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View Full Version : Remembering the not so early days of A-7E maintenance



PRB
June 9th, 2009, 18:53
As a Fire Control Technician (AQ), we were responsible for the weapon system avionics on the A-7E. Our shop was called IWT, which stood for Integrated Weapons Team. The A-7E had what was then a new fangled concept called an “integrated weapons system”, meaning the main computer, inertial navigation, radar, Doppler radar, and HUD were all “talking” to each other to provide accurate bombing solutions to the pilot.
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We did some silly things in those days. For example, if the pilot said the radar wasn’t transmitting, or if we suspected it wasn’t, our testing procedure was to apply power, walk out to the front of the plane, open the nose radome, and grab the radar feed horn with our hand. If it was warm, we knew it was transmitting!! :eek:
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The Doppler radar was a very useful system that provided radar altitude, ground speed, and drift angle. As a radar, of course, it provided radar altitude, but the antenna projected four beams, two fwd and two aft. The frequency shift between the fwd and aft beams, due to the Doppler effect, provided ground speed, and the antenna was mounted on a gimbal stabilized platform which would automatically rotate until the two fwd beams were each reflecting equal frequencies. This provided accurate drift angle. Very cool. But it was a pain to maintain. The stupid antenna was accessible only by sitting on the ground under the plane and removing about a hundred screws, several of which were guaranteed to be stripped, and would require an easy-out to remove. And on the carrier, they always parked the A-7s forward, over the catapult tracks. This meant we had to sit on the flight deck, on the cat tracks, which were hot as hell on account of the steam used to power them!
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The electrical fuzing system was a bit of a nightmare. Bombs could be armed with mechanical and/or electrical fuzes. A mechanical fuze was a “simple” device with a propeller to arm the weapon after it was dropped from the plane, like in WW-II. The electrical fuzes allowed the pilot to select a variety of fuzing options from the cockpit, like delay times, etc. The whole system was wired by coax cables from one central box, out to each bomb station (six of them), and was one big parallel circuit. This meant that if there was a short anywhere in the system, the entire system was shorted. And these coax cables were routed all over the damn place, and were always getting water in the connectors, meaning it was often shorted. Finding the short was the fun part! You got to be expert at splicing coax cables if you worked in the IWT shop in an A-7E squadron!

jmig
June 10th, 2009, 06:10
Could the pilot update the INS with the radar? In the F-4 the INS would drift about 2-3 miles per flying hour. We always had to update the system with the radar.

Grabbed the horn,huh.... :) I hope you drank a lot of beer. That is a much more fun way to destroy brain cells. :icon_lol:

PRB
June 10th, 2009, 13:47
There were a couple ways the INS could be updated in the A-7. The radar was one. The “moving map” display was another. The moving map was a roll of film containing a map of the area you were flying over that day, back lit and projected onto a screen at the lower right of the instrument panel. The map’s position was driven by the INS. So the pilot would fly over a large feature visible both on the map and outside the window then slew the map so it was positioned correctly, and update the INS that way. The FA-18’s ring laser gyro INS is much less drifty than those older systems, and in addition is constantly updated by the GPS.
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Yeah the feedhorn thing sounds really dangerous, but the fact that we could even do that indicates that it wasn’t a very powerful radar to begin with. Not like a fighter’s radar. The FA-18 radar cannot be made to transmit on deck, for example… Besides, it didn’t affect me at all… at all… at all… :d

PRB
June 10th, 2009, 16:51
And some things done were not so silly…
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In the summer of 1989, the USS Nimitz (CVN-68) was on station in the northern Arabian Sea. The A-7 squadrons embarked were VA-146 and VA-147, from NAS Lemoore, CA. One night, the ordnance shop of VA-147 went up to the flight deck to perform a gun gas purge check on one of the planes.
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The M-61A1 20mm cannon carried by the A-7E fired at 4000 or 6000 rounds per minute. Gas from the gun during firing could collect in the gun bay, and this is dangerous, so a system, driven by engine bleed air, is used to purge the gun bay of accumulated gas. The only way to test this system is by starting the plane’s engine, arming the gun, and pulling the trigger! One can imagine that you would want the gun to not be loaded during this test, no?
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The A-7E carried 1000 rounds of 20mm ammunition for that gun, and it was stored in a big drum located behind the pilot’s seat. The rounds were fed to the gun by means of a belt, which was actually a continuous “circle”, meaning the two ends were connected. With 1000 rounds of ammo loaded, there was a large part of that continuous belt that didn’t have bullets in it. I’m not sure why this was, but it allowed manual cycling of the gun belt in such a way that all the bullets were stored in the drum, and none were in the gun, see?
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To do a gun gas purge check, it is essential that the gun be unloaded (duh.) Unloading 1000 rounds out of an A-7 is a time consuming task. Ground equipment to hold the bullets must be brought to the plane, and the gun has to be manually turned over with a big crank handle until all the bullets have been removed and placed in the cart. After the maintenance is done, the gun has to be reloaded, which is another long tiresome process. But wait, we know three things. 1) It only takes a momentary “tap” of the trigger to complete the gun gas purge check. And 2), if you cycle the gun such that all the bullets are up in the drum, you have five or six feet worth of empty gun belt before actual bullets start to come down from the drum. And 3) there is a device called a “gun clearing sector clamp”, which, when properly attached, causes rounds from the belt to pass through a “clear path” instead of passing through the gun breeches, so even if there are rounds in the belt, they wouldn’t be fired.
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You see where this is going…
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So that’s what they did. They cranked all the rounds into the drum, attached the gun clearing sector clamp, started the plane, pushed in the gun circuit breaker, attached the weight-off-wheels override device into the right main wheel well, attached the gear-up-and-locked override device into the left main wheel well, selected master arm, selected the gun, and tapped the trigger. One guy was down on the deck looking up into the panel, which had been removed to provide visual access to the drum. He could see the belt being fed from the drum and could see if there were bullets coming down the belt. He would signal the man in the cockpit to “tap” the trigger with his thumb and forefinger.
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It would have worked too, but for two things. First, at 4000 rounds per minute, that’s a little fast for the “tap, ok, tap again” method of ensuring rounds are not being fed from the drum. In any case, the guy in the cockpit “tapped” too long and rounds did enter the gun. The second thing that happened was that the gun clearing sector clamp, that device that would have caused the rounds to not enter the breeches, was not properly attached.
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The plane fired three rounds. All went through a fully loaded KA-6 tanker, which exploded. The fire raged for less than 5 minutes, during which time seven planes were destroyed and two men were killed. One of those men was the plane captain for the A-7. Just a kid, really. He was only there because he was required to be there any time the plane’s engine was started up for maintenance. The other fatality was a technician from the A-6 squadron who was just walking past the ill-fated KA-6 tanker at the wrong time.
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That’s why they say all those warnings and cautions in the maintenance manuals are “written in blood.”