NTS TROUBLESHOOTING GUIDE

Written by Ken Cottman

October 30, 2000
For use by BHTI Field Representatives and other company employees only.

Table of Contents
1. Initial Power-On Indications and Expectations
2. Laser Boresight Fail
3. Laser Fail
4. Laser Interlock
5. FLIR Boresight Fail
6. FLIR Fail
7. HOT DET displayed on screen
8. FLIR does not change FOV
9. TVC does not change FOV
10. FLIR and TVC does not change FOV
11. No FLIR Video
12. No TVC Video
13. BIT Does Not Complete
14. ARM BUS 1553 Fail
15. NAV BUS 1553 Fail
16. No A/C Heading Data
17. VCR fails BIT
18. TVC Autotrack Fail
19. FLIR Autotrack Fail
20. No Autotrack Function
21. TVC Fail
22. No Video Input to PEB
23. No Image on TSU CRT
24. Partial Video Display in CRT
25. Scrolling Indicator in Field Of Regard Box
26. TSU Bucket chatters in Azimuth

Special Procedures
WINDOW MOTOR BEVEL GEAR MESH TIGHTENING
LASER BORESIGHT MIRROR ADJUSTMENT
TVC ADJUSTMENT
NTS COLLIMATOR ADJUSTMENT
TOW BIT 3 FAIL TROUBLESHOOTING
LDRS (RFTDL) REMOVAL AND REPLACEMENT
THERMAL IMAGING SENSOR (TIS) REMOVAL AND REPLACEMENT
1. Initial Power-On Indications and Expectations

Return to Table of Contents

Upon initial power-on, the NTS and TOW systems performs BIT simultaneously.
The following events will happen (and can be observed):

TMS
The TSU optics drop to approximately -66 elevation. (BIT 3)
After being down for 1 - 10 seconds, the optics "hop." (System switching
from BIT 3 to BIT 4)
A second hop occurs after 9 seconds. (Switch from BIT 4 to BIT 5)
A third hop occurs after 5 seconds. (Switch from BIT 5 to BIT 6)
The bucket moves left slightly (BIT 7) then both the bucket and the optics
slew to 0 AZ. and 0 el. (BIT 8).
The bucket slews right, the optics positioned at 13.5 el. and 13.5 AZ. (BIT 9)
The bucket returns to 0 el., 0az. (BIT 10)

NTS
Video displays FLIR test patterns.
CCU panel lights illuminate individually as the system "scrolls" down the
panel from top to bottom.
VCR records two seconds of video, rewinds it, plays back one second of the
two seconds of video that was just recorded then rewinds it all.
All NTS components are checked for electronic condition.
After the bucket returns to 0 el., 0 AZ. (BIT 10), the PEB commands the
TSU optics to drive to -60 El.
The video will display the FLIR image looking into the Collimator Adjust
Target then the Collimator changes targets to the Thermal Target.
At -60, there are two Laser interlocks that are activated in this position then
the Laser will fire onto the Collimator.
A Laser energy check is performed while the laser is firing (approx. one
second), and then the gimbal will return to the STOW position.
NTS FAIL annunciator will be illuminated on the CCU and the FAIL
symbology will appear and blink on and off as displayed on the video monitor
if there were any failures during the BIT process.

Return to Table of Contents

2. Laser Boresight Fail

Does the laser fire at all? If no, troubleshoot for "Laser Fail." If yes, go to
next step.
 Does the TSU slew 90 DEG to the right? If no, troubleshoot for "No
Autotrack Function."

Does the TSU slew 90 DEG to the right, fire the laser and the laser spot
begins to "bloom" then abort boresight process? If yes, verify the following:

1. Confirm that the laser spot AND the high magnification reticle are in
the autotrack box (as indicated by a 4-dot square). A. Enter D876 on
the Laser Code Panel then depress the offset button on the Left Hand
Grip. Note: Enter the code from left to right. B. Select the TVC
video channel and high magnification. You should see an illuminated
reticle and the autotrack box. The reticle should be inside the box (it
does not have to be exactly in the middle). C. Arm the Laser by
engaging all cockpit Laser interlocks, depress the Laser Designation
switch on the LHG and note the position of the Laser spot on the
monitor. D. If necessary, reposition the Laser spot to the center of the
reticle (or in the autotrack box) by moving the autotrack switch left,
right, up or down while continuing to fire the laser.

Note: Make sure the laser moves in the same direction that the
autotrack switch is pointed. If the laser moves in the opposite
direction, continue fire the laser while continuing to hold the autotrack
switch steady in any direction. The laser will eventually turn around
and follow the autotrack switch's direction.

E. If the Hi Magnification reticle is NOT in the box, loosen the TVC

self-locking swing bolts then reposition the TVC in its mount until the
reticle is somewhere in the autotrack box. If this does not place the
reticle in the box, then align the TVC in accordance with the TVC
ADJUSTMENT procedure contained in this document. F. Secure the
TVC by tightening the swing bolts. G. Exit the D876 mode then run
boresight again.

2. Confirm that the TVC autotrack function operates. If it does not work,
verify the integrity of the following: A. Horizontal and Vertical sync
lines between the TVC and the PEB. B. The two triax video lines
between the TVC and the PEB.

Is the Laser spot visible as it fires from the 90, -90 and 0 DEG positions? If
no, check the following:

1. Confirm that the Laser functions and is firing during boresight.

2. Attempt to align the Laser by entering D876 on the LCP and
performing the steps outlined above. Do you see the Laser? If not, go
to step three.
 3. Align the Laser Boresight mirrors. Follow the LASER BORESIGHT
MIRROR ADJUSTMENT procedure contained in this document.
4. If the Laser is not visible after performing steps 1-3, then replace TSU.
The collimator is probably defective or there is something in the
Laser's pathway affecting its travel out of the bucket.

When the TSU returns to 0 DEG azimuth during boresight, does the Laser
spot move away from the center just before the end of the process? If yes,
perform the Laser spot alignment procedure as outlined above.

Does the system automatically change the reticle from low magnification to
high magnification prior to the TSU slewing 90 DEG? If not, check the
following:

1. Confirm that while in the DVO/TVC channel, you can toggle between
high and low magnification using the LHG switch. If so, go to step 2.
2. Replace PEB.

Does the high magnification reticle illuminate prior to the Laser firing? If no,
check the reticle illumination circuit for the following:

1. Confirm continuity between PEB 2PN3-86 and 21TB2-MC then

21TB2-MB to TSU 1PN3-65. If ok, then confirm 28vdc at 1PN3-65.
2. Disconnect 1PN3, turn on system, and then select D678 on the LCP.
Observe that the TSU optics drop to -60 elevation. Check for 28vdc
at 1PN3-65. If no voltage, then replace the PEB. If there is voltage,
replace the TSU.

Does the high magnification reticle cease to illuminate just prior to the laser
firing? If no, then the reticle control circuit is the culprit. Perform the
following checks:

Confirm continuity between PEB 2PN3-92 and 1PN3-39. If ok, then

replace the PEB. If no change, then replace TSU.

Return to Table of Contents

3. Laser Fail
Does the Laser fire? If no, check the following:

1. Ensure that the LDRS circuit breaker is closed.

2. Disconnect LDRS 5PN1; turn on system and check for 115vac at 5PN1-A
and 5PN1-B. Check for 28vdc at 5PN1-G and 5PN1-L. Confirm good
ground at 5PN1-C and 5PN1-M. If all checks are satisfactory, then
replace the LDRS or TSU. If replacing the LDRS, follow the LDRS
(RFTDL) R & R procedure contained in this document.
 If the Laser fires, enter B2 on the LCP. Using the - + buttons on the CCU,
scroll through the maintenance pages until the "LDRS Failures" page is
reached. Review the failures listed. Any failure listed on the page points to
the LDRS as being the culprit without question, except PEB LDRS COMM.
This failure requires that you confirm continuity and the integrity of the
following:

1. LDRS 5PN2-1 to PEB 2PN3-67 (LDRS DATA XMTR +)

2. LDRS 5PN2-2 to PEB 2PN3-56 (LDRS DATA XMTR -)
3. LDRS 5PN2-4 to PEB 2PN3-57 (LDRS DATA RCV +)
4. LDRS 5PN2-5 to PEB 2PN3-58 (LDRS DATA RCV-)
5. LDRS 5PN2-29 to PEB 2PN3-42 (DC RETURN)

Does the Laser fail its energy check (at the completion of BIT)? If so, replace
the LDRS or TSU. If replacing the LDRS, follow the LDRS (RFTDL) R & R
procedure contained in this document.

Return to Table of Contents

4. Laser Interlock
Does this failure appear after system BIT? If so, go to the next step.

Have the exterior interlocks been met (Generators on-line or the TSU DVO
window cover installed)? If so, confirm that the DVO cover microswitch
plunger is depressed sufficiently. The NTS Laser requires 28vdc as a "Laser
Enable" signal for Laser firing. This signal is provided by either having the
engines running (generators on-line) or the DVO window cover being
installed.

Does the failure appear when attempting to manually fire the Laser? If so,
verify that all of the cockpit Laser safety interlocks have been met (Master
Arm switch to Arm, Turret Depression limit switch to Off, Sight Hand Control
to TRK, TSU Filter Select Lever to Laser, Laser First/Last to First or Last.
Confirm that the "Laser Arm" annunciator on the CCU is illuminated.

Is the "Laser Arm" annunciator on the Cockpit Control Unit illuminated? If

not, perform the following:

A. Verify that all of the cockpit Laser safety interlocks have been met.
B. Troubleshoot the Laser interlock circuits.

Return to Table of Contents

5. FLIR Boresight Fail

 Is HOT DET displayed on the symbology? If so, wait for the HOT DET to
disappear before attempting to boresight (up to 10 minutes). The system will
not attempt the FLIR boresight process until the IR detectors have cooled to a
predetermined temperature, as indicated by the HOT DET illumination.

Is the "baseball diamond" shaped target in the center of the field of view? If
not, perform the following:

1. Confirm that the TOW missile system has not failed BIT 3 (TSU BIT
Fail on THCDP scratchpad).
2. Confirm that the IR target used for boresighting is centered and
illuminated. Enter D678 on the LCP and press offset on the LHG.
Select TVC video, high magnification, and then wait approximately 5
seconds. A white dot (LED) should move into the field of view and
center on the reticle (within the inner hash marks). If the white dot is
not visible at all, troubleshoot for Collimator LED power.
A. Verify continuity between PEB 2PN2-27 and TSU 1PN3-15,
and PEB 2PN2-28 and TSU 1PN3-16.
B. Replace PEB as power originates there.
C. Replace TSU for failure in collimator.
3. If the IR target is not centered, reposition the NTS collimator unit.
Follow the NTS COLLIMATOR ADJUSTMENT procedure contained
in this document.

Does the system remain in the FLIR boresight mode for at least 10 seconds?

Is "TSU BIT FAIL" displayed on the THCDP scratchpad? If so, verify that
the TSU is failing BIT 3. TSU will stay down for an extended amount of time
if BIT 3 has failed. If BIT 3 has failed, follow the TOW BIT 3 FAIL
TROUBLESHOOTING procedure.

Return to Table of Contents

6. FLIR Fail
Does the HOT DET indication disappear within 10 minutes of initial
application of power? Is there a clear FLIR image displayed on the video
screen? If no, perform the following:

1. Confirm power is being applied to the FLIR. Check that the FLIR C/B
is closed and that there is 28vdc present at FEB 4PN1-D,E. Confirm
returns at FEB 4PN1-B,C.

2. Enter B2xx on the LCP and by using the - and + keys on the CCU,
scroll through the failure pages until the FEB failures pages is reached.
Are there any failures pertaining to the FEB? If not, then select the
TSU Failures page. Are there Thermal Imaging Sensor related failures
 listed? If so, replace the TIS or TSU. If replacing the TIS, follow the
TIS R & R procedure contained in this document.

Note: The FEB is fairly robust, failing infrequently. More often, a failed
TIS is the culprit in FLIR failures.

Return to Table of Contents

7. HOT DET displayed on screen

Does the HOT DET indication disappear within 10 minutes of initial
application of power? See troubleshooting information under FLIR Fail.

Is there a clear FLIR image displayed on the video screen? If not, see
troubleshooting information under FLIR Fail.

Return to Table to Contents

8. FLIR does not change FOV

Is there any system function available using the CRT/DVO and HI
Magnification / LO Magnification switch on the Left Hand Grip? If not,
troubleshoot for LHG function. If so, continue reading.

Can any of the FOVs (wide, medium, narrow and zoom) be selected? If so,
then see below for troubleshooting information for TIS FOV solenoid. If not,
continue reading.

Does the TVC change FOV? If no, see troubleshooting information under
step 9. If yes, then perform the following:

Wiring continuity checks between the FEB and the TSU:

From FEB 4PN4-43, 44 to TSU/TIS 1PN2-43, 44 (FOV MTR +/-)

From FEB 4PN4-25, 26 to TSU/TIS 1PN2-25, 26 (TIS Data RCV)
From FEB 4PN4-27, 28 to TSU/TIS 1PN2-27, 28 (TIS Data TX)
From FEB 4PN4-12, 13 to TSU/TIS 1PN2-12, 13 (MUX +/-)

If wiring checks fine, inspect TIS FOV solenoid.

1. Remove the right hand (No. 2 side) TSU cover to gain access.
2. With the aid of a helper, attempt to toggle between FLIR FOVs while
observing the action of the solenoid. Does it move? Verify that
nothing has come off of the solenoid mechanism. Insure that the roller
bearing is moving freely.

Replace TIS or FEB. Note: The FEB is fairly robust, failing infrequently.
More often, a failed TIS is the culprit in FLIR failures.
Return to Table of Contents

9. TVC does not change FOV

Is there any system function available using the CRT/DVO and HI
Magnification / LO Magnification switch on the Left Hand Grip? If not, go to
step 10. If so, continue reading.

Does the FLIR change FOV? If no, see troubleshooting information under
step 10. If yes, then perform the following:

Wiring continuity checks between the CCU and the TSU:

From CCU 1PN3-43 to 1PN66-43 to 1P09-a to TSU 1P03-A (FFM-HI

Select)
From CCU 1PN3-44 to 1PN66-44 to 1P09-b to TSU 1P03-X (FFM-LO
Select)

If wiring checks fine, replace the TSU or CCU.

Return to Table of Contents

10. FLIR and TVC does not change FOV

Is there any system function available using the Left Hand Grip? If not,
confirm continuity and connections between the CCU and the LHG. Also
confirm that the system is powered. If so, perform the following:

Wiring continuity checks between the CCU and the LHG:

From LHG 1PN67-31 to 1PN66-25 to CCU 3PN3-25 (HI-MAG)

From LHG 1PN67-32 to 1PN66-26 to CCU 3PN3-26 (LO-MAG)
From LHG 1PN67-56 to 1PN66-34 to CCU 3PN3-34 (Digital Gnd)

Return to Table of Contents

11. No FLIR Video

Is FLIR FAIL displayed on either video display? If so, perform
troubleshooting as listed in step 6. Is FLIR video displayed on the CRT or the
Video Display Unit (MFD to some of you)? If not, then verify that TVC
video is displayed when selected. If TVC video is displayed, then perform the
following:

Wiring continuity checks between the FEB and PEB:

From FEB 4PN5 to PEB 2PN5-B (FLIR VIDEO W/O SYMB)

From FEB 4PN6 to PEB 2PN5-A (FLIR VIDEO WITH SYMB)
From FEB 4PN2-43 to PEB 2PN3-70 (FLIR VERT SYNC -)
 From FEB 4PN2-44 to PEB 2PN3-71 (FLIR VERT SYNC +)
From FEB 4PN2-40 to PEB 2PN3-68 (FLIR HORIZ SYNC -)
From FEB 4PN2-41 to PEB 2PN3-69 (FLIR HORIZ SYNC +)

Return to Table of Contents

12. No TVC Video

Is TVC FAIL displayed on either video display? If so, perform
troubleshooting as listed in step 21. Is TVC video displayed on the CRT or
the Video Display Unit? If not, then verify that FLIR video is displayed when
selected. If FLIR video is displayed, then perform the following:

Wiring continuity checks between the TVC and the PEB:

From TVC 6PN2 to PEB 2PN5-C (TVC VIDEO SIG 1)

From TVC 6PN3 to PEB 2PN5-D (TVC VIDEO SIG 2)
From TVC 6PN1-D to PEB 2PN3-21, 53 (VERT SYNC +)
From TVC 6PN1-E to PEB 2PN3-22, 52 (VERT SYNC -)
From TVC 6PN1-G to PEB 2PN3-50 (HORIZ SYNC +)
From TVC 6PN1-H to PEB 2PN3-51 (HORIZ SYNC -)

Return to Table of Contents

13. BIT Does Not Complete

BIT will not complete ONLY if the Laser does not complete its energy check.
The Laser energy check is the last event to occur during the BIT process,
culminating with the firing of the Laser for about a second. The Laser must
fire to prevent getting the "BIT Does Not Complete" indication.

Check for the following:

1. Does the -60 solenoid actuate? Confirm by selecting D678 on the

LCP and pressing "OFFSET" on the LHG. The TSU optics will drive
down to -60 if the solenoid energizes, approximately -67 if it does
not. Observe 6000 displayed above the Field of Regard box, plus or
minus one degree (5900-6100). If not, continue to step 2.
2. Verify PEB TSU Boresight Command present. With the system
powered, use code D678 (as per step 1) to verify 28VDC for
approximately 30 seconds at TSU 1PN3-41. If not, check continuity
between TSU 1PN3-41 and PEB 2PN3-89. If so, replace PEB. If not,
repair wiring.

Steps 3-5 verify the TSU's electrical integrity for this process:

3. Verify TSU Boresight Relay Coil Resistance. Without power applied,

measure between pin TSU 1JN3-41 and 28VDC return (TSU 1J05-M
 or EPS P3-X). Resistance should be approximately 2700 ohms. If
not, replace TSU. If so, go to next step.
4. Verify continuity in aircraft wires (EPS-TSU). Without power applied,
verify continuity of wires between EPS P3-W to TSU 1J05-K
(28VDC) and EPS P3-X to TSU 1J05-M (28VDC Return). Inspect
cable and mating connectors for damage. Are the wiring/connectors
good? If not, repair as needed. If so, go to next step.
5. Verify 28VDC (Solenoid and Interlock) power present. With the
system powered, verify the presence of 28VDC at either pin EPS J3-W
or TSU 1P05-K and 28VDC return at TSU 1J05-M and/or EPS P3-X.
Is 28VDC present? If no power is present, replace EPS. If power is
present at TSU 1P05-K and NOT present at TSU 1J05-M, then replace
TSU. If power is present all the way through the circuit, then go to the
next step.
6. Verify TSU Window Cover Interlock circuit continuity. Without
power applied, verify continuity between EPS J3-W or TSU 1P05-K
and TSU 1JN3-40 WITH the DVO Window Cover Switch engaged. Is
there continuity? If not, repair the TSU Window Cover Interlock
microswitch or replace TSU.

Is the DVO protective cover properly mounted on the TSU (while using
auxiliary power)? Confirm proper installation of the DVO Window Cover.
Listen for audible "click" when the Window Cover depresses the
microswitch's plunger.

Does the Laser fail BIT? If so, troubleshoot IAW step 3, Laser Fail.

While observing the action of the TSU optics, does the DVO Narrow Field of
View "Flip Up" Cover (the crapper flapper) make positive contact with the
Laser Cover Interlock microswitch? The cover and microswitch is visible
through the DVO window. If it does not make contact, perform the following:

1. Using a 7/64" hex head wrench, remove the DVO window. Note: The
screws are captive.
2. Using a 3/32" hex head wrench, loosen and remove the "Flip Up"
Cover.
3. Inspect the Cover assembly for freedom of movement. If binding,
check for a bent shaft (shaft that the "rabbit ears" and its spring rotate
on). Loosen the shaft and straighten it, as required. Tighten the shaft
then verify freedom of movement for the "Flip Up" cover (It should
snap into place).
4. Reinstall the Cover Assy. Insure it is seated flush with the Corner
Cube Assy and is level. Confirm that the "Flip Up" cover snaps into
place (in both directions) and makes positive contact with the
microswitch.
 5. Reinstall the DVO window cover. Torque screws to approximately 10-
15 in. lbs., snug! Exercise caution, as the screws are easily broken.

Can the Laser be fired manually? If not, verify Laser arm interlocks. If so,
check for -60 solenoid function (step 1 above, in this section).

Return to Table of Contents

14. ARM BUS 1553 Fail

The THCDP is the bus controller for the armament bus; therefore, the THCDP
must be checked for proper operation.

Does the THCDP indicate any bus failures? If yes, then troubleshoot the bus
IAW NAVAIR 2-12.2. If no, then go to the next step.

Is the bus connector at PEB 2PN6 properly seated? Verify that this connector
is seated properly on the PEB. Ensure that pins A and B are seated properly
and are not recessed in the connector.

Replace the THCDP or the PEB.

Return to Table of Contents

15. NAV BUS 1553 Fail

Is the EGI powered on?

In the CDNU Comm / Nav configuration page, is the NTS "INSTALLED?"

Without "NTS: INSTALLED" displayed on the configuration page of the
CDNU, the Navigation system will not attempt to communicate with the NTS.

Does the CDNU indicate any bus failures? Since the Nav system is
communicating with the NTS via bus lines, indicated bus failures could affect
communication between the two systems. If yes, identify and repair. If no, go
to next step.

Is the bus connector at PEB 2PN6 properly seated? Verify that this connector
is seated properly on the PEB. Ensure that pins C and D are seated properly
and are not recessed in the connector.

Return to Table of Contents

16. No A/C Heading Data

Aircraft heading data is provided to the NTS two ways: The AN/ASN-75
Compass system (on non-Comm/Nav upgrade modified aircraft) or the EGI/GPS
on Comm/Nav upgraded aircraft. Determine what aircraft configuration you have
then perform the following:
 Confirm reference voltages are present. At PEB connector 2PN2, check:

1. Pin 69 (26VAC 400Hz)

2. Pin 70 (26VAC 400Hz Return)
3. Pin 67 (10VAC 400Hz)
4. Pin 68 (10VAC 400Hz Return)

Verify wiring between 3400A2 Matrix Box and PEB:

From 3400A2P1-81 to PEB 2PN2-56

From 3400A2P1-82 to PEB 2PN2-58
From 3400A2P1-83 to PEB 2PN2-57

Is the EGI powered on? If no, then turn on the EGI via the CDNU power
page. The EGI provides aircraft heading data to the NTS. If yes, then move
on to the next step.

Is the Field of Regard box indicator scrolling? If yes, then verify reference
voltages as listed above. If no, then go to next step.

Is the NTS/TOW system powered up? If no, then troubleshoot NTS/TOW

system power turn-on circuit. If yes, then follow the steps above.

Is the EPS providing power to the NTS/TOW system? If no, then

troubleshoot the NTS/TOW power circuit.

Return to Table of Contents

17. VCR fails BIT

During the NTS BIT process, the VCR records two seconds of video, rewinds it,
plays back one second of the two seconds of video that was just recorded then
rewinds it all. Due to the NTS' method of testing the VCR for proper functioning,
a fully rewound video tape is required for BIT. Perform the following checks if
the VCR fails BIT:

Is a VHS video tape installed in the VCR? If no, then insert a video cassette
into the VCR then reinitiate testing. If yes, go to the next step.

Are the VCR electrical plugs connected to the VCR? If no, properly connect
plugs to VCR. Check for bent contacts before installing. If yes, then go to
next step.

Check for VCR power and communication. Verify 28VDC at VCR 10PN1-2
and its return, VCR 10PN1-3. Verify wire integrity between the CCU and the
VCR by checking the following:
 A. CCU 3PN2-52 to VCR 10PN2-10 (VCR DATA XMTR-)
B. CCU 3PN2-51 to VCR 10PN2-9 (VCR DATA XMTR+)
C. CCU 3PN2-63 to VCR 10PN2-8 (VCR DATA RCV-)
D. CCU 3PN2-57 to VCR 10PN2-7 (VCR DATA RCV+)
E. CCU 3PN2-2 to VCR 10PN2-34 (DIGITAL GND)

Return to Table of Contents

18. TVC Autotrack Fail

Does autotrack function in the FLIR channel? If no, then go to step 19, No
Autotrack Function. If yes, then verify the integrity of the following:

A. Horizontal and Vertical sync lines between the TVC and the PEB.
B. The two triax video lines between the TVC and the PEB.

Verify that the TVC targeting reticle is in the autotrack box. Enter D555 on
the LCP. Four autotrack dots will appear, creating a box that the NTS using
for tracking targets. Is the reticle in the box (it does not have to be exactly in
the middle)? If the high magnification reticle is NOT in the box, loosen the
TVC self-locking swing bolts then reposition the TVC in its mount until the
reticle is somewhere in the autotrack box. If this does not place the reticle in
the box, then align the TVC in accordance with the TVC ADJUSTMENT
procedure contained in this document.

Return to Table of Contents

19. FLIR Autotrack Fail

Does autotrack function in the TVC channel? If no, then go to step 20, No
Autotrack Function. If yes, then verify the integrity of the following:

From FEB 4PN5 to PEB 2PN5-B (FLIR VIDEO W/O SYMB)

From FEB 4PN6 to PEB 2PN5-A (FLIR VIDEO WITH SYMB)
From FEB 4PN2-43 to PEB 2PN3-70 (FLIR VERT SYNC -)
From FEB 4PN2-44 to PEB 2PN3-71 (FLIR VERT SYNC +)
From FEB 4PN2-40 to PEB 2PN3-68 (FLIR HORIZ SYNC -)
From FEB 4PN2-41 to PEB 2PN3-69 (FLIR HORIZ SYNC +)

Return to Table of Contents

20. No Autotrack Function

Does the TSU follow commands from the SHC? If no, then troubleshoot the
stabilization and control section of the TOW system. If yes, then perform the
following:

Verify the integrity of the following:

 From PEB 2PN3-87 to SCA P1-U (AUTOTRACK)
From PEB 2PN2-43 to SCA P1-D (AUTOTRACK RTN)
From PEB 2PN2-44 to SCA-P1-C (EL AUTOTRACK)
From PEB 2PN2-45 to SCA-P1-V (AZ AUTOTRACK)

Return to Table of Contents

21. TVC Fail

Is power at the TVC? Verify correct voltages at the TVC connector:

TVC 6PN1-A, B (15VDC to TVC)

TVC 6PN1-U, V (-15VDC to TVC)
TVC 6PN1-F, g (ANALOG GND)

Replace TVC.

Return to Table of Contents

22. No Video Input to PEB

This failure appears when the video signal between FEB and PEB is missing.
Is there FLIR video? If not, go to step 11.

Return to Table of Contents

23. No Image on TSU CRT

Usually indicates that the CRT or the Low Voltage Power Supply (LVPS),
located in the PEB, is defective. Is sensor video displayed on the Video
Display Unit (MFD to some of you)? If yes, then inspect power and video
lines between the CRT and PEB. Replace either component if necessary. If
no, then inspect video connections between PEB 2PN5 and the MFD and
CRT.

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24. Partial Video Display in CRT

Usually occurs when a misalignment of the Channel Selector Assembly in the
TSU's Optical Relay Tube exists. When using the Channel Selector Lever
Arm on the right side of the ORT to toggle between DVO and CRT video, is
the full CRT video image visible? Is there discernable play in the lever arm?
Does the image move or shift a bit while gently playing with the level arm? If
yes to 2 out of the 3 questions, then perform the following:

A. Remove 4 screws holding the LHG to the ORT, disconnect connector

under eyepiece and remove LHG. Place out of the way.
B. Remove 4 screws attaching the upper ORT to the lower section, and
then remove the ORT.
 C. Inspect the forked lever arm connecting the Channel Selector lever
arm to the "Flip Flop" mirror frame. If there is play in the lever arm,
there will also be slop between the fork and where it meets the frame.
While working inside the ORT, use needle nose pliers or similar to
straighten the forked lever arm inside the ORT. Be sure the fork tongs
are parallel to each other and both are making contact with the mirror
frame's guide arm. Channel Selector level arm should have very
minimal play / slop.
D. Perform operational checkout by applying system power and while
using the LHG switch, toggle between DVO and CRT. The "Flip
Flop" mirror should rotate smoothly, with virtually no slop. The
mirror's frame should rest evenly on the bumper pads.
E. Re-assembly is the reverse of disassembly.

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25. Scrolling Indicator in Field Of Regard Box

Is the NTS/TOW system powered up? If no, then troubleshoot for NTS/TOW
system power. If yes, then go to next step.

Confirm reference voltages are present. At PEB connector 2PN2, check:

1. Pin 69 (26VAC 400Hz)

2. Pin 70 (26VAC 400Hz Return)
3. Pin 67 (10VAC 400Hz)
4. Pin 68 (10VAC 400Hz Return)

Verify wiring between 3400A2 Matrix Box and PEB:

From 3400A2P1-81 to PEB 2PN2-56

From 3400A2P1-82 to PEB 2PN2-58
From 3400A2P1-83 to PEB 2PN2-57

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26. TSU Bucket chatters in Azimuth

Does the bucket stop chattering when you place your hands on the bucket? If
yes, then tighten the Window Motor Bevel Gear Mesh. Follow the WINDOW
MOTOR BEVEL GEAR MESH TIGHTENING procedure in this document.
If no, then go to the next step.

Verify the integrity of the following Window Servo Tach and RTN wiring:

From TSU 20Z1P4-u to Test Set Disc 20P7-K to SCA 20AR2P2-s

From TSU 20Z1P4-d to Test Set Disc 20P7-J to SCA 20AR2P2-t
 Special Procedures
WINDOW MOTOR BEVEL GEAR MESH TIGHTENING

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1. Remove laser from TSU using a 9" 9/64 Allen T-Handle.

2. Check Window Motor Bevel Gear Mesh (brass gears) and make sure the Gear Mesh
has no excessive play. Gear Mesh should be tight with very little play.

3. If excessive play is evident, then loosen Bevel Gear clamp (one screw only) and
move Bevel Gear closer towards the Inner Gimbal mating gear. Using a large flat
tipped screwdriver will help you accomplish this task. This will tighten up the Gear
Mesh. Adjust Gear Mesh so that it is tight with very little play. Procedure is the same
for both gears. DO NOT over tighten and jam the two gears together.

4. After Gear Mesh is set, tighten Gear clamp screw. Apply a generous amount of
torque. If you have a torque wrench, torque clamp screw to 20 1"/lb.

5. Apply power and check bucket chatter. If okay, install laser. If it still chatters, try the
adjustment again.

6. If this does not cure the bucket chatter, it could be caused by:

A. Window Motor Tach Assembly: Check motor shaft for excessive movement.
With the TSU in STOW position, move bucket and watch window motor shaft for
movement. There should be very little movement in shaft.

B. Not enough bucket friction.

Either of these two conditions will require repair at the Depot.

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LASER BORESIGHT MIRROR ADJUSTMENT

This procedure will center the two Laser Boresight Mirrors in the Laser's path of travel,
allowing the Laser illumination to be visible when fired during boresight or while using
the D876 maintenance code.

Note: This procedure requires two personnel, a portable DC power supply capable of
providing 10-13VDC and a watch or timing device that times in seconds. Caution:
Power supply must not exceed 13VDC.
1. One person must place their ear on the left side of the TSU bucket to hear the mirror's
drive motors. Hearing the motors can be made easier by removing the left TSU
bucket panel.

2. The other person, using the portable power supply, takes the two electrical leads then
applies power to the following:

A. PEB 2PN2-35 LASER MIRROR DRIVE 1

B. PEB 2PN2-36 LASER MIRROR DRIVE 1 RTN

And

C. PEB 2PN2-37 LASER MIRROR DRIVE 2

D. PEB 2PN2-38 LASER MIRROR DRIVE 2 RTN

WARNING: Make sure power is applied to the aircraft connector, NOT the PEB jack.

3. Continue applying power, driving the mirror, until the motor stops driving (detected
audibly). Set the watch or timing instrument, reverse polarity then apply power to the
motor, measuring the time it takes for the mirror to travel from one stop to the other.

4. Reverse polarity again then drive the mirror back, but for only HALF the time it took
for the mirror to reach its stop in step 3. The mirror is now centered. The procedure
is the same for both Laser Mirror Drives.

5. Reinstall the TSU bucket cover (if removed), reconnect 2PN3, then apply system
power. Enter D876 on the LCP, press OFFSET on the LHG; engage all of the Laser
interlocks then fire the Laser. The Laser should be visible and near the middle of the
picture. If necessary, use the Autotrack switch to adjust the Laser spot. Get the Laser
spot as close as possible to the center of the FOV, then exit D876. Run system
boresight. It may be necessary to run boresight two or three times before the system
can get the Laser properly aligned.

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TVC ADJUSTMENT

1. Loosen the six screws on the TSU camera tray.

2. On the LCP, enter D555 to place the autotrack dots on the video display.

3. Adjust the position of the camera tray until the reticle is within the four autotrack
dots. Tighten the six screws.

4. Enter D876 on the LCP and depress OFFSET on the LHG. Verify that the center of
the reticle is still within the four autotrack dots. If so, then torque screws to 10" lbs.
 If not, readjust the TVC and/or camera tray until the reticle stays within the autotrack
dots both in the STOW position and the -60 position.

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NTS COLLIMATOR ADJUSTMENT

Note: The Collimator is mounted internally to the TSU using three screws. Threaded
spacers surrounding the mounting screws provide exact positioning. Adjustments to the
Collimator are made with system power applied. This procedure requires two personnel,
a 7/64" hex head ball driver, a long 7/64" hex head and a long scribe or other sharp,
narrow tool (or the right special tool).

1. Remove the TSU Wire Guide from the front of the TSU by loosening four captive
screws.

2. Remove the TSU Purge Valve and TSU Purge Vent from the front of the TSU.

3. If making an adjustment in elevation, then remove the FLIR Germanium Window. If

the adjustment is to be made is in azimuth, them remove the DVO Window.

4. Using the 7/64" hex, slightly (one-half turn) loosen the mounting screw accessible
through the TSU Purge Vent opening (this screw is the Collimator's pivot point).

5. If making the adjustment in elevation, loosen the 7/64" hex screw accessible through
the TSU Purge Valve hole (Tip: This task is made much easier by utilizing a ball
driver, accessing the screw at an angle with the FLIR Germanium Window removed).

6. If making the adjustment in azimuth, loosen the 7/64" hex screw located on the lower,
right corner of the Collimator. The screw is accessible through an access hole on the
unit, just behind where the DVO Window mounts.

7. Enter D678 on the LCP and press offset on the LHG.

8. Select TV Camera video and high Magnification on the LHG. After approximately
five seconds, a white dot should appear in the field of view.

9. Using a scribe or similar, thread or unthread the spacer surrounding the mounting
screw as required (elevation or azimuth screws), then gently tighten the screw. This
procedure may have to be repeated several times, making small adjustments in the
position of the spacer then tightening the screw until the white dot appears in the
center of the high Magnification reticle, inside of the inner hash marks.

10. Tighten the Collimator screws. Reinstallation of other parts is the reverse of the
removal.

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TOW BIT 3 FAIL TROUBLESHOOTING

Several things can cause the TOW system to fail BIT 3, including the TSU. Most often
another component or faulty aircraft wiring causes the failure. You will need a multi-
meter to perform a checkout of the circuit.

1. Check for continuity between the following: SCA P3-j - EPS P1-j (IR Tracker Pwr On
EPS). If the wire checks fine, then confirm the presence of 28vdc on this wire, from
the SCA to the EPS.

2. Power flows from the SCA to the EPS during two modes of operation only:

A. While the TOW system BITs 1-6 is in progress.

B. While in a TOW ATTACK mode.

Remove the wire at EPS P1-j. Run BIT on the system and check for voltage
while its somewhere between BITs 1-6. Alternately, turn the system off then turn
it on again, this time with the SHC in "track." Placing the SHC in track will
command the TOW system to go straight to power on, precluding the system from
running BIT. Ensure that the Master Arm switch (pilot's compartment) is in Arm,
then select ARM-MAN on the THCDP. Select TVC and hi Magnification using
the LHG. Squeeze the Action bar on the LHG. This energizes the ATTACK logic
and will cause the SCA to produce 28vdc at P3-j. If voltage is not present, reseat
the A5 circuit card inside the SCA then check again for voltage. If voltage is still
not present, then replace the SCA. If voltage is present, then confirm 115vac 3
phase from the EPS to the TSU.

3. The 115vac 3 phase from the EPS to the TSU powers the IR Tracker circuit in the
TSU. The simplest method of verifying the presence of this voltage is to activate the
TOW ATTACK circuit as describe in the preceding paragraph. While squeezing the
Action bar on the LHG, have someone look through the large red window on the TSU
optical gimbal, just below the DVO lens. Visible should be a mirror spinning in the
background. If this mirror is rotating, then the IR Tracker circuit is not faulty. Go to
step 4. If the mirror does not rotate, check the follow wires for continuity:

EPS P1-B to TSU 20Z1P3-B (PH A)

EPS P1-C to TSU 20Z1P3-Z (PH C)
EPS P1-D to TSU 20Z1P3-C (PH B)

If the wires check fine, then replace the EPS or the TSU.

4. Verify the integrity of the follow wires:

SCA P3-n to TSU 20Z1P3-p (BRSIT DR 1)

SCA P3-q to TSU 20Z1P3-n (RTN)
 SCA P3-p to TSU 20Z1P3-c (BRSIT DR 2)
SCA P3-k to TSU 20Z1P3-d (BRSIT MTR REF)
SCA P3-m to TSU 20Z1P3-L (RTN)
SCA P3-h to TSU 20Z1P3-J (DIODE DR PWR)
SCA P3-I to TSU 20Z1P3-H (NF DIODE DR RTN)

If no faults are found with the wires, then replace the SCA or the TSU.

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LDRS (RFTDL) REMOVAL AND REPLACEMENT

Replacement of the LDRS is a simple, straightforward procedure. The only tool required
for this task is a long (6" min.) 9/64" hex head wrench.

1. Remove the upper TSU fairing.

2. Remove all the mounting screws around the perimeter of the LDRS with the
exception of the rear screws.

3. Fully loosen the screws adjacent to the aircraft bulkhead. Fully loosen a "hidden"
screw (located in a hole about 4" from the front and 2" from the right, as viewing
from the front looking aft).

4. Disconnect the 2 electrical connectors.

5. Carefully lift the LDRS straight up and away from the TSU. It may be necessary to
bend the cable clamps mounted to the bulkhead slightly to enable the removal of the
LDRS.

6. Installation is the reverse of the removal. This task is made much easier by placing
the mounting screws in their holes (particularly those in the rear of the unit) prior to
positioning the LDRS on the TSU. Note: Do not forget to tighten the "hidden"
screw.

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THERMAL IMAGING SENSOR (TIS) REMOVAL AND REPLACEMENT

Removal of the TIS is a fairly simple task. Care must be taken to avoid scratching the
TIS Germanium window (or dropping the whole thing) as it is removed from the TSU
bucket. Tools and equipment required include a flat tipped screwdriver, 3/32" hex head
wrench, 7/64" hex head wrench, long 5/32" hex head wrench (6" min.) and wax covered
lacing tape. All screws involved are captive.

1. Remove the right side TSU panel.

2. Using a 7/64" hex head wrench, remove the front of the TSU by loosening all the
perimeter screws.

3. Cut and remove lacing tape or tie wrap securing ribbon cables to the TIS.

4. Remove screw securing two black (ground) wires to the TIS using a 3/32" hex head
wrench. Remove the wires and reinstall screw.

5. Using a 3/32" hex head wrench, remove small flat electrical connector to the TIS.
The long ribbon cable routed along the side and front of the TIS identifies this
connector. Move the ribbon cable out of the way.

6. Loosen four screws securing the TIS to its mounting surface on the TSU gimbal using
the long 5/32" hex head wrench.

7. Separate the TIS from its mounting surface. Pull the TIS slightly forward and tilt it
downward.

Note: For safety sake, a helper should be used for this task.

8. While holding the unit in this position, remove the remaining electrical ribbon cable
from the rear of the TIS.

9. Remove the TIS through the front of the TSU bucket.

10. Installation is the reversal of the removal. Ensure that the TIS mounted plate is
aligned properly on the TSU gimbal. Guide pins are on the mounting surface to
assure this happens.

11. Using a lint free cloth, wipe the TIS germanium window clean of fingerprints.

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