRIC
2801 Air Lane
Phoenix, AZ 85034
09205
LOCKHEED MARTIN CORP
ELECTRONICS AND MISSILES DIV
5600 Sand Lake Rd.
Orlando, FL 32819-8407
1CRL2
AMPTEC RESEARCH CORP
10900 Research Blvd.
PMB-1 Suite 160C
Austin, TX 78759
10001
NAVAL ORDNANCE SYSTEMS
COMMAND
Washington, D.C. 20360
10025
GLASSEAL PRODUCTS INC
SUB OF HCC INDUSTRIES
485 Oberlin Ave.
Lakewood, NJ 08701-6904
11710
12934
8
14083
04347
Change 1
CSTO XX21M-AIM9M-2
WP 001 00
80205
NATIONAL AEROSPACE
STANDARDS COMMITTEE
1725 DeSales N.W.
Washington, D.C. 20360
80244
GENERAL SERVICES
ADMINISTRATION
613 Green St. NW
Washington, D.C. 20001
81348
FEDERAL SPECIFICATIONS
General Services Administration
Washington, D.C. 20360
MB DYNAMICS INC
25865 Richmond Rd.
Bedford, OH 44146-1483
81349
MILITARY SPECIFICATIONS
Defense Standardization
Manual, 4120 3-M
STARRET L.S. CO.
121 Crescent St.
Athol, MA 01331-1913
83259
FEDERAL COMMERCIAL ITEM
DESCRIPTION PROMULGATED BY
GENERAL SERVICES
ADMINISTRATION
Washington D.C.
PARKER-HANNIFIN CORP.
O-SEAL DIV.
1057 Jefferson Blvd.
Culver City, CA 90234
83284
PERMABOND INTERNATIONAL CORP
Sub Of National Starch And Chemical
480 S Dean ST
Englewood, NJ 07631-4931
MASTER APPLIANCE CORP.
2420 18th St.
P.O. Box 68
Racine, WI 53401
87183
KREITER GEAR AND MACHINE CO
2530 Garrow St.
Houston, TX 77003-2321
89506
KIDDE WALTER AND CO INC
Muncie, IN 47302
96906
MILITARY STANDARDS
Defense Standardization
Manual 4120 3-M
97384
AAI CORPORATION
P.O. Box 6767
Baltimore, MD 21204
98747
OGDEN AIR LOGISTICS CENTER
FMIR Bldg 1209
Hill Air Force Base, UT 84056-5320
98752
WARNER ROBINS AIR LOGISTICS
CENTER
420 Richard Ray Blvd Ste 100
Warner Robins, GA 31098-1640
53711
NAVAL SEA SYSTEMS COMMAND
2351 Jefferson Davis Hwy.
Arlington, VA 22242-5160
55026
SIMPSON ELECTRIC CO
853 Dundee Ave.
Elgin, IL 60120-3090
55719
56542
57163
58536
61078
SNAP-ON TOOLS CO
CONTRACT SALES DEPT
2801-80TH St.
Kenosha, WI 53141-1410
61711
STANLEY COMPCO
10640 E. 59th St.
Indianapolis, IN 46236
64959
AMERICAN TELEPHONE
AND TELEGRAPH CO
Guilford Center
P.O. Box 20046
Greensboro, NC 27420-0046
71468
80058
ITT CANNON ELECTRIC
DIVISION OF ITT CORP.
10550 Talbert Ave.
P.O. Box 8040
Fountain Valley, CA 92708
JOINT ELECTRONICS TYPE
DESIGNATION SYSTEM
UNITED STATES
Change 1
9
CSTO XX21M-AIM9M-2
WP 001 00
99017
PROTECTIVE CLOSURES CO. INC.
CAPLUGS DIV.
2150 Elmwood Dr.
Buffalo, NY 14207
43. DESCRIPTION COLUMN. This column lists the
name of each assembly, its attaching parts and the
components of the assembly properly indented to show
their relationship to the assembly and to show the
relationship of the assembly to the next higher assembly.
All Up Round WPs with IPBs will illustrate only those
items authorized for replacement while missile is in the
AUR configuration. Further breakdown is located in the
SWP for each major component.
44. UNITS PER ASSEMBLY COLUMN. This column
lists the quantity of assemblies or parts required in the
immediately preceding assembly of which the given
assembly or part is a component. The quantities specified,
therefore, are not necessarily the total used per equipment.
When used the word REF in this column refers to an
assembly which is completely assembled on a preceding
illustration and is now exploded on the illustration on
which it is referenced. In this case, the DESCRIPTION
column has a notation which refers to the illustration on
which the assembly is shown completely assembled and
indexed.
47. SYMBOLS AND ABBREVIATIONS. The symbols
and abbreviations used in this Illustrated Parts Breakdown
are in accordance with ASME Y14.38M, except as
follows:
AP
AR
NHA
Attaching Part
As Required
Next Higher Assembly
48. HOW TO USE THE IPBs.
49. The following instructions indicate how to find a part
listing when the part number is not known, and how to
find the listing when the part number is known.
a.
When part number is not known.
(1) Turn to the exploded view of the assembly in
which the part is used and locate the part on
the illustration.
(2) From the illustration, obtain the index
number assigned to the part desired. Refer to
the accompanying Maintenance Parts List
for specific information regarding the part.
b.
When part number is known.
45. USABLE ON CODE COLUMN. When breakdowns
of similar models are combined in the same Illustrated
Parts Breakdown, variations within the models are
indicated by a letter symbol in the USABLE ON CODE
column. Where the USABLE ON CODE column has been
left blank, parts listed apply to all models covered by this
breakdown. An asterisk (*) in the Usable On Code
column, for parts that have an identical index number
indicates that all such parts are interchangeable.
(1) When the part number is known, refer to the
Numerical Index of Part Numbers (Table 2).
Locate the part number and note the WP/
SWP figure and index number assigned to
the part.
46. SOURCE,
MAINTENANCE,
AND
RECOVERABILITY (SMR) CODE COLUMN. This
manual contains Joint Military Service Uniform Source,
Maintenance and Recoverability codes only. Definitions
of these SMR codes are available in Table 1 and TO 0025-195.
(3) If a pictorial representation of the part or its
location is desired, refer to the same index
number on the accompanying illustration.
10
Change 1
(2) Turn to the WP/SWP figure number
indicated and locate the index number
referenced in the Numerical Index.
CSTO XX21M-AIM9M-2
WP 001 00
Table 1. SMR Coding Matrix
MAINTENANCE
SOURCE
1st Position
Procurable
2nd Position
A
Stocked
B
Insurance
C
Deteriorative
E
Support
Equipment,
Stocked
P
F
Component of
a Repair Kit
K
Manufacture
M
Assemble
A
Non-procured
RECOVERABILITY
Life of System
Support
F
Intermediate
Kit
D
Depot Kit
B
In Both Kits
O
Organizational
F
Intermediate
D
Depot
O
Organizational
F
Intermediate
D
Depot
A
Requisition
NHA
B
Reclamation
or Requisition
by Part
Number
C
REPAIR
3rd Position
4th Position
Remove/
Replace at
Organizational
Level
5th Position
No Repair
Non-reparable.
Condemn at 3rd
Position Level
Z
Z
O
Support
Equipment,
Non-Stocked
G
X
USE
Recondition
B
Remove/
Replace at
Intermediate
Level
O
Repair at
Organizational
Level
O
F
F
Repair at
Intermediate
Level
Limited
Repair at
Organizational
or Field Level
Remove/
Replace at
Depot Level
F
D
Reparable.
Condemn at
Organizational
(or Field or
Depot) Level
Reparable.
Condemn at
Intermediate (or
Depot) Level
Reparable.
Condemn at
Depot Level
only
D
Overhaul at
Depot Level
Special
Handling
Required
D
Repair at
Depot Level
A
L
Mfg Drawings
11
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index
Part Number
AS568-243
B-545
B702
B-545
B702
B-545
B702
GS549B5
M83420/2-001
MIL-S-6758
MS122076
MS14151-1
MS16555-41
MS16555-41
MS16555-625
MS16555-626
MS16555-626
MS16555-626
MS16555-626
MS16562-253
MS16562-253
MS16562-253
MS16631-4100
MS16633-4018
MS16633-4018
MS16633-4018
MS16996-25
MS16997-19
MS16998-76
MS171432
MS171432
MS171432
MS171526
MS171655
MS171655
MS171655
MS19060-4812
MS19060-4814
MS20341-6C
MS20427-3C9
MS20427-4C10
MS20427-4C9
12
Change 1
WP/Fig/Index No.
009
F008
F008
F008
F008
F009
F009
F009
008
009
009
009
008
008
009
F008
F009
F009
009
008
009
009
008
008
009
009
009
009
009
008
009
009
009
F008
F009
F009
008
008
009
009
009
009
02/07/14
05/31/08
05/31/019
05/32/08
05/32/13
04/22/08
04/22/14
00/10/01
08/02/04
05/06/32
01/16/06
02/06/14
06/12/06
06/12/24
06/19/06
02/05/08
02/06/08
02/07/08
06/18/13
01/21/21
01/15/21
01/16/29
08/02/05
01/21/09
01/15/09
01/16/39
01/16/17
02/06/13
05/06/33
01/21/25
01/15/25
01/16/21
05/06/11
01/21/21
01/15/21
01/16/29
06/12/15
06/12/19
04/22/27
05/06/26
05/06/29
05/06/37
Part Number
MS21055L6
MS21055L6
MS21075L3
MS21075L5
MS21093-06-21
MS21093-3-45
MS21093-3-45
MS21093-3-46
MS21209-C0410
MS21209-C0410
MS21209-C0410
MS21209-C0610L
MS21209-C0610L
MS21209-C0610L
MS21209-C1-15
MS21209-C1-15
MS21209-C1-15
MS21209-F820L
MS21209-F820L
MS21209-F820L
MS24585-C249
MS24585-C249
MS24673-11
MS24673-11
MS24693-S25
MS24693-S25
MS28775-027
MS29513-157
MS29513-157
MS29513-157
MS29513-157
MS29513-157
MS29513-157
MS3215-4018
MS3215-4018
MS3215-4018
MS35190-240
MS35190-240
MS35206-225
MS35275-226
MS35275-226
MS35338-138
WP/Fig/Index No.
009
009
009
009
009
009
009
009
008
009
009
008
009
009
008
009
009
008
009
009
008
009
009
009
008
009
008
F008
F008
F009
F009
F009
F009
F008
F009
F009
008
009
009
008
009
009
05/06/27
05/06/36
05/06/25
05/06/28
02/06/20
01/16/25
02/06/11
02/06/17
01/21/37
01/15/37
01/16/30
01/21/38
01/15/38
01/16/08
01/21/35
01/15/35
01/16/07
01/21/36
01/15/36
01/16/09
05/32/24
04/22/31
04/22/50
04/22/52
05/32/34
04/22/39
03/03/05
00/15/05
02/05/01
00/10/29
02/06/01
02/07/01
05/06/12
01/21/09
01/15/09
01/16/39
05/31/010
04/22/28
05/06/19
05/32/30
04/22/24
01/16/26
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
MS35338-40
MS35338-40
MS35338-48
MS35650-304
MS39086-100
MS39086-100
MS39086-100
MS51023-60
MS51844-61
MS51858-2
MS51858-2
MS51957-12
MS51957-12
MS51957-12
MS51957-25
MS51957-26
MS51966-60
MS9021-025
MS9021-025
MS9021-025
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-157
MS9021-221
MS90726-129
MS9461-07
NAS1100E06-4
NAS1102-5-8
NAS1189-3-P10
NAS1189-E3P7H
NAS1189-E3P7H
NAS1190E06P3L
NAS1190E06P3L
NAS1190E06-P3L
NAS1191-02P4N
WP/Fig/Index No.
008
009
009
009
008
009
009
008
008
008
009
008
009
009
008
009
F008
008
009
F009
008
008
009
009
009
009
009
009
009
009
009
009
008
009
F009
F008
008
009
009
009
008
F009
01/21/27
01/15/27
01/16/41
01/16/27
01/21/07
01/15/07
01/16/37
06/12/21
08/02/03
01/21/28
01/15/28
01/21/03
01/15/03
01/16/32
05/32/44
04/22/23
06/12/21
01/21/19
01/15/19
01/16/19
00/15/05
02/05/01
00/10/29
00/10/47
00/10/55
02/06/01
02/07/01
05/06/12
06/18/15
06/19/07
01/16/14
01/16/40
06/12/25
02/07/19
04/22/18
06/12/04
01/21/39
01/15/39
04/22/35
06/19/17
05/32/20
02/06/13
Part Number
NAS1219-5-12P
NAS1219-5E-8P
NAS1351-4LB14P
NAS1611-009
NAS1756-24
NAS333CPA4
NAS333CPA6
NAS334CPA5
NAS334CPA5
NAS334CPA5
NAS335CPA11
NAS335CPA5
NAS336CPA13
NAS514P632-5P
NAS620C10L
NAS620C10L
SS5702-9PSL
ZZ-R-1415
ZZ-R-1415
ZZ-R-1415
ZZ-R-1415
10850
10852
1204AS100
1204AS100
1204AS108
1204AS108
1204AS110
1204AS202
1204AS204
1204AS206
1204AS206
1204AS217
1204AS217
1204AS218
1204AS218
1517206
1517423
1517540
1517560
1555392
1555392
WP/Fig/Index No.
009
F009
008
008
F008
009
009
009
009
009
009
009
009
008
008
009
009
008
009
009
009
009
009
F008
008
008
009
008
008
008
008
009
008
009
008
009
009
009
008
008
008
F009
06/18/02
04/22/18
07/03/01
07/03/02
00/15/01
05/06/35
05/06/24
05/06/17
06/19/08
06/19/19
05/06/31
05/06/10
05/06/39
06/12/11
05/32/23
04/22/32
02/06/09
01/21/22
00/10/04
01/15/22
01/16/22
02/07/09
02/06/18
00/15/22
05/32/00
05/32/25
04/22/17
05/32/11
05/32/43
05/32/45
05/32/35
04/22/40
05/32/42
04/22/47
05/32/33
04/22/38
06/18/06
06/18/01
06/12/07
06/12/05
06/12/01
05/06/14
Change 1
13
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
1555424
1555424
1555424
1555424
1555424
1555582
1555582
1555583
1555583
1555586
1555586
1555586
1555594
1555594
1555594
1555671
1556741-2
1560588
1560588
1560588
1560589-2
1560589-2
1560589-2
1560854
1560855
1560855
1560855
1560872
1560872
1560872
1560872
1560872
1560872
1560872
1560937
1560938
1560939
1560941
1560941
1561127
1561127
1561127
14
Change 1
WP/Fig/Index No.
008
008
009
009
009
008
009
008
009
008
008
009
008
008
009
008
009
008
009
009
008
009
009
009
008
008
009
008
008
008
009
009
009
009
008
008
008
008
008
008
009
009
00/15/03
01/21/18
00/10/03
01/15/18
01/16/19
04/03/01
03/03/01
04/03/02
03/03/02
05/31/08
05/32/08
04/22/08
05/31/011
05/32/09
04/22/25
06/12/03
04/22/15
05/32/27
04/22/19
06/18/05
05/32/28
04/22/20
06/18/04
04/22/26
05/31/019
05/32/13
04/22/14
00/15/23
05/31/012
05/32/18
00/10/28
04/22/22
06/18/16
06/19/25
06/12/02
06/12/08
06/12/04
06/12/20
06/12/26
05/32/29
04/22/21
06/18/03
Part Number
1569428
1569519
1569519
1569522
1569522
1571845
1571845
2-006E652-901
2103965
2103965
2103965
2236373
2236373
2236374
2236374
2251009
2251009
2251009
2439951
2439951
250-0039-021
250-0039-021
250-0039-021
2581325
2596371
2596371
2596894
2596944
2603913
2603913
2603913
2623625
2623625
2623628
2623628
2623628
2623628
2877652
2877652
2877846
2877847
2878270
WP/Fig/Index No.
F009
009
009
009
009
008
009
008
008
009
009
008
009
008
009
008
009
009
008
009
008
009
009
009
008
009
008
008
008
009
009
008
009
008
008
009
009
008
009
008
008
008
01/16/24
04/22/49
06/19/20
04/22/51
06/19/21
01/21/16
01/15/16
08/02/07
01/21/23
01/15/23
01/16/23
01/21/15
01/15/15
01/21/14
01/15/14
01/21/24
01/15/24
01/15/40
01/21/32
01/15/32
01/21/26
01/15/26
01/16/28
04/22/30
01/21/33
01/15/33
06/12/23
06/12/22
01/21/17
01/15/17
01/16/18
05/32/38
04/22/43
00/15/32
05/32/37
00/10/31
04/22/42
05/31/09
04/22/29
06/12/09
06/12/10
01/21/20
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
2878270
2878270
2880325
43000-14S-6S-007
4904058
4904058
4904058
4904058
4904058
4904072
4904072
4904073
4904073
639AS10032
639AS10032
639AS10032
639AS10036
639AS10039
639AS10039
639AS10039
639AS10039
639AS10046
639AS10046
639AS10046
639AS10046
639AS10176
639AS10176
639AS10177
639AS10179
639AS10180
639AS10182
639AS10184
639AS10188
639AS10190
639AS1021
639AS1022
639AS1064
639AS10789
639AS1088
639AS1088
639AS1090
639AS10935
WP/Fig/Index No.
009
009
008
F009
008
008
009
009
F009
008
009
008
009
008
009
009
008
008
009
009
009
008
009
009
009
009
009
009
009
009
009
009
009
009
008
008
008
008
008
009
008
F008
01/15/20
01/16/20
01/21/17.1
02/06/18
05/32/32
05/32/41
04/22/36
04/22/46
05/06/21
05/32/39
04/22/44
05/32/40
04/22/45
05/32/19
04/22/33
06/19/15
05/32/21
05/32/22
04/22/34
05/06/20
06/19/16
05/32/10
04/22/09
05/06/22
06/19/22
00/10/48
06/19/00
06/19/01
06/19/03
06/19/02
06/19/05
06/19/18
06/19/24
06/19/04
03/03/01
03/03/02
03/03/04
08/02/00
01/21/34
01/15/34
03/03/06
01/21/17
Part Number
639AS10935
639AS10935
639AS1130
639AS1130
639AS1496
639AS1496
639AS1496
639AS1498
639AS1498
639AS1498
639AS1503
639AS1503
639AS1503
639AS1505
639AS1514
639AS1514
639AS1514
639AS1515
639AS1515
639AS1515
639AS1582
639AS1582
639AS1582
639AS1583
639AS1583
639AS1583
639AS1584
639AS1584
639AS1584
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
WP/Fig/Index No.
F009
F009
008
008
008
009
009
008
009
009
008
009
009
008
008
009
009
008
009
009
008
009
009
008
009
009
008
009
009
008
008
008
008
008
008
008
009
009
009
009
009
009
01/15/17
01/16/18
00/15/20
03/03/00
01/21/05
01/15/05
01/16/33
01/21/01
01/15/01
01/16/10
01/21/06
01/15/06
01/16/36
08/02/00
01/21/08
01/15/08
01/16/38
01/21/10
01/15/10
01/16/35
01/21/04
01/15/04
01/16/11
01/21/11
01/15/11
01/16/34
01/21/02
01/15/02
01/16/31
00/15/08
00/15/14
00/15/27
02/05/04
02/05/16
05/31/03
05/32/03
00/10/08
00/10/14
00/10/23
00/10/36
00/10/43
02/06/04
Change 1
15
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1598
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1599
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1617
639AS1618
639AS1618
639AS1618
16
Change 1
WP/Fig/Index No.
009
009
009
009
F009
009
009
009
008
008
008
008
008
008
008
009
009
009
009
009
009
009
009
009
009
009
009
009
009
008
008
008
008
008
009
009
009
009
009
008
008
008
02/06/23
02/07/04
02/07/22
04/22/03
05/06/03
06/18/09
00/10/51
06/19/11
00/15/09
00/15/15
00/15/28
02/05/05
02/05/17
05/31/04
05/32/04
00/10/09
00/10/15
00/10/24
00/10/37
00/10/44
00/10/52
02/06/05
02/06/24
02/07/05
02/07/23
04/22/04
05/06/07
06/18/10
06/19/12
00/15/18
00/15/30
02/05/20
05/31/06
05/32/06
00/10/18
00/10/27
02/06/27
02/07/26
04/22/06
00/15/13
00/15/26
02/05/15
Part Number
639AS1618
639AS1618
639AS1618
639AS1618
639AS1618
639AS1618
639AS1618
639AS2713
639AS2713
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2725
639AS2800
639AS2800
639AS2801
639AS2803
639AS2804
639AS2805
639AS2806
639AS2807
639AS2808
639AS2811
639AS2813
639AS2813
639AS2815
639AS2815
639AS2827
639AS2829
639AS2830
639AS2836
639AS2846
639AS2864
639AS2876
639AS2876
639AS2876
WP/Fig/Index No.
008
008
009
009
009
009
009
008
009
008
008
008
008
008
009
009
009
009
009
F009
009
009
009
009
009
F009
009
009
009
009
009
F009
009
009
009
009
008
F008
008
008
009
009
05/31/02
05/32/02
00/10/13
00/10/22
02/06/22
02/07/21
04/22/02
01/21/12
01/15/12
00/15/12
00/15/25
02/05/14
05/31/01
05/32/01
00/10/12
00/10/21
02/06/21
02/07/20
04/22/01
00/10/02
01/16/00
01/16/16
01/16/12
01/16/04
01/16/02
01/16/03
01/16/01
01/16/05
02/06/16
02/06/15
02/07/13
00/10/05
02/06/00
01/16/15
02/06/19
02/06/12
06/12/00
08/02/06
08/02/06
01/21/13
01/15/13
01/16/13
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
639AS2879
639AS2879
639AS2890
639AS2890
639AS2891
639AS2891
639AS2891
639AS2891
639AS2893
639AS2895
639AS2895
639AS2900
639AS2900
639AS2961
639AS2961
639AS2961
639AS2961
639AS2961
639AS2966
639AS2966
639AS3801
639AS3801
639AS3801
639AS3805
639AS3806
639AS3807
639AS3808
639AS3883
639AS3922-2
639AS3963
639AS3963
639AS3963
639AS4543
639AS4543
639AS4543
639AS4600
639AS4600
639AS4705
639AS4705
639AS4705
639AS4706
639AS4706
WP/Fig/Index No.
008
009
008
008
008
008
009
009
008
009
009
009
009
008
008
009
009
009
009
009
F008
008
F009
009
009
009
008
008
008
008
008
009
008
009
009
F008
008
008
008
F009
008
008
00/15/01
00/10/01
00/15/22
05/31/00
05/31/016
05/32/17
04/22/10
06/18/14
05/31/013
00/10/20
04/22/00
00/10/19
03/03/00
05/31/014
05/32/16
04/22/11
05/06/40
06/19/23
00/10/40
06/18/00
00/15/04
02/05/00
00/10/05
02/07/11
02/07/18
02/07/12
02/05/12
02/05/11
00/15/00
00/15/02
01/21/00
00/10/02
02/05/08
02/06/08
02/07/08
00/15/22
05/32/00
05/31/017
05/32/14
04/22/15
05/31/018
05/32/15
Part Number
639AS4706
639AS4707
639AS4707
639AS4707
639AS4717
639AS4722
639AS4722
639AS4758
639AS4761
639AS4762
639AS4765
639AS4765
639AS4770
639AS4895
639AS4929
639AS4929
639AS4931
639AS4970
639AS4979
639AS4990
639AS4990
639AS4991
639AS4991
639AS4992
639AS4992
639AS4993
639AS4993
639AS502
639AS6080
639AS6080
639AS6102
639AS6110
639AS6111
639AS6112
639AS6113
639AS6155-1
639AS6155-10
639AS6155-16
639AS6155-20
639AS6155-24
639AS6155-3
639AS6155-7
WP/Fig/Index No.
009
008
008
009
008
008
009
008
008
008
F009
009
009
008
008
009
008
009
009
F009
009
F009
009
F008
008
F008
008
009
F008
008
008
F008
F008
F008
009
009
009
009
009
009
009
009
04/22/16
05/31/015
05/32/12
04/22/13
02/05/21
01/21/30
01/15/30
06/12/13
06/12/18
06/12/17
00/10/20
04/22/00
04/22/48
06/12/00
05/32/36
04/22/41
06/12/12
01/15/00
01/16/24
00/10/02
01/15/00
00/10/20
04/22/00
00/15/22
05/32/00
00/15/22
05/32/00
01/16/03
00/15/04
02/05/00
06/12/14
05/32/11
05/32/11
05/32/11
04/22/12
00/10/00
00/10/00
00/10/00
00/10/00
00/10/00
00/10/00
00/10/00
Change 1
17
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
639AS6155-9
639AS631
639AS631
639AS6513
639AS6514
639AS6516
639AS6516
639AS6566
639AS6636
639AS6699
639AS6699
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS672
639AS6739
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
639AS688
18
Change 1
WP/Fig/Index No.
009
008
008
009
009
F009
009
009
008
008
009
008
008
009
F009
009
009
009
009
F009
009
009
008
008
008
008
008
008
008
008
009
009
009
009
009
009
009
009
009
009
009
F009
00/10/00
00/15/21
04/03/00
02/07/16
02/07/15
00/10/05
02/07/00
00/10/00
02/05/10
05/32/26
04/22/18
00/15/06
02/05/02
00/10/06
00/10/34
00/10/41
00/10/49
02/06/02
02/07/02
05/06/02
06/18/07
06/19/09
08/02/00
00/15/10
00/15/16
00/15/29
02/05/06
02/05/18
05/31/05
05/32/05
00/10/10
00/10/16
00/10/25
00/10/38
00/10/45
00/10/53
02/06/06
02/06/25
02/07/06
02/07/24
04/22/05
05/06/04
Part Number
639AS688
639AS688
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS693
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS695
639AS751
639AS761
639AS761
639AS761
639AS766
639AS767
639AS785
639AS785
WP/Fig/Index No.
009
009
008
008
008
008
008
008
008
009
009
009
009
009
009
009
009
009
009
009
F009
009
009
008
008
009
009
009
009
009
009
F009
009
009
008
008
008
009
F008
008
009
009
06/18/11
06/19/13
00/15/11
00/15/17
00/15/31
02/05/07
02/05/19
05/31/07
05/32/07
00/10/11
00/10/17
00/10/26
00/10/39
00/10/46
00/10/54
02/06/07
02/06/26
02/07/07
02/07/25
04/22/07
05/06/05
06/18/12
06/19/14
00/15/07
02/05/03
00/10/07
00/10/35
00/10/42
00/10/50
02/06/03
02/07/03
05/06/06
06/18/08
06/19/10
07/03/00
00/15/04
02/05/00
00/10/05
02/05/10
02/05/13
02/06/10
02/07/10
CSTO XX21M-AIM9M-2
WP 001 00
Table 2. Numerical Index (Continued)
Part Number
639AS793-1
639AS793-2
639AS7998
639AS845
639AS845
639AS845
639AS845
639AS845
639AS876
639AS876
639AS937
639AS937
8121427-03
8121430-03
8241153-03
8241156-10
8241212-10
8241280-30
8241283-01
8241284-01
8241285-01
8241286-10
8241286-10
8241287-03
8241288-01
8241289-01
8241290-01
8241291-30
WP/Fig/Index No.
008
008
008
008
008
009
009
009
008
009
008
009
009
009
009
009
009
009
009
009
009
009
009
009
009
009
009
009
08/02/01
08/02/02
08/02/08
00/15/19
02/05/22
00/10/32
02/06/28
02/07/27
01/21/29
01/15/29
01/21/31
01/15/31
05/06/30
05/06/38
05/06/09
05/06/34
05/06/23
05/06/13
05/06/15
05/06/14
05/06/06
00/10/34
05/06/02
05/06/08
05/06/05
05/06/03
05/06/04
05/06/01
Part Number
8241297-30
8241297-30
8413750-10
850-0106
855923-10
855923-10
855923-10
855923-10
855923-10
8742786-10
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
8934242
917AS3029
WP/Fig/Index No.
009
009
009
009
008
008
009
009
009
009
F008
F008
F008
F008
F008
F008
F008
F009
F009
F009
F009
F009
F009
F009
F009
F009
F009
008
Change 1
00/10/33
05/06/00
05/06/16
02/07/17
00/15/24
05/32/31
00/10/30
04/22/37
05/06/21
05/06/18
00/15/09
00/15/15
00/15/28
02/05/05
02/05/17
05/31/04
05/32/04
00/10/09
00/10/15
00/10/24
00/10/37
02/06/05
02/06/24
02/07/05
02/07/23
04/22/04
05/06/07
03/03/03
19/(20 Blank)
19
CSTO XX21M-AIM9M-2
WP 002 00
WORK PACKAGE
SAFETY SUMMARY AND ACCIDENT PREVENTION
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M, CATM-9M AND DATM
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 22
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-2 . . . . . . . . . . . . . . . . . . . . . . . 2
9. ... .... ... ... .... ... .... 2
16.1 added . . . . . . . . . . . . . . . . . 2
20 blank . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
3-7 . . . . . . . . . . . . . . . . . . . . . . . 1
10-13 . . . . . . . . . . . . . . . . . . . . . 0
16.2 added blank . . . . . . . . . . . . 2
Page No.
Change No.
8 . . . . . . . . . . . . . . . . . . . . . . . . .0
14-16 . . . . . . . . . . . . . . . . . . . . . . 1
17-19 . . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Instructions ....................................................................................................................................... AFI-91 Series
Aircraft Weapons Systems, Cleaning and Corrosion Control .............................................................................. TO 1-1-691
Ammunition Management and Maintenance Objectives (AMMO) ..................................................................... AFI 21-201
DOD Ammunition and Explosives Safety Standards ............................................................................. DODD 6055.9-STD
Explosives Safety Standards ......................................................................................................................... AFMAN 91-201
Fire Fighting Guidance, Transportation and Storage......................................................................................... TO 11A-1-46
Public Static Display......................................................................................................................................TO 00-80 Series
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Shields, Operational for Ammunition Operations, Criteria for Design and Test for Acceptance .................. MIL-STD-398
Table of Contents
Title
Page
Explosive Hazards .................................................................................................................................................................4
Electrically Initiated Explosives ..........................................................................................................................................4
General...................................................................................................................................................................................2
Hazardous Material Warnings................................................................................................................................................6
Lifting Hazards ......................................................................................................................................................................3
Frequency.............................................................................................................................................................................4
Height and Distance.............................................................................................................................................................4
Lifting ..................................................................................................................................................................................4
Obstacles ..............................................................................................................................................................................4
Twisting................................................................................................................................................................................4
Material Hazards....................................................................................................................................................................5
Cleaning Fluids ....................................................................................................................................................................5
Paint .....................................................................................................................................................................................5
Paint Removal......................................................................................................................................................................5
Change 2
1 of 20
CSTO XX21M-AIM9M-2
WP 002 00
Table of Contents (Continued)
Title
Page
Painting................................................................................................................................................................................ 5
Mercury and Thallium Hazards............................................................................................................................................. 6
Missile or Explosive Components Enveloped by Fire .......................................................................................................... 7
Cookoff Times and Evacuation Distances........................................................................................................................... 7
Firefighting .......................................................................................................................................................................... 7
Pneumatic Hazards ................................................................................................................................................................ 6
Public Static Display ............................................................................................................................................................. 3
Rendering Safe and Disposal................................................................................................................................................. 7
Safety Summary .................................................................................................................................................................... 2
Safety Requirements............................................................................................................................................................ 2
Warnings, Cautions, and Notes.............................................................................................................................................. 3
List of Illustrations
Title
Page
Danger Zones....................................................................................................................................................................... 19
Icons for Hazardous Materials and Examples of Application............................................................................................... 8
List of Tables
Title
Page
Fire Symbol Hazards and Actions....................................................................................................................................... 17
List of Hazardous Materials .................................................................................................................................................. 9
Minimum Withdrawl Distances for Explosives Involved in Fire........................................................................................ 18
1.
GENERAL.
2. Personnel involved in missile assembly and
maintenance shall comply with safety requirements and
precautions presented in this Technical Order (TO) and
existing directives. Personnel required to handle guided
missile explosive components shall be thoroughly trained
in safety procedures for explosives and shall demonstrate
the ability to recognize hazards associated with
explosives. Thinking safety, and working under safe
conditions shall be firmly established habits when working
with explosive, flammable, or toxic items.
3. When an abnormal condition is noted and procedures
are not available in this TO, work shall be stopped and
qualified guidance obtained. Personnel shall be evacuated
to a safe site. EOD or other authorized personnel shall be
called for help in eliminating the hazard. Operations shall
not be resumed until the hazard has been eliminated.
4.
SAFETY SUMMARY.
5. This summary is not intended to be an all inclusive
safety manual that covers every conceivable safe operating
2
Change 2
practice that a person should follow. It highlights some of
the most common hazards associated with missile
maintenance.
6. SAFETY REQUIREMENTS. General safety
requirements in AFI 91 and AFOSH 91/127 series
publications, as supplemented by this TO, shall be
complied with. Safety requirements peculiar to specific
USAF AIM-9M guided missile applications are contained
in the TO in the form of WARNINGS and CAUTIONS.
The following are general safety precautions and
instructions that people must understand and apply during
many phases of operation and maintenance to ensure
personal safety and health and the protection of Air Force
property:
a.
If hazardous conditions are encountered, shut
down all operations and evacuate all personnel to
a safe location.
b.
If transmitting antenna of radio, radar, or other
electromagnetic generating devices is in the
vicinity of items covered in this manual, the
appropriate section of the AFI 91 and AFOSH
CSTO XX21M-AIM9M-2
WP 002 00
c.
91/127 series publications will be consulted. The
applicable safety distances for electrically
initiated explosive devices will be followed.
c.
d.
e.
f.
7.
Containers showing evidence of damage or rough
handling shall be reported to responsible
munitions personnel before opening or
unpacking. Do not install a rocket motor that has
been dropped or is suspected of having been
dropped. Do not apply heat or expose a guided
missile component to open flames. Do not
operate unapproved electrically powered
equipment close to the rocket motor or warhead.
Rocket motors are shipped and stored with
igniters installed. Mk 36 rocket motors are to be
considered propulsive at all times because of the
slight chance that the forward bulkhead will not
blow out upon ignition.
Safety and protective devices are used to enhance
the safety of personnel and to prevent damage to
the missile/component. The need for safety and
protection devices is not always easily
understood or perceived. For example, it is
apparent the Dome Protection Assembly helps to
protect the optical dome from breakage, not so
apparent is the fact it also prevents the GCS gyro
from colliding with its mechanical limits during
movements of the GCS/missile when power is
not applied.
During ground handling all tactical missiles shall
have a dome protective assembly with a
REMOVE BEFORE FLIGHT flag attached, a
safety clip assembly (Mk 36 Mod 10/11), safearm key (Mk 36 Mod 8/9), an umbilical
protective cap, a TD protective cover with
REMOVE BEFORE FLIGHT flag attached, and
a forward hanger protective cover installed. A
complete list of safety and protective devices is
located in WP 004 00.
PUBLIC STATIC DISPLAY.
a.
b.
Missiles/components containing explosive items
shall not be used for display except as defined in
paragraph b. below.
Captive Air Training Missiles (CATM) in
configurations authorized by this manual may be
used on display aircraft only when “Make Safe”
requirements of TO 00-80G-XX are complied
with.
8.
Load training/standardization inert missiles/
components which are maintained by munitions
maintenance personnel may be used for display.
WARNINGS, CAUTIONS, AND NOTES.
9. WARNING and CAUTION statements in this TO are
used only to highlight unusual conditions or non-routine
procedures, and are located prior to the specific
procedures to which they apply. Normal operations or
routine procedures that require safety or accident
prevention instructions are covered in this WP.
a.
Personnel operating or maintaining the
equipment covered by this TO shall become
thoroughly familiar with all safety and accident
precautions contained in this WP.
b.
Prior to starting any task/procedure, the
WARNINGS and CAUTIONS applicable to that
task/procedure and safety information in this WP
shall be reviewed and understood.
c.
Application of WARNINGS, CAUTIONS, and
NOTES are as follows:
WARNING
Highlights an essential operating or maintenance
procedure, practice, condition, statement, etc.,
which if not strictly observed, could result in
injury to, or death of personnel, or long term
health hazards.
CAUTION
Highlights an essential operating or maintenance
procedure, practice, condition, statement, etc.,
which, if not strictly observed, could result in
damage to, or destruction of, equipment or loss of
mission effectiveness.
NOTE
Highlights an essential operating or maintenance
procedure, condition, or statement.
10. LIFTING HAZARDS.
11. The function of handling items by hand is often
necessary in order to accomplish daily tasks. In fact, it is
Change 1
3
CSTO XX21M-AIM9M-2
WP 002 00
done so repeatedly, that people often overlook the hazards
associated with lifting. Improper lifting can cause
permanent spinal column damage and leave a person with
a physical disability for life. Many things can influence the
maximum weight a person can safely lift or carry.
12. HEIGHT AND DISTANCE. The height an object
must be lifted, or the distance required to travel while
carrying an object, very quickly reduces the maximum
weight a person can safely handle.
13. FREQUENCY. The maximum permissible weight a
person can safely handle may be reduced by as much as 50
percent if that person is required to lift or carry an object
more than once in 5 minutes or more than 20 times in 8
hours.
14. OBSTACLES. An obstacle as small as 12 inches
high between the person carrying an item and the desired
location can reduce the maximum permissible weight a
person can safely handle by as much as 50 percent.
15. TWISTING. Twisting while you lift or carry
increases the load on your spine and can lead to serious
injury.
16. LIFTING. It is easier to lift properly than improperly.
Plan before acting so you can get the job done safely,
easily, and quickly. Know your lifting limit and weight of
load. Stand close to load with feet apart, knees bent, and
back straight; get a good grip on load, lift with your legs,
and avoid twisting. Ensure knees and torso are facing the
same direction when lifting and carrying.
17. This manual requires short term, non-repetitive
personnel lifts of equipment weight up to 195 pounds to
heights of about 3 feet. If local conditions mandate high
lifts, repetitive lifts, or carries greater than 9 feet consult
Public Health Services and the Safety Office. A minimum
of 3 personnel is normally required to manually handle an
AIM-9 missile with or without wings/fins.
18. While lifting missiles, it is good practice to unpack
from the outside of the container and to repack from the
inside working towards the outside. Doing this avoids
lifting one missile over another.
19. EXPLOSIVE HAZARDS.
20. Explosive components used in the guided missile are
warhead, rocket motor, guidance control section with gas
generator installed, and safety-arming device. Explosive
components will be stored in accordance with existing
directives and special requirements of this TO.
4
Change 1
21. Store complete missile in accordance with existing
directives. Explosive components must be electrically
grounded prior to maintenance. Rocket motors to be tested
will be placed behind a shield/barricade of sufficient
strength to provide maximum practical safety to personnel
and equipment in accordance with DODD 6055.9 STD,
AFMAN 91-201, AND MIL-STD-398 publications. Test
area and procedures will be designed so that no person is
exposed to the explosive component at the time of
checkout. Long test leads and remote control features shall
be utilized.
22. ELECTRICALLY INITIATED EXPLOSIVES.
23. Personnel handling Electrically Initiated Explosives
are exposed to the additional hazards that are created by
static electricity. A person can collect a charge of static
electricity by being in contact with moving nonconductive substances or coming in contact with a mass
that has been previously charged. Therefore, personnel
must be particularly careful to discharge their static
electrical potential or equalize it to that of the explosive
item before it is handled. Each individual unpacking/
handling electrically initiated explosives will make bare
skin-to-metal contact with an approved grounding device.
When a grounding device is not present in the work area,
each person will make bare skin-to-metal contact with the
rocket motor wing rib to ensure that they are at the same
electrical potential as the rocket motor when handling
rocket motors and missiles.
24. All maintenance personnel should be familiar with
AFMAN 91-201, Explosives Safety Standards. This
manual provides guidance on explosives operations safety.
The following information on minimizing the hazards of
static electricity is in 91-201:
a.
Personnel can minimize the possibility and
severity of a discharge of static electricity by
discharging their static electric potential (or
equalizing it to that of the system being handled)
prior to touching the system. Note that
maintenance personnel should always avoid
directly touching an electrical primer.
b.
When making a grounding connection, you
should attach the ground wire/cable/strap to the
item requiring grounding first, then connect the
other end of the ground wire/cable/strap to the
approved facility grounding system; this ensures
that if a spark occurs, it will occur at the
connection to the facility grounding system
instead of at the item. When a different or new
ground is needed for the same item, always make
CSTO XX21M-AIM9M-2
WP 002 00
the new ground connection first (in the same
manner as previously described) before you
disconnect the existing ground connection
(make-before-break grounding); this ensures that
the item will be grounded at all times while
transitioning from one ground connection to
another.
25 AFMAN 91-201 states (1) electrically initiated
munitions and explosive devices need not be grounded
when replacing components of AURs which do not
incorporate an electrical initiating system, and (2)
replacing components of AURs which incorporate an
electrical initiating system when the replacement
operation does not require electrical connection or
disconnection. Therefore a missile/AUR need not be
grounded when the task is limited to installation, removal,
or replacement of fins, wings, or coolant tanks. When a
ground is not used for these tasks personnel will make
bare skin-to-metal contact with the wing rib/wing
attaching screw prior to working with the missile.
26. MATERIAL HAZARDS.
27. Paints, cleaners, and chemicals must be given special
care. Keep them in approved safety containers and in
minimum quantities. Use them only in authorized areas.
Observe manufacturer’s labels and current safety
directives.
28. Exercise extreme caution to ensure paints, thinners,
corrosion removal compounds and other chemicals are
disposed of in a method approved by Bioenvironmental
Engineering Services.
29. Consult the local Bioenvironmental Engineering
Services for specific precaution, protective equipment, and
ventilation requirements.
30. PAINT. The user of this TO must understand the
dangers inherent in paint(ing). Paint and/or its vapor may
burn or ignite when exposed to spark, flame, fire, or any
other ignition source. Some paints can cause permanent
respiratory damage. Additionally, some organic coatings
do not meet the requirements of the National Ambient Air
Quality Standards. One source of pollution requiring
emission control is Volatile Organic Compound (VOC).
VOC is a form of air pollution emitted upon the
application of various paints, dopes, and varnishes. Many
items within this category can be dangerous if handled,
used, stored, or shipped improperly. Be cautious, read and
follow all label instructions.
31. PAINT REMOVAL. Chemical paint removers may
be toxic to skin, eyes, and respiratory tract. Contact
Bioenvironmental Engineering Services for determination
of need for and selection of proper respiratory protection
when it is required.
32. Motor driven abrasives can generate airborne
particles and toxic dust which can injure personnel and
create possible dust explosion from paint and abrasive
material dust. Personnel shall wear dust/particulate masks,
goggles, gloves, and full sleeved shirts when using motor
driven abrasives. Consult Bioenvironmental Engineering
Services for respiratory and ventilation requirements.
33. PAINTING. Mixing shall be done in areas that are
well ventilated and away from any source of open flame.
34. Care must be taken to ensure that paint is not applied
to certain surfaces where paint will interfere with a
function. The following should be masked or otherwise
protected during painting: Machined surfaces that move
with respect to each other, such as threads, bearing
contacts, and gear teeth; electrical parts, such as contacts,
relays, insulators, sockets, plugs, connectors, wiring, and
terminals; plastic and rubber mounts, spacers, and
lubrication fittings, cups, oil holes, etc.
35. Prior to spraying of paint, all safety regulations with
regard to electrical grounding, fire prevention, vapor
removal, etc., must be rigidly complied with.
36. CLEANING FLUIDS. When using cleaning fluids,
use care not to saturate electrical connectors or cables.
Saturated electrical connectors or cables may cause the
guided missile or missile components to malfunction.
37. Use care when using cleaning solvents. Refer to TO
1-1-691. Some cleaners can be highly flammable and
shall be used in areas with adequate fire extinguishing
devices and free of ignition sources. Use dangerous and
toxic solutions and solvents with approved ventilation
only. Avoid internal consumption, prolonged breathing of
vapors, and repeated skin contact. Maintain minimum
quantities required to accomplish tasks. Solvents shall be
contained in approved safety containers. Use only cotton
cloth for applying alcohol, never use cloth made from
synthetic material. Use protective equipment. Minimum
acceptable protective clothing is solvent-resistant gloves.
Operations where splash hazards are likely, i.e., airpressure drying, brushing threaded fasteners, etc.,
necessitate additional protection in the form of face shields
and aprons. Approval of the ventilation system, protective
equipment, disposal methods and safety containers shall
be obtained from Bioenvironmental Engineering Services/
Change 1
5
CSTO XX21M-AIM9M-2
WP 002 00
Military Public Health Services, the Safety Office, and
Fire Protection Office/Agency.
38. Avoid contact with skin, eyes, and clothing. The use
of gloves is advised to prevent irritation or inflammation
of the skin. If contact with the skin or eyes does occur,
quickly wash the affected area with water for at least 15
minutes. For eyes, seek medical attention immediately
after flushing eyes with water.
a.
Personnel shall be thoroughly familiar with and
follow all precautions as outlined in the
equipment manual when operating pneumatic
equipment.
b.
Personnel using pneumatic pressure during
cleaning/drying operations shall wear appropriate
safety clothing/equipment.
43. HAZARDOUS MATERIAL WARNINGS.
39. MERCURY AND THALLIUM HAZARDS.
40. The Guidance Control Section (GCS) shall be
handled as a delicate instrument and not be subjected to
sudden shocks by rough handling, dropping, etc. The GCS
has a damper unit which contains 0.59 gram of a mixture
of mercury (MIL-M-191, Grade II) and thallium. If the
dome is blown/broken off it will expose a rotating mirror
assembly. If the rotating mirror is broken, the mercury
thallium mixture may be present in the form of very small
silver looking droplets. Mercury and thallium shall be
handled as follows:
a.
Precautions must be taken to prevent the mixture
from coming in contact with the skin, especially
the eyes, since the mixture could cause blindness.
b.
If the eyes become contaminated, immediately
flood them with water. Refrain from rubbing
them and seek medical attention.
c.
If the skin has come in contact with the mixture,
immediately wash the affected area thoroughly
with soap and water.
d.
If clothing is contaminated, change immediately
and wash with soap and water.
e.
The small silver looking droplets may be
removed by brushing them into a container for
chemical waste disposal. The mixture must not
be exposed to a heat source, it will vaporize at
325°F, and the vapor is toxic.
f.
Contact your local Bioenvironmental Engineer
for waste disposal procedures.
41. PNEUMATIC HAZARDS.
42. Pneumatic pressure applied to the Guidance Control
Section (GCS) during test or coolant pressure tank during
recharging can create a hazard. High pressure is used in
operation of this equipment.
6
Change 1
44. Operation and maintenance procedures presented in
this TO require the use of products and materials which
contain chemicals that are hazardous to your health. The
user of this publication shall obtain the Material Safety
Data Sheets (MSDS) from Local Bioenvironmental
Engineering Services, manufacturers, or suppliers of
materials to be used. The user must become completely
familiar with the information and adhere to the
procedures, recommendations, warnings, and cautions of
the manufacturer/supplier for the safe use, handling,
storage, and disposal of these materials.
45. Warnings for the hazardous material listed and used in
this TO are designed to warn personnel of the hazards
associated with such items when they come in contact with
them by actual use. Additional information related to
hazardous material is provided in AFI 91 and AFOSH 91/
127 series publications. Consult your local safety and
health staff concerning any questions on hazardous
chemicals, MSDSs, personal protective equipment
requirement, and appropriate handling and emergency
procedures.
46. Hazardous materials used in this TO have been
assigned icons (Figure 1) and numerical identifiers (Table
1) which are also index numbers. Hazardous material
information included in this safety summary lists all
hazardous materials by index number and presents a
complete description of the hazard and protective
measures to observe.
47. In the text of this TO, the caption WARNING will not
be used for hazardous material. Instead, icons will be used
to alert personnel that the procedures to be performed
require the use of such products. Under this icon, the name
of the hazardous material and a numeric identifier will be
given. The hazardous material icon will only appear prior
to the procedure (immediately under paragraph title) in
which the material will be used.
48. All personnel operating or performing maintenance
on this equipment shall read and understand the hazards
associated with the material listed in this safety summary.
CSTO XX21M-AIM9M-2
WP 002 00
Whenever a hazardous material is called out for use,
personnel must know the specific hazards presented in
Table 1, and ensure that the required protective measures
are taken.
49. RENDERING SAFE AND DISPOSAL.
50. Damaged explosive components shall be reported and
disposed of in accordance with AFI 21-201.
51. The S-A device, Mk 13 Mod 2, shall be in a safe
condition at all times. S-A devices discovered in the
ARMED position cannot be rendered safe; notify EOD.
52. Ensure rocket motor safety-arming handle is locked in
the SAFE position. If not, move to SAFE position as
follows:
a.
For Mk 36 Mod 10/11:
(1) Pull handle to unlock and move to
vertical position; maintain pull pressure.
(2) Rotate handle 90 degrees clockwise and
move to horizontal position.
(3) Release pull pressure to lock in SAFE
position.
53. MISSILE OR EXPLOSIVE COMPONENTS
ENVELOPED BY FIRE.
54. COOKOFF
TIMES
AND
EVACUATION
DISTANCES. Fires involving conventional munitions
cannot be definitized to any one set of circumstances and
environmental conditions. This precludes development of
reliable standardized test criteria and reliable specific item
fire fighting and withdrawal times. The conclusion to be
reached from available data is that a munitions reaction to
fire is a function of case thickness and type of explosive
filler which can be varied by environmental conditions.
Since the circumstances of a fire cannot be predicted,
specific item by item fire fighting and withdrawal times
cannot be determined with any degree of reliability.
55. FIREFIGHTING. All fires starting in the vicinity of
ammunition or explosives shall be reported and fought
immediately with all available means to prevent spreading
of fire and munitions involvement (TO 11A-1-46).
Approach missile in minimum danger zones (Figure 2).
However, if fire engulfs explosives material or is
supplying heat to it, or if the fire is so large that it cannot
be extinguished with the equipment on hand, the personnel
involved shall evacuate and seek safety (Table 2).
56. Follow fire fighting guidance in AFMAN 91-201 in
all instances. Emergency withdrawal of nonessential
personnel will take place as quickly as possible.
(4) Install safety clip assembly.
b.
For Mk 36 Mod 8/9:
(1) Install handle, push in, rotate 90 degrees
clockwise and release pressure.
(2) Move handle to horizontal position.
57. Emergency withdrawal distances for nonessential
personnel depend upon fire involvement and on whether
or not the hazard classification, fire division, and quantity
of explosives are known. On scene authorities will
determine minimum withdrawal distances for essential
personnel. See Table 3 for non-essential personnel
withdrawl distance.
Change 1
7
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WP 002 00
Biological
Fire
Chemical
Poison
Explosion
Radiation
Eye Protection
Vapor
EXPLANATION OF HAZARD SYMBOLS
The abstract symbol bug shows that a material may contain bacteria or viruses that present danger to
your life or health.
The symbol of drops of liquid onto a hand shows that the material will cause burns or irritation of
human skin or tissue.
The rapidly expanding symbol shows that the material may explode if subjected to high temperatures,
sources of ignition, or high pressure.
The symbol of a person wearing goggles shows that the material will injure your eyes.
The symbol of a flame shows that a material can ignite and burn you.
The symbol of a skull and crossbones shows that a material is poisonous, or is a danger to life.
The symbol of three circular wedges shows that the material emits radioactive energy and can injure
human tissue or organs.
The symbol of a human figure in a cloud shows that vapors of a material present a danger to your life or
health.
Figure 1. Icons for Hazardous Materials and Examples of Application
8
CSTO XX21M-AIM9M-2
WP 002 00
Table 1. List of Hazardous Materials
Index
Name/Specification
Warning
HAZARD:
1
Adhesive, Epoxy MMM-A-134 Type I
Alcohol, Isopropyl, TT-I-735
Compound, Sealing, Primer,
MIL-S-22473, Grade T
Paints
Primers, Paint
Putty, Base Coat, E-400P
Compound Sealing, Top Coat, E-400F
Thinners, Paint
Very flammable and dangerous to skin and eyes. May cause a
narcotic effect, headaches, nausea, and vomiting, in high
concentrations. Irritant to respiratory tract.
APPLICATION:
Apply only in a well ventilated area. Safety goggles/face shield,
rubber gloves, and clothing sufficient to cover skin should be
used. Wash from skin with soap and water. Flush eyes with
copious amounts of water. Seek medical aid.
DISPOSAL:
Spill; isolate area and remove all ignition sources. Remove with
inert absorbent and non-sparking tools. Consult local
Bioenvironmental Engineering Services for disposal of cleaning
materials and empty containers.
HAZARD:
2
Corrosion Preventive Compound,
MIL-C-81309
Corrosion Preventive Compound,
MIL-C-85054
Sealing Compound, Scotchcal 3950
Lubricant, Solid Film, MIL- L-23398
Vapors are toxic and flammable. May cause eye irritation,
unconsciousness, headache, dizziness, nausea and upper
respiratory inflammation.
APPLICATION:
Use only in a well ventilated area and away from all sources of
ignition. Safety goggles/face shield, gloves and protective clothing
sufficient to avoid skin contact required. Wash from skin with
soap and water. Flush eyes with copious amounts of water. Seek
medical aid.
DISPOSAL:
Spill; isolate area and remove all ignition sources. Allow to
evaporate or remove with inert absorbent and non-sparking tools.
Consult local Bioenvironmental Engineering Services for disposal
of cleaning materials and empty containers.
Change 2
9
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
3
HAZARD:
Insulating Compound, GC-1300,
MIL-S-8516 Type II, Class I, Cure B
Flammable; avoid contact with open flame, heat, and strong
oxidizing agents. Vapors are toxic. Avoid contact with eyes and
skin. Contains lead. Eye, skin, and nose irritant. May cause
headache and muscular weakness.
APPLICATION:
Use only in a well ventilated area and away from all sources of
ignition. Safety goggles/face shield, gloves and protective clothing
sufficient, to avoid skin contact required. Wash from skin with
soap and water. Flush eyes with copious amounts of water. Seek
medical aid.
DISPOSAL:
Remove with inert absorbent. Consult local Bioenvironmental
Engineering Services for disposal of cleaning materials and empty
containers.
4
HAZARD:
Flammable and may cause temporary discomfort to skin and eyes.
Sealant, MIL-A-46146
APPLICATION:
Use only in a well ventilated area and away from all sources of
ignition. Wash from skin with soap and water. Flush eyes with
copious amounts of water. Seek medical aid.
DISPOSAL:
Remove with inert absorbent. Consult local Bioenvironmental
Engineering Services for disposal of cleaning materials and empty
containers.
10
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
5
HAZARD:
Skin and eye irritant.
Lubricant, Breakfree, MIL-L-63460
APPLICATION:
Use only in a well ventilated area and away from all sources of
ignition. Wash from skin with soap and water. Flush eyes with
copious amounts of water. Seek medical aid.
DISPOSAL:
Remove with inert absorbent. Consult local Bioenvironmental
Engineering Services for disposal of cleaning materials and empty
containers.
6
HAZARD:
Argon, Compressed, MIL-PRF-27415
Nitrogen, MIL-PRF-27401
Gas is odorless and colorless. Prolonged exposure can lead to
asphyxiation. Contact with pressurized escaping gas may lead to
frostbite or serious eye damage.
APPLICATION:
Do not use in a confined area where gas can accumulate and
displace the air. Avoid the escaping gas. Do not check for leaks
with hands as high pressure gas can penetrate the skin and enter
the bloodstream. Safety goggles/face shield should be worn.
DISPOSAL:
Released; evacuate area; allow gas to dissipate. For residual or
unused quantities, consult local Bioenvironmental Engineering
Services.
7
HAZARD:
Skin and eye irritant. May cause dermatitis on prolonged contact.
Adhesive, Epoweld 8173
Compound, Silicone, MIL-S-8660
Sealing Compound, MIL-S-46163
APPLICATION:
Safety goggles/face shield, rubber gloves and clothing sufficient
to cover skin should be used. Wash from skin with soap and water.
Flush eyes with copious amounts of water. Seek medical aid.
DISPOSAL:
Remove with inert absorbent. Consult local Bioenvironmental
Engineering Services for disposal of cleaning materials and empty
containers.
11
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
8
HAZARD:
Skin, eye, and respiratory tract irritant. Flammable.
Flux, Soldering, MIL-F-14256
APPLICATION:
Safety goggles/face shield, rubber gloves and clothing sufficient
to cover skin should be used. Avoid overheating closed containers.
DISPOSAL:
Clean up with rags. Consult local Bioenvironmental Engineering
Services for disposal of cleaning materials and empty containers
9
HAZARD:
Solder, SN63, QQ-S-571
Contains lead. Over exposure may cause damage to nervous and
intestinal systems.
APPLICATION:
Safety goggles/face shield, rubber gloves and clothing sufficient
to cover skin should be used. Use with adequate ventilation. Wash
from skin with soap and water.
DISPOSAL:
Clean up with rags. Consult local Bioenvironmental Engineering
Services for disposal of cleaning materials and empty containers
10
HAZARD:
Paint, High Zinc Dust Content,
MIL-P-21035 (Devcon Z Bulk or
Sprayon Aerosol P/N 740)
Toxic and flammable. Avoid contact with skin and eyes. Avoid
breathing vapors; prolonged or repeated exposure to high
concentrations may cause neural dysfunction. Keep away from
heat, sparks, and flame. Avoid contact with strong oxidizers,
acids, and bases.
APPLICATION:
Protection: full face-piece continuous-flow supplied air respirator,
butyl gloves; protective clothing required during spraying
operations.
DISPOSAL:
Eliminate sources of ignition. Absorb with sweeping compound.
Consult local Bioenvironmental Engineering Services for disposal
of cleaning materials and empty containers
12
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
11
HAZARD:
Compound, Sealing,
MIL-S-22473, Grade C
Flammable. Avoid prolonged contact with skin and eyes. Keep
away from heat, sparks, and flame. Avoid contact with oxidizers
and reducing agents.
APPLICATION:
Protection: gloves and eye protection recommended. Use good
ventilation; local exhaust. Wash hands after use.
DISPOSAL:
Provide good ventilation. Soak up spill with earth, sand, or
absorbent product (Zorbal). Consult local Bioenvironmental
Engineering Services for disposal of cleaning materials and empty
containers
13
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
12
HAZARD:
PERMABOND HM 118
Adhesive/Sealant, Anaerobic
Vapors irritate eyes. Eye contact may cause permanent damage if
eye is not immediately irrigated. Repeated or prolonged skin
contact may cause irritation and skin sensitization. Can be rapidly
absorbed through skin. Toxic vapors may be released at elevated
temperatures irritating respiratory system. Ingestion may cause
nausea, vomiting and diarrhea.
APPLICATION:
Use general ventilation. Respirator not required under normal
conditions. Use NIOSH respirator if vapor are irritating. Use
safety glasses, goggles or face shield. Wear protective gloves. No
protective clothing required for low volume use. Wash before
eating, drinking, or using toilet. First-Aid Treatment: For eyes,
immediately irrigate with eyewash solution/clean water for 10
minutes, holding eyelids apart. Obtain immediate medical
attention. For skin contact, remove with soap and water. Launder
contaminated clothing. If difficulty breathing, use respiratory
protection to immediately remove victim to fresh air. Administer
artificial respiration if breathing has stopped. If breathing is
difficult, give oxygen. Get medical attention. If ingested, do not
induce vomiting. If conscious, give milk or water. Get prompt
medical attention. Firefighting: Use self-contained breathing
apparatus. Fire/Explosion Hazard: Polymerization may take place
at elevated temperatures. Handling/Storage: Keep away from heat,
sources of ignition and direct sunlight. Do not freeze.
DISPOSAL:
Stop small leaks if minimal personal risk. Clean small spills with
sand or inert absorbent material. Place in container for disposal.
Vent disposal container to prevent buildup of pressure. For large
spills or leaks seek assistance. A large quantity may polymerize
generating significant heat and pressure. Consult local
Bioenvironmental Engineering Services for disposal of cleaning
materials and empty containers.
14
Change 1
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
13
HAZARD:
LOCTITE 7471
Primer Coating
Flammable liquid and vapor. Respiratory tract irritant. Headache,
dizziness, nausea, and loss of coordination indicate excessive
exposure. Skin irritant and can cause dermatitis. Vapors may
irritate eyes. Material in eyes will cause irritation. Moderately
toxic by ingestion.
APPLICATION:
Ventilate area during use and until all vapors are gone. Remove
ignition sources: no smoking, extinguish flames, turn off electrical
tools, heaters and appliances. Use ventilation to maintain vapor
concentration below exposure limits. Avoid contact with eyes and
skin. Use goggles or safety glasses with side shields. Use chemical
resistant, impermeable gloves. Wash thoroughly after handling.
Avoid breathing vapor and mist. Use NIOSH respirator if vapors
exceed exposure limit. If difficulty breathing, remove person to
fresh air and seek medical attention. If in eyes flush eyes with
water for at least 15 minutes, while holding eyelids open. If
ingested and victim is conscious drink water. Do not induce
vomiting. Obtain medical attention. Store away from heat, flames,
or other ignition sources. Store below 120°F (49°C). Do not store
near strong oxidizers/acids. Firefighting: Use foam, dry chemical
or carbon dioxide. Firefighters wear self-contained breathing
apparatus and full protective clothing. Vapors may accumulate in
low or confined areas, travel considerable distance to source of
ignition, and flash back.
DISPOSAL:
If spilled, prevent from entering drains or open waters. Clean-up:
Remove ignition sources. Ensure adequate ventilation. Soak up
with inert absorbent. Store in closed container for disposal.
Consult local Bioenvironmental Engineering Services for disposal
of cleaning materials and empty containers.
Change 1
15
CSTO XX21M-AIM9M-2
WP 002 00
Index
Table 1. List of Hazardous Materials (Continued)
Name/Specification
Warning
14
HAZARD:
Adhesive, Epoxy,
2216B/A
Extremely irritating to eyes upon direct contact. May cause
permanent eye damage. May cause skin irritation upon prolonged
contact. May cause sensitization in some individuals. Vapors may
be irritating to respiratory system. May cause gastrointestinal
irritation. Symptoms of overexposure: eyes: irritating. skin:
irritating may cause sensitization.
APPLICATION:
First aid: Eyes: flush with plenty of water for at least 10 minutes.
Contact a physician. Skin: wash thoroughly with soap and water.
Inhalation: provide fresh air. Swallowed: drink two glasses of
water or milk and call a physician. Ventilation: local or
mechanical exhaust. Protective gloves: impervious gloves. Eye
protection: safety glasses. Fire fighting procedures: Fire fighters
should wear self-contained breathing apparatus when fighting
fires involving this material. Extinguishing media: CO2, foam, dry
chemical, water.
DISPOSAL:
Spill release procedures: Ventilate area. Collect spilled material.
Cleanup residue and place in a metal container Dispose of clean
up material by incineration in industrial or commercial incinerator.
When fully cured, may be disposed in a sanitary landfill per
regulations. Consult local Bioenvironmental Engineering Services
to assure conformity with applicable disposal regulations.
16
Change 1
CSTO XX21M-AIM9M-2
WP 002 00
15
Table 1. List of Hazardous Materials (Continued)
HAZARD:
MIL-PRF-24176, Type II (Part A)
Exposure may cause eye irritation with tearing and redness.
Prolonged/frequent exposure may cause redness and itching skin,
or dermatitis.
APPLICATION:
Avoid eye/skin contact. Use NIOSH organic vapor respirators for
hot material, nitrile/neoprene gloves, safety glasses with splash
guards, apron, eye wash station. First aid for eyes: flush with
flowing water for at least 15 minutes. Obtain medical attention.
Remove material from skin with soap and water. If ingested
immediately seek medical attention; do not induce vomiting.
Decomposition Products: aldehydes, carbon monoxide, carbon
dioxide, phenolics, soot. Store in cool, dry area from direct
sunlight in closed container. Wash contaminated clothing before
reuse. Avoid contact with base compounds, high heat. Do not
smoke, drink or eat in work areas. Use with local ventilation..
DISPOSAL:
React with curing agent, and dispose as non-hazardous solid
according to regulation. Spill Procedure: Scoop up and return to
container. Remove residue with soap and water, or 1,1,1
trichloroethane. Neutralizing Agents: amines, organic acids.
Consult local Bioenvironmental Engineering Services for disposal
of cleaning materials and empty containers.
16
HAZARD:
MIL-PRF-24176, Type II (Part B)
Vapor/mist can irritate the nose & throat. Severely irritating to
eyes and skin..
APPLICATION:
Avoid contact with skin, eyes and clothing. Use NIOSH respirator
with organic vapor canister, with ventilation, rubber gloves, safety
glasses, apron and safety shoes. Do not smoke, drink or eat in
work areas. If ingested immediately seek medical attention; do not
induce vomiting. Wash contaminated clothing before reuse. Store
in cool, dry area from direct sun light and excessive heat in closed
containers. Avoid contact with strong oxidizing and reducing
agents..
DISPOSAL:
React with base component and dispose as non-hazardous waste
according to regulations. Spill Procedure: scoop up and return to
container. Wash area with soap and water. Consult local
Bioenvironmental Engineering Services for disposal of cleaning
materials and empty containers.
Change 2
16.1/(16.2 Blank)1
CSTO XX21M-AIM9M-2
WP 002 00
Table 2. Fire Symbol Hazards and Actions
FIRE
SYMBOL
1
MATERIALS
HAZARD
ACTION/REMARKS
1.1 Explosives and certain liquid Mass detonation 1. Do not fight fire unless rescue attempt is
planned.
propellants and 1.5 munitions
2. If there is suitable separation to symbol 1
materials and fire chief approves, firefighting forces
may attempt to extinguish the fire.
AIM-9M Missile
AIM-9M Warhead
3. If personnel safety is in doubt, take cover.
2
1.2 Ammunition and explosives
and 1.6 EIDS
Explosion with
fragments
1. Give alarm; attempt to extinguish fire if in early
stage.
2. Firefighting forces should fight fire. If not
possible, prevent spread of fire.
3. Detonation of items could occur. Provide
protection from fragments.
3
1.3 Ammunition and explosives
Mass fire
1. May be fought if explosives not directly
involved.
Moderate fire
1. Fight these fires.
AIM-9M Rocket Motor
4
1.4 Ammunition and explosives
AIM-9M Guidance and Control
Section
AIM-9M S&A Device
2. Expect minor explosions and hot fragments.
Change 1
17
CSTO XX21M-AIM9M-2
WP 002 00
Table 3. Minimum Withdrawal Distances for Explosives Involved in Fire (Reference T.O. 11A-1-46)
DISTANCE
(FEET)
CLASS/DIVISION
1.4 AIM-9M Guidance and Minimum Distance
Control Section
AIM-9M S&A Device
300
1.3 AIM-9M Rocket
Motor
Minimum Distance (See Note 2)
600
1.1 AIM-9M Missile
AIM-9M Warhead
Unknown Quantity
Aircraft, Truck, Tractor, Trailer, Facility
4000
Railcar
5000
500 lbs. or less, all modes
2500
More than 500 lbs., railcar
5000
Transportation
More than 500 lbs., all other modes including aircraft 4000
Facilities
15,000 lbs. or less
2500
More than 15,000 lbs., less than 55,285 lbs.
4000
More than 55,285 lbs.
K105
Essential Personnel (See Note 3).
Accidents Involving Explosives Without Fire (See Note 6).
NOTES:
1. For Class/Division 1.1 and 1.2 munitions, use maximum debris and fragment throw ranges, if known, in lieu of
distances in this chart.
2. For quantities of 1.3 over 100,000 pounds, withdrawal distance is equal to K16.
3. On-scene authorities will determine minimum withdrawal distances for essential personnel.
4. K105 distance is determined by: D=105W1/3 or D=KxW1/3
5. The withdrawal distances in this table apply to nonessential personnel only.
6. When accidents occur and there is no fire, the on-scene commander will determine whether to implement withdrawal
criteria.
7. This table is copied from T.O. 11A-1-46. If there is a conflict between this table and the same table in T.O. 11A-1-46
then T.O. 11A-1-46 shall take precedence.
18
Change 1
CSTO XX21M-AIM9M-2
WP 002 00
Z ONE E
WARHEAD
Z ONE D
ZONE A
Z ONE D
ROCKET
MOTO R
Z ONE C
MINIMUM
DANGER
ZONE
ZONE
MISSILE AXIS
Z ONE B
ZONE C
Z ONE B
CHARACTERISTICS
MINIMUM
DA NGER
ZONE
RADIUS
ARC
A
LETHAL BLAST
10 FEET MEASURED FROM
CENTER OF WARHEAD
130° EACH SIDE OF MISSILE
B
LETHAL FRAGMENTATION AND
BLAST PRESSURE
a. 10 FEET MEASURED FROM
YELLOW BAND ON WARHEAD
b. 250 FEET MEASURED FROM
NOZZLE OF ROCKET MOTOR
30° EACH SIDE OF MISSILE
10° EACH SIDE OF MISSILE
C
SAFEST APPROACH TO BE
USED FOR FIREFIGHTING
(FRAGMENTATION POSSIBLE)
NO CLOSER THAN 10 FEET
FROM FRONT OF ROCKET
MOTOR
20° MEASURED 10° OFF EACH
SIDE OF MISSILE AXIS
D
LETHAL FRAGMENTATION
1800 FEET
130° EACH SIDE OF MISSILE
E
LETHAL FORWARD THRUST
NOT DETERMINED
20° EACH SIDE OF MISSILE AXIS
Figure 2. Danger Zones
Change 1
19
19/(20 blank)
CSTO XX21M-AIM9M-2
WP 003 00
WORK PACKAGE
DESCRIPTION OF TACTICAL AUR
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 18
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
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6-7 . . . . . . . . . . . . . . . . . . . . . . . 0
12 . . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
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8. . . . . . . . . . . . . . . . . . . . . . . . . 1
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Page No.
Change No.
4-5 . . . . . . . . . . . . . . . . . . . . . . . . 1
9-11 . . . . . . . . . . . . . . . . . . . . . . . 0
15-18. . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Unpacking, Packaging, Inspection, and Ground Handling AIM-9M Tactical Missile..........................................WP 006 00
Table of Contents
Title
Page
Component Description .........................................................................................................................................................6
Coolant Pressure Tank (Accumulator).................................................................................................................................8
Coupling Ring Assemblies ................................................................................................................................................13
DSU-15/B, DSU-15A/B, and DSU-15B/B Target Detector ................................................................................................9
Physical Description ..........................................................................................................................................................9
Principles of Operation ......................................................................................................................................................9
Fins.......................................................................................................................................................................................8
Guidance Control Section ....................................................................................................................................................6
Physical Description ..........................................................................................................................................................7
Principles of Operation ......................................................................................................................................................7
Rocket Motor, Mk 36 Mod 7 ............................................................................................................................................. 11
Rocket Motor, Mk 36 Mod 8 and 10 ................................................................................................................................. 11
Rocket Motor, Mk 36 Mod 9 and 11.................................................................................................................................. 11
Physical Description ........................................................................................................................................................ 11
Principles of Operation .................................................................................................................................................... 11
Safety-Arming Device .........................................................................................................................................................9
Physical Description ..........................................................................................................................................................9
Principles of Operation ......................................................................................................................................................9
Warhead ............................................................................................................................................................................. 11
Physical Description ........................................................................................................................................................ 11
Principles of Operation .................................................................................................................................................... 11
Change 1
1 of 18
CSTO XX21M-AIM9M-2
WP 003 00
Table of Contents (Continued)
Title
Page
Wing, Mk 1 Mod 1 and Mk 1 Mod 2 ................................................................................................................................ 11
Physical Description ........................................................................................................................................................ 13
Principles of Operation.................................................................................................................................................... 13
Electrical and Pneumatic Power Requirements for the TS-4044/D, GCU-26A/E, and GCU-30/E.................................... 13
GCS Coolant Gas ................................................................................................................................................................ 16
Coolant Gas Basics............................................................................................................................................................ 16
Coolant Gases Contamination ........................................................................................................................................... 17
Coolant Gases Performance .............................................................................................................................................. 16
Excessive Coolant Gas Consumption................................................................................................................................ 17
Mixing Coolant Gases ....................................................................................................................................................... 16
Navy Coolant Gas.............................................................................................................................................................. 18
TMU-72 Coolant Tank Purging......................................................................................................................................... 16
TS-4044 Step 003 Failure.................................................................................................................................................. 17
General .................................................................................................................................................................................. 3
Missile Description................................................................................................................................................................ 3
Physical Description ............................................................................................................................................................ 3
Principles of Operation........................................................................................................................................................ 3
Captive Flight Phase.......................................................................................................................................................... 3
Free Flight ......................................................................................................................................................................... 6
Launch Sequence............................................................................................................................................................... 6
Pop-Out Pressure Relief Valve ............................................................................................................................................ 13
Umbilical Cable Spring Pin and Launcher Compatibility................................................................................................... 16
List of Illustrations
Title
Page
AIM-9M Guided Missile (Sidewinder) ................................................................................................................................. 3
AIM-9M Guided Missile (Sidewinder), Exploded View ...................................................................................................... 4
Coolant Gas Demand Flow System Functional Diagram...................................................................................................... 9
Coolant Pressure Tank (Accumulator) TMU-72/B, TMU-72A/B or TMU-72B/B .............................................................. 8
Coupling Ring Assemblies .................................................................................................................................................. 14
Guidance Control Section, WGU-4A/B ................................................................................................................................ 8
Launch Sequence................................................................................................................................................................... 7
Pop-Out Pressure Relief Valve ............................................................................................................................................ 15
Rocket Motor, Mk 36 Mods 7, 8, 9, 10, and 11................................................................................................................... 12
Safety-Arming Device, Mk 13 Mod 2................................................................................................................................. 10
Target Detector DSU-15/B, DSU-15A/B and DSU-15B/B................................................................................................. 10
Umbilical Cable PN 639AS10935....................................................................................................................................... 16
Warhead, WDU-17/B .......................................................................................................................................................... 10
Wings, Mk 1 Mods 1 and 2 ................................................................................................................................................. 12
List of Tables
Title
Page
Coolant Gas Specifications.................................................................................................................................................. 18
Cooling Time Per TMU-72 Coolant Tank........................................................................................................................... 18
Leading Particulars ................................................................................................................................................................ 5
2
Change 1
CSTO XX21M-AIM9M-2
WP 003 00
1.
GENERAL.
2. This WP provides a description of the Guided Missile
Intercept Aerial Sidewinder, AIM-9M Missile (Figure 1)
and the components related to the AIM-9M missile
(Figure 2). Missile and missile component leading
particulars are contained in Table 1. Missile configurations
are shown in Table 5 of WP 006 00.
3.
MISSILE DESCRIPTION.
4. The Sidewinder AIM-9M is a supersonic, airlaunched, guided missile employing passive infrared (IR)
target detection, proportional navigational guidance, a
torque balance control system, and an active optical target
detector.
5. PHYSICAL DESCRIPTION. The missile is 113
inches long and 5 inches in diameter with a wing span of
approximately 25 inches. The missile is comprised of five
major components: the Guidance Control Section (GCS),
Target Detector (TD), Safety-Arming Device (S-A),
warhead, and rocket motor. Four fin assemblies attach to
the GCS and four wing assemblies attach to the rocket
motor (Figure 2). An umbilical cable and the forward
hanger aft contact button electrically connect the missile to
the aircraft when the missile is attached to the aircraft
launcher.
cable. The missile has three basic phases of operation;
captive flight, launch, and free flight. Power is supplied
from the launcher during captive flight. The power is
switched to the missile contained thermal batteries during
the launch phase and during free flight.
7. Captive Flight Phase. The AIM-9M missile operates
electrically during captive flight from a power supply in
the launcher which receives 28 Vdc and 115 Vac, 400 Hz,
single-phase power from the aircraft and provides +25.2
Vdc to the missile (Figure 3). Aircraft power is available
to the missile as soon as electrical power is applied or, on
some aircraft, when engines are started, to allow the
missile gyro to spin and electrically cage (boresight to
missile axis). When required, the pilot initiates missile
cool-down and sets the aircraft arming circuitry to enable
missile firing (MASTER ARM-ON). When an IR source
enters the GCS Field-Of-View (FOV), an enhanced audio
signal is generated in the GCS. The pilot hears the signal
through his headset, indicating to him that the AIM-9 has a
potential target. On aircraft with Heads-Up-Display
(HUD), a visual indication is displayed, indicating where
the missile gyro has slaved. The pilot may use on-board
radar to slave the GCS gyro, however, no radar interlocks
exist in the aircraft-launcher-missile firing circuits. The
AIM-9 may therefore be fired regardless of the status of
the on-board radar. The AIM-9 requires no radar or
auxiliary fire-control system for acquisition, guidance, or
fuzing.
6. PRINCIPLES OF OPERATION. The AIM-9M
missile interfaces with the aircraft through an umbilical
Figure 1. AIM-9M Guided Missile (Sidewinder)
3
CSTO XX21M-AIM9M-2
WP 003 00
WGU-4A/B
COOLANT
PRESSURE
TANK
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 2. AIM-9M Guided Missile (Sidewinder), Exploded View
4
Change 1
CSTO XX21M-AIM9M-2
WP 003 00
Table 1. Leading Particulars
GENERAL (AIM-9M Missile)
Length .........................................................................................................................................................113 in.
Diameter......................................................................................................................................................... 5 in.
Weight (including coolant pressure tank) .............................................................................................. 191.7 lbs.
Center of gravity from nose (nominal) .........................................................................................................61 in.
Explosive.................................................................................................................................................... 7.9 lbs.
WING, Mk 1 Mod 1 and Mk 1 Mod 2
Span (attached, rolleron caged)..................................................................................................................24.8 in.
Span (attached, rolleron uncaged)..............................................................................................................25.2 in.
Weight (4 wings with rollerons).................................................................................................................. 24 lbs.
FIN, BSU-32/B
Span (installed) ..........................................................................................................................................22.3 in.
Weight (4 fins) .............................................................................................................................................. 8 lbs.
GUIDANCE CONTROL SECTION, WGU-4A/B
Length ...........................................................................................................................................................24 in.
Weight (without fins and coolant pressure tank) ........................................................................................ 26 lbs.
Explosive (LFT-6)...................................................................................................................................... 1.0 lbs.
TARGET DETECTOR, DSU-15/B, DSU-15A/B, and DSU-15B/B
Length .............................................................................................................................................................7 in.
Weight ........................................................................................................................................................... 9 lbs.
Explosive, Lead Mononitrorescorcinate/Potassium Chlorate (LMNR/KClO4) .................................. 0.0039 lbs.
SAFETY-ARMING DEVICE, Mk 13 Mod 2
Length ..........................................................................................................................................................7.1 in.
Diameter.......................................................................................................................................................1.5 in.
Weight (approximate) ................................................................................................................................ 1.4 lbs.
Explosive (CH-6) ................................................................................................................................ 0.0039 lbs.
WARHEAD, WDU-17/B
Length ........................................................................................................................................................13.5 in.
Weight ...................................................................................................................................................... 20.8 lbs.
Explosive (PBXN-3) .................................................................................................................................. 7.9 lbs.
ROCKET MOTOR, Mk 36 Mod 7, Mk 1 Mod 8, Mk 1 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11
Length ...........................................................................................................................................................70 in.
Weight (without wings)............................................................................................................................... 99 lbs.
Weight (with wings).................................................................................................................................. 123 lbs.
Explosive (HTBP propellant weight).......................................................................................................... 60 lbs.
COOLANT PRESSURE TANK (ACCUMULATOR), TMU-72/B, TMU-72A/B or TMU-72B/B
Length ..........................................................................................................................................................4.4 in.
Diameter.......................................................................................................................................................3.9 in.
Weight ........................................................................................................................................................ 3.5 lbs.
ARGON/NITROGEN/AIR PURITY REQUIREMENTS (by volume):
Water ............................................................................................................................................................2 ppm
Carbon dioxide.............................................................................................................................................2 ppm
Methane........................................................................................................................................................6 ppm
Acetylene .....................................................................................................................................................1 ppm
Hydrocarbons (all others) ............................................................................................................................3 ppm
Mechanical particles (maximum size) ...................................................................................................3 microns
Change 1
5
CSTO XX21M-AIM9M-2
WP 003 00
8. Target acquisition may also be attained with the
missile boresighted to the aircraft axis, by Sidewinder
Expanded Acquisition Mode (SEAM) or Visual Target
Acquisition System (VTAS). On aircraft with SEAM or
VTAS, AIM-9 optics can be slaved to radar commands or
a helmet mounted sight. The missile remains slaved until
an audible signal indicates seeker IR acquisition. Upon
acquisition an interlock is released (uncaged) and the
missile seeker begins target tracking. On some aircraft, an
uncaged mode is provided which allows the missile to
self-track a target after acquisition in boresight mode. In
all modes, target acquisition is indicated by an audible
tone on the aircraft intercommunication system. The AIM9 missile may be launched in any of these modes.
9. Launch Sequence. In the launch sequence (Figure 3)
the following series of events occur.
Event 1. Pilot sets SAFE-ARM switch on aircraft
MISSILE CONTROL PANEL to ARM. This arms
launcher firing circuit.
Event 2. Pilot initiates launch sequence by
depressing trigger pickle switch and all subsequent events
are automatic.
Event 3. Launcher firing voltage ignites GCS
thermal battery and servo gas generator squibs. Launcher
also unlocks the S-A device setback weight by providing a
launch latch voltage. Warhead cannot be detonated until SA mechanism senses sufficient motion to well clear launch
aircraft. If GCS is not already tracking, launcher frees
(uncages) gyro enabling GCS target tracking.
Event 4. As GCS thermal battery begins to operate,
and upon reaching 16 Vdc (launch potential) initiates two
actions through launcher; the TD thermal battery squib is
fired, and the rocket motor squib is fired. The GCS
thermal battery also provides a launch lock voltage to the
S-A device to maintain the setback weight in the unlocked
position in preparation for event 7. If the GCS thermal
battery does not power up to the 16 Vdc launch potential,
the firing relay in the launcher will not activate and event
4 and all subsequent events will not occur. The circuit is to
ensure against launching a non-functional missile. The
GCS thermal battery supplies power to the contact fuze
(inertia switch).
missile from maneuvering until it is clear of the launch
aircraft (600-1000 feet). The 2.9-second lambda
compensation circuit dampens any missile maneuver in
excess of 15 degrees during its initial 2.9-seconds of flight.
The launch sequence from fire (Event 2) to first motion
(Event 5) requires about 0.5 seconds.
Event 6. GCS and TD thermal batteries attain full
potential. The 0.4-second enable circuit initiated in Event
5 has expired, thus allowing the missile to maneuver.
Event 7. S-A has sensed sufficient acceleration
time and is armed. Warhead can now be detonated by TD
(proximity) or by inertia switch (impact). At 2.9-seconds
after first motion (Event 5), lambda compensation to rate
bias change-over occurs. If the missile should experience
acceleration problems (rocket motor failure) or minimum
distance requirements, the S-A device will not be fully
armed or will return to the SAFE position.
10. Free Flight. Shortly after firing is initiated, the
missile leaves the launching aircraft. The control system is
activated and makes an initial large correction to a
collision course. If the missile is on a pure pursuit course,
only a small correction may be required. After the initial
turn, the missile makes continuous corrections to maintain
a collision course. The missile develops control signals
that are proportional to the rate of change of the angle
between the missile heading and the Line-of-Sight (LOS)
heading to the target. These signals control the fins which
control the flight path of the missile so the rate of change
of the angle is nulled. The missile will fly a straight course
to impact as long as the LOS angle remains constant.
11. The early large correction occurs because the missile
is initially moving slowly (at aircraft launch velocity). Due
to this low velocity, proportional navigation directs the
missile toward an intercept point well ahead of the target.
As the missile’s velocity increases, the intercept point
moves back and the missile moves along a normal flight
path. When the missile passes within close proximity of
the target, the TD sends a firing signal to the explosive
train in the S-A device causing initiation of the warhead. If
contact is made with the target, a signal from the inertia
switch in the GCS initiates the explosive train in the S-A
device.
12. COMPONENT DESCRIPTION.
Event 5. The GCS thermal battery attains operating
potential of 21 volts and the GCS begins operating on
internal power. First motion begins which separates the
umbilical from the GCS and initiates a 0.4-second servo
enable and a 2.9-second lambda compensation delay
circuit. The 0.4-second servo enable circuit prevents the
6
13. GUIDANCE CONTROL SECTION. The Guidance
Control Section is the foremost section of the missile
(Figure 2).
CSTO XX21M-AIM9M-2
WP 003 00
Figure 3. Launch Sequence
14. Physical Description. The WGU-4A/B GCS, (Figure
4) has improved electronics to provide increased
sensitivity and improved background rejection over
previous Sidewinder versions. Counter-Countermeasures
(CCM) is also provided. It consists of three major
assemblies; an Infrared (IR) seeker assembly for detecting
the target, an electronic assembly for converting the
detected target information to tracking and guidance
command signals, and a hot gas servo assembly
(consisting of a gas generator, manifold, pistons, rocket
arms, electrical solenoids, and a thermal battery) where
electrical guidance commands are converted to
mechanical movement of the control fins. The GCS also
contains an inertia switch and capacitor; if the missile
strikes the target, the inertia switch actuates and discharges
the capacitor which feeds a firing pulse to the S-A device
to initiate warhead detonation. An umbilical cable is part
of the GCS but is sheared off at missile launch.
15. Principles of Operation. The GCS seeks and homes
on IR energy emitted by the target when the missile is
pointed toward a target. the IR energy gathered by the
GCS seeker is converted to electronic signals that enable
the missile to track and guide to the target. When an IR
emitting source enters the GCS field-of-view, an enhanced
audio signal is generated in the GCS. The pilot hears the
signal through his headset, indicating to him that the
missile has acquired a potential target. Target tracking is
indicated by an increase in volume of this signal when the
tracker is uncaged. The missile may be launched during
target acquisition or target tracking.
16. When launch is initiated, a firing voltage is applied
through the launcher which causes the GCS thermal
battery squib and the servo gas grain generator squib to
ignite. If the GCS seeker is not already tracking, a signal is
applied to uncage the seeker tracker and enable target
tracking. As the GCS thermal battery begins to operate,
7
CSTO XX21M-AIM9M-2
WP 003 00
ACCESS COVER TO
TMU-72 COOLANT
PRESSURE TANK
FIN
BSU-32/B
Figure 4.
Guidance Control Section, WGU-4A/B
Figure 5.
Coolant Pressure Tank (Accumulator),
TMU-72/B, TMU-72A/B or TMU-72B/B
the audio tone is disabled. When the GCS thermal battery
reaches 16 Vdc, a signal is applied through the launcher to
ignite both the TD thermal battery squib and rocket motor
squib. The GCS thermal battery also applies the launchlock signal to the S-A device so mechanical arming will
continue on separation. The GCS thermal battery applies
power to the contact fuze (inertia switch). When the GCS
thermal battery attains a 21 volt potential, the GCS begins
to operate on internal power.
initial cool down and the number of cool down cycles
have a large impact on bottle duration. A full TMU-72
bottle will provide sufficient cooling gas to last throughout
all but the longest sorties. GCSs that repeatedly fail to cool
down, especially at the end of typical sorties, may have a
leak in the coolant flow system. These GCSs must be
returned to the depot for repair. In this TO the term argon
is used exclusively when referring to the coolant used in
AIM-9M missiles. It shall be understood that nitrogen gas
or air may also be used. Argon is the preferred coolant.
See Paragraph 49 for more specific information on coolant
gases.
17. COOLANT
PRESSURE
TANK
(ACCUMULATOR). The coolant pressure tank, TMU72/B, TMU-72A/B or TMU-72B/B (Figure 5) provides
high pressure argon gas, nitrogen gas, or air to cool the
GCS Refrigerated Detector Unit (RDU) (Figure 6) during
aircraft flight. Once the missile leaves the aircraft, power
is lost to the coolant valve and the tank is no longer used.
A small reservoir in the GCS supplies coolant for
approximately one minute while the missile is in flight.
This is ample time for the missile to reach the target.
Argon, nitrogen or air may be used as a coolant. The
coolant pressure tank is capable of storing 4.92 cu. ft. (0.4
pounds) of argon, nitrogen or air at a maximum pressure
of 5,000 pounds per square inch. A fully charged coolant
tank will provide approximately 9.0 hours of continuous
cooling when filled with argon gas and approximately 5.5
hours of continuous cooling when filled with nitrogen gas
or air. Sustained cooling rates of argon, nitrogen or air are
less per hour than initial cool down rates. Coolant usage
varies due to temperature, flight time and type of sortie.
The cumulative effect of greater demand for argon during
8
Change 1
18. The repair Depot and the Navy use nitrogen with the
AIM-9M. (The difference is more nitrogen is consumed
than argon during the cooling cycle.) If the bottles are
filled with a nitrogen/argon mix gas freeze up may occur.
If necessary, purge the bottle(s) by depressurizing each
one (SWP 008 08) and refilling it (TO 35D18-5-1 for
GCU-30) three times to ensure the tank is not filled with a
gas mixture. See Paragraph 49 for more specific
information on coolant gases.
19. FINS. Four identical fins, BSU-32/B, (Figure 4)
located on the GCS provide a lift force on the airframe
proportional to the input signal from the seeker, missile
velocity, and altitude. The fins are electrically controlled
and pneumatically operated by a servo system located in
the aft part of the GCS.
CSTO XX21M-AIM9M-2
WP 003 00
NAVY GAS COOLANT BOTTLE
(LOCATED IN LAUNCHER, LAU-7/A SERIES)
LAUNCHER CONTROL VALVE
3,000 PSIG AIR/NITROGEN
INDICATES COOLANT GAS FLOW
PRESSURE INDICATOR
UMBILICAL BLOCK
CRYOGENIC COOLER
COOLANT
PRESSURE
TANK
TMU-72
28 VDC
COOLANT FLOW
CHECK VALVE
REFRIGERATED
DETECTOR UNIT
DEMAND-FLOW
CRYOSTAT
GAS
RESERVIOR
SOLENOID
VALVE
CONTAINS IR CELL
RESERVOIR CAPACITY
APPROXIMATELY 60 SECONDS
Figure 6. Coolant Gas Demand Flow System Functional Diagram
20. DSU-15/B,
DSU-15A/B,
AND
DSU-15B/B
TARGET DETECTOR. Target Detectors (Figure 7) are
functionally interchangeable on the missile. The TD is
installed between the GCS and warhead.
21. Physical Description. The major components of this
narrow-beam, active optical system are the transmitter,
receiver, signal processing logic, dc-to-dc converter, and a
thermal battery. The four TD transmitters and four
receivers are arranged in quadrants around the missile
axis. Each transmitter and receiver pair make one
quadrant. This arrangement provides 360-degree coverage
around the missile axis. The transmitter and receiver
assemblies are optically aligned and bonded into
individual cavities in the electronics housing. The TD
comes assembled with two coupling ring assemblies for
clamping to adjoining components. DSU-15/B target
detectors are hermetically sealed. Some of the /B units
were built to accommodate telemetry installation. DSU15A/B and subsequent versions are sealed but not
hermetically to allow for more extensive depot level
repair. The A/B units were not built to accommodate
telemetry installation. All DSU-15B/B target detectors
have a telemetry tube for installation of a telemetry cable.
22. Principles of Operation. The TD transmits pulsed IR
energy through all four forward windows and the reflected
IR energy is received by an IR detector through the four
aft windows. When the reflected IR energy reaches a
threshold level, the TD generates a firing pulse which is
fed to the S-A device which, if armed, initiates warhead
detonation. Variable threshold level and pulse logic
techniques are used to prevent false firing due to the sun,
clouds, or countermeasures.
23. SAFETY-ARMING DEVICE. The Safety-Arming
(S-A) Device Mk 13 Mod 2 (Figure 8) is an
electromechanical device that causes initiation of the
warhead.
24. Physical Description. The S-A device is 7.1 inches
long, 1.5 inches in diameter and weighs 1.4 pounds. It
contains 0.0039 pounds of high explosive (CH-6). The SA has two windows: one for viewing the condition of the
Safe-Arm indicator and one for viewing the condition of
the launch-latch.
25. Principles of Operation. At launch, the S-A device
launch-latch is electrically unlocked. Missile acceleration
of at least 6g causes a setback weight to move into the
enabled position. Continued acceleration causes
eccentrically weighted rotors to rotate. When the rotors
have traveled through their full movement the explosive
train is complete. On target intercept, an electrical signal
from the TD initiates the S-A device explosive train;
warhead booster ignition and warhead detonation follows.
9
CSTO XX21M-AIM9M-2
WP 003 00
Figure 7. Target Detector DSU-15/B, DSU-15A/B, and DSU-15B/B
Figure 8. Safety-Arming Device, Mk 13 Mod 2
Figure 9. Warhead, WDU-17/B
10
CSTO XX21M-AIM9M-2
WP 003 00
26. WARHEAD. The warhead WDU-17/B (Figure 9) is
an Annular Blast Fragmentation (ABF) warhead
consisting of a case assembly, two booster plates, transfer
tube assembly, high explosive, and fragmentation rods.
27. Physical Description. The warhead weighs 20.8
pounds total including 7.9 pounds of PBXN-3 explosive,
is 13.5 inches long, and 5.0 inches in diameter.
28. Principles of Operation. The S-A device explosive
output is transferred through the transfer tube assembly to
the booster plates. The initiation is then transferred
through the explosive-loaded channels of the booster
plates to the beach end of the warhead. Detonation of the
booster pellets sets off the high explosive (PBXN-3)
causing warhead detonation.
29. ROCKET MOTOR, Mk 36 Mod 7. The rocket
motor (Figure 10) is a solid propellant, high thrust motor
that comprises the aft end of the missile. The propellant is
cast into the tube and case bonded to the tube wall. The
propellant igniter train consists of a main charge, booster
charge, and a Mk 5 squib. The igniter is held in place by a
non-propulsive head closure that blows out upon
accidental ignition, making the rocket motor nonpropulsive if the warhead is not attached. This motor
differs from the Mod 8, 9, 10 and 11 because of the
installation of a Radio Interference Filter (RIF) on the
front end of the motor which was replaced by a Safe-Arm
selector assembly on the Mod 8, 9, 10 and 11. The RIF
prevents stray radio frequency energy from actuating the
rocket motor igniter.
30. ROCKET MOTOR, Mk 36 Mod 8 and 10. This
rocket motor (Figure 10) contains the same grain
propellant as Mk 36 Mod 7 but uses an igniter that
mechanically interrupts the explosive ignition train in
event of accidental squib ignition. The Mod 8 rocket
motor features a removable Safe-Arm selector handle and
the Mod 10 rocket motor features a non-removable SafeArm selector handle which is used to mechanically ARM
or SAFE the motor on the ground. The rocket motor has a
non-propulsive head closure that will blow out if a
warhead is not installed making the rocket motor nonpropulsive.
31. ROCKET MOTOR, Mk 36 Mod 9 and 11. This
rocket motor (Figure 10) is a reduced smoke motor that is
outwardly similar to Mk 36 Mod 8 and 10. The primary
difference between the motors is the type of propellant
used. The propellant used is an organic HydroxylTerminated Polybutadine (HTPB) for reducing smoke and
abrasive properties of the exhaust plume. In addition to the
propellant charge, the rocket motor incorporates an igniter,
with a charge that produces less smoke. The Mod 9 rocket
motor features a removable Safe-Arm selector handle and
the Mod 11 rocket motor features a non-removable SafeArm selector handle which is used to mechanically ARM
or SAFE the motor on the ground. The rocket motor has a
non-propulsive head closure that will blow out if a
warhead is not installed making the rocket motor nonpropulsive.
32. Physical Description. The rocket motors are 70
inches long, weight 99 pounds (without wings) 123
pounds (with wings), and have a propellant weight of 60
pounds.
33. Principles of Operation. The rocket motor
electrically and mechanically interfaces with the launcher.
The mechanical interface is by means of a forward, center,
and aft hanger. When the missile is loaded on the launcher,
two striker points within the launcher are in contact with
the two contact buttons on the forward hanger. When the
firing circuit is activated, the firing voltage is sent through
the aft contact button and fires the initiator on the SafeArm assembly. The initiator ignites the rocket motor
propellant grain, thrust is developed, and the missile is
launched. The forward contact button on the AIM-9M
missile is not used and has no electrical connection.
However, the forward striker point of the launcher is
connected to (28Vdc) a signal used as firing voltage for
the battery squibs in the target detector/influence fuse of
other AIM-9 missiles, and is applied through the fuse/TD
contact assembly. With the AIM-9M, the target detector
battery squib signal also originates in the launcher.
However, the signal is routed through the umbilical cable
to the GCS and is applied via the 9-pin cable between the
GCS and the TD.
34. Should Safe-Arm assembly initiator ignition occur in
the SAFE position, a vent groove directs the exhaust into
the cavity. In this situation the arming shaft blocks off the
output port in the housing and the gases are contained. The
rupture disc is sized to burst in the ARM position, yet be
adequate to retain any gases that might leak past the
arming shaft when the initiator is fired in the SAFE
position. If the Safe-Arm selector handle cannot be rotated
out of the SAFE position it is an indication that the SafeArm assembly has been fired.
35. WING, Mk 1 Mod 1 and Mk 1 Mod 2. Four
identical wings (Figure 11) provide aerodynamic lift and
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WP 003 00
VIEW A - A
MOD 7
MODS 8/9
MODS 10/11
RIF Assembly
Removable Safe-Arm
Selector Handle
Non-Removable
Safe-Arm Selector Handle
Figure 10. Rocket Motor, Mk 36 Mods 7, 8, 9, 10, and 11
Identification Markings Location
(Mk 1 Mod 2 Shown)
Mod 1
Cager
Mk 1 Mod 1
Mod 2
Cager
Mk 1 Mod 2
Figure 11. Wings, Mk 1 Mods 1 and 2
12
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CSTO XX21M-AIM9M-2
WP 003 00
stability during flight. The wings are attached to wing ribs
located at the aft end of the rocket motor.
installed through a TCTO when funding and procurement
action has been completed.
36. Physical Description. The wings weigh 24 pounds (4
wings) and have a span of 25.2 inches (with rolleron
caged). Each wing has a rolleron assembly that provides
pitch, yaw, and roll stabilization during free flight.
42. When the GCS pop-out pressure relief valve is
actuated by GCS internal overpressure, the valve opens,
releases the pressure, and reseats. The valve is designed to
open at a minimum of 25 PSI and a maximum of 45 PSI.
It will not actuate on hard landings or vibration. When the
valve has been actuated the red pop-out indicator provides
a visible indication of a clogged (partly clogged) seeker
vent filter. When the pop-out indicator has been actuated
(Figure 13) it can not be reset. The valve will continue to
function and prevent the dome from being blown off the
GCS. The cycling of the relief valve does not affect the
cool down capabilities of the GCS, which should remain
in use until it is required to be returned to the depot for a
defect that prevents it from functioning as designed.
37. The Mod 1 cager assembly releases the rolleron by
the rearward sliding of the cager. The release force is
adjusted by lengthening or shortening the spring. The Mod
2 cager assembly releases the rolleron by the arm
assembly rotating rearward, resulting in low maintenance
and ease of adjustment. The cager assembly engages the
slot in the rolleron. The release force is adjusted by
rotating the adjustment screw through an access hole. The
release force is provided for by minimum missile
acceleration. Neither cager can return to the caged position
while the missile is in flight.
38. Principles of Operation. The wing rolleron wheel is
designed so the passing airstream causes it to spin at a
very high speed, thus acting as a gyroscope to help
stabilize and reduce roll during flight. The entire rolleron
assembly is held in line with the longitudinal axis of the
missile during captive flight by a caging device. When the
missile is fired, the rolleron is uncaged by acceleration and
is free to move about the longitudinal axis throughout
flight. An oil-filled damper at the forward end of the
rolleron assembly is provided to smooth rolleron operation
and prevent flutter.
39. COUPLING RING ASSEMBLIES. The missile
components are joined by coupling ring assemblies which
clamp the components together (Figure 12). The same
coupling rings are used for assembling tactical and/or inert
components. Coupling ring, PN 639AS672, is used to join
the GCS and TD. Coupling ring PN 8241286-10 is used
only to join the GCS and inert missile body assembly
(MBA). PN 639AS2725 joins the TD to the warhead and
the warhead to the rocket motor.
40. POP-OUT PRESSURE RELIEF VALVE.
41. The sidewinder community has experienced incidents
of Guidance Control Section Optical Domes being blown
off the missile both in flight and on the ground. This is
caused by excessive pressure build up when the seeker
vent filter becomes clogged. The clogging effect is the
result of adhesives and conformal coating condensing and
collecting on filter. To prevent optical domes from
blowing off, an Engineering Change Proposal has been
approved to install a relief valve in the GCS under the
access cover for the coolant tank. The relief valve will be
43. ELECTRICAL AND PNEUMATIC POWER
REQUIREMENTS FOR THE TS-4044/D, GCU-26A/
E, AND GCU-30/E.
44. Electrical and pneumatic power requirements for the
TS-4044/D, GCU-26A/E, AND GCU-30/E are as follows:
Guidance Control Section Test Set, TS-4044/D
Electrical ........................................................ 110 Vac,
5 Ampere supply
Pneumatic:
Dry air or Nitrogen ......... 1500 - 3500 psig; 30 scfm
minimum flow at 1100 psig
-32°C dewpoint, oil-free
Recharging Unit Assembly GCU-26A/E
Recharging Unit
Electrical .................................................220/230 Vac,
Single-Phase,
15 Ampere supply
Air Compressor:
Electrical ..............................................220/230 Vac,
50/60 Hz, 3-Phase,
21 Ampere supply
Recharging Unit Assembly GCU-30/E
Pneumatic:
Dry Air ...................................85 - 125 psig nominal
Volume ....................................15 - 35 scfm nominal
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CSTO XX21M-AIM9M-2
WP 003 00
Figure 12. Coupling Ring Assemblies
14
CSTO XX21M-AIM9M-2
WP 003 00
RED INDICATOR
TOP FLUSH WITH
VALVE BODY
O-RING
RED INDICATOR
TOP EXTENDED
APPROXIMATELY
1/16-INCH PAST
VALVE BODY
O-RING
RELIEF VALVE
RELIEF VALVE
NORMAL
ACTUATED
RELIEF VALVE
Figure 13. Pop-Out Pressure Relief Valve
Change 1
15
CSTO XX21M-AIM9M-2
WP 003 00
45. UMBILICAL CABLE SPRING
LAUNCHER COMPATIBILITY.
PIN
AND
46. The USAF uses GCS umbilical cable PN 2603913 or
639AS10935 on tactical missiles. The only significant
difference between them is the length of the spring pin: PN
639AS10935 pin length is 1.250 inch, PN 2603913 pin
length is 1.125 inch. Before cable PN 2603913 can be
used the 1.125 inch pin must be replaced with a 1.250 inch
pin, Figure 14.
52. Argon, nitrogen, and air can be used in the TMU-72,
Table 1 and Table 2. Argon is the most efficient cooling
gas of the three. A larger volume of nitrogen or air is
required to achieve the same cooling effect as argon.
Therefore, these two gases also have a greater rate of gas
consumption to cool down and maintain the detector at the
required temperature.
53. COOLANT GASES PERFORMANCE.
54. Since the TMU-72 can only hold a limited supply of a
coolant gas, the USAF opted for the most efficient gas
(argon). Compared to nitrogen or ‘air’, argon provides the
most cooling time per unit volume of gas, thereby
providing the maximum operating time for the missile of
the three gases, Table 3. The Navy employs nitrogen as a
coolant gas. A much larger volume of gas located in the
launcher increases the amount of cooling gas available to
the missile giving the option of using a more inefficient
coolant gas, Paragraph 72 ‘NAVY COOLANT GAS’.
Figure 14. Umbilical Cable PN 639AS10935
47. The requirement for a 1.250 inch spring pin is based
on the umbilical hook retainer assembly of F-16 launcher
PN 16S210-XXX. The assembly's two retainers lose their
spring action after prolonged use. During missile launch
this can result in the umbilical cable failing to retract
properly, potentially damaging the launcher or interfering
with missile performance. The 1.250 inch pin prevents
this. The AERO-3B is the only other USAF launcher that
has a similar problem when using the 1.125 inch spring
pin.
48. Note that the longer pin is for use with missiles loaded
onto USAF launchers, such as the 16S210-XXX. Do not
use umbilical cable PN 639AS10935 with the Navy LAU7 launcher. The longer pin can cause an interference
problem with the LAU-7. The Navy uses only umbilical
cable PN 2603913 with the 1.125 inch pin.
49. GCS COOLANT GAS.
50. COOLANT GAS BASICS.
51. The TMU-72 coolant tank stores 4.92 standard (60°F
and 14.696 PSIA or 760 mm Hg) cubic feet (0.4 pounds)
of gas at a maximum pressure of 5000 PSIG.
16
Change 1
55. On initial GCS cool down, the GCS requires a
minimum of 500 PSIG of argon. Nitrogen requires
approximately double that. After the GCS detector has
reached the optimum operating temperature, argon is
consumed at an approximate rate of 500 PSIG per hour.
Nitrogen gas, nearly half as efficient as argon, is exhausted
at roughly twice the rate. These consumption rates are
approximate values and can vary dependant on: the type of
mission being flown, the duration of the flight,
temperature, altitude, and various other factors.
56. The most efficient use of the coolant gas during the
sortie is achieved by leaving the coolant on continuously
versus cycling coolant gas off and on after the initial
cooling is applied to the GCS.
57. MIXING COOLANT GASES.
58. It is recommended that an organization use only one
type of cooling gas (argon, nitrogen or air) to fill/refill
their coolant tanks. Mixing argon, nitrogen, and/or air
could result in coolant 'freeze up'. For example, argon
should not be mixed with nitrogen in the TMU-72. If
argon and nitrogen are mixed at inappropriate levels, the
argon will freeze and stop gas flow in the refrigerated
detector unit (RDU), stopping IR detection. For this
reason, mixing nitrogen and argon should be avoided. If a
TMU-72 is to be filled with a different gas than used
previously 'purging' is a necessity, Paragraph 59.
59. TMU-72 COOLANT TANK PURGING.
CSTO XX21M-AIM9M-2
WP 003 00
sticking or low consumption of gas from partial
blockage. High gas consumption reduces cooling
efficiency of the cryostat but not sensitivity of the
detector. This would be indicated by the coolant
tank being lower in pressure than normal after a
sortie (high gas consumption). A partial blockage
may result in reduced cryostat efficiency
resulting in low sensitivity and reduced
acquisition range. Particulate contamination can
only be removed from the GCS or TMU-72 at
depot.
60. To effectively ‘purge’ a coolant tank at field level of a
gas (whether argon, nitrogen, or ‘air’) the percentage of
the ‘new’ to ‘old’ gas must be maximized. Only a depot
overhaul of a tank can achieve near 100 percent gas purity.
61. Field level ‘purging’ is accomplished by removing as
much of the ‘old’ gas (by volume) as possible and
replacing it with ‘new’ gas. This is accomplished by
draining as much gas as possible (minimum PSIG) then
refilling the tank to it’s maximum volume, at 5,000 PSIG.
After this ‘drain-fill’ process is done three times, the
percentage of original gas to new gas is at an acceptable
level, minimizing the possibility of gas freeze up. Note
that a tank must never be drained to zero PSIG to prevent
possible contamination. Always maintain a positive
pressure in the tank.
62. To 'purge' a coolant tank using the TMU-72/B Bleed
Down Fixture, bleed the coolant tank to 1200 PSIG, then
refill the tank with the alternate gas. Repeat this twice.
Note that a procedure is available to modify the Bleed
Down Fixture to bleed the pressure to 120 PSIG for more
efficient purging.
63. If the GCU-26 is available use the same ‘drain-fill’
procedure three times, only bleed the pressure to 100 PSIG
versus 1200 PSIG to further improve gas purity.
64. COOLANT GASES CONTAMINATION.
65. Contaminates can seriously impact the operation of
the GCS cooling system. Water, particulates, and
hydrocarbons are the most damaging contaminants.
a.
b.
Water in cooling gas (exceeding the purity
requirement) will freeze during the cooling
process. When the water freezes, the cryostat will
become blocked until the temperature warms up
allowing the water to become liquid again and
move through the GCS cooling system. Field
level purge procedures may remove excess water
from the GCS or TMU-72 at field level. Severe
water contamination requires depot repair. The
TTU-546/E digital hygrometer can detect
moisture contamination in gas. If a TTU-546/E
hygrometer is available, perform moisture test on
the TMU-72 coolant tank per T.O. 35D18-6-2.
Particulate matter contamination can cause
several problems. Large particulate can cause
blockage of the RDU. Particulate can also
contaminate the solenoid valve, solenoid valve
filter, or a check valve. This could cause high gas
consumption through leakage caused by a valve
c.
Hydrocarbons as a contaminant can be deposited
on the inside and outside walls of the heat
exchanging tubes in the cryostat. These
contaminants reduce the localized heat transfer
and reduce the overall cryostat efficiency. This
results in increased cooling gas consumption to
achieve the same amount of detector cooling.
Hydrocarbon contamination can only be removed
from the GCS or TMU-72 at depot.
66. EXCESSIVE COOLANT GAS CONSUMPTION.
67. Several factors affect the consumption of coolant gas.
These include plumbing leaks, Dewar flask efficiency,
cryostat efficiency, contamination, and cooling gas
temperature. The first three are likely to become a greater
factor as the GCS ages. None of these factors can be
controlled or repaired at field level.
68. TS-4044 STEP 003 FAILURE.
69. If failed GCS test number is 003 (cool-down), a
possible freeze up occurred caused by moisture
contamination. Set the GCS aside for at least 2 hours. This
will allow the detector to warm to ambient temperature.
Remove the coolant tank. This eliminates the coolant tank
as the source of moisture contamination, Paragraph 64.
Inspect GCS coolant tank area for contamination. Clean if
necessary. Install a known good coolant tank filled to
5,000 PSIG.
70. Retest the GCS. If the GCS fails test number 003 set
the GCS aside for minimum of 1 hour to allow the RDU to
return to ambient temperature then retest. Do not replace
the coolant tank before retesting unless the pressure is
below 3,000 PSIG. If the GCS does not pass after
performing this procedure five times reject the GCS. The
moisture contamination cannot be cleared using this
procedure or there is another problem.
71. The TTU-546/E digital hygrometer can detect
moisture contamination in gas. If a TTU-546/E
Change 1
17
CSTO XX21M-AIM9M-2
WP 003 00
hygrometer is available, perform moisture test on the
TMU-72 coolant tank. If tank fails test then purge the tank,
Paragraph 59.
72. NAVY COOLANT GAS.
73. The Navy has nitrogen gas generators aboard aircraft
carriers. Consequently, the Navy uses nitrogen gas as a
coolant gas. Navy launchers contain a nitrogen receiver
charged to 3,800 PSIG which provides a larger volume of
cooling gas to the missile than the TMU-72 coolant tank.
Some newer Navy launchers use a high pressure pure air
generator (HIPPAG) in place of the nitrogen receiver.
Table 2. Coolant Gas Specifications
Coolant Gas
Specification
Comments
Argon
MIL-PRF-27415, Type I,
Grade A
Argon Type I Grade A, has a purity of 99.998% by volume (minimum)
Nitrogen
MIL-PRF-27401, Type I,
Grade C
Nitrogen Type 1 Grade C has a purity of 99.995% by volume
(minimum)
Air
BB-N-411 as modified by
MIL-R-81202
Some countries use 'air' in TMU-72 as a coolant gas. The 'air' must meet
the same purity requirements as argon and nitrogen.
Note: BB-N-411 is a federal specification. MIL-R-81202 contains additional requirements not in BB-N-411.
MIL-R-81202 is the military specification for the Navy LAU-7 launcher nitrogen receiver.
Table 3. Cooling Time Per TMU-72 Coolant Tank
Coolant Gas
Specification
Approximate Cooling Time
Argon
MIL-PRF-27415, Type I, Grade A
9 hours
Nitrogen
MIL-PRF-27401, Type I, Grade C
5.5 hours
Air
BB-N-411 as modified by MIL-R-81202
Approximately same as Nitrogen
Note: Air is approximately 78% nitrogen, the refrigeration properties of air are roughly the same as those of nitrogen.
18
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CSTO XX21M-AIM9M-2
SWP 003 01
SUBORDINATE WORK PACKAGE
DESCRIPTION OF TRAINING AUR
FIELD LEVEL MAINTENANCE
GUIDED MISSILE CATM-9M AND DATM
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 10
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1. ... .... ... ... .... ... .... 2
5-10 . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
2-3 . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
4 . . . . . . . . . . . . . . . . . . . . . . . . .2
Reference Material
Title
Number
Unpacking, Packing, Inspection, and Ground Handling CATM-9M and DATM Missile.....................................WP 007 00
Table of Contents
Title
Page
General...................................................................................................................................................................................2
Training Missile Description .................................................................................................................................................2
Captive Carry Missiles.........................................................................................................................................................2
Captive Flight Adapter (PN 041508-0106) .........................................................................................................................3
Captive Flight Adapter (PN 041508-0113)..........................................................................................................................3
Dummy Body Section, MDU-27/A .....................................................................................................................................3
Dummy Body Section, MDU-27A/A ..................................................................................................................................3
Dummy Rocket Motor .........................................................................................................................................................2
Dummy Warhead .................................................................................................................................................................2
Ground Training Missiles ....................................................................................................................................................2
Missile Body Assembly .......................................................................................................................................................2
Safety of Flight Defects .......................................................................................................................................................2
Training Guidance Control Section WGU-4A(T-2)/B.........................................................................................................2
Training Target Detector ......................................................................................................................................................2
Training Umbilical Cable Assembly (HRU-985A/E)..........................................................................................................3
Wings and Fins.....................................................................................................................................................................2
List of Illustrations
Title
Page
Captive Flight Adapter (PN 041508-0106 and PN 041508-0113) ........................................................................................9
Dummy Body Section, MDU-27/A and MDU-27A/A........................................................................................................10
Dummy Rocket Motor, Mk 57 Mod 1, Mk 57 Mod 2, and Mk 57 Mod 3 ...........................................................................7
Dummy Warhead (Mk 70 Mod 1) .........................................................................................................................................6
Change 2
1 of 10
CSTO XX21M-AIM9M-2
SWP 003 01
List of Illustrations (Continued)
Title
Page
HRU-985A/E Captive Training Umbilical Cable Assembly ................................................................................................ 9
Missile Body Assembly (MBA) PN 8241297-30 ................................................................................................................. 8
Training Guidance Control Section WGU-4A(T-2)/B .......................................................................................................... 6
Training Missiles (CATM-9M and DATM) Exploded View................................................................................................. 4
Training Target Detector DSU-15(T-1)/B and DSU-15(T-1)A/B.......................................................................................... 6
1.
GENERAL.
2. Training missiles are provided for training personnel
in missile assembly, handling, load training, and aircrew
training. Training missiles are divided into two different
categories: (1) captive carry missiles; and (2) ground
training missiles. Training missiles may consist of a
combination of tactical and training components or all
training components, depending on the category and
configuration. Training missile configurations are shown
in Table 5 of WP 007 00.
3.
TRAINING MISSILE DESCRIPTION.
4. CAPTIVE CARRY MISSILES. Captive carry
missiles (Figure 1) are identified by the prefix “Captive
Air Training Missile (CATM)” and are used for pilot
training in aerial target acquisition and use of aircraft
controls/displays. The training GCS described in
Paragraph 7 and the tactical AIM-9M GCS may be used as
CATM components.
5. SAFETY OF FLIGHT DEFECTS. Components
that have failed safety of flight criteria will not be used for
Captive Air Training Missile (CATM) but may be used for
load training or practice of Emergency Build Up (EBU)
procedures. Safety of flight defects include but are not
limited to failed NDI inspection, cracked wing channels,
loose ballast, etc. Components that have safety of flight
defects will have the words “DO NOT FLY” stenciled on
the outside.
6. GROUND TRAINING MISSILES. Ground training
missiles (Figure 1) are identified by the prefix “Dummy
Air Training Missile (DATM)” and are used to train
ground personnel in missile assembly, disassembly,
loading, transportation, and stowage procedures/
techniques. All components are training items (completely
inert) except for wings, fins, and the TMU-72/B, TMU72A/B or TMU-72B/B Coolant Pressure Tank. This
missile uses the AN/DSQ-29-T1 GCS, which contains no
2
Change 1
explosive or electrical components, and is not approved
for flight.
7. TRAINING GUIDANCE CONTROL SECTION,
WGU-4A(T-2)/B. The inert GCS, WGU-4A(T-2)B
(Figure 2), is identical to its tactical counterpart except
that the thermal battery and gas grain generator (part of the
servo section) have been replaced with dummy
components. This GCS may be used in CATM
configurations.
8. TRAINING TARGET DETECTOR. The training
Target Detectors (TD) (Figure 3), DSU-15(T-1)A/B and
DSU-15(T-1)/B, contains no active internal components
and are used in CATM and DATM configurations.
9. DUMMY WARHEAD. This warhead (Figure 4) has
no active internal components and is used in CATM/
DATM configurations.
10. DUMMY ROCKET MOTOR. Rocket motors
(Figure 5), Mk 57 Mod 1, Mk 57 Mod 2, and Mk 57
Mod 3, contain no explosive/propellants and are used in
CATM and DATM configurations. These rocket motors
are replicas of the tactical rocket motor Mk 36 Mod 7,
Mk 36 Mod 8, and Mk 36 Mod 10 respectively.
11. WINGS AND FINS. Wings and fins are tactical
components. Refer to WP 003 00 for physical description.
12. MISSILE BODY ASSEMBLY. The inert Missile
Body Assembly (MBA) (Figure 6), PN 8241297-30, is a
single steel tube construction representing the dimensions
and weight characteristics of an assembled target detector,
warhead, and rocket motor. The MBA comes with four
fixed wings that are bolted onto the tube for security. The
MBA is mated with a GCS for captive air training. The
MBA is 89.3 inches in length, and weighs 152 pounds.
Center of gravity is 42.25 inches from rear of MBA. Wing
span is 23.6 inches. With the GCS installed the center of
gravity is 52.0 inches from rear of MBA.
CSTO XX21M-AIM9M-2
SWP 003 01
13. DUMMY BODY SECTION, MDU-27/A. The
MDU-27/A dummy body section (Figure 9) replaces the
TD, warhead, and rocket motor. The dummy body section
is mated with a GCS for captive air training.
14. DUMMY BODY SECTION, MDU-27A/A. The
MDU-27A/A body section (Figure 9 replaces the TD,
warhead, and rocket motor. The MDU-27A/A requires the
use of tactical wings. The dummy body section is mated
with a GCS for captive air training.
15. CAPTIVE FLIGHT ADAPTER (PN 0415080106). Captive flight adapter PN 041508-0106 is used on
the CATM captive carry missile to disable missile firing
circuits. Do not use with the LAU-7 launcher. It does not
allow cooling gas to flow to the GCS from the launcher.
See Figure 7.
16. CAPTIVE FLIGHT ADAPTER (PN 041508-0113).
Captive flight adapter (CFA) PN 041508-0113 is used on
the CATM captive carry missile to disable missile firing
circuits. Similar in design to PN 041508-0106, it is
compatible with USAF and Navy launchers. The CFA
allows cooling gas to pass from the LAU-7 launcher
nitrogen receiver through the umbilical to the GCS seeker.
See Figure 7.
17. TRAINING UMBILICAL CABLE ASSEMBLY
(HRU-985A/E). The HRU-985A/E training umbilical
cable assembly (Figure 8) is used to disable missile firing
circuits and provide automatic recage on trigger squeeze.
Must be used when missile cooling gas is supplied by the
launcher through the umbilical. Otherwise, it’s use is
optional in place of the Captive Flight Adapter. When the
HRU-985A/E training umbilical is installed on a CATM
GCS the launcher umbilical block hooks will not engage
umbilical block pins. The HRU-985A/E pins were not
designed to engage the launcher hooks.
Change 1
3
CSTO XX21M-AIM9M-2
SWP 003 01
NOTE: WHEN USING TACTICAL GCS FOR TRAINING, USE HRU-985A/E TRAINING UMBILICAL CABLE, OR CAPTIVE FLIGHT ADAPTER WITH TACTICAL UMBILICAL CABLE
CAPTIVE FLIGHT
ADAPTER
HRU-985A/E
TRAINING UMBILICAL
COOLANT
PRESSURE
TANK
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
COOLANT
PRESSURE
TANK
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 1. Training Missiles (CATM-9M and DATM) Exploded View (Sheet 1 of 2)
4
Change 2
CSTO XX21M-AIM9M-2
SWP 003 01
COOLANT
PRESSURE
TANK
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
COOLANT
PRESSURE
TANK
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 1. Training Missiles (CATM-9M and DATM) Exploded View (Sheet 2 of 2)
Change 1
5
CSTO XX21M-AIM9M-2
SWP 003 01
Figure 2. Training Guidance Control Section WGU-4A(T-2)B
Figure 3. Training Target Detector DSU-15(T-1)/B
and DSU-15(T-1)A/B
6
Change 1
Figure 4. Dummy Warhead (Mk 70 Mod 1)
CSTO XX21M-AIM9M-2
SWP 003 01
MODS 2/3
MOD 2
MOD 3
MOD 1
RIF Assembly
Removable Safe-Arm
Selector Handle
Non-Removable
Safe-Arm Selector Handle
Figure 5. Dummy Rocket Motor (Mk 57 Mod 1, Mk 57 Mod 2, and Mk 57 Mod 3)
Change 1
7
CSTO XX21M-AIM9M-2
SWP 003 01
Figure 6. Missile Body Assembly (MBA) PN 8241297-30
8
Change 1
CSTO XX21M-AIM9M-2
SWP 003 01
16
26
13
12
25
1
2
17
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
Figure 7. Captive Flight Adapter (PN 041508-0106 and PN 041508-0113)
RUBBER BAND
PROTECTIVE CAP
UMBILICAL BLOCK
GC
E
OM
D
S
SECURING STRAP
GCS UMBILICAL
BASE
T-BOLT
KNURLED RETAINING
NUT
Figure 8. HRU-985A/E Captive Training Umbilical Cable Assembly
Change 1
9
CSTO XX21M-AIM9M-2
SWP 003 01
MDU-27/A
MDU-27A/A
SAFE-ARM ASSEMBLY
Figure 9. Dummy Body Section, MDU-27/A and MDU-27A/A
10
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
WORK PACKAGE
MASTER LIST OF SPECIAL TOOLS, EQUIPMENT,
AND CONSUMABLES
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M, CATM-9M AND DATM
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 34
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-2 . . . . . . . . . . . . . . . . . . . . . . . 2
6-7 . . . . . . . . . . . . . . . . . . . . . . . 2
11-13 . . . . . . . . . . . . . . . . . . . . . 0
17-18 . . . . . . . . . . . . . . . . . . . . . 2
24-26 . . . . . . . . . . . . . . . . . . . . . 1
32-33 . . . . . . . . . . . . . . . . . . . . . 2
Page No.
Change No.
3. . . . . . . . . . . . . . . . . . . . . . . . . 0
8. . . . . . . . . . . . . . . . . . . . . . . . . 0
14. . . . . . . . . . . . . . . . . . . . . . . . 2
19-22 . . . . . . . . . . . . . . . . . . . . . 1
27. . . . . . . . . . . . . . . . . . . . . . . . 0
34. . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
4-5. . . . . . . . . . . . . . . . . . . . . . . . 1
9-10. . . . . . . . . . . . . . . . . . . . . . . 2
15-16 . . . . . . . . . . . . . . . . . . . . . . 0
23 . . . . . . . . . . . . . . . . . . . . . . . . 0
28-31 . . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Colors............................................................................................................................................................... FED-STD-595
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with
IPB, Storage Containers, (AIM-9 Series Missiles) ................................................................................... TO 35E20-2-31-2
Service Instructions with IPB, AIM-9 Field Support Tools and Equipment (AGE) ..................................... TO 33D9-1-432
Table of Contents
Title
Page
Consumable and Expendable Materials.................................................................................................................................3
Containers ..............................................................................................................................................................................3
General...................................................................................................................................................................................3
Safety and Protective Devices ...............................................................................................................................................3
Special Tools..........................................................................................................................................................................3
Support/Handling Equipment ................................................................................................................................................3
Test Equipment ......................................................................................................................................................................3
List of Illustrations
Title
Page
Aft Hanger Skid Surface Wear Fixture ................................................................................................................................12
Aft Hanger Template............................................................................................................................................................12
AN/DSM-98(V) Test Set with Adapters..............................................................................................................................18
Assembly Stand ...................................................................................................................................................................22
Change 2
1 of 34
CSTO XX21M-AIM9M-2
WP 004 00
List of Illustrations (Continued)
Title
Page
C-Clamp (Modified)............................................................................................................................................................ 10
Chain Wrench ........................................................................................................................................................................ 9
Socket Wrench Screw Driver Attachment, 3/8 Drive, 3/16 Hex......................................................................................... 9
Coolant Pressure Tank Bleed Down Fixture ....................................................................................................................... 20
Coolant Pressure Tank Removal Tool ................................................................................................................................... 9
Coolant Pressure Tank Removal Tool (Fabrication) ............................................................................................................. 9
Coolant Pressure Tank Special Tools .................................................................................................................................... 8
Fixture, Compression, Preformed Packing.......................................................................................................................... 8
Tool, Removal and Insertion ............................................................................................................................................... 8
Wrench, Spanner ................................................................................................................................................................. 8
Depth Gauge, PN 643J ........................................................................................................................................................ 11
Dial, Push/Pull Gauge ......................................................................................................................................................... 15
Gas Inlet Spanner .................................................................................................................................................................. 8
Gauge (Spring Pin) .............................................................................................................................................................. 14
Guidance Control Section Test Sets, TS-4044/D and TS-3860C........................................................................................ 16
TS-3860C .......................................................................................................................................................................... 16
TS-4044/D ......................................................................................................................................................................... 16
Guided Missile AIM-9M Protective Dome Cover .............................................................................................................. 27
Guided Missile Coolant Recharging Unit, GCU-30/E ........................................................................................................ 23
GCS Assembly Fixture........................................................................................................................................................ 22
Hanger Alignment Fixture................................................................................................................................................... 13
Hanger Alignment Gauge.................................................................................................................................................... 13
Hanger Screw Extractor Assembly, PN SA497576 ............................................................................................................ 11
Holding Fixture (Local Manufacture) ................................................................................................................................. 24
Igniter Circuit Tester............................................................................................................................................................ 17
Amptec Fail-Safe OhmMeter 620A-4 ............................................................................................................................... 17
Instrument Scale, 0 to 4 lbs ................................................................................................................................................. 15
Missile Assembly Tool .......................................................................................................................................................... 7
Recharging Unit Assembly, GCU-26/E or GCU-26A/E ..................................................................................................... 21
Ring Seating Assembly Tool ................................................................................................................................................. 8
Ring Staking Tool.................................................................................................................................................................. 8
Safety and Protective Devices ............................................................................................................................................. 28
Screwdriver Handle ............................................................................................................................................................... 7
Spanner Wrench Assembly, PN SA497573, and Socket Wrench Adapter 3/8’’ to 1/4’’, PN GGG-W-641 ....................... 13
Storage and Maintenance Stand, MHU-32/E and Missile Storage Stand MHU-32A/........................................................ 20
Storage Rack Assembly (PN 7329590) ............................................................................................................................... 24
Tube Spanner Assembly Wrench .......................................................................................................................................... 8
Umbilical Cable Test Set TS-3037 A/G .............................................................................................................................. 15
Wing Tapping Tool .............................................................................................................................................................. 10
Wrench, Torque (100 in-lb, 3/8-inch Drive).......................................................................................................................... 8
List of Tables
Title
Page
Master List of Consumables................................................................................................................................................ 29
Master List of Safety and Protective Devices ..................................................................................................................... 25
Master List of Special Tools.................................................................................................................................................. 4
Master List of Support Equipment ...................................................................................................................................... 19
Master List of Test Equipment ............................................................................................................................................ 14
2
Change 2
CSTO XX21M-AIM9M-2
WP 004 00
1.
NOTE
GENERAL.
2. This WP lists all special tools, test equipment, support
equipment, and consumables required for the work
described within this TO.
3.
SPECIAL TOOLS.
WARNING
Improper use of tools and equipment can cause
injury to personnel and damage to the equipment.
4. The special tools required to assemble and
disassemble the missile are listed in Table 1 and illustrated
in Figures 1 through 10.
5. A substitute item may be used in place of any
common tool if the use does not degrade the condition and
the reliability of the material or safety of operation.
6. When ordering new/replacement tools, use General
Services Administration Catalog, Standardization and
Control of Industrial-Quality Tools.
7.
TEST EQUIPMENT.
8. The test equipment available to test components of
the missile is listed in Table 2 and illustrated in Figures 11
through 17. Test equipment shall be serviced and
maintained in accordance with applicable supporting
publications.
9.
SUPPORT/HANDLING EQUIPMENT.
10. The equipment required to support missile operations
listed in Table 3 and illustrated in Figures 18 through 23.
The maintenance and storage stand, MHU-32/E
or MHU-32A/, can be used for movement of
AIM-9 missiles within the munitions storage/
holding area but shall not be used on the flight
line.
12. SAFETY AND PROTECTIVE DEVICES.
13. Safety and protective devices used on the missile are
listed in Table 4 and illustrated in Figures 24 and 25.
14. CONSUMABLE AND EXPENDABLE
MATERIALS.
15. Military Specifications and part numbers for paints,
thinners, and primers are not included in this manual. The
nomenclature column instructs user to use low VOC, EPA
approved primers and paints. Refer to any of the
maintenance SWPs in the Paint and Marking tables and
find a color IAW Fed-Std-595. Specification for paints
change almost daily. Additionally, a specification
considered good at one location may not be at another
location. However, if low VOC, EPA approved paints
which comply with color requirements are used, the user
can get the job done.
16. Consumable and expendable materials required to
assemble and maintain the guided missile are listed in
Table 5.
17. CONTAINERS.
18. Containers needed to ship or store the guided missile
and missile components are listed in TO 35E20-2-31-2.
11. A complete list of approved handling equipment
required for the AIM-9 is also identified in TO 33D9-1432.
3
CSTO XX21M-AIM9M-2
WP 004 00
Table 1. Master List of Special Tools
Part Number
B107.14M
CAGE
Code
Figure/Index
Number
05047
Not Illustrated
Nomenclature
Wrench, Torque
Use
Torque Panhead Screw
NOTE
When 3/16-inch stock is used to replace the Allen wrench, limit the
length to approximately 2 1/4-inch to prevent flexing while under torque.
FAL6
OFEP9
11a.
Socket wrench screw driver
attachment, 3/8 inch drive,
3/16 hex
Used with chain wrench
GGGB001222
81348
Not Illustrated
Adapter, screw bit, 1/4-inch
3/8-inch drive
Used with torque wrench to tighten
rolleron hinge screw(s) to wing
assembly
GGGB001222
81348
Not Illustrated
Tip, screwdriver, 3/16-inch
1/4-inch hex drive, Type II,
Class 4
To tighten GCS connector,
tactical umbilical screws, and cager set
screws; used with torque screwdriver
GGGG17
80244
Not Illustrated
Feeler gauge, thickness, Type
VIII Class 1
Adjustment of cager flag
GGGH33
81348
Not Illustrated
Face, extra hard, yellow,
Type 1, Class 3, Style D,
Size 1 1/2-inches
Replacement face for ring
seating tool
GGGH33
81348
Not Illustrated
Holder, hammer, (Alternate to
PN 57-531 or 57-542)
Used with 1 1/2-inch yellow face to
seat coupling rings in grooves during
missile assembly
GGGP480
81348
Not Illustrated
Pliers, retaining ring, Type 1,
Class 2, Size 3, Style B
To install/remove coolant tank
retaining ring
GGGT70
81348
Not Illustrated
Tap, bottoming, 4-36
To clean GCS umbilical retaining
screw receptacle helical threads
GGGT70
81348
Not Illustrated
Tap, bottoming, 6-32,
UNC-2B
To clean dummy rocket motor
retaining plate and initiator ground
screw female threads
GGGT70
81348
Not Illustrated
Tap, bottoming, 8-32,
UNC-3B
To clean initiator stop pin female
threads
GGGT70
81348
Not Illustrated
Tap, taper, 5/16-24 UNF 2B
To clean dummy rocket motor forward
hanger attachment screw(s) female
threads
GGGU412
81348
Not Illustrated
Pin vise
Training umbilical cable assembly pin
33 disable
GGGW002843
81348
Not Illustrated
Wrench, torque, 40-200 in-lbs,
0.25-inch drive
Alternate for PN 639AS2980. Used
with spanner to install probe guide.
GGGW641
55719
Not Illustrated
Adapter, socket wrench, 1/4 to
3/8-inch drive
To adapt low range screwdriver to 3/8inch drive
4
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
Table 1. Master List of Special Tools (Continued)
CAGE
Code
Figure/Index
Number
GGGW641
55719
Not Illustrated
Adapter, torque driver, 3/16
hex, 3/8-inch drive, Type IV,
Class 6, Style B, Form 5
To install/remove coupling ring, wing
and fin attaching screws
GGGW641
55719
Not Illustrated
Bit, screwdriver, #2 Phillips,
1/4-inch hex drive, Type IV,
Class 6, Style B, Form 1
Remove/install various missile
component screws
GGGW641
55719
Not Illustrated
Extension, 5-inch, 3/8-inch
drive, Type IV, Class 4
Used with torque wrench to assemble/
disassemble missile components
GGGW641
55719
Not Illustrated
Wrench, socket, 5/32-inch
hex, 3/8-inch drive
To install/loosen GCS gas inlet plug or
extractor rim clenching clamp screw
GGGW651
81348
Not Illustrated
Wrench, strap
To install and remove training GCS
dome assembly
GGGW686
81348
Not Illustrated
Wrench, torque, (30-200 inlbs, alternate for Figure 5)
Use with spanner to install probe guide
in coolant pressure tank
GG-M-95
81348
Not Illustrated
Glass, Magnifier
Inspecting for cracks
G243089-1
64959
Not Illustrated
Handle, speed
To assemble/disassemble missile
components
HG201A
83284
Not Illustrated
Heat Gun, (120 volts)
Heat shrink tubing on umbilical cable
HG502A
83284
Not Illustrated
Heat Gun, (230 volts) or
equivalent
Alternate
Locally
Manufactured
98752
12
Wing tapping tool
To detect skin and core bonds and
delamination of wing assemblies
Locally
Manufactured
98752
9
Coolant pressure tank removal
tool
To remove coolant pressure tank from
GCS
MIL-B-9946
81349
Not Illustrated
Extractor assembly,
size 5/16-inch
To remove hi-torque screw from
dummy rocket motor forward hanger
MIL-W-26497
81349
1
Handle, torque, low-range
screwdriver, 1/4-inch drive,
Type 1, Size 2
To install GCS umbilical cable,
rolleron damper, and guide vane
attaching screws
PSDM212A
55719
Not Illustrated
Bit, screwdriver, 5/64-inch
hex, 1/4-inch drive
(long shank)
To remove/install GCS umbilical base
mounting screws
QPR217A
55719
Not Illustrated
Wrench, torque, 100 in-lb,
3/8-inch drive. Alternate for
PN 1556707
Used with adapter and 5-inch
extension to tighten coupling ring,
wing and fin attaching screws
SA2875037
30003
2
Tool, missile assembly
To protect TD windows during missile
assembly
SA2875046
30003
12934
3
Tool, assembly, ring seating
Used with hammer assembly to seat
coupling ring in grooves during missile
assembly
Part Number
Nomenclature
Use
Change 1
5
CSTO XX21M-AIM9M-2
WP 004 00
Table 1. Master List of Special Tools (Continued)
CAGE
Code
Figure/Index
Number
SA2875401
30003
Not Illustrated
Spanner, gas inlet
Alternate
SA493234-1
53711
4
Tool, ring staking
Installing gas filter assembly
SA497569
30003
Not Illustrated
Extractor assembly
To remove torque-set screw from
dummy rocket motor forward hanger
SA497573
30003
19
Spanner wrench assembly
To remove/install rocket motor forward
hanger contact buttons
SA497576
30003
14
Hanger screw extractor
assembly
Remove forward hanger screws
1298236
10001
5
Spanner, gas inlet
To tighten gas inlet fitting in umbilical
plug and GCS umbilical base
1556707
10001
6
Wrench, torque,
(100 in-lb, 3/8-inch drive)
Used with adapter and 5-inch
extension to tighten coupling ring,
wing, and fin attaching screws
2601861
30003
7
Wrench assembly,
tube spanner
To install/remove S-A device
3018090
30003
17
Gauge, hanger alignment
Align hangers
318M0014P001
49956
Not Illustrated
Pliers, spreader
To expand coupling rings during
missile assembly
380-72
57163
Not Illustrated
Straight Edge, Steel
(Note 1)
Align hangers
4132-5-1
01556
Not Illustrated
Screw tool kit
Repair forward hanger attachment
bolts internal threads
57-531
61711
Not Illustrated
Soft face, dead blow, one piece
hammer
Used to seat coupling rings during
missile assembly
57-542
01359
Not Illustrated
Soft face, dead blow, one piece
hammer
Alternate
639AS2980
30003
Not Illustrated
Wrench, torque, 13 ±1 ft-lb,
(30-200 in-lbs)
Use with spanner to install probe guide
in coolant pressure tank, alternate for
Figure 5
639AS2981
30003
8a
Wrench, spanner
To remove and replace probe assembly
cap, probe guide, and preformed
packing compression fixture in coolant
pressure tank
639AS2983
30003
8b
Tool, removal and insertion
To remove and install preformed
packing in coolant pressure tank
639AS2982
30003
8c
Fixture, compression, preformed packing
To install preformed packing in coolant
pressure tank
639AS4510
30003
10
Tool, coolant pressure tank
removal
Alternate
Part Number
6
Change 2
Nomenclature
Use
CSTO XX21M-AIM9M-2
WP 004 00
Table 1. Master List of Special Tools (Continued)
Part Number
CAGE
Code
Figure/Index
Number
Nomenclature
Use
639AS10749
30003
11
Wrench, chain
Used to install coupling rings during
missile assembly
643J
57163
13
Gauge, depth
Used for measuring scratches, wear,
pits, cuts, gouges or dents on critical
surfaces
88C-Y-061
14083
15
Aft hanger skid surface wear
fixture
Used for measuring wear on aft hanger
surface
89C-Y-S-008
14083
16
Aft hanger template
Used for measuring wear on aft hanger
surface
9176642
18876
Not Illustrated
Scriber, machinist’s
Tying electrical leads. Thread cleaning.
93D-Y-015
18
Hanger alignment fixture
Used to position and align hangers
None
11.1
C-Clamp (Modified)
Remove and replace umbilical spring
pin
None
Not Illustrated
GO/NO-GO Gauge,
5/16-24 UNF
Inspecting threads
None
Not Illustrated
GO/NO-GO Gauge,
3/8-24 UNJF
Inspecting threads
Note 1: The Steel Straight Edge, PN 380-72 (or an equivalent item), is optional equipment. It may be used as a substitute
for the hanger alignment gauge to verify rocket motor hanger alignment. Another option is local manufacture of a 'straight
edge' to verify rocket motor hanger alignment. The Steel Straight Edge (PN 380-72) is provided as an option to local
manufacture.
Figure 1.
Screwdriver Handle
Figure 2.
Missile Assembly Tool
Change 2
7
CSTO XX21M-AIM9M-2
WP 004 00
Figure 3.
Ring Seating Assembly Tool
Figure 4.
Ring Staking Tool
Figure 5.
Gas Inlet Spanner
Figure 6.
Wrench, Torque (100 in-lb, 3/8-Inch Drive)
Figure 7.
Tube Spanner Assembly Wrench
a. Wrench, Spanner
b. Tool, Removal and Insertion
Figure 8. Coolant Pressure Tank Special Tools
8
c. Fixture,
Compression,
Preformed Packing
CSTO XX21M-AIM9M-2
WP 004 00
Figure 9. Coolant Pressure Tank Removal Tool (Fabrication)
3/8” drive,
3/16” hex
Figure 10.
Coolant Pressure Tank Removal Tool
Figure 11.
Chain Wrench
Change 2
9
CSTO XX21M-AIM9M-2
WP 004 00
Figure 11.1. C-Clamp (Modified)
4.00
+000
HOLE
-002
NOTE 4
0.062
ADHESIVE
NOTE 1
0.50
HANDLE
(2024-T6-AL)
0.250
DETAIL A
STEM
NOTE 4
4.00
NOTE 3
0.25
0.500
0.06
+000
HOLE
-002
NOTE 4
0.062
1.20
0.50
0.09R
0.25R
0.25
DETAIL A
NOTES: 1.
2.
3.
4.
ADHESIVE SHALL BE MMM-A-134 TYPE 1
125 ALL MACHINED SURFACES, REF MIL-STD-10
HEAD SHOULD BE FABRICATED FROM MIL-S-6785 ALUMINUM, OR USE ANY ALUMINUM ALLOY
WIRE 0.059 DIA.
Figure 12. Wing Tapping Tool
10
Change 2
CSTO XX21M-AIM9M-2
WP 004 00
0
5
5
10
10
15
15
20
20
25
No. 643
Figure 13. Depth Gauge, PN 643J
Figure 14. Hanger Screw Extractor Assembly, PN SA497576
11
CSTO XX21M-AIM9M-2
WP 004 00
Figure 15. Aft Hanger Skid Surface Wear Fixture
Figure 16. Aft Hanger Template
12
CSTO XX21M-AIM9M-2
WP 004 00
Figure 17. Hanger Alignment Gauge
Figure 18. Hanger Alignment Fixture
Figure 19. Spanner Wrench Assembly, PN SA497573, and Socket Wrench Adapter 3/8’’ to 1/4’’, PN GGG-W-641
13
CSTO XX21M-AIM9M-2
WP 004 00
Table 2. Master List of Test Equipment
CAGE
Code
Figure/Index
Number
AN/PSM-37
80058
Not Illustrated
TS-2835/
AN/DSM-98 (V)
10001
DPP-80
Part Number
Nomenclature
Use
Multimeter, general purpose
Test continuity/shorts of tactical
umbilical cables
26
Tester, squib
Mk 36 Mod 7 firing circuit
readiness test
11710
21
Dial, push/pull gauge
To perform cager release-pull
test
Fluke-8025B
89506
Not Illustrated
Meter, short test
Perform umbilical continuity
check
TS-3037 A/G
PN 2881174
30003
23
Test Set, Umbilical Cable
Check continuity of umbilical
cables
TS-3860C
PN 639AS10140
30003
24
Test Set, Guidance Control
Section
Alternate for TS-4044/D
TS-4044/D
PN 757300-10
97384
24
Test Set, Guidance Control
Section
Test operation of GCS
639AS9334-1
and
639AS9334-2
30003
Not Illustrated
Digital Hygrometer,
TTU-546/E
(Note 1)
Test the Moisture content of
TMU-72 coolant tanks
02400081
12255
Not Illustrated
PTS-15 Portable Test Set
(Note 2)
Test DSU-15 AOTD
1863
24655
Not Illustrated
Megohmmeter or equivalent
To perform umbilical cable
Hi-Pot test
2880186
30003
22
Scale, instrument, 0 to 4 lbs
To perform cager release-pull
test, alternate for DPP-80
620A-4
1CRL2
25
Igniter circuit tester,
AMPTEC Failsafe Ohmmeter
Test operational condition of
GCS gas generator squib
639AS10059
12934
20
Gauge, spring pin
Safe-Arm selector handle
spring pin test
Note 1: The TTU-546/E is optional equipment.
Note 2: The PTS-15 is optional equipment.
Figure 20. Gauge (Spring Pin)
14
Change 2
CSTO XX21M-AIM9M-2
WP 004 00
Figure 21. Dial, Push/Pull Gauge
Figure 22. Instrument Scale, 0 to 4 lbs
J1
J3
J4
TEST
CHECK
Figure 23. Umbilical Cable Test Set TS-3037 A/G
15
CSTO XX21M-AIM9M-2
WP 004 00
TS-3860C
TS-4044/D
Figure 24. Guidance Control Section Test Sets, TS-4044/D and TS-3860C
16
CSTO XX21M-AIM9M-2
WP 004 00
ON
20
200
2000
20K
8mA
1.5mA
150μA
20μA
OHMS
OFF
CHARGING
VHI
IHI
VOLTAGE
CURRENT
VLO
ILO
Amptec Fail-Safe Ohmmeter 620A-4
Simpson Model 4-000 ITS - Deleted
Alinco Model 101-5BFG - Deleted
Figure 25. Igniter Circuit Tester
Change 2
17
CSTO XX21M-AIM9M-2
WP 004 00
INPUT
J1
J2
B
GOOD
A
D
A
D
B
TEST COVER
QUALITY
THE TEST SET, ELECTRICAL CIRCUIT, GUIDED
MISSILE AN/DSM-98(V) CONSISTS OF THE
FOLLOWING ITEMS CONTAINED IN CASE AND
COVER CY-6662/DSM98(V)
1. TEST SET, ELECTRICAL CKT.
TS-2835/DSM98(V)
68A42D10
2. TEST LEAD ASSEMBLY
68A42C8
3. SQUIB ADAPTER
68A42C30
4. SIDEWINDER ADAPTER OR
68A42C40
CHAPARRAL ADAPTER
68A42C50
5. BATTERY, 1.3 VOLT 1 REQD.
BA-1328/U
6. KEY, SOCKET HEAD SCREW
68A42A74
7. HANDBOOK
NAVAIR 16-30DSM98-1
TEST
CAL
TEST SET FACEPLATE
NOTE: Part number 68A42C40 has been replaced
by part number SA639AS11754
GN
SQUIB ADAPTER
D
MISSILE ADAPTER
Figure 26. AN/DSM-98(V) Test Set with Adapters
18
Change 2
CSTO XX21M-AIM9M-2
WP 004 00
Table 3. Master List of Support Equipment
Part Number
Locally
Manufactured
CAGE
Code
Figure/Index
Number
98752
34
Holding Fixture
Hold GCS during bench work
Not Illustrated
Cleaner, Vacuum
Remove air from barrier material
Local
Purchase
Nomenclature
Use
16ADA27807
09205
31
GCS Assembly Fixture
Holds GCS during maintenance
6077
38597
27
Storage and Maintenance
Stand, MHU-32/E
Storing and transporting missile
sections in assembly and storage area
639AS10030
30003
29
Recharging Unit Assembly,
GCU-26/E or GCU-26A/E
To charge coolant pressure tanks
639AS2999
30003
28
Coolant Pressure Tank
Bleed Down Fixture
To depressurize and support coolant
tank for maintenance
68D35756-10
98752
30
Assembly Stand
Supports missile or component(s)
during assembly/disassembly
7329590
98752
33
Storage Rack Assembly
Store missiles when not on aircraft,
trailers or in containers
8028909
98752
27
Missile Storage Stand
MHU-32A/
Storing and transporting missile
sections in assembly and storage area
8431336
98752
32
Guided Missile Coolant
Recharging Unit GCU-30/E
To charge coolant pressure tanks
Change 1
19
CSTO XX21M-AIM9M-2
WP 004 00
Figure 27. Storage and Maintenance Stand, MHU-32/E and Missile Storage Stand MHU-32A/
NOTE: The fixture is designed to safely drain gas from the coolant tank to reduce the pressure to 1200 psig. However, the fixture can be
modified to reduce the pressure to 120 psig. The modification is optional. Contact WR-ALC, 575 CBSS/GBIA, 460 Richard Ray
Blvd, Ste 200, Robins AFB, GA 31098-1813 for modification instructions.
Figure 28. Coolant Pressure Tank Bleed Down Fixture
20
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
Figure 29. Recharging Unit Assembly, GCU-26/E or GCU-26A/E
Change 1
21
CSTO XX21M-AIM9M-2
WP 004 00
Figure 30. Assembly Stand
Figure 31. GCS Assembly Fixture
22
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
Figure 32. Guided Missile Coolant Recharging Unit, GCU-30/E
23
CSTO XX21M-AIM9M-2
WP 004 00
Figure 33. Storage Rack Assembly (PN 7329590)
5 1/8
PAD
2 9/16
3 3/4
1 3/16
1 3/4
7.0
NOTES: 1.
2.
3.
4.
DIMENSIONS ARE IN INCHES
PAD 1/16 THICK RUBBER
TWO REQUIRED PER ITEM
SEE T.O. 33D9-1-432
Figure 34. Holding Fixture (Local Manufacture)
24
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
Table 4. Master List of Safety and Protective Devices
Part Number
CAGE
Code
Figure/Index
Number
B-702
99017
36/1
Cover, dust, motor tube, aft
(alternate for PN 1560855)
Prevents admittance of foreign
materials into rocket motor aft end
opening.
NAS1756-24
80205
35
Streamer, warning
‘Remove Before Flight’ flag for IR
dome protector
041508-0106
71468
36/2
Captive flight adapter
Prevent gas grain generator
ignition.
041508-0113
71468
36/2
Captive flight adapter
Prevent gas grain generator
ignition.
1555424
30003
36/3
Umbilical protective cap
Electrically shorts gas generator
igniter squib and protects umbilical
plug from entry of moisture and
foreign matter.
1555582
10001
36/4
Warhead aft protector
Protects warhead aft end mating
surfaces from damage.
1555583
10001
36/5
Warhead forward protector
Protects warhead forward end
mating surfaces from damage.
1555586
10001
36/6
Cover, dust, motor tube, fwd
Prevents admittance of foreign
materials into rocket motor forward
end opening dust and moisture seal.
1560855
10001
36/1
Cover, dust, motor tube, aft
Prevents admittance of foreign
materials into rocket motor aft end
opening dust and moisture seal.
1560872
10001
36/7
Forward hanger protective cover
Protects forward hanger and rocket
motor contact buttons from damage,
and prevents inadvertent touching
of contact buttons.
1778047
10001
36/10
S-A device protective cap
Protects and prevents admittance of
foreign materials into S-A device
connector, dust and moisture seal.
2880325
30003
36/16
HRU-985A/E Umbilical Cable
Assembly
Prevent gas grain generator
ignition.
639AS1021
30003
36/10
Cap, protective,
(alternate for PN 1778047)
Protects and prevents admittance of
foreign materials into S-A device
connector, dust and moisture seal.
639AS1088
30003
36/11
9-Pin dust cap
Protects and prevents admittance of
foreign materials into GCS 9-pin
connector.
Nomenclature
Use
Change 1
25
CSTO XX21M-AIM9M-2
WP 004 00
Table 4. Master List of Safety and Protective Devices (Continued)
Part Number
CAGE
Code
Figure/Index
Number
639AS2876
30003
36/8
Coolant inlet probe protective cap
Protects and prevents admittance of
foreign materials into GCS gas inlet
probe.
639AS2879
30003
35
and
36/9
Dome protective assembly
Polyurethane foam cover protects
optical dome of GCS and constrains
GCS gyro by means of rings of iron
particles embedded in foam that act
on bar magnet of gyro.
639AS767
30003
36/12
Sealing cap
Protects and prevents admittance of
foreign materials into TD 20-pin
test connector.
639AS845
30003
36/13
Cover, TD protector
Wraparound cover that protects TD
windows from damage.
639AS876
30003
36/14
15-Pin, sealing cap
Protects and prevents admittance of
foreign materials into GCS 15-pin
test connector.
855923-10
or
2623628
98747
36/15
Safety clip assembly (MOD 10/11)
To prevent unintended arming of
the rocket motor and to provide an
easily seen indication of rocket
motor being in the SAFE position.
26
30003
Change 1
Nomenclature
Arming key and safety flag assembly
(MOD 8/9)
Use
CSTO XX21M-AIM9M-2
WP 004 00
NOTE: The dome protector covers come with only one
bungy cord. However, a second of the same type
may be attached (as shown) if desired.
7 inches
NOTE: An alternate (locally fabricated) dome protector
cover tie-down may be used as shown.
43 inches
To fabricate, drill a 3/8 inch hole 7 inches from the open
end of the dome cover. Using approximately 68 inches of
bungy cord, pass one end through the hole in the dome
cover. Tie a 6 inch loop at each end. Install the dome
cover.
6 inches
WARNING
STREAMER
Figure 35. Guided Missile AIM-9M Protective Dome Cover
27
CSTO XX21M-AIM9M-2
WP 004 00
HRU-985A/E TRAINING
UMBILICAL (16)
Figure 36. Safety and Protective Devices
28
Change 1
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables
Nomenclature
Specification/
Part Number
CAGE
Code
Use
Reference
Cleaning/Corrosion Preventive Materials
Alcohol, Isopropyl
TT-I-735
81348 Removal of dirt, corrosion, and
grease
WP 008 00, SWP 008 01-008 03,
008 05, 008 08, WP 009 00, SWP
009 01-009 02, 009 04, 009 05,
009 06
Cloth, Emery 320 Grit P-C-1673
81348 Removal of loose paint or light to WP 006 00, SWP 006 01, 006 02,
moderate surface corrosion
006 04, 006 06, WP 007 00, SWP
007 01, 007 03, 007 04, 007 06,
WP 008 00, SWP 008 01, 008 02,
008 04, 008 05, 008 07, WP 009
00, SWP 009 01-009 05, 009 06
Compound, Cleaning, MIL-C-87937
Aerospace Equipment Type II
81348 Remove dirt, grease or corrosion. WP 008 00, SWP 008 01-008 07,
Cleaning coolant tank access
WP 009 00, SWP 009 01-009 06,
cover window
WP 011 00
Compound, Corrosion MIL-C-81309,
Preventive
Type II, Class 2
80244 Used for coupling ring seating and WP 008 00, SWP 008 02, 008 04,
008 05, WP 009 00, SWP 009 02minimize corrosion on exposed
unpainted surfaces
009 06, WP 010 00
Compound, Corrosion MIL-C-85054
Preventive
80244 To minimize corrosion on exposed SWP 006 05, WP 008 00, SWP
unpainted surfaces
008 02, 008 07, WP 009 00, SWP
009 02
Detergent
MIL-D-16791,
Type I
81349 Removal of dirt or grease
Gauze, Cotton
Local purchase
Powder, Scouring
A-A-14
81348 Cleaning wing surfaces
Tissue, Lens
NNN-P-40
81348 For cleaning GCS dome and target SWP 008 01, 008 02, SWP
detector windows
009 01, 009 02
WP 008 00, SWP 008 01, 008 02,
008 04, 008 05, WP 009 00, SWP
009 01-009 06
Coat outside of GCS and cleaning SWP 008 01, 009 01
SWP 008 06
Coolant
NOTE
BB-N-411 is a federal specification. MIL-R-81202 contains additional
requirements not in BB-N-411. MIL-R-81202 is the military
specification for the USN LAU-7 launcher nitrogen receiver.
Air
BB-N-411 as
modified by
MIL-R-81202
Used for cooling GCS
WP 003 00
Argon
MIL-P-27415,
Type 1, Grade A
81349 Used for cooling GCS
WP 003 00
Nitrogen
MIL-P-27401,
(Alternate for argon) Type 1, Grade C
81349 Used for cooling GCS
WP 003 00
Change 1
29
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables (Continued)
Nomenclature
Specification/
Part Number
CAGE
Code
Use
Reference
Miscellaneous Materials
Bag Plastic,
Polyethylene
MIL-PRF-81705D
30003 TD packaging in the CNU-286/E SWP 006 02, 007 02
container
Band, Rubber
ZZ-R-1415,
Size 64
81348 Secure umbilical cable
WP 006 00, SWP 006 01 WP
007 00, SWP 007 01
Blade, razor
GGG-R-60
81349 Cut away excess sealing
compound
SWP 008 06
Brush, Acid swabbing A-A-289 Size 1
58536 Repair of GCS anodized coating
SWP 008 06
Barrier Material
MIL-PRF-81705D
81349 Packaging components in barrier WP 006 00, SWP 006 02-006 04,
material
006 07, 007 02, 007 03
Cord, Elastic
MIL-C-5651
3/16 inch dia.
81349 Attaching dome cover to GCS
Cord, Lacing and
Tying
MIL-T-43435
81349 Initiator electrical leads spot-tying SWP 008 05, 009 04, 009 05
Desiccant/Activated
MIL-D-3464
81349 Moisture absorbing material for
packaging containers
WP 006 00, SWP 006 01- 006 07,
WP 007 00, SWP 007 02-007 04
Depressor, Tongue
GG-D-226
81348 Mixing epoxy
SWP 008 06
Flux, Soldering
MIL-F-14256
81349 TD 6-pin connector repair
SWP 009 02
Indicator, Humidity
MS20003-2,
Type II
96906 Moisture indicator for packaged
components
WP 006 00, SWP 006 01-006 07,
WP 007 00, SWP 007 01-007 04
Rope, Wire
M83420/2-001
81349 Coolant tank
SWP 008 08
Sleeving, Insulation,
Electrical
M23053/4-304-0 81349 GCS/TD cable insulation repair
MIL-I-23053/4,
Class 3, 1.570
inch dia,
color black
SWP 008 01
Sleeving, Insulation,
Electrical
M23053/4-305-0 81349 Umbilical cable insulation repair
MIL-I-23053/4,
Class 3, 1.570
inch dia,
color black
SWP 008 01
Sleeving, Insulation,
Electrical
M23053/5-109-6 81349 HRU-985A/E Training Umbilical SWP 008 01
Cable Assembly Strap Repair
MIL-I-23053/5,
Class 1, 0.750
inch dia,
color blue
Sleeving, Insulation,
Electrical
M23053/5-111-2
MIL-I-23053/5,
Class 1, 1-1/2
inch dia,
color red
30
Change 1
WP 006 00, WP 007 00
81349 Captive flight adapter installation SWP 006 01
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables (Continued)
Nomenclature
Specification/
Part Number
CAGE
Code
Use
Reference
81349 Captive flight adapter installation SWP 006 01
Sleeving, Insulation,
Electrical
M23053/5-112-2
MIL-I-23053/5,
Class 1, 2 inch
dia, color red
Sleeving, Insulation,
Electrical
M23053/6-107-1 81349 Secure telemetry pack cables
MIL-I-23053/6,
Class 1, 0.375
inch dia
WP 011 00
Solder, SN63
QQ-S-571
81348 TD 6-pin connector repair
SWP 009 02
Strapping, Steel
5/8-inch
QQ-S-781
81348 Secure containers
SWP 006 05, 007 04, 007 05,
007 06
Swab, Cotton
6-143
Commercial
Tape
DDD-T-86
Tape
Local purchase
Tape, Adhesive,
Rubber
639AS4838
Tape, Buckram
1560866-1
Center hanger replacement
SWP 009 04, 009 06
Tape, Buckram
1560866-2
Aft hanger replacement
SWP 009 04, 009 06
Tape, PressureSensitive, Color No.
10117 (brown), 13538
(yellow), and 35109
(blue)
A-A-1689
471 BR 2"
471 YL 2"
471 BL 2"
58536 To replace explosive markings
Tape, Sealing
MIL-I-15126
Ty GFT
81349 Coolant pressure tank outlet valve SWP 006 08, WP 007 00,
SWP 007 01, 008 08
Tube, Fiberboard
PPP-T-495,
Type I, Class 1,
Style D
81348 Filter for container space when
shipping containers that are not
full
WP 006 00, SWP 006 01, 006 05,
WP 007 00, SWP 007 01, 007 04
Wire, Lock,
Aluminum, 0.020inch diameter
MS20995-AB20
96906 Securing umbilical cable screws
WP 008 00, SWP 008 01,
WP 009 00, SWP 009 01
Wire, Lock, Inconel
0.020-inch diameter
MS20995-N20
96906 Alternate
Applying cleaning agents
SWP 008 08
81348 GCS packaging in the CNU-301/E WP 006 00, SWP 006 01,
and CNU-310/E containers
WP 007 00, SWP 007 01
Contain sealing, humidity cord,
plastic bag
60890 Leak test
SWP 006 02-006 04, 006 06,
006 07, 007 03
SWP 006 08
SWP 008 04, 008 05, 009 06
Change 1
31
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables (Continued)
Nomenclature
Specification/
Part Number
CAGE
Code
Use
Reference
Paints / Primers / Thinners
NOTE
Follow paint manufacturer’s instructions.
Whenever repainting or touch-up of component is required. Low VOC, EPA
approved primers shall be used.
Whenever repainted or touch-up of components is required, low VOC, EPA
approved enamel shall be used. However, polyurethane/epoxy or other durable
coatings may be used if appropriate corrosion facilities are available.
Sempen Touch-up Pen is recommended for touch-up of paint/primer and
application of conversion coating. Refer to TO 1-1-8 for detailed guidance. Use
of the Sempen reduces maintenance time, waste, and hazard to personnel.
The first digit of each paint color code indicates level or degree of gloss.
Finishes are represented as; 1-Gloss; 2-Semi-Gloss; or 3-Flat or Lusterless.
With the exception of the basic gray body color (36375) or unless otherwise
indicated, any level of gloss available is acceptable for the color code
requirements of this technical order.
Black
Color No. 37038
Markings (opaque ink, marking)
SWP 008 01-008 06,
009 01-009 05
Blue
Color No. 35109
Inert band
SWP 009 01, 009 03009 06, WP 011 00
Brown
Color No. 20117
Explosive band
SWP 008 05
Enamel
Color Clear
Cover markings
SWP 008 01-008 06,
009 02-009 05
Gray
Color No. 36375
Paint/touch-up rocket motor,
warhead and MBA exterior
surfaces
SWP 008 04, 008 05,
009 02-009 05
Green
Color No. 34230
Safe-arm background
SWP 009 04
Red
Color No. 21136
Replace GCS/safe-arm
background markings
SWP 008 01, 009 01, 009 04
White
Color No. 27875
Marking GCS
SWP 008 01, 008 04, 009 01
Yellow
Color No. 23538
Explosive markings/band
SWP 008 03, 008 04
Coating MDU-27 wing ribs
SWP 009 06
Paint, High Zinc Dust MIL-P-21035
Content
Sealers
Adhesive
32
Epoweld 8173
Change 2
04347 Bond Training GCS dome to
WP 008 00, 009 00,
dome housing. Access cover
SWP 008 01, 009 01
coolant tank retainer replacement
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables (Continued)
Nomenclature
Adhesive, Epoxy
Specification/
Part Number
MMM-A-134
Type I, Class I,
Cure B
CAGE
Code
Use
81349 Forward hanger/screw
replacement
Reference
SWP 009 04, 009 06
Forward adapter, Safe-Arm stop SWP 009 05
assembly, strap assembly hanger,
AFT closure, wing, forward,
center, and aft hanger/screw
replacement
Forward hanger/screw
replacement
Adhesive, Epoxy
2216B/A
SWP 008 05
52152 Umbilical block epoxy potting
repair, and umbilical cable
insulation to umbilical block or
launcher connector repair
SWP 008 01, SWP 009 01
Compound, Insulating MIL-S-8516,
GC-1300
Type II, Class 1,
Cure B
81349 RIF Assembly electrical lead
sealant
SWP 008 05
Compound, Sealing
81349 Training TD window replacement SWP 009 02
MIL-PRF-24176
Type II
TMU-72A/B, Lens replacement
SWP 008 08
Access cover window replacement SWP 008 01, 009 01
Compound, Sealing
MIL-S-22473,
Grade C
0ZDS4 Mk 36 Mod 8/9 Safe-Arm
assembly replacement
Compound, Sealing,
Primer
MIL-S-22473,
0ZDS4 Forward hanger replacement
Grade T, Form R
SWP 008 05, 009 04, 009 06
Compound, Sealing
MIL-S-46163,
81349 Thread Sealing
Type II, Grade N
SWP 008 05, 008 06, 009 05,
009 06
Compound, Sealing
MIL-S-46163,
Type III,
Grade R,
PN 29021
81349 Thread Sealing
SWP 008 05, 009 04
SWP 008 05, SWP 009 04
NOTE
Seal decal edges when required with 3M Co. (Cage Code 34360) Edge Sealer,
P/N 4150 under NSN 8030-00-195-7660, or P/N 3950 under NSN 8030-00936-9940. Use of other edge sealers will cause early failure of 4000 series
decal ink and MIL-P-38477 polyester film decals (TO 1-1-8).
Compound, Sealing
4150 or 3950
34360 Edge sealer
All decals as needed
Change 2
33
CSTO XX21M-AIM9M-2
WP 004 00
Table 5. Master List of Consumables (Continued)
Nomenclature
Specification/
Part Number
CAGE
Code
Use
Reference
Compound, Silicone
MIL-S-8660
81349 Preformed packing, mating
surfaces, and wing cager
lubricant/sealant
WP 006 00, SWP 008 01, 008 02,
008 05, 008 06, 008 07, 009 01,
009 02, 009 05, 009 06
Primer Coating
Loctite 7471
05972 TD Pan Head screw installation
SWP 008 02
Putty, Moldable;
Base Coat
E-400 P
14439 Wing coating repair
SWP 008 06
Sealant
MIL-A-46146
Group I, Type I
(clear preferred)
80244 Repair/replacement of S-A device SWP 008 01, 008 03, 008 05,
008 06, 009 01, 009 02, 009 04,
gasket and shock absorber
009 05, 009 06
Umbilical base sealant.
Umbilical cable repair. Sealant for
hole in center of aft closure and
training TD window replacement
Screw thread sealing primer.
Guide vane lobe cavity sealant
Safe-Arm selector handle
retaining plate
Threadlocker
Permabond
HM118
61078 TD Pan Head screw installation
SWP 008 02
Top Coat
E-400 F
14439 Wing coating repair
SWP 008 06
81349 Rolleron attaching screws, cager
flag movement
WP 006 00, SWP 006 06,
WP 007 00, SWP 008 01, 008 06,
SWP 009 01
Lubricants
Lubricant, Breakfree MIL-L-63460
Lubricate threads of dome
assembly and GCS housing
Lubricant, Solid Film MIL-L-23398
34
Change 1
81349 Lubricate hangers
WP 008 00, SWP 008 05,
WP 009 00, SWP 009 04, 009 05
CSTO XX21M-AIM9M-2
WP 005 00
WORK PACKAGE
STORAGE AND INSPECTION REQUIREMENTS
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M, CATM-9M AND DATM
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 12
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-2 . . . . . . . . . . . . . . . . . . . . . . . 2
5-12 . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
3. . . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
4 . . . . . . . . . . . . . . . . . . . . . . . . .2
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Airmunition Serviceability and Location Record ...........................................................................................AFTO Form 15
Conventional Munitions Maintenance Management ............................................................................................ AFI 21-201
Conventional Munitions, Suspended or Restricted........................................................................................ TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Fire Fighting Guidance, Transportation and Storage Management Data .......................................................... TO 11A-1-46
Missile Inspections, Flight Reports, and Supporting Maintenance Documents ................................................... TO 00-20-5
Nondestructive Inspection Methods .................................................................................................................... TO 33B-1-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Unpacking, Packaging and Inspection, Fins, BSU-32/B .....................................................................................SWP 006 07
Unpacking, Packaging and Inspection, Rocket Motor, Mk 36 Mod 7, Mk 36 Mod 8,
Mk 36 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11...........................................................................................SWP 006 05
Unpacking, Packaging and Inspection, Safety-Arming Device, Mk 13 Mod 2 ..................................................SWP 006 03
Unpacking, Packaging and Inspection, Warhead, WDU-17/B ............................................................................SWP 006 04
Unpacking, Packaging and Inspection, Wing Assembly, Guided Missile, Mk 1 Mod 1 and Mk 1 Mod 2 ........SWP 006 06
Unpacking, Packaging, Inspection and Ground Handling, AIM-9M Tactical Missile..........................................WP 006 00
Unpacking, Packaging, Inspection and Ground Handling, CATM-9M and DATM Missiles ...............................WP 007 00
Unpacking, Packaging, Inspection and Test, Guidance Control Section, WGU-4A/B .......................................SWP 006 01
Unpacking, Packaging, Inspection and Test, Target Detector, DSU-15/B, DSU-15A/B, and DSU-15B/B........SWP 006 02
Unpacking, Packaging, Inspection, Test and Servicing, Coolant Pressure Tank,
TMU-72/B, TMU-72A/B and TMU-72B/B ......................................................................................................SWP 006 08
USAF Deficiency Reporting Investigation and Resolution............................................................................. TO 00-35D-54
Table of Contents
Title
Page
Component Periodic Inspection.............................................................................................................................................8
Coolant Pressure Tank Inspection........................................................................................................................................9
Change 2
1 of 12
CSTO XX21M-AIM9M-2
WP 005 00
Table of Contents (Continued)
Title
Page
Fin Inspection ...................................................................................................................................................................... 8
Rocket Motor Inspection ..................................................................................................................................................... 9
Safety-Arming Device Inspection ....................................................................................................................................... 9
Stubby Missile Inspection ................................................................................................................................................... 9
Target Detector Inspection................................................................................................................................................... 9
Wing Inspection................................................................................................................................................................... 9
Warhead Inspection ............................................................................................................................................................. 9
Coolant Pressure Tank Testing ............................................................................................................................................ 12
Handling ................................................................................................................................................................................ 3
Special Handling ................................................................................................................................................................. 3
Identification.......................................................................................................................................................................... 3
Inspection .............................................................................................................................................................................. 6
Correctable Defects ............................................................................................................................................................. 6
Noncorrectable Defects ....................................................................................................................................................... 6
Warranty Processing for AIM-9M Missile Components..................................................................................................... 6
Inspection Criteria ................................................................................................................................................................. 6
Missile Periodic Inspection ................................................................................................................................................... 7
Captive Air Training Missile (CATM) Inspection .............................................................................................................. 8
Category A Missile Inspection ............................................................................................................................................ 7
Category B Missile Inspection ............................................................................................................................................ 7
Category C Missile Inspection ............................................................................................................................................ 7
Category D Missile Inspection ............................................................................................................................................ 7
Category Environments ....................................................................................................................................................... 7
Dummy Air Training Missile (DATM) Inspection.............................................................................................................. 8
Other Inspections................................................................................................................................................................. 12
Pre-issue Inspection........................................................................................................................................................... 12
Pre-use/Post-use Inspection............................................................................................................................................... 12
Return Munitions Inspection (RMI).................................................................................................................................. 12
Post Assembly Inspection.................................................................................................................................................. 12
Shipping/Receiving Inspections ............................................................................................................................................ 6
All-Up-Round (AUR) Shipping/Receiving Inspection ....................................................................................................... 6
Component Shipping/Receiving Inspection ........................................................................................................................ 6
Guidance Control Section Shipping/Receiving Inspection ................................................................................................. 6
Special Inspection................................................................................................................................................................ 10
Directed Special Inspection............................................................................................................................................... 10
Dropped Missile Inspection............................................................................................................................................... 11
Missile Misfire or Hangfire Processing/Troubleshooting ................................................................................................. 10
Missile Subjected to Extreme Vibration............................................................................................................................ 11
Returned Missile/CATM for Malfunction ......................................................................................................................... 11
Storage and Inspection........................................................................................................................................................... 3
General ................................................................................................................................................................................ 3
Storage Monitoring Inspection .............................................................................................................................................. 9
Storage Monitoring Inspection Procedures ....................................................................................................................... 10
Storage Requirements............................................................................................................................................................ 3
CNU-310/E Stacking Limitations ....................................................................................................................................... 5
Inert Component Storage..................................................................................................................................................... 5
Inside Storage ...................................................................................................................................................................... 5
Outside Storage.................................................................................................................................................................... 5
Special Storage Instructions ................................................................................................................................................ 5
Priority of Issue ................................................................................................................................................................... 5
Target Detector Testing........................................................................................................................................................ 12
2
Change 2
CSTO XX21M-AIM9M-2
WP 005 00
List of Tables
Title
Page
Humidity Indicator Inspection Cycle (Months).....................................................................................................................9
Storage Data...........................................................................................................................................................................4
1.
STORAGE AND INSPECTION.
2. GENERAL. Records of incoming and outgoing
shipments and component tests/inspections shall be kept in
accordance with standard procedures.
3. Compliance with the requirements of existing
instructions augmented by the special instructions in this
manual, will ensure safe handling and storage procedures
and optimum serviceability of missile and missile
explosive components. Waivers and deviations will be in
accordance with existing instructions. Stored items should
be protected from adverse climatic conditions. Refer to
Table 1 for applicable storage data. The principal hazards
accompanying the handling and storage of explosive
components listed in this manual are:
a.
Warheads - Blast with mass detonation.
b.
Safe and Arm Device - Blast with possible mass
fragmentation.
c.
Rocket Motors - Intense heat and possible
explosion.
d.
Guidance Control Section - Fire. (Gas Grain
Generator installed)
e.
Gas Grain Generator - Fire.
4. Inspection shall be performed in accordance with
applicable WP/SWP.
5.
HANDLING.
6. Damaged containers will be repaired immediately, or
segregated for repair when operational requirements
permit. When repair is complete markings shall be
restored to the repaired areas.
7. Process dropped components in accordance with
applicable WP/SWP.
8. SPECIAL HANDLING. All loaded components,
even when properly packed and sealed, will be handled
with care. This is especially true of electrically initiated
devices, which are extremely sensitive to shock and
friction. Only forklift trucks, or hand operated lifts,
meeting requirements of existing directives shall be used
when handling explosive components. Operators will be
fully qualified and specifically designated. All handling
equipment shall be inspected before use to determine safe
operating conditions. Explosive components will be
secured to pallets prior to movement. When rocket motors
are being transported at using organizations, palletizing
should be limited to stacking of containers to five high and
five wide.
9.
IDENTIFICATION.
10. The use of standard nomenclature and lot number/
serial number is mandatory for all storage records, reports,
and communications concerning munitions. Legible
identification markings will be maintained on munitions in
storage. A data entry in the Tactical Missile Record
System (TMRS) is required on all inert/explosive
components in storage. If the system is not available an
AFTO Form 15 (Airmunition Serviceability and Location
Record) will be used. Where lot number/serial number,
date of manufacture, and date of required time-change for
explosive components are included on missile forms
required by TO 00-20 Series, preparation and use of
TMRS or AFTO Form 15 as specified by AFI 21-201, is
not required until the item is removed from the missile and
returned to separate storage, at which time the item will be
entered as an unassembled component in TMRS or an
AFTO Form 15 will be prepared.
11. STORAGE REQUIREMENTS.
12. Storage data is listed in Table 1 and TO 11A-1-46.
13. The following are general requirements for storage of
explosive components of the AIM-9 missile.
Change 1
3
CSTO XX21M-AIM9M-2
WP 005 00
Table 1. Storage Data
Item
Temperature Limitations °F
Min
Max
Shelf Life
Service Life
NOTE
Missiles or components that have exceeded temperature limits will be
rejected. Document approximate temperature reached and length of
time. Submit ammunition disposition request for further instructions.
Missile
-65
+160
NA
NA
Warhead
-65
+160
INDEF
INDEF
Safe-Arm Device
Mk 13 Mod 2 (Notes 3, 6)
-65
+160
15 years
15 years
Rocket Motor
-65
+165
INDEF
INDEF
NOTE
Gas generator PN639AS754 Lots AOB-6-160, 190/199 have a service
life of 8 years.
Gas Generator
-65
+160
INDEF
INDEF
Guidance Control Section
-65
+160
INDEF
INDEF
Target Detector
DSU-15A/B &
DSU-15B/B (Note 1)
-65
+160
15 years
15 years
Target Detector
DSU-15/B (Note 2)
-65
+160
27 years
27 years
NOTE
Coolant pressure tank: Hydrostatic test required every 10 years
Coolant Pressure Tank
-65
+160
INDEF
INDEF
Note 1: DSU-15A/B & DSU-15B/B When expired, return to NSWC Crane for Life Cycle Maintenance (LCM), Note 4.
Note 2: DSU-15/B When the current service life expires, replace with DSU-15A/B or DSU-15B/B. The DSU-15/B will
no longer be re-certified by NSWC Crane.
Note 3: MK 13 Mod 2 When expired, return to NSWC Crane for Recertification, Note 4.
Note 4: Crane Division, Naval Surface Warfare Center (NSWC Crane)
Code 40541, Bldg 364, 300 Highway 361
Crane, IN 47522-5001
Note 5: Re-certification: An operational test to verify the unit meets specifications.
Note 6: Micronics (MII) Safe-Arm Devices (SAD) with serial number prefixes JSC, JSM, JSN, and KEC cannot be
recertified at the end of their service life. Condemn, place in condition code H, and request disposition instructions.
Note 7: Life Cycle Maintenance (LCM): the term for DSU-15 depot periodic maintenance. LCM consists of: (1)
Inspection and testing (2) Replacing defective parts (3) Replacing o-rings (4) Leak test and refilling the unit with inert gas
(5) Testing all parameters at all temperature variants. LCM is the maintenance process for extending (or re-certification
of) DSU-15 service life.
4
Change 2
CSTO XX21M-AIM9M-2
WP 005 00
a.
Items of different NSNs will not be stored in the
same stack.
b.
Packing materials, empty boxes, tools, handling
equipment, or any miscellaneous materials shall
not be stored in a magazine containing
explosives.
c.
Paints, oils, and other flammable materials shall
not be stored in a magazine containing
explosives.
d.
Explosive components shall be stored and
stacked according to type, lot number, quantity/
distance requirements, and compatibility group.
e.
Multi-lot/serial numbers/stacking/storing of
AIM-9 missile explosive components is
authorized except at depot activities. When
practical, oldest items should be stored at front of
stack. Stack height shall not exceed authorized
limit for component container involved.
f.
Stacks shall be arranged to permit free circulation
of air.
g.
Dunnage shall be constructed and arranged so
that stacks will not lean, fall, sag, or shift.
h.
Sealed containers shall not be opened except for
issue or inspection.
i.
Incomplete packages shall be securely closed and
properly marked in accordance with TO 11A-110 to identify contents and quantity. Only one lite
box will be permitted for each lot, per condition
code, per storage structure, and shall be stored on
the top and front of the stack.
17. INERT
COMPONENT
STORAGE.
Inert
components are shipped and stored in the same containers
(appropriately marked) used for tactical components.
18. SPECIAL STORAGE INSTRUCTIONS. The
following are specific storage instructions peculiar to
AIM-9 explosive components.
WARNING
Explosive-loaded warheads
subjected to
temperatures in excess of +170°F for 10 minutes
shall not be used.
a.
Explosive-loaded warheads
subjected to
temperatures in excess of +170°F for 10 minutes
shall not be used.
b.
The warheads should be stored in temperatures
below +160°F. Any warhead subject to
temperatures in excess of +160°F for long
periods (8 hours cumulative time) shall be
considered unserviceable.
c.
Gas generators are not stored or handled
separately in the field. Directives pertinent to the
GCS will apply for installation of the gas
generator into the GCS at the depot.
19. PRIORITY OF ISSUE.
a.
When the lot number or date of manufacture
cannot be identified, an explosive item shall not
be issued. If either one is known, the other can
normally be determined through search of
existing records. Records and container will be
marked as required. The item may then be issued.
When missing data cannot be determined locally,
forward known data, including manufacturer’s
symbol (EKO, 8, M-H, etc.) to the appropriate
Air Logistics Center (ALC) to obtain remainder
of data.
b.
The following indicates the priority of issue of
items in storage.
14. INSIDE STORAGE. Preferred storage is in
structures designated for that purpose. Minimum suitable
storage shall be provided in accordance with AFMAN 91201, AFI 91 and AFOSH 91/127 series publications.
15. OUTSIDE STORAGE. Explosive components shall
be stored outside only when inside facilities are not
available. When outside storage is necessary, minimum
suitable shelter shall be provided in accordance with
AFMAN 91-201, AFI 91 and AFOSH 91/127 series
publications.
16. CNU-310/E STACKING LIMITATIONS. AURs
are shipped and stored in the CNU-310/E containers and
may be stacked 11 high.
(1) Lite package.
(2) Items which have had least favorable
storage.
(3) Oldest items.
(4) All others.
Change 1
5
CSTO XX21M-AIM9M-2
WP 005 00
20. INSPECTION.
21. Inspection will be performed to ensure the
serviceability of missiles and components. Inspect and
mark in accordance with TO 11A-1-10 and this WP. Lot or
serial numbers will be checked against TO XX11A-1-1 to
determine if the lot/serial number is suspended or
restricted. Inspections/tests will be performed using the
criteria, and within the inspection/test interval identified in
this manual. All inspections/tests shall be recorded in
accordance with TO 21M-1-101.
22. CORRECTABLE DEFECTS. Components having
correctable defects will be segregated, marked defective,
and scheduled for maintenance. Corrective action is listed
in applicable inspection tables for each item by defect.
23. NONCORRECTABLE DEFECTS. Components
with noncorrectable defects will be rejected, segregated,
marked defective, and reported for disposition in
accordance with AFI 21-201.
24. WARRANTY PROCESSING FOR AIM-9M
MISSILE COMPONENTS. Components under warranty
are identified by a decal/stencil stating warranty expiration
date. Warranted components that inspection tables denote
maintenance required will continue to have maintenance
performed in accordance with the appropriate TO.
Warranted components tested in accordance with the
appropriate TO and proved to be rejects will be packaged
and shipped to the appropriate manufacturer. Components
under warranty rejected due to mishandling, dropping,
fire, flood, etc., are to be reported to the appropriate item
manager for disposition instructions in accordance with
TO 00-35D-54. It will be necessary to immediately ship
failed components under warranty back to the appropriate
manufacturer. Upon receipt of the components at the
manufacturer, the warranty clock stops and the expiration
date is adjusted for the time out of service. All necessary
paperwork must be completed and accompany the failed
component being shipped to the manufacturer.
27. COMPONENT SHIPPING / RECEIVING
INSPECTION. A shipping/receiving inspection will be
performed in accordance with Paragraph 29 step d
utilizing the appropriate component SWP inspection table.
28. GUIDANCE CONTROL SECTION SHIPPING/
RECEIVING INSPECTION. A shipping/receiving
inspection will be performed in accordance with the
appropriate WP/SWP inspection table utilizing Paragraph
29 step d. Use container quantity as lot/sample size,
inspect one GCS per container. Records will be generated
from container information. If the date of last operational
test cannot be determined on any GCS, an operational test
of the GCS will be performed.
29. INSPECTION CRITERIA.
30. Inspections will be performed in accordance with the
national stock class as outlined in TO 11A-1-10. Sample
size will be determined by this WP. The inspection will
consist of a visual inspection for defects listed in
applicable tables. Inspection will be evaluated in
accordance with the following:
a.
Evaluation of Inspections. When defects are
discovered during inspection, the defects will be
classified in accordance with the applicable
inspection tables. When inspection points require
measurements and the defect exceeds the
allowable tolerance, the item will be rejected.
When the defect is less than the allowable
measurement, it shall be understood the defect is
acceptable.
b.
When inspecting a selected sample size, only the
number of defective items will be counted for
consideration of lot acceptance/rejection. Under
this concept, if one item has three major and four
minor defects, they will be counted as one major
and one minor defective item for application
against the sample table for acceptance/rejection
of the lot.
c.
The same items will not be inspected each sample
inspection. The containers will be marked in
accordance with TO 11A-1-10.
d.
The number of allowable defectives per sample
size and class of defectives, will be determined
using TO 11A-1-10 unless specified otherwise. If
a critical defective is found or the number of
defectives exceeds the allowable limit, the lot
will be inspected 100 percent. All defective items
25. SHIPPING/RECEIVING INSPECTIONS.
26. ALL-UP-ROUND (AUR) SHIPPING/
RECEIVING INSPECTION. A shipping/receiving
inspection will be performed in accordance with the
appropriate WP/SWP inspection table utilizing Paragraph
29 step d. Use AUR container (AURC) quantity as the lot/
sample size. Inspect one missile per AURC. Review
records for completeness and to determine environmental
categories. If category or date of last test cannot be
determined perform a category A inspection.
6
Change 1
CSTO XX21M-AIM9M-2
WP 005 00
e.
will be segregated and handled in accordance
with applicable WP. The remainder of the lot will
be returned to serviceable status.
b.
Missile assembly (WP 008 00), AUR assembly
(WP 006 00), and post assembly inspection
Paragraph 61.
Do not over test the GCS. Operational checkout
should not be performed more frequently than
specified in this TO or reliability may be
degraded.
c.
Prepare missile for storage as required.
31. MISSILE PERIODIC INSPECTION.
32. CATEGORY ENVIRONMENTS. The following
guidelines apply to categories A, B, C and D tactical
missiles/GCSs.
a.
b.
c.
Inspection categories refer to AUR missiles
(including missiles with telemetry installed), and
Guidance Control Sections.
An AUR/GCS must be tested/inspected prior to
moving from a more inspected to a less inspected
category. For example, once a missile/GCS is
flown (CAT D), it cannot be put into category A,
B or C without testing/inspection. Additionally,
an AUR/GCS moved from a less inspected to a
more inspected category must not exceed the date
that was established while in the less inspected
category. For example, an AUR/GCS moved
from category C to category D must not exceed
the test/inspection date established while in
category C.
Containers or desiccated barrier bags that are
opened for maintenance/inspection and resealed
within 24 hours shall not change the category of
the AUR missile or GCS.
33. CATEGORY A MISSILE INSPECTION. This is a
sample inspection/test of AUR missiles or GCSs in
containers and AUR missiles in sealed desiccated barrier
bags, all of which have not been opened since last
inspection.
34. This inspection/test shall be performed annually on 10
percent of total inventory of AURs and GCSs in Category
A status. Category A missiles/GCS at the Weapon System
Evaluation Program (WSEP) need not be inspected
annually, however, missiles/GCS will not exceed 10 years
since last inspection. This inspection/test consists of:
a.
Missile disassembly (WP 008 00), component
inspection, and functional/operational test IAW
applicable SWP.
35. CATEGORY B MISSILE INSPECTION. This is a
complete inspection/test of AUR missiles or GCSs in
containers and AUR missiles in sealed desiccated barrier
bags which have been removed from containers/barrier
bags for less than seven (7) consecutive days and not
flown on an aircraft. This inspection/test shall be
accomplished not to exceed 900 days from date removed
from container, but cannot exceed the inspection date
established by the previous category inspection. This
inspection/test consists of:
a.
AUR disassembly (WP 006 00), missile
disassembly (WP 008 00), component inspection,
and functional/operational test IAW applicable
SWP.
b.
Missile assembly (WP 008 00), AUR assembly
(WP 006 00), and post assembly inspection
Paragraph 61.
c.
Prepare missile for storage as required.
36. CATEGORY C MISSILE INSPECTION. This is a
complete inspection/test of AUR missiles or GCSs
removed from the container or desiccated barrier bag for
seven or more consecutive days but not flown on aircraft.
This inspection/test shall be accomplished not to exceed
720 days from date removed from container, but cannot
exceed the inspection date established by the previous
category inspection. This inspection/test consists of:
a.
AUR disassembly (WP 006 00), missile
disassembly (WP 008 00), component inspection,
and functional/operational test IAW applicable
SWP.
b.
Missile assembly (WP 008 00), AUR assembly
(WP 006 00), and post assembly inspection
Paragraph 61.
c.
Prepare missile for storage as required.
37. CATEGORY D MISSILE INSPECTION. This is
an inspection/test of AUR missiles flown one or more
times since last inspection. This category has 20 captive
flights, 30 day and 180 day inspection requirements.
Change 1
7
CSTO XX21M-AIM9M-2
WP 005 00
NOTE
In the absence of witness marks torque will only
be checked on screws listed in the applicable
component WP/SWP torque table. All other
screws will be visually checked for looseness.
Witness marks may be applied to aid in future
inspections.
a.
After twenty captive flights, the missile will be
downloaded and placed on approved assembly
stand or handling equipment and given a
thorough visual inspection, (WP 006 00, Table
11) and will include checking the complete
missile for loose screws and component mating
joint rotation. Screws will be inspected by either
physically checking the torque on each screw or
checking the witness (reference) mark that was
applied by marking properly torqued screws to
adjacent surface during a previous inspection.
b.
The 30 day inspection (is required as long as the
missile is in category D) consists of cager
release-pull test WP 006 00. Not required on
missiles loaded on alert aircraft.
c.
The 180 day inspection requirement shall begin
on the first day flown, but cannot exceed the
inspection date established by the previous
category inspection. This inspection/test consists
of:
screws will be visually checked for looseness.
Witness marks may be applied to aid in future
inspections.
a.
All CATM’s: After twenty captive flights the
training missile will be downloaded and placed
on approved assembly stand or handling
equipment and given a thorough visual inspection
(WP 007 00, Table 15, 17, 19 or 21), to include
checking the complete missile for loose screws
and component mating joint rotation. Screws will
be inspected by either physically checking the
torque on each screw or checking the witness
(reference) mark that was applied by marking
properly torqued screws to adjacent surface
during a previous inspection. The captive flight
adapter/umbilical cable will not be removed
solely to accomplish this inspection.
b.
CATM 9M-1 (with MDU-27/A): Every 180 days
after last inspection completely disassemble the
missile and inspect each component in
accordance with appropriate SWP. The captive
flight adapter/umbilical cable will not be
removed solely to accomplish this inspection.
The frequency of aft hanger surface wear
inspections are provided in SWP 007 06.
c.
CATM 9M-3 and 9M-7 (with components):
Every 180 days after last inspection completely
disassemble the missile and inspect each
component in accordance with appropriate SWP.
Non-Destructive Inspection of the Mk 57 rocket
motor will be accomplished in accordance with
TO 33B-1-1 Chapter 2, (method b, c, or d
sensitivity level 3 or higher). This inspection will
be performed on the full flange (from the forward
edge back approximately 0.375 inches) of the
rocket motor tube. The captive flight adapter/
umbilical cable will not be removed solely to
accomplish this inspection.
d.
CATM 9M-9 and 9M-10 (with MBA): Every 180
days after last inspection completely disassemble
the missile except the wings and inspect each
component in accordance with appropriate SWP.
The captive flight adapter/umbilical cable will
not be removed solely to accomplish this
inspection.
e.
CATM 9M-16, 9M-20, 9M-24 (with MDU-27A/
A): Every 180 days after last inspection
completely disassemble the missile and inspect
each component in accordance with appropriate
(1) AUR disassembly (WP 006 00), missile
disassembly (WP 008 00), component
inspection, and functional/operational test
IAW applicable SWP.
(2) Missile assembly (WP 008 00), AUR
assembly (WP 006 00), and post assembly
inspection Paragraph 61.
(3) Prepare missile for storage as required.
Missile may be placed in category A if
desired.
38. CAPTIVE AIR TRAINING MISSILE (CATM)
INSPECTION. The CATM has a 20 captive flight and a
180 day inspection requirement.
NOTE
In the absence of witness marks torque will only
be checked on screws listed in the applicable
component WP/SWP torque table. All other
8
Change 1
CSTO XX21M-AIM9M-2
WP 005 00
SWP. The captive flight adapter/umbilical cable
will not be removed solely to accomplish this
inspection. The frequency of aft hanger surface
wear inspections are provided in SWP 007 06.
f.
CATMs/CATM components not in use (excess to
mission requirements) 10% every three years.
39. DUMMY AIR TRAINING MISSILE (DATM)
INSPECTION. Disassemble DATM (WP 009 00) and
perform component inspection in accordance with
applicable SWP every 180 days or more often when
required. DATM components not in use (excess to mission
requirements) 10% every three years.
40. COMPONENT PERIODIC INSPECTION.
41. FIN INSPECTION. This is an inspection of 10% of
the fins in storage and is accomplished every three years
after the preceding periodic or receiving inspection. If less
than 10 full containers are in storage, one full container
will be inspected. If corrosion is found during the
inspection, a 100% inspection is required. Fins will be
inspected in accordance with SWP 006 07.
42. WING INSPECTION. This is an inspection of 10%
of the wings in storage and is accomplished every three
years after the preceding periodic or receiving inspection.
If less than 10 full containers are in storage, one full
container will be inspected. If corrosion is found during
the inspection, a 100% inspection is required. Wings will
be inspected in accordance with SWP 006 06.
43. WARHEAD INSPECTION. This is an inspection of
the warheads in storage and is accomplished every three
years after the preceding periodic or receiving inspection.
Determine the sample size in accordance with TO 11A-1-
10, Sample Size/Reject Table. Warheads will be inspected
in accordance with SWP 006 04.
44. SAFETY-ARMING DEVICE INSPECTION. This
is an inspection of the S-A devices in storage and is
accomplished every three years after the preceding
periodic or receiving inspection. Determine the sample
size in accordance with TO 11A-1-10, Sample Size/Reject
Table. S-A devices will be inspected in accordance with
SWP 006 03.
45. TARGET DETECTOR INSPECTION. This is an
inspection of the target detectors in storage and is
accomplished every three years after the preceding
periodic or receiving inspection. Determine the sample
size in accordance with TO 11A-1-10, Sample Size/Reject
Table. Target detectors will be inspected in accordance
with SWP 006 02.
46. ROCKET MOTOR INSPECTION. This is an
inspection of the rocket motors in storage and is
accomplished every three years after the preceding
periodic or receiving inspection. Determine sample size in
accordance with TO 11A-1-10, Sample Size/Reject Table.
Inspect rocket motors in accordance with SWP 006 05.
47. STUBBY MISSILE INSPECTION. This is an
inspection of missile PN 8946876 (see 'Missile
Configurations' WP 006 00). Inspect missile in accordance
with the applicable steps of Table 6 WP 006 00. Inspect 10
percent of the inventory annually. Missiles will not exceed
10 years since last inspection. For Category B, C and D
missiles when GCS is removed and PN 8946876 is
assigned a Category A inspection shall be performed on
remaining missile components. Stubby missiles will be
Category A assets. Prior to reinstalling a GCS, a Category
A missile inspection is required, Paragraph 33.
Table 2. Humidity Indicator Inspection Cycle (Months)
NOTE
The local environment at each location is determined by referring to TO 1-1691. High humidity is listed as severe, medium humidity as moderate and
low humidity as mild.
Local Environment
High Humidity
Medium Humidity
Low Humidity
Inside Storage
18
20
24
Outside Storage
6
9
12
Change 1
9
CSTO XX21M-AIM9M-2
WP 005 00
with appropriate SWP. Install new humidity
indicator and new or reconditioned desiccant
before resealing container. Monitor container for
seven days following re-preservation and initiate
disposition as follows:
48. COOLANT PRESSURE TANK INSPECTION.
This is an inspection of 10% of the coolant pressure tanks
not installed in AURs and is accomplished every three
years after the preceding periodic or receiving inspection.
If less than 10 full containers are in storage, one full
container will be inspected. If corrosion is found during
the inspection a 100% inspection is required. Coolant
pressure tanks will be inspected in accordance with SWP
006 08.
(1) If indicator remains blue, container shall be
placed in serviceable stock.
(2) If indicator does not show blue, container
should be considered defective and will be
processed in accordance with TO 35E20-231-2.
49. STORAGE MONITORING INSPECTION.
50. This is an inspection to ensure safe storage of
containerized/sealed missiles and missile components and
will be accomplished on those containers having visible
humidity indicators. The inspection will be accomplished
without opening containers. The frequency will be
determined by Table 2. The initial inspection will be
performed within 48 hours after receipt of shipment.
51. STORAGE
MONITORING
INSPECTION
PROCEDURES. Determine relative humidity within
containers having humidity indicator percent dots
installed, with action required as follows:
a.
When all circles (dots) on the indicator are blue,
the relative humidity is less than 20 percent and
no action required.
b.
When circles 20 and 30 are pink or lavender and
circles 40 and 50 are blue, relative humidity is
less than 40 percent and no action is required.
c.
When circles 20, 30, and 40 are pink or lavender,
relative humidity is greater than 40 percent.
Install new or reconditioned desiccant and new
humidity indicator. Monitor container for 72
hours following replacement of desiccant and
initiate disposition as follows:
e.
52. SPECIAL INSPECTION.
53. DIRECTED SPECIAL INSPECTION. A special
inspection will be performed when directed by local
authority, major commands, or the respective ALC in
accordance with the specific instructions provided by the
directing authority.
54. MISSILE MISFIRE OR HANGFIRE
PROCESSING/TROUBLESHOOTING.
a.
Minimize the number of technicians that have
access to the aircraft, missile and launcher.
Identify aircraft, missile, launcher and power
supply involved and set aside/impound for
troubleshooting. The incident aircraft should
have a complete missile system checkout and
wiring inspection performed. Affected missile
launcher should be removed from aircraft after
the aircraft systems checks are performed and
then sent to the launcher shop for further testing
and inspection to include wiring harness and
power supply checks using appropriate launcher
test equipment. Process the missile as follows:
b.
Determine status of missile.
(1) If relative humidity remains below 40
percent, container shall be placed in
serviceable stock.
(2) If relative humidity exceeds 40 percent, the
container will be opened and contents
inspected for defects in accordance with
appropriate WP/SWP. Install new humidity
indicator and new or reconditioned desiccant
before resealing container.
d.
10
When all circles have turned white and show no
blue, pink, or lavender, the indicator has probably
become wet. Inspect components in accordance
Change 1
Inspection required by steps c and d will be
performed during period not to exceed ten days
after finding the excess humidity indication.
(1) Perform GCS squib test, and if serviceable,
perform GCS operational test.
(2) Test target detector using PTS-15 test set,
SWP 006 02 (preferred method) or test target
detector squib using procedure in SWP 006
02, alternate method.
CSTO XX21M-AIM9M-2
WP 005 00
tamper seal (Mod 9/11) or weather seal (Mod
7/8/10) is intact. The rocket motor initiator
squib has been fired. Do not test motor.
Notify EOD for disposal. Notify Warner
Robins Air Logistics Center, 575 CBSS/
GBIA, 460 Richard Ray Blvd, Ste 200,
Robins AFB, GA 31098-1813 of incident.
(3) Perform rocket motor firing circuit readiness
test (MOD 7 only) and igniter/initiator
resistance check on all rocket motors in
accordance with SWP 006 05.
c.
Based on squib status and Launch Sequence chart
(WP 003 00), proceed to troubleshooting in the
following sequence:
d.
Inspect the safe & arm device (SAD) and
warhead. The fins and wing assemblies are
considered serviceable.
e.
Missile components with fired squibs will be
reported for disposition.
f.
Telemetry Section - Return to Depot.
(1) No squibs are fired.
(a) Launcher power supply.
(b) Launcher wiring.
(c) Aircraft related problem.
(2) Only GCS squib is fired. TD squib and
rocket motor squib are serviceable.
(a) GCS battery - battery did not attain 16
VDC to initiate relay in launcher.
55. RETURNED MISSILE/CATM FOR
MALFUNCTION.
a.
Perform a thorough AUR inspection which will
include checking the complete missile for loose
screws and component mating joint rotation.
b.
For malfunctions that indicate an internal failure
of the GCS, perform an operational test of the
GCS.
(b) Launcher power supply.
(c) Launcher wiring problem.
(3) Both GCS and target detector squibs are
fired. Rocket motor squib is serviceable.
(a) Launcher striker point/rocket motor aft
contact button connection.
(b) Launcher power supply.
56. MISSILE
SUBJECTED
TO
EXTREME
VIBRATION. (Over G Inspection). This inspection shall
be accomplished whenever a missile is required to be
downloaded from an aircraft to perform the aircraft over G
inspection. This inspection is required because of
suspected extreme vibration to the missile, not a specific G
value.
(c) Launcher wiring problem.
(4) Both GCS and target detector squibs are
serviceable. Rocket motor is in SAFE but
cannot be armed. The rocket motor initiator
squib has been fired while in the SAFE
position.
a.
Disassemble and inspect components and
condition of coupling rings, coupling ring
grooves, fins, and wing assemblies.
b.
Test GCS
c.
Reject target detector (tactical missile only).
(a) Launcher power supply.
(b) Launcher wiring.
(c) Aircraft Wiring
(5) Both GCS and target detector squibs are
fired. Rocket motor Safe-Arm selector
handle is in ARMED position and cannot be
placed in SAFE position. The rocket motor
57. DROPPED MISSILE INSPECTION. Dropped
component/AUR processing criteria are contained in
applicable WPs/SWPs. If any doubt exists as to the
acceptability of dropped component/AUR, reject it. Report
dropping incidents in accordance with AFI 91-204, and
notify EOD if explosive components are involved.
Request disposition of dropped components from Warner
Robins Air Logistics Center, 575 CBSS/GBIA, 460
Richard Ray Blvd, Ste 200, Robins AFB, GA 31098-1813.
Change 1
11
CSTO XX21M-AIM9M-2
WP 005 00
58. OTHER INSPECTIONS.
59. PRE-ISSUE INSPECTION. Preform
inspection in accordance with TO 11A-1-10.
60. PRE-USE/POST-USE
INSPECTION.
inspections are performed as follows:
a.
Verify missile components are correct for the
assembled missile configuration.
c.
Verify umbilical cable spring pin length is correct
for launcher type, USAF or USN launchers.
d.
Verify dome protector, safety clip assembly
(Mk 36 Mod 10/11), Safe-Arm key (Mk 36
Mod 8/9), umbilical protective cap, TD
protective cover, and forward hanger protective
cover (when applicable) are installed.
e.
Check that torque on all missile coupling ring
screws remained as specified. If not, re-torque as
specified in applicable assembly procedure.
f.
Remove excess corrosion preventive compound
from missile joints.
g.
Verify rollerons are caged.
h.
If local maintenance policy requires witness
marks verify they have been applied.
pre-issue
These
During assembly or prior to use, 100% of the
items will be inspected for damage which would
preclude their use.
WARNING
Internal overpressure may exist within the GCS
which could rupture the IR dome. Do not stand
forward (within 180O of the center of the GCS) of
any part of the IR dome.
b.
b.
Until the AIM9M GCS has the pop-out relief
valve installed (WP 003 00) conduct visual
inspections of the dome from the side. The
inspection will only consist of verifying the
presence of the dome. This will minimize
exposure to personnel.
63. TARGET DETECTOR TESTING.
NOTE
c.
When AURs are cycled between flight line and
the munitions storage area perform an AUR
inspection (WP 006 00 or WP 007 00).
Field level testing using the PTS-15 is not a
substitute for depot level life cycle maintenance.
61. RETURN MUNITIONS INSPECTION (RMI). An
RMI is performed on missiles/components being returned
to stock. Missiles will be disassembled to the extent
required and components inspected in accordance with
their respective SWP and returned to original or equivalent
containers.
64. Target detector testing is an option. Testing will be
accomplished using the PTS-15 when directed by the
command headquarters. Test target detectors in
accordance with procedures in SWP 006 02.
62. POST ASSEMBLY INSPECTION.
66. Coolant tank testing is an option. Testing will be
accomplished using the TTU-546/E when directed by the
command headquarters. Test coolant tanks in accordance
with procedures in SWP 006 08.
a.
12
Verify Mk 36 Mod 8/9/10/11 rocket motor SafeArm selector handle is locked in the SAFE
position: For Mod 10/11, pull handle to unlock
and move to vertical position, maintain pull
pressure. Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install safety
clip assembly. For Mod 8/9, install Safe-Arm key,
push in, and while maintaining pressure rotate
key 90 degrees clockwise to the SAFE position.
Release pressure and key locks in position. Place
key in horizontal position.
Change 1
65. COOLANT PRESSURE TANK TESTING.
CSTO XX21M-AIM9M-2
WP 006 00
WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION,
AND GROUND HANDLING AIM-9M TACTICAL MISSILE
FIELD LEVEL MAINTENANCE
GUIDED MISSILE AIM-9M
THIS WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 64
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-3 . . . . . . . . . . . . . . . . . . . . . . . 2
6.1 added . . . . . . . . . . . . . . . . . . 1
9-11 . . . . . . . . . . . . . . . . . . . . . . 2
16 . . . . . . . . . . . . . . . . . . . . . . . . 2
19-24 . . . . . . . . . . . . . . . . . . . . . 1
25-34 . . . . . . . . . . . . . . . . . . . . . 1
38-40 . . . . . . . . . . . . . . . . . . . . . 2
46 . . . . . . . . . . . . . . . . . . . . . . . . 2
49-58 . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
4-5 . . . . . . . . . . . . . . . . . . . . . . . 1
6.2 blank added . . . . . . . . . . . . . 1
12. . . . . . . . . . . . . . . . . . . . . . . . 0
17. . . . . . . . . . . . . . . . . . . . . . . . 1
24.1 added . . . . . . . . . . . . . . . . . 1
34.1-34.2 added. . . . . . . . . . . . . 1
41-42 . . . . . . . . . . . . . . . . . . . . . 0
47. . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
6 . . . . . . . . . . . . . . . . . . . . . . . . .2
7-8. . . . . . . . . . . . . . . . . . . . . . . . 1
13-15 . . . . . . . . . . . . . . . . . . . . . . 1
18 . . . . . . . . . . . . . . . . . . . . . . . . 2
24.2 blank added. . . . . . . . . . . . . 1
35-37 . . . . . . . . . . . . . . . . . . . . . . 0
43-45 . . . . . . . . . . . . . . . . . . . . . . 1
48 . . . . . . . . . . . . . . . . . . . . . . . . 2
Reference Material
Title
Number
Air Force Instructions ....................................................................................................................................... AFI-91 Series
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Conventional Munitions, Suspended or Restricted........................................................................................ TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Maintenance, Assembly and Disassembly with Illustrated Parts Breakdown,
AIM-9M Tactical Missile ....................................................................................................................................WP 008 00
Maintenance with Illustrated Parts Breakdown, Guidance Control Section, WGU-4A/B ..................................SWP 008 01
Maintenance with Illustrated Parts Breakdown, Rocket Motor, Mk 36 Mod 7,
Mk 36 Mod 8, Mk 36 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11 ..................................................................SWP 008 05
Maintenance with Illustrated Parts Breakdown, Target Detector, DSU-15/B,
DSU-15A/B, and DSU-15B/B ...........................................................................................................................SWP 008 02
Maintenance with Illustrated Parts Breakdown, Wing Assembly, Guided Missile,
Mk 1 Mod 1 and Mk 1 Mod 2 ...........................................................................................................................SWP 008 06
Maintenance with Illustrated Parts Breakdown, Fins, BSU-32/B .......................................................................SWP 008 07
Maintenance with Illustrated Parts Breakdown, Coolant Pressure Tank
TMU-72/B, TMU-72A/B and TMU-72B/B ......................................................................................................SWP 008 08
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with
IPB-Storage Containers (AIM-9 Series Missiles)..................................................................................... TO 35E20-2-31-2
Positioning and Tie-Down Procedure for Non-Nuclear Munitions ...................................................................... TO 11-1-38
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Change 2
1 of 58
CSTO XX21M-AIM9M-2
WP 006 00
Reference Material (Continued)
Title
Number
Safety Summary and Accident Prevention............................................................................................................ WP 002 00
Storage and Inspection Requirements ................................................................................................................... WP 005 00
Unpacking, Inspection, Servicing, and Packaging, Wing Assembly, Guided Missile,
Mk 1 Mod 1 and Mk 1 Mod 2 ........................................................................................................................... SWP 006 06
Unpacking, Packaging, and Inspection, Fins, BSU-32/B.................................................................................... SWP 006 07
Unpacking, Packaging, Inspection, Test and Servicing,
Coolant Pressure Tank TMU-72/B, TMU-72A/B and TMU-72B/B................................................................. SWP 006 08
Table of Contents
Title
Page
AUR Inspection ................................................................................................................................................................... 37
Container Markings ............................................................................................................................................................. 58
Dropped Missile/Component Processing .............................................................................................................................. 6
Empty Container Processing .............................................................................................................................................. 6.1
Ground Handling ................................................................................................................................................................. 36
Handling and Test Equipment Preparation............................................................................................................................ 6
Incidents/Accidents ............................................................................................................................................................... 6
Inspection .............................................................................................................................................................................. 8
Cager Release-Pull Test..................................................................................................................................................... 32
Coolant Pressure Tank Inspection ....................................................................................................................................... 8
Fin Inspection ...................................................................................................................................................................... 8
Missile Inspection................................................................................................................................................................ 8
Rolleron Assembly Functional Test .................................................................................................................................. 32
Safe-Arm Selector Assembly Functional Check (Mod 8/9).............................................................................................. 33
Safe-Arm Selector Assembly Functional Check (Mod 10/11).......................................................................................... 33
Safe-Arm Selector Handle Spring Pin Inspection (Mod 10/11)........................................................................................ 33
Wing Inspection................................................................................................................................................................... 8
Wing Tap Inspection.......................................................................................................................................................... 30
Acceptance/Rejection Criteria......................................................................................................................................... 31
Tap Inspection Limitations .............................................................................................................................................. 31
Tap Inspection Preparation .............................................................................................................................................. 31
Tap Inspection Procedures............................................................................................................................................... 31
Missile Configurations ....................................................................................................................................................... 6.1
Missile Disassembly............................................................................................................................................................ 56
Packing ................................................................................................................................................................................ 56
Missile Packing in Barrier Material .................................................................................................................................. 57
Missile Packing in the CNU-310/E Container .................................................................................................................. 56
Preparing for AUR to Missile Disassembly ........................................................................................................................ 37
AUR Disassembly ............................................................................................................................................................. 37
Coolant Pressure Tank Removal .................................................................................................................................... 37
Fin Removal .................................................................................................................................................................... 56
Wing Removal ................................................................................................................................................................. 56
Preparing for Missile to AUR Assembly............................................................................................................................. 34
Missile to AUR Assembly................................................................................................................................................. 34
Coolant Pressure Tank Installation .................................................................................................................................. 34
Fin Installation................................................................................................................................................................. 36
Wing Installation ............................................................................................................................................................. 36
Safety and Accident Prevention ............................................................................................................................................ 6
2
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
Table of Contents (Continued)
Title
Page
Sequence of Operations .........................................................................................................................................................6
Test Records/Documentation .................................................................................................................................................6
Torque Requirements ..........................................................................................................................................................6.1
Unpacking ...........................................................................................................................................................................6.1
Missile Unpacking from the CNU-310/E Container ........................................................................................................6.1
List of Illustrations
Title
Page
Center and Aft Hanger Assemblies ...............................................................................................................................21, 50
Center and Aft Hanger Inspection .................................................................................................................................22, 53
CNU-310/E All-Up-Round Container (PN 785041-10) and AIM-9M Missiles .............................................................7, 56
Coolant Pressure Tank ...................................................................................................................................................26, 45
Coupling Ring Assemblies ............................................................................................................................................ 11, 40
Coupling Ring Straightedge Inspection ......................................................................................................................... 11, 40
Fin BSU-32/B ................................................................................................................................................................28, 44
Fin Cup ..........................................................................................................................................................................13, 42
Forward Hanger Assembly ............................................................................................................................................20, 50
Guidance Control Section Inspection Points .................................................................................................................12, 41
Guided Missile AIM-9M .......................................................................................................................................................6
Missile Preparation for Barrier Material..............................................................................................................................58
Missile Inspection Points ...............................................................................................................................................17, 47
Rocket Motor Aft End ................................................................................................................................................24.1, 53
Rocket Motor Inspection ...............................................................................................................................................19, 49
Rocket Motor Safe-Arm Selector Handle Spring Pin Test ..................................................................................................35
Rolleron Assembly ..............................................................................................................................................................35
Safe-Arm Selector Assembly, Rocket Motor Mk 36 Mod 8/9 and Mk 36 Mod 10/11 ....................................................34.2
Tap Hammer Procedures......................................................................................................................................................32
Umbilical Cable and GCS Umbilical Base....................................................................................................................14, 42
Wing Cager Release-Pull Test ..........................................................................................................................................34.1
Wing Cager Release-Pull Test (Preferred)........................................................................................................................34.1
Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2...............................................................................................31, 55
Wing Rib Inspection .........................................................................................................................................................24.1
List of Tables
Title
Page
AUR Inspection ...................................................................................................................................................................38
Consumable Materials ...........................................................................................................................................................4
Coolant Pressure Tank Inspection........................................................................................................................................25
Coolant Pressure Tank Pressure/Temperature Variation................................................................................................27, 45
Drop Criteria ..........................................................................................................................................................................5
Fin Inspection ......................................................................................................................................................................27
Missile Configurations...........................................................................................................................................................7
Missile Inspection ..................................................................................................................................................................9
Tools and Equipment .............................................................................................................................................................4
Torque Requirements .............................................................................................................................................................5
Wing Inspection ...................................................................................................................................................................29
Change 2
3
CSTO XX21M-AIM9M-2
WP 006 00
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Band, Rubber
ZZ-R-1415
Secure umbilical cable
Barrier Material
MIL-B-81705C
Packing AURs when containers not available
Cloth, Emery 320 Grit
P-C-1673
Removal of loose paint or light to moderate
surface corrosion
Compound, Corrosion
Preventive
MIL-C-85054
Coupling ring surface repair
Compound, Silicone
MIL-S-8660
Preformed packing, mating surfaces, and wing
cager lubricant/sealant
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Tube, Fiberboard
PPP-T-495 Type 1, Class 1 Style D
Filler for container space when shipping
containers that are not full
Indicator, Humidity
MS20003-2
Detecting moisture/humidity
Lubricant, Breakfree
MIL-L-63460
Lubricate cager flag movement
Tape
DDD-T-86
GCS packing in CNU-301/E and CNU-310/E
containers
Tape
MIL-I-15126 Ty GFT
Cover coolant pressure tank outlet valve
Table 2. Tools and Equipment
Nomenclature
4
Specification/Part Number
Use
Assembly Stand
PN 68D35756-10
Support missile or missile components
Removal of coolant tank
Cleaner, Vacuum
Local purchase
Remove air from barrier bag
Dial, Push/Pull Gauge
DPP-80
Perform cager release-pull test
Alt Scale, instrument,
0 to 4 lbs
2880186
Perform cager release-pull test
Gauge, Depth
643J
Measure scratches, wear, pits, gouges or dents
on critical surfaces
Gauge, Spring Pin
639AS10059
Safe-Arm selector handle spring pin test
Glass, Magnifier
GG-M-95
Inspecting for cracks
Missile Storage Stand
MHU-32A/ PN 8028909
Storage and transporting missile sections in
assembly area
Spanner, Gas Inlet
1298326
Tighten gas inlet umbilical connector
Storage and Maintenance
Stand
MHU-32/E PN 6077
Storage and transporting missile sections in
assembly area
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 2. Tools and Equipment (Continued)
Nomenclature
Specification/Part Number
Use
Tool, Coolant Tank Removal
Local Manufacture (WP 004 00)
Removal of coolant tank
Tool, Coolant Tank Removal
639AS4510
Removal of coolant tank
Wrench, Spanner
639AS2981
Remove and replace probe cap assembly, probe
guide, and preformed packing compression
fixture in coolant pressure tank
Wrench, Torque
1556707
Torquing of wing and fin attaching screws
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Packaged or Unpackaged
Less than 1.5
Disassemble WP 008 00, inspect (test
if applicable) all components in
accordance with appropriate SWP
Packaged or Unpackaged
1.5 to 10
Disassemble WP 008 00, reject rocket
motor, TD, (warhead if more than 3
feet). Inspect (test if applicable) other
components in accordance with
appropriate SWP
Packaged or Unpackaged
More than 10
Coolant Pressure Tank
Packaged or Unpackaged
Any height
SWP 006 08
Wings
Packaged or Unpackaged
Any height
SWP 006 06
Fins
Packaged or Unpackaged
Any height
SWP 006 07
Assembled Missile
Reject all components
Table 4. Torque Requirements
Part Number
Nomenclature
Torque Value
NAS1189-E3P7H
Housing assembly screw
27.5 ± 2.5 in-lbs
NAS1351-4LB14P
Fin attachment screw
NAS514P632-5P
Guide vane screw
1555392
Wing attachment screw
100 + 5 in-lbs
1560938
Rolleron damper screw
30 ± 2 in-lbs
1560939
Rolleron hinge screw
32 ± 1 in-lbs
2236374
Nitrogen Plug
50 + 10 in-lbs
2251009
Umbilical base screw
7 ± 1 in-lbs
2251009
DC to DC converter screw
7 ± 1 in-lbs
2596371
Exhaust valve to GCS screw
7 ± 1 in-lbs
100 + 5 in-lbs
8 ± 1 in-lbs
Change 1
5
CSTO XX21M-AIM9M-2
WP 006 00
Table 4. Torque Requirements (Continued)
Part Number
Nomenclature
Torque Value
639AS1599
Coupling ring screw
100 ± 5 in-lbs
639AS6699
Forward Hanger Attachment Bolt
(Mods 8/9/10/11 only)
550 ± 25 in-lbs
Figure 1. Guided Missile AIM-9M
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this WP is provided as a
guide in Unpacking/Packaging, and Inspection of the
missile Figure 1. Production techniques involving
preparation of more than one missile may require
deviations from the work sequence. Several procedures
may be performed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
3.
SAFETY AND ACCIDENT PREVENTION.
Report incident/accident and notify EOD. Request
disposition of dropped components from TMTCG, OOALC/GHGAMF, 235 Byron Street, Suite 19A, Robins
AFB, GA 31098-1813.
7. DROPPED MISSILE/COMPONENT
PROCESSING.
8. Dropped AUR processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
AUR, reject it. Report dropping incidents in accordance
with AFI 91-204 and AFOSH 91/127 series publications
and notify EOD.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
9.
5.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving collision or inadvertent
damage to the missile or missile components can cause the
missile to misfire, malfunction, or explode. If any doubt
exists as to acceptability of missile/component, reject it.
6
Change 2
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
12. Verify all required handling and test equipment is
available and serviceable.
CSTO XX21M-AIM9M-2
WP 006 00
13. TORQUE REQUIREMENTS.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
14. Verify torque wrenches have current calibration
sticker. Tighten fasteners to torque value given in Table 4.
15. MISSILE CONFIGURATIONS.
16. The combination of components listed in Table 5
define the only authorized configurations for the AIM-9M
tactical missile. If component replacement is required,
refer to WP 008 00. The stubby missile PN 8946876 is an
assembly of fully serviceable components and is an
authorized configuration for storage and inventory
purposes.
17. EMPTY CONTAINER PROCESSING.
18. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
19. UNPACKING.
20. MISSILE UNPACKING FROM THE CNU-310/E
CONTAINER. Before opening a container, ensure that all
markings are legible. Record markings that may be
destroyed by opening the container. Retain serviceable
packing for possible reuse. Unpack AUR(s) as follows:
Change 1
6.1/(6.2 Blank)
M
I
S
S
I
L
E
NOTE:
C
O
N
F
I
G
U
R
A
T
I
O
N
PREFERRED COMPONENT
WHD
FIN
Change 1
MK 1 MOD 2
639A S 4895
MK 1 MOD 1
639A S 2836
ROCKET MOTOR
BS U - 3 2 / B
639A S 751
MK 36 MO D 11
639A S 4993
MK 36 MO D 10
639A S 4992
MK 36 MO D 9
639A S 4600
MK 36 MO D 8
1204A S 100
MK 36 MO D 7
639A S 2890
S-A
WD U - 1 7/ B
639A S 631
TARGET
DETECTOR
MK 13 MO D 2
639A S 1130
DS U - 1 5 B/ B
639A S 6080
DS U - 1 5 A/ B
639A S 3801
COOLANT
TANK
DS U - 1 5 / B
639A S 761
TMU - 7 2/ B
639A S 1505
TMU - 7 2A / B
639A S 6739
UMB
CABLE
TMU - 7 2B / B
639A S 10789
6 3 9 AS 1 0 9 3 5
TAC T I C AL
GCS
TAC T I C AL
26039 13
WG U- 4 A / B
639A S 3963
CSTO XX21M-AIM9M-2
WP 006 00
Table 5: Missile Configurations
WING
AIM-9M
639AS3922-2
STUBBY
8946876
ALTERNATE COMPONENT
Umbilical cable PN 639AS10935 is preferred for use with USAF launchers. Umbilical cable PN 2603913 is preferred for use with USN
launchers. See WP 003 00.
Figure 2. CNU-310/E All-Up-Round Container (PN 785041-10) and AIM-9M Missiles
7
CSTO XX21M-AIM9M-2
WP 006 00
Inspect container (Figure 2) for damage. If it is
evident that container has been improperly
handled, inspect missile (Paragraph 21).
f.
If required, remove remaining missiles (step e).
g.
Remove coolant tanks, fins, and wings.
b.
Press button on pressure relief valve.
h.
Verify interior packing of container is complete
and undamaged.
c.
Beginning at each end and working toward the
center, release the 16 container latches and place
to the down position.
i.
Process empty container, Paragraph 17.
a.
21. INSPECTION.
d.
Remove container cover by either lifting at each
corner (manually) or by lifting at the lift rings
using a mechanical means.
22. MISSILE INSPECTION.
WARNING
CAUTION
Mishandling can cause damage to the missile/
components. Do not lift missile by wings, fins,
rollerons, umbilical or dome assembly. Do not
allow missile/components to come in contact
with hard objects while handling. Do not rest
missile on target detector.
e.
a.
Until the AIM-9M GCS has the pop-out relief
valve installed (WP 003 00) conduct visual
inspections of the dome from the side. The
inspection will only consist of verifying the
presence of the dome. This will minimize
exposure to personnel.
b.
Inspect Missile, Table 6.
c.
Inspect AUR Table, 11.
d.
Perform Safe-Arm Handle spring pin inspection,
Paragraph 34.
e.
Perform rocket motor Safe-Arm selector
functional check, Paragraph 34.1 for Mod 10/11
and Paragraph 34.2 for Mod 8/9 rocket motors.
Remove one missile at a time and place on
approved assembly stand or handling equipment.
(1) Ensure missile is secured to assembly stand
and grounded to a wing rib. Do not attach
ground clip in area of etched serial number.
(2) Ensure rocket motor safe-arm selector
handle Mod 8/9/10/11 is locked in the SAFE
position. If not, perform step (1) for Mod 10/
11 or step (2) for Mod 8/9.
(a) Mod 10/11, pull handle to unlock and
move to the vertical position, maintain
pull pressure. Rotate handle 90 degrees
clockwise and move to horizontal
position. Release pull pressure to lock in
SAFE position. Install safety clip
assembly.
(b) Mod 8/9, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure
to lock in SAFE position. Move key to
horizontal position.
(3) Ensure dome protector, umbilical protective
cap, TD protector cover, and forward hanger
protector cover are properly installed.
8
Internal overpressure may exist within the GCS
which could rupture the IR dome. Do not stand
forward (within 180O of the center of the GCS) of
any part of the IR dome.
Change 1
23. COOLANT PRESSURE TANK INSPECTION.
Inspect coolant pressure tank Table 7 and 8.
24. FIN INSPECTION. Inspect fins Table 9.
25. WING INSPECTION.
a.
Inspect wings, Table 10.
b.
Perform wing tap inspection Paragraph, 26.
c.
Perform rolleron assembly functional test,
Paragraph 32.
d.
Perform cager release-pull test, Paragraph 33.
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk(*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Safe-Arm selector handle is in ARM position
(except Mk 36 Mod 7)
CRITICAL
Ensure rocket motor Safe-Arm selector
handle is locked in the SAFE position. If
not, refer to Paragraph 34.1 for Mod 10/11
or Paragraph 34.2 for Mod 8/9.
2
Punctures, skin penetration by cracks or gouges
on rocket motor or warhead
CRITICAL
Replace rocket motor/warhead WP 008 00
NOTE
Several thousand Mk 36 rocket motors (serial number prefixes, MKW,
PAB, PYM) have been fielded that were suspect of having critical
defects. Most have been inspected and marked “AWB 222
ACCEPTED.” See TO 11A -1-1 to determine serviceability.
3
Rocket motors with serial numbers MKW 0004405234, PAB 00001-01606, and PYM 0049600702 that are suspended by TO XX11A-1-1
shall not be used
CRITICAL
Replace rocket motor WP 008 00
4
Coupling rings cracked, not correct part number,
not properly oriented, parts not installed correctly
(Figure 3)
CRITICAL
Replace/reinstall coupling ring WP 008 00
5
Coupling ring(s) manufactured with (Cage Code)
00784 with date of manufacture 1-90 through 1290 or 1-83 through 12-84 stamped on their outer
surface
CRITICAL
Replace coupling ring WP 008 00
5.1
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 008 00
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
6
Coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace coupling ring threaded pin
WP 008 00
7
Coupling ring screw(s) not PN 639AS1599 Rev
M or later, or PN 8934242
CRITICAL
Replace coupling ring screws
WP 008 00
8
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screws WP 008 00
Change 2
9
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
8.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screws WP 008 00
9
Coupling ring screw(s) PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 3)
CRITICAL
Replace coupling ring screws WP 008 00
10
Coupling rings fail straightedge inspection
(Figure 4)
CRITICAL
Replace coupling ring WP 008 00
11
GCS dome (Figure 5) broken, cracked, punctured
CRITICAL
Replace GCS WP 008 00
GUIDANCE CONTROL SECTION
*12
Foreign material on dome. (Various colorations of
dome do not affect missile performance.)
MINOR
Clean WP 008 00
*13
GCS dome has minor scratches, nicks, or pits
MINOR
Acceptable
14
Dome or dome retaining ring loose or cracked
MAJOR
Replace GCS WP 008 00
15
GCS dome lock ring/dome housing has dents
greater than 0.060-inch or gouges greater than
0.025-inch in depth
MAJOR
Replace GCS WP 008 00
16
GCS dome lock ring/dome housing has dents up
to 0.060-inch in depth or less
MAJOR
Remove raised metal only with flat file or
320 Grit emery cloth
17
GCS dome lock ring/dome housing has gouges up
to 0.025-inch in depth or burrs on surface
MINOR
Remove raised metal only with flat file or
320 Grit emery cloth
18
Gas generator service life expired or cannot be
determined (WP 005 00 Table 1)
MAJOR
Replace GCS WP 008 00
19
Absence of, or illegible part number, lot number,
date of manufacturer or serial number
MAJOR
Suspend and hold in condition code F.
Contact TMTCG, OO-ALC/GHGAMF
Robins AFB, GA 31098-1813 for
instructions
20
GCS skin cracked, punctured, dents greater than
0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 008 00
21
GCS skin has dents up to 0.060-inch, gouges up
to 0.025-inch in depth, burrs, scratches, or pits
penetrating anodized coating or corrosion
MINOR
Repair coating SWP 008 01
22
Metal fin cup (Figure 6) missing or loose in GCS
housing
MAJOR
Replace GCS WP 008 00
23
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange down
until seated on GCS housing
24
Metal fin cup flange cracked, buckled, or bent to
extent flange will not seat on GCS housing
MAJOR
Replace GCS WP 008 00
25
Fin rocker arm mating area damaged, or fin attach
hole(s) in rocker arm(s) worn, stripped, or
damaged so as prevent good mate of fin
MAJOR
Replace GCS WP 008 00
10
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
GCS
TARGET
DETECTOR
FWD
(1) COUPLING RING
(2) CLIP
(3) SCREW
(4) PIN
(5) THREADED PIN
(6) GUIDE PLATE ASSEMBLY
FORWARD
COUPLING RING
ASSEMBLY
PN 639AS672
WARHEAD
(1)
AFT COUPLING
RING ASSEMBLY
PN 639AS2725-2
(2)
(3)
ROCKET MOTOR
COUPLING RING
ASSEMBLY
PN 639AS2725-1
INDEXING
PIN
GUIDE
PLATE
ASSEMBLY
(4)
(5)
(6)
ROCKET MOTOR
PART
NUMBER
AFT
REVISION
MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 3. Coupling Ring Assemblies
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 4. Coupling Ring Straightedge Inspection
Change 2
11
CSTO XX21M-AIM9M-2
WP 006 00
WGU-4A/B
NOTES:
1. LOCATION OF MARKINGS IS APPROXIMATE.
2. 9M FOR WGU-4A/B. THREE PLACES.
3. WGU-4A/B FOR PN 639AS3963.
Figure 5. Guidance Control Section Inspection Points
12
CSTO XX21M-AIM9M-2
WP 006 00
Figure 6. Fin Cup
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
26
Rubber fin seal missing, damage affecting
environmental seal
MAJOR
Replace GCS WP 008 00
27
End of rocker arm protrudes above outside
surface of fin cup assembly
MAJOR
Replace GCS WP 008 00
28
Gas grain generator surrounding area shows
evidence of soot caused by gas generator firing
MAJOR
Test GCS SWP 006 01
29
Missing or loose screws on exhaust valve
(Figure 5)
MAJOR
Replace/torque screws SWP 008 01
30
Missing or damaged silicone adhesive at junction
of umbilical block and umbilical base
MAJOR
Remove damaged adhesive and apply a
small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
31
Crack in umbilical block (metal housing or
epoxy)
31.1 Top of umbilical block metal housing lip
separating from the epoxy core
32
Umbilical block spring pin (Figure 7) loose,
missing, or damaged
MAJOR
Replace umbilical SWP 008 01
MAJOR
Repair, SWP 008 01
MAJOR
Replace pin SWP 008 01
Change 1
13
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
33
Umbilical block spring pin not correct length
MAJOR
Replace pin SWP 008 01
34
Umbilical cable insulation separated from cable
block or launcher connector. Insulation damaged
to extent cable insulation is penetrated, but gas
tubing or wire insulations are not damaged
MAJOR
Repair insulation SWP 008 01
35
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of
cable assembly
MAJOR
Remove GCS WP 008 00
Replace umbilical cable
SWP 008 01
36
Loose or damaged breakaway screws or safety
wire broken/missing
MAJOR
Replace/torque screws/replace safety wire
SWP 008 01
*37
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 008 01
38
Missing, loose, damaged, or corroded umbilical
base assembly screws (Figure 5)
MAJOR
Replace/clean/torque screws SWP 008 01
39
Missing or loose housing assembly screws
MAJOR
Replace/torque screw SWP 008 01
40
DC to DC converter screws missing or loose
MAJOR
Replace/torque screw SWP 008 01
41
Missing or loose nitrogen plug
MAJOR
Replace/torque SWP 008 01
42
Umbilical protective cap missing
MAJOR
Replace cap SWP 008 01
Figure 7. Umbilical Cable and GCS Umbilical Base
14
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
43
Dirt, grease, or corrosion inside umbilical
protective cap
MAJOR
Clean WP 008 00
44
Pin 13, 19, or 21 bent, broken, or missing in
umbilical protective cap
MAJOR
Replace cap SWP 008 01
45
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace packing SWP 008 01
46
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Remove GCS WP 008 00
Replace umbilical cable SWP 008 01
47
Moisture or foreign matter on umbilical
connector
MAJOR
Clean connector WP 008 00
*48
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet spanner
*49
Umbilical cable not properly secured with rubber
band (ZZ-R-1415), retaining clip or equivalent
MINOR
Replace
50
Loose, missing or damaged components on
coolant tank access cover
MAJOR
Replace/repair SWP 008 01
NOTE
The red pop-out indicator cannot be reset. The cool down capabilities of the GCS are
not affected. The GCS should remain in use until it is required to be returned to the
depot for another defect which prevents the GCS from functioning as designed.
51
Pop-out indicator actuated (if installed)
MINOR
Acceptable. Defer for depot repair.
See WP 003 00.
52
Pop-out indicator assembly damaged
MAJOR
Reject
53
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 008 00
54
Probe sealing cap missing on GCS coolant inlet
probe
MAJOR
Replace cap Paragraph 45
(SWP 008 01 IPB)
55
Presence of foreign material/moisture or
preformed packing missing/damaged in probe
sealing cap
MAJOR
Replace cap Paragraph 45
(SWP 008 01 IPB)
56
Coolant inlet probe area dirty, moisture, corroded,
or other foreign material present
MAJOR
Clean area WP 008 00
TARGET DETECTOR
57
Exterior surface scratches (Figure 8)
MINOR
Acceptable
58
TD exterior surface cracks or punctures, pits/
gouges greater than 0.060-inch in depth, or dents
greater than 0.025-inch in depth
MAJOR
Replace TD WP 008 00
Change 1
15
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Slight degradation of the anti-reflective coating on the window(s) that
resembles water spots is acceptable.
59
TD window(s) cracked, broken, missing, loose,
scratches greater than 0.5-inch in length, or
condensation on inside of window
MAJOR
Replace TD WP 008 00
60
Loose objects seen through window(s)
MAJOR
Replace TD WP 008 00
61
TD window(s) for cleanliness
MINOR
Clean WP 008 00
62
TD protective cover missing
MINOR
Replace cover
63
Coupling ring(s) (Figure 3) has burrs, gouges,
scratches, dents, or pits that penetrate surface
finish and aggregately covers less than 2% of
entire surface (2% of entire surface is
approximately an area 0.25 inches long across the
entire width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
64
Coupling ring(s) has burrs, gouges, scratches,
dents, or pits that penetrate surface finish and
aggregately covers greater than 2% of entire
surface (2% of entire surface is approximately an
area 0.25 inches long across the entire width of
the coupling ring)
MAJOR
Replace coupling ring(s)
WP 008 00
MAJOR
Clean, SWP 008 00. Inspect for cracks. If
brown spots, specks, or discoloration
cannot be removed replace coupling ring
SWP 008 00
MAJOR
Remove GCS WP 008 00
Replace pin SWP 008 02
64.1 Coupling ring has brown spots, specks, or
discoloration
65
Forward indexing pin is loose, missing, damaged,
or corroded
WARHEAD
NOTE
The minimum required markings for explosive components are part
number, lot number, nomenclature, and date of manufacture. The filler
lot number is to be used as the warhead lot; the date loaded is
considered the date of manufacture.
66
Absence of, or illegible part number, lot number,
date of manufacture, serial number, yellow band
or stencil PBXN-3 (Figure 8)
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF
Robins AFB, GA 31098-1813 for
instructions
67
Exterior surface of warhead dented, but skin not
penetrated
MINOR
Acceptable
68
Exterior surface of warhead gouged, but skin not
penetrated
MINOR
Remove raised metal only with 320 grit
emery cloth and touch-up paint
69
Surface of warhead cracked or skin penetrated
MAJOR
Replace warhead WP 008 00
16
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
Figure 8. Missile Inspection Points
Change 1
17
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
ROCKET MOTOR SECTION
70
Rocket motor Safe-Arm selector assembly
attachment screws loose, assembly damaged, or
missing (except Mod 7, PN 639AS2890)
71
Deleted
72
Absence of, or illegible, markings (Figure 8)
MAJOR
Replace assembly, torque/ replace screws,
SWP 008 05
MAJOR
Replace decals or stencil WP 008 00
NOTE
The minimum required markings for explosive components are: part
number, lot number, nomenclature, and date of manufacture.
73
Absence of, or illegible part number, lot number,
date of manufacture, serial number, brown band
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF
Robins AFB, GA 31098-1813 for
instructions
*74
Brown band deteriorated and in need of
replacement
MINOR
Replace band SWP 008 05
NOTE
Steps 75 through 80 apply to the exterior surface of the rocket motor
(aft of coupling ring groove) between stations 0.269 and 1.880 and
between 68.725 and 70.905 (Figure 9).
75
Pits greater than 0.030-inch deep
MAJOR
Replace rocket motor WP 008 00
76
Pitted area over one square inch and pits more
than 0.015-inch deep
MAJOR
Replace rocket motor WP 008 00
77
Gouges up to 0.030-inch deep by 0.045-inch wide
by 0.075-inch long
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
78
Gouges over 0.030-inch deep or 0.045-inch wide
by 0.075-inch long
MAJOR
Replace rocket motor WP 008 00
79
Dents over 0.030-inch in depth or 0.092-inch in
diameter
MAJOR
Replace rocket motor WP 008 00
*80
Burrs or scratches
MINOR
Remove nicks or burrs with flat file or 320
grit emery cloth and touch-up paint
SWP 008 05
NOTE
Step 81applies to the exterior surface of the rocket motor (aft of
coupling ring groove and between station 2.235 and 68.725, Figure 9).
81
18
Burrs or scratches
Change 2
MAJOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
CSTO XX21M-AIM9M-2
WP 006 00
Figure 9. Rocket Motor Inspection
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
WARNING
Touching of the contact buttons in the rocket motor forward hanger
could cause rocket motor ignition. All personnel handling rocket motor
shall make bare skin-to-metal contact with rocket motor wing rib or
ground wire.
82
Forward hanger protective cover damaged or
missing
MINOR
Replace cover
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
83
Forward hanger (Figure 10) screws/bolts loose,
damaged, or missing
MAJOR
Replace SWP 008 05
84
Forward hanger or hanger screws/bolts corroded
to the extent corrosion cannot be removed
MAJOR
Replace SWP 008 05
85
Forward hanger mating surfaces and stress points
for cracks
MAJOR
Replace SWP 008 05
86
Top of forward hanger mating surface for snubber
wear in excess of 0.015 inch in depth, rear of
hanger for detent wear in excess of 0.030, or
forward detent lug wear area is rounded over all
the way across the area between the two arrows
MAJOR
Replace SWP 008 05
Change 1
19
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
WARNING
Cleaning or repairing of contact buttons shall not be attempted. Minor
amounts of dirt, grease, or corrosion will not affect missile firing.
87
Contact button(s) have severe corrosion damage,
not flush, or below hanger
MAJOR
Replace SWP 008 05
88
Contact button insulator missing
MAJOR
Replace SWP 008 05
WARNING
Use depth gauge PN 643J to measure damage to forward hanger
contact buttons, and all hanger surfaces. Prior to taking measurements
on the forward hanger/contact buttons verify missile is grounded, SafeArm selector handle is in SAFE position, and make bare skin-to-metal
contact with rocket motor wing rib or ground wire.
89
Aft contact button cut, scratched, or gouged
greater than 0.030-inches deep
MAJOR
Replace SWP 008 05
90
Forward hanger nonmating surface for dents
greater than 0.045-inches deep or 0.075-inches in
diameter
MAJOR
Replace SWP 008 05
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 10. Forward Hanger Assembly
20
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
91
Forward hanger nonmating surface for gouges
greater than 0.045-inches deep by 0.064-inches
wide by 0.075-inches long
MAJOR
Replace SWP 008 05
92
Forward hanger nonmating surfaces for cracks
MAJOR
Replace SWP 008 05
NOTE
Steps 93 through 99 apply to the center and aft hanger (area X, Figure 11).
93
Mating surfaces for dents greater than 0.015-inch
deep by 0.030-inch in diameter
MAJOR
Replace rocket motor WP 008 00
94
Mating surface for gouges greater than 0.015-inch
deep by 0.030-inch wide by 0.045-inch long
MAJOR
Replace rocket motor WP 008 00
95
Nonmating surfaces for pitted areas greater than
0.060 square inch in diameter and 0.032-inch
deep
MAJOR
Replace rocket motor WP 008 00
96
Nonmating surfaces for dents greater than 0.032inch deep or 0.064-inch in diameter
MAJOR
Replace rocket motor WP 008 00
Figure 11. Center and Aft Hanger Assemblies
Change 1
21
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
97
Nonmating surfaces for gouges greater than
0.045-inch deep or 0.064-inch wide or 0.075-inch
long
MAJOR
Replace rocket motor WP 008 00
98
Nonmating surface for cracks
MAJOR
Replace rocket motor WP 008 00
99
Mating surface for cracks
MAJOR
Replace rocket motor WP 008 00
Step
Corrective Action
NOTE
Steps 100 through 104 apply to the center and aft hanger nonmating
surfaces (area Y, Figure 11).
100
Pits greater than 0.015-inch deep and 0.020
square inch
MAJOR
Replace rocket motor WP 008 00
101
Dents greater than 0.020-inch deep or 0.050-inch
in diameter
MAJOR
Replace rocket motor WP 008 00
102
Gouges greater than 0.020-inch deep or 0.032inch wide or 0.064-inch long
MAJOR
Replace rocket motor WP 008 00
103
Cracks
MAJOR
Replace rocket motor WP 008 00
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
*104 Burrs or scratches
Figure 12. Center and Aft Hanger Inspection
22
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
105
Center/aft hangers for visible gap between hanger
strap and rocket motor mating surfaces,
Figure 12
MAJOR
Replace rocket motor WP 008 00
106
Center hanger loose
MAJOR
Replace rocket motor WP 008 00
106.1 Center hanger threaded pins (Figure 12 center
hanger Views A and B) loose, damaged, or
missing
MAJOR
Replace rocket motor WP 008 00
106.2 Center hanger shims (Figure 12 center hanger
View B) loose or missing
MAJOR
Replace rocket motor WP 008 00
106.3 Center hanger band screw(s) (Figure 12 center
hanger View C) loose, damaged, or missing
MAJOR
Replace rocket motor WP 008 00
MAJOR
Replace rocket motor WP 008 00
MAJOR
Replace rocket motor WP 008 00
107
Aft hanger loose
107.1 Aft hanger band screw(s) (Figure 12 aft hanger
View A) loose, damaged, or missing
108
Wing ribs (Figure 13) deformed, cracked,
corroded, or other damage that prevents proper
wing installation
MAJOR
Replace rocket motor WP 008 00
109
Rocket motor weather seal (Mod 7/8/10) missing,
punctured, or bulged out (Figure 14)
MAJOR
Replace rocket motor WP 008 00
110
Tamper seal (Mod 9/11) bulged out, missing, or
punctured
MAJOR
Replace rocket motor WP 008 00
111
Nozzle (Mod 7/8/10) cracks, gouges, or
delaminations
MAJOR
Replace rocket motor WP 008 00
112
Burrs or scratches on support ring
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and apply
MIL-C-85054
113
Support ring dents greater than 0.045-inch deep
or 0.064-inch in diameter
MAJOR
Replace rocket motor WP 008 00
114
Assembled missile markings/surface paint in
need of touch-up or replacing
MINOR
Paint/touch-up WP 008 00
Replace markings applicable SWP
115
Assembled missile for dirt, grease, foreign matter
or minor corrosion
MINOR
Clean missile WP 008 00
Change 1
23
CSTO XX21M-AIM9M-2
WP 006 00
Table 6. Missile Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
116
Coupling ring (Figure 3) has burrs, gouges,
scratches, dents, or pits that penetrate surface
finish and aggregately covers less than 2% of
entire surface (2% of entire surface is
approximately an area 0.25 inches long across the
entire width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
117
Coupling ring has burrs, gouges, scratches, dents,
or pits that penetrate surface finish and
aggregately covers greater than 2% of entire
surface (2% of entire surface is approximately an
area 0.25 inches long across the entire width of
the coupling ring)
MAJOR
Replace coupling ring(s)
WP 008 00
118
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, SWP 008 00. Inspect for cracks. If
brown spots, specks, or discoloration
cannot be removed replace coupling ring
SWP 008 00
Step
24
Change 1
Corrective Action
CSTO XX21M-AIM9M-2
WP 006 00
Figure 13. Wing Rib Inspection
MOD 9 / 11 ONLY
Figure 14. Rocket Motor Aft End
Change 1
24.1/(24.2 Blank)
CSTO XX21M-AIM9M-2
WP 006 00
Table 7. Coolant Pressure Tank Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
1
Identification markings (Figure 15) illegible,
or missing
MAJOR
Reject tank
2
Hydrostatic test illegible, missing or due.
(Hydrostatic test required 10 years from date
of manufacture or last hydrostatic test.)
MAJOR
Reject tank
3
Dust or dirt on coolant tank valve
MINOR
Clean SWP 008 08
4
Corrosion or contamination on coolant tank
or valve
MINOR
Clean SWP 008 08
5
Pressure gauge indicates no positive pressure
MAJOR
Service/inspect/test SWP 006 08
6
Pressure gauge glass cracked, TMU-72/B
MINOR
Discharge tank SWP 008 08, then service
SWP 006 08. If gauge operates properly it is
acceptable. If not reject tank.
Pressure gauge glass cracked, TMU-72A/B
or TMU-72B/B
MINOR
Discharge tank SWP 008 08, then service
SWP 006 08. If gauge operates properly it is
acceptable. If not replace glass, SWP 008 08.
7
Pressure gauge glass broken/missing
TMU-72/B
MAJOR
Reject tank
8
Pressure gauge glass broken/missing
TMU-72A/B or TMU-72B/B
MAJOR
Replace glass SWP 008 08
9
Pressure gauge indicates positive pressure,
but less than 4,000 psig (refer to Table 8 for
temperature/pressure variation)
MAJOR
Service SWP 006 08
10
Pressure gauge inoperative
MAJOR
Reject tank
11
Instruction plate (Figure 15) loose, damaged,
or missing
MAJOR
Replace instruction plate SWP 008 08
12
Caution plate (Figure 15) loose, damaged, or
missing
MAJOR
Replace caution plate SWP 008 08
13
Wire handle damaged or missing
MINOR
Replace handle SWP 008 08
14
Retaining ring or probe guide missing, loose,
or damaged
MAJOR
Replace ring, Replace/torque probe guide
SWP 008 08
15
Dial face not secured (moves), grasp tank
tightly in the inverted position. (Gauge
down), shake vigorously and check for
movement of dial (Figure 15)
MAJOR
Reject tank
16
Tank will not maintain pressure (leaking).
MAJOR
Service/inspect/test SWP 006 08
6.1
Change 1
25
CSTO XX21M-AIM9M-2
WP 006 00
Figure 15. Coolant Pressure Tank
26
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 8. Coolant Pressure Tank Pressure/Temperature Variation
Table 9. Fin Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
1
Fin (Figure 16) leading or trailing edge
warped in excess of 0.062 inch (Note 1)
MAJOR
Reject
2
Severe scratches or gouges in excess of 0.060
inches deep
MAJOR
Reject. Less than 0.060 inches deep, repair
SWP 008 07.
3
Cracks of any size
MAJOR
Reject
Change 1
27
CSTO XX21M-AIM9M-2
WP 006 00
Table 9. Fin Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
4
Corrosion and contamination
MINOR
Clean SWP 008 07
5
Corrosion preventive coating missing
MINOR
Apply compound SWP 008 07
NOTE
Remove screws from fin for inspection. Clean and inspect screws
thoroughly for corrosion. Replace suspect screws.
6
Fin attaching screw(s) identification dots
(minimum of 6, raised or depressed) missing
on screw head (Note 2)
MAJOR
Replace screws SWP 008 07
7
Fin attaching screw(s) corroded, missing, or
damaged
MAJOR
Replace screws SWP 008 07
8
Fin attaching screw(s), performed packing,
missing or damaged (Note 3)
MAJOR
Replace SWP 008 07
9
Trailing edge gouged in excess 0.125 inches
in depth and/or 0.5 inches in length/width
MAJOR
Reject
10
Trailing edge gouged less than 0.125
MAJOR
Repair SWP 008 07
Note 1: Trailing edge of one fin may be used as straight edge for making measurement.
Note 2: A 1/4 inch green dot may be located on the large flat surface of the fin above each attaching screw (both sides)
from a prior inspection and need not be reapplied.
Note 3: If locking rings are present replace with preformed packing.
Figure 16. Fin BSU-32/B
28
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 10. Wing Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
1
Absence of/or illegible identification markings: Mark,
Mod, and part number (Figure 17)
MINOR
Replace marking SWP 008 06
2
Over 25% of thermal coating on one side blistered,
peeling, or missing
MAJOR
Reject
3
Punctures through wing skin into honeycomb
MAJOR
Reject
*4
Wing surface greasy or dirty
MINOR
Clean SWP 008 06
NOTE
If over 25% (estimated) of thermal coating must be removed to repair,
reject.
5
Wing coating cracked, blistered, peeling, or missing in
excess of 0.250 inch in diameter but less than 25% of
thermal coating on one side
MAJOR
Repair coating SWP 008 06
6
Scratches in wing coated surface 0.062 inch wide
MAJOR
Repair coatings SWP 008 06
*7
Small hairline cracks in wing base coating
MINOR
Acceptable
8
Cracks or warpage in metal structure of wing frame
MAJOR
Reject
9
Nicks or scrapes in metal structure of wing frame
greater than 0.250 inch in depth
MAJOR
Reject
10
Circular cracks in rivet area indicating loose rivets
MAJOR
Reject
11
Dents in wing surface more than 0.125 inch in depth
MAJOR
Reject
12
Dents in wing leading edge more than 0.125 inch in
depth
MAJOR
Reject
13
Dents in wing leading edge less than 0.125 inch in depth
MINOR
Repair SWP 008 06
14
Over 25% of thermal coating missing from leading edge
MAJOR
Repair thermal coating SWP 008 06
15
Wing alignment screws missing or damaged
MAJOR
Replace screws SWP 008 06
16
Wing alignment screws corroded
MAJOR
Clean/replace screws SWP 008 06
17
Wing attachment cap screw missing, or damaged
MAJOR
Replace screws SWP 008 06
18
Wing attachment cap screw corroded
MAJOR
Clean/replace screws SWP 008 06
19
Guide vanes missing or bent (minor surface defects are
acceptable)
MAJOR
Replace guide vane SWP 008 06
20
Guide vanes corroded
MAJOR
Clean guide vanes SWP 008 06
21
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs with flat file
or 320 grit emery cloth
22
Guide vane screws loose, missing or damaged
MAJOR
Replace/torque SWP 008 06
Change 1
29
CSTO XX21M-AIM9M-2
WP 006 00
Table 10. Wing Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Corrective Action
23
Minor corrosion on rolleron assembly
MINOR
Clean SWP 008 06
24
Major corrosion on rolleron assembly affecting function
of rolleron
MAJOR
Replace rolleron SWP 008 06
25
Rolleron hinge retaining screws loose, missing, or
damaged
MAJOR
Replace/torque screws SWP 008 06
26
Rolleron hinge corroded
MAJOR
Clean SWP 008 06
27
Rolleron hinge damaged
MAJOR
Replace hinge SWP 008 06
28
Rolleron hinge damper pin hole elongated
MAJOR
Replace hinge SWP 008 06
29
Play where damper assembly is attached to the rolleron
assembly
MAJOR
Replace damper assembly
SWP 008 06
30
Damper assembly shows evidence of leaking oil
MAJOR
Perform rolleron assembly functional
test, Paragraph 32.
31
Damper assembly attaching screws loose or missing
MAJOR
Replace/torque screws SWP 008 06
32
Cager assembly binding, missing parts or inoperative
MAJOR
Repair/replace cager SWP 008 06
33
Loose cager assembly
MAJOR
Replace cager assembly set-screws
SWP 008 06
34
Reset rivet damaged or missing (Mod 2 only)
MAJOR
Replace cager assembly SWP 008 06
35
Cager assembly corroded
MAJOR
Replace/clean cager assembly
SWP 008 06
36
Cager release-pull test (Paragraph 33)
MAJOR
Repair/replace cager SWP 008 06
37
Rolleron assembly functional test (Paragraph 32)
MAJOR
Replace rolleron assembly
SWP 008 06
38
Wing tap inspection (Paragraph 26)
MAJOR
Replace wing if fails inspection.
Retain wing serviceable components
for reuse (SWP 008 06).
26. WING TAP INSPECTION. The tap method of
inspecting the bonded composite panels provides a simple,
dependable method for detecting voids in metal to metal
bonds, skin to core bonds, and delaminations of laminated
structures. The tap method of inspecting bonded panels for
voids is based on the fact that parts bonded together return
a different sound, when struck with a tap hammer, than
parts which are not bonded together. It is necessary that
the instructions contained in the following paragraphs be
followed closely in order to produce as much difference as
possible between the sounds of void free areas and the
sounds of void areas.
27. A void area will be determined by the quality of the
sound it creates when tapped with the tap hammer. The
30
Defect
Classification
Change 1
following aids shall be used in determination of void
areas:
a.
A void area sound will be less sharp or clear than
the sound of a void free area.
b.
A void sound can be described as dull or dead or
sometimes as a rattle.
c.
Different areas of a panel will cause different
sounds even through the panel is free of voids.
The following items will cause sound changes.
(1) Core splices
CSTO XX21M-AIM9M-2
WP 006 00
ALUMINUM
SKIN
DAMPER
ASSEMBLY
ROLLERON
HINGE
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING ALIGNMENT
SCREW (5)
WING
BASE
NOTES:
1.
2.
3.
4.
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER ASSEMBLY, WING
ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 17. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
surface. Remove blemishes from the hammer
head using a fine 320 grit emery cloth.
(2) Differences in core thickness
(3) Core cell size
30. Tap Inspection Procedures.
(4) Skin thickness
a.
Place wing in a vertical upright position.
b.
See Figure 18 for an illustration and instructions
on the proper use of the tap hammer.
c.
Tap thermal coated zones A and B (Figure 17)
surface at one inch spacings.
d.
Although sound will change due to variations in
construction, an area that is free of voids will
retain a sharp, clear sound.
e.
When a void is located, the size should be
determined as accurately as possible. Outline the
perimeter of the void area if any are present,
using a grease pencil.
f.
Repeat steps a through e on opposite side of
wing.
(5) Panel shape
(6) Type of adhesive used in bond
28. Tap Inspection Limitations. This inspection
technique is limited to certain areas and conditions as
follows:
a.
There is difficulty in detecting small voids. As
skin gages increase, the difficulty of detecting
voids becomes greater.
b.
This tap inspection is limited to zones A and B
only (Figure 17).
29. Tap Inspection Preparation.
a.
b.
Remove foreign matter from panel to be
inspected by wiping panel surface with clean dry
cloth.
Inspect the tap hammer head for burrs, nicks,
indentations, etc. that could damage the panel
31. Acceptance/Rejection Criteria.
a.
No single unbonded area shall be greater than
three (3) square inches in area.
Change 1
31
CSTO XX21M-AIM9M-2
WP 006 00
1. GRIP HANDLE OF TAP HAMMER FIRMLY IN HAND WITH THUMB ON HANDLE AS SHOWN. PLACE INDEX FINGER ON WIRE STEM AT A POINT
APPROXIMATELY ONE AND ONE-HALF INCHES FORWARD OF THE HANDLE.
2. RAISE HEAD OF TAP HAMMER APPROXIMATELY ONE TO ONE AND ONE-HALF INCHES ABOVE SURFACE OF PANEL AND TAP SURFACE
LIGHTLY USING A WRIST MOTION. THE HAMMER SHOULD BOUNCE BACK A SHORT DISTANCE FROM THE SURFACE OF THE PANEL AND BE
FORCED BACK DOWN BY A COMBINATION OF PRESSURE FROM THE INDEX FINGER AND WRIST ACTION CREATING A QUICK RAPID TYPE BEAT
OF APPROXIMATELY FIVE TAPS PER SECOND.
Figure 18. Tap Hammer Procedures
b.
No more than three unbonded areas, regardless of
the cumulative area, shall be permitted on each
wing side.
c.
Unbonded areas shall be separated by one (1)
inch.
d.
No unbonded areas shall have a maximum linear
dimension greater than four (4) inches.
e.
Reject wing if unacceptable. Retain serviceable
components (SWP 008 06).
or ratchet-like motion, replace rolleron assembly
(SWP 008 06).
d.
Lay wing on its side against a flat surface. Extend
rolleron assembly over flat surface edge so that
the rolleron can travel throughout its entire range
of motion without interference. Release cager
assembly. Raise rolleron to its highest point of
travel and release. The falling motion shall
indicate resistance but shall not hesitate or stop
throughout its downward travel. If there is no
resistance to rolleron travel or if there is
hesitation in the rolleron’s downward motion,
replace damper (SWP 008 06).
e.
Release cager assembly and slowly move
rolleron assembly from side to side through entire
travel. Verify rolleron does not contact wing
frame and bottom edge is parallel to wing frame.
If rolleron assembly does not conform, replace
damper and rolleron assembly (SWP 008 06).
32. ROLLERON ASSEMBLY FUNCTIONAL TEST.
a.
Set wing base on flat surface.
b.
Hold rolleron assembly (Figure 21) firmly and
grasp rolleron wheel. Move wheel from side-toside and up and down. If any movement is felt,
replace rolleron assembly (SWP 008 06).
NOTE
Some rolleron bearings are preloaded and will
cause the wheel to come to rest more quickly than
others. When rolleron wheel is spinning, bearings
should be relatively free of bearing noise.
c.
32
Spin rolleron wheel by hand. If rolleron wheel
does not turn freely or has wobbly, jerky, noisy,
Change 1
33. CAGER RELEASE-PULL TEST.
Lubricant, Breakfree, MIL-L-63460
a.
[5]
With wing in a vertical upright position, attach
instrument scale, Figure 19 or 20.
CSTO XX21M-AIM9M-2
WP 006 00
b.
Perform release-pull test as specified in Figure 19
or 20. If pull test is within tolerance, return cager
to caged position and verify cager is secured.
c.
If operation is not correct, lubricate cager flag
movement and repeat test.
attach ground clip in area of etched serial number
on wing rib.
b.
d.
If cager fails release-pull
maintenance (SWP 008 06).
test,
perform
34. SAFE-ARM SELECTOR HANDLE SPRING PIN
INSPECTION (MOD 10/11).
a.
Verify Safe-Arm selector is in the SAFE position
and AUR/Missile is grounded.
b.
Remove safety clip assembly.
c.
Using the spring pin inspection gauge, place the
tip of the gauge on one end of the spring pin
(Figure 22) and slowly push against the end of
the pin until 30 pounds (the "green" line on the
shaft is flush with the end of the tool body) has
been achieved. Hold the 30 pound load for
approximately 5 seconds.
Remove safety clip assembly, Figure 20.1.
NOTE
Verify mechanism movement is smooth (no
sticking or binding).
c.
Pull handle to unlock and move to vertical
position, maintain pull pressure.
d.
Rotate handle 90 degrees counterclockwise and
move to horizontal position.
e.
Release pull pressure to lock in ARM position.
f.
Pull handle to unlock and move to vertical
position, maintain pull pressure.
g.
Rotate handle 90 degrees clockwise and move to
horizontal position.
h.
Release pull pressure to lock in SAFE position.
i.
Unlock, lift up, and rotate Safe-Arm selector
assembly handle to the ARM position. Move to
horizontal position and release pressure to lock in
ARM position.
d.
After application of the 30 pound load, inspect
the ends of the spring pin to determine if it has
moved.
e.
If the spring has not moved, repeat step c by
pushing on the other end of the spring pin, hold
the 30 pound load for approximately 5 seconds.
j.
Unlock, lift up, and release Safe-Arm selector
handle. Ensure the handle returns unassisted to
the SAFE position within 3 seconds.
f.
If the spring pin has moved under either load it
must be replaced WP 008 00.
k.
Lock in SAFE position.
g.
Install safety clip assembly.
l.
Install Safety clip assembly.
34.1. SAFE-ARM SELECTOR ASSEMBLY
FUNCTIONAL CHECK (MOD 10/11).
WARNING
Do not touch contact buttons with Safe-Arm
selector in ARMED position. If a radio antenna,
radar, or other generating device is in the area,
consult AFMAN 91-201. The safety distance for
electroexplosive devices will be followed.
a.
Ground Missile/AUR from a wing rib or wing
attaching screw to an approved ground. Do not
m. If Safe-Arm selector assembly fails to operate
correctly, replace rocket motor (WP 008 00) or
repair Safe-Arm selector assembly, SWP 008 05.
34.2. SAFE-ARM SELECTOR ASSEMBLY
FUNCTIONAL CHECK (MOD 8/9).
WARNING
Do not touch contact buttons with Safe-Arm
selector in ARMED position. If a radio antenna,
radar, or other generating device is in the area,
consult AFMAN 91-201. The safety distance for
electroexplosive devices will be followed.
Change 1
33
CSTO XX21M-AIM9M-2
WP 006 00
a.
Release pull pressure to lock in SAFE
position. Install safety clip assembly.
Ground Missile/AUR from a wing rib or wing
attaching screw to an approved ground. Do not
attach ground clip in area of etched serial number
on wing rib.
(2) Mod 8/9, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure to
lock in SAFE position. Move key to
horizontal position.
NOTE
Verify mechanism movement is smooth (no
sticking or binding).
c.
b.
c.
d.
Push in Safe-Arm selector key, rotate 90 degrees
counterclockwise to ARM, remove key and
proceed to step c. If key cannot be removed,
return key to SAFE and replace rocket motor
(WP 008 00) or repair, SWP 008 05.
Safe-Arm selector remains in ARM position
(locking lever lobe moves outward and is locked
in key removal slot, Figure 20.1) then proceed to
step d. If Safe-Arm selector rotates back to SAFE
position replace rocket motor (WP 008 00) or
repair, SWP 008 05.
Inspect arming key pin, Figure 20.1. If arming
key pin is bent or otherwise damaged replace key.
Continue to step e.
Ensure dome protector, umbilical protective cap,
TD protective cap, and forward hanger protective
cover are properly installed.
36. MISSILE TO AUR ASSEMBLY.
a.
Prepare for missile to AUR assembly (Paragraph
35).
b.
Coolant pressure tank installation (Paragraph 37).
c.
Fin installation (Paragraph 38.)
d.
Wing installation (Paragraph 39.)
e.
Post assembly inspection (WP 005 00).
37. Coolant Pressure Tank Installation.
e.
f.
Install Safe-Arm selector key. Push in and rotate
key 90 degrees clockwise to SAFE. Release
pressure. Locking lever lobe shall be locked in
the safe hole.
b.
Ensure missile is secured to assembly stand and
grounded to a wing rib. Do not attach ground clip
in area of etched serial number.
Ensure rocket motor safe-arm selector handle
(Mod 8/9/10/11) is locked in the SAFE position.
If not, perform step (1) for Mod 10/11 or step (2)
for Mod 8/9.
(1) Mod 10/11, pull handle to unlock and move
to the vertical position, maintain pull
pressure. Rotate handle 90 degrees
clockwise and move to horizontal position.
34
Verify coolant pressure tank has been inspected
(Paragraph 23 or SWP 006 08.)
b.
Loosen cover screws and remove coolant tank
access cover from GCS.
If Safe-Arm selector assembly fails to operate
correctly, replace rocket motor (WP 008 00) or
repair Safe-Arm selector assembly, SWP 008 05.
35. PREPARING FOR MISSILE TO AUR
ASSEMBLY.
a.
a.
Change 1
NOTE
Only two pins of the four pin spanner wrench are
used to remove the probe sealing cap. It may be
necessary to retract two pins flush with housing
of spanner wrench if four pins are protruding.
c.
Using spanner wrench, remove probe sealing cap
from GCS coolant inlet probe, if installed.
d.
Verify coolant inlet probe is free of oil, dirt,
grease, or any other contaminant.
CAUTION
Failure to use care when installing coolant tank
will result in damage to inlet probe.
CSTO XX21M-AIM9M-2
WP 006 00
MOD 1 WING
PAPER CLIP ATTACHMENT
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 19. Wing Cager Release-Pull Test (Preferred)
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 20. Wing Cager Release-Pull Test
Change 1
34.1
CSTO XX21M-AIM9M-2
WP 006 00
Mod 10/11
KEY REMOVAL SLOT
LOCKING LEVER
SAFE POSITION
KEY CANNOT BE REMOVED IN THE SAFE POSITION.
THE KEY PIN IS NOT ALIGNED WITH THE REMOVAL SLOT
AND THE LOCKING LEVER’S LOBE IS POSITIONED IN THE
SAFE HOLE.
SAFE HOLE
LOCKING LEVER
KEY REMOVAL SLOT
KEY PIN
SAFE HOLE
ARM POSITION
THE KEY PIN IS ALIGNED WITH THE REMOVAL SLOT AND
KEY MAY BE REMOVED IN THE ARMED POSITION.
Mod 8/9
Figure 20.1. Safe-Arm Selector Assembly, Rocket Motor Mk 36 Mod 8/9 and Mk 36 Mod 10/11
34.2
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Figure 21. Rolleron Assembly
Figure 22. Rocket Motor Safe-Arm Selector Handle Spring Pin Test
35
CSTO XX21M-AIM9M-2
WP 006 00
e.
Remove and discard tape from coolant pressure
tank. Install and tighten fingertight using finger
lugs on coolant tank.
b.
Apply a thin coating of silicone compound to fin
mating surface, threads of retaining screw, GCS
rocker arm mating surface, and GCS fin cup.
Remove excess silicone from fin mating area.
c.
Position fin with arrows pointing forward
(toward GCS dome) and install fin attaching
screws into rocker arms. Hold fin securely while
second person torques screws in accordance with
Table 4.
d.
Repeat steps b. and c. for remaining three fins on
GCS.
e.
Rock each fin fore and aft. If either end of fin
contacts GCS skin, inspect fin-to-rocker arm
installation. If fin is attached securely to rocker
arm but fin still contacts GCS skin when rocked,
replace fin. If contact is still made, reject GCS.
NOTE
If no release of pressure is heard in step f, the
coolant inlet probe in the GCS has most likely
been damaged. If so, the GCS may require depot
maintenance.
f.
g.
Turn coolant tank counterclockwise enough to
determine if the tank valve assembly is operating
(a release of pressure with an abrupt cut off
should be heard). Turn coolant tank clockwise
fingertight using finger lugs on coolant tank.
Ensure leaking can not be heard with the tank
fully installed. If leaking can be heard, the
coolant tank preformed packing should be
changed before the tank is rejected.
(SWP 008 08).
39. Wing Installation.
a.
Verify wings have been inspected and serviced
(Paragraph 25 or SWP 006 06.)
b.
Verify alignment screws when viewed from
bottom of wing are at same angle (approximately
45 degrees) as slots in rocket motor wing rib. If
screws are not aligned, adjust with screwdriver.
c.
If installed, remove aft protective cap from rocket
motor. Position wing on rocket motor wing rib,
making final adjustment to wing rib screws if
necessary.
d.
Ensure wing fits properly, then tighten wing
attachment cap screw (Figure 17) until wing is
seated firmly on rocket motor. Torque wing
attachment screw in accordance with Table 4. If
wing does not fit or is loose, try another wing.
e.
Repeat steps a. through d. for remaining three
wings. Prior to installing last wing, remove
ground strap and reconnect to an installed wing’s
attaching screw.
CAUTION
Failure to use care when installing access cover
will result in damage to the coolant tank gauge.
Do not trap wire handle between access cover
and gauge glass when installing cover.
h.
Install coolant pressure tank access cover; tighten
screws until snug.
38. Fin Installation.
Compound, Silicone MIL-S-8660
a.
Verify fins have been inspected (Paragraph 24 or
SWP 006 07.)
CAUTION
Only fin attaching screws PN NAS1351-4LB14P
are to be used. Screws must have head markings
of a minimum of six (6) dots, raised or depressed.
Use of other screws may allow separation of fin
from missile in flight.
36
[7]
40. GROUND HANDLING.
CAUTION
Mishandling can cause damage to the missile/
components. Do not lift missile by wings, fins,
rollerons, umbilical or dome assembly. Do not
CSTO XX21M-AIM9M-2
WP 006 00
clockwise and move to horizontal position.
Release pull pressure to lock in SAFE
position. Install safety clip assembly.
allow missile/components to come in contact
with hard objects while handling. Do not rest
missile on target detector.
a.
Procedures for loading
contained in TO 11-1-38.
and
(2) Mod 8/9, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure to
lock in SAFE position. Move key to
horizontal position.
tie-down are
WARNING
c.
Safety and Protective devices must be installed
during all ground handling. Damage to the
missile, serious injury or death of personnel
could result.
b.
During any ground handling, all tactical missiles
shall have the following:
(1) A dome protector with
BEFORE FLIGHT flag.
a
REMOVE
(2) A safety clip assembly (Mk 36 Mod 10/11)
or safety - arming key (Mk 36 Mod 8/9).
(3) A protective cap on the umbilical.
Ensure dome protector, umbilical protective cap,
TD protective cover, and forward hanger
protective cover are properly installed.
44. AUR DISASSEMBLY.
a.
Prepare AUR for disassembly (Paragraph 43).
b.
Coolant pressure tank removal (Paragraph 45).
c.
Fin removal (Paragraph 46).
d.
Wing removal (Paragraph 47).
45. Coolant Pressure Tank Removal.
a.
(4) A TD protective cover with a REMOVE
BEFORE FLIGHT flag.
Loosen access cover screws and remove cover
from GCS.
WARNING
(5) A protective cover on the forward hanger.
41. AUR INSPECTION.
42. This inspection will be performed on all AURs prior
to returning to stock or before and after usage. Inspect
AUR Table 11.
43. PREPARING FOR AUR TO MISSILE
DISASSEMBLY.
a.
b.
Ensure missile is secured to assembly stand and
grounded to a wing attaching screw. Do not
attach ground clip in area of etched serial
number.
Ensure rocket motor Safe-Arm selector handle
Mod 8/9/10/11 is locked in the SAFE position. If
not, perform step (1) for Mod 10/11 or step (2)
for Mod 8/9.
(1) Mod 10/11, pull handle to unlock and move
to the vertical position, maintain pull
pressure. Rotate handle 90 degrees
If a sustained gas venting is heard while
removing coolant pressure tank, tank removal
shall be stopped. Tank shall be allowed to
discharge in place and removed only after
venting ceases.
b.
Use finger lugs on coolant pressure tank and
remove coolant pressure tank. If unable to
remove tank by hand, use coolant tank removal
tool.
c.
Install new sealing tape over coolant pressure
tank outlet valve as follows:
(1) Cut two pieces of tape, one approximately 1inch square and another approximately 2inch square. Center and apply adhesive side
of 1-inch tape to the adhesive side of the 2inch tape.
37
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Safe-Arm selector handle is in ARM position
(except Mk 36 Mod 7)
CRITICAL
Ensure rocket motor Safe-Arm selector
handle is locked in the SAFE position. If
not, refer to Paragraph 34.1 for Mod 10/
11 or Paragraph 34.2 for Mod 8/9.
2
Punctures, skin penetration by cracks or gouges on
rocket motor or warhead
CRITICAL
Replace rocket motor/warhead
WP 008 00
NOTE
Several thousand Mk 36 rocket motors (serial number prefixes, MKW,
PAB, PYM) have been fielded that were suspect of having critical
defects. Most have been inspected and marked “AWB 222
ACCEPTED.” See TO XX11A-1-1 to determine serviceability.
3
Rocket motors with serial numbers MKW 0004405234, PAB 00001-01606, and PYM 00496-00702
that are suspended by TO XX11A-1-1 shall not be
used
CRITICAL
Replace rocket motor WP 008 00
4
Coupling rings cracked, not correct part number, not
properly oriented, parts not installed correctly
(Figure 23)
CRITICAL
Replace/reinstall coupling ring
WP 008 00
5
Coupling ring(s) manufactured with (Cage Code)
00784 with date of manufacture 1-90 through 12-90
or 1-83 through 12-84 stamped on their outer
surface
CRITICAL
Replace coupling ring WP 008 00
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 008 00
5.1
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
6
Coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace coupling ring threaded pin
WP 008 00
7
Coupling ring screw(s) not PN 639AS1599 Rev M
or later, or PN 8934242
CRITICAL
Replace coupling ring screws WP 008 00
8
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screws WP 008 00
8.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screws WP 008 00
38
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
9
Coupling ring screw(s) PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 23)
CRITICAL
Replace coupling ring screws WP 008 00
10
Coupling ring(s) fail straightedge inspection
(Figure 24)
CRITICAL
Replace coupling ring(s) WP 008 00
11
GCS dome (Figure 25) broken, cracked, or
punctured
CRITICAL
Replace GCS WP 008 00
GUIDANCE CONTROL SECTION
*12
Foreign material on dome. (Various colorations of
dome do not affect missile performance)
MINOR
Clean WP 008 00
*13
GCS dome has minor scratches, nicks, or pits
MINOR
Acceptable
14
Dome or dome retaining ring loose or cracked
MAJOR
Replace GCS WP 008 00
15
GCS dome lock ring/dome housing has dents
greater than 0.060-inch or gouges greater than
0.025-inch in depth
MAJOR
Replace GCS WP 008 00
16
GCS dome lock ring/dome housing has dents up to
0.060-inch in depth or less, gouges up to 0.025-inch
in depth or burrs on surface
MAJOR
Remove raised metal only with flat file or
320 grit emery cloth
17
Gas generator service life expired or cannot be
determined (WP 005 00 Table 1)
MAJOR
Replace GCS WP 008 00
18
Absence of, or illegible, part number, lot number,
date of manufacturer or serial number (Figure 25)
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF,
Robins AFB, GA 31098-1813 for
instructions
19
GCS skin cracked, punctured, dents greater than
0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 008 00
20
GCS skin has dents up to 0.060-inch, gouges up to
0.025-inch in depth, burrs, scratches, or pits
penetrating anodized coating or corrosion)
MINOR
Repair coating SWP 008 01
21
Metal fin cup (Figure 26) missing or loose in GCS
housing
MAJOR
Replace GCS WP 008 00
22
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange down
until seated on GCS housing
23
Metal fin cup flange cracked, buckled, or bent to
extent flange will not seat on GCS housing
MAJOR
Replace GCS WP 008 00
24
Gas grain generator surrounding area shows
evidence of soot caused by gas generator firing
MAJOR
Test GCS SWP 006 01
25
Missing or loose screws on exhaust valve
(Figure 25)
MAJOR
Replace/torque screws
SWP 008 01
Change 2
39
CSTO XX21M-AIM9M-2
WP 006 00
TARGET
DETECTOR
GCS
FWD
(1) COUPLING RING
(2) CLIP
(3) SCREW
(4) PIN
(5) THREADED PIN
(6) GUIDE PLATE ASSEMBLY
FORWARD
COUPLING RING
ASSEMBLY
PN 639AS672
WARHEAD
(1)
AFT COUPLING
RING ASSEMBLY
PN 639AS2725-2
(2)
(3)
ROCKET MOTOR
COUPLING RING
ASSEMBLY
PN 639AS2725-1
INDEXING
PIN
GUIDE
PLATE
ASSEMBLY
(4)
(5)
(6)
ROCKET MOTOR
PART
NUMBER
AFT
REVISION
MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 23. Coupling Ring Assemblies
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 24. Coupling Ring Straightedge Inspection
40
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
WGU-4A/B
NOTES:
1. LOCATION OF MARKINGS IS APPROXIMATE.
2. 9M FOR WGU-4A/B. THREE PLACES.
3. WGU-4A/B FOR PN 639AS3963.
Figure 25. Guidance Control Section Inspection Points
41
CSTO XX21M-AIM9M-2
WP 006 00
Figure 26. Fin Cup
Figure 27. Umbilical Cable and GCS Umbilical Base
42
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Step
26
Inspection
(Inspect for the following defects)
Defect
Classification
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MAJOR
Corrective Action
Remove damaged adhesive and apply a
small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
27
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 008 01
27.1
Top of umbilical block metal housing lip separating
from the epoxy core
MAJOR
Repair, SWP 008 01
Umbilical block spring pin (Figure 27) loose,
missing, or damaged
MAJOR
Replace spring pin SWP 008 01
28
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
29
Umbilical block spring pin not correct length
MAJOR
Replace spring pin SWP 008 01
30
Umbilical cable insulation separated from cable
block or launcher connector. Insulation damaged to
extent cable insulation is penetrated, but gas tubing
or wire insulations are not damaged
MAJOR
Repair insulation SWP 008 01
31
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Remove GCS WP 008 00
Replace umbilical cable SWP 008 01
32
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace/torque screws/replace safety
wire SWP 008 01
33
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 008 01
34
Missing, loose, damaged, or corroded umbilical
base assembly screws (Figure 25)
MAJOR
Replace/clean/torque screws SWP 008 01
35
Missing or loose housing assembly screws
MAJOR
Replace/torque screws SWP 008 01
36
DC to DC converter screws loose, missing
MAJOR
Replace/torque screws SWP 008 01
37
Missing or loose nitrogen plug
MAJOR
Replace/torque plug SWP 008 01
38
Umbilical protective cap missing
MAJOR
Replace cap SWP 008 01
39
Dirt, grease, or corrosion inside umbilical protective
cap
MAJOR
Clean WP 008 00
40
Pin 13, 19, or 21 bent, broken, or missing in
umbilical protective cap
MAJOR
Replace cap SWP 008 01
41
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace packing SWP 008 01
42
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Remove GCS WP 008 00
Replace umbilical cable SWP 008 01
Change 1
43
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
43
Moisture or foreign matter on umbilical connector
MAJOR
Clean connector WP 008 00
*44
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*45
Umbilical cable not properly secured with rubber
band (ZZ-R-1415), retaining clip or equivalent
MINOR
Replace/secure
MAJOR
Service/inspect/test SWP 006 08
*45.1 Pressure gauge indicates no positive pressure
*46
Coolant pressure tank gauge (Table 12) is in the
yellow or red area (Figure 29)
MAJOR
Replace/service tank Paragraphs 45/37
*47
Coolant pressure tank gauge glass broken or
missing (TMU-72/B)
MAJOR
Replace tank Paragraphs 45/37
48
Coolant pressure tank gauge glass broken or
missing (TMU-72A/B or TMU-72B/B)
MAJOR
Replace tank Paragraphs 45/37
Repair tank SWP 008 08
49
Loose, missing or damaged components on coolant
tank access cover
MAJOR
Replace/repair SWP 008 01
*50
Corrosion preventive compound missing on fin
(Figure 28)
MINOR
Replace compound SWP 008 07
51
Forward or aft end of fin contacts GCS skin when
rocked
MAJOR
Check fin installation Paragraph 46/38
52
Fins have corrosion, contamination, warped,
gouges, cracks, or severe scratches
MAJOR
Inspect Table 9. Repair/replace. If reject,
replace Paragraph 46/38.
53
Fin attaching screws corroded, missing, or damaged
MAJOR
Replace/clean screws Paragraph 46/38
54
Fin attaching screw(s), identification dot (minimum
of 6, raised or depressed) missing
MAJOR
Replace screws Paragraph 46/38
FINS
Figure 28. Fin, BSU-32/B
44
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 12. Coolant Pressure Tank Pressure/Temperature Variation
T
H T ON
IG
LY
IN
T
YELLOW
N
ER
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
FI
G
S
RED
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
PSI X 1000
Figure 29. Coolant Pressure Tank
Change 1
45
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
TARGET DETECTOR
55
TD exterior surface cracks or punctures, pits/gouges
greater than 0.060-inch in depth, or dents greater
than 0.025-inch in depth (Figure 30)
MAJOR
Replace TD WP 008 00
56
Exterior surface scratches
MINOR
Acceptable
NOTE
Slight degradation of the anti-reflective coating on the window(s) that
resembles water spots is acceptable.
57
TD window(s) cracked, broken, missing, loose,
scratches greater than 0.5-inch in length, or
condensation on inside of window
MAJOR
Replace TD WP 008 00
58
Loose objects seen through window(s)
MAJOR
Replace TD WP 008 00
59
TD window(s) for cleanliness
MINOR
Clean WP 008 00
60
TD protective cover missing
MINOR
Replace cover
61
Coupling ring(s) (Figure 23) has burrs, gouges,
scratches, dents, or pits that penetrate surface finish
and aggregately covers less than 2% of entire
surface (2% of entire surface is approximately an
area 0.25 inches long across the entire width of the
coupling ring)
MINOR
Clean and apply MIL-C-85054
62
Coupling ring(s) has burrs, gouges, scratches, dents,
or pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of
entire surface is approximately an area 0.25 inches
long across the entire width of the coupling ring)
MAJOR
Replace coupling ring(s)
WP 008 00
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, SWP 008 00. Inspect for cracks. If
brown spots, specks, or discoloration
cannot be removed replace coupling ring
SWP 008 00.
Forward indexing pin is loose, missing, damaged, or
corroded
MAJOR
Remove GCS WP 008 00
Replace pin SWP 008 02
62.1
63
WARHEAD
NOTE
The minimum required markings for explosive components are part
number, lot number, nomenclature, and date of manufacture. The filler
lot number is to be used as the warhead lot; the date loaded is
considered the date of manufacture.
64
46
Absence of, or illegible part number, lot number,
date of manufacture, serial number, yellow band or
stencil PBXN-3 (Figure 30)
Change 2
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF
Robins AFB, GA 31098-1813 for
instructions
CSTO XX21M-AIM9M-2
WP 006 00
Figure 30. Missile Inspection Points
Change 1
47
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
65
Exterior surface of warhead dented, but skin not
penetrated
MINOR
Acceptable
66
Exterior surface of warhead gouged, but skin not
penetrated
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
67
Surface of warhead cracked or skin penetrated
MAJOR
Replace warhead WP 008 00
MAJOR
Replace assembly, torque/ replace screws,
SWP 008 05
MAJOR
Replace decals or stencil SWP 008 05
ROCKET MOTOR SECTION
68
Rocket motor Safe-Arm selector assembly
attachment screws loose, assembly damaged,
missing, (except Mk 36 Mod 7)
69
Deleted
70
Absence of, or illegible, markings (Figure 30)
NOTE
The minimum required markings for explosive components are: part
number, lot number, nomenclature, and date of manufacture.
71
Absence of, or illegible part number, lot number,
date of manufacture, serial number, or brown band
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF
Robins AFB, GA 31098-1813 for
instructions
*72
Brown band deteriorated and in need of replacement
MINOR
Replace band SWP 008 05
NOTE
Steps 73 through 78 apply to the exterior surface of the rocket motor
(aft of coupling ring groove) between stations 0.269 and 1.880 and
between 68.725 and 70.905 (Figure 31).
73
Pits greater than 0.030-inch deep
MAJOR
Replace rocket motor WP 008 00
74
Pitted area over one square inch and pits more than
0.015-inch deep
MAJOR
Replace rocket motor WP 008 00
75
Gouges up to 0.030-inch deep by 0.045-inch wide
by 0.075-inch long
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
76
Gouges over 0.030-inch deep or 0.045-inch wide by
0.075-inch long
MAJOR
Replace rocket motor WP 008 00
77
Dents over 0.030-inch in depth or 0.092-inch in
diameter
MAJOR
Replace rocket motor WP 008 00
*78
Burrs or scratches
MAJOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
48
Change 2
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Step 79 applies to the exterior surface of the rocket motor (aft of
coupling ring groove and between station 2.235 and 68.725, Figure 31).
*79
Burrs or scratches
MAJOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
WARNING
Touching of the contact buttons in the rocket motor forward hanger
could cause rocket motor ignition. All personnel handling rocket
motor shall make bare skin-to-metal contact with rocket motor wing
rib or ground wire.
80
Forward hanger protective cover damaged or
missing
MINOR
Replace cover
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
81
Forward hanger (Figure 32) screws/bolts loose,
damaged, or missing
MAJOR
Replace screws/bolts SWP 008 05
82
Forward hanger or hanger screws/bolts corroded to
the extent corrosion cannot be removed
MAJOR
Replace SWP 008 05
Figure 31. Rocket Motor Inspection
Change 1
49
CSTO XX21M-AIM9M-2
WP 006 00
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 32. Forward Hanger Assembly
Figure 33. Center and Aft Hanger Assemblies
50
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
83
Forward hanger mating surfaces and stress points
for cracks
MAJOR
Replace SWP 008 05
84
Top of forward hanger mating surface for snubber
wear in excess of 0.015 inch in depth, rear of hanger
for detent wear in excess of 0.030, or forward detent
lug wear area is rounded over all the way across the
area between the two arrows
MAJOR
Replace SWP 008 05
WARNING
Cleaning or repairing of contact buttons shall not be attempted. Minor
amounts of dirt, grease, or corrosion will not affect missile firing.
85
Contact button(s) have severe corrosion damage,
not flush, or below hanger
MAJOR
Replace SWP 008 05
86
Contact button insulator missing
MAJOR
Replace SWP 008 05
WARNING
Use depth gauge PN 643J to measure damage to forward hanger
contact buttons, and all hanger surfaces. Prior to taking measurements
on the forward hanger/contact buttons verify missile is grounded,
Safe-Arm selector handle is in SAFE position, and make bare skin-tometal contact with rocket motor wing rib or ground wire.
87
Aft contact button cut, scratched, or gouged greater
than 0.030-inches deep
MAJOR
Replace SWP 008 05
88
Forward hanger nonmating surface for dents greater
than 0.045-inches deep or 0.075-inches in diameter
MAJOR
Replace SWP 008 05
89
Forward hanger nonmating surface for gouges
greater than 0.045-inches deep by 0.064-inches
wide by 0.075-inches long
MAJOR
Replace SWP 008 05
90
Forward hanger nonmating surfaces for cracks
MAJOR
Replace SWP 008 05
NOTE
Steps 91 through 97 apply to the center and aft hanger (Figure 33, area X).
91
Mating surfaces for dents greater than 0.015-inch
deep by 0.030-inch in diameter
MAJOR
Replace rocket motor WP 008 00
92
Mating surface for gouges greater than 0.015-inch
deep by 0.030-inch wide by 0.045-inch long
MAJOR
Replace rocket motor WP 008 00
93
Nonmating surfaces for pitted areas greater than
0.060 square inch in diameter and 0.032-inch deep
MAJOR
Replace rocket motor WP 008 00
Change 1
51
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
94
Nonmating surfaces for dents greater than 0.032inch deep or 0.064-inch in diameter
MAJOR
Replace rocket motor WP 008 00
95
Nonmating surfaces for gouges greater than 0.045inch deep or 0.064-inch wide or 0.075-inch long
MAJOR
Replace rocket motor WP 008 00
96
Nonmating surface for cracks
MAJOR
Replace rocket motor WP 008 00
97
Mating surface for cracks
MAJOR
Replace rocket motor WP 008 00
NOTE
Steps 98 through 102 apply to the center and aft hanger nonmating
surfaces (area Y & Figure 33).
98
Pits greater than 0.020 square inch and 0.015-inch
deep
MAJOR
Replace rocket motor WP 008 00
99
Dents greater than 0.020-inch deep or 0.050-inch in
diameter
MAJOR
Replace rocket motor WP 008 00
100
Gouges greater than 0.020-inch deep or 0.032-inch
wide or 0.064-inch long
MAJOR
Replace rocket motor WP 008 00
101
Cracks
MAJOR
Replace rocket motor WP 008 00
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and touch-up paint
SWP 008 05
*102 Burrs or scratches
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
103
Center/aft hangers for visible gap between hanger
strap and rocket motor mating surfaces, Figure 34
MAJOR
Replace rocket motor WP 008 00
104
Center hanger loose
MAJOR
Replace rocket motor WP 008 00
104.1 Center hanger threaded pins (Figure 34 center
hanger Views A and B) loose, damaged, or missing
MAJOR
Replace rocket motor WP 008 00
104.2 Center hanger shims (Figure 34 center hanger
View B) loose or missing
MAJOR
Replace rocket motor WP 008 00
104.3 Center hanger band screw(s) (Figure 34 center
hanger View C) loose, damaged, or missing
MAJOR
Replace rocket motor WP 008 00
MAJOR
Replace rocket motor WP 008 00
MAJOR
Replace rocket motor WP 008 00
MAJOR
Replace rocket motor WP 008 00
105
Aft hanger loose
105.1 Aft hanger band screw(s) (Figure 34 aft hanger
View A) loose, damaged, or missing
106
52
Rocket motor weather seal (Mod 7/8/10) missing,
punctured, or bulged out (Figure 35)
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
Figure 34. Center and Aft Hanger Inspection
MOD 9 / 11 ONLY
Figure 35. Rocket Motor Aft End
Change 1
53
CSTO XX21M-AIM9M-2
WP 006 00
Table 11. AUR Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
107
Tamper seal (Mod 9/11) bulged out, missing, or
punctured
MAJOR
Replace rocket motor WP 008 00
108
Nozzle (Mod 7/8/10) cracks, gouges, or
delaminations
MAJOR
Replace rocket motor WP 008 00
109
Burrs or scratches on support ring
MINOR
Remove raised metal only with flat file or
320 grit emery cloth and apply
MIL-C-85054
110
Support ring dents greater than 0.045-inch deep or
0.064-inch in diameter
MAJOR
Replace rocket motor WP 008 00
111
Coupling ring (Figure 23) has burrs, gouges,
scratches, dents, or pits that penetrate surface finish
and aggregately covers less than 2% of entire
surface (2% of entire surface is approximately an
area 0.25 inches long across the entire width of the
coupling ring)
MINOR
Clean and apply MIL-C-85054
112
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of
entire surface is approximately an area 0.25 inches
long across the entire width of the coupling ring)
MAJOR
Replace coupling ring WP 008 00
MAJOR
Clean, SWP 008 00. Inspect for cracks. If
brown spots, specks, or discoloration
cannot be removed replace coupling ring
SWP 008 00
112.1 Coupling ring has brown spots, specks, or
discoloration
WINGS
113
Wing (Figure 36) thermal coating cracked,
blistered, peeling, or missing in excess of 0.250inch in diameter but less than 25 percent on one side
MAJOR
Remove wing Paragraph 47/39
Repair coating SWP 008 06
114
Dent(s) in wing surface more than 0.125-inch in
depth
MAJOR
Replace wing Paragraph 47/39
115
Dent(s) in leading edge of wing greater than 0.125inch in depth
MAJOR
Replace wing Paragraph 47/39
116
Wing attachment cap screw missing, damaged, or
corroded
MAJOR
Replace/clean SWP 008 06
*117 Rolleron not caged
MINOR
Recage
118
Loose cager assembly
MAJOR
Remove wing Paragraph 47/39
Replace setscrews SWP 008 06
119
Reset rivet damaged or missing (Mk 1 Mod 2)
MAJOR
Remove wing Paragraph 47/39
Replace cager assembly SWP 008 06
120
Play where damper assembly is attached to rolleron
assembly
MAJOR
Remove wing Paragraph 47/39
Replace damper assembly SWP 008 06
54
Change 1
CSTO XX21M-AIM9M-2
WP 006 00
ALUMINUM
SKIN
ROLLERON
HINGE
DAMPER
ASSEMBLY
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING
BASE
NOTES:
WING ALIGNMENT
SCREW (5)
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
1. ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER
ASSEMBLY, WING ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
2. DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
3. WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
4. WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 36. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
Table 11. AUR Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
121
Guide vanes missing, bent, or corroded (minor
surface defects are acceptable)
MAJOR
Remove wing Paragraph 47/39
Replace guide vanes SWP 008 06
122
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs with flat file or
320 grit emery cloth
123
Guide vane screws loose, missing, damaged, or
corroded
MAJOR
Remove wing Paragraph 47/39
Torque/replace screws
SWP 008 06
NOTE
If over 25% (estimated) of thermal coating must be removed to repair, reject.
124
Wing coating cracked, blistered, peeling, or missing
in excess of 0.250 inch in diameter but less than
25% of thermal coating on one side
MAJOR
Remove/replace Paragraph 47/39
Repair coating SWP 008 06
125
Assembled missile markings/surface paint in need
of touch-up or replacing
MINOR
Replace markings using applicable SWP,
Paint/touch-up WP 008 00
*126 Assembled missile for dirt, grease, foreign matter or
minor corrosion
MINOR
Clean WP 008 00
127
MAJOR
Repair/replace cager SWP 008 06
Cager release-pull test (Paragraph 32)
Change 1
55
CSTO XX21M-AIM9M-2
WP 006 00
STAND OFF (6)
LIFT RINGS (4)
PRESSURE
RELIEF
VALVE
FINS
AFT
COOLANT
PRESSURE
TANKS
HUMIDITY
INDICATOR
TAPE
WINGS
SLOTS (6)
DOME
PROTECTOR SLOT
Figure 37. CNU-310/E All-Up-Round Container (PN 785041-10) and AIM-9M Missiles
(2) Position 1-inch square tape over outlet valve
and secure. Do not reuse tape once applied.
d.
e.
Verify probe sealing cap is free of contaminants
and preformed packing is in place and install
probe sealing cap fingertight on GCS coolant
inlet probe.
NOTE
Wing(s) may be removed at anytime to facilitate
handling missile.
a.
Remove one wing by loosening wing attachment
screw at aft end of wing about 1/2 to 3/4 inch.
Lift wing from rocket motor with forward
motion. It may be necessary to jar wing from aft
end with heel of hand or nonmetallic mallet.
b.
Relocate missile ground strap to wing rib where
wing removed in step a. was attached. Avoid
placing ground strap over etched serial number
on wing rib.
c.
Remove remaining wings (step a).
Install access cover on GCS, tighten screws until
snug.
46. Fin Removal.
CAUTION
One person must hold fin securely while second
person loosens fin-attaching screws to prevent
damage to fin cup.
Fin screws are captive, just loosen to remove fin.
49. If complete missile disassembly is required, refer to
WP 008 00 for disassembly and applicable WP/SWPs for
inspection and packing.
a.
50. PACKING.
NOTE
Loosen fin-attaching screws and remove fins
from GCS.
47. Wing Removal.
56
48. MISSILE DISASSEMBLY.
Change 1
51. MISSILE PACKING
CONTAINER.
IN
THE
CNU-310/E
CSTO XX21M-AIM9M-2
WP 006 00
a.
Press button on pressure relief valve.
l.
b.
Beginning at each end and working toward the
center release the 16 latches and place latches in
the DOWN position.
m. Ensure four 16-unit bags or equivalent of
activated desiccant are in container.
n.
If humidity indicator is pink or white, replace.
c.
Remove container cover by either lifting at each
corner (manually) or by lifting at the lift rings
(Figure 37) using a mechanical means.
o.
Verify container latches are at approximately a
60° angle to the bottom side of container prior to
applying force to close latches.
Ensure that all container cushions are positioned
according to the diagrams appearing on the lid
and container lower section.
p.
Place container cover on lower section and secure
latches, and seal TO 11A-1-60.
d.
e.
Place wings in lower section as illustrated in
Figure 37. Ensure wings fit securely in dunnage.
f.
Place fins in lower section as illustrated in Figure
37. Ensure fins are staggered.
g.
Place full coolant tanks in cavities located
between fins.
52. MISSILE PACKING IN BARRIER MATERIAL.
The preferred and recommended method of packing
assembled missiles is in the assembled missile containers.
For short term storage when containers are not available,
this packing method may be used provided all other
requirements of this TO and AFR/AFOSH-127 series are
met. Proceed as follows:
a.
Place 3 by 12-foot sheet of barrier material across
missile chocks printed side down (Figure 38).
b.
Position guided missile into place on top of
barrier material with umbilical cable up. Position
guided missile in such a manner that the chocks
engage it at proper chocking area locations.
c.
Ensure that dome protector, umbilical moisture
sealing cap, TD protective cover, and forward
hanger protective cover are properly installed.
NOTE
If the AUR is to be stored or shipped with the
GCS removed a fiber board tube shall be installed
in the empty area where the GCS is normally
located to preclude any shifting of the remaining
portion of the AUR.
h.
Verify umbilicals are flat against GCSs. If not,
tape or use a rubber band to secure.
NOTE
If the AUR is to be stored or shipped with less
than four missiles a fiberboard tube shall be
installed in the empty area where the missile is
normally located to preclude any shifting of the
remaining missiles. When fiberboard tube is not
available, recommend using locally procured
carpet or PVC tubing of the appropriate diameter
and cut to appropriate length.
i.
If only 2 or 3 missiles are to be loaded, the empty
slots shall be on the outside. If only 1 missile is to
be loaded, it shall be on the inside.
j.
For shipment of 1, 2, and 3 missiles, a fiberboard
tube shall be used to fill empty slots.
k.
Lower missile into container with hangers in the
up position. Ensure that dome protector fits snug
into forward end cushion (Figure 37).
Load remaining missiles, steps h, i, j, and k.
NOTE
Damaged or punctured barrier material may be
repaired with suitable tape.
d.
Place 64 units of serviceable desiccant around the
missile.
e.
Install serviceable humidity indicator through
barrier material at approximate location shown in
Figure 38.
f.
Fold barrier material over top of missile and align
edges.
NOTE
Barrier material must be tightly gathered at
umbilical cable and suspension lug locations to
facilitate sealing.
Change 1
57
CSTO XX21M-AIM9M-2
WP 006 00
g.
h.
Insert vacuum cleaner nozzle through unsealed
area and collapse bag around missile.
i.
Remove vacuum cleaner nozzle and immediately
seal remaining area.
j.
Verify humidity indicator is blue after 24 hours of
packaging. Repackage missile if humidity
indicator is not blue after 24 hours.
k.
(3) Type of warhead section.
Using heat sealing machine, seal ends and side of
barrier material. Leave small area unsealed for
nozzle of vacuum cleaner.
Record the following information directly on the
outside of the barrier material:
(4) Missile type and other data as required by
using command.
l.
For extended storage, wings and fins not stored in
containers may be protected by sealing in a 3 by
6-foot sheet of barrier material in the same
manner as the guided missile is packaged, except
humidity indicator is not required. Desiccant is
optional.
53. CONTAINER MARKINGS.
54. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
(1) Location of umbilical cable, and forward end
of guided missile.
(2) Serial number of missile.
Figure 38. Missile Preparation for Barrier Material
58
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION AND TEST
FIELD LEVEL MAINTENANCE
GUIDANCE CONTROL SECTION WGU-4A/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 34
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1. ... .... ... ... .... ... .... 2
5-8 . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . . . . . . . . . 0
18 . . . . . . . . . . . . . . . . . . . . . . . . 1
24-28 . . . . . . . . . . . . . . . . . . . . . 1
34 blank . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
2-3 . . . . . . . . . . . . . . . . . . . . . . . 1
9. . . . . . . . . . . . . . . . . . . . . . . . . 0
16. . . . . . . . . . . . . . . . . . . . . . . . 1
19-21 . . . . . . . . . . . . . . . . . . . . . 2
29-30 . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
4 . . . . . . . . . . . . . . . . . . . . . . . . .2
10-14 . . . . . . . . . . . . . . . . . . . . . . 1
17 . . . . . . . . . . . . . . . . . . . . . . . . 2
22-23 . . . . . . . . . . . . . . . . . . . . . . 0
31-33 . . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Digital Hygrometer, TTU-546/E, Part Numbers 639AS9334-1 and 639AS9334-2............................. CSTO XX35D18-6-2
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Inspection of Reusable Munitions Containers and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance with Illustrated Parts Breakdown,
Coolant Pressure Tank TMU-72/B, TMU-72A/B and TMU-72B/B .................................................................SWP 008 08
Maintenance with Illustrated Parts Breakdown, Guidance Control Section, WGU-4A/B ..................................SWP 008 01
Operation/Maintenance Manual, Amptec Research Model 620A-4
FailSafe Digital Ohmmeter/Igniter Circuit Tester, NSN 6625-01-460-1499AQ......................................TO 33D5-14-52-1
Operation and Maintenance Instructions with IPB, Test Set, Guidance Control
Section (TS-3860C) .............................................................................................................................. FMS TS3860 Series
Operation and Maintenance Instructions with IPB, Test Set, Guidance Control
Section (TS-4044/D)........................................................................................................................... TO XX33D9-54-67-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Storage and Inspection Requirements....................................................................................................................WP 005 00
Unpacking, Packaging, Inspection, Test and Servicing, Coolant Pressure Tank,
TMU-72/B, TMU-72A/B and TMU-72B/B ......................................................................................................SWP 006 08
Change 2
1 of 34
CSTO XX21M-AIM9M-2
SWP 006 01
Table of Contents
Title
Page
Container Markings ............................................................................................................................................................. 32
Dropped GCS Processing ...................................................................................................................................................... 5
Empty Container Processing ................................................................................................................................................. 5
Handling and Test Equipment Preparation............................................................................................................................ 5
Incidents/Accidents ............................................................................................................................................................... 4
Inspection .............................................................................................................................................................................. 6
Packing ................................................................................................................................................................................ 31
GCS Packing in the CNU-300/E Container ...................................................................................................................... 31
GCS Packing in the CNU-301/E Container ...................................................................................................................... 31
Safety and Accident Prevention ............................................................................................................................................ 4
Sequence of Operations ......................................................................................................................................................... 4
Testing ................................................................................................................................................................................... 6
Captive Flight Adapter Installation ................................................................................................................................... 25
CATM GCS Test with HRU-985A/E Training Umbilical Cable Assembly ..................................................................... 25
CATM Training Umbilical Cable HRU-985A/E (PN 2880325) Installation .................................................................... 27
CATM Training Umbilical Cable HRU-985A/E (PN 2880325) Removal........................................................................ 27
GCS Moisture Purge Procedure ........................................................................................................................................ 25
GCS Operational Test........................................................................................................................................................ 17
GCS Test Preparation for TS-4044/D or TS-3860C Test Set.............................................................................................. 6
Test Set Repeat Capability for No-Go............................................................................................................................... 24
Test Records/Documentation................................................................................................................................................. 5
Torque Requirements............................................................................................................................................................. 5
Unpacking.............................................................................................................................................................................. 5
GCS Unpacking from the CNU-300/E Container ............................................................................................................... 5
GCS Unpacking from the CNU-301/E Container ............................................................................................................... 6
List of Illustrations
Title
Page
Access Cover and Probe Sealing Cap ................................................................................................................................. 14
CATM-9M Umbilical Cable Assembly With Captive Flight Adapter ................................................................................ 26
CNU-300/E Container, PN 639AS2880 .......................................................................................................................... 5, 31
CNU-301/E Container, PN 776013-30............................................................................................................................ 7, 33
Fin Cup Assembly and Rocker Arm ................................................................................................................................... 10
GCS Aft End........................................................................................................................................................................ 13
GCS Inspection Areas ........................................................................................................................................................... 9
GCS Test Precaution............................................................................................................................................................ 18
Guidance Control Section...................................................................................................................................................... 4
HRU-985A/E Captive Training Umbilical Cable Assembly .............................................................................................. 27
HRU-985A/E Training Umbilical Cable Connectors P1003 & P1004 ............................................................................... 30
Torque Measurement Assembly Installation ....................................................................................................................... 15
Umbilical Cable and GCS Umbilical Base ......................................................................................................................... 11
Umbilical Base Connector................................................................................................................................................... 30
Umbilical Block Damage .................................................................................................................................................... 10
Umbilical Block with Typical Lock Wire Installation ........................................................................................................ 28
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 3
Drop Criteria.......................................................................................................................................................................... 4
2
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
List of Tables (Continued)
Title
Page
GCS Inspection ......................................................................................................................................................................8
HRU-985A/E Training Umbilical Inspection ......................................................................................................................29
Tools and Equipment .............................................................................................................................................................3
Torque Requirements .............................................................................................................................................................4
Umbilical Base Inspection ...................................................................................................................................................30
WGU-4A/B Test Times .......................................................................................................................................................18
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Alcohol, Isopropyl
TT-I-735
Remove dirt, corrosion, grease
Band, Rubber
ZZ-R-1415
Secure GCS umbilical cable
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface
irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2
Detecting moisture/humidity
Sealant
MIL-A-46146
Umbilical base sealant
Tape
DDD-T-86
GCS packing
Tape
MIL-I-15126 Ty GFT
Cover coolant tank outlet valve
Tube, Fiberboard
PPP-T-495 Type 1, Class 1 Style D
Filler for container space when shipping
containers that are not full
Tubing, Heat Shrink
M23053/5-111-2 (1-1/2 inch dia) or
M23053/5-112-2 (2 inch dia)
Captive flight adapter
Wire, Lock, Aluminum,
0.020-inch diameter
MS20995-AB20
Securing umbilical cable screws, training
umbilical knurled retaining nut
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Coolant Pressure Tank
Removal Tool
Local Manufacture (WP 004 00)
Remove coolant pressure tank
Coolant Pressure Tank
Removal Tool
PN 639AS4510
Remove coolant pressure tank
Failsafe Ohmmeter,
AMPTEC
620A-4
Test igniter circuit of GCS
GCS Fixture Assembly
16ADA27807
Hold GCS
Gun, Heat
HG-210A (120 Volts) or
HG502A (230 Volts)
Heat shrink tubing on umbilical cable
Hygrometer, Digital (Note 1)
TTU-546/E
Test moisture content of coolant tanks
Screwdriver, Torque
MIL-W-26497
Rim clenching clamp
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 01
Table 2. Tools and Equipment (Continued)
Nomenclature
Specification/Part Number
Use
Spanner, Gas Inlet
1298326
Tighten gas inlet
Test Set, TS-3860C
639AS10140
Test GCS
Test Set, TS-4044/D
9281700-10
Test GCS
Wrench, Spanner
639AS2981
GCS coolant inlet probe sealing cap
Wrench, Torque
GGGW686
Nitrogen plug
Note 1: Optional equipment.
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
GCS
Packaged or Unpackaged
Less than 10
Inspect Table 5 and test Paragraph 21.
Packaged or Unpackaged
More than 10
Reject
Table 4. Torque Requirements
Part Number
Nomenclature
Torque Value
2236374
Nitrogen Plug
50 + 10 in-lbs
2878270
Umbilical Cable Breakaway Screws
80 + 8 in-ozs
639AS2710
Rim Clenching Clamp Screw
25 + 1 in-lbs
639AS4722
15-pin Connector Captive Screws
48 ± 8 in-oz
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, Inspection and Testing
Guidance Control Sections (Figure 1). Production
techniques involving preparation of more than one GCS
may require deviations from the work sequence. Several
procedures, may be performed simultaneously, and in
different work areas, provided they do not invalidate or
interfere with a preceding or subsequent step and safety
precautions are strictly observed..
3.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the GCS can cause the
missile to misfire or malfunction. If any doubt exists as to
acceptability of GCS, reject it. Report incident/accident
and notify EOD.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
Figure 1. Guidance Control Section
4
Change 2
CSTO XX21M-AIM9M-2
SWP 006 01
7.
DROPPED GCS PROCESSING.
8. Dropped GCS processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
GCS, reject it. Report dropping incidents in accordance
with AFI 91-204 and AFOSH 91/127 series publications
and notify EOD. Request disposition of dropped
components from WR-ALC, 575 CBSS/GBIA, 460
Richard Ray Blvd, Ste 200, Robins AFB, GA 31098-1813.
9.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. TORQUE REQUIREMENTS.
14. Verify torque wrenches have current calibration
sticker. Tighten all fasteners to torque value given in Table
4.
Figure 2.
CNU-300/E Container, PN 639AS2880
15. EMPTY CONTAINER PROCESSING.
16. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
17. UNPACKING.
18. GCS UNPACKING FROM THE CNU-300/E
CONTAINER.
a.
Inspect container (Figure 2) exterior for damage.
If it is evident that container has been improperly
handled, the GCS shall be inspected Table 5, and
tested Paragraph 21.
b.
Press pressure relief valve, and remove container
cover and cushion.
c.
GCS must not be carried by extractor handle
alone, or damage to GCS dome could occur.
d.
Place container on side. Remove one GCS at a
time from container (two GCSs are normally
shipped in each container) by pulling extractor
handle.
e.
Place GCS on holding fixture and install dome
protector.
f.
Loosen rim clenching clamp and carefully
separate extractor from GCS.
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 01
g.
Remove second GCS from container and repeat
steps e. and f.
forward (within 180O of the center of the GCS) of
any part of the IR dome.
h.
Verify interior packing of container is complete
and undamaged.
a.
i.
Place extractor(s), clamp(s), support insert
tube(s) if removed, and packing in container and
close cover.
j.
Process empty container Paragraph 15.
19. GCS UNPACKING FROM THE CNU-301/E
CONTAINER.
a.
b.
Inspect container (Figure 3) exterior for damage.
If it is evident that container has been improperly
handled, the GCS shall be inspected Table 5, and
tested Paragraph 21.
Press button on pressure relief valve. Release
container latches and place to the down position.
c.
Remove upper section.
d.
Lift front of GCS and remove the support insert
tube.
e.
Remove GCS from container and gently place on
holding fixture.
NOTE
If GCS has HRU-985A/E Training Umbilical
Cable installed, inspect in accordance with Tables
5 and 7. (For Table 7, do not remove cable for
inspection. Inspect items visible with cable
installed unless cable serviceability is suspect.)
b.
Install dome protector.
g.
Remove aft dust cover and place in container.
h.
Repeat steps d through g for remaining GCSs.
i.
Verify interior packing of container is complete
and undamaged.
j.
k.
GCS test not applicable for CATM 180 day
inspection.
20. INSPECTION.
WARNING
Internal overpressure may exist within the GCS
which could rupture the IR dome. Do not stand
6
Change 1
Test GCS Paragraph 21. If the GCS was removed
to facilitate other maintenance on the missile and
no maintenance was performed on the GCS,
testing is not required.
21. TESTING.
22. GCS TEST PREPARATION FOR THE TS-4044/D
OR TS-3860C TEST SET.
a.
Perform test set preparation and self-test in
accordance with TO XX33D9-54-67-1 (TS-4044/
D) or FMS TS3860 series (TS-3860C).
b.
Verify GCS has been inspected in accordance
with Paragraph 20.
Place support insert tube and packing in container
and close cover.
Process empty container Paragraph 15.
Inspect GCS Table 5.
NOTE
c.
f.
Until the AIM-9M GCS has the pop-out relief
valve installed (WP 003 00) conduct visual
inspections of the dome from the side. The
inspection will only consist of verifying the
presence of the dome. This will minimize
exposure to personnel.
NOTE
If GCS has HRU-985A/E Training Umbilical
Cable installed refer to Paragraph 27.
c.
Verify tactical umbilical cable, PN 2603913 or
639AS10935, is installed.
d.
If captive flight adapter is installed, remove as
follows:
CSTO XX21M-AIM9M-2
SWP 006 01
Figure 3. CNU-301/E Container, PN 776013-30
Change 1
7
CSTO XX21M-AIM9M-2
SWP 006 01
Table 5. GCS Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
The minimum required markings for explosive components are part
number, lot number, nomenclature, and date of manufacture.
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 008 01.
8
1
GCS (Figure 4) dome broken, cracked, punctured, or
severely scratched
CRITICAL
Reject
2
GCS mating area cracked or coupling ring groove dented,
cracked, or otherwise damaged so that coupling ring will
not seat properly
CRITICAL
Reject
*3
Foreign material on dome. (Various colorations of dome
do not affect missile performance)
MINOR
Clean SWP 008 01
*4
GCS dome has minor scratches, nicks, or pits
MINOR
Acceptable
5
Dome or dome retaining ring loose or cracked
MAJOR
Reject
6
GCS dome lock ring/dome housing has dents greater than
0.060 inch in depth or gouges greater than 0.025 inch
MAJOR
Reject
7
GCS dome lock ring/dome housing has dents up to 0.060
inch in depth
MINOR
Remove raised metal only using
flat file or 320 grit emery paper
8
GCS dome lock ring/dome housing has gouges up to
0.025 inch in depth
MINOR
Remove raised metal only using
flat file or 320 grit emery paper
9
Gas generator service life expired or cannot be
determined (WP 005 00 Table 1)
MINOR
Reject
10
Absence of, or illegible part number, lot number, date of
manufacturer, or serial number
MINOR
Suspend and hold in condition
code E. Contact (WR-ALC) 575
CBSS/GBIA Robins AFB, GA
31098-1813 for instructions
11
GCS skin cracked or punctured, dents greater than 0.060
inch, or gouges greater than 0.025 inch in depth
MAJOR
Reject
12
GCS skin has gouges up to 0.025 inch, dents up to 0.060
inch in depth, burrs, scratches, or pits penetrating
anodized coating, or corrosion
MINOR
Repair GCS SWP 008 01
*13
GCS skin has dirt or grease
MINOR
Clean SWP 008 01
14
Metal fin cup (Figure 5) missing or loose in GCS housing
MAJOR
Reject
15
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS
housing
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
WGU-4A/B
NOTES:
1. LOCATION OF MARKINGS IS APPROXIMATE.
2. 9M FOR WGU-4A/B. THREE PLACES.
3. WGU-4A/B FOR PN 639AS3963.
Figure 4. GCS Inspection Areas
9
CSTO XX21M-AIM9M-2
SWP 006 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 5. Fin Cup Assembly and Rocker Arm
Figure 5.1. Umbilical Block Damage
Table 5. GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
16
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Reject
17
Fin rocker arm mating area damaged or fin attach hole(s)
in rocker arm(s) worn, stripped, or damaged so as to
prevent good mate of fin
MAJOR
Reject
CAUTION
Rubber fin seal shall not be probed.
18
Rubber fin seal missing, damage affecting environmental
seal
MAJOR
Reject
19
End of rocker arm protrudes above outside surface of fin
cup assembly
MAJOR
Reject
20
Gas grain generator surrounding area shows evidence of
soot caused by gas generator firing (Figure 4)
MAJOR
Test GCS Paragraph 21
21
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws
SWP 008 01
22
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MINOR
Remove damaged adhesive and
apply a small bead of adhesive at
junction
NOTE
Scratches, shallow gouges, or dents in the umbilical block (metal
housing or epoxy) are acceptable.
23
10
Crack in umbilical block (metal housing or epoxy)
Change 1
MAJOR
Replace umbilical SWP 008 01
CSTO XX21M-AIM9M-2
SWP 006 01
Figure 6. Umbilical Cable and GCS Umbilical Base
Table 5. GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
23.1
Top of umbilical block metal housing lip separating from
the epoxy core, Figure 5.1
MAJOR
Repair SWP 008 01
24
Umbilical block spring pin (Figure 6) loose, missing, or
damaged (not applicable to HRU-985A/E)
MAJOR
Replace pin SWP 008 01
Step
Corrective Action
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
25
Umbilical block spring pin not correct length
(not applicable to HRU-985A/E)
MAJOR
Replace pin SWP 008 01
26
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated but gas tubing or wire insulations
are not damaged
MAJOR
Repair cable insulation
SWP 008 01
27
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Replace cable SWP 008 01
28
Loose or damaged breakaway screws, or safety wire
broken or missing
MAJOR
Replace/torque screws, replace
safety wire SWP 008 01
29
Breakaway screws improperly safety wired
MAJOR
Safety wire screws SWP 008 01
30
Missing, loose, damaged, or corroded attaching screws
on umbilical base assembly (Figure 4)
MAJOR
Replace/torque/clean screws
SWP 008 01
31
Missing or loose housing assembly screws
MAJOR
Replace/torque screws
SWP 008 01
32
Missing or loose nitrogen plug
MAJOR
Replace plug SWP 008 01
Change 1
11
CSTO XX21M-AIM9M-2
SWP 006 01
Table 5. GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
33
Burrs or minor surface irregularities on coupling ring
groove or mating surface
MAJOR
Remove raised metal only using
flat file or 320 grit emery cloth
34
Dirt, grease, paint, foreign matter, or corrosion on mating
area and/or coupling ring groove
MINOR
Clean SWP 008 01
35
Umbilical protective cap missing or damaged (Figure 6)
MAJOR
Replace cap SWP 008 01
36
Dirt, grease, or corrosion inside umbilical
protective cap
MAJOR
Clean cap SWP 008 01
37
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 008 01
38
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace performed packing
SWP 008 01
39
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Replace umbilical cable
SWP 008 01
40
Moisture or foreign matter on umbilical connector
MAJOR
Clean SWP 008 01
41
Loose gas inlet fitting in umbilical cable
MINOR
Tighten finger tight using gas
inlet spanner
*42
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent (Figure 6)
MINOR
Replace
43
GCS/TD 9-pin cable assembly (Figure 7) is worn or
damaged to extent cable insulation is damaged
MAJOR
Repair cable SWP 008 01
44
GCS/TD 9-pin cable wire insulation is damaged
(conductor exposed)
MAJOR
Reject
45
GCS/TD 9-pin connector has corroded socket(s), plugged
socket(s) or any other damage that would prevent good
electrical or mechanical mate to TD
MAJOR
Reject
46
Foreign material/moisture present on GCS/TD 9-pin
cable assembly and connector
MAJOR
Clean SWP 008 01
47
GCS/TD 9-pin cable assembly screw(s), nylon retaining
nut(s), or dust cap missing or damaged
MAJOR
Replace screws/nuts /dust cap
SWP 008 01
CAUTION
GCS/TM 15-pin connector when exposed to conductive gas and burnt
gas residue could short out GCS and cause missile failure. (Sealing
cap (Figure 7) must be installed when 15-pin connector is not used.)
12
48
15-pin connector sealing cap loose or missing
MAJOR
Torque captive screws (Table 4)
or replace cap SWP 008 01
49
15-pin connector has corroded socket(s) plugged
socket(s), or other damage that would prevent good
electrical or mechanical mate of TM unit
MAJOR
Reject
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
Table 5. GCS Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
*50
15-pin sealing cap screw(s) broken off in jack screw or
missing
MINOR
Replace jack screw SWP 008 01
51
Loose, missing, or damaged components on coolant tank
access cover (Figure 8)
MAJOR
Replace/repair access cover
SWP 008 01
NOTE
Remove coolant inlet probe cap or coolant pressure tank to inspect
coolant inlet probe and cap (if installed), Paragraph 22.
52
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 008 00
53
Probe sealing cap missing on GCS coolant inlet probe
MAJOR
Replace probe sealing cap
SWP 008 01 (IPB)
54
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap
SWP 008 01 (IPB)
55
Coolant inlet probe area dirty, moisture, corroded, or
other foreign material present
MAJOR
Clean SWP 008 01
NOTE
The red pop-out indicator cannot be reset. The cool down capabilities of the GCS are
not affected. The GCS should remain in use until it is required to be returned to the
depot for another defect which prevents the GCS from functioning as designed.
56
Pop-out indicator actuated (if installed)
MINOR
Acceptable. Defer for depot
repair. See WP 003 00.
57
Pop-out indicator assembly damaged
MAJOR
Reject
Figure 7. GCS Aft End
Change 1
13
CSTO XX21M-AIM9M-2
SWP 006 01
Figure 8. Access Cover and Probe Sealing Cap
(1) To prevent damage to the umbilical cable
carefully cut heat shrink tubing from adapter
and remove tubing.
(2) Remove captive flight adapter.
(3) Remove protective cap from captive flight
adapter and install on umbilical connector.
necessary to retract two pins flush with housing
of spanner wrench if four pins are protruding.
(3) Using spanner wrench, remove probe sealing
cap from GCS coolant inlet probe, if
installed.
(4) Verify coolant inlet probe is free of oil, dirt,
grease, or any other contaminant.
NOTE
For TS-3860C, GCS may be tested with or
without a TMU-72 coolant tank installed. If
TMU-72 coolant tank is to be used continue with
step e. If no coolant tank is required proceed to
step f.
e.
If a serviceable, fully charged coolant tank is
installed proceed to step f. If not, install the GCS
coolant pressure tank as follows:
(1) Verify coolant pressure tank has been
inspected and is fully charged.
(2) Loosen cover screws and remove coolant
tank access cover from GCS.
CAUTION
Failure to use care when installing coolant tank
will result in damage to coolant inlet probe.
(5) Remove and discard tape from coolant
pressure tank. Install and tighten fingertight
using finger lugs on coolant tank.
NOTE
If no release of pressure is heard in step (6), the
coolant inlet probe in the GCS has most likely
been damaged. If so, the GCS may require depot
maintenance.
NOTE
Only two pins of the four pin spanner wrench are
used to remove the probe sealing cap. It may be
14
Change 1
(6) Turn coolant tank counterclockwise enough
to determine if the tank valve assembly is
CSTO XX21M-AIM9M-2
SWP 006 01
B
TOP TORQUE ROD
A
TOP FIN ADAPTER
9-PIN CONNECTOR
RIGHT SIDE FIN ADAPTER
CLAMP
ROTATE
CLAMP HOOK
CLAMP WIRE CONNECTOR
GCS REFERENCE NOTCH
GCS TELEMTRY CONNECTOR
GCS UMBILICAL CONNECTOR
REAR VIEW OF GCS
Figure 9. Torque Measurement Assembly Installation
operating (a release of pressure with an
abrupt cut off should be heard.) Turn coolant
tank clockwise fingertight using finger lugs
on coolant tank.
(7) Ensure leaking can not be heard with the
tank fully installed. If leaking can be heard,
the coolant tank preformed packing should
be changed before the tank is rejected (SWP
008 08).
CAUTION
Failure to use care when installing access cover
will result in damage to coolant tank gauge.
(8) Install coolant pressure tank access cover;
tighten screws until snug.
f.
Install two fin adapters to GCS. When viewed
from the aft end of the GCS, the fin adapters must
be positioned (Figure 9), counterclockwise from
umbilical base with raised (highest) edge
pointing forward.
g.
Remove the protective caps on the GCS 15-pin
and 9-pin connectors.
h.
Perform the following procedures to install GCS
on test set:
(1) Remove blind plug and connect W3 cable to
test set, if required.
(2) Unlatch and open the test set GCS support
assemblies.
CAUTION
Applying power to GCS with the dome protector
installed causes excessive current demand, which
may lead to premature failure of spin bearings in
the seeker assembly.
15
CSTO XX21M-AIM9M-2
SWP 006 01
(2) Position the torque measurement assembly
around the GCS with the torque
measurement assembly decal arrow facing
forward. The torque measurement assembly
housings go over the fin adapters with the
torque measurement assembly torsion rods
to the rear of the fin adapter.
(3) Remove GCS dome cover.
(4) Carefully position the GCS in the support
assemblies with the dome end pointing
toward the IR target simulator. Ensure that
the mounting groove around the aft end of
the GCS mates with the support wheels on
the aft GCS support assembly.
(3) Slide the torque measurement assembly
forward until fin adapters mate with the
torsion rods in the torque measurement
assembly and stop against the raised lip of
the fin adapter.
(5) Adjust the forward GCS support assembly so
the GCS seats firmly.
(6) If required, tighten the screws on the forward
GCS support assembly.
(7) Rotate the GCS counterclockwise until the
GCS telemetry connector (15-pin) is clear of
the test set aft GCS support assembly index
plate.
(4) Connect torque measurement assembly
clamp hooks to wire connector and push
handles down to secure.
j.
Install the servo air adapter on the GCS as
follows:
(8) Mate W3P2 with 15-pin connector.
(9) Mate W3P4 with GCS 9-pin connector.
(10) Remove the protective cap from GCS
umbilical connector.
(11) Mate W3P3 with umbilical connector.
(12) Rotate the GCS so that the GCS reference
notch aligns with the upper guide pin on the
aft GCS support assembly.
(13) Push in and hold the upper guide pin and
align the GCS so the guide pin seats into the
GCS reference notch.
(14) Close and fasten the GCS support assembly
clamps.
(15) Release the guide pin.
i.
Install the torque measurement assembly on the
GCS as follows:
(1) If required, remove dust covers from torsion
rods.
CAUTION
Care shall be used when installing torque
measurement assembly to avoid damage to
umbilical cable assembly.
16
Change 1
(1) Remove nitrogen plug and sealing ring from
GCS air inlet fitting. Inspect for presence
and serviceability of gas filter assembly. If
not in place or unserviceable, replace (SWP
008 01).
(2) Install servo air adapter, PN 757075, on GCS
then tighten finger tight.
(3) Connect push-on connector of pneumatic
hose assembly W7 to servo air adapter
installed in previous step and secure restraint
loop.
(4) Connect the other end of hose assembly to
the OUTLET TO GCS pneumatic connector
and secure restraint loop.
(5) Hold torque measurement assembly and
release fore and aft GCS support assembly
clamps.
(6) Push the lower guide pin in and rotate the
GCS 90 degrees counterclockwise until the
GCS reference notch aligns with the lower
guide pin on the aft GCS support assembly.
(7) Fasten the fore and aft GCS support
assembly clamps.
(8) Release the lower guide pin.
CSTO XX21M-AIM9M-2
SWP 006 01
(9) For TS-3860C, turn on the facility external
SERVO pneumatic pressure.
(6) The PROCEED switch is used to start or
continue testing sequence and to bypass
failed test numbers other than 001 or 002.
NOTE
(7) The STOP switch can be used to stop
automatic test and reset to the beginning.
The test is then restarted at test number 001,
by operating PROCEED switch.
If GCS coolant tank is used, RDU COOLING
GAS switch must be in the INTERNAL position.
(10) For TS-3860C, turn on the external facility
RDU pneumatic pressure source. Verify that
the RDU COOLING GAS switch is in the
EXTERNAL position.
(8) Table 6 contains a complete list of the WGU4A/B test number and test times.
(9) If GCS fails test number 003 see Paragraph
24. The GCS repeat capability is applicable
to GCS tests 4 through 19, 21 through 27,
and steps 50 through 55. For a NO GO
indication, refer to Paragraph 24.
23. GCS OPERATIONAL TEST.
WARNING
Internal overpressure may exist within the GCS
which could rupture the IR dome. Personnel will
not stand forward (within 180O of the center of
the GCS) of any part of the IR dome during GCS
test, Figure 9.1. This will minimize exposure to
personnel.
a.
Review the following GCS operational test
fundamentals prior to conducting test procedures.
(1) Prior to sending a GCS to Depot level repair
for failed test, always question the IR target
simulator (replace), the test set (perform selftest), the coolant tank (replace), and the
umbilical cable (replace).
(2) If LOW PRESSURE indicator lights at any
time and cannot be reset by operating the
PRESSURE RESET switch, the pneumatic
pressure is low and problem must be
corrected (step c.(5)).
(3) WAIT indicator illuminates when a test is in
progress.
(4) GO indicator flashes when each test passes.
(5) NO GO indicator will illuminate and will
stay illuminated when a test fails. Repeat
test. If the failure occurs again, replace
umbilical cable and repeat test.
NOTE
Perform squib resistance test in accordance with
step b.
b.
Perform Squib resistance test using the AMPTEC
620A-4 as follows:
(1) Verify GCS has been properly inspected and
GCS and test set are prepared for test. Place
the CALIBRATE / SELF-TEST / GCS /
RESERVED switch is in the GCS position.
WARNING
Never use a standard multimeter type tester on
igniter circuits. Their operating current exceeds
the minimum amount required to initiate the
igniter circuit. Serious injury or death to
personnel could result.
(2) Verify the failsafe ohmmeter has current
calibration date. Perform 620A-4 preoperational and serviceability check in
accordance with TO 33D5-14-52-1.
(3) If serviceability of ohmmeter is in question,
have it checked by competent authority
(PMEL) prior to use.
(4) Verify test set POWER switch is ON and the
power indicator lamp is illuminated.
Change 2
17
CSTO XX21M-AIM9M-2
SWP 006 01
Table 6. WGU-4A/B Tests Times
Test
No.
Name
Time
(Sec)
Test
No.
Name
Time
(Sec)
001
B- Volt/B+ Current
24
021
System Gain (D-U)
20
002
Gyro Spin Frequency
2
022
System Gain (U-D)
20
003
Cooldown
10-30
023
Crosstalk (D-U)
23
004
Nulling
2
024
Crosstalk (U-D)
23
005
Missile Audio
8
025
Servo Max Torque (U-D)
20
006
AGC
14
026
Servo Disable/Enable
23
008
Rate Bias
24
050
CCM (A)
8
009
Slaving/Seam Reference
14
051
CCM (B)
36
010
Tracking (R-L)
20
052
CCM TA, TB
23
011
Tracking (L-R)
20
053
CCM TC
12
012
Lambda Comp +12
15
054
CCM CV/CT TC
25
013
Lambda Comp +28
18
055
CCM Duty Cycle
28
014
System Gain (R-L)
20
027
Gas Supply
65
015
System Gain (L-R)
20
028
Firing Interlock
2
016
Crosstalk (R-L)
23
029
Launch Lock
1
017
Crosstalk (L-R)
23
030
Missile ID
1
018
Servo Disable/Enable
23
031
UMB/Fuze Continuity
2
019
Servo Max Torque (L-R)
20
032
Early Launch Current
1
020
Rotate
4
099
Test Complete
DANGER AREA
RISK OF INJURY IF DOME
SHOULD BLOW OUT
DO NOT STAND
FORWARD OF THIS LINE
DURING GCS TEST
NOTE: PERSONNEL WILL NOT STAND FORWARD OF THE GCS DURING TEST. A FAILURE OF THE COOLANT SYSTEM COULD
RESULT IN THE DOME BEING BLOWN OUTWARD WITH SUFFICIENT FORCE TO SERIOUSLY INJURY PERSONNEL.
EYE PROTECTION IS RECOMMENDED FOR THE TEST OPERATOR.
Figure 9.1. GCS Test Precaution
18
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
(5) On the front panel of the failsafe ohmmeter
depress the pushbutton nearest to the
POWER switch (20 ohms/8mA position) so
that it remains in the depressed position.
(13) Set the TEST ENABLE/OFF switch to OFF.
(14) Disconnect meter leads.
c.
Deleted
(6) Connect the 620A-4 test leads to the red and
black SQUIB RESISTANCE terminals on
the test set.
(7) Set the SQUIB RESISTANCE TEST
ENABLE/OFF switch to TEST ENABLE. If
the OVERCURRENT indicator lamp does
not illuminate, proceed to step (10) to
continue the test. If the OVERCURRENT
indicator lamp illuminated, perform steps (8)
and (9).
(8) Cycle the TEST ENABLE/OFF switch to
OFF and then to TEST ENABLE. If the
OVERCURRENT light is OFF, proceed to
step (10); otherwise, proceed to step (9).
(9) The illuminated OVERCURRENT lamp
indicates that too much current is being
supplied to the GCS by the ohmmeter. Turn
the TEST ENABLE/OFF switch to OFF, and
replace the ohmmeter and repeat steps (2)
through (9).
(10) On the front panel of the failsafe ohmmeter
place the POWER switch in the ON position
and record the resistance value displayed.
(11) Place the failsafe ohmmeter POWER switch
to the OFF position.
(12) Add the test lead resistance value recorded in
the 620A-4 Zero Offset Check to the
resistance indicated on the test set decal, then
subtract this resistance from the resistance
recorded in step 10. The result is the squib
resistance and shall be 2.5 to 3.5 ohms.
NOTE
If GCS fails squib resistance test, reject GCS,
perform the following:
(a) Rotate the GCS 90° in clockwise
direction until GCS reference notch is
aligned with upper guide pin.
(b) Remove GCS using procedures in step f.
Change 2
19
CSTO XX21M-AIM9M-2
SWP 006 01
(1) The test set has successfully passed self-test.
(2) The GCS is properly installed on the test set.
(3) All cables and hoses are properly connected
and all restraint loops secured.
(4) Test set storage compartments are empty and
vents are fully opened.
(5) The external (for TS-3860C, SERVO)
pneumatic pressure source is applied to the
test set and adjusted for a pressure of 1400 to
1600 psig.
NOTE
For TS-3860C, if GCS coolant tank is used, RDU
COOLING GAS switch must be in the
INTERNAL position.
(6) For TS-3860C, turn on the external facility
RDU pneumatic pressure source. Verify that
the RDU COOLING GAS switch is in the
EXTERNAL position.
e.
Perform the following procedures to test the
GCS:
(1) Verify power indicator lamp is illuminated.
(2) Open test set INLET pneumatic pressure
valve to the fully open position
(counterclockwise).
(3) Verify pneumatic control panel pressure
gauge indicates approximately 1150 ± 100
psig.
(4) Verify that CALIBRATE/SELF-TEST/GCS/
RESERVED switch is in GCS position.
(5) Remove IR target simulator dust cover.
(6) Press and release the STOP push button
switch; WAIT indicator lamp illuminates.
(7) After WAIT indicator lamp goes out, reset
LOW PRESSURE indicator lamp by
actuating RESET PRESSURE switch.
d.
20
Verify that the following procedures have been
completed:
Change 2
(8) Press and hold TARGET DRIVE RELEASE
push button switch and align the index knob
CSTO XX21M-AIM9M-2
SWP 006 01
with the scribed line on the test set. Release
switch to lock IR target simulator in position.
WARNING
Pneumatic pressure applied to the GCS during
test can create a hazard. The optical dome can
shatter or be blown outward and the umbilical
cable can rupture/separate violently during
operational checkout. Do not stand in front of
GCS or in the near vicinity of the umbilical cable
during checkout or serious injury could result.
NOTE
The test set performs a series of mini-self-tests.
When the test set completes the mini-self-test, it
performs a GCS identity check to determine
which type of GCS is mounted. Once the miniself-test is complete, the GCS test proceeds
automatically.
(9) Press and release the PROCEED push button
switch.
NOTE
The null adjustment mechanically aligns the GCS
with the IR source (target) so that the GCS
detects the maximum IR signal (center of target).
(10) After approximately 55 seconds, the GCS
NULL indicator illuminates and the threedigit display indicates a null voltage. If the
three digit display indicates a null voltage of
000, proceed to step (11). If not, adjust the
azimuth and elevation on the IR target
simulator as follows:
NOTE
Adjustment of both azimuth and elevation is
critical to properly align GCS to IR source. Both
steps should be completed in full even though a
000 reading may be obtained during azimuth
adjustment. These steps should be repeated until
the technician is certain that the IR source is
aligned with the GCS.
(a) Adjust azimuth by pressing and holding
the TARGET DRIVE RELEASE push
button switch and move the drive arm R/
L until 000 is displayed or the lowest
possible reading is obtained. Release the
TARGET DRIVE RELEASE push
button.
(b) Do not press TARGET DRIVE
RELEASE. Adjust the elevation by
turning the elevation knob located on
the underside of drive platform under
the IR target simulator. Perform one of
the following two steps.
[1] If 000 is displayed, turn the
elevation knob in either direction
until the display shows the first
reading beyond 000. Next, turn the
elevation wheel in the opposite
direction taking note how far the
wheel is turned. Stop when the first
reading other than 000 is displayed.
Turn elevation knob back half way.
This will accurately null the IR
source for the GCS. This completes
the null.
[2] If display reads other than 000,
adjust elevation knob either
direction until 000 is obtained, then
re-adjust the elevation per step [1]
above. If 000 can not be obtained,
adjust to the lowest reading, and
then re-adjust the azimuth per step
(10a).
(11) Press and release the PROCEED switch. If
the null voltage is acceptable, test continues
and NULL indicator lamp goes out and
remains out. Proceed to step (13). If the null
voltage is unacceptable, the NULL lamp
goes out for approximately 2 seconds and
then illuminates again.
(12) If the null voltage is unacceptable, readjust
IR target simulator to a null display of 000
using procedures of step (10). Press and
release the PROCEED push button switch. If
the null voltage is acceptable, the test
continues; if unacceptable, NO GO is
indicated.
(13) After approximately 3 minutes, providing no
GCS failure occurs, the ROTATE indicator
illuminates.
Change 2
21
CSTO XX21M-AIM9M-2
SWP 006 01
direction until 000 is obtained, then
re-adjust the elevation per step [1]
above. If 000 can not be obtained,
adjust to the lowest reading, and
then re-adjust the azimuth per step
(19a).
(14) Hold torque measurement assembly and
release both fore and aft GCS support
assembly clamps.
(15) Push in and hold upper guide pin and rotate
GCS 90 degrees clockwise. Align GCS so
the guide pin seats into the GCS reference
notch.
(20) Press and release the PROCEED switch. If
the null voltage is acceptable, the remaining
tests will be automatic and NULL indicator
lamp goes out and remains out. Proceed to
step (22). If the null voltage is unacceptable,
the NULL lamp goes out for approximately
2 seconds and then illuminates again.
(16) Fasten the fore and aft GCS support
assembly clamps.
(17) Release upper guide pin.
(18) Press and release PROCEED push button
switch.
(21) If the null voltage is unacceptable, readjust
IR target simulator to a null display of 000,
using procedures of step (19). Press and
release the PROCEED push button switch. If
the null voltage is acceptable, the test
continues; if unacceptable, NO GO is
indicated.
(19) The GCS NULL indicator illuminates and
the three-digit display indicates a null
voltage. If the three-digit display indicates a
null voltage of 000, proceed to step (20). If
not, adjust the azimuth and elevation on the
IR target simulator as follows.
(22) When all tests are completed, the
COMPLETE indicator illuminates and the
three-digit display indicates 099. This
completes the GCS automatic tests.
(a) Adjust azimuth by pressing the
TARGET DRIVE RELEASE push
button switch and move drive arm R/L
until 000 is displayed or the lowest
possible reading is obtained. Release the
TARGET DRIVE RELEASE push
button.
(b) Do not press TARGET DRIVE
RELEASE. Adjust the elevation by
turning the elevation knob located on
the underside of drive platform under
the IR target simulator. Perform one of
the following two steps.
(23) Press STOP push button.
(24) If retest of GCS is required, refer to
Paragraph 24.
f.
Remove GCS from test set as follows:
(1) Remove servo hose W7 from the servo air
adapter.
(2) Remove the servo air adapter from the GCS.
[1] If 000 is displayed, turn the
elevation knob in either direction
until the display shows the first
reading beyond 000. Next, turn the
elevation wheel in the opposite
direction taking note how far the
wheel is turned. Stop when the first
reading other than 000 is displayed.
Turn elevation knob back half way.
This will accurately null the IR
source for the GCS. This completes
the null.
[2] If display reads other than 000,
adjust elevation knob either
22
(3) Inspect for serviceability and install nitrogen
plug (Figure 4) and sealing ring. Torque plug
in accordance with Table 4.
(4) Hold torque measurement assembly, release
torque measurement assembly clamps and
slide the assembly aft until the torsion rods
are clear of the fin adapters.
(5) Remove the torque measurement assembly
and stow it in the torque measurement
assembly storage fixture. Install dust covers
on torsion rods.
CSTO XX21M-AIM9M-2
SWP 006 01
(6) Disconnect umbilical cable connector W3
from the GCS and install umbilical
protective cap.
[2] Position 1-inch square tape over
outlet valve and secure. Do not
reuse tape once applied.
(7) Release forward and aft support clamps and
rotate GCS to allow removal of 15-pin
connector.
(d) If GCS is to be shipped or stored, verify
probe sealing cap is free of
contaminants and preformed packing is
in place, install probe sealing cap
fingertight on GCS coolant inlet probe.
(8) Remove 9-pin and 15-pin connectors.
(e) If GCS is to be placed in service, install
coolant tank Paragraph 22e.
(9) Remove GCS from test set.
(10) Install dome protector on GCS.
(f) Install access cover on GCS, tighten
screws until snug.
(11) Install GCS 9-pin and 15-pin connector
sealing caps. Torque 15-pin screw, Table 4.
g.
(12) Remove the fin adapters from the GCS.
(13) Secure umbilical cable in the stowed
position using a rubber band ZZ-R-1415 or
equivalent.
(14) Remove coolant pressure tank as follows:
(a) Loosen access cover screws and remove
cover from GCS.
WARNING
If a sustained gas venting is heard while
removing coolant pressure tank, tank removal
shall be stopped. Tank shall be allowed to
discharge in place and removed only after
venting ceases.
(b) Use finger lugs on coolant pressure tank
and remove coolant pressure tank. If
unable to remove tank by hand, use
coolant tank removal tool.
(c) Install new sealing tape over coolant
pressure tank outlet valve as follows:
[1] Cut two pieces of tape, one
approximately 1-inch square and
another
approximately
2-inch
square. Center and apply adhesive
side of 1-inch tape to the adhesive
side of the 2-inch tape.
If no additional GCS testing is
accomplished, perform the following:
to
be
(1) Install IR source dust cover.
(2) Depressurize the test set as follows:
(a) Press and release the STOP push button
switch.
(b) Place the test set POWER switch to
OFF.
(c) Close external pneumatic inlet pressure
valve.
(d) Slowly open SAMPLE OUTLET
pneumatic pressure valve and allow test
set to depressurize until GCS
PRESSURE gauge indicates zero psig.
(e) When no further gas escapes and GCS
PRESSURE gauge indicates zero psig,
close SAMPLE OUTLET pneumatic
pressure valve.
(f) Remove pneumatic bleed fixture.
(g) Install SAMPLE OUTLET
disconnect fitting dust cover.
quick-
(h) Close pneumatic inlet pressure valve.
(3) Refer to test set TO to prepare test set for
storage as required.
23
CSTO XX21M-AIM9M-2
SWP 006 01
NOTE
If the GCS is to be used for captive flight training
and a HRU-985A/E Training Umbilical Cable is
to be installed on the GCS proceed to Paragraph
27.
h.
i.
If the GCS is to be used for captive flight
training, install the captive flight adapter
Paragraph 26.
If the GCS is to be used as a tactical asset, install
protective cap:
(1) Connect the protective cap to umbilical and
turn knurled connector on umbilical until it
locks (snaps) in place on the protective cap.
(2) Verify three rivets on protective cap can be
seen through the lock verification ports on
the umbilical connector.
(3) Secure umbilical cable in stowed position
using a rubber band (ZZ-R-1415), retaining
clip or equivalent.
j.
Report GCS test results in accordance with TO
21M-1-101.
24. TEST SET REPEAT CAPABILITY FOR NO-GO.
a.
GCS test may be repeated during a GCS test with
the WAIT light on, a test number displayed, and
the test to be repeated is in process; or when the
NO GO light is on, the test set is stopped (due to
GCS failure of test), and the desired test to be
repeated is displayed and the test set is waiting
for a PROCEED. To exercise the repeat test:
(1) Place the CALIBRATE/SELF-TEST/GCS/
RESERVED switch in the RESERVED
position.
(2) Press and release the PROCEED push
button.
(3) The WGU-4A/B test number and test times
can be found in Table 6.
(4) Once the GCS has a GO indication in the
RESERVED
position
place
the
CALIBRATE/SELF-TEST/GCS/
RESERVED switch in the GCS position and
24
Change 1
press and release the PROCEED push
button.
b.
If a NO GO indication occurs during operational
test, proceed as follows until fault has been
isolated.
(1) Repeat test.
(2) If test fails, perform self-test in accordance
with TO XX33D9-54-67-1 (TS-4044/D) or
FMS TS3860 series (TS-3860C).
(3) If test set fails self-test, reject test set. If no
failure was indicated, proceed to step (4).
(4) Repeat test. If failure occurs again at same
test number, remove umbilical cable
assembly and test (SWP 008 01). If cable
fails test, replace (SWP 008 01) and repeat
operational test. If cable is good, reinstall on
GCS (SWP 008 01). Reject GCS if either test
number 001 or 002 was the failed test
number. If failed test number was 003,
proceed to step (5). Otherwise, proceed to
step (7).
NOTE
A damaged coolant inlet probe may result in step
003 failure. Moisture in coolant gas may also
result in step 003 failure.
(5) If failed test number was 003 remove coolant
tank and inspect the GCS coolant inlet probe
for damage (steps (a) and (b)) then proceed
to step (6), unless GCS is rejected in step (a):
(a) If coolant inlet probe is damaged
reject GCS.
NOTE
Coolant tank testing is optional. The TTU-546/E
Digital Hygrometer will be used for testing.
(b) If undamaged, test coolant tank for
moisture using TTU-546/E Digital
Hygrometer or purge tank, SWP
006 08.
(6) Purge GCS (Paragraph 25) and retest GCS
using a known good coolant tank. If GCS
fails retest, proceed to step (7).
CSTO XX21M-AIM9M-2
SWP 006 01
(7) If three consecutive GCSs fail the same test,
or four GCSs fail consecutively for any test,
calibrate test set and retest failed GCSs.
g.
Verify three rivets on captive flight adapter can
be seen through the lock verification ports on the
umbilical connector.
25. GCS MOISTURE PURGE PROCEDURE. This
procedure may be used on a GCS suspected of moisture
contamination.
h.
Slide shrink tubing over knurled connector at the
umbilical cable end of the captive flight adapter.
Ensure tubing does not interfere with the knurled
connector at the launcher end of the captive flight
adapter.
i.
Heat tubing until tubing shrinks to a tight fit
around the knurled connector at the umbilical end
of the captive flight adapter.
j.
Secure umbilical cable in stowed position using a
rubber band ZZ-R-1415 (or equivalent).
a.
Set the GCS aside for at least 2 hours. This will
allow the detector to warm to ambient
temperature.
b.
After allowing the GCS to set for at least 2 hours
remove the coolant tank.
c.
Inspect GCS coolant tank area for contamination.
Clean if necessary, SWP 008 01.
d.
Install a known good coolant tank filled to 5,000
PSIG.
e.
Retest the GCS.
27. CATM GCS TEST WITH HRU-985A/E
TRAINING UMBILICAL CABLE ASSEMBLY.
NOTE
NOTE
Do not replace the coolant tank before retesting
unless the pressure is below 3,000 PSIG.
f.
g.
If the GCS fails test number 003 set the GCS
aside for minimum of 1 hour then retest.
If the GCS does not pass step 003 after retesting
five times reject the GCS.
26. CAPTIVE FLIGHT ADAPTER INSTALLATION.
a.
Pin 11, 13, 19, 27, 32, and 33 will be missing. If
required, remove plastic inserts from female end
of captive flight adapter. This may be
accomplished using a 0.082 inch bit, drilled to a
depth not to exceed 0.300 inches.
b.
Inspect captive flight adapter (Figure 10) for
damage or corrosion.
c.
Install protective cap on the captive flight
adapter.
d.
Slide a two and one-half inch length of shrink
tubing over the umbilical plug.
e.
Remove protective cap from umbilical.
f.
Connect captive flight adapter to umbilical cable.
Procedure is only for test of CATM GCS being
used with HRU-985A/E training cable (Figure
11).
a.
Remove HRU-985A/E training
accordance with Paragraph 28.
cable
in
b.
Inspect umbilical base, Table 8.
c.
Verify umbilical cable PN 2603913 or
639AS10935 being used for test is serviceable.
d.
Install gasket on umbilical cable, if necessary
CAUTION
Carefully align pins with connectors in GCS base
and press umbilical block straight down to install
training umbilical and prevent damage to
connecting pins. Do not rock umbilical block
side-to-side or fore-and-aft when installing or
removing.
e.
Press umbilical block firmly against gasket and
umbilical base. Install breakaway screws and
tighten fingertight ensuring umbilical block is
fully seated on GCS base. Torque screws (aft
screw first) Table 4. Verify no visible gap
between umbilical block and GCS base
Change 1
25
CSTO XX21M-AIM9M-2
SWP 006 01
26
13
12
25
1
2
17
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
9
ITT CANNON
16
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
1
16
2
3
19
4
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
Figure 10. CATM-9M Umbilical Cable Assembly With Captive Flight Adapter
26
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
Figure 11. HRU-985A/E Captive Training Umbilical Cable Assembly
c.
f.
Test GCS in accordance with Paragraph 21.
g.
Remove umbilical breakaway screws. If screws
break off and cannot be removed with hand tools,
(drilling is not authorized) reject GCS.
h.
Grasping the umbilical block, carefully pull
straight up to remove umbilical cable from GCS.
CAUTION
Carefully remove the umbilical cable from GCS
to prevent damaging the umbilical connecting
pins. Do not rock umbilical block side-to-side or
fore-and-aft when removing, lift straight up.
NOTE
If HRU-985A/E is suspected of being defective,
inspect cable in accordance with step i and also
test in accordance with SWP 008 01.
d.
training
cable
Cut sealant between umbilical block and GCS
base. Do this carefully so the protective coating
on GCS skin is not damaged. Repair protective
coating if damaged.
i.
Inspect HRU-985A/E
accordance with Table 8.
in
j.
Install HRU-985A/E training umbilical cable in
accordance with Paragraph 29.
Lift umbilical block straight up to remove
training umbilical from GCS.
29. CATM TRAINING UMBILICAL CABLE HRU985A/E (PN 2880325) INSTALLATION.
28. CATM TRAINING UMBILICAL CABLE HRU985A/E (PN 2880325) REMOVAL.
a.
Remove safety wire, loosen knurled nut, and
disconnect strap and T-bolt.
b.
Remove lock wire, sealant from umbilical
screws, and umbilical screws. Discard screws if
damaged or excessively worn. If screws break
off and cannot be removed with common tools
then reject GCS.
Sealant, MIL-A-46146
[4]
Alcohol, Isopropyl, TT-I-735
[1]
Change 1
27
CSTO XX21M-AIM9M-2
SWP 006 01
NOTE
j.
When the HRU-985A/E training umbilical is
installed on a CATM GCS, the launcher
umbilical block hooks will not engage umbilical
block pins.
Safety wire so that tension is applied on the
screws should they try to loosen (Figure 12).
k.
Lock safety wire so that loop around the screw
head stays down and does not try to come up over
the head and leave a slack loop.
a.
Verify GCS is serviceable, test or inspect as
necessary.
l.
Pigtail wire end ¼ to ½-inch and bend down or
under to prevent it from becoming a snag.
b.
If required, remove installed tactical umbilical
cable assembly (Paragraph 26).
c.
Inspect GCS umbilical base (Table 7).
m. Apply silicone adhesive, MIL-A-46146, around
base of umbilical to prevent moisture intrusion.
Ensure silicone seals area where strap attaches to
block. Seal heads of attaching screws.
d.
Verify cable is serviceable. Inspect (Table 8) and/
or test (SWP 008 01) if necessary.
f.
If necessary, clean GCS umbilical block and
surrounding area of dirt, grease, or other
contaminates in accordance with SWP 008 01.
Remove old sealant with alcohol to ensure good
bonding surface for new sealant.
g.
Install serviceable umbilical gasket on training
umbilical block connector.
CAUTION
Do not overtighten knurled nut. Excessive
tightening of knurled nut will cause umbilical
block to separate at seam.
CAUTION
Over torque or excessive lateral force may shear
breakaway screws. Do not over torque or exert
excessive lateral force on breakaway screws
when safety wiring. Carefully align pins with
connectors in GCS base and press umbilical
block straight down to install training umbilical
and prevent damage to connecting pins. Do not
rock umbilical block side-to-side or fore-and-aft
when installing.
h.
Press training umbilical block firmly against
gasket and GCS umbilical base, ensuring
umbilical block is fully seated on GCS base.
Install serviceable screws tightening fingertight.
Torque screws using torque screwdriver with
screwdriver bit (aft screw first) in accordance
with Table 4. Verify no visible gap between
umbilical
block
and
GCS
base.
i.
Safety wire screws using aluminum lock wire
(0.020-inch diameter). Apply using double twist
method (Figure 12) as follows:
Figure 12.
Umbilical Block with Typical Lock Wire Installation
28
Change 1
CSTO XX21M-AIM9M-2
SWP 006 01
Table 7. HRU-985A/E Training Umbilical Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
1
Training umbilical other than PN 2880325 (identified by
HRU-985A/E stencil on aft end of umbilical block)
MAJOR
Reject
2
Umbilical protective cap (Figure 11) missing or damaged
MAJOR
Replace cap, SWP 008 01
3
Dirt, grease, or corrosion on inside of umbilical protective
cap
MINOR
Clean SWP 008 01
4
Umbilical protective cap preformed packing missing,
loose, or damaged
MINOR
Replace preformed packing
SWP 008 01
5
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 008 01
4
Damaged insert, plugged, or corroded sockets on umbilical
connector P1003
MAJOR
Reject
5
Moisture or foreign matter on umbilical connector P1003
MAJOR
Clean SWP 008 01
6
Umbilical block has separation on either side from center
of block
MAJOR
Reject
7
Loose gas inlet fitting in umbilical cable connector P1003
MINOR
Tighten fingertight using gas inlet
spanner
8
Umbilical cable insulation separated from cable block or
insulation is damaged to extent cable insulation is
penetrated but gas tubing or wire insulations are not
damaged
MAJOR
Repair SWP 008 01
9
Umbilical cable shows evidence of being crushed, kinked,
or deformed to point the integrity of the wiring is suspect
MAJOR
Test SWP 008 01
10
Umbilical cable block connector pins bent or broken
MAJOR
Reject
11
Moisture or other foreign material present on umbilical
cable block connector pins
MINOR
Clean SWP 008 01
12
Umbilical cable block gas outlet broken
MAJOR
For launcher/missile
combinations using TMU-72 for
gas supply, remove probe so it is
flush with umbilical block. For
launcher/missile combinations
using nitrogen receiver for gas
supply, reject umbilical cable.
13
Umbilical cable block mating area has burrs or damage that
would prevent good mate to GCS
MAJOR
Reject
14
Strap assembly broken or not complete (Figure 11)
MAJOR
Reject
15
Shrinkable insulation sleeving on strap assembly cracked/
deteriorated
MINOR
Replace, SWP 008 01
16
Pin 33 present in P1003, Pins 11 and 33 present in P1004
(Figure 14)
MAJOR
Remove, SWP 008 01, if
approved by command
17
Umbilical block pin loose, missing, or damaged
MAJOR
Reject
29
CSTO XX21M-AIM9M-2
SWP 006 01
Table 8. Umbilical Base Inspection
Step
Inspection
(Inspect for the following defects)
Corrective Action
1
Missing or loose attaching screws on umbilical base
assembly
MAJOR
Replace/tighten SWP 008 01
2
Umbilical base assembly has shearing or breakaway damage
MAJOR
Reject GCS
3
Umbilical base guide pin installed (Figure 13)
MINOR
Remove pin with common
hand tools.
4
Umbilical cable mounting screw hole(s) damaged
MAJOR
Reject GCS
5
Umbilical base connector (Figure 13) has corroded sockets,
plugged sockets, or damage
MAJOR
Reject GCS
6
Umbilical base connector has moisture or foreign material
present
MAJOR
Clean SWP 008 01
7
Umbilical base assembly gas inlet fitting severely corroded
or damaged
MAJOR
Reject GCS
8
Umbilical cable gas outlet fitting sheared off in umbilical
base inlet fitting (Figure 13) and cannot be removed with
common hand tools
MAJOR
Reject GCS
9
Umbilical base assembly mating area has burrs or damage
that would prevent good mate to umbilical cable assembly
MAJOR
Reject GCS
10
Umbilical base assembly has dirt, grease, or foreign material
MAJOR
Clean SWP 008 01
Figure 13.
Umbilical Base Connector
30
Defect
Classification
Figure 14.
HRU-985A/E Training Umbilical Cable Connectors
P1003 & P1004
CSTO XX21M-AIM9M-2
SWP 006 01
n.
Attach strap to T-bolt and gently tighten knurled
retaining nut fingertight until strap is flush
against the GCS skin.
o.
Safety wire knurled retaining nut using aluminum
lock wire (0.020-inch diameter) as follows:
p.
Safety wire using the single fastener application
double-twist method.
q.
Insert wire through hole in knurled retaining nut.
Lock wire to near strap in a manner that tension is
placed on knurled retaining nut should it try to
loosen.
u.
Pigtail end of wire ¼ to ½-inch and bend back to
prevent it from becoming a snag.
r.
Secure umbilical using rubber band ZZ-R-1415
(size No. 64 or equivalent).
30. PACKING.
31. GCS
PACKING
IN
CONTAINER (Figure 15).
THE
CNU-300/E
a.
Ensure tactical umbilical cable and protective cap
is installed on GCS during shipment and storage
to prevent accidental firing of the gas grain
generator.
b.
Ensure umbilical protective cap is installed.
c.
Ensure probe sealing cap is installed.
d.
Verify umbilicals are flat against GCSs. If not,
tape or use rubber band to secure.
h.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container, one in each cavity.
e.
Press pressure relief valve and remove container
cover and top cushion.
i.
If humidity indicator is pink or white, replace.
j.
f.
Install extractor to GCS with rim clenching
clamp. Ensure arrows on rim clenching clamp are
pointing forward (towards GCS), and clamp
screw is in line with umbilical cable. Torque
clamp screw in accordance with Table 4.
Tie one humidity indicator to handle of one
extractor.
k.
Place rear cushion and cover on container. Secure
cover and seal TO 11A-1-60.
g.
Place container on its side, remove dome
protector and place GCS in container making
sure that dunnage (nose support and polyethylene
rear cushion) is in place. Return container to
upright position.
Figure 15.
CNU-300/E Container, PN 639AS2880
32. GCS
PACKING
IN
CONTAINER (Figure 16).
a.
THE
CNU-301/E
Tactical umbilical cable and protective cap shall
be installed on GCS during shipment and storage
to prevent accidental firing of the gas grain
generator.
Change 1
31
CSTO XX21M-AIM9M-2
SWP 006 01
NOTE
When fiberboard tube is not available,
recommend using locally procured carpet or PVC
tubing of the appropriate diameter and cut to
appropriate length.
b.
For special shipment of 1, 2, or 3 GCSs, a
fiberboard tube shall be used to fill the empty
slot(s).
c.
Ensure umbilical protective cap is installed.
d.
Ensure probe sealing cap is installed.
e.
Press button on pressure relief valve and release
the latches and place in the down position.
Remove container cover and top dunnage.
f.
Remove dome protector and install support insert
tube on GCS dome and dust cover on aft end of
each GCS.
g.
If fiberboard tube is placed in empty slot, tape
insert tube on forward end and place dust cover
on other end.
h.
Fasten umbilical connector firmly to body of
GCS using tape or rubber band.
i.
Place two GCSs in lower container cushion (aft
end of GCS on same end as container nameplate).
j.
Position center cushion over GCSs and fit
umbilical cables into slots.
k.
Place two GCSs on center cushion and fit
umbilical cables into slots.
l.
Ensure two 8-unit bags or equivalent of activated
desiccant are in lower section of container.
m. If humidity indicator is pink or white, replace.
32
n.
Place container cover on container.
o.
To ensure proper seal, container latches should be
at approximately 60° angle to the bottom side of
container prior to applying force to close latches.
Secure container latches and seal container TO
11A-1-60.
Change 1
33. CONTAINER MARKINGS.
34. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
CSTO XX21M-AIM9M-2
SWP 006 01
Figure 16. CNU-301/E Container, PN 776013-30
Change 1
33/(34 Blank)
33
CSTO XX21M-AIM9M-2
SWP 006 02
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION AND TEST
FIELD LEVEL MAINTENANCE
TARGET DETECTOR, DSU-15/B, DSU-15A/B, AND DSU-15B/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 18
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-4 . . . . . . . . . . . . . . . . . . . . . . . 2
9-10 . . . . . . . . . . . . . . . . . . . . . . 1
13-16 . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
5. . . . . . . . . . . . . . . . . . . . . . . . . 1
11 . . . . . . . . . . . . . . . . . . . . . . . . 2
17. . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
6-8. . . . . . . . . . . . . . . . . . . . . . . . 2
12 . . . . . . . . . . . . . . . . . . . . . . . . 1
18 blank . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Conventional Munitions Restricted and Suspended ...................................................................................... TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives ........................................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Target Detector, DSU-15/B,
DSU-15A/B, and DSU-15B/B ...........................................................................................................................SWP 008 02
Operation/Maintenance Manual, Amptec Research Model 620A-4
FailSafe Digital Ohmmeter/Igniter Circuit Tester, NSN 6625-01-460-1499AQ......................................TO 33D5-14-52-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
PTS-15 Portable Test Set, Part Number 02400081.......................................................................... CSTO XX33D9-20-13-1
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings .............................................................................................................................................................17
Dropped TD Processing.........................................................................................................................................................4
Empty Container Processing..................................................................................................................................................4
Handling and Test Equipment Preparation ............................................................................................................................4
Incidents/Accidents................................................................................................................................................................4
Inspection...............................................................................................................................................................................4
Change 2
1 of 18
CSTO XX21M-AIM9M-2
SWP 006 02
Table of Contents (Continued)
Title
Page
Packing ................................................................................................................................................................................ 16
Target Detector Packing in the CNU-286/E Container ..................................................................................................... 16
Target Detector Packing in the M548 Container ............................................................................................................... 17
Safety and Accident Prevention ............................................................................................................................................ 4
Sequence of Operations......................................................................................................................................................... 4
Target Detector Squib Test .................................................................................................................................................. 13
Testing ................................................................................................................................................................................. 12
Testing DSU-15 Using PTS-15 Test Set............................................................................................................................ 12
Test Records/Documentation................................................................................................................................................. 4
Unpacking.............................................................................................................................................................................. 4
Target Detector Unpacking from the CNU-286/E or M548 Container ............................................................................... 4
List of Illustrations
Title
Page
Igniter Circuit Tester............................................................................................................................................................ 14
DSU-15 9-Pin Connector .................................................................................................................................................... 15
PTS-15 Portable Test Set PN 02400081.............................................................................................................................. 12
Target Detector ...................................................................................................................................................................... 5
Target Detector Container CNU-286/E, PN 2133808 ........................................................................................................... 5
Target Detector Container M548 (PN 777951-10)................................................................................................................ 5
Target Detector Markings and Inspection Points .................................................................................................................. 7
Target Detector, DSU-15/B, DSU-15A/B, and DSU-15B/B............................................................................................... 10
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 3
Drop Criteria.......................................................................................................................................................................... 3
Target Detector Inspection..................................................................................................................................................... 6
Target Detector Testing........................................................................................................................................................ 12
Tools and Equipment ............................................................................................................................................................. 3
2
Change 2
CSTO XX21M-AIM9M-2
SWP 006 02
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packing components
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface
irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local purchase
Secure humidity card in TD
containers, Securing plastic bag
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Failsafe Ohmmeter, AMPTEC
620A-4
Test DSU-15 squib
PTS-15 Portable Test Set (Note 1)
02400081
Test DSU-15 Target Detector
Note 1: Not all units will be provided a PTS-15. See paragraph on testing.
Table 3. Drop Criteria
Item
Target Detector
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Packaged
Less than 1.5
Inspect Table 4
Packaged
More than 1.5
Reject
Unpackaged
Any height
Reject
Change 2
3
CSTO XX21M-AIM9M-2
SWP 006 02
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, Inspection and Testing
target detectors (Figure 1). Production techniques
involving preparation of more than one TD may require
deviations from the work sequence. Several procedures
may be performed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
3.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
b.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the TD can cause the
missile to misfire, malfunction, or explode. If any doubt
exists as to acceptability of TD, reject it. Report incident/
accident.
15. UNPACKING.
16. TARGET DETECTOR UNPACKING FROM
THE CNU-286/E OR M548 CONTAINER.
a.
8. Dropped TD processing criteria are contained in Table
3. If any doubt exists as to acceptability of dropped TD,
reject it. Report dropping incidents in accordance with
AFI 91-204 and AFOSH 91/127 series publications and
notify EOD. Request disposition of dropped components
from TMTCG, OO-ALC/GHGAMF, 235 Byron Street,
Suite 19A, Robins AFB, GA 31098-1813.
Visually inspect container(s) (Figure 2 or Figure
3) for damage. If it is evident that container has
been improperly handled, inspect TD Paragraph
17.
b.
Release container latches.
9.
TD shall not be carried by its plastic bag.
7.
DROPPED TD PROCESSING.
TEST RECORDS/DOCUMENTATION.
CAUTION
10. Record and report data in accordance with existing
directives when required.
c.
Open container, remove TDs, and place TDs on a
clean workbench.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
d.
Remove plastic bag(s) (when required) and
examine TDs for handling damage.
12. Verify all required handling and test equipment is
available and serviceable.
e.
Verify interior packing of container is complete
and undamaged. Place packing in container and
close cover.
f.
Process empty container Paragraph 13.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
4
Do not remove interior packing unless it is wet or
damaged beyond use.
Change 2
17. INSPECTION.
18. Inspect Target Detector Table 4.
CSTO XX21M-AIM9M-2
SWP 006 02
Figure 1. Target Detector
Figure 2. Target Detector Container
CNU-286/E, PN 2133808
Figure 3. Target Detector Container
M548 (PN 777951-10)
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 02
Table 4. Target Detector Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
All screws will be visually checked for looseness. If a screw appears to
be loose refer to SWP 008 02.
1
TD (Figure 4) mating area cracked or coupling ring grooves
dented, cracked, or otherwise damaged so that coupling ring
will not seat properly
CRITICAL
Reject
2
Coupling ring(s) manufactured with (Cage Code) 00784 with
date of manufacture 1-90 through 12-90 or 1-83 through 1284 stamped on their outer surface
CRITICAL
Replace SWP 008 02
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
SWP 008 02
3
Forward coupling ring assembly cracked or damaged
CRITICAL
Replace coupling ring assembly
SWP 008 02
4
Forward coupling ring screw not PN 639AS1599 REV M or
later or PN 8934242
CRITICAL
Replace coupling ring screw
SWP 008 02
5
Forward coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
SWP 008 02
5.1
Forward coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
SWP 008 02
6
Forward coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 4)
CRITICAL
Replace coupling ring screw
SWP 008 02
7
Forward coupling ring assembly not PN 639AS672
CRITICAL
Replace coupling ring assembly
SWP 008 02
8
Directional arrows on forward TD coupling ring not pointing
forward
CRITICAL
Replace/repair coupling ring
assembly SWP 008 02
9
Forward coupling ring or attaching parts not installed
correctly
CRITICAL
Replace/repair coupling ring
assembly SWP 008 02
2.1
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
6
10
Forward coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace threaded pin
SWP 008 02
11
Aft coupling ring assembly (TD aft end) cracked or damaged
CRITICAL
Replace coupling ring assembly
SWP 008 02
12
Aft coupling ring screw not PN 639AS1599 REV M or later
or PN 8934242
CRITICAL
Replace coupling ring screw
SWP 008 02
13
Aft coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
SWP 008 02
Change 2
CSTO XX21M-AIM9M-2
SWP 006 02
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
DOM
CAGE
CODE
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 4. Target Detector Markings and Inspection Points
Change 2
7
CSTO XX21M-AIM9M-2
SWP 006 02
Table 4. Target Detector Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
13.1
Defect
Classification
Corrective Action
Aft coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
SWP 008 02
14
Aft coupling ring screw PN 639AS1599 Rev N manufactured
by (Cage Code) MC (Figure 4)
CRITICAL
Replace coupling ring screw
SWP 008 02
15
Aft coupling ring assembly not PN 639AS2725
CRITICAL
Replace/repair coupling ring
assembly SWP 008 02
16
Directional arrows on aft coupling ring not pointing toward
warhead
CRITICAL
Replace/repair coupling ring
assembly SWP 008 02
17
Aft coupling ring or attaching parts not installed correctly
CRITICAL
Replace/repair coupling ring
assembly SWP 008 02
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
18
Aft coupling ring threaded pin not stamped with heat treat
marking
19
TD has been removed from a GCS whose gas grain generator
has been fired
CRITICAL
MAJOR
Replace threaded pin
SWP 008 02
Reject
NOTE
Some TDs may have Warranty Expiration Date in lieu of Date of
Manufacture on the Identification Plate. If so, the Date of Manufacture
is three years prior to Warranty Expiration Date. For TDs that have
been to depot, use the recertified/life cycle maintenance date as the
date of manufacture.
8
20
Absence of, or illegible part number, date of manufacture, or
serial number (Figures 4, 5)
MAJOR
Suspend and hold in condition
code J. Contact TMTCG, OOALC/GHGAMF Robins AFB,
GA 31098-1813 for instructions
*21
External identification markings missing or illegible
(Figures 4, 5)
MINOR
Replace markings SWP 008 02
22
Corroded exterior surface between coupling rings
MAJOR
Clean SWP 008 02
23
Corroded area adjacent to coupling ring
MAJOR
Clean SWP 008 02
24
Exterior surface pits greater than 0.060 inch in depth
MAJOR
Reject
25
Exterior surface dents greater than 0.025 inch in depth
MAJOR
Reject
26
Exterior surface gouges greater than 0.060 inch in depth
MAJOR
Reject
*27
Exterior surface scratches
MINOR
Acceptable
28
Exterior surface cracks or punctures
MAJOR
Reject
*29
TD mating surface(s) with scratches, dents, pits, burrs or
gouges present that do not prevent proper mating
MINOR
Acceptable
30
TD mating surface(s) with burrs or gouges present that
prevent proper mating
MAJOR
Reject
Change 2
CSTO XX21M-AIM9M-2
SWP 006 02
Table 4. Target Detector Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
31
Forward and aft coupling ring grooves for corrosion, dirt,
grease, or other matter present
MAJOR
Clean SWP 008 02
32
Burrs or minor surface irregularities on forward and aft
coupling ring grooves
MAJOR
Remove raised metal only using
flat file or 320 grit emery cloth
NOTE
Slight degradation of the anti-reflective coating on the window(s) that
resembles water spots is acceptable.
33
TD window(s) cracked, broken, missing, loose, or
condensation on inside of window
MAJOR
Reject
34
TD window scratches greater than 0.5 inch in length
MAJOR
Reject
*35
TD window(s) for cleanliness
MINOR
Clean SWP 008 02
36
Loose objects seen through window(s) or rattling noises
inside TD
MAJOR
Reject
37
Forward coupling ring or attaching parts corroded
MAJOR
Clean/replace SWP 008 02
38
Coupling ring(s) has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers less than
2% of entire surface (2% of entire surface is approximately
an area 0.25 inches long across the entire width of the
coupling ring)
MINOR
Clean and apply MIL-C-85054
39
Coupling ring(s) has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring(s)
SWP 008 02
39.1
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 008 02. Inspect for
cracks. If brown spots, specks,
or discoloration cannot be
removed replace coupling ring
SWP 008 02
40
Forward pin (indexing) is loose, missing, damaged, or
corroded
MAJOR
Replace pin SWP 008 02
Forward pin (indexing) protrudes above inner surface of
housing
MAJOR
Replace pin SWP 008 02
41
Forward pin (indexing) touching coupling ring screw
MINOR
Repair SWP 008 02
42
Preformed packing located forward end of TD is missing,
nicked, or damaged
MAJOR
Replace preformed packing
SWP 008 02
43
Aft coupling ring assembly guide pin (Figure 4) sheared off
in TD and unable to remove with common hand tools
MAJOR
Reject
44
Aft coupling ring or attaching parts corroded
MAJOR
Clean/replace SWP 008 02
45
Aft coupling ring has burrs, gouges, scratches, dents, or pits
present that penetrate surface finish
MAJOR
Replace coupling ring assembly
SWP 008 02
46
Damaged, bent, or broken pins on 9-pin connector
MAJOR
Reject
40.1
Change 1
9
CSTO XX21M-AIM9M-2
SWP 006 02
Figure 5. Target Detector, DSU-15/B, DSU-15A/B, and DSU-15B/B
10
Change 1
CSTO XX21M-AIM9M-2
SWP 006 02
Table 4. Target Detector Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
47
Connector sealing gasket in TD 9-pin connector (Figure 5) is
missing, deformed, or damaged so as to prevent proper
connection of GCS
MAJOR
Reject
48
Corrosion or foreign material in 9-pin connector
MAJOR
Clean SWP 008 02
*49
Dirt, grease, or foreign material around 9-pin connector
MINOR
Clean SWP 008 02
Step
Corrective Action
NOTE
Steps 48 through 49 apply to TDs, PN 639AS761 and 639AS6080
only. Some TDs, PN 639AS761, do not have communication tube
expanding plug.
50
Tube expanding plug (Figure 5) loose
MINOR
Tighten plug SWP 008 02
51
Tube expanding plug missing or damaged
MAJOR
Replace plug SWP 008 02
52
Evacuation tube not properly sealed, loose, or damaged
MAJOR
Reject
52.1
Solder seal on tip of evacuation tube damaged to the extent
that copper of evacuation tube showing
MAJOR
Reject
53
TD/S-A 6-pin connector loose or has damaged or missing
insert
MAJOR
Reject
54
TD/S-A 6-pin connector has damage, stripped threads, burrs,
or any other condition that would prevent assembly of S-A
device
MAJOR
Reject
55
Dirt, grease or foreign material in or around TD/S-A 6-pin
connector
MAJOR
Clean SWP 008 02
56
TD/S-A 6-pin connector corrosion
MAJOR
Clean SWP 008 02
57
Damaged, bent, or broken pins on TD 20-pin test connector
MAJOR
Reject
58
Dirt, grease, or foreign matter in or around TD 20-pin test
connector
MAJOR
Clean SWP 008 02
59
TD 20-pin test connector corroded
MAJOR
Clean SWP 008 02
*60
TD 20-pin test connector protective cap damaged or missing
MINOR
Replace cap
*61
TD protective cover missing
MINOR
Replace cover
62
Missing panhead screw(s) (4 ea.) Figure 5, on aft end of A/B
or B/B
MAJOR
Reject
63
Loose panhead screw(s) (4 ea.) Figure 5, on aft end of DSU15A/B or DSU-15B/B.
a. If no more than two (2) screws are loose
b. If more than two (2) screws are loose
MAJOR
a. Repair, SWP 008 02
b. Reject
Change 2
11
CSTO XX21M-AIM9M-2
SWP 006 02
19. TESTING.
NOTE
Target detector testing is optional. The PTS-15
test set will be used for testing.
20. The PTS-15 (Figure 6) is a portable test set used for
field level testing of the DSU-15A/B and DSU-15B/B
target detectors only. The DSU-15/B cannot be tested.
21. Test target detector in accordance with Table 5.
22. TESTING DSU-15 USING PTS-15 TEST SET.
23. Test target detectors as follows:
a.
Verify target detector has been inspected, Table 4.
b.
Test target detector using PTS-15 test set. Refer
to CSTO XX33D9-20-13-1 for test set
preparation for use and operating instructions.
c.
Target detectors passing test are serviceable.
d.
Target detectors failing test are unserviceable.
Report failure data in accordance with command
directives.
Figure 6. PTS-15 Portable Test Set PN 02400081
Table 5. Target Detector Testing
WP 005 00 Reference Paragraph
Action
Shipping / Receiving Inspections - All-Up-Round (AUR)
Shipping / Receiving Inspection
Test AOTD of missile selected for GCS test in
TO 11A-1-10 sample inspection.
Shipping / Receiving Inspections - Component Shipping /
Receiving Inspection
Test all AOTDs received from depot or manufacturer.
Test AOTD selected for visual inspection in receiving TO
11A-1-10 sample inspection.
Missile Periodic Inspection - Category Environments
Test AOTD during Category A, B, C and D inspection.
Component Periodic Inspection - Target Detector
Inspection
Test AOTD selected for visual inspection in storage TO
11A-1-10 sample inspection.
Special Inspection - Missile Misfire Or Hangfire
Inspection
Test AOTD as part of the missile misfire or hangfire
inspection.
Other Inspections - Pre-issue Inspection
Test a replacement AOTD prior to assembly on tactical
missile.
Note 1: Those paragraphs listed in the ‘WP 005 00 Reference Paragraph’ column are in WP 005 00. When a visual
inspection of the DSU-15 is required in the paragraph also test the DSU-15 using the PTS-15 test set. ‘Action’
column provides specific test guidance for each paragraph.
Note 2: These recommendations for testing may be modified by the command headquarters.
12
Change 1
CSTO XX21M-AIM9M-2
SWP 006 02
24. TARGET DETECTOR SQUIB TEST.
NOTE
The preferred method to determine target
detector serviceability is to test the TD using the
PTS-15 test set.
25. Test DSU-15 target detector squib for serviceability
using procedure in step a or b. If using the AMPTEC
620A-4 use step a. If using the Alinco model 101-5BFG or
Simpson model 4-000ITS use step b.
a.
Perform the target detector battery squib
resistance check using the AMPTEC 620A-4
(Figure 7) as follows:
WARNING
Never use a standard multimeter type tester for
testing squibs. Their operating current exceeds
the minimum amount required to initiate the
squib.
Use of unauthorized testers or failure to follow
procedure could result in activating the TD and
serious injury to personnel. If activated, the lasers
will function (damaging eyes) and the TD case
will become hot.
To minimize risk: Only personnel performing the
task will be in the test area. The TD cover will be
securely installed to cover the TD windows. The
Mk 13 Safe-Arm device will be removed. The
test will be performed at a location separate from
explosive devices and approved by the local
explosives safety office.
If the TD is activated evacuate the area for a
minimum of 15 minutes to allow the battery to
drain (lasers will stop operating). Allow the TD
case to cool before handling.
(1) Verify the Mk 13 Mod 2 Safe and Arm
Device is removed from the target detector.
(2) Verify the target detector cover is securely
installed on the target detector and
completely covers the windows.
pre-operational and serviceability check in
accordance with TO 33D5-14-52-1. If
serviceability of ohmmeter is in question,
have it checked by competent authority
(PMEL) prior to use.
(4) Connect the test leads to the failsafe
ohmmeter.
(5) Short test leads together.
(6) On front panel of failsafe ohmmeter (Figure
7) depress pushbutton nearest to POWER
switch (20 ohms/8mA position) so that it
remains in the depressed position.
(7) Place the POWER switch in the ON position
and record resistance value displayed.
(8) Place the POWER switch in the OFF
position.
(9) Unshort test leads.
(10) Locate the 9-pin connector on the forward
end of the target detector, Figure 8.
(11) Place one test lead on pin 1 of the 9-pin
connector.
(12) Place the other test lead on pin 9 of the 9-pin
connector.
(13) Place the POWER switch to the ON position
and record resistance value displayed.
(14) Place the POWER switch in the OFF
position.
(15) Remove the test leads from the target
detector.
(16) Compute the target detector battery squib
resistance by subtracting the test lead
resistance recorded in step (7) from the
resistance recorded in step (13). Squib
resistance shall be 6.1 to 7.1 ohms. If squib
resistance is out of tolerance the target
detector shall be rejected.
(17) Remove the test leads from the ohmmeter.
(3) Verify the failsafe ohmmeter has a current
calibration
date.
Perform
620A-4
Change 1
13
CSTO XX21M-AIM9M-2
SWP 006 02
OHMS
OFF
FAILSAFE OHMMETER, AMPTEC 620A-4
0
IGNITER CIRCUIT TESTER, MODEL 4-000ITS
OHMS ADD
IGNITER CIRCUIT TESTER, MODEL 101-5BFG
Figure 7. Igniter Circuit Testers
14
Change 1
CSTO XX21M-AIM9M-2
SWP 006 02
Figure 8. DSU-15 9-Pin Connector
WARNING
To minimize risk: Only personnel performing the
task will be in the test area. The TD cover will be
securely installed to cover the TD windows. The
Mk 13 Safe-Arm device will be removed. The
test will be performed at a location separate from
explosive devices and approved by the local
explosives safety office.
Never use a standard multimeter type tester for
testing squibs. Their operating current exceeds
the minimum amount required to initiate the
squib.
If the TD is activated evacuate the area for a
minimum of 15 minutes to allow the battery to
drain (lasers will stop operating). Allow the TD
case to cool before handling.
b.
Perform the target detector battery squib
resistance check using the Alinco model 1015BFG or Simpson model 4-000ITS (Figure 7) as
follows:
Use of unauthorized testers or failure to follow
procedure could result in activating the TD and
serious injury to personnel. If activated, the lasers
will function (damaging eyes) and the TD case
will become hot.
(1) Verify the Mk 13 Mod 2 Safe and Arm
Device is removed from the target detector.
(2) Verify the target detector cover is securely
installed on the target detector and
completely covers the windows.
Change 1
15
CSTO XX21M-AIM9M-2
SWP 006 02
(3) Verify igniter circuit tester, Alinco model
101-5BFG or Simpson model 4-000ITS, has
current calibration date. Perform preoperational and serviceability check in
accordance with TO 33D5-14-20-1 or TO
33D5-14-44-1. If serviceability of tester is in
question, have it checked by competent
authority (PMEL) prior to use.
WARNING
When performing test, do not keep KEY
depressed for more than 3 seconds. Damage
could occur to the target detector.
(13) Press and hold tester KEY. Adjust OHMS
knob to zero meter needle. Release KEY and
record resistance value.
(4) Remove shunt and install test probes.
NOTE
(5) Preset the OHMS dial and OHMS ADD
controls (four OHMS knobs) on the tester to
the 00.00 position.
(14) Compute the target detector battery squib
resistance by subtracting the test lead
resistance recorded in step (8). from the
resistance value recorded in step (13). Squib
resistance shall be 6.1 to 7.1 ohms. If squib
resistance is out of tolerance, the target
detector shall be rejected.
(6) Short test probes of igniter circuit tester to
together.
(15) Remove the test probes from the target
detector.
Controls in parentheses pertain to igniter Circuit
tester Simpson model 4-000ITS.
CAUTION
Until the meter is null, momentarily depress the
operating KEY to prevent violent motion of the
needle and possible damage to the meter.
(16) Remove test probes tester and install shunt
on tester.
26. PACKING.
27. TARGET DETECTOR
CNU-286/E CONTAINER.
PACKING
IN
THE
NOTE
If the meter deflects to the left, add resistance
with the OHMS dial control (OHMS knobs). If
the needle deflects to the right, decrease the
resistance value.
(7) Momentarily depress the operating KEY and
adjust OHMS knob(s) until there is no
needle deflection.
a.
Remove container cover and top cushion.
b.
Ensure protective cover and 20-pin test connector
protective cap are installed on TD.
c.
Place each TD in a static dissipation bag/barrier
material and securely tape plastic bag closed.
CAUTION
(8) Record and retain test lead resistance value.
(9) Unshort test probes of igniter circuit tester.
(10) Locate the 9-pin connector on the forward
end of the target detector, Figure 8.
(11) Attach the negative test lead to pin 1 of the
9-pin connector.
(12) Attach the positive lead to pin 9 of the 9-pin
connector.
16
Change 1
TD shall not be carried by its plastic bag.
d.
Place four TDs in cutouts of body cushioning in
container Figure 2.
e.
Place cover cushioning on top of body
cushioning.
f.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
g.
If humidity indicator is pink or white, replace.
CSTO XX21M-AIM9M-2
SWP 006 02
h.
Tape humidity indicator card to top cushion.
NOTE
29. CONTAINER MARKINGS.
28. Mark container TO 35E20-2-31-2 and TO 11A-1-10.
Barrier materials shall be positioned to prevent
contact between container lid and humidity
indicator card.
i.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container lid.
j.
Place cover on container and secure hasps. Seal
container TO 11A-1-60.
28. TARGET DETECTOR PACKING IN THE M548
CONTAINER.
a.
Ensure protective cover and 20-pin test connector
protective cap are installed on TD.
b.
Open container (Figure 3) and remove all but
bottom cushion.
c.
Place each TD in a static dissipation bag/barrier
material and securely tape closed.
CAUTION
TD shall not be carried by its plastic bag.
d.
Place two TDs in lower cushion and align so that
the coupling ring screws lay in the slot provided.
e.
Install remaining cushions and TDs as in step d.
f.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
g.
If humidity indicator is pink or white, replace.
h.
Tape humidity indicator card to top cushion.
NOTE
Barrier material shall be positioned to prevent
contact between container lid and humidity
indicator card.
i.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container lid (Figure 2).
j.
Secure container cover and seal TO 11A-1-60.
Change 1
17
17/(18 Blank)
CSTO XX21M-AIM9M-2
SWP 006 03
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, AND INSPECTION
FIELD LEVEL MAINTENANCE
SAFETY-ARMING DEVICE, MK 13 MOD 2
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 8
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-6 . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
7. . . . . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
8 . . . . . . . . . . . . . . . . . . . . . . . . .1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Conventional Munitions Restricted and Suspended ...................................................................................... TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives ........................................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Safety-Arming Device, Mk 13 Mod 2.....................................SWP 008 03
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings ...............................................................................................................................................................8
Dropped S-A Device Processing ...........................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................5
Packing...................................................................................................................................................................................7
Safety-Arming Device Packing in the CNU-189/E Container ............................................................................................7
Safety-Arming Device Packing in the M548 Container ......................................................................................................8
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
Safety-Arming Device Unpacking from the CNU-189/E or M548 Container ....................................................................3
Change 1
1 of 8
CSTO XX21M-AIM9M-2
SWP 006 03
List of Illustrations
Title
Page
S-A Device ............................................................................................................................................................................ 3
Safety-Arming Device........................................................................................................................................................... 5
Safety-Arming Device Container CNU-189/E, PN 612AS100 ............................................................................................ 4
Safety-Arming Device Container M548 (PN 777964-10) .................................................................................................... 4
Safety-Arming Device, Mk 13 Mod 2 Markings .................................................................................................................. 6
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Safety-Arming Device Inspection ......................................................................................................................................... 5
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packing components
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local purchase
Secure humidity card in S-A
containers
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
None
Table 3. Drop Criteria
Item
S-A Device
2
Change 1
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Packaged
Less than 10
Inspect Table 4
Packaged
More than 10
Reject
Unpackaged
Any height
Reject
CSTO XX21M-AIM9M-2
SWP 006 03
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of SafetyArming Device (Figure 1). Production techniques
involving preparation of more than one Safety-Arming
device may require deviations from the work sequence.
Several procedures, may be performed simultaneously,
and in different work areas, provided they do not
invalidate or interfere with a preceding or subsequent step
and safety precautions are strictly observed.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
Figure 1. S-A Device
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the S-A device can
cause the missile to misfire, malfunction, or explode. If
any doubt exists as to acceptability of S-A device, reject it.
Report incident/accident and notify EOD.
7.
DROPPED S-A DEVICE PROCESSING.
8. Dropped S-A device processing criteria are contained
in Table 3. If any doubt exists as to acceptability of
dropped S-A device, reject it. Report dropping incidents in
accordance with AFI 91-204 and AFOSH 91/127 series
publications and notify EOD. Request disposition of
dropped components from WR-ALC, 575 CBSS/GBIA,
460 Richard Ray Blvd, Ste 200, Robins AFB, GA 310981813.
9.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directive when required.
15. UNPACKING.
16. SAFETY-ARMING
DEVICE
UNPACKING
FROM THE CNU-189/E OR M548 CONTAINER.
a.
Inspect container (Figures 2 and 3) exterior for
damage. If it is evident that container has been
improperly handled, inspect S-A device
Paragraph 17.
b.
Open container and remove S-A device. Examine
carefully for handling damage. Reject S-A device
if damaged.
c.
Inspect the S-A device (Figure 4) safe-arm
indicator and launch-latch window as follows:
(1) If silver S (bare metal) on green field is fully
visible in safe-arm window, device is safe. If
silver A (bare metal) on red field is visible,
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 03
Figure 2. Safety-Arming Device Container CNU-189/E, PN 612AS100
Figure 3. Safety-Arming Device Container M548 (PN 777964-10)
4
Change 1
CSTO XX21M-AIM9M-2
SWP 006 03
or if no letter is visible in window, stop
operation and notify EOD.
(2) If any red area is visible in launch-latch
window, launch-latch is not properly
engaged and S-A device is unsafe, stop
operation and notify EOD.
d.
Remove protective cap from end of S-A device
and place in container prior to replacing cover.
e.
Verify interior packing of container is complete
and undamaged. Place in container and close
cover.
f.
Process empty container Paragraph 13.
17. INSPECTION.
18. Inspect S-A device Mk 13 Mod 2 Table 4.
Figure 4. Safety-Arming Device
Table 4. Safety-Arming Device Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
1
Unsafe safe-arm or launch-latch indication
CRITICAL
Stop operation and notify EOD
2
Safe-arm and/or launch-latch window(s) cracked,
broken, or loose
CRITICAL
Reject
3
Explosive loaded plug loose or protruding beyond aft
end of S-A device housing
CRITICAL
Reject
4
Moisture on inside of safe-arm and/or launch-latch
window(s)
MAJOR
Reject
5
S-A device not PN 639AS1130
MAJOR
Reject
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 03
Table 4. Safety-Arming Device Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
The minimum required markings for explosive components are: part
number, lot number, nomenclature, and date of manufacture.
Some S-A devices may have Warranty Expiration Date in lieu of Date
of Manufacture on the Identification Plate. If so, the Date of
Manufacture is three years prior to the Warranty Expiration Date.
6
Absence of, or illegible part number, lot number, date of
manufacturer, or serial number (Figure 5)
MAJOR
Suspend and hold in condition
code J. Contact WR-ALC 575
CBSS/GBIA Robins AFB, GA
31098-1813 for instructions
7
Yellow band and/or stencil CH-6 missing
MAJOR
Suspend and hold in condition
code J pending receipt of
information from WR-ALC 575
CBSS/GBIA Robins AFB, GA
31098-1813
*8
Yellow band in need of replacement or touch-up
MINOR
Replace/touch-up SWP 008 03
9
Gasket on forward end of S-A device loose, missing, or
damaged
MAJOR
Replace/repair gasket
SWP 008 03
10
Solder seal on tip of evacuation tube damaged and
copper of evacuation tube showing
MAJOR
Reject
11
Minor corrosion or rust on exterior surface
MINOR
Clean SWP 008 03
*12
Dirt or grease on exterior surface
MINOR
Clean SWP 008 03
13
Severe corrosion or rust on exterior surface
MAJOR
Reject
14
Exterior surface dents greater than 0.006 inch in depth
MAJOR
Reject
15
Exterior surface gouges greater than 0.010 inch in depth
MAJOR
Reject
Figure 5. Safety-Arming Device, Mk 13 Mod 2 Markings
6
Change 1
CSTO XX21M-AIM9M-2
SWP 006 03
Table 4. Safety-Arming Device Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
16
Burrs on exterior surface that prevent smooth entrance
into warhead
MAJOR
Reject
17
Exterior surface pits greater than 0.010 inch in depth
MAJOR
Reject
*18
Exterior surface scratches
MINOR
Acceptable
19
Exterior surface cracks or punctures
MAJOR
Reject
Step
Corrective Action
NOTE
Self-locking nut nylok insert no longer required.
20
Self-locking nut threads have nicks, burrs, or deformed
so as to prevent proper mate to TD
MINOR
Replace self-locking nut
SWP 008 03
*21
Preformed packing missing or damaged
MINOR
Replace preformed packing
SWP 008 03
22
6-pin connector corroded
MAJOR
Clean SWP 008 03
23
Dirt or grease on 6-pin connector
MAJOR
Clean SWP 008 03
24
6-pin connector alignment key damaged or missing
MAJOR
Reject
25
6-pin connector pins loose, missing or damaged
MAJOR
Reject
26
Shock absorber loose, missing, or damaged
MINOR
Replace shock absorber
SWP 008 03
*27
Forward protective dust cap missing
MINOR
Replace dust cap
19. PACKING.
c.
Place one cushion, with cavity side up, in
container.
20. SAFETY-ARMING DEVICE PACKING IN THE
CNU-189/E CONTAINER.
d.
Place four S-A devices in cavities in cushion.
NOTE
e.
Place one cushion, with cavity side down, over
S-A devices.
f.
Repeat steps c through e to build five layers.
Alternate ends of S-A devices for each layer.
g.
Place one spacer plate on top layer.
h.
Place filler pad as required on spacer plate to
ensure a tight pack.
i.
Secure container cover and seal TO 11A-1-60.
Lot numbers used on safety-arming devices may
be repeated on different production runs. In order
to maintain lot number integrity during packing,
ensure items being placed in the same container
have the same manufacturer, lot number, and year
of manufacture.
a.
b.
Open container (Figure 2) and remove filler pads,
spacer plates, and cushions. Leave spacer plate in
bottom of container.
Ensure dust caps are installed.
7
CSTO XX21M-AIM9M-2
SWP 006 03
21. SAFETY-ARMING DEVICE PACKING IN THE
M548 CONTAINER.
f.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
NOTE
g.
If humidity indicator is pink or white, replace.
Lot numbers used on safety-arming devices may
be repeated on different production runs. In order
to maintain lot number integrity during packing,
ensure items being placed in the same container
have the same manufacturer, lot number, and year
of manufacture.
h.
Tape humidity indicator card to top cushion.
a.
Open container (Figure 3) and remove all but
bottom cushion.
b.
Ensure dust caps are installed.
c.
Place four S-A devices in cushion.
d.
Install cushion on S-A devices.
e.
Repeat step c and d for remaining S-A devices.
NOTE
Barrier material shall be positioned to prevent
contact between container lid and humidity
indicator card.
i.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container lid.
j.
Secure container cover and seal TO 11A-1-60.
22. CONTAINER MARKINGS.
23. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
8
Change 1
CSTO XX21M-AIM9M-2
SWP 006 04
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, AND INSPECTION
FIELD LEVEL MAINTENANCE
WARHEAD, WDU-17/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 8
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-7 . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
8 blank. . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Conventional Munitions Restricted and Suspended ...................................................................................... TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Inspection of Reusable Munitions, Containers, and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance With Illustrated Parts Breakdown, Warhead WDU-17/B..............................................................SWP 008 04
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Safety Summary and Accident Prevention ...........................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings ...............................................................................................................................................................7
Dropped Warhead Processing ................................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................4
Packing...................................................................................................................................................................................7
Warhead Packing in the Mk 386 Mod 0 Container..............................................................................................................7
Warhead Packing in the M548 Container ............................................................................................................................7
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
Warhead Unpacking from the Mk 386 or M548 Container .................................................................................................3
Change 1
1 of 8
CSTO XX21M-AIM9M-2
SWP 006 04
List of Illustrations
Title
Page
Warhead ................................................................................................................................................................................. 3
Warhead Container Mk 386 Mod 0, PN 1516431 ................................................................................................................. 4
Warhead Container M548 (PN 777948-10)........................................................................................................................... 4
Warhead Markings and Inspection Points ............................................................................................................................. 5
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Tools and Equipment ............................................................................................................................................................. 2
Warhead Inspection ............................................................................................................................................................... 5
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packing components
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface
irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local purchase
Secure humidity card in warhead
containers
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
None
Table 3. Drop Criteria
Item
Warhead
2
Change 1
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Packaged or Unpackaged
3 or less
Inspect Table 4
Packaged or Unpackaged
More than 3
Reject
CSTO XX21M-AIM9M-2
SWP 006 04
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of the
warhead (Figure 1). Production techniques involving
preparation of more than one warhead may require
deviations from the work sequence. Several procedures
may be performed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
9.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
Figure 1. Warhead
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving collision or dropping
the warhead can cause the warhead to explode. If any
doubt exists as to acceptability of warhead, reject it.
Report incident/accident and notify EOD.
7.
DROPPED WARHEAD PROCESSING.
8. Dropped warhead processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
warhead, reject it. Report dropping incidents in
accordance with AFI 91-204 and AFOSH 91/127 series
publications and notify EOD. Request disposition of
dropped components from WR-ALC, 575 CBSS/GBIA,
460 Richard Ray Blvd, Ste 200, Robins AFB, GA 310981813.
15. UNPACKING.
16. WARHEAD UNPACKING FROM THE MK 386
OR M548 CONTAINER.
a.
Inspect container (Figure 2 and 3) exterior for
damage. If container shows obvious rough
handling damage, inspect warheads Paragraph
17.
b.
Remove warheads from container.
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 04
c.
Verify interior packing of container is complete
and undamaged.
d.
Remove protective caps from ends of warhead
and place in container prior to replacing cover.
e.
Process empty containers Paragraph 13.
17. INSPECTION.
18. Inspect warhead Table 4.
Figure 2. Warhead Container Mk386 Mod 0, PN 1516431
Figure 3. Warhead Container M548 (PN 777948-10)
4
Change 1
CSTO XX21M-AIM9M-2
SWP 006 04
Table 4. Warhead Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
1
Yellow band (Figure 4) or stencil (PBXN-3) missing
CRITICAL
Suspend and hold in condition
code J pending receipt of
information from WR-ALC 575
CBSS/GBIA Robins AFB, GA
31098-1813
2
Exterior surface of warhead cracked or skin penetrated
CRITICAL
Reject
3
Warhead mating area cracked or coupling ring groove
dented, cracked or otherwise damaged so that coupling
ring will not seat properly
CRITICAL
Reject
*4
Yellow band in need of touch-up
MINOR
Paint/touch-up yellow band
SWP 008 04
Figure 4. Warhead Markings and Inspection Points
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 04
Table 4. Warhead Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
The minimum required markings for explosive components are part
number, lot number, nomenclature, and date of manufacture. The filler
lot number is to be used as the warhead lot; the date loaded is
considered the date of manufacture.
6
5
Absence of, or illegible loaded assembly part number,
lot number, date of manufacture, or serial number
MAJOR
Suspend and hold in condition
code J. Contact WR-ALC 575
CBSS/GBIA Robins AFB, GA
31098-1813 for instructions
*6
Exterior surface paint in need of touch-up or replacing
MINOR
Paint/touch-up SWP 008 04
7
Exterior surface corrosion present
MINOR
Clean SWP 008 04
*8
Exterior surface grease or dirt present
MINOR
Clean SWP 008 04
*9
Exterior surface of warhead dented, but skin not
penetrated
MINOR
Acceptable
10
Exterior surface of warhead gouged, but skin not
penetrated
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
and touch-up paint, SWP 008 04
11
Forward end cap of warhead loose, cracked, or not
securely crimped
MAJOR
Reject
12
Forward end cap for corrosion
MAJOR
Clean SWP 008 04
*13
Forward end cap for grease or dirt
MINOR
Clean SWP 008 04
14
Burrs or minor surface irregularities on coupling ring
grooves or mating surface
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
and apply corrosion preventive
compound, SWP 008 04
15
Forward and aft mating areas and coupling ring
grooves, corrosion present
MAJOR
Clean SWP 008 04
*16
Forward and aft mating areas and coupling ring
grooves, grease or dirt present
MINOR
Clean SWP 008 04
*17
Shock absorber present in warhead S-A device cavity
MINOR
Remove with non-sparking tool
18
Corrosion present in warhead S-A device cavity
MINOR
Clean SWP 008 04
*19
Grease or dirt present in warhead S-A device cavity
MINOR
Clean SWP 008 04
*20
Protective aft or forward end cap missing
MINOR
Replace cap
Change 1
CSTO XX21M-AIM9M-2
SWP 006 04
19. PACKING.
b.
Ensure forward and aft protective caps are
installed on warhead.
20. WARHEAD PACKING IN THE MK 386 MOD 0
CONTAINER.
c.
Place warhead in lower cushion.
a.
Remove container cover Figure 2.
d.
Install remaining cushions and warhead.
b.
Ensure forward and aft protective caps are
installed on warhead.
e.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
c.
Place warheads in container. No dunnage is
required.
f.
If humidity indicator is pink or white, replace.
g.
Tape humidity indicator card to top cushion.
d.
Place two 8-unit bags or equivalent of activated
desiccant in container.
e.
Ensure barrier material, approximately 6 inch by
6 inch, is taped to the inside of container cover.
f.
If humidity indicator is pink or white, replace.
g.
Tape humidity indicator card to barrier material.
h.
Secure container cover and seal TO 11A-1-60.
21. WARHEAD
CONTAINER.
PACKING
IN
THE
M548
NOTE
Barrier material shall be positioned to prevent
contact between container lid and humidity
indicator card.
h.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container lid.
i.
Secure container cover and seal TO 11A-1-60.
22. CONTAINER MARKINGS.
23. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
a.
Open container (Figure 3) and remove all but
bottom cushion.
Change 1
7/(8 Blank)7
CSTO XX21M-AIM9M-2
SWP 006 05
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, AND INSPECTION
FIELD LEVEL MAINTENANCE
ROCKET MOTOR, MK 36 MOD 7, MK 36 MOD 8, MK 36 MOD 9,
MK 36 MOD 10, AND MK 36 MOD 11
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 34
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-4 . . . . . . . . . . . . . . . . . . . . . . . 2
8-9 . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . . . . . . . . 2
16-22 . . . . . . . . . . . . . . . . . . . . . 1
29-30 . . . . . . . . . . . . . . . . . . . . . 2
Page No.
Change No.
5-6 . . . . . . . . . . . . . . . . . . . . . . . 1
10-11 . . . . . . . . . . . . . . . . . . . . . 2
14. . . . . . . . . . . . . . . . . . . . . . . . 1
23-26 . . . . . . . . . . . . . . . . . . . . . 2
31-34 . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
7 . . . . . . . . . . . . . . . . . . . . . . . . .2
12 . . . . . . . . . . . . . . . . . . . . . . . . 1
15 . . . . . . . . . . . . . . . . . . . . . . . . 2
27-28 . . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Conventional Munitions Restricted and Suspended ...................................................................................... TO XX11A-1-1
Explosive Safety Standards........................................................................................................................... AFMAN 91-201
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives ........................................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Rocket Motor,
Mk 36 Mod 7, Mk 36 Mod 8, Mk 36 Mod 9, Mk 36 Mod 10, and Mk 36 Mod 11 ..........................................SWP 008 05
Operation/Maintenance Manual, Amptec Research Model 620A-4
FailSafe Digital Ohmmeter/Igniter Circuit Tester, NSN 6625-01-460-1499AQ......................................TO 33D5-14-52-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions
with IPB, Shipping and Storage Containers AIM-9 Series Missiles ........................................................ TO 35E20-2-31-2
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings .............................................................................................................................................................33
Dropped Component Processing ...........................................................................................................................................4
Empty Container Processing..................................................................................................................................................4
Handling and Test Equipment Preparation ............................................................................................................................4
Incidents/Accidents................................................................................................................................................................4
Change 2
1 of 34
CSTO XX21M-AIM9M-2
SWP 006 05
Table of Contents (Continued)
Title
Page
Inspection .............................................................................................................................................................................. 7
Rocket Motor Igniter Safing Procedure .............................................................................................................................. 8
Safe-Arm Selector Assembly Functional Check (Mk 36 Mod 8/9) .................................................................................... 8
Safe-Arm Selector Assembly Functional Check (Mk 36 Mod 10/11) ................................................................................ 8
Safe-Arm Selector Handle Spring Pin Inspection (Mod 10/11).......................................................................................... 9
Packing ................................................................................................................................................................................ 31
Rocket Motor Packing in the CNU-289/E Container........................................................................................................ 33
Rocket Motor Packing in the Mk 287 or Mk 37 Container............................................................................................... 31
Rocket Motor Test Procedures ............................................................................................................................................ 22
Mk 36 Mod 7, Firing Circuit Readiness Test .................................................................................................................... 22
Mk 36 Mod 7, Igniter Squib Resistance Test (AMPTEC 620A-4) ................................................................................... 28
Mk 36 Mod 8/9/10/11 Initiator Test (AMPTEC 620A-4) ................................................................................................. 30
Safety and Accident Prevention ............................................................................................................................................ 4
Sequence of Operations......................................................................................................................................................... 4
Test Records/Documentation................................................................................................................................................. 4
Unpacking.............................................................................................................................................................................. 4
Rocket Motor Unpacking from the CNU-289/E Container ................................................................................................ 5
Rocket Motor Unpacking from the Mk 287 Mod 0 or Mk 37 Mod 0 Container ................................................................ 4
List of Illustrations
Title
Page
AN/DSM-98(V) Test Set with Adapters ............................................................................................................................. 23
Center and Aft Hanger Inspection....................................................................................................................................... 20
Forward Hanger Assembly.................................................................................................................................................. 17
Igniter Circuit Tester............................................................................................................................................................ 25
Mk 36 Mod 7 Initiator and Radio Interference Filter (RIF) Assemblies ............................................................................ 27
Mk 36 Mod 8/910/11 Safe-Arm Selector in Safe Position.................................................................................................. 22
Rocket Motor......................................................................................................................................................................... 4
Rocket Motor Aft End ......................................................................................................................................................... 21
Rocket Motor Center and Aft Hangers................................................................................................................................ 18
Rocket Motor Container CNU-289/E, PN 776013-10 .................................................................................................... 7, 34
Rocket Motor Container Mk 287 (PN 1516486) or Mk 37, PN 1516261....................................................................... 5, 31
Rocket Motor Inspection ..................................................................................................................................................... 16
Rocket Motor Inspection (Forward End) ............................................................................................................................ 13
Rocket Motor Mk 36 Mod 7, 8, 9, 10, and 11 Markings..................................................................................................... 12
Rocket Motor MK 36 Mod 8/9/10/11 Safe-Arm Assembly in Armed and Safe Positions ................................................. 14
Rocket Motor Safe-Arm Selector Handle Spring Pin Test (Mod 10/11)............................................................................... 9
Safe-Arm Selector Assembly, Rocket Motor Mk 36 Mod 8/9 and Mk 36 Mod 10/11 ................................................... 6, 32
Wing Rib Inspection ............................................................................................................................................................ 21
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 3
Drop Criteria.......................................................................................................................................................................... 3
Rocket Motor Inspection ..................................................................................................................................................... 10
Tools and Equipment ............................................................................................................................................................. 3
2
Change 2
CSTO XX21M-AIM9M-2
SWP 006 05
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Strapping, Steel 5/8 inch
QQ-S-781
Securing wooden boxes
Tube, Fiberboard
PPP-T-495, Type I, Class I, Style D
Filler for container space when shipping containers
that are not full
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Assembly Stand
68D35756-10
Holds missile/components during inspection
Extractor Assembly,
Hanger Screw
SA497576
Remove forward hanger screws
Extractor, Screw
SA497569
Remove forward hanger screws
Failsafe Ohmmeter,
AMPTEC
620A-4
Squib resistance testing
Gauge, Depth
643J
Measure scratches, wear, pits, gouges or dents on
critical surfaces
Gauge, Spring Pin
639AS10059
Safe-Arm selector handle spring pin test
Glass, Magnifier
GG-M-95
Inspecting for cracks
Stand, Assembly, Guided
Missile
68D35756-10
Supports rocket motor during maintenance
Tester, Squib
TS-2835/AN/DSM-98 (V)
Mk 36 Mod 7 firing circuit readiness test
Table 3. Drop Criteria
Item
Rocket Motor
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Packaged or Unpackaged
Less than 1.5
Inspect Table 4
Packaged or Unpackaged
More than 1.5
Reject
Change 2
3
CSTO XX21M-AIM9M-2
SWP 006 05
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of rocket
motors Figure 1. Production techniques involving
preparation of more than one rocket motor may require
deviations from the work sequence. Several procedures
may be preformed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
3.
DROPPED COMPONENT PROCESSING.
8. Dropped component processing criteria are contained
in Table 3. If any doubt exists as to acceptability of
dropped rocket motor, reject it. Report dropping incidents
in accordance with AFI 91-204 and AFOSH 91/127 series
publications and notify EOD. Request disposition of
dropped components from TMTCG, OO-ALC/GHGAMF,
235 Byron Street, Suite 19A, Robins AFB, GA 310981813.
9.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
INCIDENTS/ACCIDENTS.
6. Incidents/accident involving the rocket motor can
cause the missile to misfire, malfunction, or explode. If
any doubt exists as to acceptability of rocket motor, reject
it. Report incident/accident and notify EOD.
7.
If packing is wet, remove and allow packing and
container to dry.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
b.
15. UNPACKING.
16. ROCKET MOTOR UNPACKING FROM THE
MK 287 MOD 0 OR MK 37 MOD 0 CONTAINER.
a.
Visually inspect container (Figure 2) for damage
and verify at least one metal strap is in place. If
container shows obvious rough handling damage,
reject rocket motor.
WARNING
The Mk 36 rocket motor is thin-skinned and the
propellant grain can be easily cracked which may
cause rocket motor blowup at launch. Two
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
4
Do not remove interior packing unless it is wet or
damaged beyond use.
Change 2
Figure 1. Rocket Motor
CSTO XX21M-AIM9M-2
SWP 006 05
persons are required to remove rocket motor from
container.
b.
Cut and remove metal straps securing cover.
Remove cover.
c.
Visually inspect interior of container and external
surface of rocket motor for damage. Reject rocket
motor if visible handling damage is present.
d.
Remove rocket motor from container and place
on assembly stand. Secure with tie-down strap.
e.
Ground rocket motor from a wing rib to an
approved ground. Do not attach ground clip in
area of etched serial number on wing rib.
f.
Verify rocket motor safe-arm selector handle
Mod 8/9/10/11 is locked in the SAFE position
(Figure 3). If not, place in SAFE position
Paragraph 19.
g.
h.
i.
Figure 2.
Rocket Motor Container
Mk 287 (PN 1516486) or Mk 37, PN 1516261
Verify interior packing of container is complete
and undamaged.
e.
Remove protective caps from ends of rocket
motor and place in container prior to replacing
cover.
Visually inspect external surface of rocket motor
for damage. Reject rocket motor if visible
handling damage is present.
f.
Remove rocket motor from container and place
on assembly stand. Secure with tie-down strap.
g.
Ground rocket motor from a wing rib to an
approved ground. Do not attach ground clip in
area of etched serial number on wing rib.
h.
Verify rocket motor safe-arm selector handle
Mod 8/9/10/11 is locked in the SAFE position
(Figure 3). If not, place in SAFE position
Paragraph 19.
Process empty container Paragraph 13.
17. ROCKET MOTOR UNPACKING FROM THE
CNU-289/E CONTAINER.
a.
Visually inspect container (Figure 4) for damage.
If container shows obvious rough handling
damage, reject rocket motors.
b.
Press button on pressure relief valve and remove
security lead seals.
i.
Repeat steps e through h for remaining rocket
motors.
Release container latches and remove upper
section.
j.
Verify interior packing of container is complete
and undamaged.
k.
Remove protective caps from ends of rocket
motors and place in container prior to replacing
cover.
l.
Process empty container Paragraph 13.
c.
d.
Remove top layer of dunnage.
WARNING
The Mk 36 rocket motor is thin-skinned and the
propellant grain can be easily cracked which may
cause rocket motor blowup at launch. Two
persons are required to remove rocket motor from
container.
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 05
Mod 10/11
KEY REMOVAL SLOT
LOCKING LEVER
SAFE POSITION
KEY CANNOT BE REMOVED IN THE SAFE POSITION.
THE KEY PIN IS NOT ALIGNED WITH THE REMOVAL SLOT
AND THE LOCKING LEVER’S LOBE IS POSITIONED IN THE
SAFE HOLE.
SAFE HOLE
LOCKING LEVER
KEY REMOVAL SLOT
KEY PIN
SAFE HOLE
ARM POSITION
THE KEY PIN IS ALIGNED WITH THE REMOVAL SLOT AND
KEY MAY BE REMOVED IN THE ARMED POSITION.
Mod 8/9
Figure 3. Safe-Arm Selector Assembly, Rocket Motor Mk 36 Mod 8/9 and Mk 36 Mod 10/11
6
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
MOD 8/9/10/11
SAFE-ARM
KEY SLOT
Figure 4. Rocket Motor Container CNU-289/E, PN 776013-10
18. INSPECTION.
c.
For new rocket motors only, install a wing on
each wing rib to verify fit, WP 008 00.
d.
Test rocket motor:
NOTE
The safe-arm selector functional check may be
performed prior to missile disassembly or after
missile assembly, if rocket motor is part of an
AUR, Missile, Stubby, or Special Inspection, WP
005 00.
a.
Inspect rocket motor Table 4.
b.
Perform rocket motor safe-arm selector
functional check, Paragraph 20 or Paragraph 21.
(1) Test Mod 7 IAW Paragraphs 23, 24, and 27.
(2) Test Mod 8/9/0/11 IAW Paragraphs 23 and
31.
Change 2
7
CSTO XX21M-AIM9M-2
SWP 006 05
19. ROCKET
MOTOR
IGNITER
SAFING
PROCEDURE. To place the igniter in the SAFE position:
perform step a for Mod 10/11 or step b for Mod 8/9.
CAUTION
If binding occurs when attempting to turn the
Safe-Arm handle to the SAFE position stop.
Warhead installation may be necessary to prevent
binding of a serviceable mechanism, or the
mechanism may be unserviceable. Proceed to
Paragraph 20 for Mod 10/11 or Paragraph 21 for
Mod 8/9.
a.
b.
Mod 10/11, pull handle to unlock and move to the
vertical position, maintain pull pressure. Rotate
handle 90 degrees clockwise and move to
horizontal position. Release pull pressure to lock
in SAFE position. Install safety clip assembly.
Mod 8/9, insert key, push in, and while
maintaining pressure rotate handle 90 degrees
clockwise then release pressure to lock in SAFE
position. Move key to horizontal position.
20. SAFE-ARM
SELECTOR
ASSEMBLY
FUNCTIONAL CHECK (MK 36 MOD 10/11).
CAUTION
f.
Release pull pressure to lock in ARM position.
g.
Pull handle to unlock and move to vertical
position, maintain pull pressure.
h.
Rotate handle 90 degrees clockwise and move to
horizontal position.
i.
Release pull pressure to lock in SAFE position.
j.
Repeat steps d through i a minimum of two more
times.
k.
Unlock, lift up, and rotate Safe-Arm selector
assembly handle to the ARM position. Move to
horizontal position and release pressure to lock in
ARM position.
l.
Unlock, lift up, and release Safe-Arm selector
handle. Ensure the handle returns unassisted to
the SAFE position within 3 seconds. If the SafeArm selector fails to operate freely, replace SafeArm assembly, SWP 008 05.
m. Lock in SAFE position.
n.
Install safety clip assembly.
o.
Remove warhead, WP 008 00 or 009 00.
21. SAFE-ARM SELECTOR ASSEMBLY
FUNCTIONAL CHECK (MK 36 MOD 8/9).
A tactical or inert warhead shall be installed to
bring the igniter plate into alignment with the
arming rod. Failure to do so may cause binding of
the Safe-Arm selector assembly.
CAUTION
a.
Ground rocket motor.
b.
Install warhead, WP 008 00 or 009 00.
A tactical or inert warhead shall be installed to
bring the igniter plate into alignment with the
arming rod. Failure to do so may cause binding
of the Safe-Arm selector assembly.
c.
Remove safety clip assembly, Figure 3.
a.
Ground rocket motor.
NOTE
b.
Install warhead WP 008 00 or 009 00.
NOTE
Verify mechanism movement is smooth (no
sticking or binding), inspect/repair, SWP 008 05.
d.
Pull handle to unlock and move to vertical
position, maintain pull pressure.
Verify mechanism movement is smooth (no
sticking or binding), inspect/repair, SWP 008 05.
c.
e.
8
Rotate handle 90 degrees counterclockwise and
move to horizontal position.
Change 1
Push in Safe-Arm selector key, rotate 90 degrees
counterclockwise to ARM, and remove key. If
key cannot be removed, return key to SAFE and
CSTO XX21M-AIM9M-2
SWP 006 05
proceed to SWP 008 05 for repair, otherwise
continue with step d.
d.
Safe-Arm selector remains in ARM position
(locking lever lobe moves outward and is locked
in key removal slot, Figure 3) then proceed to
step e. If Safe-Arm selector rotates back to SAFE
position go to SWP 008 05 for repair.
e.
Inspect arming key pin, Figure 3. If arming key
pin is bent or otherwise damaged repair pin or
replace key SWP 008 05. Continue to step f.
f.
Install Safe-Arm selector key. Push in and rotate
key 90 degrees clockwise to SAFE. Release
pressure. Locking lever lobe shall be locked in
the safe hole.
g.
Repeat steps c through f a minimum of two more
times.
h.
Remove warhead, WP 008 00 or 009 00.
22. SAFE-ARM SELECTOR HANDLE SPRING PIN
INSPECTION (MOD 10/11).
a.
Ensure selector is in the SAFE position.
b.
Remove safety clip assembly.
c.
Using the spring pin inspection gauge place the
tip of the gauge on one end of the spring pin
(Figure 5) and slowly push against the end of the
pin until 30 pounds (the “green” line on the shaft
is flush with the end of the tool body) has been
achieved. Hold the 30 pound load for
approximately 5 seconds.
d.
After application of the 30 pound load, inspect
the ends of the spring pin to determine if it has
moved.
e.
If the spring has not moved, repeat step c by
pushing on the other end of the spring pin, hold
the 30 pound load for approximately 5 seconds.
f.
If the spring pin has moved under either load it
must be replaced SWP 008 05.
g.
Install safety clip assembly.
Figure 5. Rocket Motor Safe-Arm Selector Handle Spring Pin Test (Mod 10/11)
Change 1
9
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 008 05.
WARNING
Verify Safe-Arm Selector Assembly is PN 639AS10032. Use of other
than PN 639AS10032 on the Mod 10/11 could place the rocket motor
igniter in the ARMED position when the selector handle is locked in
the SAFE position
1
For Mod 10/11 only, verify safe and arm arming rod is
not in the ARMED position with safe-arm selector
handle locked in the SAFE position. When the indicator
arrow on the igniter assembly points to A on the arming
rod the igniter assembly is ARMED, Figure 8)
CRITICAL
Replace Safe-Arm Selector
Assembly SWP 00 05
1.1
Verify safe-arm selector handle is locked in the SAFE
position (for Mod 8, 9, 10, 11 only), Figure 3
CRITICAL
Place rocket motor safe-arm
selector handle in SAFE position,
Paragraph 19.
2
Absence of brown band (Figure 6)
CRITICAL
Suspend and hold in condition
Code J. Contact TMTCG, OOALC/GHGAMF Robins AFB, GA
31098-1813 for instructions
3
Rocket motor non-propulsive head closure displaced or
damaged (Figure 7)
CRITICAL
Reject
4
Rocket motor mating area cracked or coupling ring
groove dented, cracked or otherwise damaged so that
coupling ring will not seat properly
CRITICAL
Reject
5
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace SWP 008 05
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
SWP 008 05
6
Coupling ring assembly not PN 639AS2725 (Figure 7)
not properly orientated, has missing parts, corroded,
damaged, or no longer serviceable
CRITICAL
Replace coupling ring assembly
SWP 008 05
7
Coupling ring screw not PN 639AS1599 Rev M or later
or 8934242
CRITICAL
Replace coupling ring screw
SWP 008 05
8
Coupling ring screw PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
SWP 008 05
5.1
10
Change 2
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Step
8.1
9
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
Coupling ring screw PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
SWP 008 05
Coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 7)
CRITICAL
Replace coupling ring screw
SWP 008 05
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
10
Coupling ring threaded pin not stamped with heat treat
marking
CRITICAL
Replace threaded pin SWP 008 05
11
Punctures, skin penetration by cracks or gouges on the
rocket motor
CRITICAL
Reject
NOTE
Several thousand MK 36 rocket motors (serial number prefixes,
MKW, PAB, PYM) have been fielded that were suspect of having
critical defects. Most have been inspected and marked “AWB 222
ACCEPTED.” See TO 11A -1-1 to determine serviceability.
12
Rocket motors with serial numbers MKW 0004405234, PAB 00001-01606, and PYM 00496-00702 that
are suspended by TO XX11A-1-1 shall not be used.
CRITICAL
Reject
NOTE
Steps 13 through 18 apply to Mk 36 Mod 7 (Figure 7).
13
RIF shield plate screws loose
MAJOR
Torque screws SWP 008 05
14
RIF shield plate missing
MAJOR
Replace shield plate SWP 008 05
15
RIF assembly corroded
MAJOR
Reject
16
Sealing compound on RIF assembly terminals
improperly applied, damaged, or deteriorated to where
moisture intrusion is possible
MAJOR
Replace compound SWP 008 05
17
RIF assembly has gouges, dents, cracks, or punctures
MAJOR
Reject
18
Gap in silicone rubber shielding gasket (if present)
installed under RIF assembly
MAJOR
Reject
NOTE
Steps 19 through 29 do not apply to Mk 36 Mod 7.
19
Initiator leads (Figure 7) not spot-tied or properly
positioned to prevent crimping during assembly
MAJOR
Spot tie leads SWP 008 05
20
Positive (red) lead connector loose
MAJOR
Push male and female connectors
together. (Ensure a tight fit; if not,
reject rocket motor)
Change 2
11
CSTO XX21M-AIM9M-2
SWP 006 05
NOTES:
1.
LOCATIONS OF DECALS AND MARKINGS ARE
APPROXIMATE. CHECK POSITION REFERENCE IS:
HANGERS IN UP POSITION, STAND IN FRONT OF
ROCKET MOTOR.
8.
DECAL (TIGHTEN WING SCREWS TO 100 ± 5 INCHPOUNDS) 1/2 INCH FORWARD OF AFT END OF
ROCKET MOTOR AT 3 O'CLOCK AND 9 O'CLOCK
POSITIONS.
2.
DECAL (TIGHTEN COUPLING RING SCREW TO 100 ± 5
INCH-POUNDS) AT 3 O'CLOCK AND 9 O'CLOCK
POSITIONS.
9.
IDENTIFICATION DECAL 15-7/8 INCHES AFT AT 3
O'CLOCK POSITION.
3.
DECAL (MOD 7) (TIGHTEN COUPLING RING SCREW TO
100 ± 5 INCH-POUNDS) AT 2 O'CLOCK AND 10 O'CLOCK
POSITIONS.
4.
BROWN BAND (MOD 7) (PAINT OR A-A-1689 TAPE)
APPROXIMATELY 2 INCHES WIDE 4 1/2-INCHES AFT
OF FORWARD END OF ROCKET MOTOR PN
639AS2890.
5.
BROWN BAND (MOD 8, 9, 10, 11) (PAINT OR A-A-1689
TAPE) APPROXIMATELY 2-INCHES WIDE 11-12 INCHES
AFT OF FORWARD END OF ROCKET MOTOR.
6.
DECALS (DO NOT ROLL, TUMBLE, OR DROP) 1 INCH
AFT OF IDENTIFICATION DECAL AT 3 O'CLOCK AND 9
O'CLOCK POSITIONS.
7.
DECAL (WARNING, DO NOT REMOVE, ADJUST OR
OTHERWISE TAMPER WITH HANGERS) 6 INCHES
FROM AFT END OF ROCKET MOTOR AT 3 O'CLOCK
AND 9 O'CLOCK POSITIONS.
10. ROCKET MOTOR P/N 639AS2890, CENTER OF
GRAVITY DECAL AT 9 O'CLOCK POSITION AND 20
INCHES AFT OF FORWARD END OF ROCKET MOTOR.
11. ROCKET MOTOR PN 639AS4992, PN 639AS4993, PN
1204AS100 AND PN 639AS4600 CENTER OF GRAVITY
DECAL AT 9 O'CLOCK POSITION AND 19-1/4 INCHES
AFT OF FORWARD END OF ROCKET MOTOR.
12. SAFE-ARM DECAL INSTALLED SO THAT THE SAFE
AND ARM CENTER ON THE RETAINING PLATE.
13. MOD 11 DIFFERENCE IS WORD MOD 11 AND PN IS
639AS4993. MOD 8 DIFFERENCE IS WORD MOD 8 AND
PN IS 1204AS100. MOD 9 DIFFERENCE IS WORD MOD
9 AND PN IS 639AS4600.
14. IN THE ABSENCE OF DECALS STENCIL/SPRAY PAINT
AS REQUIRED IN 1/4-INCH MINIMUM CHARACTERS.
Figure 6. Rocket Motor Mk 36 Mod 7, 8, 9, 10, and 11 Markings
12
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
MK36 MOD 7
DETAIL A
MK36 MOD 8/9/10/11
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 7. Rocket Motor Inspection (Forward End)
Change 2
13
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Finger pressure must be applied to ground terminal lugs when
checking security of ground screw.
21
Ground lead attaching screw loose or missing
MAJOR
Replace/torque SWP 008 05
22
Wire insulation damage or bare wire showing
MAJOR
Reject
23
Safe-Arm selector retaining plate forward screw
protrudes through inside of rocket motor case (no
tolerance allowed)
MAJOR
Replace SWP 008 05
24
Constant force spring attaching screw loose or missing
MAJOR
Reject
25
Constant force spring damaged or missing
MAJOR
Reject
26
Threaded holes not filled with silicone
MINOR
Fill holes with silicone
SWP 008 05
27
Safe-Arm assembly initiator loose or damaged
MAJOR
Reject
28
Rocket motor safe-arm selector assembly attachment
screws loose, assembly damaged, or missing
MAJOR
Replace assembly, replace/torque
screws SWP 008 05
29
Mod 10/11 Safe-Arm handle spring pin fails inspection
(Paragraph 22)
MAJOR
Replace pin SWP 008 05
Figure 8. Rocket Motor MK 36 Mod 8/9/10/11 Safe-Arm Assembly in Armed and Safe Positions
14
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
30
Retaining ring damaged or has missing teeth
(nine required)
MAJOR
Replace ring SWP 008 05
31
Guide plate pin sheared off in rocket motor and unable
to remove with common hand tools
MAJOR
Reject
*32
Paint cracked or peeling
MINOR
Paint SWP 008 05
33
Dirt or grease on exterior surfaces of rocket motor
MINOR
Clean SWP 008 05
34
Corrosion on exterior surfaces of rocket motor
MINOR
Clean SWP 008 05
35
Absence of, or illegible, decals (Figure 6)
MAJOR
Replace SWP 008 05
NOTE
The minimum required markings for explosive components are: part
number, lot number, nomenclature, and date of manufacture.
36
Absence of, or illegible, part number, lot number, date
of manufacture, or serial number (Figure 6)
MAJOR
Suspend and hold in condition
code J. Contact TMTCG, OOALC/GHGAMF Robins AFB, GA
31098-1813 for instructions.
37
Brown band deteriorated and in need of replacement
MINOR
Replace band SWP 008 05
NOTE
Steps 38 through 43 apply to the exterior surface of the rocket motor
(aft of coupling ring groove) between stations 0.269 and 1.880 and
between 68.725 and 70.905 (Figure 9).
38
Pits greater than 0.030-inch deep
MAJOR
Reject
39
Pitted area over one square inch and pits more than
0.015-inch deep
MAJOR
Reject
40
Gouges up to 0.030-inch deep by 0.045-inch wide by
0.075-inch long
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
and touch-up paint SWP 008 05
41
Gouges over 0.030-inch deep by 0.045-inch wide by
0.075-inch long
MAJOR
Reject
42
Dents over 0.030-inch in depth or 0.092-inch in
diameter
MAJOR
Reject
43
Burrs or scratches
MAJOR
Remove raised metal only with
flat file or 320 grit emery cloth
and touch-up paint SWP 008 05
NOTE
Step 44 applies to the exterior surface of the rocket motor (aft of
coupling ring groove and between station 2.235 and 68.725, Figure 9).
44
Burrs or scratches
MAJOR
Remove raised metal only with
flat file or 320 grit emery cloth
and touch-up paint SWP 008 05
Change 2
15
CSTO XX21M-AIM9M-2
SWP 006 05
Figure 9. Rocket Motor Inspection
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
WARNING
Touching of the contact buttons in the rocket motor forward hanger
could cause rocket motor ignition. All personnel handling rocket
motor shall make bare skin-to-metal contact with rocket motor wing
rib or ground wire.
45
Forward hanger protective cover damaged or missing
MINOR
Replace cover
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
16
46
Forward hanger (Figure 10) screws/bolts loose,
damaged, or missing
MAJOR
Replace screws/bolts SWP 008 05
47
Forward hanger or hanger screws/bolts corroded to the
extent corrosion cannot be removed
MAJOR
Replace SWP 008 05
48
Forward hanger mating surfaces and stress points for
cracks (Figure 10)
MAJOR
Replace SWP 008 05
49
Top of forward hanger mating surface for snubber wear
in excess of 0.015 inch in depth, rear of hanger for
detent wear in excess of 0.030, or forward detent lug
wear area is rounded over all the way across the area
between the two arrows (Figure 10).
MAJOR
Replace SWP 008 05
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
WARNING
Cleaning or repairing of contact buttons shall not be attempted. Minor
amounts of dirt, grease, or corrosion on contact buttons will not affect
missile firing.
50
Contact button(s) have severe corrosion damage, not
flush, or below hanger
MAJOR
Replace SWP 008 05
51
Contact button insulator missing
MAJOR
Replace SWP 008 05
WARNING
Use depth gauge PN 643J to measure damage to forward hanger
contact buttons, and all hanger surfaces. Prior to taking measurements
on the forward hanger/contact buttons verify missile is grounded,
Safe-Arm selector handle is in SAFE position, and make bare skin-tometal contact with rocket motor wing rib or ground wire.
52
Aft contact button cut, scratched, or gouged greater than
0.030-inches deep
MAJOR
Replace SWP 008 05
53
Forward hanger non-mating surface for dents greater
than 0.045-inches deep or 0.075-inches in diameter
MAJOR
Replace SWP 008 05
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 10. Forward Hanger Assembly
Change 1
17
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
54
Forward hanger non-mating surface for gouges greater
than 0.045-inches deep by 0.064-inches wide by 0.075inches long
MAJOR
Replace SWP 008 05
55
Forward hanger non-mating surfaces for cracks
MAJOR
Replace SWP 008 05
Step
Corrective Action
NOTE
Steps 56 through 62 apply to the center and aft hanger (Figure 11, area X).
56
Mating surfaces for dents greater than 0.015-inch deep
by 0.030-inch in diameter
MAJOR
Reject
57
Mating surface for gouges greater than 0.015-inch deep
by 0.030-inch in diameter
MAJOR
Reject
58
Non-mating surfaces for pitted areas greater than 0.060
square inch in diameter and 0.032-inch deep
MAJOR
Reject
59
Non-mating surfaces for dents greater than 0.032-inch
deep or 0.064-inch in diameter
MAJOR
Reject
60
Non-mating surfaces for gouges greater than 0.045-inch
deep or 0.064-inch wide or 0.075-inch long
MAJOR
Reject
Figure 11. Rocket Motor Center and Aft Hangers
18
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
61
Non-mating surface for cracks
MAJOR
Reject
62
Mating surface for cracks
MAJOR
Reject
NOTE
Steps 63 through 67 apply to the center and aft hanger non-mating
surfaces (area Y, Figure 11).
63
Pits greater than 0.020 square inch and 0.015-inch deep
MAJOR
Reject
64
Dents greater than 0.020-inch deep or 0.050-inch
diameter
MAJOR
Reject
*65
Burrs or scratches
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
66
Cracks
MAJOR
Reject
67
Gouges greater than 0.020-inch deep or 0.032-inch
wide or 0.064-inch long
MAJOR
Reject
CAUTION
No hanger maintenance/repairs are authorized except for those
specified in the Corrective Action column.
68
Center/aft hangers for visible gap between hanger strap
and rocket motor mating surfaces
MAJOR
Reject
69
Center hanger loose
MAJOR
Reject
69.1
Center hanger threaded pins (Figure 12 center hanger
Views A and B) loose, damaged, or missing
MAJOR
Reject
69.2
Center hanger shims (Figure 12 center hanger View B)
loose or missing
MAJOR
Reject
69.3
Center hanger band screw(s) (Figure 12 center hanger
View C) loose, damaged, or missing
MAJOR
Reject
Aft hanger loose
MAJOR
Reject
70.1
Aft hanger band screw(s) (Figure 12 aft hanger View A)
loose, damaged, or missing
MAJOR
Reject
71
Wing ribs (Figure 13) deformed, cracked, corroded, or
other damage that prevents proper wing installation
MAJOR
Reject
72
Rocket motor (Mod 7/8/10) weather seal (Figure 14)
missing, punctured, or bulged out
MAJOR
Reject
73
Tamper seal (Mod 9/11) bulged out, missing, or
punctured (Figure 14)
MAJOR
Reject
74
Nozzle (Mod 7/8/10) cracks, gouges, or delaminations
MAJOR
Reject
70
Change 1
19
CSTO XX21M-AIM9M-2
SWP 006 05
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
75
Burrs or scratches on support ring
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
76
Support ring dents greater than 0.045-inch deep or
0.064-inch in diameter
MAJOR
Reject
*77
Corrosion preventive compound missing
MINOR
SWP 008 05
78
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
less than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
79
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
greater than 2% of entire surface (2% of entire surface
is approximately an area 0.25 inches long across the
entire width of the coupling ring)
MAJOR
Replace coupling ring
SWP 008 05
80
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 008 05. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 008 05
Figure 12. Center and Aft Hanger Inspection
20
Corrective Action
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
Figure 13. Wing Rib Inspection
MOD 9 / 11 ONLY
Figure 14. Rocket Motor Aft End
Change 1
21
CSTO XX21M-AIM9M-2
SWP 006 05
23. ROCKET MOTOR TEST PROCEDURES.
WARNING
WARNING
Prior to making contact with any part of rocket
motor, personnel shall be at the same electrical
potential as the rocket motor. Static electricity
could cause rocket motor ignition.
Rocket motor to be tested will be placed behind a
shield/barricade of sufficient strength to provide
maximum practical safety to personnel and
equipment in accordance with DODD 6055.9STD,
AFMAN
91-201,
MIL-STD-398
publications. Test area and procedures will be
designed so that no person is exposed to the
explosive component at the time of checkout.
Long test leads and remote control features shall
be utilized.
a.
d.
Personnel shall be grounded using wrist-stat
connected to the same ground as the rocket
motor. (Other grounding methods may be used
when approved by safety).
24. MK 36 MOD 7, FIRING CIRCUIT READINESS
TEST.
Ensure rocket motor Safe-Arm selector handle
Mod 8/9/10/11 is locked in the SAFE position
(Figure 15). If not, place in SAFE position,
Paragraph 19.
a.
Comply with Paragraph 23.
NOTE
b.
Ensure rocket motor is grounded at wing
attaching screw or wing rib. Do not attach to area
with serial number etched on the wing rib.
Only the AN/DSM-98(V) test set (Figure 16)
shall be used for conducting continuity test
through the RIF.
c.
Place rocket motor on assembly stand with
hangers UP.
b.
Verify test set is functioning properly and has
current calibration date.
LOCKING LEVER LOBE
POSITIONED IN SAFE HOLE
ARM
SAFE
SAFETY CLIP
INSTALLED
Mod 8/9
Mod 10/11
Figure 15. Mk 36 Mod 8/910/11 Safe-Arm Selector in Safe Position
22
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
INPUT
J1
J2
B
GOOD
A
D
A
D
B
TEST COVER
QUALITY
THE TEST SET, ELECTRICAL CIRCUIT, GUIDED
MISSILE AN/DSM-98(V) CONSISTS OF THE
FOLLOWING ITEMS CONTAINED IN CASE AND
COVER CY-6662/DSM98(V)
1. TEST SET, ELECTRICAL CKT.
TS-2835/DSM98(V)
68A42D10
2. TEST LEAD ASSEMBLY
68A42C8
3. SQUIB ADAPTER
68A42C30
4. SIDEWINDER ADAPTER OR
68A42C40
CHAPARRAL ADAPTER
68A42C50
5. BATTERY, 1.3 VOLT 1 REQD.
BA-1328/U
6. KEY, SOCKET HEAD SCREW
68A42A74
7. HANDBOOK
NAVAIR 16-30DSM98-1
TEST
CAL
TEST SET FACEPLATE
NOTE: Part number 68A42C40 has been replaced
by part number SA639AS11754
POSITIVE
TEST LEAD
CONNECTION
TEST SET INVENTORY LIST
STOP PINS
TEST LEAD
CONNECTION
FW
D
GN
D
GROUND (NEGATIVE)
TEST LEAD CONNECTION
3.33 IN.
APPROX.
SQUIB ADAPTER
MISSILE ADAPTER
Figure 16. AN/DSM-98(V) Test Set with Adapters
Change 2
23
CSTO XX21M-AIM9M-2
SWP 006 05
retest. If meter still indicates in BAD area, reject
rocket motor.
WARNING
1.
Never use a standard multimeter type tester on
igniter circuits. Their operating current exceeds
the minimum amount required to initiate the
igniter circuit. Serious injury or death to
personnel could result.
c.
d.
Short remote test leads together at ends to be
connected to TS-2835/DSM-98(V).
Connect positive remote test lead to positive (+)
connector of missile adapter.
m. Remove missile adapter from motor hanger by
lifting spring-loaded positive test lead connection
and sliding adapter off hanger before releasing
the spring loaded connector. Reinstall forward
hanger protective cover.
n.
Remove test lead assembly W1 from missile
adapter and remote test leads.
o.
Proceed to Paragraph 27 (to test using the
AMPTEC 620A-4).
e.
Connect negative remote test lead to GND
connector of missile adapter.
f.
Remove forward hanger protective cover, and
install missile adapter (with the arrow on the
adapter pointing toward the forward end of rocket
motor) on motor forward hanger by lifting
spring-loaded positive test lead connector (Figure
16) and sliding adapter on to hanger until stops
contact the hanger. Positive test lead connector
must make good contact with aft contact button.
25. Deleted.
g.
From within protective test area, disconnect
remote test leads shorted together in step c.
26. Deleted.
h.
Connect remote positive test lead (step d) to
binding post J2 on AN/DSM-98(V) test set panel.
i.
Connect remote negative test lead (step e) to
binding post J1 on AN/DSM-98(V) test set panel.
j.
Depress CAL switch on TS-2835/DSM-98(V)
and adjust CAL control to obtain center scale
indication on QUALITY meter.
NOTE
A reading in the BAD area (right side of scale)
indicates a short within the RIF or associated
circuitry or a shorted diode. A reading in the
BAD area (left side of scale) indicates an open
fire circuit; recheck all connections for good
electrical connection.
k.
24
Disconnect remote test leads from test set and
short together.
Depress TEST switch. QUALITY meter should
indicate in GOOD area. If meter indicates in
BAD area, repeat steps b thru k checking all
connections for good electrical connections and
Change 2
CSTO XX21M-AIM9M-2
SWP 006 05
OHMS
OFF
FAILSAFE OHMMETER, AMPTEC 620A-4
IGNITER CIRCUIT TESTER, MODEL 4-000ITS- Deleted
IGNITER CIRCUIT TESTER, MODEL 101-5BFG- Deleted
Figure 17. Igniter Circuit Tester
Change 2
25
CSTO XX21M-AIM9M-2
SWP 006 05
All information on this page has been deleted.
26
Change 2
CSTO XX21M-AIM9M-2
SWP 006 05
POSITIVE LEAD
WIRE (RED)
CERAMIC INSULATED
TERMINAL
LEAD WIRE NUTS
RIF ASSEMBLY
SHIELDING PLATE
SIDE
VIEW
NEGATIVE LEAD
WIRE (BLACK)
SEALING
COMPOUND
LOCATION OF RIF
ASSEMBLY GASKET
IF PRESENT
FORWARD HEAD
CLOSURE
IGNITER SQUIB
HEXAGON FLANGE
INSULATOR
IGNITER POST
ANNULAR GASKET
RIF LEAD WIRE
IGNITER NUT
SEALING COMPOUND
SHORTING WASHER
CERAMIC INSULATOR
TERMINAL (+)
SEALING COMPOUND
RETAINING RING
RIF SHIELDING PLATE
TERMINAL (-)
END
VIEW
MACHINE SCREWS
COUPLING RING
ASSEMBLY
PN 639AS2725
Figure 18. Mk 36 Mod 7 Initiator and Radio Interference Filter (RIF) Assemblies
Change 1
27
CSTO XX21M-AIM9M-2
SWP 006 05
27. MK 36 MOD 7, IGNITER SQUIB RESISTANCE
TEST (AMPTEC 620A-4).
Compound, Sealing, Thread Locking
MIL-S-46163, Type II, Grade N
Comply with Paragraph 23.
WARNING
Never use a standard multimeter type tester on
igniter circuits. Their operating current exceeds
the minimum amount required to initiate the
igniter circuit. Serious injury or death could
result.
b.
j.
Install squib adapter on RIF assembly by
compressing spring clip on adapter and inserting
adapter into hole in RIF housing.
k.
Turn connecting post screws on the squib adapter
until point penetrates epoxy coating and makes
good contact with squib terminal stud (Figure
18).
l.
Attach one remote test lead to positive (+)
connector of missile adapter.
Verify the failsafe ohmmeter has current
calibration date. Perform 620A-4 pre-operational
and serviceability check in accordance with TO
33D5-14-52-1. If serviceability of ohmmeter is in
question, have it checked by competent authority
(PMEL) prior to use.
m. Attach other remote test lead to GND connector
of missile adapter.
n.
From within protective area, disconnect remote
leads shorted together in step h and connect
remote test leads to alligator clip test leads.
o.
Place the POWER switch to the ON position and
record resistance value displayed.
p.
Place the POWER switch in the OFF position.
NOTE
If proper resistance is not obtained in step q,
check missile adapter ground contact.
q.
Compute igniter squib circuit resistance by
subtracting reading obtained in step f from the
reading obtained in step o. Squib resistance shall
be 0.5 to 0.9 ohms.
r.
Remove remote leads from the ohmmeter and
short them together.
c.
Short the remote ends of the remote test leads
together.
d.
Connect the other end of the remote test leads to
the alligator clip test leads. Connect the alligator
clip test leads to the failsafe ohmmeter.
s.
e.
On front panel of failsafe ohmmeter (Figure 17)
depress pushbutton nearest to POWER switch
(20 ohms/8mA position) so that it remains in the
depressed position.
Remove squib adapter from RIF assembly by
compressing spring clip and pulling adapter from
hole.
t.
Remove remote test leads from squib adapter and
forward hanger.
Place the POWER switch in the ON position and
record resistance value displayed.
u.
Install RIF shielding plate as follows:
f.
28
Remove two screws and RIF shielding plate from
RIF assembly. Discard screws.
[7]
28. The firing circuit readiness test (Paragraph 24),
detects a defective RIF or an open squib. It will not detect
a shorted squib. For a complete test, the squib must be
checked by using the SQUIB adapter (supplied with the
TS-2835/DSM-98(V)) (Figure 16) and the AMPTEC
620A-4 failsafe ohmmeter, Figure 17.
a.
i.
g.
Place the POWER switch in the OFF position.
h.
Remove remote test leads from alligator clip test
leads and short remote test leads together.
Change 1
(1) Place RIF shielding plate over hole in RIF
assembly.
CSTO XX21M-AIM9M-2
SWP 006 05
(2) Coat threads with sealing compound and
insert coated screws into holes through
shielding plate and into RIF assembly.
(3) Torque screws Table 4.
29. Deleted.
30. Deleted.
Change 2
29
CSTO XX21M-AIM9M-2
SWP 006 05
g.
Place the POWER switch in the OFF position.
h.
Remove remote test leads from alligator clip test
leads and short remote test leads together.
i.
Remove forward hanger protective cover. Install
missile adapter (with the arrow pointed toward
the forward end of motor when adapter is
installed on motor forward hanger) by lifting
spring-loaded positive test lead connector (Figure
16) and sliding adapter onto hanger until stops
contact the hanger.
j.
Attach one remote test lead to positive (+)
connector of missile adapter.
k.
Attach other remote test lead to GND connector
of missile adapter.
l.
From within protective area, disconnect remote
leads shorted together in step h and connect
remote test leads to alligator clip test leads.
31. MK 36 MOD 8/9/10/11 INITIATOR TEST
(AMPTEC 620A-4).
32. The igniter squib must be check by using the MISSILE
adapter (supplied with the TS-2835/DSM-98(V)) and the
AMPTEC 620A-4 failsafe ohmmeter.
a.
Comply with Paragraph 23.
WARNING
Never use a standard multimeter type tester on
igniter circuits. Their operating current exceeds
the minimum amount required to initiate the
igniter circuit. Serious injury or death could
result.
b.
c.
Short the remote ends of the remote test leads
together.
d.
Connect the other end of the remote test leads to
the alligator clip test leads. Connect the alligator
clip test leads to the failsafe ohmmeter.
e.
On front panel of failsafe ohmmeter (Figure 17)
depress pushbutton nearest to POWER switch
(20 ohms/8mA position) so that it remains in the
depressed position.
f.
30
Verify the failsafe ohmmeter has current
calibration date. Perform 620A-4 pre-operational
and serviceability check in accordance with TO
33D5-14-52-1. If serviceability of ohmmeter is in
question, have it checked by competent authority
(PMEL) prior to use.
Place the POWER switch in the ON position and
record resistance value displayed.
Change 2
m. Place the POWER switch to the ON position and
record resistance value displayed.
n.
Place the POWER switch in the OFF position.
NOTE
If proper resistance is not obtained in step o,
check missile adapter ground contact.
o.
Compute igniter squib circuit resistance by
subtracting the test lead resistance recorded in
step f from the resistance value recorded in step
m. Squib resistance shall be 0.4 to 0.7 ohm. If
squib resistance is out of tolerance, motor shall
be rejected.
p.
Remove remote leads from the ohmmeter and
short them together.
q.
Remove positive and negative leads from missile
adapter
r.
Remove missile adapter by lifting spring-loaded
positive test lead connector and sliding adapter
off rocket motor hanger. Reinstall forward hanger
protective cover.
CSTO XX21M-AIM9M-2
SWP 006 05
33. PACKING.
WARNING
34. ROCKET MOTOR PACKING IN THE MK 287
OR MK 37 CONTAINER.
a.
Verify rocket motor safe-arm selector handle
Mod 8/9/10/11 is locked in the SAFE position
(Figure 20). If not, place in SAFE position
Paragraph 19.
The Mk 36 rocket motor is thin-skinned and the
propellant grain can be easily cracked which may
cause rocket motor blowup at launch. Two
persons are required to remove rocket motor from
container.
b.
Tighten coupling ring sufficiently to prevent
movement.
f.
c.
Remove container cover.
d.
Ensure forward and aft protective caps are on
rocket motor.
e.
Ensure that forward hanger protective cover is
installed.
Remove grounding strap and place rocket motor
in container (Figure 19), positioning rocket motor
on its side so it does not rest on coupling ring or
hangers. The aft end of the rocket motor shall be
located at the end of the container marked
“AFT”. If required, add filler/blocks to ensure a
tight pack. Secure cover with three 5/8-inch wide
steel straps clinched with strapping tool.
g.
Seal container TO 11A-1-60.
Figure 19.
Rocket Motor Container Mk 287 (PN 1516486) or Mk 37, PN 1516261
Change 1
31
CSTO XX21M-AIM9M-2
SWP 006 05
Mod 10/11
KEY REMOVAL SLOT
LOCKING LEVER
SAFE POSITION
KEY CANNOT BE REMOVED IN THE SAFE POSITION.
THE KEY PIN IS NOT ALIGNED WITH THE REMOVAL SLOT
AND THE LOCKING LEVER’S LOBE IS POSITIONED IN THE
SAFE HOLE.
SAFE HOLE
LOCKING LEVER
KEY REMOVAL SLOT
KEY PIN
SAFE HOLE
ARM POSITION
THE KEY PIN IS ALIGNED WITH THE REMOVAL SLOT AND
KEY MAY BE REMOVED IN THE ARMED POSITION.
Mod 8/9
Figure 20. Safe-Arm Selector Assembly, Rocket Motor Mk 36 Mod 8/9 and Mk 36 Mod 10/11
32
Change 1
CSTO XX21M-AIM9M-2
SWP 006 05
35. ROCKET MOTOR
CNU-289/E CONTAINER.
PACKING
IN
THE
WARNING
NOTE
When fiberboard tube is not available,
recommend using locally procured carpet or PVC
tubing of the appropriate diameter and cut to
appropriate length.
a.
For shipment of 1, 2, or 3 rocket motors, a
fiberboard tube shall be used to fill empty slot.
b.
Verify rocket motor safe-arm selector handle
Mod 8/9/10/11 is locked in the SAFE position
(Figure 20). If not, place in SAFE position
Paragraph 19.
c.
Tighten coupling ring sufficiently to prevent
movement.
d.
Press button on pressure relief valve.
e.
Release the latches and place in the DOWN
position. Remove container cover (Figure 21)
and top dunnage.
f.
Ensure forward and aft protective caps are
installed.
g.
Ensure that forward hanger protective cover is
installed.
h.
Ensure cushions are aligned with markings in
upper and lower sections of container.
The Mk 36 rocket motor is thin-skinned and the
propellant grain can be easily cracked which may
cause rocket motor blowup at launch. Two
persons are required to remove rocket motor from
container.
i.
Remove ground strap and place two rocket
motors in lower section. The aft end of the rocket
motors shall be located at the end of the container
marked AFT.
j.
Install center cushions over rocket motors.
k.
Remove ground strap and place remaining two
rocket motors on center cushions.
l.
Ensure four 8-unit bags or equivalent of activated
desiccant are in lower section of container.
m. If humidity indicator is pink or white, replace.
n.
Place container upper section on lower section.
o.
Secure container cover and install seals, TO 11A1-60.
36. CONTAINER MARKINGS.
37. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
NOTE
Ensure the safe-arm selector is aligned in the slot
provided (except rocket motor Mk 36 Mod 7).
Change 1
33
CSTO XX21M-AIM9M-2
SWP 006 05
MOD 8/9/10/11
SAFE-ARM
KEY SLOT
Figure 21. Rocket Motor Container CNU-289/E, PN 776013-10
34
Change 1
CSTO XX21M-AIM9M-2
SWP 006 06
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, AND INSPECTION
FIELD LEVEL MAINTENANCE
WING ASSEMBLY, GUIDED MISSILE, MK 1 MOD 1 AND MK 1 MOD 2
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 12
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-10 . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
11 . . . . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
12 . . . . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Material Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance With Illustrated Parts Breakdown, Wing Assembly,
Guided Missile, Mk 1 Mod 1 and Mk 1 Mod 2 .................................................................................................SWP 008 06
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Unpacking, Packaging, and Inspection, Fins, BSU-32/B ....................................................................................SWP 006 07
Table of Contents
Title
Page
Cager Release-Pull Test .......................................................................................................................................................10
Container Markings .............................................................................................................................................................12
Dropped Wing Processing .....................................................................................................................................................3
Empty Container Processing..................................................................................................................................................4
Handling and Test Equipment Preparation ............................................................................................................................4
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................4
Packaging.............................................................................................................................................................................12
Wing and Fin Packing in the CNU-283A/E Container. ....................................................................................................12
Wing Packing in CNU-304/E Container...........................................................................................................................12
Rolleron Assembly Functional Test.....................................................................................................................................10
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Change 1
1 of 12
CSTO XX21M-AIM9M-2
SWP 006 06
Table of Contents (Continued)
Title
Page
Unpacking.............................................................................................................................................................................. 4
CNU-283A/E Container Unpacking................................................................................................................................... 4
CNU-304/E Container Unpacking. .................................................................................................................................... 4
Wing Tap Inspection.............................................................................................................................................................. 8
Acceptance/Rejection Criteria............................................................................................................................................ 9
Tap Inspection Limitations. ................................................................................................................................................ 9
Tap Inspection Preparation. ................................................................................................................................................ 9
Tap Inspection Procedures.................................................................................................................................................. 9
List of Illustrations
Title
Page
Container, CNU-283A/E (PN 639AS2702) with Wings and Fins ........................................................................................ 5
Container, Shipping and Storage, CNU-304/E (PN 776013-190) with Wings ..................................................................... 5
Rolleron Assembly .............................................................................................................................................................. 10
Tap Hammer Procedures ....................................................................................................................................................... 9
Wing Cager Release-Pull Test ............................................................................................................................................. 11
Wing Cager Release-Pull Test (Preferred) .......................................................................................................................... 11
Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2 ...................................................................................................... 6
Wing, Mk 1 Mod 2 ................................................................................................................................................................ 3
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 3
Tools and Equipment ............................................................................................................................................................. 2
Wing Inspection..................................................................................................................................................................... 6
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Lubricant, Breakfree
MIL-L-63460
Cager Flag movement lubrication
Tape
Local purchase
Seal containers
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Dial, Push/pull
DPP-80
Cager release-pull test
Scale, Instrument 0-4 pounds
2880186 (Alternate for DPP-80)
Cager release-pull test
2
Change 1
CSTO XX21M-AIM9M-2
SWP 006 06
Table 2. Tools and Equipment (Continued)
Nomenclature
Wing Tapping Tool
Specification/Part Number
Local Manufacture (WP 004 00)
Use
Tap inspection
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Fins
Packaged or Unpackaged
Any Height
SWP 006 07
Wings
Packaged or Unpackaged
Any Height
Inspect and test Paragraph 18
1.
5.
SEQUENCE OF OPERATIONS.
2. The work sequence given in the SWP is provided as a
guide in Unpacking/Packaging, Servicing and Inspection
of the wing (Figure 1). Production techniques involving
preparation of more than one wing may require deviations
from the work sequence. Several procedures may be
performed simultaneously, and in different work areas,
provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the wing can cause the
missile to malfunction. If any doubt exists as to
acceptability of the wing, reject it. Report incident/
accident.
7.
DROPPED WING PROCESSING.
8. Dropped wing processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
wing, reject it. Request disposition of dropped components
from WR-ALC, 575 CBSS/GBIA, 460 Richard Ray Blvd,
Ste 200, Robins AFB, GA 31098-1813.
9.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
Figure 1. Wing, Mk 1 Mod 2
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 06
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
d.
Remove upper section.
e.
Remove and open fiberboard box(s), as required.
12. Verify all required handling and test equipment is
available and serviceable.
f.
Carefully remove dunnage and wings.
13. EMPTY CONTAINER PROCESSING.
g.
Verify interior packing of container is complete
and undamaged. Place in container and close
cover.
h.
Process empty container Paragraph 13.
14. Empty shipping containers and dunnage are reusable.
Process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged.
17. CNU-283A/E CONTAINER UNPACKING.
a.
Inspect container exterior (Figure 2) for damage.
If it is evident that container has been improperly
handled, inspect wings Paragraph 18 and fins
SWP 006 07.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
b.
Inspect humidity indicator. If not blue, inspect
interior/contents for moisture. Replace desiccant/
indicator before closing empty container.
e.
Certify container TO 11A-1-60.
c.
Open pressure relief valve and open container.
f.
Store serviceable containers for reuse or return
them to issuing activity.
d.
Remove upper cushion assembly and remove fin
tray.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
e.
If fins are to be inspected at this time, remove
fins and inspect, SWP 006 07.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
f.
Remove wing assemblies from container.
g.
Verify interior packing of container is complete
and undamaged. Place packing in container and
close cover.
h.
Process empty container (Paragraph 13).
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
15. UNPACKING.
16. CNU-304/E CONTAINER UNPACKING.
18. INSPECTION.
a.
4
Visually inspect container (Figure 3) for damage.
If it is evident that container has been improperly
handled, inspect wings Paragraph 18, and fins
SWP 006 07.
b.
Inspect humidity indicator. If not blue, inspect
interior/contents for moisture. Replace desiccant/
indicator before closing empty container.
c.
Press button on pressure relief valve, and release
container latches and place latches in the down
position.
Change 1
a.
Inspect wing Table 4 and Figure 4.
b.
Perform wing tap inspection Paragraph 19.
c.
Perform rolleron
Paragraph 25.
d.
Perform cager release-pull test Paragraph 26.
assembly
functional
test
CSTO XX21M-AIM9M-2
SWP 006 06
Figure 2.
Container, CNU-283A/E
(PN 639AS2702)
with Wings and Fins
Figure 3.
Container, Shipping and Storage, CNU-304/E (PN 776013-190)
with Wings
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 06
ALUMINUM
SKIN
ROLLERON
HINGE
DAMPER
ASSEMBLY
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING
BASE
NOTES:
WING ALIGNMENT
SCREW (5)
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
1. ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER
ASSEMBLY, WING ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
2. DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
3. WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
4. WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 4. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
Table 4. Wing Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 008 06.
6
1
Absence of/or illegible identification markings: Mark,
Mod, and part number (Figure 4)
MINOR
Replace marking SWP 008 06
2
Over 25% of thermal coating on one side blistered,
peeling, or missing
MAJOR
Reject
3
Punctures through wing skin into honeycomb
MAJOR
Reject
*4
Wing surface greasy or dirty
MINOR
Clean SWP 008 06
Change 1
CSTO XX21M-AIM9M-2
SWP 006 06
Table 4. Wing Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
If over 25% (estimated) of thermal coating must be removed to repair,
reject.
5
Wing coating cracked, blistered, peeling, or missing in
excess of 0.250 inch in diameter but less than 25% of
thermal coating on one side
MAJOR
Repair coating SWP 008 06
6
Scratches in wing coated surface 0.062 inch wide
MAJOR
Repair coating SWP 008 06
*7
Small hairline cracks in wing base coating
MINOR
Acceptable
8
Cracks or warpage in metal structure of wing frame
MAJOR
Reject
9
Nicks or scrapes in metal structure of wing frame
greater than 0.250 inch in depth
MAJOR
Reject
10
Circular cracks in rivet area indicating loose rivets
MAJOR
Reject
11
Dents in wing surface more than 0.125 inch in depth
MAJOR
Reject
12
Dents in wing leading edge more than 0.125 inch in
depth
MAJOR
Reject
13
Dents in wing leading edge less than 0.125 inch in
depth
MINOR
Repair coating SWP 008 06
14
Over 25% of thermal coating missing from leading
edge
MAJOR
Repair coating SWP 008 06
15
Wing alignment screws missing or damaged
MAJOR
Replace screw SWP 008 06
16
Wing alignment screws corroded
MAJOR
Clean SWP 008 06
17
Wing attachment cap screw missing, or damaged
MAJOR
Replace cap screw SWP 008 06
18
Wing attachment cap screw corroded
MAJOR
Clean SWP 008 06
19
Guide vanes missing or bent (minor surface defects are
acceptable)
MAJOR
Replace guide vane SWP 008 06
20
Guide vanes corroded
MAJOR
Clean SWP 008 06
21
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs with flat file
or 320 grit emery cloth
22
Guide vane screws loose, missing or damaged
MAJOR
Replace/torque screws
SWP 008 06
23
Guide vane screws corroded
MAJOR
Clean SWP 008 06
24
Minor corrosion on rolleron assembly
MINOR
Clean SWP 008 06
25
Major corrosion on rolleron assembly affecting
function of rolleron
MAJOR
Replace rolleron assembly
SWP 008 06
26
Rolleron hinge retaining screws loose, missing, or
damaged
MAJOR
Replace/torque screws
SWP 008 06
27
Rolleron hinge corroded
MAJOR
Clean SWP 008 06
Change 1
7
CSTO XX21M-AIM9M-2
SWP 006 06
Table 4. Wing Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
28
Rolleron hinge damaged
MAJOR
Replace rolleron hinge
SWP 008 06
29
Rolleron hinge damper pin hole elongated
MAJOR
Replace rolleron hinge
SWP 008 06
30
Play where damper assembly is attached to the
rolleron assembly
MAJOR
Replace damper assembly
SWP 008 06
31
Damper assembly shows evidence of leaking oil
MAJOR
Perform rolleron assembly
functional test, Paragraph 25
32
Damper assembly attaching screws loose or missing
MAJOR
Replace/torque screws
SWP 008 06
33
Cager assembly binding, missing parts or inoperative
MAJOR
Repair/ replace cager assembly
SWP 008 06
34
Reset rivet damaged or missing (Mod 2 wing only)
MAJOR
Replace cager assembly
SWP 008 06
35
Loose cager assembly
MAJOR
Inspect for loose, damaged, or
worn parts. Disassemble for
inspection if necessary. Replace/
tighten set screw (Mod 2). Check
for loose headless pin/worn pin
hole (Mod 1) SWP 008 06
36
Cager assembly corroded
MAJOR
Replace/clean. Corrosion on cager
assembly barrel or cager bore hole
mating surfaces (Mod 1) reject.
SWP 008 06
19. WING TAP INSPECTION. The tap method of
inspecting the bonded composite panels provides a simple,
dependable method for detecting voids in metal to metal
bonds, skin to core bonds, and delaminations of laminated
structures. The tap method of inspecting bonded panels for
voids is based on the fact that parts bonded together return
a different sound, when struck with a tap hammer, than
parts which are not bonded together. It is necessary that
the instructions contained in the following paragraphs be
followed closely in order to produce as much difference as
possible between the sounds of void free areas and the
sounds of void areas.
a.
A void area sound will be less sharp or clear than
the sound of a void-free area.
b.
A void sound can be described as dull or dead or
sometimes as a rattle.
c.
Different areas of a panel will cause different
sounds even through the panel is free of voids.
The following items will cause sound changes:
(1) Core splices
(2) Differences in core thickness
20. A void area will be determined by the quality of the
sound it creates when tapped with the tap hammer. The
following aids shall be used in determination of void
areas:
8
Change 1
(3) Core cell size
(4) Skin thickness
CSTO XX21M-AIM9M-2
SWP 006 06
23. Tap Inspection Procedures. Perform tap inspection
procedures as follows:
(5) Panel shape
(6) Type of adhesive used to bond parts
21. Tap Inspection Limitations. This inspection
technique is limited to certain areas and conditions as
follows:
a.
There is difficulty in detecting small voids. As
skin gauges increase, the difficulty of detecting
voids becomes greater.
b.
This tap inspection is limited to zones A and B
only Figure 4.
22. Tap Inspection Preparation. Prepare for tap
inspection by accomplishing the following items:
a.
Place wing in a vertical upright position.
b.
See Figure 5 for an illustration and instructions
on the proper use of the tap hammer.
c.
Tap thermal coated zones A and B (Figure 4)
surface at one inch spacings.
d.
Although sound will change due to variations in
construction, an area that is free of voids will
retain a sharp, clear sound.
e.
When a void is located, the size should be
determined as accurately as possible. Outline the
perimeter of the void area if any are present,
using a grease pencil.
f.
Repeat steps a through e on opposite side of
wing.
a. Remove foreign matter from panel to be inspected by
wiping panel surface with clean dry cloth.
b. Inspect the tap hammer head for burrs, nicks,
indentations, etc. that could damage the panel surface.
Remove blemishes from the hammer head using a fine 320
grit emery cloth.
1.
2.
24. Acceptance / Rejection Criteria. Acceptance/
rejection criteria is as follows:
GRIP HANDLE OF TAP HAMMER FIRMLY IN HAND WITH THUMB ON HANDLE AS SHOWN. PLACE INDEX FINGER ON WIRE
STEM AT A POINT APPROXIMATELY ONE AND ONE-HALF INCHES FORWARD OF THE HANDLE.
RAISE HEAD OF TAP HAMMER APPROXIMATELY ONE TO ONE AND ONE-HALF INCHES ABOVE SURFACE OF PANEL AND
TAP SURFACE LIGHTLY USING A WRIST MOTION. THE HAMMER SHOULD BOUNCE BACK A SHORT DISTANCE FROM THE
SURFACE OF THE PANEL AND BE FORCED BACK DOWN BY A COMBINATION OF PRESSURE FROM THE INDEX FINGER AND
WRIST ACTION CREATING A QUICK RAPID TYPE BEAT OF APPROXIMATELY FIVE TAPS PER SECOND.
Figure 5. Tap Hammer Procedures
Change 1
9
CSTO XX21M-AIM9M-2
SWP 006 06
a.
No single unbonded area shall be greater than
three (3) square inches in area.
b.
No more than three unbonded areas, regardless of
the cumulative area, shall be permitted on each
wing side.
c.
Unbonded areas shall be separated by one (1)
inch.
replace damper and/or rolleron assembly SWP
008 06.
26. CAGER RELEASE-PULL TEST.
Lubricant, Breakfree, MIL-L-63460
d.
No unbonded areas shall have a maximum linear
dimension greater than four (4) inches.
a.
With wing in a vertical upright position, attach
instrument scale Figure 7 or 8.
e.
Reject wing if unacceptable. Retain serviceable
components (SWP 008 06).
b.
Perform release-pull test as specified in Figure 7
or 8. The cager should release with a pull of 1.8
to 2.2 pounds (Mod 2) or 2.0 to 2.5 pounds (Mod
1). If pull test is within tolerance, return cager to
caged position and verify cager is secured.
c.
If pull test is not within tolerance, for Mod 2
lubricate cager flag movement, for Mod 1
lubricate cager assembly, then repeat test.
d.
If cager fails release-pull test, repair or replace
cager assembly, SWP 008 06.
25. ROLLERON ASSEMBLY FUNCTIONAL TEST.
a.
Set wing base on flat surface.
b.
Hold rolleron assembly (Figure 6) firmly and
grasp rolleron wheel. Move wheel from side-toside and up and down. If any movement is felt,
replace rolleron assembly SWP 008 06.
NOTE
Some rolleron bearings are pre-loaded and will
cause the wheel to come to rest more quickly than
others. When rolleron wheel is spinning, bearings
should be relatively free of bearing noise.
10
[5]
c.
Spin rolleron wheel by hand. If rolleron wheel
does not turn freely or has wobbly, jerky, noisy,
or ratchet-like motion, replace rolleron assembly
SWP 008 06.
d.
Lay wing on its side against a flat surface. Extend
rolleron assembly over flat surface edge so that
the rolleron can travel throughout its entire range
of motion without interference. Release cager
assembly Figure 4. Raise rolleron to its highest
point of travel and release. The falling motion
shall indicate resistance but shall not stop
throughout its downward travel. If there is no
resistance to rolleron travel or if the rolleron
stops during its downward motion, replace
damper SWP 008 06.
e.
Release cager assembly and slowly move
rolleron assembly from side to side through entire
travel. Verify rolleron assembly does not contact
wing frame and bottom edge is parallel to wing
frame. If rolleron assembly does not conform,
Change 1
Figure 6. Rolleron Assembly
CSTO XX21M-AIM9M-2
SWP 006 06
MOD 1 WING
PAPER CLIP ATTACHMENT
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 7. Wing Cager Release-Pull Test (Preferred)
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 8. Wing Cager Release-Pull Test
11
CSTO XX21M-AIM9M-2
SWP 006 06
27. PACKAGING.
j.
Place remaining boxes in container.
28. WING PACKING IN CNU-304/E CONTAINER.
k.
If humidity indicator was pink or white, replace.
Inspect humidity indicator. If not blue, inspect
interior/contents for moisture. Replace desiccant/
indicator before closing container.
l.
Place cover on container.
b.
Press button on pressure relief valve.
c.
Release latches and place in the down position.
To ensure proper seal, container latches should be
at approximately a 60° angle to the bottom side
of container prior to applying force to close
latches.
d.
Remove container cover and remove fiberboard
boxes.
a.
e.
Open fiberboard box (Figure 3) and remove loose
interior cushions and plastic film.
f.
Place four (4) wings in box as follows:
NOTE
m. Secure container latches and seal TO 11A-1-60.
29. WING AND FIN PACKING IN THE CNU-283A/E
CONTAINER.
a.
Inspect humidity indicator. If not blue, inspect
interior/contents for moisture. Replace desiccant/
indicator before closing container.
b.
Open pressure relief valve.
c.
Open container cover and remove top cushion.
d.
Ensure bottom cushion is in container and place
wings (eight per container) in wing and fin
container (Figure 2).
(5) Place six (6)-inch cushion over wing.
e.
Ensure wing dunnage and wings are properly
positioned in container.
(6) Repeat steps (4) and (5) for third and fourth
wings.
f.
Place plastic fin tray in container and place fins in
fin tray.
g.
Install top cushion.
h.
Secure container cover and seal TO 11A-1-60.
(1) Center plastic film over open box.
(2) Place first wing in box (either end), forcing
plastic film in place between box and wing.
(3) Place nine (9)-inch cushion over wing.
(4) Second wing shall be rotated 180° for
installation in opposite end of box.
(7) Fold plastic film over and close box.
(8) Seal box with paper tape.
g.
Repeat steps b and c for remaining boxes.
h.
Place first box in container.
i.
Ensure two 8-unit bags or equivalent of activated
desiccant are in lower section of container.
30. CONTAINER MARKINGS.
31. Mark container TO 35E20-2-31-2 and TO 11A-1-10.
12
Change 1
CSTO XX21M-AIM9M-2
SWP 006 07
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, AND INSPECTION
FIELD LEVEL MAINTENANCE
FINS, BSU-32/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 6
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-6 . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
Page No.
Change No.
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance With Illustrated Parts Breakdown Fins, BSU-32/B.......................................................................SWP 008 07
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ...........................................................................................................WP 002 00
Unpacking, Packaging, and Inspection, Wing Assembly, Guided Missile, Mk 1 Mod 1 and Mk 1 Mod 2........SWP 006 06
Table of Contents
Title
Page
Container Markings ...............................................................................................................................................................5
Dropped Fin Processing.........................................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................5
Packing...................................................................................................................................................................................5
Fin Packing in the CNU-283A/E Container ..........................................................................................................................5
Fin Packing in the M548 Container .......................................................................................................................................5
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
Fin Unpacking from CNU-283A/E Container.....................................................................................................................3
Fin Unpacking from M548 Container .................................................................................................................................3
Change 1
1 of 6
CSTO XX21M-AIM9M-2
SWP 006 07
List of Illustrations
Title
Page
Fin.......................................................................................................................................................................................... 4
Fin Container, M548 (PN 777956-10) .................................................................................................................................. 4
Fin BSU-32/B........................................................................................................................................................................ 6
Wing and Fin Container, CNU-283A/E (PN 639AS2702).................................................................................................... 4
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Fin Inspection ........................................................................................................................................................................ 5
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packing components
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local purchase
Secure humidity indicator in containers,
Secure barrier material to container lid
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
None
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Fins
Packaged or Unpackaged
Any Height
Inspect Table 4
Wings
Packaged or Unpackaged
Any Height
SWP 006 06
2
Change 1
CSTO XX21M-AIM9M-2
SWP 006 07
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of the fins
(Figure 1). Production techniques involving preparation of
more than one set of fins may require deviations from the
work sequence. Several procedures may be performed
simultaneously, and in different work areas, provided they
do not invalidate or interfere with a preceding or
subsequent step and safety precautions are strictly
observed.
3.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
15. UNPACKING.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the fins can cause the
missile to malfunction. If any doubt exists as to
acceptability of fins, reject it. Report incident/accident.
16. FIN UNPACKING FROM THE M548
CONTAINER.
a.
Visually inspect container (Figure 2) for damage.
If it is evident that container has been improperly
handled, inspect fins Paragraph 18.
8. Dropped fin processing criteria are contained in Table
3. If any doubt exists as to acceptability of dropped fin,
reject it. Request disposition of dropped components from
WR-ALC, 575 CBSS/GBIA, 460 Richard Ray Blvd, Ste
200, Robins AFB, GA 31098-1813.
b.
Open container and remove cover.
c.
Remove top and middle cushions.
d.
Remove fins.
9.
e.
Verify interior packing of container is complete
and undamaged.
f.
Install middle and top cushions.
g.
Install cover.
h.
Process empty container Paragraph 13.
7.
DROPPED FIN PROCESSING.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
17. FIN UNPACKING FROM THE CNU-283A/E
CONTAINER.
13. EMPTY CONTAINER PROCESSING.
a.
Inspect container (Figure 3) exterior for damage.
If it is evident that container has been improperly
handled, inspect fins Paragraph 18 and wings
SWP 006 06.
b.
Open pressure relief valve and open container.
c.
Remove upper cushion assembly and remove fin
tray.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
b.
Do not remove interior packing unless it is wet or
damaged beyond use.
If packing is wet, remove and allow packing and
container to dry.
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 07
Figure 1. Fin
Figure 2. Fin Container, M548 (PN 777956-10)
4
Change 1
Figure 3. Wing and Fin Container,
CNU-283A/E (PN 639AS2702)
CSTO XX21M-AIM9M-2
SWP 006 07
d.
If wings are to be inspected at this time, remove
wing assemblies and inspect SWP 006 06.
e.
Verify interior packing of container is complete
and undamaged. Place in container and close
cover.
f.
Process empty container Paragraph 13.
NOTE
Barrier material shall be positioned to prevent
contact between container lid and humidity
indicator card.
18. INSPECTION.
i.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container lid.
j.
Secure container cover, and seal TO-11A-1-60.
22. FIN
PACKING
CONTAINER.
19. Inspect fin Table 4.
IN
THE
CNU-283A/E
20. PACKING.
a.
Open pressure relief valve.
b.
Open container and remove cover.
c.
Remove top cushion.
d.
If wings are to be packaged, place wings (eight
per container) in wing and fin container (Figure
3) with lower cushion assembly in place.
21. FIN PACKING IN THE M548 CONTAINER.
a.
Open container and remove cover.
b.
Remove top and middle cushions Figure 2.
c.
Place eight fins in bottom cushion, each one
rotated 180° from the adjacent fin.
d.
Install middle cushion and place fins in cushion
as in step c.
e.
Ensure wing dunnage and wings are properly
positioned in container.
e.
Install top cushion.
f.
Place plastic fin tray in containers and place fins
in fin tray.
f.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
g.
Install top cushion.
g.
If humidity indicator is pink or white, replace.
h.
Secure container cover and seal TO 11A-1-60.
h.
Tape humidity indicator card to top cushion.
23. CONTAINER MARKINGS.
24. Mark container TO 35E20-2-31-2 and TO 11A-1-10.
Table 4. Fin Inspection
Inspection
(Inspect for the following defects)
Defect
Classification
1
Leading or trailing edge warped in excess of 0.062 inch
(Note 1)
MAJOR
Reject
2
Severe scratches or gouges in excess of 0.060 inches
deep
MAJOR
Reject
Scratches or gouges less than 0.060 inches deep
MINOR
Repair SWP 008 07
Cracks of any size
MAJOR
Reject
Step
2.1
3
Corrective Action
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 07
Table 4. Fin Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
4
Corrosion and contamination
MINOR
Clean SWP 008 07
5
Corrosion preventive coating missing
MINOR
Apply corrosion preventive coat
SWP 008 07
NOTE
Remove screws from fin for inspection. Clean and inspect screws
thoroughly for corrosion. Replace suspect screws.
6
Fin attaching screw(s) (Figure 4) identification dots
(minimum of 6, raised or depressed) missing on screw
head (Note 2)
MAJOR
Replace screws SWP 008 07
7
Fin attaching screw(s) corroded, missing, or damaged
MAJOR
Replace screws SWP 008 07
8
Fin attaching screw(s), preformed packing, missing or
damaged (Note 3)
MAJOR
Replace SWP 008 07
9
Trailing edge gouged in excess 0.125 inches in depth
and/or 0.5 inches in length/width
MAJOR
Reject
10
Trailing edge gouged less than 0.125
MINOR
Repair SWP 008 07.
Remove displaced metal of gouge.
Note 1:
Note 2:
Note 3:
Trailing edge of one fin may be used as straight edge for making measurement.
A 1/4 inch green dot may be located on the large flat surface of the fin above each attaching screw (both sides)
from a prior inspection and need not be reapplied.
If locking rings are present replace with preformed packing.
Figure 4. Fin BSU-32/B
6
Change 1
CSTO XX21M-AIM9M-2
SWP 006 08
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION, TEST AND SERVICING
FIELD LEVEL MAINTENANCE
COOLANT PRESSURE TANK, TMU-72/B, TMU-72A/B AND TMU-72B/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 12
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-11 . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
12 blank . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Digital Hygrometer, TTU-546/E, Part Numbers 639AS9334-1 and 639AS9334-2............................. CSTO XX35D18-6-2
Inspection of Reusable Munitions, Containers, and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Safety Investigations and Reports......................................................................................................................... AFI 91-204
Maintenance With Illustrated Parts Breakdown, Coolant Pressure Tank,
TMU-72/B, TMU-72A/B and TMU-72B/B ......................................................................................................SWP 008 08
Operation and Maintenance Instruction with IPB, Guided Missile Coolant Recharging
Unit GCU-30/E .............................................................................................................................................. TO 35D18-5-1
Operation and Maintenance Instructions with IPB,
Recharging Unit Assembly GCU-26A/E PN 639AS10030........................................................................... TO 35D18-4-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings ............................................................................................................................................................. 11
Coolant Pressure Tank Servicing ...........................................................................................................................................4
Dropped Coolant Tank Processing.........................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................4
Packing................................................................................................................................................................................. 11
Coolant Pressure Tank Packing in the CNU-282/E Container ......................................................................................... 11
Coolant Pressure Tank Packing in the M548 Container ................................................................................................... 11
Purge Procedure .....................................................................................................................................................................9
Change 1
1 of 12
CSTO XX21M-AIM9M-2
SWP 006 08
Table of Contents (continued)
Title
Page
Safety and Accident Prevention ............................................................................................................................................ 3
Sequence of Operations ......................................................................................................................................................... 3
Servicing and Test Equipment Preparation ........................................................................................................................... 3
Test Records/Documentation................................................................................................................................................. 3
Testing ................................................................................................................................................................................... 8
Leak Test Procedure ........................................................................................................................................................... 9
Testing Coolant Tank for Moisture Content Using Digital Hygrometer ............................................................................ 8
Unpacking.............................................................................................................................................................................. 4
Coolant Pressure Tank Unpacking from the CNU-282/E or M548 Container................................................................... 4
List of Illustrations
Title
Page
Coolant Pressure Tank ........................................................................................................................................................... 3
Coolant Pressure Tank (Accumulator) Markings .................................................................................................................. 7
Coolant Pressure Tank Container CNU-282/E, PN 754855.................................................................................................. 4
Coolant Pressure Tank Container M548 (PN 776027-10) .................................................................................................... 5
Coolant Pressure Tank Vent Hole.......................................................................................................................................... 9
Digital Hygrometer, TTU-546/E ........................................................................................................................................... 8
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Coolant Pressure Tank Inspection ......................................................................................................................................... 5
Coolant Pressure Tank Leak Troubleshooting Chart........................................................................................................... 10
Coolant Pressure Tank Temperature/Pressure Variation ....................................................................................................... 7
Coolant Tank Testing............................................................................................................................................................. 8
Drop Criteria.......................................................................................................................................................................... 3
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Tape, Adhesive, Rubber
639AS4838
Leak test
Tape, Sealing
MIL-I-15126 Ty GFT
Seal accumulator output valve
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Digital Hygrometer, TTU-546/E
(Note 1)
639AS9334-1 and 639AS9334-2
Test the moisture content of TMU-72
coolant tanks
Recharging Unit, GCU-26A/E or
GCU-26/E
639AS10030
Coolant pressure tank servicing
2
Change 1
CSTO XX21M-AIM9M-2
SWP 006 08
Table 2. Tools and Equipment (Continued)
Nomenclature
Specification/Part Number
Recharging Unit, GCU-30/E
Use
8431336
Coolant pressure tank servicing
Note 1: Optional equipment. See paragraph on testing.
Table 3. Drop Criteria
Item
Coolant Pressure Tank
1.
Packaged/Unpackaged
Drop Distance (Feet)
Packaged
Any Height
Inspect Table 4
Unpackaged
Less than 10
Inspect Table 4
Unpackaged
More than 10
Reject
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, Inspection, and Servicing
of the coolant pressure tank, Figure 1. Production
techniques involving preparation of more than one coolant
pressure tank may require deviations from the work
sequence. Several procedures may be performed
simultaneously, and in different work areas, provided they
do not invalidate or interfere with a preceding or
subsequent step and safety precautions are strictly
observed.
3.
Required Action
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving dropping or damage to
the coolant tank can cause the AUR to malfunction. If any
doubt exists as to acceptability of the coolant tank, reject
it. Report incident/accident.
7.
DROPPED COOLANT TANK PROCESSING.
8. Dropped coolant tank processing criteria are
contained in Table 3. If any doubt exists as to acceptability
of dropped coolant tank, reject it. Report dropping
incidents in accordance with AFI 91-204 and AFOSH
91/127 series publications. Request disposition of dropped
components from WR-ALC, 575 CBSS/GBIA, 460
Richard Ray Blvd, Ste 200, Robins AFB, GA 31098-1813.
9.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. SERVICING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required servicing and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
Figure 1. Coolant Pressure Tank
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
Change 1
3
CSTO XX21M-AIM9M-2
SWP 006 08
g.
If M548 container is to be reused, ensure breather
holes are drilled in accordance with TO 35E20-231-2.
h.
Verify interior packing of container is complete
and undamaged.
i.
Place cushions in container and secure cover.
j.
Process empty container Paragraph 13.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
19. COOLANT PRESSURE TANK SERVICING.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
20. Service the coolant pressure tank in accordance with
TO 35D18-4-1 (GCU-26A/E or GCU-26A/E) or TO
35D18-5-1 (GCU-30/E).
17. INSPECTION.
18. Inspect coolant pressure tanks Table 4.
h.
15. UNPACKING.
16. COOLANT PRESSURE TANK UNPACKING
FROM THE CNU-282/E OR M548 CONTAINER.
STENCIL CAUTION
ON CONTAINER COVER
IN 1/4-INCH RED LETTERS
ON WHITE BACKGROUND.
WARNING
Coolant pressure tanks contain high pressure
argon gas. Containers may have internal pressure
buildup from leaking coolant tanks.
a.
Inspect container (Figure 2 or Figure 3) exterior
for damage and bulging. If it is evident that
container has been mishandled, inspect coolant
pressure tanks Table 4.
b.
If container shows evidence of internal pressure
buildup, open in accordance with steps c or d
below.
c.
To relieve internal pressure buildup in the CNU282/E container, carefully unlatch one latch then
unlatch remaining latches.
d.
To relieve internal pressure buildup in the M548
container, raise one latch just far enough to allow
pressure to equalize then unlatch both latches.
e.
Open container
assembly.
f.
4
and
remove
Remove coolant pressure tanks.
Change 1
top
cushion
Figure 2.
Coolant Pressure Tank Container
CNU-282/E, PN 754855
CSTO XX21M-AIM9M-2
SWP 006 08
Figure 3. Coolant Pressure Tank Container M548 (PN 776027-10)
Table 4. Coolant Pressure Tank Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria in sampling tables.
1
Identification markings (Figure 4) illegible, or missing.
MAJOR
Reject tank
2
Hydrostatic test illegible, missing, or due (Hydrostatic
test required 10 years from date of manufacture or last
hydrostatic test.)
MAJOR
Reject tank
3
Dust or dirt on coolant tank valve
MINOR
Clean SWP 008 08
4
Corrosion or contamination on coolant tank
or valve
MINOR
Clean SWP 008 08
Change 1
5
CSTO XX21M-AIM9M-2
SWP 006 08
Table 4. Coolant Pressure Tank Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Testing coolant tanks is optional. The TTU-546/E Digital Hygrometer
will be used for testing.
5
Pressure gauge indicates no positive pressure
MAJOR
See Table 7: Service tank Paragraph
19, Test Paragraph 21, Test
Paragraph 28, as applicable
6
Pressure gauge glass cracked, TMU-72/B
MINOR
Discharge tank SWP 008 08, then
service Paragraph 19. If gauge
operates properly it is acceptable. If
not reject tank.
Pressure gauge glass cracked, TMU-72A/B or
TMU-72B/B
MINOR
Discharge tank SWP 008 08, then
service Paragraph 19. If gauge
operates properly it is acceptable. If
not replace glass, SWP 008 08.
7
Pressure gauge glass broken/missing TMU-72/B
MAJOR
Reject
8
Pressure gauge glass broken/missing TMU-72A/B or
TMU-72B/B
MAJOR
Replace glass SWP 008 08
9
Pressure gauge indicates positive pressure, but less
than 4,000 psig (refer to Table 5 for
temperature/pressure variation)
MAJOR
Service tank Paragraph 19. See WP
003 00 for information on coolant
gas selection and mixing.
10
Pressure gauge inoperative
MAJOR
Reject tank
11
Instruction plate (Figure 4) loose, damaged, or missing
MAJOR
Replace instruction plate
SWP 008 08
12
Caution plate (Figure 4) loose, damaged, or missing
MAJOR
Replace caution plate SWP 008 08
13
Wire handle damaged or missing
MINOR
Replace wire handle SWP 008 08
14
Retaining ring or probe guide missing, loose, or
damaged
MAJOR
Replace ring, replace/torque probe
guide SWP 008 08
15
Dial face not secured (moves) grasp tank tightly in the
inverted position. (Gauge down), shake vigorously and
check for movement of dial face (Figure 4)
MAJOR
Reject tank
16
Inspect preformed packing for nicks, cuts, dry rot
(cracking) or damage (it is not necessary to remove
packing for inspection)
MAJOR
Replace packing SWP 008 08
6.1
NOTE
If tank leaks when installed in GCS ensure leak is not caused by
unserviceable o-ring (preformed packing) before rejecting.
17
6
Tank will not maintain pressure (leaking)
Change 1
MAJOR
Test Paragraph 28
CSTO XX21M-AIM9M-2
SWP 006 08
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 4. Coolant Pressure Tank (Accumulator) Markings
Table 5. Coolant Pressure Tank Temperature/Pressure Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
Change 1
7
CSTO XX21M-AIM9M-2
SWP 006 08
26. TESTING COOLANT TANK FOR MOISTURE
CONTENT USING DIGITAL HYGROMETER.
21. TESTING.
NOTE
27. Test coolant tank as follows:
Testing coolant tanks for moisture content is
optional. The TTU-546/E Digital Hygrometer
will be used for testing.
22. The TTU-546/E Digital Hygrometer (Figure 5) is a
portable moisture analyzer used to test TMU-72 coolant
tanks, argon/nitrogen storage cylinders/containers,
argon/nitrogen/air generators, GCU-30/E Recharging Unit
coolant gas output, and other coolant gas sources for
moisture content.
a.
Verify coolant tank has been inspected, Table 4.
b.
Test coolant tanks using digital hygrometer. Refer
to CSTO XX35D18-6-2 for hygrometer
preparation for use and operating instructions.
23. Test coolant tank in accordance with Table 6.
24. A coolant tank may be tested any time the coolant
tank is suspected of being contaminated with moisture.
Test coolant tank in accordance with Paragraph 26.
25. CSTO XX35D18-6-2 (Digital Hygrometer) has
recommendations for coolant gas testing in addition to
those in this T.O. See Coolant Gas Moisture Testing table.
Figure 5. Digital Hygrometer, TTU-546/E
Table 6. Coolant Tank Testing
WP 005 00 Reference Paragraph
Action
Shipping / Receiving Inspections - All-Up-Round (AUR)
Shipping / Receiving Inspection
Test coolant tank of missile selected for GCS test in
TO 11A-1-10 sample inspection.
Shipping / Receiving Inspections - Component Shipping /
Receiving Inspection
Test all coolant tanks received from depot or manufacturer.
Test coolant tank selected for visual inspection in receiving
TO 11A-1-10 sample inspection.
Missile Periodic Inspection - Category Environments
Test coolant tank during Category A, B, C and D
inspection.
Component Periodic Inspection - Coolant Pressure Tank
Inspection
Test coolant tank selected for visual inspection in storage
TO 11A-1-10 sample inspection.
Special Inspection - Returned Missile/CATM for
Malfunction
For malfunctions that indicate a failure of the GCS to cool,
test the coolant tank for moisture contamination. (Note 3)
Other Inspections - Pre-issue Inspection
Test a replacement coolant tank prior to use in a tactical
missile.
Note 1: Those paragraphs listed in the ‘WP 005 00 Reference Paragraph’ column are in WP 005 00. When a visual
inspection of the coolant tank is required in the paragraph also test the coolant tank using the TTU-546/E Digital
Hygrometer. ‘Action’ column provides specific test guidance for each paragraph.
Note 2: These recommendations for testing may be modified by the command headquarters.
Note 3: Moisture contamination of coolant gas may result in no cooling gas flow or the flow may be intermittent. When
testing a GCS following a ‘malfunction’ use the coolant tank which was in the missile during flight, if possible.
8
Change 1
CSTO XX21M-AIM9M-2
SWP 006 08
c.
A coolant tank passing test is serviceable.
b.
Place a small piece of tape, PN 639AS4838, over
the vent hole of the gauge, Figure 6.
d.
A coolant tank failing test is unserviceable
(moisture contaminated). Report unserviceable
tanks in accordance with command directives.
c.
Submerge coolant pressure tank in a container of
isopropyl alcohol.
d.
Observe both valve and gauge end of the coolant
pressure tank for one minute for signs of leakage.
If more than eight bubbles leak out of either end
the coolant pressure tank has failed the leak test.
e.
Remove coolant pressure tank from alcohol
container. Blow dry with shop air or canned air.
Remove tape from gauge vent hole.
f.
If leakage does not exceed specified limit in step
c the coolant pressure tank passed the leak test. If
coolant pressure tank fails the leak test return to
depot for repair.
e.
If testing determines a coolant tank is
contaminated with moisture, verify the gas used
to fill the tank meets moisture purity
requirements (WP 004 00) to prevent other tanks
being contaminated.
28. LEAK TEST PROCEDURE. To test a TMU-72
coolant tank for leaks perform the following procedure:
Alcohol, Isopropyl, TT-I-735
[1]
NOTE
This test is recommended only for tanks
suspected of leaking, not routine testing. A
serviceable tank in long term storage may not
maintain maximum pressure. A tank in a GCS
may lose pressure due to an unserviceable tank
o-ring (preformed packing), damaged coolant
probe, defective check valve, or leaks within the
GCS. See Table 7 for troubleshooting.
a.
Inspect tank, Table 4. Fill tank to maximum
pressure, Paragraph 19.
29. PURGE PROCEDURE. Purge tank to avoid mixing
coolant gases or reduce moisture content, WP 003 00.
Using a Bleed Down Fixture or GCU-26 perform the
following:
NOTE
This purge procedure may not reduce the
moisture content to an acceptable level. The
TTU-546/E Digital Hygrometer can determine
the moisture content of a gas. If a TTU-546/E is
available test tank for moisture, Paragraph 21.
a.
Inspect coolant tank valve area for contaminates.
Clean if necessary, SWP 008 08.
CAUTION
To prevent contamination do not reduce tank
pressure to zero PSIG. A minimum pressure of
100 psig is recommended.
b.
Bleed coolant tank to 1200 psig, or less if
possible, using a Bleed Down Fixture or a GCU26, SWP 008 08.
c.
Refill tank to maximum pressure, 5,000 PSIG,
using a GCU-30 or GCU-26.
d.
Repeat steps b and c two more times.
e.
Return coolant tank to service.
Figure 6. Coolant Pressure Tank Vent Hole
Change 1
9
CSTO XX21M-AIM9M-2
SWP 006 08
Table 7. Coolant Pressure Tank Leak Troubleshooting Chart
Gauge Reads Zero
PSIG Following Sortie
Gauge Indicates Zero PSIG
When Removed from
Ready Use Coolant Tank
Container
Inspect GCS Coolant Probe
Probe Serviceable
or
When Removed from AURC or
Component Storage Container
Probe Damaged
Refill Tank, Paragraph 19
Reject GCS
Return Tank
to Service
Leak Test, Paragraph 28
Refill Tank, Paragraph 19
Passes Test
Fails Test - Reject
Leak Test, Paragraph 28
Fails Test - Reject
Hygrometer Available
for Testing
Test Tank,
Paragraph 21
No Hygrometer
Available for Testing
Purge Procedure,
Paragraph 29
Hygrometer Available
for Testing
No Hygrometer
Available for Testing
Test Tank,
Paragraph 21
Purge Procedure,
Paragraph 29
Return to Service
Refill Tank, Paragraph 19
Install Tank in GCS
Listen for Gas Leak
Monitor Gauge for 24 Hours
No Leak Detected
No Drop in Pressure Return tank to Service
Test GCS. Monitor coolant gas
consumption during test. During
test if gas consumption is clearly
excessive reject GCS. Otherwise
return GCS to service.
Audible Leak Detected or
Gauge Indicates Pressure Loss
Remove and Inspect Tank O-Ring for
Wear, Cracks, Breaks, Dry Rot.
Replace if Necessary, SWP 008 05.
Refill Tank, Paragraph 19
Install Tank in GCS
Listen for Gas Leak
Monitor Gauge for 24 Hours
Audible Leak Detected or Gauge
Indicates Pressure Drop - Reject Tank.
No Leak Detected Return Tank to Service.
Use chart as a guide in determining if a tank is serviceable when suspected of leaking gas and/or the gauge indicates zero pisg when:
1. A coolant tank removed from an AURC, Component Storage Container, or Ready Use Coolant Tank Container.
2. A coolant tank removed from a GCS following a sortie.
Note 1: Generally, tanks should retain maximum, or near maximum, pressure for an extended period of time. Tanks in storage for an
extended period (years) can be expected to lose some pressure.
Note 2: Coolant consumed during a sortie varies due to temperature, flight time, ground time, etc. Generally following a sortie, unless the
sortie is extremely long, the tank gauge should indicate positive pressure. Zero pressure may indicate a leak in the tank/GCS. See WP
003 00.
Note 3: This guide is not all inclusive. Due to the variables involved which may affect tank pressure, pressure loss, and/or gas
consumption more specific troubleshooting guidance cannot be provided.
10
Change 1
CSTO XX21M-AIM9M-2
SWP 006 08
30. PACKING.
c.
Open container (Figure 3) and remove cover.
31. COOLANT PRESSURE TANK PACKING IN
THE CNU-282/E CONTAINER.
d.
Verify breather holes have been drilled in
container. If not, refer to TO 35E20-2-31-2.
e.
Remove all but the bottom cushion.
f.
Place four coolant pressure tanks in the bottom
cushion.
a.
Prior to shipment, serviceable coolant pressure
tanks must indicate a minimum of 1200 ± 200
psig and a maximum of 5,000 ± 200 psig.
Unserviceable tanks may be shipped at any
pressure.
b.
Ensure valve is sealed with tape.
c.
Remove container cover.
d.
Place coolant pressure tank (six per container) in
container (Figure 2) with lower cushion assembly
in place. Install top cushion assembly.
CAUTION
To ensure maximum protection for the coolant
tanks in the container, orient the cushions so that
the tanks are not placed directly above one
another Figure 3.
g.
Install remaining cushions and tanks as in step f.
NOTE
Containers used for flight line support only (not
for shipping or storage) may be marked:
NOTE
Containers used for flight line support only (not
for shipping or storage) may be marked:
Tank, Pressure Coolant TMU-72.
Tank, Pressure Coolant TMU-72.
e.
f.
g.
Secure container cover. Ensure container
markings include: Tank, Pressure Coolant, TMU72/B, TMU-72A/B or TMU-72B/B, as
appropriate.
Verify “CAUTION” is stenciled on container
cover.
h.
Install and secure container cover. Ensure
container markings include: Tank, Pressure
Coolant, TMU-72/B, TMU-72A/B or TMU72B/B as appropriate.
i.
Verify “CAUTION” is stenciled on container
cover.
j.
Seal containers TO 11A-1-60.
Seal container TO 11A-1-60.
32. COOLANT PRESSURE TANK PACKING IN
THE M548 CONTAINER.
NOTE
33. CONTAINER MARKINGS.
34. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
Shipment of tanks by commercial carrier must be
in compliance with DOT regulations.
a.
Prior to shipment, serviceable coolant pressure
tanks must indicate a minimum of 1,200 ± 200
psig and a maximum of 5,000 ± 200 psig.
Unserviceable tanks may be shipped at any
pressure.
b.
Ensure valve is sealed with tape.
Change 1
11
11/(12 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION,
AND GROUND HANDLING CATM-9M AND DATM MISSILE
FIELD LEVEL MAINTENANCE
TRAINING MISSILE CATM-9M AND DATM
THIS WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE WP PAGES
Total Number of Pages in this WP is 150
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
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117 . . . . . . . . . . . . . . . . . . . . . . . 0
120. . . . . . . . . . . . . . . . . . . . . . . 1
124. . . . . . . . . . . . . . . . . . . . . . . 0
127. . . . . . . . . . . . . . . . . . . . . . . 2
130.2 added blank . . . . . . . . . . . 1
135-136 . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
6.1-6.2 added . . . . . . . . . . . . . . . 1
9 . . . . . . . . . . . . . . . . . . . . . . . . .1
13 . . . . . . . . . . . . . . . . . . . . . . . . 2
16-17 . . . . . . . . . . . . . . . . . . . . . . 1
18.2 added blank. . . . . . . . . . . . . 1
25-28 . . . . . . . . . . . . . . . . . . . . . . 1
32 . . . . . . . . . . . . . . . . . . . . . . . . 0
33 . . . . . . . . . . . . . . . . . . . . . . . . 0
40 . . . . . . . . . . . . . . . . . . . . . . . . 0
42.2 added blank. . . . . . . . . . . . . 1
47 . . . . . . . . . . . . . . . . . . . . . . . . 1
50 . . . . . . . . . . . . . . . . . . . . . . . . 0
53-54 . . . . . . . . . . . . . . . . . . . . . . 0
56.2 added blank. . . . . . . . . . . . . 1
62 . . . . . . . . . . . . . . . . . . . . . . . . 2
65-68 . . . . . . . . . . . . . . . . . . . . . . 0
73-75 . . . . . . . . . . . . . . . . . . . . . . 2
80 . . . . . . . . . . . . . . . . . . . . . . . . 1
83 . . . . . . . . . . . . . . . . . . . . . . . . 1
91-92 . . . . . . . . . . . . . . . . . . . . . . 1
96 . . . . . . . . . . . . . . . . . . . . . . . . 0
99-102. . . . . . . . . . . . . . . . . . . . . 1
106 . . . . . . . . . . . . . . . . . . . . . . . 2
109-110 . . . . . . . . . . . . . . . . . . . . 1
114.2 added blank . . . . . . . . . . . . 1
118 . . . . . . . . . . . . . . . . . . . . . . . 1
121 . . . . . . . . . . . . . . . . . . . . . . . 0
125 . . . . . . . . . . . . . . . . . . . . . . . 2
128-130. . . . . . . . . . . . . . . . . . . . 1
131 . . . . . . . . . . . . . . . . . . . . . . . 1
Change 2
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CSTO XX21M-AIM9M-2
WP 007 00
Reference Material
Title
Number
Air Force Instructions........................................................................................................................................AFI-91 Series
Air Force Munitions Surveillance Program and Serviceability Procedures.......................................................TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives............................................................................................TO 11A-1-60
Maintenance, Assembly and Disassembly with Illustrated Parts Breakdown,
AIM-9M Tactical Missile .................................................................................................................................... WP 008 00
Maintenance, Assembly and Disassembly with Illustrated Parts Breakdown,
AIM-9M Training Missile ................................................................................................................................... WP 009 00
Maintenance with Illustrated Parts Breakdown, Coolant Pressure Tank TMU-72/B, TMU-72A/B
and TMU-72B/B................................................................................................................................................ SWP 008 08
Maintenance with Illustrated Parts Breakdown, Dummy Body Section, MDU-27/A and MDU-27A/A ........... SWP 009 06
Maintenance with Illustrated Parts Breakdown, Fins, BSU-32/B....................................................................... SWP 008 07
Maintenance with Illustrated Parts Breakdown, Guidance Control Section, WGU-4A/B.................................. SWP 008 01
Maintenance with Illustrated Parts Breakdown, Guidance Control Section,
WGU-4A(T-2)/B, and AN/DSQ-29-T1............................................................................................................. SWP 009 01
Maintenance with Illustrated Parts Breakdown, Missile Body Assembly .......................................................... SWP 009 05
Maintenance with Illustrated Parts Breakdown,
Rocket Motor, Mk 57 Mod 1, Mk 57 Mod 2, and Mk 57 Mod 3...................................................................... SWP 009 04
Maintenance with Illustrated Parts Breakdown, Target Detector,
DSU-15(T-1)/B and DSU-15(T-1)A/B .............................................................................................................. SWP 009 02
Maintenance with Illustrated Parts Breakdown, Warhead Mk 70 Mod 1 ........................................................... SWP 009 03
Maintenance with Illustrated Parts Breakdown, Wing Assembly, Guided Missile,
Mk 1 Mod 1 and Mk 1 Mod 2 ........................................................................................................................... SWP 008 06
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with
IPB, Shipping and Storage Containers AIM-9 Series Missiles .................................................................TO 35E20-2-31-2
Positioning and Tie-Down Procedure for Nonnuclear Munitions........................................................................ TO 11-1-38
Safety Investigations and Reports ........................................................................................................................ AFI 91-204
Safety Summary and Accident Prevention............................................................................................................ WP 002 00
Storage and Inspection Requirements ................................................................................................................... WP 005 00
Unpacking, Packing, Inspection, and Test, Guidance Control Section, WGU-4A/B.......................................... SWP 006 01
Table of Contents
Title
Page
AUR Inspection ................................................................................................................................................................. 133
CATM/DATM Missile Inspection ......................................................................................................................................... 9
Aft Hanger Surface Wear Inspection.......................................................................................................... 20, 56.1, 85, 130
Cager Release-Pull Test..................................................................................................................................................... 67
Coolant Pressure Tank Inspection ....................................................................................................................................... 9
Fin Inspection ...................................................................................................................................................................... 9
Rolleron Assembly Functional Test .................................................................................................................................. 66
Safe-Arm Selector Handle Spring Pin Inspection ............................................................................................................. 67
Wing Inspection................................................................................................................................................................... 9
Wing Tap Inspection.......................................................................................................................................................... 65
Acceptance/Rejection Criteria......................................................................................................................................... 66
Tap Inspection Limitations .............................................................................................................................................. 65
Tap Inspection Preparation .............................................................................................................................................. 65
Tap Inspection Procedures............................................................................................................................................... 65
Container Markings ........................................................................................................................................................... 135
2
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table of Contents (Continued)
Title
Page
Dropped Missile/Component Processing............................................................................................................................6.1
Empty Container Processing..................................................................................................................................................8
Ground Handling ...............................................................................................................................................................133
Handling and Test Equipment Preparation .........................................................................................................................6.1
Incidents/Accidents.............................................................................................................................................................6.1
Inspection...............................................................................................................................................................................9
Missile Configurations........................................................................................................................................................6.2
Missile Disassembly ..........................................................................................................................................................134
Packing...............................................................................................................................................................................134
Missile Packing in the CNU-310/E Container.................................................................................................................134
Preparing for AUR to Missile Disassembly ......................................................................................................................133
AUR Disassembly............................................................................................................................................................133
Coolant Pressure Tank Removal ....................................................................................................................................133
Fin Removal...................................................................................................................................................................134
Wing (Fixed MBA) Removal ........................................................................................................................................134
Wing Removal, Mk 1 Mod 1 or Mk 1 Mod 2................................................................................................................134
Preparing for Missile to AUR Assembly .............................................................................................................................69
Missile to AUR Assembly .................................................................................................................................................71
Coolant Pressure Tank Installation ..................................................................................................................................71
Fin Installation .................................................................................................................................................................71
Wing Installation, Mk 1 Mod 1 or Mk 1 Mod 2 ..............................................................................................................72
Wing (Fixed MBA) Installation .......................................................................................................................................72
Safe-Arm Selector Functional Check ..................................................................................................................................69
Safety and Accident Prevention..........................................................................................................................................6.1
Sequence of Operations ......................................................................................................................................................6.1
Test Records/Documentation ..............................................................................................................................................6.1
Torque Requirements ..........................................................................................................................................................6.2
Unpacking ..............................................................................................................................................................................8
Missile Unpacking from the CNU-310/E Container ...........................................................................................................8
List of Illustrations
Title
Page
Aft Hanger Flat Skid Surface...........................................................................................................................21, 57, 86, 132
Aft Hanger Skid Surface Wear Fixture ............................................................................................................22, 58, 87, 132
Aft Hanger Template........................................................................................................................................21, 57, 86, 131
Captive Flight Adapter, Umbilical Cable and GCS Base ...................................................... 12, 26, 37, 47, 76, 91, 105, 118
CATM-1 Inspection Points ............................................................................................................................................19, 84
CATM-3 and -7 Inspection Points .................................................................................................................................33, 96
CATM-9 and -10 Inspection Points ............................................................................................................................. 43, 113
CATM-16, -20 and -24 Inspection Points ....................................................................................................................54, 124
CATM Missile.....................................................................................................................................................................6.2
Center and Aft Hanger Assemblies (MDU-27) ............................................................................................18.1, 56, 82, 127
Center and Aft Hanger Assemblies (Mk 57) .................................................................................................................32, 98
Center and Aft Hanger Inspection (Mk 57) ......................................................................................................................32.1
CNU-310/E All-Up-Round Container (PN 785041-10) and CATM/DATM Missiles ..................................................9, 136
Coolant Pressure Tank (Accumulator), Markings ................................................................................... 61, 80, 95, 110, 123
Coupling Ring Assemblies (Mk 57) ..............................................................................................................................23, 88
Coupling Ring Assembly................................................................................................................................. 11, 35, 75, 104
Change 1
3
CSTO XX21M-AIM9M-2
WP 007 00
List of Illustrations (Continued)
Title
Page
Coupling Ring, PN 639AS672 .................................................................................................................................... 45, 116
Coupling Ring Straightedge Inspection..................................................................................11, 23, 35, 46, 75, 88, 104, 117
Fin, BSU-32/B..............................................................................................................................................................59, 111
Fin Cup .................................................................................................................................. 13, 27, 38, 49, 77, 90, 107, 119
Forward Hanger Assembly................................................................................................................................ 17, 32, 82, 98
Forward Hanger Assembly (MBA) .......................................................................................................................... 42.1, 112
Guidance Control Section Inspection Points..................................................................................... 29, 40, 50, 93, 108, 121
Guidance Control Section Inspection Points, WGU-4A/B ........................................................................................... 15, 79
HRU-985A/E Training Umbilical ......................................................................................... 13, 25, 36, 46, 74, 90, 103, 117
MDU-27A/A Forward Hanger Assembly ................................................................................................................... 53, 126
Rolleron Assembly .............................................................................................................................................................. 66
Safe-Arm Selector Assembly (Mk 57 Mod 3/MBA) .......................................................................................................... 69
Safe-Arm Selector Assembly (Mk 57 Mod 2) .................................................................................................................... 70
Safe-Arm Selector Handle Spring Pin Test ......................................................................................................................... 67
Tap Hammer Procedures ..................................................................................................................................................... 65
Umbilical Block Alignment ........................................................................................................................................... 114.1
Wing Cager Release-Pull Test ............................................................................................................................................. 68
Wing Cager Release-Pull Test (Preferred) .......................................................................................................................... 68
Wing Inspection, Fixed (MBA)...................................................................................................................................... 114.1
Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2 .................................................................................... 64, 102, 129
List of Tables
Title
Page
AUR Inspection CATM-1 (MDU-27/A) ............................................................................................................................. 73
AUR Inspection CATM-3 and -7 ........................................................................................................................................ 87
AUR Inspection CATM-9 and -10 .................................................................................................................................... 103
AUR Inspection CATM-16, -20 and -24 (MDU-27A/A).................................................................................................. 115
Consumable Materials ........................................................................................................................................................... 5
Coolant Pressure Tank Inspection ....................................................................................................................................... 60
Coolant Pressure Tank Pressure/Temperature Variation ......................................................................... 61, 80, 95, 110, 123
Drop Criteria.......................................................................................................................................................................... 6
Fin Inspection ...................................................................................................................................................................... 58
Missile Configurations .......................................................................................................................................................... 7
Missile Inspection CATM-1 (MDU-27/A).......................................................................................................................... 10
Missile Inspection CATM-3 and -7 ..................................................................................................................................... 22
Missile Inspection CATM-9 and -10 ................................................................................................................................... 34
Missile Inspection CATM-16, -20 and -24 (MDU-27A/A)................................................................................................. 44
Tools and Equipment ............................................................................................................................................................. 5
Torque Requirements............................................................................................................................................................. 6
Wing Inspection, Fixed (MBA) .......................................................................................................................................... 62
Wing Inspection, Mk 1 Mod 1 or Mk 1 Mod 2 ................................................................................................................... 62
4
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Band, Rubber
ZZ-R-141
Secure umbilical cable
Cloth, Emery 320 Grit
P-C-1673
Removal of loose paint or light to moderate
surface corrosion
Compound, Sealing
MIL-S-46163
Fixed wing screws
Compound, Silicone
MIL-S-8660
Preformed packing, mating surfaces, and wing
cager lubricant/sealant
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS 20003-2
Detecting moisture/humidity
Lubricant, Breakfree
MIL-L-63460
Lubricate cager flag
Tape
DDD-T-86
GCS packaging in the CNU-301/E and
CNU-310/E containers
Tape, Sealing
MIL-I-15126 Ty GFT
Cover coolant pressure tank outlet valve
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Aft Hanger Skid Surface Wear
Fixture
88C-Y-061
Gauge skid wear on aft hanger, MDU-27
Aft Hanger Template
89C-Y-S-008
Inspect aft hanger, MDU-27
Assembly Stand
68D35756-10
Supports missile or missile components
Alt Scale, instrument, 0 to 4 lbs
30003
Perform cager release-pull test
Cleaner, Vacuum
Local purchase
Remove air from barrier bag
Dial, Push/Pull Gauge
DDP-80
Perform cager release-pull test
Gauge, Depth
643J
Measure scratches, wear, pits, gouges or dents on
critical surfaces
Gauge, Spring Pin
639AS10059
Safe-Arm selector handle spring pin test
Glass, Magnifier
GG-M-95
Inspecting for cracks
Missile Storage Stand
MHU-32-A/ PN 8028909
Storing and transporting missile sections in
assembly area
Spanner, Gas Inlet
1298236
Tighten gas inlet umbilical connector
Storage and Maintenance Stand
MHU-32/E PN 6077
Storage and transporting missile sections in
assembly area
Tool, Coolant Tank Removal
Local Manufacture (WP 004 00) Remove coolant tank
Tool, Coolant Tank Removal
639AS4510
Remove coolant tank
Wrench, Spanner
639AS2981
Remove and replace probe cap assembly, probe
guide, and preformed packing compression fixture
in coolant pressure tank
Wrench, Torque
1556707
Torquing of wing and fin attaching screws
Change 1
5
CSTO XX21M-AIM9M-2
WP 007 00
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Assembled Missile
Packaged or Unpackaged
Any height
Disassemble WP 009 00, inspect (test
if applicable) all components in
accordance with appropriate SWP
Coolant Pressure Tank
Packaged or Unpackaged
Any Height
SWP 006 08
Wings
Packaged or Unpackaged
Any height
SWP 006 06
Fins
Packaged or Unpackaged
Any Height
SWP 006 07
Table 4. Torque Requirements
Nomenclature
Specification/Part Number
Torque Value
Guidance Control Section (GCS)
DC to DC converter screw (GCS)
2251009
7 ± 1 in-lbs
Exhaust valve to GCS screw (GCS)
2596371
7 ± 1 in-lbs
Fin attachment screw (GCS)
NAS1351-4LB14P
100 + 5 in-lbs
Housing assembly screw (GCS)
NAS1189-E3P7H
27.5 ± 2.5 in-lbs
Nitrogen Plug (GCS)
2236374
50 + 10 in-lbs
Umbilical base screw (GCS)
2251009
7 ± 1 in-lbs
Coupling Ring(s) (MK 57, MBA, MDU-27)
Coupling ring screw
639AS1599
100 ± 5 in-lbs
Coupling ring screw
8934242
100 ± 5 in-lbs
Aft/Center hanger bolts (4) (MK 57)
MS24673-11
40 ± 5 in-lbs
Forward Hanger Attachment Bolt (MK 57)
639AS6699
550 ± 25 in-lbs
Forward Hanger Attachment Screw (MK 57)
NAS1219-5E-8P alternate for
PN 639AS6699
200 ± 5 in-lbs
Wing attachment screw (Tactical Wing)
1555392
100 + 5 in-lbs
Guide vane screw (Tactical Wing)
NAS514P632-5P
8 ± 1 in-lbs
Rolleron damper screw (Tactical Wing)
1560938
30 ± 2 in-lbs
Rolleron hinge screw (Tactical Wing)
1560939
32 ± 1 in-lbs
Aft closure retainer screws (MBA)
NAS335CPA5
100 ± 5 in-lbs
Center/Aft hanger screws (MBA)
NAS336CPA13
200 ± 10 in-lbs
Mark 57 Rocket Motor (MK-57)
Missile Body Assembly (MBA)
6
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 4. Torque Requirements (Continued)
Nomenclature
Specification/Part Number
Torque Value
Forward adapter retaining screws (MBA)
NAS335CPA5
100 ± 5 in-lbs
Forward hanger bolts (MBA)
NAS335CPA11
200 ± 10 in-lbs
Fixed wing to MBA attachment screw (MBA)
8241283-01
140 ± 10 in-lbs
Wing attachment screws (MBA)
NAS335CPA5
140 ± 10 in-lbs
Wing positioning screw (MBA)
8241284-01
100 maximum in-lbs
Wing positioning screw (MBA)
1555392 alternate
for 8241284-01)
100 maximum in-lbs
Dummy Body Section (MDU-27)
Adapter Bolt (MDU-27)
NAS335CPA5
Aft/Center Hanger Screws (MDU-27)
MS24673-11
40 ± 5 in-lbs
Forward Hanger Bolt (MDU-27)
639AS10190
490 ± 10 in-lbs
Forward Hanger Screws (MDU-27)
NAS1219-5-12P
140 ± 5 in-lbs
Tactical wing attachment screw (MDU-27A/A)
1555392
100 + 5 in-lbs
Guide vane screw (Tactical Wing)
NAS514P632-5P
8 ± 1 in-lbs
Rolleron damper screw (Tactical Wing)
1560938
30 ± 2 in-lbs
Rolleron hinge screw (Tactical Wing)
1560939
32 ± 1 in-lbs
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this WP is provided as a
guide in Unpacking/Packaging, and Inspection of the
CATM-9M and DATM missiles (Figure 1). Production
techniques involving preparation of more than one missile
may require deviations from the work sequence. Several
procedures may be performed simultaneously, and in
different work areas, provided they do not invalidate or
interfere with a preceding or subsequent step and safety
precautions are strictly observed.
3.
of missile/component, reject it. Report incident/accident.
Request disposition of dropped components from WRALC, 575 CBSS/GBIA, 460 Richard Ray Blvd, Ste 200,
Robins AFB, GA 31098-1813.
7. DROPPED MISSILE/COMPONENT
PROCESSING.
8. Dropped AUR processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
AUR, reject it. Report dropping incidents in accordance
with AFI 91-204 and AFOSH 91/127 series publications.
SAFETY AND ACCIDENT PREVENTION.
9.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
150 ± 10 in-lbs
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving collision or inadvertent
damage to the missile or missile components can cause
missile malfunction. If any doubt exists as to acceptability
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives as required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
Change 1
6.1
CSTO XX21M-AIM9M-2
WP 007 00
INERT COMPONENT
CATM
MDU-27A/A
MBA
MDU-27/A
Figure 1. CATM Missile
13. TORQUE REQUIREMENTS.
a.
CATMs will be equipped with wings and fins,
unless specific authorization to the contrary is
granted by the applicable aircraft system
manager, through Seek Eagle Certification and
inclusion in the aircraft loading and pilot’s
manuals.
b.
Safe-Arm handles/safety clip assemblies or SafeArm keys may be removed from CATMS at the
direction of MAJCOMs. When this option is
exercised the items must be removed and when
required reinstalled in accordance with the
applicable paragraph(s) in this manual. While the
above items are removed the SAFE-ARM decal
need not be maintained in serviceable condition.
All items removed under this option must be
maintained in serviceable condition for
installation prior to the end item being removed
from the supply point.
14. Verify torque wrenches have current calibration
sticker. Tighten all fasteners to torque value given in Table
4.
15. MISSILE CONFIGURATIONS.
16. The combination of components listed in Table 5
define the only authorized configurations for the CATM9M and DATM missiles. If component replacement is
required, refer to WP 009 00.
CAUTION
Free flight aerodynamic characteristics of the
missile are such that a missile without wing and
fin assemblies can be unstable. In the event of
missile separation from launcher in flight, the
training missile has a high probability of
contacting the aircraft.
6.2
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
GUIDANCE
CONTROL
SECTION
DATM
639AS6566
CATM-9M-24
639AS6160-24
CATM-9M-20
639AS6160-20
CATM-9M-16
639AS6160-16
CATM-9M-10
639AS6160-10
CATM-9M-9
639AS6160-9
CATM-9M-7
639AS6160-7
CATM-9M-3
639AS6160-3
MISSILE
CONFIGURATION
CATM-9M-1
639AS6160-1
Table 5. Missile Configurations
NOTES:
WGU-4A/B
639 AS 396 3
WGU-4A(T-2)/B
639 AS 499 0
AN/DSQ-29-T1
639 AS 280 0 (e)
UMBILICAL
Tactical Umbilical
639 AS 109 35 (e)
a
a
a
a
c
Tactical Umbilical
260 3913
a
a
a
a
c
Training Umbilical
HRU-985A/E
288 0325
CAPTIVE
FLIGHT
ADAPTER
Captive Flight
Adapter
041 508-0 106
or 0 41508 -0113
TMU-72B/B
639 AS 107 89
COOLANT
TANK
TARGET
DETECTOR
b. If PN 639AS2815 or 639AS6516 are not
available, PN 639AS761, 639AS3801, or
639AS6080 may be used. S-A device will not be
used. All protective covers will be installed and
GCS 9-pin connector will not be connected to the
TD. The GCS 9-pin connector cap will be
installed if available, and the cable taped to the
GCS so as not to interfere with GCS to TD
mating.
c. The DATM missile does not require a fully
serviceable umbilical cable. However, cables with
excessively worn or damaged connectors must
be rejected.
TMU-72A/B
639 AS 673 9
TMU-72/B
639 AS 150 5
FINS
a. Use of either the Captive Flight Adapter or HRU985A/E will be determined by local requirements.
Captive flight adapter PN 041508-0106 or
041508-0113 shall be installed on tactical
umbilical cable when a tactical GCS is used for
training. Captive flight adapter will not be used
with the HRU-985A/E.
d. Wing assemblies with rollerons, dampers, and
cager assemblies removed may be used on the
CATM missile provided all four wings have these
assemblies removed.
BSU-32/B
639 AS 751
DSU-15/B
639 AS 761
b
b
b
DSU-15A/B
639 AS 380 1
b
b
b
DSU-15B/B
639 AS 608 0
b
b
b
e. Umbilical cable PN 639AS10935 is preferred for use
with USAF launchers. Umbilical cable PN 2603913
is preferred for use with USN launchers. See WP
003 00.
DSU-15(T-1)/B
639 AS 281 5
DSU-15(T-1)A/B
639 AS 651 6
WARHEAD
MK 70 MOD 1
639 AS 290 0
MK 57 MOD 1
639 AS 289 5
ROCKET
MOTOR
MK 57 MOD 2
639 AS 476 5
MK 57 MOD 3
639 AS 499 1
MBA
WINGS
MBA
824 1297- 30
MK 1 MOD 0
639 AS 151 7535
d
d
MK 1 MOD 1
639 AS 283 6
d
d
MK 1 MOD 2
639 AS 489 5
d
d
WING FIXED
824 1280- 30
MDU-27
MDU-27A/A
639 AS 101 76
MDU-27/A
639 AS 296 6
PREFERRED
ALTERNATE
Change 1
7
CSTO XX21M-AIM9M-2
WP 007 00
c.
Deleted.
b.
Press button on pressure relief valve.
c.
Beginning at each end and working toward the
center, release the 16 container latches and place
to the down position.
d.
Remove container cover by either lifting at each
corner (manually) or by lifting at the lift rings
using a mechanical means.
CAUTION
17. EMPTY CONTAINER PROCESSING.
18. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
Mishandling can cause damage to the missile/
components. Do not lift missile by wings, fins,
rollerons, umbilical or dome assembly. Do not
allow missile/components to come in contact
with hard objects while handling. Do not rest
missile on target detector.
e.
NOTE
For steps f, g, and i, comply with requirements
applicable to the missile configuration.
f.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
a.
8
Inspect container (Figure 2) for damage. If it is
evident that container has been improperly
handled, inspect missile in accordance with the
appropriate inspection table.
Change 2
Ensure Safe-Arm selector handle is locked in the
SAFE position. If not, perform step (1) for Mod 3
or step (2) for Mod 2.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure to
lock in SAFE position. Move key to
horizontal position.
19. UNPACKING.
20. MISSILE UNPACKING FROM THE CNU-310/E
CONTAINER. Before opening a container, ensure that all
markings are legible. Record markings that may be
destroyed by opening the container. Retain serviceable
packing for possible reuse. Unpack AUR(s) as follows:
Remove one missile at a time and place on
approved assembly stand or handling equipment.
g.
Ensure dome protector, umbilical protective cap,
TD protective cover, and forward hanger (MK 57
Mod 2 and Mod 3) protective cover are properly
installed.
h.
If required, remove remaining missiles (steps e, f,
and g).
i.
Remove coolant tanks, fins, and wings.
CSTO XX21M-AIM9M-2
WP 007 00
j.
Verify interior packing of container is complete
and undamaged. Place in container. Close cover.
k.
Process empty container Paragraph 17.
i.
The DATM missile does not require flight worthy
components. Table 7 or 17 shall be used only to
ensure that the DATM can be used for its
intended purpose.
23. COOLANT PRESSURE TANK INSPECTION.
Inspect coolant pressure tank Table 11.
21. INSPECTION.
22. CATM/DATM MISSILE INSPECTION.
24. FIN INSPECTION. Inspect fins Table 10.
a.
Inspect missile CATM-1, Table 6.
b.
Inspect missile CATM-3 and -7, Table 7.
c.
Inspect missile CATM-9 and -10, Table 8.
d.
Inspect missile CATM-16, -20, and -24, Table 9.
e.
Inspect AUR CATM-1, Table 15.
f.
Inspect AUR CATM-3 and -7, Table 17.
g.
Inspect AUR CATM-9 and -10, Table 19.
h.
Inspect AUR CATM-16, -20, and -24, Table 21.
25. WING INSPECTION.
a.
Inspect MBA fixed wings Table 13.
b.
Inspect Mk 1 Mod 1 or Mod 2 wings Table 14.
c.
Perform Mk 1 Mod 1 or Mod 2 wing tap
inspection Paragraph 27.
d.
Perform rolleron
Paragraph 33.
e.
Perform cager release-pull test Paragraph 34.
assembly
functional
test
STAND OFF (6)
LIFT RINGS (4)
PRESSURE
RELIEF
VALVE
FINS
AFT
COOLANT
PRESSURE
TANKS
HUMIDITY
INDICATOR
TAPE
WINGS
SLOTS (6)
DOME
PROTECTOR SLOT
Figure 2. CNU-310/E All-Up-Round Container (PN 785041-10) and CATM/DATM Missiles
Change 1
9
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Coupling ring cracked, not PN 639AS672, not
properly orientated, parts not installed correctly
(Figure 3)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code)
00784 with date of manufacture 1-90 through 12-90
or 1-83 through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or
later
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
6
Coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 3)
CRITICAL
Replace coupling ring screw
WP 009 00
7
Coupling ring fails straightedge inspection (Figure 4)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 5) missing or
HRU-985A/E training umbilical (Figure 6) not
installed. Captive flight adapter must be used with
tactical umbilical (PN 2603913 or 639AS10935) on
tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 8) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
GUIDANCE CONTROL SECTION
10
10
Missing or damaged shrink tubing (Figure 5) (must
be used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
11
Captive flight adapter or HRU-985A/E training
umbilical connector socket/pins damaged
MAJOR
Replace captive flight adapter or HRU985A/E training umbilical SWP 006 01
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
(1) COUPLING RING
GCS
(2) CLIP
(1)
(3) SCREW
FWD
(4) PIN
(5) THREADED PIN
(2)
(3)
(4)
(5)
INDEXING
PIN
AFT
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 3. Coupling Ring Assembly
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 4. Coupling Ring Straightedge Inspection
Change 2
11
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
GCS
SKIN
SAFETY WIRE
UMBILICAL BLOCK
DETAIL A
GASKET
GUIDE PIN
UMBILICAL BASE
GUIDE PIN
Figure 5. Captive Flight Adapter, Umbilical Cable and GCS Base
12
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
*12
Foreign material on dome (Various colorations of
dome do not affect missile performance) (Figure 8)
MINOR
Clean WP 009 00
*13
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
14
Dome or dome lock ring loose or cracked
MAJOR
Replace GCS WP 009 00
15
GCS dome lock ring/dome housing has dents greater
than 0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 009 00
16
GCS dome lock ring/dome housing has dents up to
0.060-inch in depth or less or gouges up to 0.025inch in depth or burrs on surface
MAJOR
Remove raised metal only with flat file
or 320 grit emery cloth
17
Gas generator service life expired (Figure 11)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
18
Absence of, or illegible, part number, lot number,
date of manufacturer or serial number
MAJOR
Suspend and hold in condition Code J.
Contact TMTCG, OO-ALC/GHGAMF,
Robins AFB, GA 31098-1813 for
instructions
19
GCS skin cracked, punctured, dents greater than
0.060-inch or gouges greater than 0.025-inch in
depth (Figure 8)
MAJOR
Replace GCS WP 009 00
20
GCS skin has dents up to 0.060-inch, gouges up to
0.025-inch in depth, burrs, scratches, or pits
penetrating anodized coating or corrosion
MINOR
Repair coating WP 009 00
21
Metal fin cup (Figure 7) missing or loose in GCS
housing
MAJOR
Replace GCS WP 009 00
RUBBER BAND
PROTECTIVE CAP
SCREW THREADS
RUBBER FIN SEAL
UMBILICAL
BLOCK
GC
E
OM
D
S
SECURING
STRAP
ROCKER ARM
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 6. HRU-985A/E Training Umbilical
CUP FLANGE
FIN CUP
Figure 7. Fin Cup
Change 2
13
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
22
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange down
until seated on GCS housing
23
Metal fin cup flange cracked, buckled, or bent to
extent flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
24
Fin rocker arm mating area damaged, or fin
attach hole(s) in rocker arm(s) worn, stripped, or
damaged so as prevent good mate with fin
MAJOR
Replace GCS WP 009 00
25
Rubber fin seal missing or damage affecting
environmental seal
MAJOR
Replace GCS WP 009 00
26
End of rocker arm protrudes above outside surface of
fin cup assembly
MAJOR
Replace GCS WP 009 00
27
Missing or loose screws on exhaust valve (Figure 8)
MAJOR
Replace/torque screws SWP 009 01
28
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MAJOR
Remove damaged adhesive and apply a
small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
29
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
29.1
Top of umbilical block metal housing lip separating
from the epoxy core
MAJOR
Repair, SWP 008 01
30
Umbilical block spring pin (Figure 5) loose, missing,
or damaged (tactical umbilical cable PN 2603913 or
639AS10935)
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
31
Umbilical block spring pin not correct length
(tactical umbilical cable PN 2603913 or
639AS10935)
MINOR
Replace spring pin SWP 009 01
32
Umbilical cable insulation separated from cable
block or launcher connector. Insulation damaged to
extent cable insulation is penetrated, but gas tubing
or wire insulations are not damaged
MAJOR
Repair insulation SWP 009 01
33
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical cable)
34
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace screws and safety wire
SWP 009 01
*35
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
14
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NOTE 2
NITROGEN PLUG
FORWARD
SCREWS (2)
AFT SCREW
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
WINDOW
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
FLIGHT TEST
TLM
EXHAUST VALVE
SCREWS (4)
EQUIP INCLUDED
DOME ASSEMBLY
NOTES: 1. LOCATION OF MARKINGS IS APPROXIMATE.
2. 9M FOR WGU-4A/B. THREE PLACES.
3. WGU-4A/B FOR PN 639AS3963.
NOTE 2
COOLANT TANK
ACCESS COVER
Figure 8. Guidance Control Section Inspection Points, WGU-4A/B
15
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
36
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 8)
MAJOR
Clean/replace/torque screws
SWP 009 01
37
Missing or loose housing assembly screws
MAJOR
Replace/torque screws SWP 009 01
38
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws SWP 009 01
39
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
40
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
41
Dirt, grease, or corrosion inside umbilical protective
cap
MAJOR
Clean WP 009 00
42
Pin 13, 19, or 21 bent, broken, or missing in
umbilical protective cap
MAJOR
Replace cap SWP 009 01
43
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
44
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
45
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01
(HRU-985A/E training umbilical)
*46
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*47
Umbilical cable not properly secured with rubber
band (ZZ-R-1415), retaining clip or equivalent
MINOR
Secure cable
48
Loose, missing or damaged components on coolant
tank access cover
MAJOR
Replace/repair cover SWP 009 01
49
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 009 00
*50
Probe sealing cap missing on GCS coolant inlet
probe
MAJOR
Replace probe sealing cap Paragraph 51
(SWP 009 01 IPB)
*51
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap Paragraph 51
(SWP 009 01 IPB)
*52
Coolant inlet probe area dirty, moisture, corroded, or
other foreign material present
MAJOR
Clean SWP 009 01
Step
Corrective Action
DUMMY BODY SECTION
16
53
Body section for cuts or scratches in excess of
0.125-inch in depth (Figure 11)
MINOR
Repair if welding shop available
54
Absence of, or illegible, identification markings
MAJOR
Replace markings
55
Exterior paint cracked, peeling, scaling, or scuffed
MINOR
Paint SWP 009 06
56
Corrosion, dirt, or grease present on body
MINOR
Clean SWP 009 06
57
Contact buttons have dirt, grease, or corrosion
(Figure 9)
MAJOR
Clean SWP 009 06
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
FWD CONTACT BUTTON
AFT CONTACT BUTTON
MATING SURFACES
MATING
SURFACES
DETAIL A
STRESS POINTS
NONMATING
SURFACES
ATTACHING
SCREW
NOTE 1: TOP SURFACES OF CONTACT BUTTONS MUST BE EVEN WITH OR BELOW THE TOP SURFACE OF
FORWARD HANGER TO PREVENT INTERFERENCE WITH THE LAUNCHER STRIKER POINTS.
NOTE 2: WHEN CHECKING FOR CRACKS CAREFULLY CLEAN HANGER (REMOVE ALL PAINT IF PRESENT). CHECK
CLOSELY ON ALL FOUR CORNERS FOR CRACKS. USE A 10X MAGNIFYING GLASS IF NECESSARY.
Figure 9. Forward Hanger Assembly
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
58
Contact buttons have severe corrosion
MAJOR
Replace buttons SWP 009 06
59
Contact buttons not flush or below hanger
MAJOR
Replace/torque SWP 009 06
60
Forward hanger has bolts installed
MAJOR
Reject
61
Forward hanger attaching screws loose or missing
MAJOR
Replace/torque SWP 009 06
62
Forward/center/aft hanger mating surfaces have
grease, dirt, or corrosion (Figures 9 and 10)
MAJOR
Clean SWP 009 06
63
Forward/center/aft hanger nonmating surfaces for
corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
64
Forward/center hanger for burrs or scratches
MAJOR
Remove raised metal with flat file or
320 emery cloth. Touch-up paint
SWP 009 06
65
Forward/center hanger nonmating surfaces for burrs
or scratches
MAJOR
Remove metal with flat file or 320
emery cloth. Touch-up paint
SWP 009 06
66
Forward hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Replace forward hanger SWP 009 06
67
Center hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Reject
Change 1
17
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
68
Forward hanger mating surfaces have gouges greater
than 0.015-inch deep by 0.030-inch wide by 0.045inch long
MAJOR
Replace forward hanger SWP 009 06
69
Center hanger mating surfaces have gouges greater
than 0.015-inch deep by 0.030-inch wide by 0.045inch long
MAJOR
Reject
70
Forward hanger mating surfaces and stress points for
cracks (Figure 9)
MAJOR
Replace forward hanger SWP 009 06
71
Center/aft hanger mating surface has cracks
MAJOR
Reject
72
Forward hanger nonmating surfaces for dents greater
than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Replace forward hanger SWP 009 06
73
Center hanger nonmating surfaces for dents greater
than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Reject
74
Forward hanger nonmating surfaces for gouges
greater than 0.045-inch deep by 0.064-inch wide by
0.075-inch long
MAJOR
Replace forward hanger SWP 009 06
75
Center hanger nonmating surfaces for gouges greater
than 0.045-inch deep by 0.064-inch wide by 0.075inch long
MAJOR
Reject
76
Forward hanger nonmating surfaces for cracks
MAJOR
Replace forward hanger SWP 009 06
77
Center/aft hanger nonmating surfaces for cracks
MAJOR
Reject
78
Center hanger for loose shims or gap between shims
and hanger strap (Figure 10)
MAJOR
Reject
79
Center hanger has no shims and has gap between
hanger strap and hanger
MAJOR
Reject
80
Center/aft hanger band for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
81
Center/aft hanger band loose
MAJOR
Reject
82
Aft hanger mating surfaces for dents, scratches, or
gouges (Figure 10)
MAJOR
Smooth raised metal with flat file or
320 emery cloth
83
Aft hanger surface wear inspection (Paragraph 26)
MAJOR
Reject if fails inspection
84
Aft hanger nonmating surfaces have dents, burrs, or
gouges
MAJOR
Smooth raised metal with flat file or
320 emery cloth. Touch-up paint
SWP 009 06
85
Indexing pin missing, bent, or broken (Figure 11)
MAJOR
Replace indexing pin SWP 009 06
86
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire
surface is approximately an area 0.25 inches long
across the entire width of the coupling ring)
MINOR
Clean and apply corrosion preventive
compound
Step
18
Change 2
Corrective Action
CSTO XX21M-AIM9M-2
WP 007 00
Table 6. Missile Inspection CATM-1 (MDU-27/A) (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
87
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of
entire surface is approximately an area 0.25 inches
long across the entire width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
88
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, WP 009 00. Inspect for cracks.
If brown spots, specks, or discoloration
cannot be removed replace coupling
ring WP 009 00
Step
Corrective Action
MATING
SURFACES
SHIMS
MATING SURFACES OF
CENTER AND AFT
HANGER
AFT HANGER
CENTER HANGER
NOTE: MATING SURFACES ARE THE AREAS OF THE HANGER ASSEMBLY THAT TOUCH THE LAUNCHER
RAIL. ALL OTHER AREAS OF THE HANGER ASSEMBLY ARE NONMATING SURFACES.
Figure 10. Center and Aft Hanger Assemblies (MDU-27)
Change 1
18.1/(18.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
9M FOR WGU-4A/B
3 PLACES
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
DASHS SIMULATE
COUPLING RING
INERT
BODY SECTION
GUIDED MISSILE DUMMY MDU-27/A
30003-639AS2966
CONTR
MFG
ROCKET MOTOR SECTION
WARHEAD SECTION
BLUE BAND
FUZE SECTION
NOTE:
MARKINGS WILL PLACED AS SHOWN.
DECALS OR STENCILS ARE ACCEPTABLE.
NOTE:
FOR COMPLETE COMPONENT MARKING
REQUIREMENTS REFER TO SWP 009 XX
D
FW
INDEXING
PIN
Figure 11. CATM-1 Inspection Points
19
CSTO XX21M-AIM9M-2
WP 007 00
26. AFT HANGER SURFACE WEAR INSPECTION.
a.
Verify body section aft hanger is clean.
b.
Place template (Figure 12) on forward edges of
aft hanger. Using a fine tip felt pen, mark a
reference line across both sides of hanger flat
skid surfaces (Figure 13).
c.
Place template on aft edges of aft hanger. Using a
fine tip felt pen, mark a reference line across both
sides of hanger flat skid surfaces.
d.
Measure left side (when facing forward) of aft
hanger as follows:
NOTE
Ensure surface wear
calibration sticker.
fixture
has
current
(1) Slide guide block of surface wear fixture
(Figure 14) onto aft hanger from forward end
of hanger until indicator tip rests on inside of
edge of aft reference line (Figure 13). Lateral
adjustment of indicator tip may be required
to position tip on aft reference point.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point.
(2) Hand tighten two knurled locking screws to
secure guide block in place (Figure 14).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip in
place. Ensure indicator tip remains on aft
reference point. Set dial indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indicator tip
rests on forward reference line (Figure 13).
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. Reject body section with
a wear of 0.034-inch or greater.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
20
e.
Measure right side (when facing forward) of aft
hanger as follows:
(1) Slide guide block of surface wear fixture
onto aft hanger from aft end.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point on the flat surface of the
skid. Do not locate the indicator on the inner
curvature of the hanger.
(2) Hand tighten two knurled locking screws to
secure guide blocks in place (Figure 14).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip
remains on aft reference point. Set dial
indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indictor tip
rests on forward reference line.
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. Reject body section with
wear of greater than 0.034-inch.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
(7) Body sections passing skid wear inspection
shall be identified for tracking purposes by
serial numbers of body sections or serial
numbers of aft hangers. Locally assigned ID
numbers may be used if body sections do not
have serial numbers.
(8) Dummy assembly body sections that have
been subjected to captive flight since the last
inspection shall be reinspected every thirty
days until the skid surface wear reaches
0.024-inch, at which time the inspection
frequency shall be increased to every two
weeks.
CSTO XX21M-AIM9M-2
WP 007 00
Figure 12. Aft Hanger Template
INDICATOR TIP ON AFT
REFERENCE LINE AT THIS POINT
INDICATOR TIP ON FORWARD
REFERENCE LINE AT THIS POINT
FORWARD AND AFT
REFERENCE LINES
F-5/LAU-100 WEAR
INTERFACE REGION
LAU-7 WEAR
D
FW
Figure 13. Aft Hanger Flat Skid Surface
21
CSTO XX21M-AIM9M-2
WP 007 00
INDICATOR DIAL
MOUNTING POST
MOUNTING POST
KNURLED LOCKING
SCREWS (2)
GUIDE BLOCK
INDICATOR TIP
INDICATOR TIP
FORWARD
Figure 14. Aft Hanger Skid Surface Wear Fixture
Table 7. Missile Inspection CATM-3 and -7
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
22
1
Coupling ring cracked, not PN 639AS672, not
properly orientated, parts not installed correctly
(Figure 15)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code)
00784 with date of manufacture 1-90 through 12-90
or 1-83 through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
WP 009 00
3
Coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace coupling ring WP 009 00
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
GCS
TARGET
DETECTOR
FWD
(1) COUPLING RING
(2) CLIP
(3) SCREW
(4) PIN
(5) THREADED PIN
(6) GUIDE PLATE ASSEMBLY
FORWARD
COUPLING RING
ASSEMBLY
PN 639AS672
WARHEAD
(1)
AFT COUPLING
RING ASSEMBLY
PN 639AS2725-2
(2)
(3)
ROCKET MOTOR
COUPLING RING
ASSEMBLY
PN 639AS2725-1
INDEXING
PIN
GUIDE
PLATE
ASSEMBLY
(4)
(5)
(6)
ROCKET MOTOR
PART
NUMBER
AFT
REVISION
MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 15. Coupling Ring Assemblies (Mk 57)
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 16. Coupling Ring Straightedge Inspection
Change 2
23
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
4
Coupling ring screw(s) not PN 639AS1599 Rev M or
later, or PN 8934242
CRITICAL
Replace coupling ring screw(s)
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw(s)
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw(s)
WP 009 00
6
Coupling ring screw(s) PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 15)
CRITICAL
Replace coupling ring screw(s)
WP 009 00
7
Coupling ring(s) fails straight edge inspection
(Figure 16)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 18) missing or
HRU-985A/E training umbilical (Figure 17) not
installed. Captive flight adapter must be used with
tactical umbilical (PN 2603913 or 639AS10935) on
tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 20) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Rocket motor Mk 57 Mod 2 or Mk 57 Mod 3
Safe-Arm selector is in the ARM position
Step
Corrective Action
MAJOR
Ensure rocket motor Safe-Arm selector
handle is locked in the SAFE position. If
not, perform step (1) for Mod 3 or step
(2) for Mod 2: (1) Mod 3, pull handle to
unlock and move to the vertical position,
maintain pull pressure. Rotate handle 90
degrees clockwise and move to
horizontal position. Release pull
pressure to lock in SAFE position.
Install safety clip assembly. (2) Mod 2,
insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure
to lock in SAFE position. Move key to
horizontal position.
GUIDANCE CONTROL SECTION
24
11
Missing or damaged shrink tubing (Figure 18) (must
be used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
12
Captive flight adapter or HRU-985A/E training
umbilical connector socket/pins damaged
MAJOR
Replace captive flight adapter or HRU985A/E training umbilical SWP 006 01
13
Gas generator service life expired (Figure 23)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
14
Absence of, or illegible, part number, lot number, date
of manufacturer or serial number
MAJOR
Suspend and hold in condition Code J.
Contact TMTCG, OO-ALC/GHGAMF,
Robins AFB, GA 31098-1813 for
instructions
*15
Foreign material on dome. (Various colorations of
dome do not affect missile performance) (Figure 20)
MINOR
Clean WP 009 00
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
*16
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
17
Dome or dome lock ring loose or cracked
MAJOR
Replace GCS WP 009 00
18
GCS dome lock ring/dome housing has dents greater
than 0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 009 00
19
GCS dome lock ring/dome housing has dents up to
0.060-inch in depth or less or gouges up to 0.025-inch
in depth or burrs on surface
MAJOR
Remove raised metal only with flat file
or 320 grit emery cloth
20
GCS skin cracked, punctured, dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
(Figure 20)
MAJOR
Replace GCS WP 009 00
21
GCS skin has dents up to 0.060-inch, gouges up to
0.025-inch in depth, burrs, scratches, or pits
penetrating anodized coating or corrosion
MINOR
Repair coating WP 009 00
22
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws SWP 009 01
23
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MAJOR
Remove damaged adhesive and apply a
small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
24
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical cable assembly
SWP 009 01
24.1
Top of umbilical block metal housing lip separating
from the epoxy core
MAJOR
Repair, SWP 008 01
25
Metal fin cup (Figure 19) missing or loose in GCS
housing
MAJOR
Replace GCS WP 009 00
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
GC
S
DO
ME
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 17. HRU-985A/E Training Umbilical
Change 1
25
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
GCS
SKIN
SAFETY WIRE
UMBILICAL BLOCK
DETAIL A
GASKET
GUIDE PIN
UMBILICAL BASE
GUIDE PIN
Figure 18. Captive Flight Adapter, Umbilical Cable and GCS Base
26
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 19. Fin Cup
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
26
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange down
until seated on GCS housing
27
Metal fin cup flange cracked, buckled, or bent to
extent flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
28
Fin rocker arm mating area damaged, or fin
attach hole(s) in rocker arm(s) worn, stripped, or
damaged so as prevent good mate with fin
MAJOR
Replace GCS WP 009 00
29
Rubber fin seal missing or damage affecting
environmental seal
MAJOR
Replace GCS WP 009 00
30
End of rocker arm protrudes above outside surface of
fin cup assembly
MAJOR
Replace GCS WP 009 00
31
Umbilical block spring pin (Figure 18) loose,
missing, or damaged (tactical umbilical cable
PN 2603913 or 639AS10935)
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
32
Umbilical block spring pin not correct length (tactical
umbilical cable PN 2603913 or 639AS10935)
MINOR
Replace spring pin SWP 009 01
33
Umbilical cable insulation separated from cable block
or launcher connector. Insulation damaged to extent
cable insulation is penetrated, but gas tubing or wire
insulations are not damaged
MAJOR
Repair insulation SWP 009 01
34
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical cable)
35
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace screws and safety wire
SWP 009 01
Change 1
27
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
*36
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
37
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 20)
MAJOR
Clean/replace/torque screws
SWP 009 01
38
Missing or loose housing assembly screws
MAJOR
Replace/torque screws SWP 009 01
39
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws SWP 009 01
40
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
41
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
42
Dirt, grease, or corrosion inside umbilical protective
cap
MAJOR
Clean WP 009 00
43
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
44
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing SWP 009 01
45
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical)
46
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*47
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*48
Umbilical cable not properly secured with rubber
band (ZZ-R-1415), retaining clip or equivalent
MINOR
Secure cable
49
Loose, missing or damaged components on coolant
tank access cover
MAJOR
Replace/repair cover SWP 009 01
50
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 009 00
*51
Probe sealing cap missing on GCS coolant inlet probe
MAJOR
Replace probe sealing cap Paragraph 51
(SWP 009 01 IPB)
*52
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap Paragraph 51
(SWP 009 01 IPB)
*53
Coolant inlet probe area dirty, moisture, corroded, or
other foreign material present
MAJOR
Clean SWP 009 01
MINOR
Clean and apply MIL-C-85054
Corrective Action
TARGET DETECTOR
54
28
Coupling ring(s) (Figure 15) has burrs, gouges,
scratches, dents, or pits that penetrate surface finish
and aggregately covers less than 2% of entire surface
(2% of entire surface is approximately an area 0.25
inches long across the entire width of the coupling
ring)
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 20. Guidance Control Section Inspection Points
29
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
Coupling ring(s) has burrs, gouges, scratches, dents,
or pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of entire
surface is approximately an area 0.25 inches long
across the entire width of the coupling ring)
MAJOR
Replace coupling ring(s) WP 009 00
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, WP 009 00. Inspect for cracks. If
brown spots, specks, or discoloration
cannot be removed replace coupling ring
WP 009 00
56
Forward indexing pin is loose, missing, damaged, or
corroded
MAJOR
Replace pin SWP 009 02
57
Exterior surface scratches (Figure 23)
MINOR
Acceptable
58
TD markings missing or illegible
MAJOR
Replace markings SWP 009 02
59
TD window(s) cracked, broken, missing, loose, or
condensation on inside of window
MAJOR
Replace window(s) SWP 009 02
60
TD window(s) for cleanliness
MINOR
Clean WP 009 00
61
TD protective cover missing
MINOR
Replace cover
Step
55
55.1
Corrective Action
WARHEAD
62
Exterior surface of warhead dented, but skin not
penetrated (Figure 23)
MINOR
Acceptable
63
Exterior surface of warhead gouged, but skin not
penetrated
MINOR
Remove raised metal only with flat file
or 320 grit emery cloth and touch-up
paint WP 009 00
*64
Absence of, or illegible, markings
MAJOR
Replace markings SWP 009 03
65
Surface of warhead cracked or skin penetrated
MAJOR
Replace warhead WP 009 00
ROCKET MOTOR SECTION
30
66
Rocket motor Safe-Arm selector assembly attachment
screws loose, assembly damaged, or missing,
(Mod 2/3) (Figures 52 and 53)
MAJOR
Torque/replace screws, replace assembly
SWP 009 04
67
Safe-Arm selector handle (Mod 3) spring pin fails
inspection Paragraph 36
MAJOR
Replace spring pin WP 009 04
68
Safe-Arm selector damaged or fails functional check
Paragraph 37
MAJOR
Repair/replace Safe-Arm selector
assembly SWP 009 04
69
Absence of, or illegible, markings (Figure 23)
MAJOR
Replace markings SWP 009 04
70
Top of forward hanger (Figure 21) mating surface for
snubber wear in excess of 0.015 inch in depth, rear of
hanger for detent wear in excess of 0.030, or forward
detent lug wear area is rounded over all the way
across the area between the two arrows.
MAJOR
Replace hanger SWP 009 04
71
Forward hanger mating surfaces and stress points for
cracks
MAJOR
Replace hanger SWP 009 04
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
72
Rocket motor contact buttons have severe corrosion
damage or are not flush or below hanger
MAJOR
Replace/tighten contact buttons
SWP 009 04
73
Forward hanger protective cover damaged or missing
MINOR
Replace cover
74
Rocket motor hangers have damage present that
would cause difficulty when installing missile on
launcher
MAJOR
Replace hanger(s) SWP 009 04
NOTE
Steps 75 through 81 apply to the center and aft hanger (Figure 22, area X)
75
Mating surfaces for dents greater than 0.015-inch
deep by 0.030-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
76
Mating surface for gouges greater than 0.015-inch
deep by 0.030-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
77
Non-mating surfaces for pitted areas greater than
0.060 square inch in diameter and 0.032-inch deep
MAJOR
Replace hanger(s) SWP 009 04
78
Non-mating surfaces for dents greater than 0.032inch deep by 0.064-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
79
Non-mating surfaces for gouges greater than 0.045inch deep or 0.064-inch wide or 0.075-inch long
MAJOR
Replace hanger(s) SWP 009 04
80
Non-mating surface for cracks
MAJOR
Replace hanger(s) SWP 009 04
81
Mating surface for cracks
MAJOR
Replace hanger(s) SWP 009 04
NOTE
Steps 82 through 86 apply to center and aft hanger non-mating surfaces
(Figure 22, area Y)
82
Pits greater than 0.020 square inch and 0.015-inch
deep
MAJOR
Replace hanger(s) SWP 009 04
83
Dents greater than 0.020-inch deep or 0.050-inch in
diameter
MAJOR
Replace hanger(s) SWP 009 04
84
Burrs or scratches
MAJOR
Remove raised metal only with flat file
or 320 grit emery cloth
85
Cracks
MAJOR
Replace hanger(s) SWP 009 04
86
Gouges greater than 0.020-inch deep or 0.032-inch
wide or 0.064-inch long
MAJOR
Replace hanger(s) SWP 009 04
87
Hangers for visible gap between hanger strap and
rocket motor mating surfaces
MAJOR
Replace hanger(s) SWP 009 04
87.1
Center hanger loose
MAJOR
Replace hanger SWP 009 04
87.2
Center hanger threaded pins (Figure 22.1 center
hanger Views A and B) loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
87.3
Center hanger shims (Figure 22.1 center hanger
View B) loose or missing
MAJOR
Replace hanger SWP 009 04
Change 1
31
CSTO XX21M-AIM9M-2
WP 007 00
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
NOTE 1: TOP SURFACES OF CONTACT BUTTONS MUST BE EVEN WITH OR BELOW THE TOP SURFACE OF
FORWARD HANGER TO PREVENT INTERFERENCE WITH THE LAUNCHER STRIKER POINTS.
NOTE 2: WHEN CHECKING FOR CRACKS CAREFULLY CLEAN HANGER (REMOVE ALL PAINT IF PRESENT). CHECK
CLOSELY ON ALL FOUR CORNERS FOR CRACKS. USE A 10X MAGNIFYING GLASS IF NECESSARY.
Figure 21. Forward Hanger Assembly
0O
45O
VERTICAL CENTERLINE
AREA X
45O
NOTE: MATING SURFACES ARE THE AREAS OF
THE HANGER ASSEMBLY THAT TOUCH THE
LAUNCHER RAIL. ALL OTHER AREAS OF
THE HANGER ASSEMBLY ARE NONMATING
SURFACES.
HANGER MATING
SURFACES
DETAIL A
HANGER
SCREWS
AREA Y
Figure 22. Center and Aft Hanger Assemblies (Mk 57)
32
CSTO XX21M-AIM9M-2
WP 007 00
Table 7. Missile Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
87.4
Center hanger band screw(s) (Figure 22.1 center
hanger View C) loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
87.5
Aft hanger loose
MAJOR
Replace hanger SWP 009 04
87.6
Aft hanger band screw(s) (Figure 22.1 aft hanger
View A) loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
88
Coupling ring (Figure 15) has burrs, gouges,
scratches, dents, or pits that penetrate surface finish
and aggregately covers less than 2% of entire surface
(2% of entire surface is approximately an area 0.25
inches long across the entire width of the coupling
ring)
MINOR
Clean and apply MIL-C-85054
89
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of entire
surface is approximately an area 0.25 inches long
across the entire width of the coupling ring)
MAJOR
Replace coupling ring WP 009 00
90
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, WP 009 00. Inspect for cracks.
If brown spots, specks, or discoloration
cannot be removed replace coupling
ring WP 009 00
Figure 22.1. Center and Aft Hanger Inspection (Mk 57)
Change 1
32.1/(32.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
WGU-4A(T-2)/B
9M FOR WGU-4A/B
3 PLACES
Figure 23. CATM-3 and -7 Inspection Points
33
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by and asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
34
1
Coupling ring cracked, not PN 639AS672, not properly
orientated, parts not installed correctly (Figure 24)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or later, or
PN 8934242
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
6
Coupling ring screw PN 639AS1599 Rev N manufactured
by (Cage Code) MC (Figure 24)
CRITICAL
Replace coupling ring screw
WP 009 00
7
Coupling ring fails straightedge inspection (Figure 25)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 27) missing or
HRU-985A/E training umbilical (Figure 26) not installed.
Captive flight adapter must be used with tactical umbilical
(PN 2603913 or 639AS10935) on tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 29) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Deleted
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
(1) COUPLING RING
GCS
(2) CLIP
(1)
(3) SCREW
FWD
(4) PIN
(5) THREADED PIN
(2)
(3)
(4)
(5)
INDEXING
PIN
AFT
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 24. Coupling Ring Assembly
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 25. Coupling Ring Straightedge Inspection
Change 2
35
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
GUIDANCE CONTROL SECTION
11
Missing or damaged shrink tubing (Figure 27) (must be
used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
12
Gas generator service life expired (Figure 31)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
13
Absence of, or illegible, part number, lot number, date of
manufacturer or serial number
MAJOR
Suspend and hold in condition
Code J. Contact TMTCG, OOALC/GHGAMF, Robins AFB, GA
31098-1813 for instructions
*14
Foreign material on dome. (Various colorations of dome
do not affect missile performance) (Figure 29)
MINOR
Clean WP 009 00
*15
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
16
Dome or dome lock ring loose or cracked
MAJOR
Replace GCS WP 009 00
17
GCS dome lock ring/dome housing has dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
18
GCS dome lock ring/dome housing has dents up to 0.060inch in depth or less or gouges up to 0.025-inch in depth or
burrs on surface
MAJOR
Remove raised metal only with flat
file or 320 grit emery cloth
19
GCS skin cracked, punctured, dents greater than 0.060inch or gouges greater than 0.025-inch in depth (Figure 29)
MAJOR
Replace GCS WP 009 00
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
OM
SD
C
G
E
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 26. HRU-985A/E Training Umbilical
36
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
1.250 INCH
LONG
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
DETAIL A
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 27. Captive Flight Adapter, Umbilical Cable and GCS Base
Change 1
37
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
20
GCS skin has dents up to 0.060-inch, gouges up to 0.025inch in depth, burrs, scratches, or pits penetrating anodized
coating or corrosion
MINOR
Repair coating SWP 009 01
21
Captive flight adapter or HRU-985A/E training umbilical
connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
22
Metal fin cup (Figure 28) missing or loose in GCS housing
MAJOR
Replace GCS WP 009 00
23
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
24
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
25
Fin rocker arm mating area damaged, or fin
attach hole(s) in rocker arm(s) worn, stripped, or damaged
so as prevent good mate with fin
MAJOR
Replace GCS WP 009 00
26
Rubber fin seal missing or damage affecting
environmental seal
MAJOR
Replace GCS WP 009 00
27
End of rocker arm protrudes above outside surface of fin
cup assembly
MAJOR
Replace GCS WP 009 00
28
Missing or loose screws on exhaust valve (Figure 29)
MAJOR
Replace/torque screws
SWP 009 01
29
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MAJOR
Remove damaged adhesive and
apply a small bead of adhesive at
junction
Step
Corrective Action
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
30
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 28. Fin Cup
38
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
30.1
Top of umbilical block metal housing lip separating from
the epoxy core
MAJOR
Repair, SWP 008 01
31
Umbilical block spring pin (Figure 27) loose, missing, or
damaged (tactical umbilical cable PN 2603913 or
639AS10935)
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
32
Umbilical block spring pin not correct length (tactical
umbilical cable PN 2603913 or 639AS10935)
MINOR
Replace spring pin SWP 009 01
33
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated, but gas tubing or wire insulations
are not damaged
MAJOR
Repair insulation SWP 009 01
34
Umbilical cable shows evidence of being kinked, crushed,
or deformed as to affect integrity of cable assembly
MAJOR
Replace umbilical cable SWP 009
01 (tactical umbilical cable PN
2603913 or 639AS10935)/SWP
006 01 (HRU-985A/E training
umbilical cable)
35
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace screws and safety wire
SWP 009 01
*36
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
37
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 29)
MAJOR
Clean/replace/torque screws
SWP 009 01
38
Missing or loose housing assembly screws
MAJOR
Replace/torque screws
SWP 009 01
39
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws
SWP 009 01
40
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
41
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
42
Dirt, grease, or corrosion inside umbilical protective cap
MAJOR
Clean WP 009 00
43
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
44
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
45
Damaged insert, plugged or corroded sockets on umbilical
connector
MAJOR
Replace umbilical cable
SWP 009 01 (tactical umbilical
cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical)
Change 1
39
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 29. Guidance Control Section Inspection Points
40
CAUTION
NO
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
46
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*47
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*48
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MINOR
Secure cable
49
Loose, missing or damaged components on coolant tank
access cover
MAJOR
Replace/repair cover SWP 009 01
50
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 009 00
*51
Probe sealing cap missing on GCS coolant inlet probe
MAJOR
Replace probe sealing cap
Paragraph 51 (SWP 009 01 IPB)
*52
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap
Paragraph 51 (SWP 009 01 IPB)
*53
Coolant inlet probe area dirty, moisture, corroded, or other
foreign material present
MAJOR
SWP 009 01
MISSILE BODY SECTION
54
Coupling ring (Figure 24) has burrs, gouges, scratches,
dents, or pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire surface
is approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
55
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 00
56
Exterior surface scratches (Figure 31)
MINOR
Acceptable
57
Missile body section for cuts or scratches in excess of
0.125 in depth
MINOR
Repair if welding shop is available
58
Forward indexing pin is loose, missing, damaged, or
corroded
MAJOR
Replace pin SWP 009 05
59
Forward adapter retaining screws loose/missing
MAJOR
Remove GCS WP 009 00
Torque/replace screws
SWP 009 05
55.1
Change 2
41
CSTO XX21M-AIM9M-2
WP 007 00
Table 8. Missile Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
If Safe-Arm Selector Assembly is present, remove and replace with
cover plate, SWP 009 05.
60
Cover plate loose or missing. Cover plate attaching screws
loose or missing. (Figure 31)
MAJOR
Replace cover plate. Tighten or
replace screws. SWP 009 05
61
Deleted
62
Deleted
63
Deleted
64
Top of forward hanger (Figure 30) mating surface for
snubber wear in excess of 0.015 inch in depth, rear of
hanger for detent lug wear in excess of 0.030, or forward
detent lug wear area is rounded all the way across the area
between the two arrows
MAJOR
Remove GCS WP 009 00
Replace hanger SWP 009 05
65
Forward hanger mating surfaces and stress points for
cracks
MAJOR
Remove GCS WP 009 00
Replace Hanger SWP 009 05
NOTE
Additional attention should be given to the center and aft hanger screw
heads during hanger inspection. Head of screw may crack/separate
from shank and remain adhered by paint and/or corrosion.
42
66
Forward, center, or aft hanger screws, damaged or missing
(Figure 31
MAJOR
Remove GCS WP 009 00
Repair SWP 009 05
67
Firmly grasp each hanger by hand and vigorously attempt
to move the hanger. Any movement is unacceptable.
MAJOR
Remove GCS WP 009 00
Replace hanger screws
SWP 009 05
68
Center or aft hanger(s) mating surface (Figures 30 and 31)
for cracks
MAJOR
Remove GCS WP 009 00
Replace hanger(s) SWP 009 05
69
Forward, center, or aft hanger(s) non-mating surface
(Figures 30 and 31) for cracks
MAJOR
Remove GCS WP 009 00
Replace hanger(s) WP 009 05
70
Aft closure retaining screws loose (Figure 31)
MAJOR
Torque screws SWP 009 05
71
Sealant missing from hole in aft closure
MINOR
Replace sealant SWP 009 05
72
Absence of, or illegible markings
MAJOR
Replace markings
SWP 009 01/SWP 009 05
73
Deleted
74
Contact button (hex bar stock) loose, missing or not flush
or below hanger (Figure 30)
MAJOR
Replace/repair SWP 009 05
75
Exterior paint cracked, peeling, scaling or scruffed
(Figure 31)
MINOR
Touch-up paint WP 009 00
76
Corrosion, dirt or grease present
MINOR
Clean WP 009 00
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
SIMULATED CONTACT BUTTONS
DETAIL A
STRESS POINTS
MATING
SURFACES
NON-MATING
SURFACES
FORWARD DETENT LUG
WEAR AREA
NOTE:
CAREFULLY CLEAN (REMOVE ALL PAINT
IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A
10X MAGNIFYING GLASS IF NECESSARY.
SCREW
Figure 30. Forward Hanger Assembly (MBA)
Change 1
42.1/(42.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
WGU-4A(T-2)/B
9M FOR WGU-4A/B
Figure 31. CATM-9 and -10 Inspection Points
Change 2
43
CSTO XX21M-AIM9M-2
WP 007 00
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by and asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
44
1
Coupling ring cracked, not PN 639AS672, not properly
orientated, parts not installed correctly (Figure 32)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or later
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
6
Coupling ring screw PN 639AS1599 Rev N manufactured
by (Cage Code) MC (Figure 32)
CRITICAL
Replace coupling ring screw
WP 009 00
7
Coupling ring fails straightedge inspection (Figure 33)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 35) missing or
HRU-985A/E training umbilical (Figure 34) not installed.
Captive flight adapter must be used with tactical umbilical
(PN 2603913 or 639AS10935) on tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 37) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Safe-Arm selector is in the ARM position (Figure 39)
MAJOR
Change 2
Pull handle to unlock and move to
vertical position, maintain pull
pressure. Rotate handle 90 degrees
clockwise and move to horizontal
position. Release pull pressure to
lock in SAFE position. Install
safety clip assembly.
CSTO XX21M-AIM9M-2
WP 007 00
FO
RW
AR
D
9 N
6 3
9
9
1 5
A S
DUMMY BODY SECTION
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
PART
NUMBER
REVISION
MARKING
GUIDANCE
CONTROL
SECTION
ARROWS POINT
FORWARD
AF
T
COUPLING RING ASSEMBLY
PN 639AS672
CAGE
CODE
INDEXING PIN
DOM
COUPLING RING SCREW
TYPICAL HEAD MARKING
COUPLING RING
CLIP
COUPLING RING SCREW
RD
A
RW
FO
COUPLING RING PIN
THREADED PIN
HEAT TREAT STAMP
Figure 32. Coupling Ring, PN 639AS672
Change 2
45
CSTO XX21M-AIM9M-2
WP 007 00
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 33. Coupling Ring Straightedge Inspection
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
GC
S
DO
ME
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 34. HRU-985A/E Training Umbilical
46
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
1.250 INCH
LONG
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
DETAIL A
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 35. Captive Flight Adapter, Umbilical Cable and GCS Base
Change 1
47
CSTO XX21M-AIM9M-2
WP 007 00
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
GUIDANCE CONTROL SECTION
11
Missing or damaged shrink tubing (Figure 35) (must be
used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
12
Captive flight adapter or HRU-985A/E training umbilical
connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
*13
Foreign material on dome. (Various colorations of dome
do not affect missile performance) (Figure 37)
MINOR
Clean WP 009 00
*14
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
15
Dome or dome lock ring loose or cracked
MAJOR
Replace GCS WP 009 00
16
GCS dome lock ring/dome housing has dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
17
GCS dome lock ring/dome housing has dents up to 0.060inch in depth or less or gouges up to 0.025-inch in depth or
burrs on surface
MAJOR
Remove raised metal only with flat
file or 320 grit emery cloth
18
Missing or loose screws on exhaust valve (Figure 37)
MAJOR
Replace/torque screws
SWP 009 01
19
Tactical GCS gas generator service life expired (Figure 39)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
20
Absence of, or illegible, part number, lot number, date of
manufacturer or serial number
MAJOR
Suspend and hold in condition
Code J. Contact TMTCG, OOALC/GHGAMF, Robins AFB, GA
31098-1813 for instructions
21
GCS skin cracked, punctured, dents greater than 0.060inch or gouges greater than 0.025-inch in depth (Figure 37)
MAJOR
Replace GCS WP 009 00
22
GCS skin has dents up to 0.060-inch, gouges up to 0.025inch in depth, burrs, scratches, or pits penetrating anodized
coating or corrosion
MINOR
Repair coating SWP 009 01
23
Metal fin cup (Figure 36) missing or loose in GCS housing
MAJOR
Replace GCS WP 009 00
24
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
25
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
26
Fin rocker arm mating area damaged, or fin
attach hole(s) in rocker arm(s) worn, stripped, or damaged
so as prevent good mate with fin
MAJOR
Replace GCS WP 009 00
27
Rubber fin seal missing or damage affecting
environmental seal
MAJOR
Replace GCS WP 009 00
28
End of rocker arm protrudes above outside surface of fin
cup assembly
MAJOR
Replace GCS WP 009 00
48
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 36. Fin Cup
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
29
Inspection
(Inspect for the following defects)
Defect
Classification
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 35)
MAJOR
Corrective Action
Remove damaged adhesive and
apply a small bead of adhesive at
junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
30
30.1
31
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
Top of umbilical block metal housing lip separating from
the epoxy core
MAJOR
Repair, SWP 008 01
Umbilical block spring pin loose, missing, or damaged
(tactical umbilical cable PN 2603913 or 639AS10935)
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
32
Umbilical block spring pin not correct length
(tactical umbilical cable PN 2603913 or 639AS10935)
MINOR
Replace spring pin SWP 009 01
33
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated, but gas tubing or wire insulations
are not damaged
MAJOR
Repair insulation SWP 009 01
34
Umbilical cable shows evidence of being kinked, crushed,
or deformed as to affect integrity of cable assembly
MAJOR
Remove GCS WP 009 00
Replace umbilical cable
SWP 009 01 for tactical umbilical
cable PN 2603913 or 639AS10935
SWP 006 01 for HRU-985A/E
training umbilical cable
35
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace screws and safety wire
SWP 009 01
Change 1
49
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 37. Guidance Control Section Inspection Points
50
CAUTION
NO
CSTO XX21M-AIM9M-2
WP 007 00
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
*36
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
37
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 37)
MAJOR
Clean/replace/torque screws
SWP 009 01
38
Missing or loose housing assembly screws
MAJOR
Replace/torque screws
SWP 009 01
39
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws
SWP 009 01
40
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
41
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
42
Dirt, grease, or corrosion inside umbilical protective cap
MAJOR
Clean WP 009 00
43
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
44
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
45
Damaged insert, plugged or corroded sockets on umbilical
connector
MAJOR
Replace umbilical cable SWP 009
01 (tactical umbilical cable PN
2603913 or 639AS10935)/SWP
006 01 (HRU-985A/E training
umbilical)
46
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*47
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*48
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MINOR
Secure cable
49
Loose, missing or damaged components on coolant tank
access cover
MAJOR
Replace/repair cover WP 009 00
50
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 009 00
*51
Probe sealing cap missing on GCS coolant inlet probe
MAJOR
Replace probe sealing cap
Paragraph 51 (SWP 009 01 IPB)
*52
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap
Paragraph 51 (SWP 009 01 IPB)
*53
Coolant inlet probe area dirty, moisture, corroded, or other
foreign material present
MAJOR
Clean WP 009 00
DUMMY BODY SECTION
54
Adapter mating screws loose or missing (Figure 39)
MAJOR
Replace/torque SWP 009 06
55
Adapter straight pin bent, missing, or damaged
MAJOR
Replace SWP 009 06
56
Body section for cuts or scratches in excess of
0.125-inch in depth
MINOR
Repair if welding shop available
Change 1
51
CSTO XX21M-AIM9M-2
WP 007 00
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Corrective Action
57
Absence of, or illegible, identification markings
MAJOR
Replace markings
58
Exterior paint cracked, peeling, scaling, or scuffed
MINOR
Paint SWP 009 06
59
Exterior body surface dents, gouges, burrs, or scratches
MINOR
Repair burrs SWP 009 06
60
Corrosion, dirt, or grease present on body
MINOR
Clean SWP 009 06.
61
Safe-Arm selector handle in ARM position
MINOR
Place in SAFE position
62
Safe-Arm selector safety clip and/or flag missing
MINOR
Install safety clip and/or flag
63
Safe-Arm selector screws missing or loose
MAJOR
Replace/torque SWP 009 06
64
Safe-Arm selector fails spring pin inspection
(Paragraph 36)
MAJOR
Replace pin SWP 009 06
65
Safe-Arm selector fails functional test (Paragraph 37)
MAJOR
Replace stop assembly
SWP 009 06
66
Contact buttons have dirt, grease, or corrosion (Figure 38)
MAJOR
Clean SWP 009 06
67
Contact buttons have severe corrosion
MAJOR
Replace buttons SWP 009 06
68
Contact buttons not flush or below hanger
MAJOR
Replace/torque SWP 009 06
69
Forward hanger bolt, loose or missing
MAJOR
Replace/torque SWP 009 06
70
Forward/center hanger mating surfaces have grease or
corrosion (Figures 38 and 40)
MAJOR
Clean SWP 009 06
71
Forward/center hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Replace hanger SWP 009 06
72
Forward/center hanger for burrs or scratches
MAJOR
Remove metal with flat file or 320
emery cloth. Touch-up paint
SWP 009 06
73
Forward/center hanger mating surfaces have gouges
greater than 0.015-inch deep by 0.030-inch wide by
0.045-inch long
MAJOR
Replace hanger SWP 009 06
74
Forward hanger mating surfaces and stress points for
cracks (Figure 38)
MAJOR
Replace hanger SWP 009 06
Center hanger mating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
75
Forward/center hanger nonmating surfaces for corrosion,
dirt, or grease
MAJOR
Clean SWP 009 06
76
Forward/center hanger nonmating surfaces for dents
greater than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Replace hanger SWP 009 06
77
Forward/center hanger nonmating surfaces for burrs or
scratches
MAJOR
Remove raised metal with flat file
or 320 emery cloth. Touch-up paint
SWP 009 06.
78
Forward/center hanger nonmating surfaces for gouges
greater than 0.045-inch deep by 0.064-inch wide by
0.075-inch long
MAJOR
Replace hanger SWP 009 06
79
Forward/center hanger nonmating surfaces for cracks
MAJOR
Replace hanger SWP 009 06
74.1
52
Defect
Classification
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
NOTE 1: TOP SURFACES OF CONTACT BUTTONS MUST BE EVEN WITH
OR BELOW THE TOP SURFACE OF FORWARD HANGER TO
PREVENT INTERFERENCE WITH THE LAUNCHER STRIKER
POINTS.
FWD CONTACT BUTTON
AFT CONTACT BUTTON
MATING SURFACES
MATING
SURFACES
NONMATING
SURFACES
DETAIL A
STRESS POINTS
NOTE 2: WHEN CHECKING FOR CRACKS CAREFULLY CLEAN HANGER
(REMOVE ALL PAINT IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
RECESSES
RECESSES
FWD CONTACT BUTTON
AFT CONTACT BUTTON
INSULATOR
MATING SURFACES
MATING
SURFACES
NONMATING
SURFACES
FORWARD HANGER
BOLT
Figure 38. MDU-27A/A Forward Hanger Assembly
53
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
NOTE:
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
FLIGHT TEST
TLM EQUIP INCLUDED
OR
FOR COMPLETE COMPONENT
MARKING REQUIREMENTS
REFER TO SWP 009 XX
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
9M FOR WGU-4A/B
3 PLACES
WING RIBS
AFT HANGER
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
CENTER HANGER
INERT
CENTER OF GRAVITY
FORWARD
HANGER
ROCKET MOTOR SECTION
DASHS SIMULATE
COUPLING RING
FORWARD
ADAPTER
DETAIL A
DETAIL B
BODY SECTION
GUIDED MISSILE DUMMY MDU-27A/A
30003-639AS10176
SERIAL NO.
CONTRACT NO.
MFG.
WARHEAD SECTION
D
FW
BLUE BAND
COUPLING
RING
FUZE SECTION
FORWARD ADAPTER
MATING SCREWS
SAFE-ARM
SELECTOR ASSEMBLY
SAFE
ARM
(SAFE POSITION)
DETAIL A
STRAIGHT PIN
(INDEXING PIN)
DETAIL B
(PREFORMED GCS, PACKING &
COUPLING RING REMOVED)
Figure 39. CATM-16, -20 and -24 Inspection Points
54
CSTO XX21M-AIM9M-2
WP 007 00
Table 9. Missile Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
80
Center hanger for loose shims or gap between hanger strap
and hanger (Figure 40)
MAJOR
Replace hanger/shims
SWP 009 06
81
Center hanger has no shims and has gap between hanger
strap and hanger
MAJOR
Replace hanger/shims
SWP 009 06
82
Aft hanger mating surfaces for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
83
Aft hanger mating surfaces for dents, scratches, or gouges
MAJOR
Replace hanger SWP 009 06
84
Aft hanger surface wear inspection (Paragraph 27)
MAJOR
Replace hanger SWP 009 06
85
Aft hanger mating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
86
Aft hanger nonmating surfaces for corrosion, dirt, or
grease
MAJOR
Clean SWP 009 06
87
Aft hanger nonmating surfaces have dents, burrs, or
gouges
MINOR
Smooth raised metal with flat file
or 320 emery cloth. Touch-up paint
SWP 009 06.
88
Aft hanger nonmating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
89
Center/aft hanger band for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
90
Center/aft hanger band loose
MAJOR
Replace hanger SWP 009 06
91
Wing ribs dirt, grease, or corrosion (Figure 39)
MINOR
Clean SWP 009 06
92
Wing rib not etched with serial number
MINOR
Etch serial number on rib
93
Wing ribs deformed, cracked, excessive corrosion, or has
other damage that would prevent proper wing assembly
MAJOR
Reject
94
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers less
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply corrosion
preventive compound
95
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
96
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, WP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring WP 009 00
Step
Corrective Action
Change 1
55
CSTO XX21M-AIM9M-2
WP 007 00
MATING
SURFACES
SHIMS
MATING SURFACES OF
CENTER AND AFT
HANGER
AFT HANGER
CENTER HANGER
NOTE: MATING SURFACES ARE THE AREAS OF THE HANGER ASSEMBLY THAT TOUCH THE LAUNCHER
RAIL. ALL OTHER AREAS OF THE HANGER ASSEMBLY ARE NONMATING SURFACES.
Figure 40. Center and Aft Hanger Assemblies (MDU-27)
56
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
27. AFT HANGER SURFACE WEAR INSPECTION.
a.
Verify body section aft hanger is clean.
b.
Place template (Figure 41) on forward edges of
aft hanger. Using a fine tip felt pen, mark a
reference line across both sides of hanger flat
skid surfaces (Figure 42).
c.
Place template on aft edges of aft hanger. Using a
fine tip felt pen, mark a reference line across both
sides of hanger flat skid surfaces.
d.
Measure left side (when facing forward) of aft
hanger as follows:
NOTE
Ensure surface wear
calibration sticker.
fixture
has
current
(1) Slide guide block of surface wear fixture
(Figure 43) onto aft hanger from forward end
of hanger until indicator tip rests on inside of
edge of aft reference line (Figure 42). Lateral
adjustment of indicator tip may be required
to position tip on aft reference point.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point.
(2) Hand tighten two knurled locking screws to
secure guide block in place (Figure 43).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip in
place. Ensure indicator tip remains on aft
reference point. Set dial indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indicator tip
rests on forward reference line (Figure 42).
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. If hanger wear exceeds
0.034-inch, replace hanger.
e.
Measure right side (when facing forward) of aft
hanger as follows:
(1) Slide guide block of surface wear fixture
onto aft hanger from aft end.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point on the flat surface of the
skid. Do not locate the indicator on the inner
curvature of the hanger.
(2) Hand tighten two knurled locking screws to
secure guide blocks in place (Figure 43).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip
remains on aft reference point. Set dial
indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indictor tip
rests on forward reference line.
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. If hanger wear exceeds
0.034-inch, replace hanger.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
(7) Body sections passing skid wear inspection
shall be identified for tracking purposes by
serial numbers of body sections or serial
numbers of aft hangers. Locally assigned ID
numbers may be used if body sections do not
have serial numbers.
(8) Dummy assembly body sections that have
been subjected to captive flight since the last
inspection shall be reinspected every thirty
days until the skid surface wear reaches
0.024-inch, at which time the inspection
frequency shall be increased to every two
weeks.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
Change 1
56.1/(56.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
Figure 41. Aft Hanger Template
INDICATOR TIP ON AFT
REFERENCE LINE AT THIS POINT
INDICATOR TIP ON FORWARD
REFERENCE LINE AT THIS POINT
FORWARD AND AFT
REFERENCE LINES
F-5/LAU-100 WEAR
INTERFACE REGION
LAU-7 WEAR
D
FW
Figure 42. Aft Hanger Flat Skid Surface
57
CSTO XX21M-AIM9M-2
WP 007 00
INDICATOR DIAL
MOUNTING POST
MOUNTING POST
KNURLED LOCKING
SCREWS (2)
GUIDE BLOCK
INDICATOR TIP
INDICATOR TIP
FORWARD
Figure 43. Aft Hanger Skid Surface Wear Fixture
Table 10. Fin Inspection
Inspection
(Inspect for the following defects)
Defect
Classification
1
Leading or trailing edge warped in excess of 0.062 inch
(Note 1)
MAJOR
Reject
2
Severe scratches or gouges in excess of 0.060 inches
deep
MAJOR
Reject. Less than 0.060 inches
deep, repair SWP 008 07.
Scratches or gouges less than 0.060 inches deep
MINOR
Repair SWP 008 07
3
Cracks of any size
MAJOR
Reject
4
Corrosion and contamination
MINOR
Clean SWP 008 07
Step
2.1
58
Change 1
Corrective Action
CSTO XX21M-AIM9M-2
WP 007 00
Table 10. Fin Inspection (Continued)
Step
5
Inspection
(Inspect for the following defects)
Defect
Classification
Corrosion preventive coating missing
MINOR
Corrective Action
Apply corrosion preventive
compound SWP 008 07
NOTE
Remove screws from fin for inspection. Clean and inspect screws
thoroughly for corrosion. Replace suspect screws.
6
Fin attaching screw(s) identification dots (minimum of
6, raised or depressed) missing on screw head (Note 2)
(Figure 44)
MAJOR
Replace screws SWP 008 07
7
Fin attaching screw(s) corroded, missing, or damaged
MAJOR
Replace screws SWP 008 07
8
Fin attaching screw(s), preformed packing, missing or
damaged (Note 3)
MAJOR
Replace SWP 008 07
9
Trailing edge gouged in excess 0.125 inches in depth
and/or 0.5 inches in length/width
MAJOR
Reject
10
Trailing edge gouged less than 0.125
MAJOR
Repair SWP 008 07.
Remove displaced metal of gouge.
Note 1:
Note 2:
Note 3:
Trailing edge of one fin may be used as straight edge for making measurement.
A 1/4 inch green dot may be located on the large flat surface of the fin above each attaching screw (both sides)
from a prior inspection and need not be reapplied.
If locking rings are present replace with preformed packing.
Figure 44. Fin, BSU-32/B
Change 1
59
CSTO XX21M-AIM9M-2
WP 007 00
Table 11. Coolant Pressure Tank Inspection
60
Step
Inspection
(Inspect for the following defects)
Defect
Classification
1
Identification markings (Figure 45) illegible or missing
MAJOR
Reject
2
Hydrostatic test illegible, missing or due (Hydrostatic
test required 10 years from date of manufacture or last
hydrostatic test)
MAJOR
Reject
3
Dust or dirt on coolant tank valve
MINOR
Clean SWP 008 08
4
Corrosion or contamination on coolant tank or valve
MINOR
Clean SWP 008 08
5
Pressure gauge indicates no positive pressure
MAJOR
Service/inspect/test SWP 006 08
6
Pressure gauge glass cracked
MINOR
Discharge tank SWP 008 08, then
service SWP 006 08. If gauge
operates properly it is acceptable.
If not, (1) for TMU-72/B reject
(2) for TMU-72A/B and TMU72B/B only, if cracked glass is
preventing gauge from operating
properly replace glass, otherwise
reject.
7
Pressure gauge glass broken/missing TMU-72/B
MAJOR
Reject
8
Pressure gauge glass broken/missing TMU-72A/B or
TMU-72B/B
MAJOR
Replace glass SWP 008 08
9
Pressure gauge indicates positive pressure, (refer to
Table 12 for temperature/pressure variation) but less
than 4,000
MAJOR
Service SWP 006 08
10
Pressure gauge inoperative
MAJOR
Reject tank
11
Instruction plate loose, damaged, or missing
MAJOR
Replace plate SWP 008 08
12
Caution plate loose, damaged, or missing
MAJOR
Replace plate SWP 008 08
13
Wire handle damaged or missing
MINOR
Replace handle SWP 008 08
14
Retaining ring or probe guide missing, loose, or
damaged
MAJOR
Replace ring or replace/torque
probe guide SWP 008 08
15
Dial face not secured (moves) grasp tank tightly in the
inverted position (gauge down), shake vigorously, and
check for movement of dial face
MAJOR
Reject tank
16
Tank will not maintain pressure (leaking)
MAJOR
Damaged/worn preformed
packing will cause argon to leak.
Inspect/replace preformed
packing (SWP 008 08) and test. If
tank still leaks reject.
Change 1
Corrective Action
CSTO XX21M-AIM9M-2
WP 007 00
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 45. Coolant Pressure Tank (Accumulator), Markings
Table 12. Coolant Pressure Tank Pressure/Temperature Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
Change 1
61
CSTO XX21M-AIM9M-2
WP 007 00
Table 13. Wing Inspection, Fixed (MBA)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance rejection criteria.
1
Leading or trailing edge bent in excess of 0.250 inch
MAJOR
Reject
2
Leading or trailing edge bent less than 0.250 inch
MAJOR
Remove raised metal only with
flat file or 320 grit emery cloth
3
Severe scratches or gouges in excess of 0.250 inch deep
MAJOR
Reject
4
Scratches or gouges less than 0.250 inch deep
MAJOR
Remove raised metal only with
flat file or 320 grit emery cloth
5
Cracks in excess of 0.250 inch
MAJOR
Reject
6
Exterior paint cracked, peeling, scaling or scruffed
MINOR
Paint/touch-up WP 009 00
7
Dirt, grease, or corrosion on wing
MINOR
Clean SWP 009 05
Table 14. Wing Inspection, Mk 1 Mod 1 or Mk 1 Mod 2
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance rejection criteria.
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 008 06.
1
Absence of/or illegible identification markings: Mark,
Mod, and part number (Figure 46)
MINOR
Replace markings SWP 008 06
2
Over 25% of thermal coating on one side blistered,
peeling, or missing
MAJOR
Reject
3
Punctures through wing skin into honeycomb
MAJOR
Reject
*4
Wing surface greasy or dirty
MINOR
Clean SWP 008 06
NOTE
If over 25% (estimated) of thermal coating must be removed to repair,
reject.
62
5
Wing coating cracked, blistered, peeling, or missing in
excess of 0.250 inch in diameter but less than 25% of
thermal coating on one side
MAJOR
Repair coating SWP 008 06
6
Scratches in wing coated surface 0.062 inch wide
MAJOR
Repair coating SWP 008 06
*7
Small hairline cracks in wing base coating
MINOR
Acceptable
8
Cracks or warpage in metal structure of wing frame
MAJOR
Reject
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
Table 14. Wing Inspection, Mk 1 Mod 1 or Mk 1 Mod 2 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
9
Nicks or scrapes in metal structure of wing frame
greater than 0.250 inch in depth
MAJOR
Reject
10
Circular cracks in rivet area indicating loose rivets
MAJOR
Reject
11
Dents in wing surface more than 0.125 inch in depth
MAJOR
Reject
12
Dents in wing leading edge more than 0.125 inch in
depth
MAJOR
Reject
13
Dents in wing leading edge less than 0.125 inch in
depth
MINOR
Repair SWP 008 06
14
Over 25% of thermal coating missing from leading
edge
MAJOR
Repair coating SWP 008 06
15
Wing alignment screws missing or damaged
MAJOR
Replace screws SWP 008 06
16
Wing alignment screws corroded
MAJOR
Clean/replace SWP 008 06
17
Wing attachment cap screw missing, or damaged
MAJOR
Replace screws SWP 008 06
18
Wing attachment cap screw corroded
MAJOR
Clean/replace SWP 008 06
NOTE
Steps 19 through 37 not applicable to wings without rollerons
installed.
19
Guide vanes missing or bent (minor surface defects are
acceptable)
MAJOR
Replace guide vanes SWP 008 06
20
Guide vanes corroded
MAJOR
Clean SWP 008 06
21
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs with flat
file or 320 grit emery cloth
22
Guide vane screws loose, corroded, damaged, or
missing
MAJOR
Torque/clean/replace screws
SWP 008 06
23
Minor corrosion on rolleron assembly
MINOR
Clean SWP 008 06
24
Major corrosion on rolleron assembly affecting function
of rolleron
MAJOR
Replace rolleron assembly
SWP 008 06
25
Rolleron hinge retaining screws loose, missing, or
damaged
MAJOR
Replace/torque screws
SWP 008 06
26
Rolleron hinge corroded
MAJOR
Clean SWP 008 06
27
Rolleron hinge damaged
MAJOR
Replace hinge SWP 008 06
28
Rolleron hinge damper pin hole elongated
MAJOR
Replace hinge SWP 008 06
29
Play where damper assembly is attached to the rolleron
assembly
MAJOR
Replace damper assembly
SWP 008 06
30
Damper assembly shows evidence of leaking oil
MAJOR
Perform rolleron assembly
functional test (Paragraph 34)
63
CSTO XX21M-AIM9M-2
WP 007 00
Table 14. Wing Inspection, Mk 1 Mod 1 or Mk 1 Mod 2 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
31
Damper assembly attaching screws loose or missing
MAJOR
Replace/torque screws
SWP 008 06
32
Cager assembly binding, missing parts or inoperative
MAJOR
Repair cager assembly
SWP 008 06
33
Loose cager assembly
MAJOR
Replace cager assembly setscrews
SWP 008 06
34
Reset rivet missing or damaged (Mod 2)
MAJOR
Replace cager assembly
SWP 008 06
35
Cager assembly corroded
MAJOR
Clean/replace SWP 008 06
36
Cager release-pull test (Paragraph 35)
MAJOR
Repair/replace SWP 008 06
37
Rolleron assembly functional test (Paragraph 34)
MAJOR
Repair/replace cager SWP 008 06
ALUMINUM
SKIN
ROLLERON
HINGE
DAMPER
ASSEMBLY
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING
BASE
NOTES:
WING ALIGNMENT
SCREW (5)
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
1. ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER
ASSEMBLY, WING ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
2. DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
3. WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
4. WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 46. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
64
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
28. WING TAP INSPECTION. The tap method of
inspecting the bonded composite panels provides a simple,
dependable method for detecting voids in metal to metal
bonds, skin to core bonds, and delaminations of laminated
structures. The tap method of inspecting bonded panels for
voids is based on the fact that parts bonded together return
a different sound, when struck with a tap hammer, than
parts which are not bonded together. It is necessary that
the instructions contained in the following paragraphs be
followed closely in order to produce as much difference as
possible between the sounds of void free areas and the
sounds of void areas.
29. A void area will be determined by the quality of the
sound it creates when tapped with the tap hammer. The
following aids shall be used in determination of void
areas:
a.
A void area sound will be less sharp or clear than
the sound of a void free area.
b.
A void sound can be described as dull or dead or
sometimes as a rattle.
c.
(5) Panel shape
(6) Type of adhesive used to bond parts
30. Tap Inspection Limitations. This inspection
technique is limited to certain areas and conditions as
follows:
a.
There is difficulty in detecting small voids. As
skin gauges increase, the difficulty of detecting
voids becomes greater.
b.
This tap inspection is limited to zones A and B
only (Figure 46).
31. Tap Inspection Preparation. Prepare for tap
inspection by accomplishing the following items:
a.
Remove foreign matter from panel to be
inspected by wiping panel surface with clean dry
cloth.
b.
Inspect the tap hammer head for burrs, nicks,
indentations, etc. that could damage the panel
surface. Remove blemishes from the hammer
head using a fine 320 grit emery cloth.
Different areas of a panel will cause different
sounds even though the panel is free of voids.
The following items will cause sound changes:
32. Tap Inspection Procedures. Perform tap inspection
procedures as follows:
(1) Core splices
(2) Differences in core thickness
a.
Place wing in a vertical upright position.
(3) Core cell size
b.
See Figure 47 for an illustration and instructions
on the proper use of the tap hammer.
(4) Skin thickness
TAP HAMMER
1.0 TO 1.5 INCH
(APPROXIMATELY
FROM PANEL)
1.5 INCH
(APPROX.)
PANEL SURFACE
Figure 47. Tap Hammer Procedures
65
CSTO XX21M-AIM9M-2
WP 007 00
c.
Tap thermal coated zones A and B (Figure 46)
surface at one inch spacings.
d.
No unbonded areas shall have a maximum linear
dimension greater than four (4) inches.
d.
Although sound will change due to variations in
construction, an area that is free of voids will
retain a sharp, clear sound.
e.
Reject wing if unacceptable. Retain serviceable
components (SWP 008 06).
e.
When a void is located, the size should be
determined as accurately as possible. Outline the
perimeter of the void area if any are present,
using a grease pencil.
34. ROLLERON ASSEMBLY FUNCTIONAL TEST.
f.
a.
Set wing base on flat surface.
b.
Hold rolleron assembly (Figure 48) firmly and
grasp rolleron wheel. Move wheel from side-toside and up and down. If any movement is felt,
replace rolleron assembly SWP 008 06.
Repeat steps c through e on opposite side of
wing.
33. Acceptance/Rejection
Criteria.
rejection criteria is as follows:
NOTE
Acceptance/
a.
No single unbonded area shall be greater than
three (3) square inches in area.
Some rolleron bearings are pre-loaded and will
cause the wheel to come to rest more quickly than
others. When rolleron wheel is spinning, bearings
should be relatively free of bearing noise.
b.
No more than three unbonded areas, regardless of
the cumulative area, shall be permitted on each
wing side.
c.
c.
Unbonded areas shall be separated by one (1)
inch.
Spin rolleron wheel by hand. If rolleron wheel
does not turn freely or has wobbly, jerky, noisy,
or ratchet-like motion, replace rolleron assembly
SWP 008 06.
ROLLERON
WHEEL
ASSEMBLY
ROLLERON
ASSEMBLY
Figure 48. Rolleron Assembly
66
CSTO XX21M-AIM9M-2
WP 007 00
d.
e.
Lay wing on its side against a flat surface. Extend
rolleron assembly over flat surface edge so that
the rolleron can travel throughout its entire range
of motion without interference. Release cager
assembly Figures 50 and 51. Raise rolleron to its
highest point of travel and release. The falling
motion shall indicate resistance but shall not
hesitate or stop throughout its downward travel.
If there is no resistance to rolleron travel or if
there is hesitation in the rolleron’s downward
motion, replace damper SWP 008 06.
Release cager assembly and slowly move
rolleron assembly from side to side through entire
travel. Verify rolleron does not contact wing
frame and bottom edge is parallel to wing frame.
If rolleron assembly does not conform, replace
damper and rolleron assembly SWP 008 06.
c.
If operation is not correct, lubricate cager flag
movement and repeat test.
d.
If cager fails release-pull
maintenance SWP 008 06.
a.
b.
[5]
a.
Ensure selector is in the SAFE position.
b.
Remove safety clip assembly.
c.
Using the spring pin inspection gauge, place the
tip of the gauge on one end of the spring pin
(Figure 49) and slowly push against the end of
the pin until 30 pounds (the "green" line on the
shaft is flush with the end of the tool body) has
been achieved. Hold the 30 pound load for
approximately 5 seconds.
d.
After application of the 30 pound load, inspect
the ends of the spring pin to determine if it has
moved.
e.
If the spring has not moved, repeat step c by
pushing on the other end of the spring pin, hold
the 30 pound load for approximately 5 seconds.
f.
If the spring pin has moved under either load it
must be replaced WP 009 00.
g.
Install safety clip assembly.
With wing in a vertical upright position, attach
instrument scale Figure 50 or 51.
Perform release-pull test as specified in Figure 50
or 51. If pull test is within tolerance, return cager
to caged position and verify cager is secured.
perform
36. SAFE-ARM SELECTOR HANDLE SPRING PIN
INSPECTION.
35. CAGER RELEASE-PULL TEST.
Lubricant, Breakfree, MIL-L-63460
test,
TOOL BODY
GREEN LINE
GAUGE TIP
SPRING PIN
Figure 49. Safe-Arm Selector Handle Spring Pin Test
67
CSTO XX21M-AIM9M-2
WP 007 00
MOD 1 WING
PAPER CLIP ATTACHMENT
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 50. Wing Cager Release-Pull Test (Preferred)
1.8 TO 2.2 LBS
NOTE:
CAGER RELEASE PULL-TEST VALUES
MK 1 MOD 1 WING PULL-TEST VALUE IS 2.0 TO 2.5
MK 1 MOD 2 WING PULL-TEST VALUE IS 1.8 TO 2.2
Figure 51. Wing Cager Release-Pull Test
68
CSTO XX21M-AIM9M-2
WP 007 00
37. SAFE-ARM SELECTOR FUNCTIONAL
CHECK.
(9) Install safety clip assembly.
b.
a.
Perform functional check for Mk 57 Mod 3
(Figure 52) as follows:
(1) Remove safety clip assembly.
(2) Pull handle to unlock and move to vertical
position, maintain pull pressure.
(3) Rotate handle 90 degrees counterclockwise
and move to horizontal position.
(4) Release pull pressure to lock in ARM
position.
(5) Pull handle to unlock and move to vertical
position, maintain pull pressure.
(6) Rotate handle 90 degrees clockwise and
move to horizontal position.
(7) Release pull pressure to lock in SAFE
position.
(8) The Safe-Arm selector assembly should
operate freely with no binding. If the SafeArm selector fails to operate freely, replace
SWP 009 04 (Mk 57).
Perform functional check for Mk 57 Mod 2
(Figure 53) as follows:
(1) Push in Safe-Arm selector key, rotate 90°
counterclockwise to ARM, and remove key.
If key cannot be removed, return key to
SAFE and repair SWP 009 04.
(2) Safe-arm selector remains in ARM position
(locking lever lobe moves outward and is
locked in key removal slot. If Safe-Arm
selector rotates back to SAFE position repair
SWP 009 04.
(3) Install Safe-Arm selector key. Push in and
rotate key 90° clockwise to SAFE. Locking
lever lobe shall be locked in the safe hole.
Ensure mechanism movement is smooth and
continuous with no binding, if not, repair
SWP 009 04.
38. PREPARING FOR MISSILE TO AUR
ASSEMBLY.
NOTE
For following steps comply with requirements
applicable to the missile configuration.
SAFE-ARM SELECTOR HANDLE
(SAFE POSITION)
SAFE
ARM
SAFETY CLIP
SAFETY CLIP
WARNING FLAG
SAFE-ARM SELECTOR
SPRING PIN
SAFE-ARM SELECTOR
ASSEMBLY
Figure 52. Safe-Arm Selector Assembly (Mk 57 Mod 3)
Change 2
69
CSTO XX21M-AIM9M-2
WP 007 00
a.
Ensure missile is secured to assembly stand and
grounded to a wing rib (or forward hanger for
MDU-27/A). Do not attach ground clip in area of
etched serial number.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
b.
Ensure Safe-Arm selector handle is locked in the
SAFE position. If not, perform step (1) for Mod 3
or step (2) for Mod 2.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure to
lock in SAFE position. Move key to
horizontal position.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Figure 53. Safe-Arm Selector Assembly (Mk 57 Mod 2)
70
CSTO XX21M-AIM9M-2
WP 007 00
c.
Ensure dome protector, umbilical protective cap,
TD protective cover, and forward hanger (MK 57
Mod 2 or Mod 3) protective cover are properly
installed.
39. MISSILE TO AUR ASSEMBLY.
NOTE
NOTE
If no release of pressure is heard in step f, the
coolant inlet probe in the GCS has most likely
been damaged. If so, the GCS may require depot
maintenance.
f.
Turn coolant tank counterclockwise enough to
determine if the tank valve assembly is operating
(a release of pressure with an abrupt cut off
should be heard). Turn coolant tank clockwise
fingertight using finger lugs on coolant tank.
g.
Ensure leaking can not be heard with the tank
fully installed. If leaking can be heard, the
coolant tank preformed packing should be
changed before the tank is rejected (SWP 008
08).
For following steps comply with requirements
applicable to the missile configuration.
a.
Preparations for missile to AUR assembly
completed (Paragraph 38).
b.
Coolant pressure tank installation (Paragraph 40).
c.
Fin installation (Paragraph 41).
d.
Wing installation (Paragraph 42/43).
e.
Post assembly inspection (WP 005 00).
40. Coolant Pressure Tank Installation.
a.
b.
Verify coolant pressure tank has been inspected
Table 11.
Loosen cover screws and remove coolant tank
access cover from GCS.
CAUTION
Failure to use care when installing access cover
will result in damage to the coolant tank gauge.
h.
Install coolant pressure tank access cover; tighten
screws until snug.
41. Fin Installation.
NOTE
Only two pins of the four pin spanner wrench are
used to remove the probe sealing cap. It may be
necessary to retract two pins flush with housing
of spanner wrench if four pins are protruding.
Compound, Silicone MIL-S-8660
c.
Using spanner wrench, remove probe sealing cap
from GCS coolant inlet probe, if installed.
a.
d.
Verify coolant inlet probe is free of oil, dirt,
grease, or any other contaminant.
CAUTION
Failure to use care when installing coolant tank
will result in damage to inlet probe.
e.
Remove and discard tape from coolant pressure
tank. Install and tighten fingertight using finger
lugs on coolant tank.
[7]
Verify fins have been inspected Table 10.
CAUTION
Only fin attaching screws PN NAS1351-4LB14P
are to be used. Screws must have head markings
of a minimum of six (6) dots, raised or depressed.
Use of other screws may allow separation of fin
from missile in flight.
b.
Apply a thin coating of silicone compound to fin
mating surface, threads of retaining screw, GCS
rocker arm mating surface, and GCS fin cup.
Remove excess silicone from fin mating area.
71
CSTO XX21M-AIM9M-2
WP 007 00
c.
Position fin with arrows pointing forward
(toward GCS dome) and install fin attaching
screws into rocker arms. Hold fin securely while
second person torques screws Table 4.
d.
Repeat steps b and c for remaining three fins on
GCS.
e.
Rock each fin fore and aft. If either end of fin
contacts GCS skin, inspect fin-to-rocker arm
installation. If fin is attached securely to rocker
arm but fin still contacts GCS skin when rocked,
replace fin. If replacement fin contacts GCS skin
reject GCS.
42. Wing Installation, Mk 1 Mod 1 or Mk 1 Mod 2.
a.
Verify wings have been inspected and serviced
Paragraph 28 and Table 14.
b.
Verify alignment screws when viewed from
bottom of wing are at same angle (approximately
45 degrees) as slots in rocket motor wing rib. If
screws are not aligned, adjust with screwdriver.
c.
If installed, remove aft protective cap from rocket
motor. Position wing on rocket motor wing rib,
making final adjustment to wing rib screws if
necessary.
d.
e.
Ensure wing fits properly, then tighten wing
attachment cap screw (Figure 46) until wing is
seated firmly on rocket motor. Torque wing
attachment screw Table 4. If wing does not fit or
is loose, try another wing.
Repeat steps c and d for remaining three wings.
Prior to installing last wing, remove ground strap
and reconnect to an installed wing’s attaching
screw.
43. Wing (Fixed MBA) Installation.
Compound, Sealing, MIL-S-46163,
Type II, Grade N
a.
72
Verify wings have been inspected Table 13.
[7]
b.
Verify alignment screws when viewed from
bottom of wing are at same angle (approximately
45 degrees) as slots in missile body wing rib. If
screws are not aligned, adjust with screwdriver.
NOTE
On new missile body assemblies, the wings are
identified to be placed on specific location.
Identifying marks are located on the wing ribs
and the under side of the wings.
c.
Position wing on missile body wing rib, making
final adjustment to alignment screws, if
necessary.
d.
Ensure wing fits properly, by pushing rearward
until wing is completely seated on missile body
assembly and the four attachment screw holes are
aligned. If necessary, torque positioning screw
(not to exceed 100 inch-pounds) to align holes for
attachment screws. If wing does not fit properly,
is loose or attachment screw holes do not align
sufficiently to allow screw installation, obtain
and try another wing.
e.
Clean new wing attachment screws. Use thread
chaser and clean threaded holes in missile body.
f.
Apply a small amount of adhesive on the first
four threads of the new wing attachment screws.
g.
Install attachment screws and torque Table 4.
h.
Remove wing positioning screw.
i.
Repeat steps a through h for remaining three
wings. Prior to installing last wing, remove
ground strap and reconnect to AFT hanger.
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Coupling ring cracked, not PN 639AS672, not
properly orientated, parts not installed correctly
(Figure 55)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code)
00784 with date of manufacture 1-90 through 12-90
or 1-83 through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat
treat markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or
later
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
6
Coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 55)
CRITICAL
Replace coupling ring screw
WP 009 00
7
Coupling ring fails straightedge inspection
(Figure 56)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 57) missing or HRU985A/E training umbilical (Figure 54) not installed.
Captive flight adapter must be used with tactical
umbilical (PN 2603913 or 639AS10935) on tactical
GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 59) broken, cracked, punctured
or severely scratched
CRITICAL
Replace GCS WP 009 00
GUIDANCE CONTROL SECTION
10
Missing or damaged shrink tubing (Figure 57) (must
be used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
Change 2
73
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
11
Captive flight adapter or HRU-985A/E training
umbilical connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
12
Gas generator service life expired (Figure 63)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
13
Absence of, or illegible part number, lot number,
date of manufacture or serial number
MAJOR
Suspend and hold in condition code J.
Contact TMTCG, OO-ALC/GHGAMF,
Robins AFB, GA 31098-1813 for
instructions
*14
Foreign material on dome. (Various colorations of
dome do not affect missile performance) (Figure 59)
MINOR
Clean WP 009 00
*15
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
16
Dome or dome retaining ring loose or cracked
MAJOR
Replace GCS WP 009 00
17
GCS dome lock ring/dome housing has dents greater
than 0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 009 00
18
GCS dome lock ring/dome housing has dents up to
0.060-inch in depth or less or gouges up to 0.025inch in depth or burrs on surface
MAJOR
Remove raised metal only with flat file
or 300 Grit emery cloth
19
GCS skin cracked, punctured, dents greater than
0.060-inch or gouges greater than 0.025-inch in
depth
MAJOR
Replace GCS WP 009 00
20
GCS skin has dents up to 0.060-inch, gouges up to
0.025-inch in depth, burrs, scratches, or pits
penetrating anodized coating or corrosion
MINOR
Repair coating SWP 009 01
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
OM
SD
C
G
E
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
Figure 54. HRU-985A/E Training Umbilical
74
Change 2
KNURLED
RETAINING
NUT
CSTO XX21M-AIM9M-2
WP 007 00
(1) COUPLING RING
GCS
(2) CLIP
(1)
(3) SCREW
FWD
(4) PIN
(5) THREADED PIN
(2)
(3)
(4)
(5)
INDEXING
PIN
AFT
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 55. Coupling Ring Assembly
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 56. Coupling Ring Straightedge Inspection
Change 2
75
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 57. Captive Flight Adapter, Umbilical Cable and GCS Base
76
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
21
Metal fin cup (Figure 58) missing or loose in GCS
housing
MAJOR
Replace GCS WP 009 00
22
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange down
until seated on GCS housing
23
Metal fin cup flange cracked, buckled, or bent to
extent flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
24
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 57)
MAJOR
Remove damaged adhesive and apply a
small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
25
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
25.1
Top of umbilical block metal housing lip separating
from the epoxy core
MAJOR
Repair, SWP 008 01
Umbilical block spring pin missing or damaged
MAJOR
Replace spring pin SWP 009 01
26
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
27
Umbilical block spring pin not correct length
MINOR
Replace spring pin SWP 009 01
28
Umbilical cable insulation separated from cable
block or launcher connector. Insulation damaged to
extent cable insulation is penetrated, but gas tubing
or wire insulations are not damaged
MAJOR
Repair insulation SWP 009 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 58. Fin Cup
Change 1
77
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
29
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical)
30
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace/torque screws and safety wire
SWP 009 01
*31
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
32
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 59)
MAJOR
Clean/replace/torque screws
SWP 009 01
33
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws SWP 009 01
34
Missing or loose housing assembly screws
MAJOR
Replace/torque screws SWP 009 01
35
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws SWP 009 01
36
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
37
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
38
Dirt, grease, or corrosion inside umbilical protective
cap
MAJOR
Clean WP 009 00
39
Pin 13, 19, or 21 bent, broken, or missing in
umbilical protective cap
MAJOR
Replace cap SWP 009 01
40
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace packing SWP 009 01
41
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Replace umbilical cable SWP 009 01
(tactical umbilical cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical)
42
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*43
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*44
Umbilical cable not properly secured with rubber
band (ZZ-R-1415), retaining clip or equivalent
MINOR
Secure umbilical
45
Loose, missing or damaged components on coolant
tank access cover
MAJOR
Replace/repair cover SWP 009 01
Coolant pressure tank gauge indicates no positive
pressure
MAJOR
Service/inspect/test SWP 006 08
46
Coolant pressure tank gauge (Table 16) is in the
yellow or red area (Figure 60)
MAJOR
Replace/service tank Paragraph 51/40
47
TMU-72/B Coolant pressure tank gauge glass
broken or missing
MAJOR
Replace tank Paragraph 51/40
48
TMU-72A/B or TMU-72B/B coolant pressure tank
gauge glass broken or missing
MAJOR
Replace tank Paragraph 51/40
Replace glass SWP 008 08
45.1
78
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NOTE 2
NITROGEN PLUG
AFT SCREW
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
CAUTION
NO
FORWARD
SCREWS (2)
SUPPORT OR HANDLING
FORWARD OF LINE
WINDOW
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
FLIGHT TEST
TLM
EXHAUST VALVE
SCREWS (4)
EQUIP INCLUDED
DOME ASSEMBLY
NOTES: 1. LOCATION OF MARKINGS IS APPROXIMATE.
2. 9M FOR WGU-4A/B. THREE PLACES.
3. WGU-4A/B FOR PN 639AS3963.
NOTE 2
COOLANT TANK
ACCESS COVER
Figure 59. Guidance Control Section Inspection Points, WGU-4A/B
79
CSTO XX21M-AIM9M-2
WP 007 00
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 60. Coolant Pressure Tank (Accumulator), Markings
Table 16. Coolant Pressure Tank Pressure/Temperature Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
80
Change 1
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
DUMMY BODY SECTION
49
Body section for cuts or scratches in excess of
0.125-inch in depth (Figure 63)
MINOR
Remove GCS WP 009 00. Repair if
welding shop available
50
Absence of, or illegible, identification markings
MAJOR
Replace markings
51
Exterior paint cracked, peeling, scaling, or scuffed
MINOR
Paint SWP 009 06
52
Corrosion, dirt, or grease present on body
MINOR
Clean SWP 009 06
53
Contact buttons have dirt, grease, or corrosion
(Figure 61)
MAJOR
Clean SWP 009 06
54
Contact buttons have severe corrosion
MAJOR
Replace buttons SWP 009 06
55
Contact buttons not flush or below hanger
MAJOR
Replace/torque SWP 009 06
56
Forward hanger has bolts installed
57
Forward hanger screws loose or missing
MAJOR
Replace/torque SWP 009 06
58
Forward/center hanger mating surfaces have grease
or corrosion (Figures 61 and 62)
MAJOR
Clean SWP 009 06
59
Forward/center hanger nonmating surfaces for
corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
60
Forward/center hanger for burrs or scratches
MAJOR
Remove raised metal with flat file or
320 emery cloth. Touch-up paint
SWP 009 06
61
Forward/center hanger nonmating surfaces for burrs
or scratches
MAJOR
Remove metal with flat file or 320
emery cloth. Touch-up paint
SWP 009 06
62
Forward hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Replace forward hanger SWP 009 06
63
Forward hanger mating surfaces have gouges greater
than 0.015-inch deep by 0.030-inch wide by 0.045inch long
MAJOR
Replace forward hanger SWP 009 06
64
Forward hanger mating surfaces and stress points for
cracks (Figure 61)
MAJOR
Replace forward hanger SWP 009 06
65
Forward hanger nonmating surfaces for dents greater
than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Replace forward hanger SWP 009 06
66
Forward hanger nonmating surfaces for gouges
greater than 0.045-inch deep by 0.064-inch wide by
0.075-inch long
MAJOR
Replace forward hanger SWP 009 06
67
Forward hanger nonmating surfaces for cracks
MAJOR
Replace forward hanger SWP 009 06
68
Center hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Reject
69
Center hanger mating surfaces have gouges greater
than 0.015-inch deep by 0.030-inch wide by 0.045inch long
MAJOR
Reject
CRITICAL
Replace with screws SWP 009 06
Change 2
81
CSTO XX21M-AIM9M-2
WP 007 00
NOTE 1: TOP SURFACES OF CONTACT BUTTONS MUST BE EVEN WITH
OR BELOW THE TOP SURFACE OF FORWARD HANGER TO
PREVENT INTERFERENCE WITH THE LAUNCHER STRIKER
POINTS.
FWD CONTACT BUTTON
AFT CONTACT BUTTON
MATING SURFACES
MATING
SURFACES
NONMATING
SURFACES
DETAIL A
STRESS POINTS
NOTE 2: WHEN CHECKING FOR CRACKS CAREFULLY CLEAN HANGER
(REMOVE ALL PAINT IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 61. Forward Hanger Assembly
MATING
SURFACES
SHIMS
MATING SURFACES OF
CENTER AND AFT
HANGER
AFT HANGER
CENTER HANGER
NOTE: MATING SURFACES ARE THE AREAS OF THE HANGER ASSEMBLY THAT TOUCH THE LAUNCHER
RAIL. ALL OTHER AREAS OF THE HANGER ASSEMBLY ARE NONMATING SURFACES.
Figure 62. Center and Aft Hanger Assemblies (MDU-27)
82
CSTO XX21M-AIM9M-2
WP 007 00
Table 15. AUR Inspection CATM-1 (MDU-27/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
70
Center hanger mating surface has cracks
MAJOR
Reject
71
Center hanger nonmating surfaces for dents greater
than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Reject
72
Center hanger nonmating surfaces for gouges greater
than 0.045-inch deep by 0.064-inch wide by 0.075inch long
MAJOR
Reject
73
Center hanger nonmating surfaces for cracks
MAJOR
Reject
74
Center hanger for loose shims or gap between shims
and hanger strap
MAJOR
Reject
75
Center hanger has no shims and has gap between
hanger strap and hanger
MAJOR
Reject
76
Center/aft hanger band for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
77
Center/aft hanger band loose
MAJOR
Reject
78
Aft hanger mating surfaces for corrosion, dirt, or
grease (Figure 62)
MAJOR
Clean WP 009 06
79
Aft hanger mating surfaces for dents, scratches, or
gouges
MAJOR
Smooth raised metal with flat file or
320 emery cloth
80
Aft hanger surface wear inspection (Paragraph 44)
MAJOR
Reject if fails inspection
81
Aft hanger mating surfaces has cracks
MAJOR
Reject
82
Aft hanger nonmating surfaces for corrosion, dirt, or
grease
MAJOR
Clean SWP 009 06
83
Aft hanger nonmating surfaces have dents, burrs, or
gouges
MAJOR
Smooth raised metal with flat file or
320 emery cloth. Touch-up paint
SWP 009 06
84
Aft hanger nonmating surfaces has cracks
MAJOR
Reject
85
Indexing pin missing, bent, or broken (Figure 63)
MAJOR
Replace indexing pin SWP 009 06
86
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire
surface is approximately an area 0.25 inches long
across the entire width of the coupling ring)
MINOR
Clean and apply corrosion preventive
compound
87
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately
covers greater than 2% of entire surface (2% of
entire surface is approximately an area 0.25 inches
long across the entire width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
88
Coupling ring has brown spots, specks, or
discoloration
MAJOR
Clean, WP 009 00. Inspect for cracks.
If brown spots, specks, or discoloration
cannot be removed replace coupling
ring WP 009 00
Change 1
83
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
9M FOR WGU-4A/B
3 PLACES
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
DASHS SIMULATE
COUPLING RING
INERT
BODY SECTION
GUIDED MISSILE DUMMY MDU-27/A
30003-639AS2966
CONTR
MFG
ROCKET MOTOR SECTION
WARHEAD SECTION
BLUE BAND
FUZE SECTION
NOTE:
MARKINGS WILL PLACED AS SHOWN.
DECALS OR STENCILS ARE ACCEPTABLE.
NOTE:
FOR COMPLETE COMPONENT MARKING
REQUIREMENTS REFER TO SWP 009 XX
D
FW
INDEXING
PIN
Figure 63. CATM-1 Inspection Points
84
CSTO XX21M-AIM9M-2
WP 007 00
44. AFT HANGER SURFACE WEAR INSPECTION.
a.
Verify body section aft hanger is clean.
b.
Place template (Figure 64) on forward edges of
aft hanger. Using a fine tip felt pen, mark a
reference line across both sides of hanger flat
skid surfaces (Figure 65).
c.
Place template on aft edges of aft hanger. Using a
fine tip felt pen, mark a reference line across both
sides of hanger flat skid surfaces.
d.
Measure left side (when facing forward) of aft
hanger as follows:
NOTE
Ensure surface wear
calibration sticker.
fixture
has
current
(1) Slide guide block of surface wear fixture
(Figure 66) onto aft hanger from forward end
of hanger until indicator tip rests on inside of
edge of aft reference line (Figure 65). Lateral
adjustment of indicator tip may be required
to position tip on aft reference point.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point.
(2) Hand tighten two knurled locking screws to
secure guide block in place (Figure 66).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip in
place. Ensure indicator tip remains on aft
reference point. Set dial indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indicator tip
rests on forward reference line (Figure 65).
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. Reject body section with
a wear of 0.034-inch or greater.
e.
Measure right side (when facing forward) of aft
hanger as follows:
(1) Slide guide block of surface wear fixture
onto aft hanger from aft end.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point on the flat surface of the
skid. Do not locate the indicator on the inner
curvature of the hanger.
(2) Hand tighten two knurled locking screws to
secure guide blocks in place (Figure 66).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip
remains on aft reference point. Set dial
indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indictor tip
rests on forward reference line.
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. Reject body section with
wear of greater than 0.034-inch.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
(7) Body sections passing skid wear inspection
shall be identified for tracking purposes by
serial numbers of body sections or serial
numbers of aft hangers. Locally assigned ID
numbers may be used if body sections do not
have serial numbers.
(8) Dummy assembly body sections that have
been subjected to captive flight since the last
inspection shall be reinspected every thirty
days until the skid surface wear reaches
0.024-inch, at which time the inspection
frequency shall be increased to every two
weeks.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
85
CSTO XX21M-AIM9M-2
WP 007 00
Figure 64. Aft Hanger Template
INDICATOR TIP ON AFT
REFERENCE LINE AT THIS POINT
INDICATOR TIP ON FORWARD
REFERENCE LINE AT THIS POINT
FORWARD AND AFT
REFERENCE LINES
F-5/LAU-100 WEAR
INTERFACE REGION
LAU-7 WEAR
D
FW
Figure 65. Aft Hanger Flat Skid Surface
86
CSTO XX21M-AIM9M-2
WP 007 00
INDICATOR DIAL
MOUNTING POST
MOUNTING POST
KNURLED LOCKING
SCREWS (2)
GUIDE BLOCK
INDICATOR TIP
INDICATOR TIP
FORWARD
Figure 66. Aft Hanger Skid Surface Wear Fixture
Table 17. AUR Inspection CATM-3 and -7
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Coupling ring cracked, not PN 639AS672, not properly
orientated, parts not installed correctly (Figure 67)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
WP 009 00
Change 2
87
CSTO XX21M-AIM9M-2
WP 007 00
TARGET
DETECTOR
GCS
FWD
(1) COUPLING RING
(2) CLIP
(3) SCREW
(4) PIN
(5) THREADED PIN
(6) GUIDE PLATE ASSEMBLY
FORWARD
COUPLING RING
ASSEMBLY
PN 639AS672
WARHEAD
(1)
AFT COUPLING
RING ASSEMBLY
PN 639AS2725-2
(2)
(3)
ROCKET MOTOR
COUPLING RING
ASSEMBLY
PN 639AS2725-1
INDEXING
PIN
GUIDE
PLATE
ASSEMBLY
(4)
(5)
(6)
ROCKET MOTOR
PART
NUMBER
AFT
REVISION
MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 67. Coupling Ring Assemblies (Mk 57)
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 68. Coupling Ring Straightedge Inspection
88
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
3
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw(s) not PN 639AS1599 Rev M or later,
or PN 8934242
CRITICAL
Replace coupling ring screw(s)
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw(s)
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw(s)
WP 009 00
6
Coupling ring screw(s) PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 67)
CRITICAL
Replace coupling ring screw(s)
WP 009 00
7
Coupling ring fails straightedge inspection (Figure 68)
CRITICAL
Replace coupling ring WP 009 00
8
Captive flight adapter (Figure 71) missing or HRU-985A/E
training umbilical (Figure 69) not installed. Captive flight
adapter must be used with tactical umbilical (PN 2603913
or 639AS10935) on tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 72) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Rocket motor, Mk 57 Mod 2 or Mk 57 Mod 3, Safe-Arm
selector is in the ARM position
MAJOR
Ensure rocket motor Safe-Arm
selector handle is locked in the
SAFE position. If not, perform step
(1) for Mod 3 or step (2) for Mod
2: (1) Mod 3, pull handle to unlock
and move to the vertical position,
maintain pull pressure. Rotate
handle 90 degrees clockwise and
move to horizontal position.
Release pull pressure to lock in
SAFE position. Install safety clip
assembly. (2) Mod 2, insert key,
push in, and while maintaining
pressure rotate handle 90 degrees
clockwise then release pressure to
lock in SAFE position. Move key
to horizontal position.
GUIDANCE CONTROL SECTION
11
Missing or damaged shrink tubing (Figure 71) (must be
used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
12
Captive flight adapter or HRU-985A/E training umbilical
connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
*13
Foreign material on dome. (Various colorations of dome do
not affect missile performance) (Figure 72)
MINOR
Clean WP 009 00
*14
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
Change 2
89
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
15
Dome or dome retaining ring loose or cracked
MAJOR
Replace GCS WP 009 00
16
GCS dome lock ring/dome housing has dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
17
GCS dome lock ring/dome housing has dents up to 0.060inch in depth or less or gouges up to 0.025-inch in depth or
burrs on surface
MAJOR
Remove raised metal only with flat
file or 300 Grit emery cloth
18
Gas generator service life expired (Figure 74)
(WP 005 00 Table 1)
MAJOR
Replace GCS WP 009 00
19
Absence of, or illegible part number, lot number, date of
manufacture or serial number
MAJOR
Suspend and hold in condition
code J. Contact TMTCG, OOALC/GHGAMF, Robins AFB, GA
31098-1813 for instructions
20
GCS skin cracked, punctured, dents greater than 0.060-inch
or gouges greater than 0.025-inch in depth (Figure 72)
MAJOR
Replace GCS WP 009 00
21
GCS skin has dents up to 0.060-inch, gouges up to 0.025inch in depth, burrs, scratches, or pits penetrating anodized
coating or corrosion
MINOR
Repair coating SWP 009 01
22
Metal fin cup (Figure 70) missing or loose in GCS housing
MAJOR
Replace GCS WP 009 00
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
SD
GC
E
OM
SCREW THREADS
RUBBER FIN SEAL
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 69. HRU-985A/E Training Umbilical
90
Change 2
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 70. Fin Cup
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 71. Captive Flight Adapter, Umbilical Cable and GCS Base
Change 1
91
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
23
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
24
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
25
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 70)
MAJOR
Remove damaged adhesive and
apply a small bead of adhesive at
junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
26
26.1
27
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
Top of umbilical block metal housing lip separating from
the epoxy core
MAJOR
Repair, SWP 008 01
Umbilical block spring pin missing or damaged
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
28
Umbilical block spring pin not correct length
MINOR
Replace spring pin SWP 009 01
29
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated, but gas tubing or wire insulations
are not damaged
MAJOR
Repair insulation SWP 009 01
30
Umbilical cable shows evidence of being kinked, crushed,
or deformed as to affect integrity of cable assembly
MAJOR
Replace umbilical cable
SWP 009 01
31
Loose or damaged breakaway screws or safety wire broken/
missing
MAJOR
Replace/torque screws and safety
wire SWP 009 01
*32
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
33
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 72)
MAJOR
Replace/torque/clean screws
SWP 009 01
34
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws
SWP 009 01
35
Missing or loose housing assembly screws
MAJOR
Replace/torque screws
SWP 009 01
36
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws
SWP 009 01
37
Missing or loose nitrogen plug
MAJOR
Replace/torque plug SWP 009 01
38
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
39
Dirt, grease, or corrosion inside umbilical protective cap
MAJOR
Clean WP 009 00
92
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 72. Guidance Control Section Inspection Points
93
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
40
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
41
Missing, loose, or damaged preformed packing in umbilical
protective cap
MAJOR
Replace packing SWP 009 01
42
Damaged insert, plugged or corroded sockets on umbilical
connector
MAJOR
Remove GCS WP 009 00
Replace umbilical cable
SWP 008 01/SWP 009 01
43
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*44
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*45
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MINOR
Secure umbilical
46
Loose, missing or damaged components on coolant tank
access cover
MAJOR
Replace/repair cover SWP 009 01
46.1
Coolant pressure tank gauge indicates no positive pressure
MAJOR
Service/inspect/test SWP 006 08
47
Coolant pressure tank gauge (Table 18) is in the yellow or
red area (Figure 73)
MAJOR
Replace/service tank
Paragraph 51/40
48
TMU-72/B Coolant pressure tank gauge glass broken or
missing
MAJOR
Replace tank Paragraph 51/40
49
TMU-72A/B or TMU-72B/B coolant pressure tank gauge
glass broken or missing
MAJOR
Replace tank Paragraph 51/40
Replace glass SWP 008 08
50
Corrosion preventative compound missing on fin
MAJOR
Replace compound SWP 008 07
51
Forward or aft end of fin contacts GCS skin when rocked
MAJOR
Check fin installation
Paragraph 52/41
52
Fins have corrosion, contamination, warped, gouges, cracks,
or severe scratches
MAJOR
Inspect Table 10. Repair/replace. If
reject, replace Paragraph 52/41.
53
Fin attaching screws corroded, missing, or damaged
MAJOR
Replace/clean screws
Paragraph 52/41
54
Fin attaching screw(s), identification dot (minimum of 6,
raised or depressed) missing
MAJOR
Replace screws Paragraph 52/41
MINOR
Clean and apply MIL-C-85054
FINS
TARGET DETECTOR
55
94
Coupling ring(s) (Figure 67) has burrs, gouges, scratches,
dents, or pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 73. Coolant Pressure Tank (Accumulator), Markings
Table 18. Coolant Pressure Tank Pressure/Temperature Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
Change 1
95
CSTO XX21M-AIM9M-2
WP 007 00
Figure 74. CATM-3 and -7 Inspection Points
96
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
Coupling ring(s) has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring(s)
WP 009 00
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 00
57
Forward indexing pin is loose, missing, damaged, or
corroded
MAJOR
Remove TD WP 009 00
Replace pin SWP 009 02
58
Exterior surface scratches (Figure 74)
MINOR
Acceptable
59
TD markings missing or illegible
MAJOR
Replace markings WP 009 02
60
TD window(s) cracked, broken, missing, loose, or
condensation on inside of window
MAJOR
Replace window(s) SWP 009 02
61
TD window(s) for cleanliness
MINOR
Clean WP 009 00
62
TD protective cover missing
MINOR
Replace cover
Step
56
56.1
Corrective Action
WARHEAD
63
Exterior surface of warhead dented, but skin not penetrated
MINOR
Acceptable
64
Exterior surface of warhead gouged, but skin not penetrated
MINOR
Remove raised metal only with flat
file or 320 grit emery cloth and
touch-up paint WP 009 00
*65
Absence of, or illegible, markings (Figure 74)
MAJOR
Replace markings SWP 009 03
66
Surface of warhead cracked or skin penetrated
MAJOR
Replace warhead WP 009 00
ROCKET MOTOR SECTION
67
Rocket motor Safe-Arm selector assembly attachment
screws loose, assembly damaged, or missing (Mod 2/3)
MAJOR
Torque/replace screws, replace
assembly SWP 009 04
68
Safe-Arm selector handle (Mod 3) spring pin fails
inspection (Paragraph 36)
MAJOR
Replace spring pin SWP 009 04
69
Safe-Arm selector damaged or fails functional check
(Paragraph 37)
MAJOR
Repair/replace Safe-Arm selector
assembly SWP 009 04
70
Absence of, or illegible, markings (Figure 74)
MAJOR
Replace markings SWP 009 04
71
Rocket motor hangers have damage present that would
cause difficulty when installing missile on launcher
MAJOR
Replace hanger(s) SWP 009 04
72
Top of forward hanger (Figure 75) mating surface for
snubber wear in excess of 0.015 inch in depth, rear of
hanger for detent lug wear in excess of 0.030, or forward
detent lug wear area is rounded over all the way across the
area between the two arrows
MAJOR
Replace hanger SWP 009 04
73
Forward hanger mating surface and stress points for cracks
MAJOR
Replace hanger SWP 009 04
Change 1
97
CSTO XX21M-AIM9M-2
WP 007 00
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 75. Forward Hanger Assembly
0O
45O
VERTICAL CENTERLINE
AREA X
45O
NOTE: MATING SURFACES ARE THE AREAS OF
THE HANGER ASSEMBLY THAT TOUCH THE
LAUNCHER RAIL. ALL OTHER AREAS OF
THE HANGER ASSEMBLY ARE NONMATING
SURFACES.
HANGER MATING
SURFACES
DETAIL A
HANGER
SCREWS
AREA Y
Figure 76. Center and Aft Hanger Assemblies (Mk 57)
98
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
74
Rocket motor contact buttons have severe corrosion damage
or are not flush or below hanger
MAJOR
Replace/tighten contact buttons
SWP 009 04
75
Forward hanger protective cover damaged or missing
MINOR
Replace cover
Step
Corrective Action
NOTE
Steps 76 through 82 apply to the center and aft hanger (Figure 76, area X).
76
Mating surfaces for dents greater than 0.015-inch deep by
0.030-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
77
Mating surface for gouges greater than 0.015-inch deep by
0.030-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
78
Non-mating surfaces for pitted areas greater than 0.060
square inch in diameter and 0.032-inch deep
MAJOR
Replace hanger(s) SWP 009 04
79
Non-mating surfaces for dents greater than 0.032-inch deep
by 0.064-inch in diameter
MAJOR
Replace hanger(s) SWP 009 04
80
Non-mating surfaces for gouges greater than 0.045-inch
deep or 0.064-inch wide or 0.075-inch long
MAJOR
Replace hanger(s) SWP 009 04
81
Non-mating surface for cracks
MAJOR
Replace hanger(s) SWP 009 04
82
Mating surface for cracks
MAJOR
Replace hanger(s) SWP 009 04
NOTE
Steps 83 through 87 apply to center and aft hanger non-mating surfaces
(Figure 76, area Y)
83
Pits greater than 0.020 square inch and 0.015-inch deep
MAJOR
Replace hanger(s) SWP 009 04
84
Dents greater than 0.020-inch deep or 0.050-inch deep
MAJOR
Replace hanger(s) SWP 009 04
85
Burrs or scratches
MAJOR
Removed raised metal only with
flat file or 320 grit emery cloth
86
Cracks
MAJOR
Replace hanger(s) SWP 009 04
87
Gouges greater than 0.020-inch deep or 0.032-inch wide or
0.064-inch long
MAJOR
Replace hanger(s) SWP 009 04
88
Center/aft hangers for visible gap between hanger strap and
rocket motor mating surfaces
MAJOR
Replace hanger(s) SWP 009 04
89
Coupling ring (Figure 67) has burrs, gouges, scratches,
dents, or pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
90
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
Change 1
99
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
90.1
Defect
Classification
Coupling ring has brown spots, specks, or discoloration
Corrective Action
MAJOR
Clean, SWP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 00
WINGS
91
Absence of/or illegible identification markings: Mark, Mod,
and part number (Figure 77)
MINOR
Replace marking SWP 008 06
92
Wing surface greasy or dirty
MINOR
Clean SWP 008 06
NOTE
If over 25% (estimated) of thermal coating must be removed to repair,
reject
93
Over 25% of thermal coating on one side cracked, blistered,
peeling, or missing
MAJOR
Reject/replace Paragraph 53/42
94
Thermal coating cracked, blistered, peeling, or missing in
excess of 0.250-inch in diameter but less than 25% of
coating on one side
MAJOR
Replace wing Paragraph 53/42
Repair coating SWP 008 06
95
Over 25% of thermal coating missing from leading edge
MAJOR
Replace Paragraph 53/42
Repair coating SWP 008 06
96
Small hairline cracks in wing thermal base coating
MINOR
Acceptable
97
Thermal top coat in need of touch-up or replacement
MINOR
Touch-up/replace SWP 008 06
98
Scratches in wing coated surface 0.062-inch wide
MAJOR
Repair coating SWP 008 06
99
Punctures through wing skin into honeycomb
MAJOR
Reject/replace Paragraph 53/42
100
Cracks or warpage in metal structure of wing frame
MAJOR
Reject/replace Paragraph 53/42
101
Nicks or scrapes in metal structure of wing frame greater
than 0.250-inch in depth
MAJOR
Reject/replace Paragraph 53/42
102
Circular cracks in rivet area indicating loose rivets
MAJOR
Reject/replace Paragraph 53/42
103
Dents in wing surface more than 0.125-inch in depth
MAJOR
Reject/replace Paragraph 53/42
104
Dents in wing leading edge more than 0.125-inch in depth
MAJOR
Reject/replace Paragraph 53/42
105
Dents in wing leading edge less than 0.125-inch in depth
MINOR
Repair SWP 008 06
106
Wing alignment screws missing or damaged
MAJOR
Replace screws SWP 008 06
107
Wing alignment screws corroded
MAJOR
Clean/replace SWP 008 06
108
Wing attachment cap screw loose, missing or damaged
MAJOR
Replace screw SWP 008 06
109
Wing attachment cap screw corroded
MAJOR
Clean SWP 008 06
Replace Paragraph 53/42
100
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps 110 through 128 not applicable to wings without rolleron,
damper, and cager assemblies installed Table 5.
110
Guide vane(s) missing or bent (minor surface defects are
acceptable)
MAJOR
Replace Paragraph 53/42
Replace guide vane(s) SWP 008 06
111
Guide vane(s) corroded
MAJOR
Replace Paragraph 53/42
Remove/treat minor corrosion or
replace vane(s) SWP 008 06
112
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs (raised
metal only) with flat file or 320 grit
emery cloth
113
Guide vane screws loose, corroded, damaged, or missing
MAJOR
Replace Paragraph 53/42
Torque/clean/replace screws
SWP 008 06
114
Minor corrosion on rolleron assembly
MINOR
Clean SWP 008 06
115
Major corrosion on rolleron assembly affecting function of
rolleron
MAJOR
Replace Paragraph 53/42
Replace rolleron assembly
SWP 008 06
116
Rolleron hinge retaining screws loose, missing, or damaged
MAJOR
Replace/torque screws
SWP 008 06
117
Rolleron hinge corroded
MAJOR
Clean SWP 008 06
118
Rolleron hinge damaged
MAJOR
Replace Paragraph 53/42
Replace hinge SWP 008 06
119
Rolleron hinge damper pin hole elongated
MAJOR
Replace Paragraph 53/42
Replace hinge SWP 008 06
120
Play where damper assembly is attached to the rolleron
assembly
MAJOR
Replace wing Paragraph 53/42
Replace/torque screws or replace
damper assembly SWP 008 06
121
Damper assembly shows evidence of leaking oil
MAJOR
Replace Paragraph 53/42
Perform rolleron assembly
functional test (Paragraph 34)
122
Damper assembly attaching screws loose or missing
MAJOR
Replace/torque screws
SWP 008 06
123
Cager assembly binding, missing parts or inoperative
MAJOR
Replace Paragraph 53/42
Repair cager assembly
SWP 008 06
124
Cager assembly loose
MAJOR
Replace wing Paragraph 53/42
Replace/repair cager assembly
SWP 008 06
Change 1
101
CSTO XX21M-AIM9M-2
WP 007 00
Table 17. AUR Inspection CATM-3 and -7 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
125
Reset rivet missing or damaged (Mod 2)
MAJOR
Replace Paragraph 53/42
Replace cager assembly
SWP 008 06
126
Cager assembly corroded
MAJOR
Replace Paragraph 53/42
Clean/replace SWP 008 06
127
Rolleron assembly not caged
MINOR
Cage
128
Cager release-pull test (Paragraph 35)
MAJOR
Repair/replace SWP 008 06
MINOR
Clean WP 009 00
ASSEMBLED MISSILE
129
Assembled missile for dirt, grease, foreign matter, or minor
corrosion
ALUMINUM
SKIN
ROLLERON
HINGE
DAMPER
ASSEMBLY
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING
BASE
NOTES:
WING ALIGNMENT
SCREW (5)
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
1. ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER
ASSEMBLY, WING ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
2. DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
3. WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
4. WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 77. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
102
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Coupling ring cracked, not PN 639AS672, not properly
orientated, parts not installed correctly (Figure 79)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or later,
or PN 8934242
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
Coupling ring screw PN 639AS1599 Rev N manufactured
by (Cage Code) MC (Figure 79)
CRITICAL
Replace coupling ring screw
WP 009 00
6
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
OM
SD
C
G
E
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 78. HRU-985A/E Training Umbilical
Change 2
103
CSTO XX21M-AIM9M-2
WP 007 00
(1) COUPLING RING
GCS
(2) CLIP
(1)
(3) SCREW
FWD
(4) PIN
(5) THREADED PIN
(2)
(3)
(4)
(5)
INDEXING
PIN
AFT
PART
NUMBER
REVISION
MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
DOM
CAGE
CODE
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 79. Coupling Ring Assembly
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 80. Coupling Ring Straightedge Inspection
104
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 81. Captive Flight Adapter, Umbilical Cable and GCS Base
Change 1
105
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
7
Coupling ring fails straightedge inspection (Figure 80)
CRITICAL
Replace coupling ring WP 009 00
8
Captive flight adapter (Figure 81) missing or
HRU-985A/E training umbilical (Figure 78) not installed.
Captive flight adapter must be used with tactical umbilical
(PN 2603913 or 639AS10935) on tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 83) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Deleted
GUIDANCE CONTROL SECTION
11
Missing or damaged shrink tubing (Figure 81) (must be
used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing
SWP 006 01
12
Captive flight adapter or HRU-985A/E training umbilical
connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
13
Gas generator service life has expired (Figure 87)
(WP 005 00 Table 1)
MAJOR
Replace GCS WP 009 00
14
Absence of, or illegible, part number, lot number, date of
manufacture or serial number
MAJOR
Suspend and hold in condition code J.
Contact TMTCG,
OO-ALC/GHGAMF, Robins AFB,
GA 31098-1813 for instructions
15
Foreign material on dome. (Various colorations of dome
do not affect missile performance) (Figure 83)
MINOR
Clean WP 009 00
16
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
17
Dome or dome retaining ring loose or cracked
MAJOR
Replace GCS WP 009 00
18
GCS dome lock ring/dome housing has dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
19
GCS dome lock ring/dome housing has dents up to 0.060inch in depth or less or gouges up to 0.025-inch in depth
or burrs on surface
MAJOR
Remove burrs with flat file or 320 grit
emery cloth
20
GCS skin cracked, punctured, dents greater than 0.060inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
21
GCS skin has dents up to 0.060-inch, gouges up to 0.025inch in depth, burrs, scratches, or pits penetrating
anodized coating or corrosion
MINOR
Repair coating SWP 009 01
22
Metal fin cup (Figure 82) missing or loose in GCS
housing
MAJOR
Replace GCS WP 009 00
106
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
23
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
24
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
25
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 81)
MAJOR
Remove damaged adhesive and apply
a small bead of adhesive at junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
26
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
26.1 Top of umbilical block metal housing lip separating from
the epoxy core
MAJOR
Repair, SWP 008 01
MAJOR
Replace spring pin SWP 009 01
27
Umbilical block spring pin loose, missing, or damaged
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
28
Umbilical block spring pin not correct length
MINOR
Replace spring pin SWP 009 01
29
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated, but gas tubing or wire insulations
are not damaged
MAJOR
Repair insulation SWP 009 01
30
Umbilical cable shows evidence of being kinked, crushed,
or deformed as to affect integrity of cable assembly
MAJOR
Replace cable SWP 008 01/
SWP 009 01
31
Loose or damaged breakaway screws or safety wire
missing
MAJOR
Replace/torque screws and safety wire
SWP 009 01
32
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 82. Fin Cup
Change 1
107
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 83. Guidance Control Section Inspection Points
108
CAUTION
NO
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
33
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 83)
MAJOR
Replace/torque/clean screws
SWP 009 01
34
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws SWP 009 01
35
DC to DC converter screw loose or missing
MAJOR
Replace/torque screws SWP 009 01
36
Missing or loose housing assembly screws
MAJOR
Replace/torque screws SWP 009 01
37
Missing or loose nitrogen plug
MAJOR
Replace/torque plug SWP 009 01
38
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
39
Dirt, grease, or corrosion inside umbilical protective cap
MAJOR
Clean WP 009 00
40
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
41
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
42
Damaged insert, plugged or corroded sockets on umbilical
connector
MAJOR
Replace umbilical cable SWP 008 01/
SWP 009 01
43
Moisture or foreign matter on umbilical connector
MAJOR
Clean SWP 009 01
44
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
45
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MAJOR
Replace/secure
46
Loose, missing or damaged components on coolant tank
access cover
MAJOR
Replace/repair cover SWP 009 01
MAJOR
Service/inspect/test SWP 006 08
46.1 Coolant pressure tank gauge indicates no positive pressure
47
Coolant pressure tank gauge (Figure 84) is in the yellow
or red area (Table 20)
MAJOR
Replace/service tank Paragraph 51/40
48
TMU-72/B Coolant pressure tank gauge glass broken or
missing
MAJOR
Replace tank Paragraph 51/40
49
TMU-72A/B or TMU-72B/B coolant pressure tank gauge
glass broken or missing
MAJOR
Replace tank Paragraph 51/40
Replace glass SWP 008 08
50
Corrosion preventative compound missing on fin
MAJOR
Replace compound SWP 008 07
51
Fin attaching screw(s), identification dot (minimum of 6,
raised or depressed) missing (Figure 85)
MAJOR
Replace screws Paragraph 52/41
52
Forward or aft end of fin contacts GCS skin when rocked
MAJOR
Check fin installation Paragraph 52/41
53
Fins have corrosion, contamination, warped, gouges,
cracks, or severe scratches
MAJOR
Inspect Table 10. Repair/replace. If
reject, replace Paragraph 52/41.
54
Fin attaching screws corroded, missing, or damaged
MAJOR
Replace/clean screws Paragraph 52/41
FINS
Change 1
109
CSTO XX21M-AIM9M-2
WP 007 00
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 84. Coolant Pressure Tank (Accumulator), Markings
Table 20. Coolant Pressure Tank Pressure/Temperature Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
110
Change 1
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
CSTO XX21M-AIM9M-2
WP 007 00
Figure 85. Fin, BSU-32/B
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
MISSILE BODY SECTION
55
Coupling ring (Figure 79) has burrs, gouges, scratches,
dents, or pits that penetrate surface finish and aggregately
covers less than 2% of entire surface (2% of entire surface
is approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Repair/replace WP 009 00
56
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers
greater than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring WP 009 00
MAJOR
Clean, SWP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 00
56.1 Coupling ring has brown spots, specks, or discoloration
57
Exterior surface scratches (Figure 87)
MINOR
Acceptable
58
Forward indexing pin is missing
MAJOR
Replace pin SWP 009 05
59
Missile body for cuts or scratches in excess of 0.125-inch
in depth
MINOR
Repair if welding shop is available
60
Forward adapter retaining screws (4) loose/missing
MAJOR
Torque/replace screws SWP 009 05
Change 2
111
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
If Safe-Arm Selector Assembly is present, remove and replace with
cover plate, SWP 009 05.
61
Cover plate loose or missing. Cover plate attaching
screws loose or missing. (Figure 31)
MAJOR
Replace cover plate. Tighten or
replace screws. SWP 009 05
62
Deleted
63
Deleted
64
Deleted
65
Top of forward hanger (Figure 86) mating surface for
snubber wear in excess of 0.015 inch in depth, rear of
hanger for detent lug wear in excess of 0.030, or forward
detent lug wear area is rounded over all the way across the
area between the two arrows
MAJOR
Replace hanger SWP 009 05
66
Forward hanger mating surface and stress points for
cracks
MAJOR
Replace hanger SWP 009 05
67
Center or aft hanger(s) mating surface (Figures 86 and 87)
for cracks
MAJOR
Replace hanger SWP 009 05
68
Forward, center, or aft hanger(s) non-mating surface for
cracks
MAJOR
Replace hanger SWP 009 05
SIMULATED CONTACT BUTTONS
DETAIL A
STRESS POINTS
MATING
SURFACES
NON-MATING
SURFACES
FORWARD DETENT LUG
WEAR AREA
NOTE:
CAREFULLY CLEAN (REMOVE ALL PAINT
IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A
10X MAGNIFYING GLASS IF NECESSARY.
Figure 86. Forward Hanger Assembly (MBA)
112
Change 2
SCREW
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
WGU-4A(T-2)/B
9M FOR WGU-4A/B
Figure 87. CATM-9 and -10 Inspection Points
Change 2
113
CSTO XX21M-AIM9M-2
WP 007 00
Table 19. AUR Inspection CATM-9 and -10 (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Additional attention should be given to the center and aft hanger screw
heads during hanger inspection. Head of screw may crack/separate
from shank and remain adhered by paint and/or corrosion.
69
Forward, center, or aft hanger screws, damaged or missing
(Figure 87)
MAJOR
Repair SWP 009 05
70
Firmly grasp each hanger by hand and vigorously attempt
to move the hanger. Any movement is unacceptable.
MAJOR
Replace hanger screws SWP 009 05
71
Aft closure retaining screws (4) loose/missing
MAJOR
Torque/replace screws SWP 009 05
72
Sealant missing from hole in aft closure
MINOR
Replace sealant SWP 009 05
73
Absence of, or illegible, markings
MAJOR
Replace markings SWP 009 05
74
Deleted
75
Contact button (hex bar stock) loose, missing or not flush
or below hanger (Figure 86)
MAJOR
Repair SWP 009 05
76
Visually check alignment of center line of umbilical block
with center line of hangers (Figure 88)
MAJOR
Repair MBA SWP 009 05
WINGS
77
Leading or trailing edge bent in excess of 0.250-inch
(Figure 89)
MAJOR
Replace wing Paragraph 54/43
78
Leading or trailing edge bent less than 0.250-inch
MAJOR
Remove raised metal only with flat
file or 320 grit emery cloth
79
Severe scratches or gouges in excess of 0.250-inch deep
MAJOR
Replace wing Paragraph 54/43
80
Scratches or gouges less than 0.250-inch deep
MAJOR
Remove raised metal only with flat
file or 320 grit emery cloth
81
Cracks in excess of 0.250-inch
MAJOR
Replace wing Paragraph 54/43
82
Wing positioning screw installed
MINOR
Remove SWP 009 05
83
Wing attachment screws loose or missing
MAJOR
Torque/replace screws
Paragraph 54/43
84
Exterior paint cracked, peeling, scaling, or scruffed
(Figure 87)
MINOR
Paint/touch-up WP 009 00
85
Corrosion, dirt, or grease present
MINOR
Clean WP 009 00
114
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL CABLE BLOCK
HANGERS
CENTER LINE
NOTE
The center line of hangers and umbilical cable block should be 0° ± 0.5°. If these items are not in alignment, a
problem will occur with some launchers as the CATM is being mounted to aircraft. When this problem exists it
will be necessary to reposition the indexing pin located in the forward adapter SWP 009 05.
Figure 88. Umbilical Block Alignment
WING ATTACHMENT SCREWS (2)
WING ALIGNMENT SCREWS (5)
Figure 89. Wing Inspection, Fixed (MBA)
Change 1
114.1/(114.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Steps identified by and asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
In the absence of witness marks torque will only be checked on screws
listed in Table 4. All other screws will be visually checked for
looseness. Witness marks may be applied to aid in future inspections.
1
Coupling ring cracked, not PN 639AS672, not properly
orientated, parts not installed correctly (Figure 90)
CRITICAL
Replace coupling ring WP 009 00
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace coupling ring WP 009 00
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring WP 009 00
3
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace coupling ring WP 009 00
4
Coupling ring screw not PN 639AS1599 Rev M or later
CRITICAL
Replace coupling ring screw
WP 009 00
5
Coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace coupling ring screw
WP 009 00
5.1
Coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace coupling ring screw
WP 009 00
6
Coupling ring screw PN 639AS1599 Rev N manufactured
by (Cage Code) MC (Figure 90)
CRITICAL
Replace coupling ring screw
WP 009 00
7
Coupling ring fails straightedge inspection (Figure 91)
CRITICAL
Replace WP 009 00
8
Captive flight adapter (Figure 93) missing or
HRU-985A/E training umbilical (Figure 92) not installed.
Captive flight adapter must be used with tactical umbilical
(PN 2603913 or 639AS10935) on tactical GCS.
CRITICAL
Install captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
9
GCS dome (Figure 95) broken, cracked, punctured or
severely scratched
CRITICAL
Replace GCS WP 009 00
10
Safe-Arm selector is in the ARM position (Figure 97)
MAJOR
Pull handle to unlock and move to
vertical position, maintain pull
pressure. Rotate handle 90 degrees
clockwise and move to horizontal
position. Release pull pressure to
lock in SAFE position. Install
safety clip assembly.
Change 2
115
CSTO XX21M-AIM9M-2
WP 007 00
FO
RW
AR
D
9 N
6 3
9
9
1 5
A S
DUMMY BODY SECTION
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
PART
NUMBER
REVISION
MARKING
GUIDANCE
CONTROL
SECTION
ARROWS POINT
FORWARD
AF
T
COUPLING RING ASSEMBLY
PN 639AS672
CAGE
CODE
INDEXING PIN
DOM
COUPLING RING SCREW
TYPICAL HEAD MARKING
COUPLING RING
CLIP
COUPLING RING SCREW
RD
A
RW
FO
COUPLING RING PIN
THREADED PIN
HEAT TREAT STAMP
Figure 90. Coupling Ring, PN 639AS672
116
Change 2
CSTO XX21M-AIM9M-2
WP 007 00
SCREW APPEARS
STRAIGHT AND CENTERED
A STRAIGHT EDGE CAN BE USED TO VERIFY THAT
BOTH BOSS SURFACES ARE RELATIVELY FLAT
SCREW APPEARS BENT
A STRAIGHT EDGE CAN BE USED
TO VERIFY RING BOSS ALIGNMENT
COUPLING RING INSPECTION
(ACCEPTABLE)
COUPLING RING INSPECTION
(REJECT)
Figure 91. Coupling Ring Straightedge Inspection
RUBBER BAND
PROTECTIVE CAP
UMBILICAL
BLOCK
G
CS
DO
ME
SECURING
STRAP
GCS
UMBILICAL BASE
T-BOLT
KNURLED
RETAINING
NUT
Figure 92. HRU-985A/E Training Umbilical
117
CSTO XX21M-AIM9M-2
WP 007 00
16
26
13
12
1
2
17
25
19
33 28
32
35
21
30
22
24
4
20
29
34
31
11
3
18
27
5
6
7
23
8
10
1
9
16
2
3
20
5
29
26
32
34
30
12
24
23
8
9
13
25
35
31
22
7
14
27
28 33
21
6
15
17
18
19
4
ITT CANNON
15
14
N-T41508-106
DESIGNATES PLUGGED CAVITY
10
11
COOLANT GAS TUBE IS
PLUGGED IN PN 041508-0106
AND OPEN IN PN 041508-0113
FACE VIEW - PIN INSERT
CAPTIVE FLIGHT ADAPTER
PN 041508-0106 SHOWN
FACE VIEW - SOCKET INSERT
NOTES: 1. SOCKET/PIN CONTACTS 13, 19, 27, 32, & 33 ARE PLUGGED/OMITTED.
2. SOCKET/PIN CONTACT 11 OMITTED AND HAS A PRESSURE RELIEF TUBE INSTALLED IN THE CAVITY.
3. THE ADAPTERS ARE IDENTICAL EXCEPT FOR IDENTIFICATION MARKING AND COOLANT GAS TUBE.
THE COOLANT GAS TUBE IS OPEN IN PN 041508-0113 TO ALLOW COOLING GAS TO FLOW FROM LAU-7 LAUNCHER
TO GCS.
NOTE:
ENSURE RED SHRINK TUBING COVERS KNURLED END
OF CONNECTOR ON UMBILICAL CABLE
UMBILICAL BLOCK
SPRING PIN
BREAKAWAY
SCREWS (3)
1.250 INCH
LONG
CAPTIVE FLIGHT
ADAPTER
PROTECTIVE CAP
RUBBER BAND
RED SHRINK
TUBING
UMBILICAL
BLOCK
SPRING PIN
UMBILICAL
CABLE
ASSEMBLY
BREAKAWAY
SCREWS (3)
DETAIL A
UMBILICAL BLOCK
DETAIL A
GUIDE PIN
GCS
SKIN
SAFETY WIRE
GASKET
UMBILICAL BASE
GUIDE PIN
Figure 93. Captive Flight Adapter, Umbilical Cable and GCS Base
118
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
GUIDANCE CONTROL SECTION
11
Missing or damaged shrink tubing (Figure 93) (must be
used with captive flight adapter on tactical GCS)
MAJOR
Replace shrink tubing SWP 006 01
12
Captive flight adapter or HRU-985A/E training umbilical
connector socket/pins damaged
MAJOR
Replace captive flight adapter or
HRU-985A/E training umbilical
SWP 006 01
*13
Foreign material on dome (Various colorations of dome do
not affect missile performance) (Figure 95)
MINOR
Clean WP 009 00
*14
GCS dome has scratches, nicks, or pits
MINOR
Acceptable
15
Dome or dome lock ring loose or cracked
MAJOR
Replace GCS WP 009 00
16
GCS dome lock ring/dome housing has dents greater than
0.060-inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
17
GCS dome lock ring/dome housing has dents up to 0.060inch in depth or less or gouges up to 0.025-inch in depth or
burrs on surface
MAJOR
Remove raised metal only with flat
file or 320 grit emery cloth
18
GCS skin cracked, punctured, dents greater than 0.060inch or gouges greater than 0.025-inch in depth
MAJOR
Replace GCS WP 009 00
19
GCS skin has dents up to 0.060-inch, gouges up to 0.025inch in depth, burrs, scratches, or pits penetrating anodized
coating or corrosion
MINOR
Repair coating SWP 009 01
20
Tactical GCS gas generator service life expired (Figure 97)
(WP 005 00, Table 1)
MAJOR
Replace GCS WP 009 00
21
Absence of, or illegible, part number, lot number, date of
manufacturer or serial number
MAJOR
Suspend and hold in condition
Code J. Contact TMTCG, OOALC/GHGAMF, Robins AFB, GA
31098-1813 for instructions
22
Metal fin cup (Figure 94) missing or loose in GCS housing
MAJOR
Replace GCS WP 009 00
23
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 94. Fin Cup
Change 2
119
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
24
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Replace GCS WP 009 00
25
Fin rocker arm mating area damaged, or fin
attach hole(s) in rocker arm(s) worn, stripped, or damaged
so as prevent good mate with fin
MAJOR
Replace GCS WP 009 00
26
Rubber fin seal missing or damage affecting
environmental seal
MAJOR
Replace GCS WP 009 00
27
End of rocker arm protrudes above outside surface of fin
cup assembly
MAJOR
Replace GCS WP 009 00
28
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 95)
MAJOR
Remove damaged adhesive and
apply a small bead of adhesive at
junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
29
29.1
30
Crack in umbilical block (metal housing or epoxy)
(Figure 93)
MAJOR
Replace umbilical SWP 009 01
Top of umbilical block metal housing lip separating from
the epoxy core
MAJOR
Repair, SWP 008 01
Umbilical block spring pin loose, missing, or damaged
(tactical umbilical cable PN 2603913 or 639AS10935)
MAJOR
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
31
Umbilical block spring pin not correct length
(tactical umbilical cable PN 2603913 or 639AS10935)
MINOR
Replace spring pin SWP 009 01
32
Umbilical cable insulation separated from cable block or
launcher connector. Insulation damaged to extent cable
insulation is penetrated, but gas tubing or wire insulations
are not damaged
MAJOR
Repair insulation SWP 009 01
33
Umbilical cable shows evidence of being kinked, crushed,
or deformed as to affect integrity of cable assembly
MAJOR
Replace umbilical cable
SWP 009 01 (tactical umbilical
cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical cable)
34
Loose or damaged breakaway screws or safety wire
broken/missing
MAJOR
Replace screws and safety wire
SWP 009 01
*35
Breakaway screws improperly safety wired
MINOR
Safety wire screws SWP 009 01
36
Missing, loose, damaged, or corroded umbilical base
assembly screws (Figure 95)
MAJOR
Clean/replace/torque screws
SWP 009 01
120
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
WINDOW
AFT SCREW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 95. Guidance Control Section Inspection Points
121
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
37
Missing or loose screws on exhaust valve
MAJOR
Replace/torque screws
SWP 009 01
38
Missing or loose housing assembly screws
MAJOR
Replace/torque screws
SWP 009 01
39
DC to DC converter screws loose or missing
MAJOR
Replace/torque screws
SWP 009 01
40
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
41
Umbilical protective cap missing
MAJOR
Replace cap SWP 009 01
42
Dirt, grease, or corrosion inside umbilical protective cap
MAJOR
Clean WP 009 00
43
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
44
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
45
Damaged insert, plugged or corroded sockets on umbilical
connector
MAJOR
Replace umbilical cable
SWP 009 01 (tactical umbilical
cable PN 2603913 or
639AS10935)/SWP 006 01 (HRU985A/E training umbilical)
46
Moisture or foreign matter on umbilical connector
MAJOR
Clean WP 009 00
*47
Loose gas inlet fitting in umbilical connector
MAJOR
Tighten finger tight using gas inlet
spanner
*48
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MINOR
Secure cable
49
Loose, missing or damaged components on coolant tank
access cover
MAJOR
Replace/repair cover SWP 009 01
49.1
Coolant pressure tank gauge indicates no positive pressure
MAJOR
Service/inspect/test SWP 006 08
50
Coolant pressure tank gauge (Table 22) is in the yellow or
red area (Figure 96)
MAJOR
Replace/service tank
Paragraph 51/40
51
TMU-72/B Coolant pressure tank gauge glass broken or
missing
MAJOR
Replace tank Paragraph 51/40
52
TMU-72A/B or TMU-72B/B coolant pressure tank gauge
glass broken or missing
MAJOR
Replace tank Paragraph 51/40
Replace glass SWP 008 08
53
Corrosion preventative compound missing on fin
MAJOR
Replace compound SWP 008 07
54
Forward or aft end of fin contacts GCS skin when rocked
MAJOR
Check fin installation
Paragraph 52/41
55
Fins have corrosion, contamination, warped, gouges,
cracks, or severe scratches
MAJOR
Inspect Table 10. Repair/replace. If
reject, replace Paragraph 52/41.
FINS
122
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
RED
T
H T ON
IG
LY
IN
YELLOW
N
ER
S
T
FI
G
TANK, PRESSURE COOLANT, (ACCUMULATOR) ________
TANK SERIAL NUMBER _________________
MFR CODE IDENT _______________________
DATE MFR ___________________________
L
AL
GREEN
H
IG
CA
H
PR
U T I ON
E S S U R E AR
GO
N
PSI X 1000
TMU-72/B,
TMU-72A/B,
OR
TMU-72B/B
Figure 96. Coolant Pressure Tank (Accumulator), Markings
Table 22. Coolant Pressure Tank Pressure/Temperature Variation
OUTSIDE AIR TEMPERATURE
0O
40O
80O
-40O
GREEN
120O
YELLOW
4000
3000
RED
COOLANT TANK ACTUAL PRESSURE
5000
4850
2000
2000
3000
NOTE 2
COOLANT TANK INDICATED PRESSURE
3500
4000
5000
NOTE 1
PSIG
NOTES:
1. COOLANT TANK GAUGE INDICATES 5000 PSIG AT 80O F.
COOLANT TANK ACTUAL PRESSURE 5000 PSIG.
2. COOLANT TANK GAUGE INDICATES 3500 PSIG AT 0O F.
COOLANT TANK ACTUAL PRESSURE 4850 PSIG.
Change 1
123
CSTO XX21M-AIM9M-2
WP 007 00
WGU-4A/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
GAS GENERATOR LOADING DATE
GAS GENERATOR LOT NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
NOTE:
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
FLIGHT TEST
TLM EQUIP INCLUDED
OR
FOR COMPLETE COMPONENT
MARKING REQUIREMENTS
REFER TO SWP 009 XX
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
9M FOR WGU-4A/B
3 PLACES
WING RIBS
AFT HANGER
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF THIS LINE
CENTER HANGER
INERT
CENTER OF GRAVITY
FORWARD
HANGER
ROCKET MOTOR SECTION
DASHS SIMULATE
COUPLING RING
FORWARD
ADAPTER
DETAIL A
DETAIL B
BODY SECTION
GUIDED MISSILE DUMMY MDU-27A/A
30003-639AS10176
SERIAL NO.
CONTRACT NO.
MFG.
WARHEAD SECTION
D
FW
BLUE BAND
COUPLING
RING
FUZE SECTION
ADAPTER
MATING SCREWS
SAFE-ARM
SELECTOR ASSEMBLY
SAFE
ARM
(SAFE POSITION)
DETAIL A
STRAIGHT PIN
(INDEXING PIN)
DETAIL B
(PREFORMED GCS, PACKING &
COUPLING RING REMOVED)
Figure 97. CATM-16, -20 and -24 Inspection Points
124
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
56
Fin attaching screws corroded, missing, or damaged
MAJOR
Replace/clean screws
Paragraph 52/41
57
Fin attaching screw(s), identification dot (minimum of 6,
raised or depressed) missing
MAJOR
Replace screws Paragraph 52/41
DUMMY BODY SECTION
58
Adapter screws loose or missing (Figure 97)
MAJOR
Replace/torque SWP 009 06
59
Adapter straight pin bent, missing, damaged
MAJOR
Replace SWP 009 06
60
Body section for cuts or scratches in excess of
0.125-inch in depth
MINOR
Repair if welding shop available
61
Absence of, or illegible, identification markings
MAJOR
Replace markings
62
Exterior paint cracked, peeling, scaling, or scuffed
MINOR
Paint SWP 009 06
63
Exterior body surface dents, gouges, burrs, or scratches
MINOR
Repair burrs SWP 009 06
64
Corrosion, dirt, or grease present on body
MINOR
Clean SWP 009 06.
65
Safe-Arm Selector handle in ARM position
MINOR
Place in SAFE position
66
Safe-Arm Selector safety clip and/or flag missing
MINOR
Install safety clip and/or flag
67
Safe-Arm Selector screws missing or loose
MAJOR
Replace/torque SWP 009 06
68
Safe-Arm Selector fails functional test (Paragraph 37)
MAJOR
Replace stop assembly
SWP 009 06
69
Safe-Arm Selector fails spring pin inspection
(Paragraph 36)
MAJOR
Replace pin SWP 009 06
70
Contact buttons have dirt, grease, or corrosion (Figure 98)
MAJOR
Clean SWP 009 06
71
Contact buttons have severe corrosion
MAJOR
Replace buttons SWP 009 06
72
Contact buttons not flush or below hanger
MAJOR
Replace/torque SWP 009 06
73
Forward hanger bolt, loose or missing
MAJOR
Replace/torque SWP 009 06
74
Forward/center hanger mating surfaces have grease or
corrosion (Figures 98 and 99)
MAJOR
Clean SWP 009 06
75
Forward/center hanger mating surfaces have dents greater
than 0.015-inch deep by 0.030-inch in diameter
MAJOR
Replace hanger SWP 009 06
76
Forward/center hanger for burrs or scratches
MAJOR
Remove metal with flat file or 320
emery cloth. Touch-up paint
SWP 009 06
77
Forward/center hanger mating surfaces have gouges
greater than 0.015-inch deep by 0.030-inch wide by
0.045-inch long
MAJOR
Replace hanger SWP 009 06
78
Forward hanger mating surfaces and stress points for
cracks (Figure 98)
MAJOR
Replace hanger SWP 009 06
Center hanger mating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
78.1
Change 2
125
CSTO XX21M-AIM9M-2
WP 007 00
NOTE 1: TOP SURFACES OF CONTACT BUTTONS MUST BE EVEN WITH
OR BELOW THE TOP SURFACE OF FORWARD HANGER TO
PREVENT INTERFERENCE WITH THE LAUNCHER STRIKER
POINTS.
FWD CONTACT BUTTON
AFT CONTACT BUTTON
MATING SURFACES
MATING
SURFACES
NONMATING
SURFACES
DETAIL A
STRESS POINTS
NOTE 2: WHEN CHECKING FOR CRACKS CAREFULLY CLEAN HANGER
(REMOVE ALL PAINT IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
RECESSES
RECESSES
FWD CONTACT BUTTON
AFT CONTACT BUTTON
INSULATOR
MATING SURFACES
MATING
SURFACES
NONMATING
SURFACES
FORWARD HANGER
BOLT
Figure 98. MDU-27A/A Forward Hanger Assembly
126
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
79
Forward/center hanger nonmating surfaces for corrosion,
dirt, or grease
MAJOR
Clean SWP 009 06
80
Forward/center hanger nonmating surfaces for dents
greater than 0.045-inch deep by 0.075-inch in diameter
MAJOR
Replace hanger SWP 009 06
81
Forward/center hanger nonmating surfaces for burrs or
scratches
MAJOR
Remove raised metal with flat file
or 320 emery cloth. Touch-up paint
SWP 009 06.
82
Forward/center hanger nonmating surfaces for gouges
greater than 0.045-inch deep by 0.064-inch wide by
0.075-inch long
MAJOR
Replace hanger SWP 009 06
83
Forward/center hanger nonmating surfaces for cracks
MAJOR
Replace hanger SWP 009 06
84
Center hanger for loose shims or gap between hanger strap
and hanger (Figure 99)
MAJOR
Replace hanger/shims
SWP 009 06
85
Center hanger has no shims and has gap between hanger
strap and hanger
MAJOR
Replace hanger/shims
SWP 009 06
86
Aft hanger mating surfaces for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
87
Aft hanger mating surfaces for dents, scratches, or gouges
MAJOR
Replace hanger SWP 009 06
88
Aft hanger surface wear inspection (Paragraph 45)
MAJOR
Replace hanger SWP 009 06
89
Aft hanger mating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
90
Aft hanger nonmating surfaces for corrosion, dirt, or
grease
MAJOR
Clean SWP 009 06
MATING
SURFACES
SHIMS
MATING SURFACES OF
CENTER AND AFT
HANGER
AFT HANGER
CENTER HANGER
NOTE MATING SURFACES ARE THE AREAS OF THE HANGER ASSEMBLY THAT TOUCH THE LAUNCHER
RAIL. ALL OTHER AREAS OF THE HANGER ASSEMBLY ARE NONMATING SURFACES.
Figure 99. Center and Aft Hanger Assemblies (MDU-27)
Change 2
127
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
91
Aft hanger nonmating surfaces have dents, burrs, or
gouges
MINOR
Smooth raised metal with flat file
or 320 emery cloth. Touch-up paint
SWP 009 06.
92
Aft hanger nonmating surfaces has cracks
MAJOR
Replace hanger SWP 009 06
93
Center/aft hanger band for corrosion, dirt, or grease
MAJOR
Clean SWP 009 06
94
Center/aft hanger band loose
MAJOR
Replace hanger SWP 009 06
86
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers less
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply corrosion
preventive compound
87
Coupling ring has burrs, gouges, scratches, dents, or pits
that penetrate surface finish and aggregately covers greater
than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MAJOR
Replace coupling ring
WP 009 00
88
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, WP 009 00. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring WP 009 00
WINGS
95
Absence of/or illegible identification markings: Mark,
Mod, and part number (Figure 100)
MINOR
Replace marking SWP 008 06
96
Wing surface greasy or dirty
MINOR
Clean SWP 008 06
NOTE
If over 25% (estimated) of thermal coating must be removed to repair,
reject
97
Over 25% of thermal coating on one side cracked,
blistered, peeling, or missing
MAJOR
Reject/replace Paragraph 53/42
98
Thermal coating cracked, blistered, peeling, or missing in
excess of 0.250-inch in diameter but less than 25% of
coating on one side
MAJOR
Replace wing Paragraph 53/42
Repair coating SWP 008 06
99
Over 25% of thermal coating missing from leading edge
MAJOR
Replace Paragraph 53/42
Repair coating SWP 008 06
100
Small hairline cracks in wing thermal base coating
MINOR
Acceptable
101
Thermal top coat in need of touch-up or replacement
MINOR
Touch-up/replace SWP 008 06
102
Scratches in wing coated surface 0.062-inch wide
MAJOR
Repair coating SWP 008 06
103
Punctures through wing skin into honeycomb
MAJOR
Reject/replace Paragraph 53/42
104
Cracks or warpage in metal structure of wing frame
MAJOR
Reject/replace Paragraph 53/42
128
Change 1
CSTO XX21M-AIM9M-2
WP 007 00
ALUMINUM
SKIN
ROLLERON
HINGE
DAMPER
ASSEMBLY
GUIDE
VANE
ROLLERON
WHEEL
ROLLERON
ASSEMBLY
THERMAL
COATING
SIDEPLATE
SCREWS
RIVET AND
FRAME AREA
CAGER
ASSEMBLY
WING ASSEMBLY
MK 1 MOD 2
30003-639AS4895
WARRANTY EXP
DATE
ZONE A
DRAIN
HOLE
ZONE B
WING ATTACHMENT
SCREW
WING
BASE
NOTES:
WING ALIGNMENT
SCREW (5)
HONEYCOMB
MARKINGS
(NOTE 3)
THERMAL
COATING
1. ENTIRE SURFACE OF WING EXCEPT ROLLERON ASSEMBLY, DAMPER ASSEMBLY, ROLLERON HINGE, CAGER
ASSEMBLY, WING ATTACHMENT SCREW, AND UNDERSIDE OF WING IS THERMAL COATED.
2. DIFFERENCE BETWEEN MOD 1 AND MOD 2 WING IS THE CAGER ASSEMBLY. MOD 2 IS SHOWN.
3. WING PART NUMBER, MK, MOD, AND WARRANTY. MOD 2 WING MARKINGS SHOWN.
4. WARRANTY EXPIRATION DATE APPLIES ONLY TO MK 1 MOD 2 WINGS UNDER WARRANTY.
Figure 100. Wing Inspection/Marking, Mk 1 Mod 1 or Mk 1 Mod 2
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
105
Nicks or scrapes in metal structure of wing frame greater
than 0.250-inch in depth
MAJOR
Reject/replace Paragraph 53/42
106
Circular cracks in rivet area indicating loose rivets
MAJOR
Reject/replace Paragraph 53/42
107
Dents in wing surface more than 0.125-inch in depth
MAJOR
Reject/replace Paragraph 53/42
108
Dents in wing leading edge more than 0.125-inch in depth
MAJOR
Reject/replace Paragraph 53/42
109
Dents in wing leading edge less than 0.125-inch in depth
MINOR
Repair SWP 008 06
110
Wing alignment screws missing or damaged
MAJOR
Replace screws SWP 008 06
111
Wing alignment screws corroded
MAJOR
Clean/replace SWP 008 06
112
Wing attachment cap screw loose, missing or damaged
MAJOR
Replace screw SWP 008 06
113
Wing attachment cap screw corroded
MAJOR
Clean SWP 008 06
Replace Paragraph 53/42
Change 1
129
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps 114 through 132 not applicable to wings without rolleron,
damper, and cager assemblies installed Table 5
114
Guide vane(s) missing or bent (minor surface defects are
acceptable)
MAJOR
Replace Paragraph 53/42
Replace guide vane(s) SWP 008 06
115
Guide vane(s) corroded
MAJOR
Replace Paragraph 53/42
Remove/treat minor corrosion or
replace vane(s) SWP 008 06
116
Nicks or burrs on tip of guide vane(s)
MAJOR
Remove nicks or burrs (raised
metal only) with flat file or 320 grit
emery cloth
117
Guide vane screws loose, corroded, damaged, or missing
MAJOR
Replace Paragraph 53/42
Torque/clean/replace screws
SWP 008 06
118
Minor corrosion on rolleron assembly
MINOR
Clean SWP 008 06
119
Major corrosion on rolleron assembly affecting function of
rolleron
MAJOR
Replace Paragraph 53/42
Replace rolleron assembly
SWP 008 06
120
Rolleron hinge retaining screws loose, missing, or
damaged
MAJOR
Replace/torque screws
SWP 008 06
121
Rolleron hinge corroded
MAJOR
Clean SWP 008 06
122
Rolleron hinge damaged
MAJOR
Replace Paragraph 53/42
Replace hinge SWP 008 06
123
Rolleron hinge damper pin hole elongated
MAJOR
Replace Paragraph 53/42
Replace hinge SWP 008 06
45. AFT HANGER SURFACE WEAR INSPECTION.
a.
d.
Measure left side (when facing forward) of aft
hanger as follows:
Verify body section aft hanger is clean.
NOTE
b.
c.
130
Place template (Figure 101) on forward edges of
aft hanger. Using a fine tip felt pen, mark a
reference line across both sides of hanger flat
skid surfaces (Figure 102).
Place template on aft edges of aft hanger. Using a
fine tip felt pen, mark a reference line across both
sides of hanger flat skid surfaces.
Change 1
Ensure surface wear
calibration sticker.
fixture
has
current
(1) Slide guide block of surface wear fixture
(Figure 103) onto aft hanger from forward
end of hanger until indicator tip rests on
inside of edge of aft reference line (Figure
102). Lateral adjustment of indicator tip may
CSTO XX21M-AIM9M-2
WP 007 00
Table 21. AUR Inspection CATM-16, -20 and -24 (MDU-27A/A) (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
124
Play where damper assembly is attached to the rolleron
assembly
MAJOR
Replace wing Paragraph 53/42
Replace/torque screws or replace
damper assembly SWP 008 06
125
Damper assembly shows evidence of leaking oil
MAJOR
Replace Paragraph 53/42
Perform rolleron assembly
functional test (Paragraph 34)
126
Damper assembly attaching screws loose or missing
MAJOR
Replace/torque screws
SWP 008 06
127
Cager assembly binding, missing parts or inoperative
MAJOR
Replace Paragraph 53/42
Repair cager assembly
SWP 008 06
128
Cager assembly loose
MAJOR
Replace wing Paragraph 53/42
Replace/repair cager assembly
SWP 008 06
129
Reset rivet missing or damaged (Mod 2)
MAJOR
Replace Paragraph 53/42
Replace cager assembly
SWP 008 06
130
Cager assembly corroded
MAJOR
Replace Paragraph 53/42
Clean/replace SWP 008 06
131
Rolleron assembly not caged
MINOR
Cage
132
Cager release-pull test (Paragraph 35)
MAJOR
Repair/replace SWP 008 06
MINOR
Clean WP 009 00
ASSEMBLED MISSILE
133
Assembled missile for dirt, grease, foreign matter, or
minor corrosion
Change 1
130.1/(130.2 Blank)
CSTO XX21M-AIM9M-2
WP 007 00
be required to position tip on aft reference
point.
NOTE
Indicator tip must remain on extreme inside edge
of aft reference point.
(2) Hand tighten two knurled locking screws to
secure guide block in place (Figure 103).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip in
place. Ensure indicator tip remains on aft
reference point. Set dial indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indicator tip
rests on forward reference line (Figure 102).
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. If hanger wear exceeds
0.034-inch, replace hanger.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
e.
Measure right side (when facing forward) of aft
hanger as follows:
(1) Slide guide block of surface wear fixture
onto aft hanger from aft end.
NOTE
(2) Hand tighten two knurled locking screws to
secure guide blocks in place (Figure 103).
Hand tighten mounting post to secure
indicator tip in place. Ensure indicator tip
remains on aft reference point. Set dial
indicator to zero.
(3) Loosen both knurled locking screws and
slide guide block forward until indictor tip
rests on forward reference line.
(4) Hand tighten two knurled locking screws to
secure guide block in place.
(5) Read indicator dial: maximum allowable
wear is 0.034-inch. If hanger wear exceeds
0.034-inch, replace hanger.
(6) Loosen both knurled locking screws and
remove surface wear fixture.
(7) Body sections passing skid wear inspection
shall be identified for tracking purposes by
serial numbers of body sections or serial
numbers of aft hangers. Locally assigned ID
numbers may be used if body sections do not
have serial numbers.
(8) Dummy assembly body sections that have
been subjected to captive flight since the last
inspection shall be reinspected every thirty
days until the skid surface wear reaches
0.024-inch, at which time the inspection
frequency shall be increased to every two
weeks.
Indicator tip must remain on extreme inside edge
of aft reference point on the flat surface of the
skid. Do not locate the indicator on the inner
curvature of the hanger.
Figure 101. Aft Hanger Template
Change 1
131
CSTO XX21M-AIM9M-2
WP 007 00
INDICATOR TIP ON AFT
REFERENCE LINE AT THIS POINT
INDICATOR TIP ON FORWARD
REFERENCE LINE AT THIS POINT
FORWARD AND AFT
REFERENCE LINES
F-5/LAU-100 WEAR
INTERFACE REGION
LAU-7 WEAR
D
FW
Figure 102. Aft Hanger Flat Skid Surface
INDICATOR DIAL
MOUNTING POST
MOUNTING POST
KNURLED LOCKING
SCREWS (2)
GUIDE BLOCK
INDICATOR TIP
INDICATOR TIP
FORWARD
Figure 103. Aft Hanger Skid Surface Wear Fixture
132
CSTO XX21M-AIM9M-2
WP 007 00
NOTE
46. GROUND HANDLING.
For following steps comply with requirements
applicable to the missile configuration.
CAUTION
Mishandling can cause damage to the missile/
components. Do not lift missile by wings, fins,
rollerons, umbilical or dome assembly. Do not
allow missile/components to come in contact
with hard objects while handling. Do not rest
missile on target detector.
a.
a.
Ensure missile is secured to assembly stand and
grounded to a wing attachment screw at aft end of
wing (Mk 57), aft hanger (MBA), or forward
hanger (MDU-27/A).
b.
Ensure Safe-Arm selector handle is locked in the
SAFE position. If not, perform step (1) for Mod 3
or step (2) for Mod 2.
Procedures for missile loading on trailer and
missile tie-down are contained in TO 11-1-38.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
WARNING
Safety and Protective devices must be installed
during all ground handling. Damage to the
missile, serious injury or death of personnel
could result.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure to
lock in SAFE position. Move key to
horizontal position.
NOTE
For following steps comply with requirements
applicable to the missile configuration.
b.
c.
During any ground handling, all missiles shall
have the following:
Ensure dome protector, umbilical protective cap,
TD protective cover, and forward hanger (Mk 57
Mod 2 and Mod 3) protective cover are properly
installed.
50. AUR DISASSEMBLY.
(1) A dome protector with
BEFORE FLIGHT flag.
a
REMOVE
(2) A safety clip assembly (Mk 57 Mod 3) or
safety-arming key (Mk 57 Mod 2).
(3) A protective cap on the umbilical.
(4) A TD protective cover with a REMOVE
BEFORE FLIGHT flag.
(5) A protective cover on the (Mk 57 Mod 2 or
Mk 57 Mod 3) forward hanger.
NOTE
For following steps comply with requirements
applicable to the missile configuration.
a.
Preparations for AUR to missile disassembly
completed (Paragraph 49).
b.
Coolant pressure tank removal (Paragraph 51).
c.
Fin removal (Paragraph 52).
d.
Wing removal, Mk 1 Mod 1 or Mk 1 Mod 2
(Paragraph 53).
e.
Wing (MBA fixed) removal (Paragraph 54).
47. AUR INSPECTION.
48. This inspection will be performed on all AURs prior
to returning to stock or before and after usage. Inspect
AURs Table 15, Table 17, Table 19, or Table 21.
49. PREPARING FOR AUR TO MISSILE
DISASSEMBLY.
51. Coolant Pressure Tank Removal.
a.
Loosen access cover screws and remove cover
from GCS.
133
CSTO XX21M-AIM9M-2
WP 007 00
NOTE
WARNING
If a sustained gas venting is heard while
removing coolant pressure tank, tank removal
shall be stopped. Tank shall be allowed to
discharge in place and removed only after
venting ceases. Inspect/repair SWP 008 08.
b.
Use finger lugs on coolant pressure tank and
remove coolant pressure tank. If unable to
remove tank by hand, use coolant tank removal
tool.
c.
Install new sealing tape over coolant pressure
tank outlet valve as follows:
(1) Cut two pieces of tape, one approximately 1inch square and another approximately 2inch square. Center and apply adhesive side
of 1-inch tape to the adhesive side of the 2inch tape.
(2) Position 1-inch square tape over outlet valve
and secure. Do not reuse tape once applied.
d.
e.
Verify probe sealing cap is free of contaminants
and preformed packing is in place and install
probe sealing cap fingertight on GCS coolant
inlet probe.
Install access cover on GCS, and tighten screws
until snug.
Wing(s) may be removed at anytime to facilitate
handling missile.
a.
Remove one wing by loosening wing attachment
screw at aft end of wing about 1/2 to 3/4 inch.
Lift wing from rocket motor with forward
motion. It may be necessary to jar wing from aft
end by gentle tapping with heel of hand or
nonmetallic mallet on trailing edge of wing.
b.
Relocate missile ground strap to wing rib where
wing removed in step a was attached. Avoid
placing ground strap over etched serial number
on wing rib.
c.
Remove remaining wings (step a).
54. Wing (Fixed MBA) Removal.
NOTE
Heat may be necessary to loosen adhesive on the
screws.
a.
Loosen wing positioning screw, if installed.
b.
Remove four attachment screws securing wing to
missile body assembly.
NOTE
On new missile body assemblies, the wings are
identified to be placed on specific location.
Identifying marks are located on the wing ribs
and the under side of the wings.
52. Fin Removal.
c.
Remove wing from wing rib and mark for
position if necessary.
d.
Treat affected areas as required for corrosion
SWP 009 05.
CAUTION
One person must hold fin securely while second
person loosens fin attaching screws to prevent
damage to fin cup.
Fin screws are captive. Loosen to remove fin.
56. If complete missile disassembly is required, refer to
WP 009 00 for disassembly and applicable WP/SWPs for
inspection and packing.
a.
57. PACKING.
NOTE
Loosen fin attaching screws and remove fins
from GCS.
53. Wing Removal, Mk 1 Mod 1 or Mk 1 Mod 2.
134
55. MISSILE DISASSEMBLY.
58. MISSILE PACKING
CONTAINER.
IN
THE
CNU-310/E
CSTO XX21M-AIM9M-2
WP 007 00
installed in the empty area where the missile is
normally located to preclude any shifting of the
remaining missiles. When fiberboard tube is not
available, recommend using locally procured
carpet or PVC tubing of the appropriate diameter
and cut to appropriate length.
a.
Press button on pressure relief valve.
b.
Beginning at each end and working toward the
center, release the 16 container latches and place
latches in the DOWN position.
c.
Remove container cover by either lifting at each
corner (manually) or by lifting at the lift rings
(Figure 104) using a mechanical means.
i.
If only 2 or 3 missiles are to be loaded, the empty
slots shall be on the inside. If only 1 missile is to
be loaded, it shall be on the inside.
Ensure that all container cushions are positioned
according to the diagrams appearing on the cover
and container lower section.
j.
For shipment of 1, 2, and 3 missiles, a fiberboard
tube shall be used to fill empty slots.
k.
Lower missile into container with hangers in the
up position. Ensure that dome protector fits snug
into forward end cushion.
l.
Load remaining missiles, steps h, i, j, and k.
d.
e.
Place wings in lower section. Ensure wings fit
securely in dunnage.
f.
Place fins in lower section. Ensure fins are
staggered.
NOTE
If the AUR is to be stored or shipped with the
GCS removed a fiber board tube shall be installed
in the empty area where the GCS is normally
located to preclude any shifting of the remaining
portion of the AUR.
g.
h.
Place full coolant tanks in cavities located
between fins.
Secure umbilicals flat against GCSs using tape or
rubber band.
NOTE
m. Ensure four 16-unit bags or equivalent of
activated desiccant are in container.
n.
If humidity indicator is pink or white, replace.
o.
Verify container latches are at approximately a
60° angle to the bottom side of container prior to
applying force to close latches.
p.
Place container cover on lower section, secure
latches, and seal TO 11A-1-60.
59. CONTAINER MARKINGS.
60. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
If the AUR is to be stored or shipped with less
than four missiles a fiberboard tube shall be
Change 1
135
CSTO XX21M-AIM9M-2
WP 007 00
LIFT RINGS (4)
STAND OFF (6)
PRESSURE
RELIEF
VALVE
FINS
AFT
COOLANT
PRESSURE
TANKS
HUMIDITY
INDICATOR
TAPE
WINGS
DOME
PROTECTOR SLOT
SLOTS (6)
Figure 104. CNU-310/E All-Up-Round Container (PN 785041-10) and CATM/DATM Missiles
136
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING, INSPECTION AND TEST
FIELD LEVEL MAINTENANCE
GUIDANCE CONTROL SECTION, WGU-4A(T-2)/B AND AN/DSQ-29-T1
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 30
Date of Issue: Change 1 - 14 September 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-8 . . . . . . . . . . . . . . . . . . . . . . . 1
13 . . . . . . . . . . . . . . . . . . . . . . . . 0
17-19 . . . . . . . . . . . . . . . . . . . . . 1
24-27 . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
9. . . . . . . . . . . . . . . . . . . . . . . . . 0
14-15 . . . . . . . . . . . . . . . . . . . . . 1
20. . . . . . . . . . . . . . . . . . . . . . . . 0
28-30 . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
10-12. . . . . . . . . . . . . . . . . . . . . . 1
16 . . . . . . . . . . . . . . . . . . . . . . . . 0
21-23. . . . . . . . . . . . . . . . . . . . . . 1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions Containers and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Coolant Pressure Tank,
TMU-72/B, TMU-72A/B and TMU-72B/B ......................................................................................................SWP 008 08
Maintenance with Illustrated Parts Breakdown, Guidance Control Section,
WGU-4A(T-2)/B and AN/DSQ-29-T1 ..............................................................................................................SWP 009 01
Operation and Maintenance Instructions with IPB, Test Set, Guidance Control
Section (TS-3860C) .............................................................................................................................. FMS TS3860 Series
Operation and Maintenance Instructions with IPB, Test Set,
Guidance Control Section, TS-4044/D ............................................................................................... TO XX33D9-54-67-1
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings .............................................................................................................................................................29
Dropped GCS Processing ......................................................................................................................................................4
Empty Container Processing..................................................................................................................................................4
Handling and Test Equipment Preparation ............................................................................................................................4
Incidents/Accidents................................................................................................................................................................4
Inspection...............................................................................................................................................................................6
Change 1
1 of 30
CSTO XX21M-AIM9M-2
SWP 007 01
Table of Contents (Continued)
Title
Page
Packing ................................................................................................................................................................................ 27
GCS Packing in the CNU-300/E Container ...................................................................................................................... 27
GCS Packing in the CNU-301/E Container ...................................................................................................................... 28
Safety and Accident Prevention ............................................................................................................................................ 4
Sequence of Operations ......................................................................................................................................................... 4
Test Records/Documentation................................................................................................................................................. 4
Testing ................................................................................................................................................................................... 6
GCS Operational Test........................................................................................................................................................ 21
GCS Test Preparation for TS-4044/D or TS-3860C Test Set.............................................................................................. 6
Test Set Repeat Capability for No-Go............................................................................................................................... 27
Torque Requirements............................................................................................................................................................. 4
Unpacking.............................................................................................................................................................................. 4
GCS Unpacking from the CNU-300/E Container ............................................................................................................... 5
GCS Unpacking from the CNU-301/E Container ............................................................................................................... 6
List of Illustrations
Title
Page
Access Cover and Probe Sealing Cap ........................................................................................................................... 13, 19
AN/DSQ-29-T1 GCS Aft End............................................................................................................................................. 18
CNU-300/E Container, PN 639AS2880 .......................................................................................................................... 5, 28
CNU-301/E Container, PN 776013-30............................................................................................................................ 7, 30
Fin Cup Assembly and Rocker Arm ............................................................................................................................. 11, 18
GCS Inspection Areas ..................................................................................................................................................... 9, 16
GCS Test Precaution............................................................................................................................................................ 23
Guidance Control Section...................................................................................................................................................... 5
Torque Measurement Assembly Installation ....................................................................................................................... 20
Umbilical Block Damage .............................................................................................................................................. 11, 14
Umbilical Cable and GCS Umbilical Base ................................................................................................................... 11, 17
WGU-4A/B GCS Aft End ................................................................................................................................................... 13
List of Tables
Title
Page
AN/DSQ-29-T1 Training Guidance Control Section Inspection ........................................................................................ 15
Consumable Materials ........................................................................................................................................................... 3
Drop Criteria.......................................................................................................................................................................... 3
Tools and Equipment ............................................................................................................................................................. 3
Torque Requirements............................................................................................................................................................. 3
WGU-4A(T-2)/B GCS Inspection ......................................................................................................................................... 8
WGU-4A(T-2)/B Test Times ............................................................................................................................................... 23
2
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Band, Rubber
ZZ-R-1415
Secure umbilical cable
Cloth, Emery 320 Grit
P-C-1673
Remove burrs and minor surface
irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
DDD-T-86
GCS packing
Tape, Sealing
MIL-I-15126 Type GFT
Coolant pressure tank outlet valve
Tube, Fiberboard
PPP-T-495, Type 1, Class 1, Style D
Filler for container space when
shipping containers that are not full
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Coolant Pressure Tank Wrench
Local Manufacture (WP 004 00)
Remove coolant pressure tank from
GCS
Coolant Tank Removal Tool
PN 639AS4510
Alternate
GCS Assembly Fixture
16ADA27807
Hold GCS on work bench
Screwdriver, Torque
MIL-W-26497
Rim clenching clamp
Spanner, Gas
1298236
Tighten gas inlet in umbilical base
Test Set, TS-3860C
639AS10140
Test GCS
Test Set TS-4044/D
9281700-10
Test GCS
Wrench, Spanner
639AS2981
GCS coolant inlet probe
Wrench, Strap
GGGW651
Tighten dome housing
(AN/DSQ-29-T1)
Wrench, Torque
GGGW686
Nitrogen plug
Table 3. Drop Criteria
Item
GCS
Packaged/Unpackaged
Packaged or Unpackaged
Drop Distance (Feet)
Required Action
Any Height
Inspect Table 5 or Table 6 and test Paragraph 21.
Table 4. Torque Requirements
Part Number
Nomenclature
Torque Value
2236374
Nitrogen Plug Screw
50 ± 10 (in-lbs)
639AS2710
Rim Clenching Clamp Screw
25 ± 1 (in-lbs)
Change 1
3
CSTO XX21M-AIM9M-2
SWP 007 01
Table 4. Torque Requirements (Continued)
Part Number
Nomenclature
Torque Value
639AS4722
15-pin Connector Captive Screws
48 ± 8 in-oz
MS90726-129
Ballast Weight Cap Screw
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, Inspection and Testing
Guidance Control Sections (Figure 1). Production
techniques involving preparation of more than one GCS
may require deviations from the work sequence. Several
procedures, may be performed simultaneously, and in
different work areas, provided they do not invalidate or
interfere with a preceding or subsequent step and safety
precautions are strictly observed.
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
14. Verify torque wrenches have current calibration
sticker. Tighten all fasteners to torque value given in Table
4.
15. EMPTY CONTAINER PROCESSING.
16. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
4
13. TORQUE REQUIREMENTS.
DROPPED GCS PROCESSING.
8. Dropped GCS processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
GCS, reject it. Request disposition of dropped components
from WR-ALC, 575 CBSS/GBIA, 460 Richard Ray Blvd,
Ste 200, Robins AFB, GA 31098-1813.
9.
12. Verify all required handling and test equipment is
available and serviceable.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the GCS can cause the
GCS to malfunction. If any doubt exists as to acceptability
of GCS, reject it. Report incident/accident.
7.
60 ± 10 (in-lbs)
Change 1
17. UNPACKING.
CSTO XX21M-AIM9M-2
SWP 007 01
c.
GCS must not be carried by extractor handle
alone, or damage to GCS dome could occur.
Inspect container (Figure 2) exterior for damage.
If it is evident that container has been improperly
handled, the GCS shall be inspected in
accordance with Table 5 for WGU-4A(T-2)/B
and Table 6 for AN/DSQ-29-T1. WGU-4A(T-2)/
B shall be tested in accordance with Paragraph
21.
d.
Place container on side. Remove one GCS at a
time from container (two GCSs are normally
shipped in each container) by pulling extractor
handle.
e.
Place GCS on holding fixture and install dome
protector.
Press pressure relief valve, and remove container
cover and cushion.
f.
Loosen rim clenching clamp and carefully
separate extractor from GCS.
18. GCS UNPACKING FROM THE CNU-300/E
CONTAINER.
a.
b.
Figure 1. Guidance Control Section
Figure 2. CNU-300/E Container, PN 639AS2880
Change 1
5
CSTO XX21M-AIM9M-2
SWP 007 01
g.
Verify interior packing of container is complete
and undamaged.
h.
Place extractor(s), clamp(s), support insert
tube(s) if removed, and packing in container and
close cover.
i.
Process empty container Paragraph 15.
a.
Until the AIM9M GCS has the pop-out relief
valve installed (WP 003 00) conduct visual
inspections of the dome from the side. The
inspection will only consist of verifying the
presence of the dome. This will minimize
exposure to personnel.
b.
Inspect the guidance control section WGU-4A(T2)/B2 Table 5, and AN/DSQ-29-T1 Table 6.
19. GCS UNPACKING FROM THE CNU-301/E
CONTAINER.
a.
Inspect container (Figure 3) exterior for damage.
If it is evident that container has been improperly
handled, the GCS shall be inspected in
accordance with Table 5 for WGU-4A(T-2)/B
and Table 6 for AN/DSQ-29-T1. WGU-4A(T-2)/
B shall be tested in accordance with Paragraph
21.
b.
Press button on pressure relief valve. Release
container latches and place to the down position.
c.
Remove upper section.
d.
Lift front of GCS and remove the support insert
tube.
e.
Remove GCS from container and gently place on
holding fixture.
f.
Install dome protector.
g.
Remove aft dust cap and place in container.
h.
Repeat steps d. through g. for remaining GCSs.
i.
Verify interior packing of container is complete
and undamaged. Place support tube(s) and
packing in container and close cover.
j.
Process empty container Paragraph 15.
WARNING
Internal overpressure may exist within the GCS
which could rupture the IR dome. Do not stand
forward (within 180O of the center of the GCS) of
any part of the IR dome.
Change 1
GCS test not applicable for CATM 180 day
inspection.
c.
Test WGU-4A(T-2)/B Paragraph 21. If the GCS
was removed to facilitate other maintenance on
the missile and no maintenance was performed
on the GCS, testing is not required.
21. TESTING.
22. GCS TEST PREPARATION FOR THE TS-4044/
D OR TS-3860C TEST SET.
a.
Perform test set preparation and self-test in
accordance with TO XX33D9-54-67-1 (TS-4044/
D) or FMS TS3860 series (TS-3860C).
b.
Verify GCS has been inspected in accordance
with Paragraph 20.
c.
Verify tactical umbilical cable, PN 2603913 or
639AS10935, is installed.
NOTE
For TS-3860C, GCS may be tested with or
without a TMU-72 coolant tank installed. If
TMU-72 coolant tank is to be used continue with
step d. If no coolant tank is required proceed to
step e.
d.
20. INSPECTION.
6
NOTE
If a serviceable, fully charged coolant tank is
installed proceed to step e. If not, install the GCS
coolant pressure tank as follows:
(1) Verify coolant pressure tank has been
inspected and is fully charged.
(2) Loosen cover screws and remove coolant
tank access cover from GCS.
CSTO XX21M-AIM9M-2
SWP 007 01
Figure 3. CNU-301/E Container, PN 776013-30
Change 1
7
CSTO XX21M-AIM9M-2
SWP 007 01
Table 5. WGU-4A(T-2)/B GCS Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps identified by an asterisk (*) will not be used when evaluating
acceptance/rejection criteria.
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 009 01.
8
1
GCS (Figure 4) dome broken, cracked, punctured, or
severely scratched
CRITICAL
Reject
2
GCS mating area cracked or coupling ring groove
dented, cracked, or otherwise damaged so that coupling
ring will not seat properly
CRITICAL
Reject
*3
Foreign material on dome. (Various colorations of dome
do not affect missile performance)
MINOR
Clean SWP 009 01
*4
GCS dome has minor scratches, nicks, or pits
MINOR
Acceptable
5
Dome or dome retaining ring loose or cracked
MAJOR
Reject
6
GCS dome lock ring/dome housing has dents greater
than 0.060 inch in depth or gouges greater than 0.025
inch
MAJOR
Reject
7
GCS dome lock ring/dome housing has dents up to
0.060 inch in depth
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
8
GCS dome lock ring/dome housing has gouges up to
0.025 inch in depth
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
9
Absence of, or illegible part number, lot number, date of
manufacture, or serial number
MAJOR
Suspend and hold in condition
code J. Contact WR-ALC 575
CBSS/GBIA Robins AFB, GA
31098-1813 for instructions
10
GCS skin cracked or punctured, dents greater than
0.060 inch, or gouges greater than 0.025 inch in depth
MAJOR
Reject
11
GCS skin has gouges up to 0.025 inch, dents up to
0.060 inch in depth, burrs, scratches, or pits penetrating
anodized coating, or corrosion
MINOR
Repair SWP 009 01
*12
GCS skin has dirt or grease
MINOR
Clean SWP 009 01
13
Metal fin cup (Figure 5) missing or loose in GCS
housing
MAJOR
Reject
14
Metal fin cup flange bent
MAJOR
Use suitable tool and press flange
down until seated on GCS housing
15
Metal fin cup flange cracked, buckled, or bent to extent
flange will not seat on GCS housing
MAJOR
Reject
16
Fin rocker arm mating area damaged or fin attach
hole(s) in rocker arm(s) worn, stripped, or damaged so
as to prevent good mate of fin
MAJOR
Reject
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
AFT SCREW
WINDOW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 4. GCS Inspection Areas
9
CSTO XX21M-AIM9M-2
SWP 007 01
Table 5. WGU-4A(T-2)/B GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
CAUTION
Rubber fin seal shall not be probed.
17
Rubber fin seal missing, damage affecting
environmental seal
MAJOR
Reject
18
End of rocker arm protrudes above outside surface of
fin cup assembly
MAJOR
Reject
19
Missing or loose screws on exhaust valve (Figure 4)
MAJOR
Replace/torque screws
SWP 009 01
20
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base (Figure 6)
MINOR
Remove damaged adhesive and
apply a bead of adhesive to seal
junction
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
21
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
21.1
Top of umbilical block metal housing lip separating
from the epoxy core, Figure 5.1
MAJOR
Repair SWP 009 01
Umbilical block spring pin loose, missing, or damaged
MAJOR
Replace spring pin SWP 009 01
22
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
10
23
Umbilical block spring pin not correct length
MINOR
Replace spring pin SWP 009 01
24
Umbilical cable insulation separated from cable block
or launcher connector. Insulation damaged to extent
cable insulation is penetrated but gas tubing or wire
insulations are not damaged
MAJOR
Repair insulation SWP 009 01
25
Umbilical cable shows evidence of being kinked,
crushed, or deformed as to affect integrity of cable
assembly
MAJOR
Replace cable SWP 009 01
26
Loose or damaged breakaway screws, or safety wire
broken or missing
MAJOR
Replace screws/safety wire
SWP 009 01
27
Breakaway screws improperly safety wired
MAJOR
Safety wire screws SWP 009 01
28
Missing, loose, damaged, or corroded attaching screws
on umbilical base assembly (Figure 4)
MAJOR
Replace/torque/clean screws
SWP 009 01
29
Missing or loose housing screw(s)
MAJOR
Replace/torque screws
SWP 009 01
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 5. Fin Cup Assembly and Rocker Arm
Figure 5.1. Umbilical Block Damage
Figure 6. Umbilical Cable and GCS Umbilical Base
Change 1
11
CSTO XX21M-AIM9M-2
SWP 007 01
Table 5. WGU-4A(T-2)/B GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
30
Missing or loose nitrogen plug
MAJOR
Replace/torque nitrogen plug
SWP 009 01
31
Burrs or minor surface irregularities on coupling ring
groove or mating surface
MAJOR
Remove raised metal only using
flat file or 320 grit emery cloth
32
Dirt, grease, paint, foreign matter, or corrosion on
mating area and/or coupling ring groove
MINOR
Clean SWP 009 01
33
Umbilical protective cap missing or damaged (Figure 6)
MAJOR
Replace cap SWP 009 01
34
Dirt, grease, or corrosion inside umbilical
protective cap
MAJOR
Clean SWP 009 01
35
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MAJOR
Replace cap SWP 009 01
36
Missing, loose, or damaged preformed packing in
umbilical protective cap
MAJOR
Replace preformed packing
SWP 009 01
37
Damaged insert, plugged or corroded sockets on
umbilical connector
MAJOR
Replace umbilical cable
SWP 009 01
38
Moisture or foreign matter on umbilical connector
MAJOR
Clean SWP 009 01
39
Loose gas inlet fitting in umbilical cable (Figure 4)
MINOR
Tighten finger tight using gas inlet
spanner
*40
Umbilical cable not properly secured with rubber band
(ZZ-R-1415), retaining clip or equivalent
MINOR
Replace
41
GCS/TD 9-pin cable assembly (Figure 7) is worn or
damaged to extent cable insulation is damaged
MAJOR
Repair cable assembly
SWP 009 01
42
GCS/TD 9-pin cable wire insulation is damaged
(conductor exposed)
MAJOR
Reject
43
GCS/TD 9-pin connector has corroded socket(s),
plugged socket(s) or any other damage that would
prevent good electrical or mechanical mate to TD
MAJOR
Reject
44
Foreign material/moisture present on GCS/TD 9-pin
cable assembly and connector
MAJOR
Clean SWP 009 01
45
GCS/TD 9-pin cable assembly screw(s) or nylon
retaining nut(s) missing or damaged
MAJOR
Replace screws/nuts SWP 009 01
CAUTION
GCS/TM 15-pin connector, when exposed to conductive gas and burnt
gas residue, could short out GCS and cause missile failure. (Sealing
cap must be installed when 15-pin connector is not used.)
46
12
15-pin connector sealing cap missing or loose
Change 1
MAJOR
Replace SWP 009 01
CSTO XX21M-AIM9M-2
SWP 007 01
Figure 7. WGU-4A/B GCS Aft End
Figure 8. Access Cover and Probe Sealing Cap
13
CSTO XX21M-AIM9M-2
SWP 007 01
Table 5. WGU-4A(T-2)/B GCS Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
47
15-pin connector has corroded socket(s) plugged
socket(s), or other damage that would prevent good
electrical or mechanical mate of TM unit
MAJOR
Reject GCS
48
15-pin sealing cap screw(s) broken off in jack screw or
missing
MINOR
Replace screws/jack screw
SWP 009 01
49
Loose, missing, or damaged components on coolant
tank access cover (Figure 8)
MAJOR
Replace cover SWP 009 01
50
GCS coolant inlet probe missing or damaged
MAJOR
Replace GCS WP 009 00
51
Probe sealing cap missing on GCS coolant inlet probe
MAJOR
Replace probe sealing cap
(SWP 009 01 IPB)
52
Presence of foreign material/moisture or preformed
packing missing/damaged in probe sealing cap
MAJOR
Replace probe sealing cap
(SWP 009 01 IPB)
53
Coolant inlet probe area dirty, moisture, corroded, or
other foreign material present
MAJOR
Clean SWP 009 01
NOTE
The red pop-out indicator cannot be reset. The cool down capabilities of the GCS are
not affected. The GCS should remain in use until it is required to be returned to the
depot for another defect which prevents the GCS from functioning as designed.
54
Pop-out indicator actuated (if installed)
MINOR
Acceptable. Defer for depot
repair. See WP 003 00.
55
Pop-out indicator assembly damaged
MAJOR
Reject
Figure 8.1. Umbilical Block Damage
14
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
Table 6. AN/DSQ-29-T1 Training Guidance Control Section Inspection
Inspection
(Inspect for the following defects)
Defect
Classification
1
GCS mating area cracked or coupling ring groove
dented, cracked or otherwise damaged so coupling ring
will not seat properly (Figure 9)
CRITICAL
2
Identification markings illegible
MAJOR
Replace marking SWP 009 01
3
Dents, cracks, or gouges that penetrate GCS housing
MAJOR
Reject
4
Foreign material on dome
MAJOR
Clean SWP 009 01
5
Dome or dome housing cracked, punctured, or
otherwise damaged to extent security to GCS is affected
MAJOR
Replace SWP 009 01
6
Dome housing loose
MAJOR
Tighten using strap wrench until
secure
7
Dome protector assembly damaged or missing
MINOR
Replace or install
8
Loose, damaged, or improperly safety wired breakaway
screws (Figure 10)
MAJOR
Replace/torque and safety wire
screws SWP 009 01
9
Umbilical protective cap loose, missing, or damaged
MINOR
Replace cap SWP 009 01
10
Dirt, grease, or corrosion inside umbilical protective
cap
MINOR
Clean SWP 009 01
11
Missing, loose, or damaged preformed packing in
umbilical protective cap
MINOR
Replace preformed packing
SWP 009 01
12
Pin 13, 19, or 21 bent, broken, or missing in umbilical
protective cap
MINOR
Replace cap SWP 009 01
13
Umbilical cable insulation separated from cable block
or launcher connector
MINOR
Repair insulation SWP 009 01
14
Missing or damaged silicone adhesive at junction of
umbilical block and umbilical base
MINOR
Remove damaged adhesive and
apply a small bead of adhesive at
junction
Step
Corrective Action
Reject
NOTE
Scratches, gouges, or dents in the umbilical block (metal housing or
epoxy) are acceptable.
15
Crack in umbilical block (metal housing or epoxy)
MAJOR
Replace umbilical SWP 009 01
15.1
Top of umbilical block metal housing lip separating
from the epoxy core, Figure 8.1
MAJOR
Repair SWP 009 01
16
Umbilical cable insulation damaged to extent cable
insulation is penetrated but gas tubing or wiring
insulations are not damaged
MINOR
Repair cable SWP 009 01
17
Damaged insert, plugged, or corroded sockets on
umbilical connector
MINOR
Replace umbilical cable
SWP 009 01
18
Loose gas inlet fitting in umbilical cable (Figure 9)
MINOR
Tighten fingertight using gas inlet
spanner
Change 1
15
CSTO XX21M-AIM9M-2
SWP 007 01
UMBILICAL
CONNECTOR
PROTECTIVE
CAP
1
UMBILICAL
CABLE
ASSEMBLY
RUBBER
BAND
16
2
3
19
4
20
5
29
32
30
12
24
23
9
13
25
35
31
8
UMBILICAL
BLOCK
26
34
22
7
14
27
28 33
21
6
15
17
18
10
11
GCS SKIN
SAFETY WIRE
GAS INLET
FITTING
UMBILICAL BASE
FW
GASKET
BREAKAWAY
SCREWS (3)
GUIDE PIN
D
UMBILICAL CONNECTOR
SHOWN WITH PROTECTIVE
CAP REMOVED
BASE SCREWS (4)
DETAIL A
DETAIL A
KEYWAYS
DETAIL B
METAL CUP
FLANGE
DETAIL B
RUBBER FIN SEAL
FIN ROCKER ARM
CAUTION
NO
SUPPORT OR HANDLING
FORWARD OF LINE
DC TO DC
CONVERTER
SCREWS (3)
NITROGEN PLUG
COOLANT TANK
ACCESS COVER
HOUSING ASSEMBLY
SCREWS (8)
LOCK RING
BLUE BAND
WGU-4A(T-2)/B
SUPPORT OR HANDLING
FORWARD OF LINE
DOME HOUSING
DOME
UMBILICAL BASE
SCREWS (4)
WGU-4A(T-2)/B
SERIAL NO.
CONTRACT NO.
ASSEMBLY NO.
TEST
TLM FLIGHT
EQUIP INCLUDED
EXHAUST VALVE
SCREWS (4)
DOME ASSEMBLY
FORWARD SCREWS (2)
AFT SCREW
WINDOW
AN/DSQ-29-T1 TRAINING
PN 639AS2800
SN
INERT
Figure 9. GCS Inspection Areas
16
CAUTION
NO
CSTO XX21M-AIM9M-2
SWP 007 01
Table 6. AN/DSQ-29-T1 Training Guidance Control Section Inspection (Continued)
Step
19
Inspection
(Inspect for the following defects)
Defect
Classification
Umbilical block spring pin loose, missing, or damaged
(Figure 10)
MAJOR
Corrective Action
Replace spring pin SWP 009 01
NOTE
Spring pin length will be 1.250 inches for use with USAF launchers,
1.125 inches for USN launchers. See WP 003 00.
20
Umbilical block spring pin not correct length
MINOR
Replace spring pin SWP 009 01
21
Umbilical cable not properly secured with rubber band
ZZ-R-1415 or equivalent or retaining clip
MINOR
Secure cable
22
9-pin cable or attaching parts loose, missing, or
damaged (Figure 11)
MINOR
Replace parts/tighten SWP 009 01
23
Rocker arm mating area damaged so as to prevent good
mate of fin (Figure 12)
MAJOR
Reject
24
Loose, missing, or damaged components on coolant
tank access cover (Figure 13)
MAJOR
Replace/repair cover SWP 009 01
25
GCS coolant inlet probe missing or damaged
MINOR
Replace probe SWP 009 01 (IPB)
26
Coolant inlet probe has moisture or other foreign
material on it
MINOR
Clean SWP 009 01
27
Coolant inlet dirty, corroded, or other foreign material
on it
MINOR
Clean SWP 009 01
Figure 10. Umbilical Cable and GCS Umbilical Base
Change 1
17
CSTO XX21M-AIM9M-2
SWP 007 01
Table 6. AN/DSQ-29-T1 Training Guidance Control Section Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
28
Probe sealing cap missing on GCS coolant inlet probe
MINOR
Replace probe sealing cap
(SWP 009 01 IPB)
29
Burrs or minor surface irregularities on coupling ring
groove or mating surface (Figure 9)
MAJOR
Remove raised metal with flat file
or 320 grit emery cloth
30
Dirt, grease, corrosion, paint, or other foreign matter on
mating area and/or coupling ring groove
MAJOR
Clean SWP 009 01
31
Ballast weight cap screw not secure (Figure 12)
MAJOR
Torque/replace screw SWP 009 01
SCREW THREADS
RUBBER FIN SEAL
ROCKER ARM
CUP FLANGE
FIN CUP
Figure 11. Fin Cup Assembly and Rocker Arm
9-PIN CONNECTOR
MATING SURFACE
UMBILICAL CONNECTOR
BALLAST WEIGHT CAP SCREW
PROTECTIVE CAP
Figure 12. AN/DSQ-29-T1 GCS Aft End
18
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
Figure 13. Access Cover and Probe Sealing Cap
NOTE
Only two pins of the four pin spanner wrench are
used to remove the probe sealing cap. It may be
necessary to retract two pins flush with housing
of spanner wrench if four pins are protruding.
been damaged. If so, the GCS may require depot
maintenance.
(6) Turn coolant tank counterclockwise enough
to determine if the tank valve assembly is
operating (a release of pressure with an
abrupt cut off should be heard.) Turn coolant
tank clockwise fingertight using finger lugs
on coolant tank.
(3) Using spanner wrench, remove probe sealing
cap from GCS coolant inlet probe, if
installed.
(7) Ensure leaking can not be heard with the
tank fully installed. If leaking can be heard,
the coolant tank preformed packing should
be changed before the tank is rejected (SWP
008 08).
(4) Verify coolant inlet probe is free of oil, dirt,
grease, or any other contaminant.
CAUTION
CAUTION
Failure to use care when installing coolant tank
will result in damage to inlet probe.
(5) Remove and discard tape from coolant
pressure tank. Install and tighten fingertight
using finger lugs on coolant tank.
Failure to use care when installing access cover
will result in damage to coolant tank gauge.
(8) Install coolant pressure tank access cover;
tighten screws until snug.
NOTE
If no release of pressure is heard in step (6), the
coolant inlet probe in the GCS has most likely
e.
Install two fin adapters to GCS. When viewed
from the aft end of the GCS, the fin adapters must
be positioned (Figure 14), counterclockwise from
Change 1
19
CSTO XX21M-AIM9M-2
SWP 007 01
B
TOP TORQUE ROD
A
TOP FIN ADAPTER
9-PIN CONNECTOR
RIGHT SIDE FIN ADAPTER
CLAMP
ROTATE
CLAMP HOOK
CLAMP WIRE CONNECTOR
GCS REFERENCE NOTCH
GCS TELEMTRY CONNECTOR
GCS UMBILICAL CONNECTOR
REAR VIEW OF GCS
Figure 14. Torque Measurement Assembly Installation
umbilical base with raised (highest) edge
pointing forward.
f.
Remove the protective caps on the GCS 15-pin
and 9-pin connectors.
g.
Perform the following procedures to install GCS
on test set:
(4) Carefully position the GCS in the support
assemblies with the dome end pointing
toward the IR target simulator. Ensure that
the mounting groove around the aft end of
the GCS mates with the support wheels on
the aft GCS support assembly.
(1) Remove blind plug and connect W3 cable to
test set, if required.
(5) Adjust the forward GCS support assembly so
the GCS seats firmly.
(2) Unlatch and open the test set GCS support
assemblies.
(6) If required, tighten the screws on the forward
GCS support assembly.
CAUTION
Applying power to GCS with the dome protector
installed causes excessive current demand, which
may lead to premature failure of spin bearings in
the seeker assembly.
20
(3) Remove GCS dome cover.
Change 1
(7) Rotate the GCS counterclockwise until the
GCS telemetry connector (15-pin) is clear of
the test set aft GCS support assembly index
plate.
(8) Mate W3P2 with 15-pin connector.
(9) Mate W3P4 with GCS 9-pin connector.
CSTO XX21M-AIM9M-2
SWP 007 01
(10) Remove the protective cap from GCS
umbilical connector.
(11) Mate W3P3 with umbilical connector.
(12) Rotate the GCS so that the GCS reference
notch aligns with the upper guide pin on the
aft GCS support assembly.
(13) Push in and hold the upper guide pin and
align the GCS so the guide pin seats into the
GCS reference notch.
(14) Close and fasten the GCS support assembly
clamps.
(15) Release the guide pin.
h.
Install the torque measurement assembly on the
GCS as follows:
(1) If required, remove dust covers from torsion
rods.
CAUTION
Care shall be used when installing torque
measurement assembly to avoid damage to
umbilical cable assembly.
(2) Position the torque measurement assembly
around the GCS with the torque
measurement assembly decal arrow facing
forward. The torque measurement assembly
housings go over the fin adapters with the
torque measurement assembly torsion rods
to the rear of the fin adapter.
(3) Slide the torque measurement assembly
forward until fin adapters mate with the
torsion rods in the torque measurement
assembly and stop against the raised lip of
the fin adapter.
(1) Remove nitrogen plug and sealing ring from
GCS air inlet fitting. Inspect for presence
and serviceability of gas filter assembly. If
not in place or unserviceable, replace (SWP
009 01).
(2) Install servo air adapter, PN 757075, on GCS
then tighten finger tight.
(3) Connect push-on connector of pneumatic
hose assembly W7 to servo air adapter
installed in previous step and secure restraint
loop.
(4) Connect the other end of hose assembly to
the OUTLET TO GCS pneumatic connector
and secure restraint loop.
(5) Hold torque measurement assembly and
release fore and aft GCS support assembly
clamps.
(6) Push the lower guide pin in and rotate the
GCS 90 degrees counterclockwise until the
GCS reference notch aligns with the lower
guide pin on the aft GCS support assembly.
(7) Fasten the fore and aft GCS support
assembly clamps.
(8) Release the lower guide pin.
(9) For TS-3860C, turn on the facility external
SERVO pneumatic pressure.
NOTE
If GCS coolant tank is used, RDU COOLING
GAS switch must be in the INTERNAL position.
(10) For TS-3860C, turn on the external facility
RDU pneumatic pressure source. Verify that
the RDU COOLING GAS switch is in the
EXTERNAL position.
23. GCS OPERATIONAL TEST.
(4) Connect torque measurement assembly
clamp hooks to wire connector and push
handles down to secure.
i.
Install the servo air adapter on the GCS as
follows:
WARNING
Internal overpressure may exist within the GCS
which could rupture the IR dome. Personnel will
not stand forward (within 180O of the center of
Change 1
21
CSTO XX21M-AIM9M-2
SWP 007 01
PROCEED push button to bypass the failed
test number.
the GCS) of any part of the IR dome during GCS
test, Figure 14.1. This will minimize exposure to
personnel.
a.
(11) Verify GCS has been properly inspected and
GCS and test set are prepared for test.
Review the following GCS operational test
fundamentals prior to conducting test procedures.
b.
(1) Prior to sending a GCS to Depot level repair
for failed test, always question the IR target
simulator (replace), the test set (perform selftest), the coolant tank (replace), and the
umbilical cable (replace).
(1) The test set has successfully passed self-test.
(2) The GCS is properly installed on the test set.
(2) If LOW PRESSURE indicator lights at any
time and cannot be reset by operating the
PRESSURE RESET switch, the pneumatic
pressure is low and problem must be
corrected (step b.(5)).
(3) All cables and hoses are properly connected
and all restraint loops secured.
(3) WAIT indicator illuminates when a test is in
progress.
(5) The external (for TS-3860C, SERVO)
pneumatic pressure source is applied to the
test set and adjusted for a pressure of 1400 to
1600 psig.
(4) Test set storage compartments are empty and
vents are fully opened.
(4) GO indicator flashes when each test passes.
(5) NO GO indicator will illuminate and will
stay illuminated when a test fails. Repeat
test. If the failure occurs again, replace
umbilical cable and repeat test.
NOTE
For TS-3860C, if GCS coolant tank is used, RDU
COOLING GAS switch must be in the
INTERNAL position.
(6) The PROCEED switch is used to start or
continue testing sequence and to bypass
failed test numbers other than 001 or 002.
(7) The STOP switch can be used to stop
automatic test and reset to the beginning.
The test is then restarted at test number 001,
by operating PROCEED switch.
(8) Table 7 contains a complete list of the WGU4A(T-2)/B test number and test times.
(9) If GCS fails test number 003 see Paragraph
24, or Note 1, Table 7. The GCS repeat
capability is applicable to GCS tests 4
through 19, 21 through 27, and steps 50
through 55. For a NO GO indication, refer to
Paragraph 24.
(10) Test steps 8, 12-26, 28, 29, and 32 are not
applicable to the WGU-4A(T-2)/B inert
GCS. If a NO GO indication occurs at these
steps during operational test, press the
22
Verify that the following procedures have been
completed:
Change 1
(6) For TS-3860C, turn on the external facility
RDU pneumatic pressure source. Verify that
the RDU COOLING GAS switch is in the
EXTERNAL position.
c.
Perform the following procedures to test the
GCS:
(1) Verify power indicator lamp is illuminated.
(2) Open test set INLET pneumatic pressure
valve to the fully open position
(counterclockwise).
(3) Verify pneumatic control panel pressure
gauge indicates approximately 1150 ± 100
psig.
(4) Verify that CALIBRATE/SELF-TEST/GCS/
RESERVED switch is in GCS position.
(5) Remove IR target simulator dust cover.
CSTO XX21M-AIM9M-2
SWP 007 01
Table 7. WGU-4A(T-2)/B Test Times
Test
No.
Name
Time
(Sec)
Test
No.
Time
(Sec)
Name
001
B- Volt/B+ Current
24
021
System Gain (D-U)
Note 1
20
002
Gyro Spin Frequency
2
022
System Gain (U-D)
Note 1
20
003
Cooldown
10-30
023
Crosstalk (D-U)
Note 1
23
004
Nulling
2
024
Crosstalk (U-D)
Note 1
23
005
Missile Audio
8
025
Servo Max Torque (U-D)
Note 1
20
006
AGC
14
026
Servo Disable/Enable
Note 1
23
008
Rate Bias
24
050
CCM (A)
8
009
Slaving/Seam Reference
14
051
CCM (B)
36
010
Tracking (R-L)
20
052
CCM TA, TB
23
011
Tracking (L-R)
20
053
CCM TC
12
012
Lambda Comp +12
Note 1
15
054
CCM CV/CT TC
25
013
Lambda Comp +28
Note 1
18
055
CCM Duty Cycle
28
014
System Gain (R-L)
Note 1
20
027
Gas Supply
65
015
System Gain (L-R)
Note 1
20
028
Firing Interlock
Note 1
2
016
Crosstalk (R-L)
Note 1
23
029
Launch Lock
Note 1
1
017
Crosstalk (L-R)
Note 1
23
030
Missile ID
1
018
Servo Disable/Enable
Note 1
23
031
UMB/Fuze Continuity
2
019
Servo Max Torque (L-R)
Note 1
20
032
Early Launch Current
020
Rotate
Note 1
4
099
Test Complete
004
Nulling
Note 1:
Note 1
Note 1
1
2
These tests are not applicable to the WGU-4A(T-2)/B.
DANGER AREA
RISK OF INJURY IF DOME
SHOULD BLOW OUT
DO NOT STAND
FORWARD OF THIS LINE
DURING GCS TEST
NOTE: PERSONNEL WILL NOT STAND FORWARD OF THE GCS DURING TEST. A FAILURE OF THE COOLANT SYSTEM COULD
RESULT IN THE DOME BEING BLOWN OUTWARD WITH SUFFICIENT FORCE TO SERIOUSLY INJURY PERSONNEL.
EYE PROTECTION IS RECOMMENDED FOR THE TEST OPERATOR.
Figure 14.1. GCS Test Precaution
Change 1
23
CSTO XX21M-AIM9M-2
SWP 007 01
(6) Press and release the STOP push button
switch; WAIT indicator lamp illuminates.
(7) After WAIT indicator lamp goes out, reset
LOW PRESSURE indicator lamp by
actuating RESET PRESSURE switch.
(8) Press and hold TARGET DRIVE RELEASE
push button switch and align the index knob
with the scribed line on the test set. Release
switch to lock IR target simulator in position.
WARNING
Pneumatic pressure applied to the GCS during
test can create a hazard. The optical dome can
shatter or be blown outward and the umbilical
cable can rupture/separate violently during
operational checkout. Do not stand in front of
GCS or in the near vicinity of the umbilical cable
during checkout or serious injury could result.
NOTE
The test set performs a series of mini-self-tests.
When the test set completes the mini-self-test, it
performs a GCS identity check to determine
which type of GCS is mounted. Once the miniself-test is complete, the GCS test proceeds
automatically.
(9) Press and release the PROCEED push button
switch.
NOTE
The null adjustment mechanically aligns the GCS
with the IR source (target) so that the GCS
detects the maximum IR signal (center of target).
(10) After approximately 55 seconds, the GCS
NULL indicator illuminates and the threedigit display indicates a null voltage. If the
three digit display indicates a null voltage of
000, proceed to step (11). If not, adjust the
azimuth and elevation on the IR target
simulator as follows:
000 reading may be obtained during azimuth
adjustment. These steps should be repeated until
the technician is certain that the IR source is
aligned with the GCS.
(a) Adjust azimuth by pressing and holding
the TARGET DRIVE RELEASE push
button switch and move the drive arm R/
L until 000 is displayed or the lowest
possible reading is obtained. Release the
TARGET DRIVE RELEASE push
button.
(b) Do not press TARGET DRIVE
RELEASE. Adjust the elevation by
turning the elevation knob located on
the underside of drive platform under
the IR target simulator. Perform one of
the following two steps.
[1] If 000 is displayed, turn the
elevation knob in either direction
until the display shows the first
reading beyond 000. Next, turn the
elevation wheel in the opposite
direction taking note how far the
wheel is turned. Stop when the first
reading other than 000 is displayed.
Turn elevation knob back half way.
This will accurately null the IR
source for the GCS. This completes
the null.
[2] If display reads other than 000,
adjust elevation knob either
direction until 000 is obtained, then
re-adjust the elevation per step [1]
above. If 000 can not be obtained,
adjust to the lowest reading, and
then re-adjust the azimuth per step
(10a).
(11) Press and release the PROCEED switch. If
the null voltage is acceptable, test continues
and NULL indicator lamp goes out and
remains out. Proceed to step (13). If the null
voltage is unacceptable, the NULL lamp
goes out for approximately 2 seconds and
then illuminates again.
NOTE
Adjustment of both azimuth and elevation is
critical to properly align GCS to IR source. Both
steps should be completed in full even though a
24
(12) If the null voltage is unacceptable, readjust
IR target simulator to a null display of 000
using procedures of step (10). Press and
release the PROCEED push button switch. If
CSTO XX21M-AIM9M-2
SWP 007 01
reading other than 000 is displayed.
Turn elevation knob back half way.
This will accurately null the IR
source for the GCS. This completes
the null.
the null voltage is acceptable, the test
continues; if unacceptable, NO GO is
indicated.
(13) After approximately 3 minutes, providing no
GCS failure occurs, the ROTATE indicator
illuminates.
[2] If display reads other than 000,
adjust elevation knob either
direction until 000 is obtained, then
re-adjust the elevation per step [1]
above. If 000 can not be obtained,
adjust to the lowest reading, and
then re-adjust the azimuth per step
(19a).
(14) Hold torque measurement assembly and
release both fore and aft GCS support
assembly clamps.
(15) Push in and hold upper guide pin and rotate
GCS 90 degrees clockwise. Align GCS so
the guide pin seats into the GCS reference
notch.
(20) Press and release the PROCEED switch. If
the null voltage is acceptable, the remaining
tests will be automatic and NULL indicator
lamp goes out and remains out. Proceed to
step (22). If the null voltage is unacceptable,
the NULL lamp goes out for approximately
2 seconds and then illuminates again.
(16) Fasten the fore and aft GCS support
assembly clamps.
(17) Release upper guide pin.
(18) Press and release PROCEED push button
switch.
(21) If the null voltage is unacceptable, readjust
IR target simulator to a null display of 000,
using procedures of step (19). Press and
release the PROCEED push button switch. If
the null voltage is acceptable, the test
continues; if unacceptable, NO GO is
indicated.
(19) The GCS NULL indicator illuminates and
the three-digit display indicates a null
voltage. If the three-digit display indicates a
null voltage of 000, proceed to step (20). If
not, adjust the azimuth and elevation on the
IR target simulator as follows.
(22) When all tests are completed, the
COMPLETE indicator illuminates and the
three-digit display indicates 099. This
completes the GCS automatic tests.
(a) Adjust azimuth by pressing the
TARGET DRIVE RELEASE push
button switch and move drive arm R/L
until 000 is displayed or the lowest
possible reading is obtained. Release the
TARGET DRIVE RELEASE push
button.
(b) Do not press TARGET DRIVE
RELEASE. Adjust the elevation by
turning the elevation knob located on
the underside of drive platform under
the IR target simulator. Perform one of
the following two steps.
(23) Press STOP push button.
(24) If retest of GCS is required, refer to
Paragraph 24.
d.
Remove GCS from test set as follows:
(1) Remove servo hose W7 from the servo air
adapter.
(2) Remove the servo air adapter from the GCS.
[1] If 000 is displayed, turn the
elevation knob in either direction
until the display shows the first
reading beyond 000. Next, turn the
elevation wheel in the opposite
direction taking note how far the
wheel is turned. Stop when the first
(3) Inspect for serviceability and install nitrogen
plug (Figure 4) and sealing ring. Torque plug
in accordance with Table 4.
(4) Hold torque measurement assembly, release
torque measurement assembly clamps and
25
CSTO XX21M-AIM9M-2
SWP 007 01
(b) Use finger lugs on coolant pressure tank
and remove coolant pressure tank. If
unable to remove tank by hand, use
coolant tank removal tool.
slide the assembly aft until the torsion rods
are clear of the fin adapters.
(5) Remove the torque measurement assembly
and stow it in the torque measurement
assembly storage fixture. Install dust covers
on torsion rods.
(c) Install new sealing tape over coolant
pressure tank outlet valve as follows:
[1] Cut two pieces of tape, one
approximately 1-inch square and
another
approximately
2-inch
square. Center and apply adhesive
side of 1-inch tape to the adhesive
side of the 2-inch tape.
(6) Disconnect umbilical cable connector W3
from the GCS and install umbilical
protective cap.
(a) Connect the protective cap to umbilical
and turn knurled connector on umbilical
until it locks (snaps) in place on the
protective cap.
[2] Position 1-inch square tape over
outlet valve and secure. Do not
reuse tape once applied.
(b) Verify three rivets on protective cap can
be seen through the lock verification
ports on the umbilical connector.
(d) If GCS is to be shipped or stored, verify
probe sealing cap is free of
contaminants and preformed packing is
in place, install probe sealing cap
fingertight on GCS coolant inlet probe.
(7) Release forward and aft support clamps and
rotate GCS to allow removal of 15-pin
connector.
(e) If GCS is to be placed in service, install
coolant tank Paragraph 22.
(8) Remove 9-pin and 15-pin connectors.
(9) Remove GCS from test set.
(f) Install access cover on GCS, tighten
screws until snug.
(10) Install dome protector on GCS.
(11) Install GCS 9-pin and 15-pin connector
sealing caps. Torque 15-pin screw, Table 4.
e.
If no additional GCS testing is
accomplished, perform the following:
(12) Remove the fin adapters from the GCS.
(1) Install IR source dust cover.
(13) Secure umbilical cable in the stowed
position using a rubber band ZZ-R-1415 or
equivalent.
(2) Depressurize the test set as follows:
to
be
(a) Press and release the STOP push button
switch.
(14) Remove coolant pressure tank as follows:
(a) Loosen access cover screws and remove
cover from GCS.
WARNING
If a sustained gas venting is heard while
removing coolant pressure tank, tank removal
shall be stopped. Tank shall be allowed to
discharge in place and removed only after
venting ceases.
26
(b) Place the test set POWER switch to
OFF.
(c) Close external pneumatic inlet pressure
valve.
(d) Slowly open SAMPLE OUTLET
pneumatic pressure valve and allow test
set to depressurize until GCS
PRESSURE gauge indicates zero psig.
(e) When no further gas escapes and GCS
PRESSURE gauge indicates zero psig,
CSTO XX21M-AIM9M-2
SWP 007 01
(4) Repeat test. If failure occurs again at same
test number, remove umbilical cable
assembly and test (SWP 009 01). If cable
fails test, replace cable (SWP 009 01) and
repeat operational test. If cable is good,
reinstall on GCS (SWP 009 01). Reject GCS
if either test number 001 or 002 was the
failed test number. If failed test number was
not 001 or 002, proceed to step (5).
close SAMPLE OUTLET pneumatic
pressure valve.
(f) Remove pneumatic bleed fixture.
(g) Install SAMPLE OUTLET
disconnect fitting dust cover.
quick-
(h) Close pneumatic inlet pressure valve.
(5) If failed test number was 003, a possible
freeze up occurred caused by moisture
contamination. Set the GCS aside for at least
2 hours. This will allow the detector to warm
to ambient temperature. To eliminate
possible coolant tank contamination, replace
coolant tank. Repeat operational test. If the
GCS again indicates a NO GO remove GCS
(Paragraph 23) and reject.
(3) Refer to test set TO to prepare test set for
storage as required.
24. TEST SET REPEAT CAPABILITY FOR NO-GO.
a.
GCS test may be repeated during a GCS test with
the WAIT light on, a test number displayed, and
the test to be repeated is in process; or when the
NO GO light is on, the test set is stopped (due to
GCS failure of test), and the desired test to be
repeated is displayed and the test set is waiting
for a PROCEED. To exercise the repeat test:
(1) Place the CALIBRATE/SELF-TEST/GCS/
RESERVED switch in the RESERVED
position.
(2) Press and release the PROCEED push
button.
(6) If three consecutive GCSs fail the same test,
or four GCSs fail consecutively for any test,
calibrate test set and retest failed GCSs.
25. PACKING.
26. GCS
PACKING
CONTAINER.
b.
If a NO GO indication occurs during operational
test, proceed as follows until fault has been
isolated.
CNU-300/E
Ensure tactical umbilical cable and protective cap
is installed on GCS during shipment and storage.
b.
Ensure umbilical protective cap is installed.
c.
Ensure probe sealing cap is installed.
d.
Verify umbilicals are flat against GCSs. If not,
tape or use rubber bands to secure.
e.
Press button on pressure relief valve.
f.
Remove container cover and top cushion.
g.
Install extractor to GCS with rim clenching
clamp. Ensure arrows on rim clenching clamp are
pointing forward (towards GCS), and clamp
screw is in line with umbilical cable. Torque
clamp screw Table 4.
h.
Place container (Figure 15) on its side, remove
dome protector and place GCS in container
making sure that dunnage (nose support and
polyethylene rear cushion) is in place. Return
container to upright position.
(1) Repeat test.
(2) If test fails, perform self-test in accordance
with TO XX33D9-54-67-1 (TS-4044/D) or
FMS TS3860 series (TS-3860C).
(3) If test set still fails self-test, reject test set. If
no failure was indicated, proceed to step (4).
THE
a.
(3) The WGU-4A(T-2)/B test times can be
found in Table 7.
(4) Once the GCS has a GO indication in the
RESERVED
position
place
the
CALIBRATE/SELF-TEST/GCS/
RESERVED switch in the GCS position and
press and release the PROCEED push
button.
IN
27
CSTO XX21M-AIM9M-2
SWP 007 01
i.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container, one in each cavity.
j.
If humidity indicator is pink or white, replace.
k.
Tie one humidity indicator to handle of one
extractor.
l.
Place rear cushion and cover on container. Secure
cover and seal TO 11A-1-60.
27. GCS
PACKING
CONTAINER.
a.
IN
THE
CNU-301/E
Tactical umbilical cable and protective cap shall
be installed on GCS during shipment and storage.
NOTE
When fiberboard tube is not available,
recommend using locally procured carpet or PVC
tubing of the appropriate diameter and cut to
appropriate length.
b.
For special shipment of 1, 2, or 3 GCSs, a
fiberboard tube shall be used to fill the empty
slot(s).
c.
Ensure umbilical protective cap is installed.
d.
Ensure probe sealing cap is installed.
e.
Press button on pressure relief valve.
Figure 15. CNU-300/E Container, PN 639AS2880
28
Change 1
CSTO XX21M-AIM9M-2
SWP 007 01
f.
Release the latches and place in the down
position.
n.
Ensure two 8-unit bags or equivalent of activated
desiccant are in lower section of container.
g.
Remove container cover and top dunnage.
o.
If humidity indicator is pink or white, replace.
h.
Remove dome protector and install support insert
tube on GCS dome and dust cover on aft end of
each GCS, Figure 16.
p.
Place container upper section on lower section.
q.
To ensure proper seal, container latches should be
at approximately 60° angle to the bottom side of
container prior to applying force to close latches.
Secure container latches and seal container TO
11A-1-60.
i.
If fiberboard tube is placed in empty slot, tape
insert tube on forward end and place dust cover
on other end.
j.
Fasten umbilical connector firmly to body of
GCS using tape or rubber band.
k.
Place two GCSs in lower container cushion (aft
end of GCS on same end as container nameplate).
l.
Position center cushion over GCSs and fit
umbilical cables into slots.
28. CONTAINER MARKINGS.
29. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
m. Place two GCSs on center cushion and fit
umbilical cables into slots.
Change 1
29
CSTO XX21M-AIM9M-2
SWP 007 01
Figure 16. CNU-301/E Container, PN 776013-30
30
Change 1
CSTO XX21M-AIM9M-2
SWP 007 02
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING AND INSPECTION
FIELD LEVEL MAINTENANCE
TARGET DETECTOR, DSU-15(T-1)/B AND DSU-15(T-1)A/B
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 10
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1. ... .... ... ... .... ... .... 2
7-10 . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
2. . . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
3-6. . . . . . . . . . . . . . . . . . . . . . . . 2
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Material
Generated from Items Exposed to or Containing Explosives......................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Target Detector,
DSU-15(T-1)/B and DSU-15(T-1)A/B .............................................................................................................SWP 009 02
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles........................................................................ TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings .............................................................................................................................................................10
Dropped TD Processing.........................................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................4
Packing.................................................................................................................................................................................10
Target Detector Packing in the CNU-286/E Container......................................................................................................10
Target Detector Packing in the M548 Container ...............................................................................................................10
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
Target Detector Unpacking from the CNU-286/E or M548 Container ...............................................................................3
Change 2
1 of 10
CSTO XX21M-AIM9M-2
SWP 007 02
List of Illustrations
Title
Page
Target Detector ...................................................................................................................................................................... 3
Target Detector Container CNU-286/E, PN 2133808 ........................................................................................................... 4
Target Detector Container M548 (PN 777951-10)................................................................................................................ 4
Target Detector Coupling Ring Assemblies .......................................................................................................................... 5
Training Target Detector Forward/Aft End ........................................................................................................................... 9
Training Target Detector Markings ....................................................................................................................................... 6
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Tools and Equipment ............................................................................................................................................................. 2
Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection ....................................................................... 4
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Bag, Plastic
2162385
TD packaging in the CNU-286/E
container
Barrier Material
MIL-B-81705C
Packaging components
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface
irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local Purchase
Attaching barrier material to cover,
securing plastic bag
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
None
Table 3. Drop Criteria
2
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Target Detector
Packaged or Unpackaged
Any Height
Inspect Table 4
Change 1
CSTO XX21M-AIM9M-2
SWP 007 02
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, Inspection and Testing
target detectors Figure 1. Production techniques involving
preparation of more than one TD may require deviations
from the work sequence. Several procedures may be
performed simultaneously, and in different work areas,
provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
3.
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
Figure 1.
Target Detector
f.
Store serviceable containers for reuse or return
them to issuing activity.
SAFETY AND ACCIDENT PREVENTION.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving the TD can cause the
missile to malfunction. If any doubt exists as to
acceptability of TD, reject it. Report incident/accident.
7.
16. TARGET DETECTOR UNPACKING FROM
THE CNU-286/E OR M548 CONTAINER.
a.
Visually inspect container(s) (Figure 2 and 3) for
damage. If it is evident that container has been
improperly handled, inspect TD Paragraph 17.
b.
Release container latches.
DROPPED TD PROCESSING.
8. Dropped TD processing criteria are contained in Table
3. If any doubt exists as to acceptability of dropped TD,
reject it. Request disposition of dropped components from
TMTCG, OO-ALC/GHGAMF, 460 Richard Ray Blvd, Ste
200, Robins AFB, GA 31098-1813.
9.
15. UNPACKING.
TEST RECORDS/DOCUMENTATION.
CAUTION
TD shall not be carried by its plastic bag.
Change 2
3
CSTO XX21M-AIM9M-2
SWP 007 02
c.
Open container, remove TDs, and place TDs on a
clean workbench.
d.
Remove plastic bag(s) (when required) and
examine TDs for handling damage.
f.
Process empty container Paragraph 13.
17. INSPECTION.
e.
18. Inspect Target Detector Table 4.
Verify interior packing of container is complete
and undamaged. Place in container and close
cover.
Figure 2.
Target Detector Container
CNU-286/E, PN 2133808
Figure 3.
Target Detector Container M548 (PN 777951-10)
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 009 02.
1
TD mating area cracked or coupling ring grooves
dented, cracked, or otherwise damaged so that coupling
ring will not seat properly
CRITICAL
Reject
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace SWP 009 02
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
SWP 009 02
2.1
4
Change 2
CSTO XX21M-AIM9M-2
SWP 007 02
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
3
Forward coupling ring assembly cracked or damaged
CRITICAL
Replace coupling ring
SWP 009 02
4
Forward coupling ring screw not PN 639AS1599 REV
M or later or PN 8934242
CRITICAL
Replace screw SWP 009 02
5
Forward coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace screw SWP 009 02
5.1
Forward coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace screw SWP 009 02
6
Forward coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC (Figure 4)
CRITICAL
Replace screw SWP 009 02
7
Forward coupling ring assembly not PN 639AS672
CRITICAL
Replace coupling ring
SWP 009 02
8
Directional arrows (Figure 4) on forward coupling ring
not pointing forward
CRITICAL
Replace/repair coupling ring
SWP 009 02
PART
NUMBER
REVISION
MARKING
CAGE
CODE
DOM
COUPLING RING SCREW
TYPICAL HEAD MARKING
9 N
6 3
9
9
1 5
A S
MC
COUPLING RING SCREW
(PN 639AS1599N, CAGE CODE MC)
HEAD MARKING
Figure 4. Target Detector Coupling Ring Assemblies
Change 2
5
CSTO XX21M-AIM9M-2
SWP 007 02
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
9
Defect
Classification
Forward coupling ring or attaching parts not installed
correctly
CRITICAL
Corrective Action
Replace/repair coupling ring
SWP 009 02
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
10
Forward coupling ring threaded pin not stamped with
heat treat markings
CRITICAL
SWP 009 02
11
Aft coupling ring assembly (TD aft end) cracked or
damaged
CRITICAL
Replace coupling ring
SWP 009 02
12
Aft coupling ring screw not PN 639AS1599 Rev M or
later or PN 8934242
CRITICAL
Replace screw SWP 009 02
13
Aft coupling ring screw(s) PN 639AS1599 Rev P
CRITICAL
Replace screw SWP 009 02
13.1
Aft coupling ring screw(s) PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace screw SWP 009 02
14
Aft coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC
CRITICAL
Replace screw SWP 009 02
15
Aft coupling ring assembly not PN 639AS2725
CRITICAL
Replace coupling ring
SWP 009 02
16
Directional arrows on aft coupling ring not pointing
toward warhead
CRITICAL
Replace/repair coupling ring
SWP 009 02
17
Aft coupling ring or attaching parts not installed
correctly
CRITICAL
Replace/repair coupling ring
SWP 009 02
DSU-15(T-1)/B TRAINING
OR
DSU-15(T-1)A/B TRAINING
NSN
PN 639AS2815 or 639AS6516
INERT
Figure 5. Training Target Detector Markings
6
Change 2
CSTO XX21M-AIM9M-2
SWP 007 02
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
18
Aft coupling ring threaded pin not stamped with heat
treat marking
CRITICAL
Replace pin SWP 009 02
19
TD has been removed from a GCS whose gas grain
generator has been fired
MAJOR
Clean SWP 009 02
20
Exterior identification marking(s) (Figure 5) missing or
illegible
MAJOR
Replace markings SWP 009 02
21
Corroded exterior surface between coupling rings
MINOR
Clean SWP 009 02
22
Corroded area adjacent to coupling rings
MAJOR
Clean SWP 009 02
23
Exterior surface scratches
MINOR
Acceptable
24
Exterior surface cracks or punctures
MAJOR
Reject
25
Mating surface(s) with scratches, dents, burrs, or pits
present that do not prevent proper mating
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
26
Mating surface(s) with burrs or gouges present that
prevent proper mating
MAJOR
Reject
27
Forward and aft coupling ring grooves for corrosion,
dirt, grease, or other foreign matter present
MAJOR
Clean SWP 009 02
28
Forward and aft coupling ring grooves for burrs or
minor surface irregularities
MAJOR
Remove raised metal only using
flat file or 320 grit emery cloth
NOTE
Slight degradation of the anti-reflective coating on the window(s) that
resembles water spots is acceptable.
29
Window(s) cracked, broken, missing, loose, or
condensation on inside of window
MAJOR
Replace window SWP 009 02
30
Windows scratched
MINOR
Acceptable
31
Forward coupling ring or attaching parts corroded
MINOR
Clean SWP 009 02
32
Forward coupling ring or attaching parts severely
corroded
MAJOR
Replace coupling ring
SWP 009 02
33
Coupling ring(s) has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
less than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
Change 1
7
CSTO XX21M-AIM9M-2
SWP 007 02
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
34
Coupling ring(s) has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
greater than 2% of entire surface (2% of entire surface
is approximately an area 0.25 inches long across the
entire width of the coupling ring)
MAJOR
Replace coupling ring(s)
SWP 009 02
34.1
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 009 02. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 02
35
Forward pin (indexing) is loose, missing, damaged, or
corroded
MAJOR
Replace pin SWP 009 02
36
Forward pin (indexing) touching coupling ring screw
MAJOR
Repair SWP 009 02
37
Preformed packing located on forward end of TD is
missing, nicked, or damaged
MAJOR
Replace preformed packing
SWP 009 02
38
Aft coupling ring assembly guide plate sheared off in
TD and unable to remove with common hand tools
MAJOR
Reject
39
Aft coupling ring or attaching parts corroded
MAJOR
Clean SWP 009 02
40
Aft coupling ring has burrs, gouges, scratches, dents, or
pits present that penetrate surface finish
MAJOR
Replace SWP 009 02
41
9-pin connector has attaching screws loose, missing or
damaged
MAJOR
Replace/tighten screws
SWP 009 02
42
Damaged, bent, or broken pins on 9-pin connector
MAJOR
Replace connector SWP 009 02
43
Connector sealing gasket in 9-pin connector (Figure 6)
is missing, deformed or damaged so as to prevent
proper connection of GCS/TD 9-pin connector
MINOR
Replace gasket SWP 009 02
44
Corrosion or foreign material in 9-pin connector
MINOR
Clean SWP 009 02
45
Dirt, grease, or foreign material around 9-pin connector
MINOR
Clean SWP 009 02
Step
Corrective Action
NOTE
Some TDs do not have communication tube (hole) for installing tube
expanding plug.
8
46
Dummy tube expanding plug loose
MINOR
Tighten plug SWP 009 02
47
Dummy tube expanding plug missing or damaged
MAJOR
Replace plug SWP 009 02
48
6-pin connector loose or has damaged or missing insert
MAJOR
Replace SWP 009 02
49
6-pin connector has damaged, stripped threads, burrs, or
any combination that would prevent assembly of S-A
device
MAJOR
Replace SWP 009 02
50
Dirt, grease or foreign material in or around 6-pin
connector
MAJOR
Clean SWP 009 02
51
6-pin connector corrosion
MAJOR
Clean SWP 009 02
Change 1
CSTO XX21M-AIM9M-2
SWP 007 02
Table 4. Training Target Detector, DSU-15(T-1)/B and DSU-15(T-1)A/B Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
52
Loose or missing panhead screw(s) (4 ea.) (Figure 6) on
aft end of A/B
MAJOR
Replace/torque SWP 009 02
53
TD protective cover missing
MINOR
Replace cover
Step
Corrective Action
PAN HEAD SCREWS
(4 EACH)
6-PIN
CONNECTOR
AFT END
AFT END
AFT GUIDE PLATE
DUMMY EXPANSION
PLUG
9-PIN CONNECTOR
FORWARD END
FORWARD
INDEXING PIN
DSU-15(T-1)/B
FORWARD END
DSU-15(T-1)A/B
Figure 6. Training Target Detector Forward/Aft End
Change 1
9
CSTO XX21M-AIM9M-2
SWP 007 02
j.
19. PACKING.
20. TARGET DETECTOR PACKING IN THE CNU286/E CONTAINER.
a. Remove container cover and top cushion.
Place cover on container and secure hasps. Seal
container TO 11A-1-60.
21. TARGET DETECTOR PACKING IN THE M548
CONTAINER.
b.
Ensure protective cover and 20-pin test connector
protective cap are installed on TD.
a.
Ensure protective cover and 20-pin test connector
protective cap are installed on TD.
c.
Place each TD in a plastic bag and securely tape
plastic bag closed.
b.
Open container (Figure 3) and remove all but
bottom cushion.
c.
Place two TDs in lower cushion and align so that
the coupling ring screws lay in the slot provided.
d.
Install remaining cushions and TDs as in step c.
e.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
f.
If humidity indicator card is pink or white,
replace.
g.
Tape humidity indicator card to top cushion.
CAUTION
TD shall not be carried by its plastic bag.
d.
Place four TDs in cutouts of body cushioning in
container Figure 2.
e.
Place cover cushioning on top of body
cushioning.
f.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
g.
If humidity indicator card is pink or white,
replace.
h.
Tape humidity indicator card to top cushion.
NOTE
Barrier material shall be positioned to prevent
contact between container cover and humidity
indicator card.
h.
Ensure barrier material, approximately 6 inch x 6
inch, is taped to inside of container cover
Figure 3.
i.
Secure container cover and seal TO 11A-1-60.
NOTE
Barrier materials shall be positioned to prevent
contact between container cover and humidity
indicator card.
22. CONTAINER MARKINGS.
i.
10
Ensure barrier material, approximately 6 inch x 6
inch is taped to inside of container cover.
Change 1
23. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
CSTO XX21M-AIM9M-2
SWP 007 03
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING AND INSPECTION
FIELD LEVEL MAINTENANCE
WARHEAD MK 70 MOD 1
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this WP is 6
Date of Issue: Change 1 - 16 March 2007
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-4 . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
5. . . . . . . . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
6 . . . . . . . . . . . . . . . . . . . . . . . . .1
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Metal Generated from Items
Exposed to or Containing Explosives .............................................................................................................. TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Warhead Mk 70 Mod 1............................................................SWP 009 03
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ...........................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings ...............................................................................................................................................................6
Dropped Warhead Processing ................................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................2
Inspection...............................................................................................................................................................................6
Packing...................................................................................................................................................................................6
Warhead Packing in the Mk 386 Mod 0 Container..............................................................................................................6
Warhead Packing in the M548 Container ............................................................................................................................6
Safety and Accident Prevention.............................................................................................................................................2
Sequence of Operations .........................................................................................................................................................2
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
Warhead Unpacking from the Mk 386 or M548 Container .................................................................................................3
Change 1
1 of 6
CSTO XX21M-AIM9M-2
SWP 007 03
List of Illustrations
Title
Page
Warhead Container Mk 386 Mod 0, PN 1516431 ................................................................................................................. 4
Warhead Container M548 (PN 777948-10)........................................................................................................................... 4
Warhead Markings and Inspection Points ............................................................................................................................. 5
Warhead Training Dummy Mk 70 Mod 1 ............................................................................................................................. 3
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Dummy Warhead Mk 70 Mod 1 Inspection .......................................................................................................................... 4
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packaging components
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs or minor surface irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Tape
Local Purchase
Secure humidity indicator card in containers
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
None
Table 3. Drop Criteria
1.
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Warhead
Packaged or Unpackaged
Any Height
Inspect Table 4
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of the
warhead Figure 1. Production techniques involving
preparation of more than one warhead may require
deviations from the work sequence. Several procedures
may be performed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
2
Change 1
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accidents involving collision or dropping
components can cause the missile to malfunction. If any
CSTO XX21M-AIM9M-2
SWP 007 03
doubt exists as to acceptability of warhead reject it. Report
incident/accident.
7.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
DROPPED WARHEAD PROCESSING.
8. Dropped warhead processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
warhead, reject it. Request disposition of dropped
components from WR-ALC, 575 CBSS/GBIA, 460
Richard Ray Blvd, Ste 200, Robins AFB, GA 31098-1813.
9.
d.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
15. UNPACKING.
16. WARHEAD UNPACKING FROM THE MK 386
OR M548 CONTAINER.
a.
Inspect container (Figure 2 and 3) exterior for
damage. If container shows obvious rough
handling damage, inspect warheads Table 4.
b.
Open container and inspect interior of container
for moisture and proper storage of warheads.
Improperly stored units must be carefully
examined. If moisture is noted, inspect warheads.
c.
Remove warheads from container.
d.
Verify interior packing of container is complete
and undamaged.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
Figure 1. Warhead Training Dummy Mk 70 Mod 1
Change 1
3
CSTO XX21M-AIM9M-2
SWP 007 03
Figure 2.
Warhead Container Mk 386 Mod 0, PN 1516431
Figure 3.
Warhead Container M548 (PN 777948-10)
Table 4. Dummy Warhead Mk 70 Mod 1 Inspection
4
Step
Inspection
(Inspect for the following defects)
Defect
Classification
1
Exterior surface of warhead cracked or skin penetrated
CRITICAL
Reject
2
Warhead mating area (Figure 4) cracked or coupling
ring groove dented, cracked or otherwise damaged so
that coupling ring will not seat properly
CRITICAL
Reject
3
Blue band in need of touch-up
MINOR
Touch-up blue band SWP 009 03
4
Absence of, or illegible identification markings
MAJOR
Replace markings SWP 009 03
5
Exterior surface paint in need of touch-up or replacing
MINOR
Touch-up paint SWP 009 03
6
Exterior surface corrosion present
MINOR
Clean SWP 009 03
7
Exterior surface grease or dirt present
MINOR
Clean SWP 009 03
8
Exterior surface of warhead dented, but skin not
penetrated
MINOR
Acceptable
9
Exterior surface of warhead gouged, but skin not
penetrated
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
and touch-up paint SWP 009 03
10
Forward end cap of warhead loose, cracked, or not
securely crimped
MAJOR
Reject
11
Forward end cap for corrosion
MAJOR
Clean SWP 009 03
Change 1
Corrective Action
CSTO XX21M-AIM9M-2
SWP 007 03
Figure 4. Warhead Markings and Inspection Points
Table 4. Dummy Warhead Mk 70 Mod 1 Inspection (Continued)
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
12
Forward end cap for grease or dirt
MINOR
Clean SWP 009 03
13
Burrs or minor surface irregularities on coupling ring
grooves or mating surface
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth,
apply corrosion preventive
compound SWP 009 03
14
Forward and aft mating areas and coupling ring
grooves, corrosion present
MAJOR
Clean SWP 009 03
15
Forward and aft mating areas and coupling ring
grooves, grease or dirt present
MINOR
Clean SWP 009 03
16
Corrosion present in warhead S-A device cavity
MINOR
Clean SWP 009 03
17
Grease or dirt present in warhead S-A device cavity
MINOR
Clean SWP 009 03
18
Aft or forward protective cap missing
MINOR
Replace
5
CSTO XX21M-AIM9M-2
SWP 007 03
e.
Remove protective caps from ends of warhead
and place in container prior to replacing cover.
f.
Process empty containers Paragraph 13.
21. WARHEAD
CONTAINER.
PACKING
IN
THE
M548
a.
Open container (Figure 3) and remove all but
bottom cushion.
b.
Ensure forward and aft protective caps are
installed on warhead.
19. PACKING.
c.
Place warhead in lower cushion.
20. WARHEAD PACKING IN THE MK 386 MOD 0
CONTAINER.
d.
Install remaining cushions and warhead.
e.
Ensure two 8-unit bags or equivalent of activated
desiccant are in container.
f.
If humidity indicator is pink or white, replace.
g.
Tape humidity indicator card to top cushion.
17. INSPECTION.
18. Inspect warhead Table 4.
a.
Remove container cover Figure 2.
b.
Ensure forward and aft protective caps are
installed on warhead.
c.
Place warhead in container. No dunnage is
required.
NOTE
d.
Place two 8-unit bags or equivalent of activated
desiccant in container.
Barrier material shall be positioned to prevent
contact between container cover and humidity
indicator card.
e.
Ensure barrier material, approximately 6 inch by
6 inch, is taped to the inside of container cover.
h.
Ensure barrier material, approximately 6 inch x 6
inch is taped to inside of container cover.
i.
Secure container cover and seal TO 11A-1-60.
f.
If humidity indicator is pink or white, replace.
g.
Tape humidity indicator card to barrier material.
h.
Secure container cover and seal TO 11A-1-60.
22. CONTAINER MARKINGS.
23. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
6
Change 1
CSTO XX21M-AIM9M-2
SWP 007 04
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING AND INSPECTION
FIELD LEVEL MAINTENANCE
ROCKET MOTOR, MK 57 MOD 1, MK 57 MOD 2, MK 57 MOD 3
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 18
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1. ... .... ... ... .... ... .... 2
4. ... .... ... ... .... ... .... 1
8-9 . . . . . . . . . . . . . . . . . . . . . . . 2
12.2 added blank . . . . . . . . . . . . 1
15-16 . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
2. . . . . . . . . . . . . . . . . . . . . . . . . 1
5-6 . . . . . . . . . . . . . . . . . . . . . . . 0
10-12 . . . . . . . . . . . . . . . . . . . . . 1
13. . . . . . . . . . . . . . . . . . . . . . . . 1
Page No.
Change No.
3 . . . . . . . . . . . . . . . . . . . . . . . . .2
7 . . . . . . . . . . . . . . . . . . . . . . . . .1
12.1 added. . . . . . . . . . . . . . . . . . 1
14 . . . . . . . . . . . . . . . . . . . . . . . . 0
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives ........................................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Rocket Motor,
Mk 57 Mod 1, Mk 57 Mod 2, Mk 57 Mod 3 .....................................................................................................SWP 009 04
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings .............................................................................................................................................................15
Dropped Rocket Motor Processing........................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................6
Safe-Arm Selector Handle Spring Pin Inspection (Mk 57 Mod 3)......................................................................................6
Packing.................................................................................................................................................................................14
Rocket Motor Packing in the CNU-289/E Container ........................................................................................................14
Rocket Motor Packing in the Mk 287 or Mk 37 Container ...............................................................................................14
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Change 2
1 of 16
CSTO XX21M-AIM9M-2
SWP 007 04
Table of Contents (Continued)
Title
Page
Unpacking.............................................................................................................................................................................. 4
Rocket Motor Unpacking from the CNU-289/E Container ................................................................................................ 4
Rocket Motor Unpacking from the Mk 287 or Mk 37 Container ....................................................................................... 4
List of Illustrations
Title
Page
Center and Aft Hanger Inspection....................................................................................................................................... 11
Forward Hanger Assembly.................................................................................................................................................. 11
Rocket Motor Mk 57 Mod 1, Mk 57 Mod 2, Mk 57 Mod 3 ................................................................................................. 3
Rocket Motor Mk 57 Mod 1, Mk 57 Mod 2, Mk 57 Mod 3 Markings ............................................................................... 16
Rocket Motor Center and Aft Hangers............................................................................................................................. 12.1
Rocket Motor Container CNU-289/E, PN 776013-10 .......................................................................................................... 7
Rocket Motor Container Mk 287 (PN 1516486) or Mk 37, PN 1516261............................................................................. 4
Rocket Motor Inspection (Forward End) .............................................................................................................................. 9
Rocket Motor (Mod 3) Safe-Arm Selector Handle Spring Pin Test ..................................................................................... 6
Safe-Arm Selector Assembly, Rocket Motor Mk 57 Mod 2 and Mk 57 Mod 3 ................................................................... 5
Wing Rib Inspection ............................................................................................................................................................ 14
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 3
Rocket Motor Inspection ....................................................................................................................................................... 8
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Cloth, Emery 320 Grit
P-C-1673
Removal of burrs and minor surface irregularities
Desiccant, Activated
MIL-D-3464
Moisture absorbing material
Tube, Fiberboard
PPP-T-495, Type 1, Class 1,
Style D
Filler for container space when shipping
containers that are not full
Indicator, Humidity
MS20003-2, Type II
Detecting moisture/humidity
Strapping, Steel 5/8 in
QQ-S-781
Secures wooden containers
Table 2. Tools and Equipment
Nomenclature
2
Specification/Part Number
Use
Assembly Stand
68D35756-10
Supports missile/components during
inspection
Gauge, Depth
643J
Measure scratches, wear, pits, gouges
or dents on critical surfaces
Glass, Magnifier
GG-M-95
Inspecting for cracks
Change 1
CSTO XX21M-AIM9M-2
SWP 007 04
Table 2. Tools and Equipment (Continued)
Nomenclature
Specification/Part Number
Spring Pin Gauge
639AS10059
Use
Safe-Arm selector handle spring pin
test
Table 3. Drop Criteria
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Rocket Motor
Packaged or Unpackaged
Any Height
Inspect Table 4
Figure 1. Rocket Motor Mk 57 Mod 1, Mk 57 Mod 2, Mk 57 Mod 3
1.
SEQUENCE OF OPERATIONS.
9.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of rocket
motors Figure 1. Production techniques involving
preparation of more than one rocket motor may require
deviations from the work sequence. Several procedures
may be performed simultaneously, and in different work
areas, provided they do not invalidate or interfere with a
preceding or subsequent step and safety precautions are
strictly observed.
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
12. Verify all required handling and test equipment is
available and serviceable.
13. EMPTY CONTAINER PROCESSING.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Do not remove interior packing unless it is wet or
damaged beyond use.
b.
If packing is wet, remove and allow packing and
container to dry.
c.
If packing is damaged, replace.
d.
Replace container cover immediately after
components are removed to prevent container or
dunnage damage and contamination.
e.
Certify container TO 11A-1-60.
f.
Store serviceable containers for reuse or return
them to issuing activity.
INCIDENTS/ACCIDENTS.
6. Incidents/accident involving the rocket motor can
cause the missile to malfunction. If any doubt exists as to
acceptability of rocket motor, reject it. Report incident/
accident.
7.
TEST RECORDS/DOCUMENTATION.
DROPPED ROCKET MOTOR PROCESSING.
8. Dropped rocket motor processing criteria are
contained in Table 3. If any doubt exists as to acceptability
of dropped rocket motor, reject it. Request disposition of
dropped components from TMTCG, OO-ALC/GHGAMF,
235 Byron Street, Suite 19A, Robins AFB, GA 310981813.
Change 2
3
CSTO XX21M-AIM9M-2
SWP 007 04
g.
Set damaged containers aside for repair TO
35E20-2-31-2.
h.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
15. UNPACKING.
16. ROCKET MOTOR UNPACKING FROM THE
MK 287 OR MK 37 CONTAINER.
a.
Visually inspect container (Figure 2) for damage
and verify at least one metal strap is in place. If
container shows obvious rough handling damage,
inspect rocket motor.
b.
Cut and remove metal straps securing cover.
Remove cover.
c.
Visually inspect interior of container and external
surface of rocket motor for damage. Reject rocket
motor if visible handling damage is present.
d.
Remove rocket motor from container and place
on assembly stand. Secure with tie-down strap.
e.
Ground rocket motor from a wing rib to an
approved ground. Do not attach ground clip in
area of etched serial number on wing rib.
f.
Ensure rocket motor Safe-Arm selector handle
(Mod 2 or Mod 3) is locked in the SAFE position
(Figure 3). If not, perform step (1) for Mod 3 or
step (2) for Mod 2.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure.
Move key to horizontal position.
4
g.
Verify interior packing of container is complete
and undamaged.
h.
Remove protective caps from ends of rocket
motor and place in container prior to replacing
cover.
Change 1
Figure 2.
Rocket Motor Container
Mk 287 (PN 1516486) or Mk 37, PN 1516261
i.
Process empty container Paragraph 13.
17. ROCKET MOTOR UNPACKING FROM THE
CNU-289/E CONTAINER.
a.
Visually inspect container (Figure 5) for damage.
If container shows obvious rough handling
damage, inspect rocket motors.
b.
Press button on pressure relief valve and remove
security lead seals.
c.
Release container latches and remove upper
section.
d.
Remove top layer of dunnage.
e.
Visually inspect external surface of rocket motor
for damage. Reject rocket motor if visible
handling damage is present.
f.
Remove rocket motor from container and place
on assembly stand. Secure with tie-down strap.
g.
Ground rocket motor from a wing rib to an
approved ground. Do not attach ground clip in
area of etched serial number on wing rib.
h.
Ensure rocket motor Safe-Arm selector handle
(Mod 2, Mod 3) is locked in the SAFE position
CSTO XX21M-AIM9M-2
SWP 007 04
Mod 3
KEY REMOVAL SLOT
LOCKING LEVER
SAFE POSITION
KEY CANNOT BE REMOVED IN THE SAFE POSITION.
THE KEY PIN IS NOT ALIGNED WITH THE REMOVAL SLOT
AND THE LOCKING LEVER’S LOBE IS POSITIONED IN THE
SAFE HOLE.
SAFE HOLE
LOCKING LEVER
KEY REMOVAL SLOT
KEY PIN
SAFE HOLE
ARM POSITION
THE KEY PIN IS ALIGNED WITH THE REMOVAL SLOT AND
KEY MAY BE REMOVED IN THE ARMED POSITION.
Mod 2
Figure 3. Safe-Arm Selector Assembly, Rocket Motor Mk 57 Mod 2 and Mk 57 Mod 3
5
CSTO XX21M-AIM9M-2
SWP 007 04
(Figure 3). If not, perform step (1) for Mod 3 or step
(2) for Mod 2.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
19. Inspect rocket motors Table 4.
20. SAFE-ARM SELECTOR HANDLE SPRING PIN
INSPECTION (MK 57 MOD 3).
a.
Ensure selector is in the SAFE position.
b.
Remove safety clip assembly.
c.
Using the spring pin inspection gauge, place the
tip of the gauge on one end of the spring pin
(Figure 4) and slowly push against the end of the
pin until 30 pounds (the “green” line on the shaft
is flush with the end of the body) has been
achieved. Hold the 30 pound load for
approximately 5 seconds.
d.
After application of the 30 pound load, inspect
the ends of the spring pin to determine if it has
moved.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure.
Move key to horizontal position.
i.
Repeat steps e through h for remaining rocket
motors.
j.
Verify interior packing of container is complete
and undamaged.
k.
Remove protective caps from ends of rocket
motors and place in container prior to replacing
cover.
e.
If the spring has not moved, repeat step c by
pushing on the other end of the spring, hold the
30 pound load for approximately 5 seconds.
l.
Process empty container Paragraph 13.
f.
If the spring pin has moved under either load, it
must be replaced SWP 009 04.
g.
Install safety clip assembly.
18. INSPECTION.
Figure 4. Rocket Motor (Mod 3) Safe-Arm Selector Handle Spring Pin Test
6
CSTO XX21M-AIM9M-2
SWP 007 04
Figure 5. Rocket Motor Container CNU-289/E, PN 776013-10
Change 1
7
CSTO XX21M-AIM9M-2
SWP 007 04
Table 4. Rocket Motor Inspection
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
All screws will be visually checked for looseness. If a screw appears
to be loose refer to SWP 009 04.
1
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface
CRITICAL
Replace SWP 009 04
Coupling ring(s) manufactured with CAGE Code
39484, 32887, 3Z260, or 1DPK8
CRITICAL
Replace SWP 009 04
2
Coupling ring screw not PN 639AS1599 Rev M or later
or 8934242
CRITICAL
Replace screw SWP 009 04
3
Coupling ring screw PN 639AS1599 Rev P
CRITICAL
Replace screw SWP 009 04
3.1
Coupling ring screw PN 639AS1599 Rev U
manufactured by (Cage Code) 62206
CRITICAL
Replace screw SWP 009 04
Forward coupling ring screw PN 639AS1599 Rev N
manufactured by (Cage Code) MC
CRITICAL
Replace screw SWP 009 04
1.1
4
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
8
5
Coupling ring threaded pin not stamped with heat treat
marking
CRITICAL
Replace threaded pin SWP 009 04
6
Rocket motor mating area cracked or coupling ring
groove dented, cracked or otherwise damaged so that
coupling ring will not seat properly
CRITICAL
Reject
7
Punctures
CRITICAL
Reject
8
Coupling ring assembly not PN 639AS2725 (Figure 6)
not properly orientated, has missing parts, corroded,
damaged, or no longer serviceable
CRITICAL
Replace coupling ring
SWP 009 04
9
Safe-arm selector is in ARM position (Mod 2 or Mod 3
only)
MAJOR
Change 2
Ensure rocket motor Safe-Arm
selector handle is locked in the
SAFE position (Figure 3). If not,
for Mod 3 pull handle to unlock
and move to vertical position,
maintain pull pressure. Rotate
handle 90 degrees clockwise and
move to horizontal position.
Release pull pressure to lock in
SAFE position. Install safety clip
assembly. For Mod 2, insert key,
push in, and while maintaining
pressure rotate handle 90 degrees
clockwise then release pressure.
Move key to horizontal position.
CSTO XX21M-AIM9M-2
SWP 007 04
PART
NUMBER
REVISION
MARKING
CAGE
CODE
DOM
COUPLING RING SCREW
TYPICAL HEAD MARKING
Figure 6. Rocket Motor Inspection (Forward End)
Change 2
9
CSTO XX21M-AIM9M-2
SWP 007 04
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
10
Safe-arm selector assembly attachment screws loose,
assembly damaged or missing, (Mod 2 or Mod 3 only)
MAJOR
Replace assembly, torque/ replace
screws SWP 009 04
11
Safe-arm handle spring pin fails inspection (Mod 3
only) (Paragraph 20)
MAJOR
Replace SWP 009 04
12
Rocket motor non-propulsive head closure displaced or
damaged (Figure 6)
MAJOR
Reject
Step
Corrective Action
NOTE
Steps 13 through 15 apply to Mk 57 Mod 1 (Figure 6).
10
13
RIF shield plate screws loose
MAJOR
Torque SWP 009 04
14
RIF shield plate missing
MAJOR
Replace SWP 009 04
15
RIF assembly corroded
MAJOR
Reject
16
Retaining ring damaged or has missing teeth (nine
required)
MAJOR
Replace SWP 009 04
17
Guide plate pin sheared off in rocket motor and unable
to remove with common hand tools
MAJOR
Reject
18
Paint cracked or peeling
MINOR
Paint SWP 009 04
19
Dirt or grease on exterior surfaces of rocket motor
MINOR
Clean SWP 009 04
20
Corrosion on exterior surfaces of rocket motor
MINOR
Clean SWP 009 04
21
Absence of, or illegible manufacturer, (Figure 11)
identification, markings or decals
MAJOR
Replace decal or stencil
SWP 009 04
22
Blue band deteriorated and in need of replacement
MINOR
Replace blue band SWP 009 04
23
Gouges, ruptures or crushed casing on rocket motor
MAJOR
Reject
24
Forward hanger protective cover damaged or missing
MINOR
Replace cover
25
Forward hanger screws/bolts loose, damaged, or
missing
MAJOR
Replace/repair SWP 009 04
26
Forward hanger or hanger screws/bolts corroded to the
extent corrosion cannot be removed
MAJOR
Replace screws/bolts SWP 009 04
27
Forward hanger mating surfaces and stress points for
cracks (Figure 7)
MAJOR
Replace SWP 009 04
28
Top of forward hanger mating surface for snubber wear
in excess of 0.015 inch in depth, rear of hanger for
detent wear in excess of 0.030, or forward detent lug
wear area is rounded over all the way across the area
between the two arrows (Figure 7)
MAJOR
Replace SWP 009 04
29
Contact button(s) have severe corrosion damage, not
flush, or below hanger
MAJOR
Replace buttons SWP 009 04
30
Contact button insulator missing
MAJOR
Replace insulator SWP 009 04
Change 1
CSTO XX21M-AIM9M-2
SWP 007 04
DETAIL A
STRESS POINTS
NOTE: CAREFULLY CLEAN (REMOVE ALL
PAINT IF PRESENT). CHECK CLOSELY
ON ALL FOUR CORNERS FOR
CRACKS. USE A 10X MAGNIFYING
GLASS IF NECESSARY.
Figure 7. Forward Hanger Assembly
Figure 8. Center and Aft Hanger Inspection
Change 1
11
CSTO XX21M-AIM9M-2
SWP 007 04
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Defect
Classification
31
Contact button(s) cut, scratched, or gouged greater than
0.030-inches deep
MAJOR
Replace contact buttons
SWP 009 04
32
Forward hanger non-mating surface for dents greater
than 0.045-inches deep or 0.075-inches in diameter
MAJOR
Replace SWP 009 04
33
Forward hanger non-mating surface for gouges greater
than 0.045-inches deep by 0.064-inches wide by 0.075inches long
MAJOR
Replace SWP 009 04
34
Forward hanger non-mating surfaces for cracks
MAJOR
Replace SWP 009 04
35
Center hanger loose
MAJOR
Replace hanger SWP 009 04
35.1
Center hanger threaded pins (Figure 8 center hanger
Views A and B) loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
35.2
Center hanger shims (Figure 8 center hanger View B)
loose or missing
MAJOR
Replace hanger SWP 009 04
35.3
Center hanger band screw(s) (Figure 8 center hanger
View C) loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
Aft hanger loose
MAJOR
Replace hanger SWP 009 04
36.1
Aft hanger band screw(s) (Figure 8 aft hanger View A)
loose, damaged, or missing
MAJOR
Replace hanger SWP 009 04
37
Wing ribs (Figure 10) deformed, cracked, corroded, or
other damage that would prevent proper wing assembly
MAJOR
Reject
38
Ballast weight in rocket motor loose
MAJOR
Reject
Step
36
Corrective Action
NOTE
Steps 39 through 45 apply to the center and aft hanger (Figure 9, area X).
12
39
Mating surfaces for dents greater than 0.015-inch deep
by 0.030-inch in diameter
MAJOR
Replace SWP 009 04
40
Mating surface for gouges greater than 0.015-inch deep
by 0.030-inch in diameter
MAJOR
Replace SWP 009 04
41
Non-mating surfaces for pitted areas greater than 0.060
square inch in diameter and 0.032-inch deep
MAJOR
Replace SWP 009 04
42
Non-mating surfaces for dents greater than 0.032-inch
deep or 0.064-inch in diameter
MAJOR
Replace SWP 009 04
43
Non-mating surfaces for gouges greater than 0.045-inch
deep or 0.064-inch wide or 0.075-inch long
MAJOR
Replace SWP 009 04
44
Non-mating surface for cracks
MAJOR
Replace SWP 009 04
45
Mating surface for cracks
MAJOR
Replace SWP 009 04
Change 1
CSTO XX21M-AIM9M-2
SWP 007 04
Figure 9. Rocket Motor Center and Aft Hangers
Change 1
12.1/(12.2 Blank)
CSTO XX21M-AIM9M-2
SWP 007 04
Table 4. Rocket Motor Inspection (Continued)
Inspection
(Inspect for the following defects)
Step
Defect
Classification
Corrective Action
NOTE
Steps 46 through 51 apply to the center and aft hanger non-mating
surfaces (area Y, Figure 9).
46
Pits greater than 0.020 square inch and 0.015-inch deep
MAJOR
Replace SWP 009 04
47
Dents greater than 0.020-inch deep or 0.050-inch
diameter
MAJOR
Replace SWP 009 04
*48
Burrs or scratches
MINOR
Remove raised metal only with
flat file or 320 grit emery cloth
49
Cracks
MAJOR
Replace SWP 009 04
50
Gouges greater than 0.020-inch deep or 0.032-inch
wide or 0.064-inch long
MAJOR
Replace SWP 009 04
51
Center/aft hangers for visible gap between hanger strap
and rocket motor mating surfaces
MAJOR
Replace SWP 009 04
52
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
less than 2% of entire surface (2% of entire surface is
approximately an area 0.25 inches long across the entire
width of the coupling ring)
MINOR
Clean and apply MIL-C-85054
53
Coupling ring has burrs, gouges, scratches, dents, or
pits that penetrate surface finish and aggregately covers
greater than 2% of entire surface (2% of entire surface
is approximately an area 0.25 inches long across the
entire width of the coupling ring)
MAJOR
Replace coupling ring
SWP 009 04
54
Coupling ring has brown spots, specks, or discoloration
MAJOR
Clean, SWP 009 04. Inspect for
cracks. If brown spots, specks, or
discoloration cannot be removed
replace coupling ring SWP 009 04
Change 1
13
CSTO XX21M-AIM9M-2
SWP 007 04
Figure 10. Wing Rib Inspection
21. PACKING.
d.
Remove container cover.
22. ROCKET MOTOR PACKING IN THE MK 287
OR MK 37 CONTAINER.
e.
Ensure forward and aft protective caps are on
rocket motor.
a.
Ensure rocket motor is properly grounded to
wing rib and approved ground.
f.
Ensure that forward hanger protective cover is
installed.
b.
Ensure rocket motor Safe-Arm selector handle
(Mod 2 or Mod 3) is locked in the SAFE position
(Figure 3). If not, perform step (1) for Mod 3 or
step (2) for Mod 2.
g.
Remove grounding strap and place rocket motor
in container (Figure 2), positioning rocket motor
on its side so it does not rest on coupling ring or
hangers. The aft end of the rocket motor shall be
located at the end of the container marked AFT. If
required, add filler/blocks to ensure a secure
pack. Secure cover with three 5/8-inch wide steel
straps clinched with strapping tool.
h.
Install seals on container TO 11A-1-60.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure.
Move key to horizontal position.
c.
14
Tighten coupling ring sufficiently to prevent
movement.
23. ROCKET MOTOR PACKING IN THE CNU-289/
E CONTAINER.
a.
Ensure rocket motor is properly grounded to
wing rib and approved ground.
b.
Ensure rocket motor Safe-Arm selector handle
(Mod 2 or Mod 3) is locked in the SAFE position
CSTO XX21M-AIM9M-2
SWP 007 04
(Figure 3). If not, perform step (1) for Mod 3 or
step (2) for Mod 2.
i.
Ensure that forward hanger protective cover is
installed.
(1) Mod 3, pull handle to unlock and move to
the vertical position, maintain pull pressure.
Rotate handle 90 degrees clockwise and
move to horizontal position. Release pull
pressure to lock in SAFE position. Install
safety clip assembly.
j.
Ensure cushions are aligned with markings in
upper and lower sections of container.
k.
Remove ground strap and place two rocket
motors in lower section. The aft end of the rocket
motors shall be located at the end of the container
marked AFT.
l.
Ensure that the Safe-Arm selector is aligned in
the slot provided (Mod 2 or Mod 3).
(2) Mod 2, insert key, push in, and while
maintaining pressure rotate handle 90
degrees clockwise then release pressure.
Move key to horizontal position.
m. Install center cushions over rocket motors.
NOTE
When fiberboard tube is not available,
recommend using locally procured carpet or PVC
tubing of the appropriate diameter and cut to
appropriate length.
c.
For shipment of 1, 2, or 3 rocket motors, a
fiberboard tube shall be used to fill empty slot.
d.
Tighten coupling ring sufficiently to prevent
movement.
e.
Press button on pressure relief valve.
f.
Release the latches and place in the DOWN
position.
g.
Remove container cover (Figure 5) and top
dunnage.
h.
Ensure forward and aft protective caps are
installed.
n.
Remove ground strap and place remaining two
rocket motors on center cushions.
o.
Ensure four 8-unit bags or equivalent of activated
desiccant are in lower section of container.
p.
If humidity indicator is pink or white, replace.
q.
Place container upper section on lower section.
r.
Secure container cover and install seals TO 11A1-60.
24. CONTAINER MARKINGS.
25. Mark containers TO 35E20-2-31-2 and TO 11A-1-10.
Change 1
15
CSTO XX21M-AIM9M-2
SWP 007 04
FW
D
FW
D
ROCKET MOTOR TRAINING
MARK 57 MOD 2
30003-639AS4765
DATE OF MFR
LOADED WT
LB
SERIAL NO
CONTRACT NO.
LOT NO
GOVERNMENT INSP
MFR INSP
US
NOTES:
1.
LOCATIONS OF DECALS AND MARKINGS ARE
APPROXIMATE. CHECK POSITION REFERENCE IS:
HANGERS IN UP POSITION, STAND IN FRONT OF
ROCKET MOTOR.
7.
IDENTIFICATION DECAL 15 7/8-INCHES AFT AT 3
O'CLOCK POSITION.
8.
DECAL (MOD 1) (TIGHTEN COUPLING RING SCREW TO
100 ± 5 INCH-POUNDS) AT 3 O'CLOCK AND 9 O'CLOCK
POSITIONS.
SAFE-ARM DECAL INSTALLED SO THAT THE WORDS
SAFE AND ARM CENTER ON THE RETAINING PLATE
HOLE.
9.
IDENTIFICATION DECAL 15 7/8-INCHES AFT AT 3
O'CLOCK POSITION.
3.
DECAL (MODS 2 & 3) (TIGHTEN COUPLING RING SCREW
TO 100 ± 5 INCH) AT 2 O'CLOCK AND 10 O'CLOCK
POSITIONS.
10. CENTER OF GRAVITY DECAL AT 9 O'CLOCK POSITION
AND 20 INCHES AFT OF FORWARD END OF ROCKET
MOTOR, PN 639AS2895.
4.
DECALS (DO NOT ROLL, TUMBLE, OR DROP) 1-INCH AFT
OF IDENTIFICATION DECAL AT 3 O'CLOCK AND 9
O'CLOCK POSITIONS.
11. CENTER OF GRAVITY DECAL AT 9 O'CLOCK POSITION
AND 19 1/4-INCHES AFT OF FORWARD END OF ROCKET
MOTOR PN 639AS4991.
5.
DECAL WARNING-DO NOT REMOVE, ADJUST, OR
OTHERWISE TAMPER WITH HANGERS) 6-INCHES FROM
AFT END OF ROCKET MOTOR AT 3 O'CLOCK AND 9
O'CLOCK POSITIONS.
12. BLUE BAND (PAINT OR PPP-T-60 TAPE) 2 INCHES WIDE,
11-12 INCHES AFT OF FORWARD END OF ROCKET
MOTOR (MODS 2 & 3) .
6.
DECAL (TIGHTEN END SCREWS TO 100 ± 5 INCHPOUNDS) 1/2-INCH FORWARD OF AFT END OF ROCKET
MOTOR AT 3 O'CLOCK AND 9 O'CLOCK POSITIONS.
2.
13. BLUE BAND (PAINT OR PPP-T-60 TAPE) 2 INCHES WIDE
APPROXIMATELY 4 1/2-INCHES AFT OF FORWARD END
OF ROCKET MOTOR (MOD 1).
14. IN ABSENCE OF DECALS, STENCIL AS REQUIRED IN 1/4INCH CHARACTERS.
Figure 11. Rocket Motor Mk 57 Mod 1, Mk 57 Mod 2, Mk 57 Mod 3 Markings
16
Change 1
CSTO XX21M-AIM9M-2
SWP 007 05
SUBORDINATE WORK PACKAGE
UNPACKING, PACKAGING AND INSPECTION
FIELD LEVEL MAINTENANCE
MISSILE BODY ASSEMBLY
THIS SUBORDINATE WORK PACKAGE INCOMPLETE WITHOUT WP 002 00
LIST OF EFFECTIVE SWP PAGES
Total Number of Pages in this SWP is 10
Date of Issue: Change 2 - 22 August 2012
Zero in Change No. column indicates an original page.
Page No.
Change No.
1-9 . . . . . . . . . . . . . . . . . . . . . . . 2
Page No.
Change No.
10 blank. . . . . . . . . . . . . . . . . . . 0
Page No.
Change No.
Reference Material
Title
Number
Air Force Munitions Surveillance Program and Serviceability Procedures ...................................................... TO 11A-1-10
Inspection of Reusable Munitions, Containers, and Scrap Material Generated
from Items Exposed to or Containing Explosives ........................................................................................... TO 11A-1-60
Maintenance with Illustrated Parts Breakdown, Missile Body Assembly...........................................................SWP 009 05
Organizational, Intermediate Maintenance and Depot Overhaul Instructions with IPB,
Shipping and Storage Containers AIM-9 Series Missiles......................................................................... TO 35E20-2-31-2
Safety Summary and Accident Prevention ............................................................................................................WP 002 00
Table of Contents
Title
Page
Container Markings ...............................................................................................................................................................9
Dropped MBA Processing .....................................................................................................................................................3
Empty Container Processing..................................................................................................................................................3
Handling and Test Equipment Preparation ............................................................................................................................3
Incidents/Accidents................................................................................................................................................................3
Inspection...............................................................................................................................................................................3
Safe-Arm Selector Handle Spring Pin Inspection (Deleted) ...............................................................................................3
Packing...................................................................................................................................................................................8
MBA Packing in the Wooden Crate.....................................................................................................................................8
Safety and Accident Prevention.............................................................................................................................................3
Sequence of Operations .........................................................................................................................................................3
Test Records/Documentation .................................................................................................................................................3
Unpacking ..............................................................................................................................................................................3
MBA Unpacking from the Wooden Crate ...........................................................................................................................3
Change 2
1 of 10
CSTO XX21M-AIM9M-2
SWP 007 05
List of Illustrations
Title
Page
Coupling Ring Assembly, PN 8241286-10 or PN 639AS672 (Added) ................................................................................ 4
Missile Body Assembly (MBA)............................................................................................................................................ 4
Missile Body Assembly......................................................................................................................................................... 6
MBA Safe-Arm Selector Handle Spring Pin Test (Deleted)................................................................................................. 9
Safe-Arm Selector Assembly, Missile Body Assembly (Deleted) ........................................................................................ 4
List of Tables
Title
Page
Consumable Materials ........................................................................................................................................................... 2
Drop Criteria.......................................................................................................................................................................... 2
Missile Body Assembly Inspection ....................................................................................................................................... 5
Tools and Equipment ............................................................................................................................................................. 2
Table 1. Consumable Materials
Nomenclature
Specification/Part Number
Use
Barrier Material
MIL-B-81705C
Packaging components in barrier material
Cloth, Emery 320 Grit
P-C-1673
Removing burrs and minor surface irregularities
Strap, Steel 5/8 in
QQ-S-781
Secures wooden containers
Table 2. Tools and Equipment
Nomenclature
Specification/Part Number
Use
Assembly Stand
68D35756-10
Secures MBA during inspection
Cleaner, Vacuum
Local Purchase
Remove air from barrier material during
packaging.
Gauge, Depth
643J
Measure scratches, wear, pits, gouges or
dents on critical surfaces
Glass, Magnifier
GG-M-95
Inspecting for cracks
Table 3. Drop Criteria
2
Item
Packaged/Unpackaged
Drop Distance (Feet)
Required Action
Missile Body Assembly
Packaged or Unpackaged
Any Height
Inspect Table 4
Change 2
CSTO XX21M-AIM9M-2
SWP 007 05
1.
SEQUENCE OF OPERATIONS.
2. The work sequence given in this SWP is provided as a
guide in Unpacking/Packaging, and Inspection of the
Missile Body Assembly (MBA) Figure 1. Production
techniques involving preparation of more than one MBA
may require deviations from the work sequence. Crew
members
may
perform
several
procedures,
simultaneously, and in different work areas, provided they
do not invalidate or interfere with a preceding or
subsequent step and safety precautions are strictly
observed.
3.
SAFETY AND ACCIDENT PREVENTION.
4. All personnel involved in the performance of the
procedures in this TO shall be thoroughly familiar with the
safety and accident prevention information contained in
WP 002 00.
5.
INCIDENTS/ACCIDENTS.
6. Incidents/accident involving the MBA can cause a
malfunction. If any doubt exists as to acceptability of the
MBA, reject it. Report incident/accident.
7.
Store serviceable containers for reuse or return
them to issuing activity.
c.
Set damaged containers aside for repair.
d.
Certify container TO 11A-1-60.
e.
Disposition instructions for empty excess
containers can be obtained from OO-ALC/WM,
Hill AFB, UT 84056-5819.
15. UNPACKING.
16. MBA UNPACKING FROM THE WOODEN
CRATE.
a.
Visually inspect crate for damage and verify at
least one metal strap is in place. If crate shows
obvious rough handling damage, inspect MBA.
b.
Cut and remove metal straps securing cover.
Remove cover.
c.
Visually inspect interior of crate and external
surface of MBA for damage. Inspect MBA if
visible handling damage is present.
d.
Remove MBA from crate and place on assembly
stand. Secure with tie-down strap.
e.
Remove wings from crate.
f.
Deleted.
g.
Process empty crate Paragraph 13.
DROPPED MBA PROCESSING.
8. Dropped MBA processing criteria are contained in
Table 3. If any doubt exists as to acceptability of dropped
MBA, reject it. Request disposition of dropped
components from TMTCG, OO-ALC/GHGAMF, 235
Byron Street, Suite 19A, Robins AFB, GA 31098-1813.
9.
b.
TEST RECORDS/DOCUMENTATION.
10. Record and report data in accordance with existing
directives when required.
11. HANDLING AND TEST EQUIPMENT
PREPARATION.
17. INSPECTION.
12. Verify all required handling and test equipment is
available and serviceable.
18. Inspect MBAs Table 4.
13. EMPTY CONTAINER PROCESSING.
19. Deleted.
14. Empty containers and dunnage are reusable. Carefully
process empty containers as follows:
a.
Replace container cover immediately after
components are removed.
Change 2
3
CSTO XX21M-AIM9M-2
SWP 007 05
Figure 1. Missile Body Assembly (MBA)
Figure 2. Safe-Arm Selector Assembly, Missile Body Assembly (Deleted)
PART
NUMBER
REVISION
MARKING
CAGE
CODE
DOM
COUPLING RING SCREW
TYPICAL HEAD MARKING
LEGEND
(1) CLIP
(2) SCREW
(3) COUPLING RING
(4) THREADED PIN
(5) PIN
Figure 2.1. Coupling Ring Assembly, PN 8241286-10 or PN 639AS672 (Added)
4
Change 2
CSTO XX21M-AIM9M-2
SWP 007 05
Table 4. Missile Body Assembly Inspection
Step
Inspection
(Inspect for the following defects)
Defect
Classification
Corrective Action
NOTE
All screws will be visually checked for looseness. If a screw appears to
be loose refer to SWP 009 05.
1
Missile body mating area cracked or coupling ring groove
dented, cracked, or otherwise damaged so coupling ring
will not seat properly (Figure 3)
CRITICAL
Replace forward adapter
SWP 009 05
2
Coupling ring(s) manufactured with (Cage Code) 00784
with date of manufacture 1-90 through 12-90 or 1-83
through 12-84 stamped on their outer surface (Figure 2.1)
CRITICAL
Replace SWP 009 05
2.1
Coupling ring(s) manufactured with CAGE Code 39484,
32887, 3Z260, or 1DPK8
CRITICAL
Replace coupling ring
SWP 009 05
3
Coupling ring assembly cracked or damaged
CRITICAL
Replace coupling ring
SWP 009 05
4
Coupling ring screw not PN 639AS1599 REV M or later,
or PN 8934242
CRITICAL
Replace screw SWP 009 05
5
Coupling ring screw PN 639AS1599 Rev P
CRITICAL
Replace screw SWP 009 05
Coupling ring screw PN 639AS1599 Rev U manufactured
by (Cage Code) 62206
CRITICAL
Replace screw SWP 009 05
6
Forward coupling ring screw PN 639AS1599 Rev N
manufactured by (CAGE Code) MC
CRITICAL
Replace screw SWP 009 05
7
Coupling ring assembly not PN 8241286-10 or 639AS672
CRITICAL
Replace coupling ring
SWP 009 05
8
Directional arrow on coupling ring not pointing forward
CRITICAL
Replace/repair coupling ring
SWP 009 05
9
Coupling ring or attaching parts not installed correctly
CRITICAL
Replace/repair coupling ring
SWP 009 05
5.1
NOTE
Each threaded pin PN 639AS693 shall have a traceable heat treat lot
number metal stamped on one end. The lot number may be alpha or
numeric or a combination of alpha/numeric.
Threaded pins that are part of coupling ring assembly PN 8241286-10
do not require a stamped heat treat marking.
10
Coupling ring threaded pin not stamped with heat treat
markings
CRITICAL
Replace threaded pin SWP 009 05
11
Missile body for cuts or scratches in excess of 0.125 in
depth
MINOR
Repair if welding shop is
available
12
Wing loose or missing screws
MAJOR
Replace/torque screws
SWP 009 05
Change 2
5
CSTO XX21M-AIM9M-2
SWP 007 05
SIMULATED CONTACT BUTTONS
DETAIL C
STRESS POINTS
MATING
SURFACES
NON-MATING
SURFACES
FORWARD DETENT LUG
WEAR AREA
NOTE:
CAREFULLY CLEAN (REMOVE ALL PAINT
IF PRESENT). CHECK CLOSELY ON ALL
FOUR CORNERS FOR CRACKS. USE A
10X MAGNIFYING GLASS IF NECESSARY.
DETAIL B
FORWARD
HANGER
(DETAIL B)
Figure 3. Missile Body Assembly
6
Change 2
SCREW
CSTO XX21M-AIM9M-2
SWP 007 0