Service Manual for T60
Contents
1. S LEFT DOWN BOTTOM CABLE GAGE POINTER LOCK BUTTON DIAL FACE CABLE GAGE STOP PIN ACTUATING HANDLE POINTER UNLOCK BUTTON HANDLE LATCH PRESET ACTUATING RING d Slowly release the actuating handle allowing the jaws to grip the calibration bar Note the reading on the dial indicator The reading obtained in this manner should correspond with the reading marked on the identification tab within 2 of the value marked The Tensiometer s serial number shall be marked on the bar Caution The TEST BAR shall be placed flush against the riser faces such that the faces of the risers are parallel with the test bar 4 10 OVERLOAD The cable Tensiometer is a durable precision instrument and cannot be damaged by use on cables loaded in excess of the amount indicated by the dial on the Tensiometer SOP TN 002 Rev Q T60 Operations and Service Manual 5 1 SECTION V PERIODIC INSPECTION MAINTENANCE AND LUBRICATION GENERAL No periodic inspection maintenance or lubrication is required for cable Tensiometers As a matter of general practice the instrument should be kept clean at all times Particular attention should be paid to the two sectors and the riser block to see that they are always free from foreign matter The instrument as shipped by the manufacturer has been lubricated In the event that repairs are made as outlined in Section VI lubrication should be accomplished as listed in table 3 Method of applicati2. e 9100 optimanufacturing fio Scientiti nN yma AN EIVI OPERATION amp SERVICE MANUAL FOR CABLE TENSIOMETER 160 serres PART NUMBERS T60 1001 C8 1A NSN 6635 00 530 1128 T60 1001 C9 1A NSN 6635 00 530 1129 RS T60 1002 C8 00 BRITISH MODEL FOR CWT CABLES ganun T60 1002 C9 00 BRITISH MODEL FOR CWT CABLES SOP TN 002 Rev Q T60 Operations and Service Manual TABLE OF CONTENTS INTRODUCTION AND DESCRIPTION oo eeeeeceeeeeneeeeeeaeeeeeeeeeeeeaaeeeseeaaeeeeeeeeeeeeaaeeeseeaaeeeeeeeeeeesaeeesesaaeeeseneeeeesneeeenenaeeesneaaees 2 Tete INTRODUCTION ii Siete te Ate ete Pele ae es Rate tae ela rere cle a Mia a ates ad Raa a 2 1224 PURROSE ia ea ee eet des oe ina eae et tere era es 2 1232 IDESCRIBTION ict e fee ea eee eel a i A nes eed a aa te a 2 1 4 WARRANTY iii ein centres a Rid qd cheval gent eed anne ed need Ae ee 2 Table 1 Type Identifications A ieidescezecea ted A E it 2 SPECIAL SERVICE TOOLS ui tae 3 221 7 SPEGIAL SERVICE TOOLS 0 elation elt tes date teen hath ean ated tt Vain ca Sad 3 PREPARATION FOR USE STORAGE and SHIPMENT 000 cc ceeececceeeesneeeeeeeeeeeseeeeeeeaeeeeeneeeeesaeeeeeeaeeeseeeeeeesneeeesenaeeeeeeaaees 3 3 1 sPREPARATION FOR USE 00 cease Ana ratita aed aes ead tee ias 3 3 2 PERFORMANCE aid to tie at ieee nate td aden eh id sae Rieger art eats tale Alacer 3 IA MOS EO TIAC EEE E e tc aces Peat ne hee Zara E Rats Pees ads Pea aea 3 EE SE IEMENTE a A a aa chee ao
3. 0 005 inch thick and place them on the bottom of the pins After the bite is balanced place equal shim thickness on each side of the instrument for subsequent calibration Proceed with calibration by preloading the 7 32 cable with a load equal to the high end of the instrument range The high end is 200 lbs for the type C8 and 450 Ibs for the type C9 Measure the tension and add or remove shim 3 as necessary to make indicator read between 190 195 Ibs for Type C8 and between 430 440 Ibs for the Type C9 Remember the addition of shims 3 makes lower readings On the other hand the remove of shims 3 makes higher readings Try to set as close as possible to 200 lbs for type C8 and 450 lbs for type C9 Proceed to verify calibration by preloading the 7 32 cable with a load equal to the low end of the instrument Measure tension and add or remove shims 3 as necessary to make indicator read between 75 80 lbs for Type C8 and between 142 150 lbs for the type C9 SOP TN 002 Rev Q T60 Operations and Service Manual Repeat steps and j for 1 16 cable on Type C8 and 1 8 cable on Type C9 to improve indicator accuracy to 5 If closest possible accuracy is desired take three to five reading at slightly different locations on the cable and average them On step j for 1 16 amp 1 8 cable on Type C8 the low end is 10 Ibs and the desired indicator read between 9 15 Do not remove the 0 010 inch shims from the top of the fr
4. of sectors 24 There shall be 0 015 inch maximum clearance between sectors 24 and frame 41 This is controlled by number of washers 25 placed under the sectors 24 Place a washer 8 on each top pin of frame 41 Position mainspring 7 and secure with clips 6 Check that post shaft 12 just or almost contacts mainspring 7 and that mainspring does not deflect shaft post and consequently pointer of dial indicator 35 If necessary adjust position of post shaft 12 on indicator shaft 13 by loosening setscrews 11 to obtain this condition Be careful not to get a false position This can occur if indicator shaft 13 is not bottomed in dial indicator 35 Position risers block 5 The riser block should not deflect the mainspring 7 If it does select a riser block with a low tolerance Place clips 4 on the lower pins of frame 41 Between the pins and the top of the clip place a 0 010 inch shim 3 on each side of the instrument Drop spring 10 onto shaft 13 and secure with screw 9 Check for a symmetrical bite On a pre loaded 7 32 cable start to take a tension reading but do not remove all restraint from handle With the Tensiometer in this position wiggle the cable with free hand to determine that the resistance to movement is the same at both sectors 24 Add shims 3 as necessary to balance bite Add shims to obtain lower readings and remove shims to obtain higher readings Use shims that are 0 003 or
5. squeezing the actuating handle Retain the actuating handle unlatched against the side of the Tensiometer Place the instrument on the cable making certain that the cable is squarely aligned in the jaws and against the jaw base Slowly release the actuating handle allowing the sectors to slide up and grip the cable Remove all restraint from the actuating handle c With the Tensiometer clamped on the cable the tension is read directly by the pointer position on the dial face d To remove the Tensiometer compress the actuating handle firmly against the side of the Tensiometer and latch the handle in position with the handle latch SOP TN 002 Rev Q T60 Operations and Service Manual 4 5 TAKING TENSION READINGS TYPE C9 The Type C9 cable Tensiometer is used in the same manner as the Type C8 with the following exception the larger size cables have two rows of preset squares one row identified by 250 the other row identified by 250 When measuring cable tensions below 250 pounds use corresponding squares in the row indicated by 250 and conversely for the opposite condition use 250 See Fig 3 5 SET POINTER DIRECTLY SET POINTER OVER CENTER OF LINE OVER CENTER OF WHEN READING TENSION LOADS LINE TO THE CABLE DIAMETER IN EXESS OF 250 POUNDS R a R lt xX 25h i 200 Se 0 y INAK 50 ZON o 3009 il a 3008 iy Ml 250 350 1 2 4h 32 q 150 a 8 MB ANA 400 LA SET POINTER OVER CENTER OF LINE E WH
6. the accuracy of readings the operating temperature range are 65 F to 160 F 53 C to 71 C STORAGE When the cable Tensiometer is not in use it must be placed in its carrying case There are no special instructions or precautions relative to storage SHIPMENT If the cable Tensiometer is to be shipped it shall be placed in its carrying case and packed in such a manner as to avoid damage by common carrier Figure 1 1 Wrist Band SOP TN 002 Rev Q T60 Operations and Service Manual UP TOP 4 RIGHT _ CALIBRATION BAR LEFT DOWN BOTTOM RISER CABLE GAGE POINTER LOCK BUTTON JAW BASE DIAL FACE SECTOR CABLE GAGE STOP PIN ACTUATING HANDLE POINTER UNLOCK BUTTON HANDLE LATCH PRESET ACTUATING RING T60 TENSIOMETER Net Weight 1 58 Ib 72 kg Shipping Weight 3 Ibs 1 36 kg i 1o h 38 1mm FRONT VIEW REAR VIEW SIDE VIE Not Scale Not Scale Not Scale Figure 1 Cable Tensiometer Typical SECTION IV OPERATION INSTRUCTIONS 4 1 GENERAL INSTRUCTIONS Each time the instrument is removed from its case for use check the serial number on the nameplate to ascertain that it agrees with the serial number on the calibration bar Before using the instrument check the calibration by means of the calibration bar See paragraph 4 9 Warning Cable Tensiometers should not be used for adjusting the rig load in a cabl
7. 1 13 T60026 SHAFT Indicator 1 14 COML 0901100 99 SCREW 10 32 x 5 16 inch long socket head 1 15 160018 PIN Center 1 16 T60022 INDICATOR Cable size 1 A B 160058 INDICATOR Cable size British Model 1 C D 17 160019 WASHER Center pin 1 18 160068 WASHER Spacer 3 19 T60014 1 HANDLE ASSY 1 20 160037 WASHER Spacer 1 21 160070 LINER Pin 1 22 160071 LINER Roller 1 23 160023 YOKE ASSY 1 24 1537 SECTOR 2 25 160052 WASHER 6 26 160030 ROLLER Guide yoke 1 27 JAN531 4RF6 id 4 40 X 3 8 thread cutting Phillips head 82 2 28 T60008 PLATE 1 29 T60050 SPRING Trigger 1 30 160035 SPRING Switch 1 31 160048 PIN Switch spring 1 32 160006 SHAFT Switch 1 33 ms35207 203 SCREW Indicator 2 64 x 1 4 long round head gt P hillips Recess UNF 2A SOP TN 002 Rev Q T60 Operations and Service Manual FIG amp UNITS USABLE ae PART NUMBER DESCRIPTION PER ON ASSY CODE EZ AN960 3L WASHER 35 160059 INDICATOR Dial FACE Dial British Model INDICATOR Dial FACE Dial British Model 36 COML 0908100 03 BALL BEARING 0 093 dia cres 37 COML 0913200 02 PIN Groove type 4 1 16 dia x 5 16 inch long 38 160025 CAP Handle lock 39 160028 SPRING Handle latch 40 T60024 PLUNGER Handle lock 41 T60021 Frame Assy T60074 not shown BEARING FRAME PIN FRAME TEST BAR ASSY Calibrating TAG TEST BAR MS20470AD2 3 RIVET 1 6 di
8. ABLE TENSION READINGS TYPE C8 a Preset dial by rotating the knurled rim of the dial indicator until the pointer is directly over the line corresponding to the cable diameter See Figure 3a SET POINTER DIRECTLY SET POINTER OVER CENTER OF LINE OVER CENTER OF WHEN READING TENSION LOADS LINE TO THE CABLE DIAMETER IN EXESS OF 125 POUNDS w Y gt mM SS us Un 25 i 7 t E L10 le 3b 163 87 116 10 32 SET POINTER OVER CENTER OF LINE WHEN READING TENSION LOADS LESS THAN 125 POUNDS PACIFIC CABLE TENSIOMETER 30 100 POUNDS TENSION 90 80 gt 40 50 70 60 Figure 3 Preset Instructions Type C8 Note Shown figure is for reference purpose actual dial may vary NOTE 1 An examination of the dial will indicate that for the larger size cables there are two rows preset lines One row is identified by 125 the other row is identified by 125 When measuring tensions below 125 pounds use the lower line when measuring tensions in excess of 125 pounds use the high line See Figure 3b NOTE 2 When used the cable coated type you shall preset the dial in cable s O D including coated insulation For example if your 5 32 coated cable has an OD of 7 32 then the dial pointer preset shall be in the 7 32 mark and not on the 5 32 To obtain the cable OD measurement you may use the instrument s integrated cable size gauge and procedure sec 4 3 b Release the handle latch by
9. EN READING TENSION LOADS A y LESS THAN 250 POUNDS 450 PACIFIC CABLE TENSIOMETER POUNDS TENSION Figure 3 5 Preset Instructions Type C9 Note Shown figure is for reference purpose actual dial may vary 4 6 DIFFICULT LOCATIONS When taking readings among closely grouped cables or in awkward or blind locations let the actuating handle remain open with the instrument clamped on the cable While in this position press the pointer lock button down Remove the Tensiometer by compressing the actuating handle against the case and remove The dial indicator pointer will be locked in a position directly over the tension reading obtained on the cable To release this reading press up on the pointer unlock button Note Do not attempt to take cable tension readings with the pointer lock button pressed down If the pointer lock button is depressed during a tension reading a false reading will result due to the friction of the brake mechanism 4 7 ACCURACY Because of the uneven surface of stranded cable slight variations in reading may occur on the same cable at the same tension This is especially true of 5 32 inch diameter cable and larger To obtain the greatest possible accuracy take three to five readings at slightly different locations on the cable Average these readings to obtain the maximum degree of accuracy ls consider out of tolerance if not meet with the specification of following table 2 Table 2 T60 Accuracy Toler
10. ION AND DESCRIPTION INTRODUCTION This publication is issued as the basic Manual of Operation and Service Instructions for Types C8 and C9 Cable Tensiometers manufactured by OPTI Manufacturing Corp Luquillo Puerto Rico USA The equipment covered are listed in table 1 Instructions contained in this publication apply to both types listed unless specifically noted otherwise PURPOSE The cable Tensiometer are designed for use in accurate rigging of airborne control cables DESCRIPTION Used extensively it is considered the standard of the industry in many countries and has proven it s durably under long and continual service Each instrument is suitable for use over a wide range of tension measurements and different cable sizes Firm positive 3 point cable grip prevents dislodgement when instrument hanging free on control cable The T60 requires no alternate riser for the various size cables There are no losable parts in the T60 The instrument is always ready for instant use An easy to operate accurate built in gage eliminates guess work as to size of cable to be tested Simple comfortable lever grip permits one hand operation without operator fatigue In severe cold service mittens or gloves may be worm without any loss efficiency of operation A simple lock holds dial pointer at exact reading on cables in areas where instrument cannot be seen A touch unlocks the pointer preparatory for the next reading Large clear numerals make readin
11. a todla sda leat tg ashen tl id sunt ETNEA 8 SECTION Vos ee A ei ee ea ei en ee eal 9 PERIODIC INSPECTION MAINTENANCE AND LUBRICATION 0 000 ccceeeceeeeeeeeeeeeenaeeeeeeeeeeeseaeeeeeeaaeeeseeeeeeesnaeeeeseaeeeeneneees 9 Dale GENERA les a o el id ia dl Dd e Mads acted 9 Fable 3 Lubrication Chart ion iaa 9 SECTION Vlitrcococoo ccoo da tratan ire debilidad 9 TROUBLE SHOOTING cocina a a E ches Sing TAE see ghd eed ond N E R 9 A A SS A es 9 6 2 SERVICE TROUBLES AND REMEDIES 0 ccccccccceeeeeeececeeeeeeecacaeceeeeeeescaaeaeeeeeeesesenneeeeeeeeetenseaees 9 Table 4 Trouble Shooting Chart i ce secaecescsoctees rta dicte Rata taa 9 SECHON Vil A A A cad 10 CALIBRATION cout ias 10 T I EQUIPMENT RE QURE A na Daia ng 10 7 2 DISASSEMBLY PRIOR TO CALIBRATION c ccccceeeeeeceeceeeeeeeseceeaeeeeeeeeeseccaeaeeeeeeesesenciaeeeeeeeteteees 10 SS O 10 TA INDICATOR CABLE SIZE e cia adas tone ie a raaa a T a 11 Table 5 STD Cable Size to British CWT Cable Size Equivalent cccccccceecceceeeeeseeeeeeeeeeeeeseceacaeeeeeeeseesneaeeeeees 11 SECTION VID ay e a an fd leg An els cles tec cule ein MeO te 12 GROUP ASSEMBLY PARTS EIS Toti ca 12 Figure 6 Cable Tensiometer Type C8 and CODoconcccconocicononaccnnnonnnonanonononononnn nan nnr naar rn rr neon nro n nena n rre ran rar nn rn rr anna rn cnn 12 Table o Patsy iii A ado 13 SOP TN 002 Rev Q T60 Operations and Service Manual 1 1 1 2 SECTION INTRODUCT
12. a x 3 16 inch long T5138 60 CARRYING CASE ASSY 0922100 88 BLACK CASE INSERT CUSHION CUSHION T60 INSTRUCTIONS SHEET Operating INSTRUCTIONS SHEET British Model LABEL INSTRUCTIONS LABEL NAMEPLATE a SOP TN 002 OPERATION AND SERVICE MANUAL 48 T60007 WRIST BAND Denotes non subassembly or final component part Denotes subassembly parts A A A AA NAAA A A OO AAA j _ OPTI Manufacturing Corp Road 992 Km 0 3 Luquillo Industrial Park Luquillo PR 00773 2581 USA Phone 787 889 2285 Fax 787 889 2805 fax CopyrightO OPTI Manufacturing Corp All Rights Reserved Point of Contacts General Info info optimanufacturing com Sales Shipment sales optimanufacturing com Technical Support RMA is jorge optimanufacturing com For the latest revision of this manual refer to our website http www optimanufacturing com SOP TN 002 Rev Q T60 Operations and Service Manual REVISION HISTORY Previous Actual Effective Change Description Revision Revision Date F G 2 9 2006 Section VII Calibration procedures updated G H 8 26 2006 Table 1 1 Section VII revised H 3 16 2007 Section 1 4 added J 7 13 2007 Section 5 1 amp table of Figure 8 1 revised J K 4 1 2009 Update Fig Table Sec 8 Change the number identification to Tables and Figures Update Figure 3 A
13. ables either coated or non coated shall conform to MIL DTL 83420 Most Aircraft systems use the Flexible cable Some aircraft A 10 and F 15 use both Flexible and Non Flexible cables A Tensiometer instrument calibrated on Flexible cable will not give accurate tension readings when measuring Non Flexible cable Non Flexible cables shall conform to MIL DTL 87161 Supersedes MIL W87161 amp MIL W 5693 Again the Tensiometer instrument shall be calibrated on the same type of cables on which the Tensiometer instrument will be used 4 9 USE OF CALIBRATION BAR A Calibration bar is supplied with each Tensiometer This provides an immediate means of checking the accuracy of the instrument while in use The calibration bar has been carefully checked to read the load marked on the identification tab The identification tab also carries the serial number of the instrument for which that particular calibration bar is provided To check calibration proceed as follows a Preset the indicator dial face to the smallest cable size listed 1 16 for C8 and 1 8 for C9 3cwt for C8 and 10cwt for C9 British models b Grasp the calibration bar identification tab in the left hand c Place the bar in the instrument with the identification tab facing the user and the right end of the bar flush with the edge of the instrument See Figure 4 Figure 4 Calibration Bar Instruction UP TOP E RIGHT CALIBRATION BAR FLUSH TO THIS SURFACE p 4
14. ame pins After this the unit shall make linearity for all cables and tension ranges Replace cover 2 and secure with screws 1 Preset the indicator dial to the smallest cable size Measure the load required to deflect the calibration bar Remove the load marked on the identification tab and mark the new value indicated on the Tensiometer Note Due principally to the uneven surface of the stranded cables slight variations in readings may occur on the same cable at the same tension If closest possible accuracy is desired take three or five reading at slightly different locations on the test area of the cable and average them It is considered a unit to be out of calibration when the average reading is more than 5 of indicator or one minor division whichever is greater 7 4 INDICATOR CABLE SIZE To re establish the accuracy of the indicator cable size proceed as follows a b C d Remove existing mark on center pin washer 17 with a fine file With handle in locked position rotate indicator cable size 16 counterclockwise until it contacts stop on handle assembly 19 See figure 2 for reference For C8 model set at 100 Ibs on cable 1 16 for C9 model set at 150 Ibs on cable 1 8 clamp the Tensiometer on a cable Return handle to lock position Note In next step do not move the indicator cable size 16 e Mark center pin washer 17 with a scribe opposite on known diameter 1 16 or 1 8 on i
15. ance RANGE MODEL LBS TENSION ACCURACY E E Ss T60 C8 110 200 5 of indicator or one minor division from dial scale whichever is greater values taken from dial scale average reading T60 C9 150 450 5 of indicator or one minor division from dial scale whichever is greater values taken from dial scale average reading SOP TN 002 Rev Q T60 Operations and Service Manual Due principally to the uneven surface of the stranded cables slight variations in readings may occur on the same cable at the same tension If closest possible accuracy is desired take three or five readings at slightly different locations on the cable and average them 4 8 TYPE OF CABLE The cable Tensiometer is calibrated for use on standard multiple strand aircraft cable of 7 x 7 or 7 x 19 stranding in sizes of 1 16 3 32 and 7 x 19 stranding for 1 8 through 1 4 inch diameter on cable Do not attempt to use the cable Tensiometer on cables of a different construction Cables construction and specification in accordance with MIL DTL 83420 general specification for flexible wire rope for aircraft control cables See TABLE 5 for British Equivalent The Tensiometer instrument shall be calibrated on the same type of cables on which the Tensiometer instrument will be used such as coated cables used externally on helicopters The T60 series cable Tensiometer are standard calibrated on Flexible wire rope for aircraft control cables Flexible c
16. dd Figure 3 5 Tables 2 4 Sections 4 3 6 1 and 7 2 TABLE 7 i E S 19 2010 change the Manual title Correct Table 1 p 2 Table 2 p 6 TABLE 7 p 12 Add red note p 6 amp 10 add TABLE 6 L M 8 31 2011 10 DCN 11 090 Correct Sec 4 8 Type of Cable Correct address add Point of Contact add sec IX M N 4 13 2012 Dimension and Weight DCN 12 048 On Sec 4 4 add note of OD when use cable coated type p 5 Correct quantity used N O 8 10 2012 jon item 18 T60068 before 2 now 3 and correct P N on item 34 before AN960 3 now AN960 3L of Table 6 P12 13 DCN 12 071 Add fig 1 1 p 3 change Fig 3 p 5 Fig 3 5 p 6 correct sec 4 9 a add ACCURACY O P 10 18 2013 GRAPH TYPE C8 amp C9 tab 5 p 10 correct sec 7 4 c e correct Fig 6 correct table 7 DCN 13 077 Add information from T60 catalog and add weight specs on 1 3 add dimension P Q 08 06 15 specs on fig 1 add Performance section 3 2 correct fig 3 3 5 delete Accuracy graph on page 10 and relocate section VIII DCN 15 039 SOP TN 002 Rev Q T60 Operations and Service Manual NOTES
17. e 3 Figur TT Wrist Bari tec A A 3 Figure 1 Cable Tensiometer TypiCall 0 cccccccecceceeeceeeeeeeceeeeeeeeeeaaeae cesses aaeaeceeeeesecaaeaeceeeeesecaeaeeeeeeeeeeceaeeeeeeeseeeeaees 4 SECTION as el LUN 4 OPERATION INSTRUCTIONS Sora tt ita toi ata air 4 4 1 GENERAL INSTRUCTIONS iiit i h e di rates di A gies oni a a 4 4 2 OPERATING INSTRUCTIONS Sosnin ei ie denen RA aera ia 5 4 3 MEASURING CABLE DIAMETERS erin aira aeaa eaae aaa aaa aeaaaee aa e aeiaai aah aaia 5 Figure 2 T60 Cable Diameters ccoo A 5 4 4 TAKING CABLE TENSION READINGS TYPE C8 0 cccccccececccecececeeeeeecneaeeeeeeeeeeecaeaeeeeeeesetecnaeaeeeeees 6 Figure 3 Preset Instructions Type UBiviciicninnini A E E TRAE AEEA EEN REE 6 4 5 TAKING TENSION READINGS TYPE C9 cocoocccnconoconocnnccnnnnnnnncnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnrnnannnes 7 Figure 3 5 Preset Instructions Type Chica iii ada 7 4 6 lt DIFFIGUET LOCATION S cc scaacteateucecnesanazean dined sad a ar iones Rina tae dined accede acl pease asia ida 7 A ACCURACY A O 7 Table 2 T60 Accuracy Tolerance c ccccceccccecceceeeceeeeeaneeceee cece aaeaeceee ee caeaaeaececeeescaaaaececeeseqgeaaaeaeceseseeeesaeeeeeeeeeeeesunaeeeeess 7 4 8 TYPE OFCABLE lt lt 0000000tiaia da edie nied eid dd ates 8 4 9 USE OF CALIBRATION BAR i eniai ionene A dd cda 8 Figure 4 Calibration Bar Instruction assornir i e ee eevee neh diane ese E vie aea 8 A 110 ONBREOAD EE E A EA E E A neat hd
18. e system where an automatic cable tension regulator is installed All such cable systems should be rigged by adjusting them so that the pointer on the cable tension regulator scale indicates the correct number based on the surrounding temperature as indicated on the chart provided by the aircraft Maintenance Manual The Tensiometer may be used to check the tension so obtained but it must be remembered that the actual cable tension will vary from the nominal depending on the errors in the instrument itself manufacturing tolerance of springs in the regulators rate of the regulator spring and condition of the control cable Cable tension readings taken on a regulated control system therefore can be misleading and can result in damage through improper rigging SOP TN 002 Rev Q T60 Operations and Service Manual 4 2 OPERATING INSTRUCTIONS Either the right or left hand may be used to operate this instrument The handle latch retains the actuating handle The latch is automatically released when the actuating handle is squeezed To re latch the actuating handle the handle must be squeezed firmly against the side of the Tensiometer and the handle latch pushed up from the bottom against its spring load and held in the extended position while the actuating handle is slowly released against the handle latch The latch end will be retained in the detent socket provided in the actuating handle Note When operating the instrument handle the handle should ne
19. ent via email jorge optimanufacturing com or via fax 787 889 2805 Table 1 Type Identification MFR S TYPE PART NUMBER CABLES RANGE Type C8 T60 1001 C8 1A 1 16 3 32 1 8 10 to 200 Ibs tension 5 32 3 16 30 to 200 lbs tension 7 32 1 4 80 to 200 Ibs tension British T60 1002 C8 00 3 CWT 5 CWT 10 CWT 10 to 200 Ibs tension 15 CWT 25 CWT 30 to 200 Ibs tension 35 CWT 45 CWT 80 to 200 Ibs tension Type C9 T60 1001 C9 1A 1 8 5 32 3 16 7 32 1 4 150 to 450 Ibs tension British T60 1002 C9 00 1OCWT 15CWT 25CWT 35CWT 45CWT 150 to 450 lbs tension SOP TN 002 Rev Q T60 Operations and Service Manual 2 1 3 1 3 2 3 3 3 4 SECTION II SPECIAL SERVICE TOOLS SPECIAL SERVICE TOOLS No special tools are required for service or maintenance of the cable Tensiometer SECTION Ill PREPARATION FOR USE STORAGE and SHIPMENT PREPARATION FOR USE The cable Tensiometer is shipped by the manufacturer in its own carrying case and is ready for use for avoid damage on common use the operator shall be use the Wrist Band adjustable see figure 1 1 Each time the cable Tensiometer is used it shall be removed from the case and the serial number stamped on the nameplate checked against the serial number on the tab of the calibration bar PERFORMANCE The Tensiometer shall be capable for use under extreme conditions of heat or cold without affecting
20. eter reads high Faulty dial indicator 35 Replace dial indicator and calibrate Weak trigger spring 29 Replace trigger spring and calibrate Dirt and foreign matter between frame Clean and reassemble 41 and sectors 24 Tensiometer reads low Worn out sectors 24 or riser Block 5 Replace sectors and riser block then calibrate Faulty dial indicator 35 Replace dial indicator and calibrate Pointer lock will not function Switch spring 30 broken Replace switch spring and calibrate Handle latch will not lock Handle latch spring 39 weak or Replace latch spring Do not calibrate handle in close position broken SOP TN 002 Rev Q T60 Operations and Service Manual SECTION VII CALIBRATION 7 1 EQUIPMENT REQUIRED Calibrating the cable Tensiometer it will be necessary to have aircraft cables of various sizes and a method of accurately loading these cables with a range of loads from 10 to 450 pounds 7 2 DISASSEMBLY PRIOR TO CALIBRATION See Figure 6 Disassemble the instrument following the order of the index numbers starting with index number 1 down through and including index number 10 7 3 CALIBRATION Calibrate the instrument as follows a Move post shaft 12 up and down and check for free movement and that the pointer returns to the same position on the dial indicator each time If binding or erratic indication occurs disassemble the instrument further to ascertain the cause Check for free movement
21. gs easy and accurate Bezel is easily turned to the correct zero setting for the proper cable size determined by the gage in the handle head The T60 is a durable precision instrument and is not damaged by use on cable tensions beyond its range The cable Tensiometer is a hand held instrument A jaw is located at the top of instrument Actual contact on the cable is made by the riser block and the two sectors located in the jaw A sliding yoke slides up the frame of the instrument to provide a measuring force A dial indicator is located at the bottom of the instrument to give the actual tension indication An actuating handle is pivoted at the center of the instrument and is motivated by a trigger spring within the body of the Tensiometer A pointer lock button is situated just above the dial indicator and a handle latch is located on the left side of the frame to engage the detent notch of the actuating handle See figure 1 WARRANTY The T60 cable Tensiometer has a warranty to the original customer for a period of 1 one year on new units and 6 six months for repaired units from the invoice date This warranty is to ensure the cable Tensiometer is free of defects in materials and workmanship under correct and normal use The warranty can be void if the unit has been tampered altered dropped or damaged by an accident All returns must have a Return Material Authorization RMA number In order to obtain a RMA please contact our Quality Departm
22. ndicator cable size Table 5 STD Cable Size to British CWT Cable Size Equivalents INCHES BRITISH CWT 1 16 3 3 32 5 1 8 10 5 32 15 3 16 25 7 32 35 1 4 45 9 32 70 5 16 80 SOP TN 002 Rev Q T60 Operations and Service Manual SECTION VIII GROUP ASSEMBLY PARTS LIST Figure 6 Cable Tensiometer Type C8 and C9 SOP TN 002 Rev Q T60 Operations and Service Manual Table 6 Part List FIG amp UNITS USABLE INDEX PART NUMBER DESCRIPTION PER ON NO ASSY CODE 6 T60 1001 C8 1A TENSIOMETER ASSY Cable REF A T60 1001 C9 1A TENSIOMETER ASSY Cable REF B T60 1002 C8 00 TENSIOMETER ASSY Cable British Model REF C T60 1002 C9 00 TENSIOMETER ASSY Cable British Model REF D 1 COML 0901 100 55 SCREW 4 40 x inch long Phillips oval head 2 2 160012 COVER Head 1 3 15033 3 SHIM Clip 0 003 inch thick A R T5033 5 SHIM Clip 0 005 inch thick A R T5033 10 SHIM Clip 0 010 inch thick A R 4 15018 CLIP 2 5 T5013 BLOCK Riser 1 6 T5020 CLIP Mainspring 2 7 T5019 1 MAINSPRING 1 A C T5019 3 MAINSPRING 1 B D 8 15034 WASHER 2 9 T60032 SCREW Spring adjusting 1 10 1541 SPRING Follower riser 1 11 COML 0901100 48 SCREW 4 40 x 3 16 inch long hexagonal gt socket head cup point black oxide 12 160031 POST Shaft
23. on is a light wipe Explanation D C 33 Dow Corning Grease 33 fluid type or equivalent to NATO G 395 fluid type per MIL PRF 81322 Table 3 Lubrication Chart FIG 6 INDEX NO LUBRICATION LOCATION 20 D C 33 Both sides 23 D C 33 On OD of pins and flat face 26 D C 33 ID and OD 29 D C 33 OD 32 D C 33 OD 38 D C 33 OD 40 D C 33 OD SECTION VI TROUBLE SHOOTING 6 1 GENERAL The instrument will be free from trouble such as would be caused by nominal use The instrument however can be damaged by mistreatment and improper usage If a detail part of the instrument becomes damaged or broken disassemble the instrument in the order of the index numbers indicated on the exploded view Figure 6 All detail parts of the instrument are so integrated that in order to perform a disassembly operation it is necessary that disassembly be started with index number 1 and continued in numerical sequence The only exception to this is the latch mechanism 37 through 40 Figure 6 Reassembly is the opposite of disassembly Whenever the instrument has been disassembled it must be recalibrated See Section VII 6 2 SERVICE TROUBLES AND REMEDIES See table 4 a listing of common troubles together with their probable causes and remedies is presented as a trouble shooting chart table 4 Table 4 Trouble Shooting Chart PROBABLE CAUSE TROUBLE See Figure 6 REMEDY Tensiom
24. ver be allowed to snap open it should be released gradually allowing the unit to clamp firmly on the cable 4 3 MEASURING CABLE DIAMETERS Figure 2 T60 Cable Diameters 1 EXAMPLE INDICATOR CABLE SIZE ALL CABLE SIZE UN E CABLE SIZE GAGE gt STOP PIN HANDLE HANDLE LATCH a With the actuating handle in the latched position move the cable size gage to the left against the cable stop pin See Figure 2a b Release handle latch by squeezing the actuating handle Retain the actuating handle unlatched against the side of the Tensiometer Place the instrument on the cable making certain that the cable is squarely aligned in the jaws and resting on the sectors and riser block Care should be taken that the cable is resting flat against the jaw base Slowly release the actuating handle allowing the sectors to slide up and grip the cable Remove all restraint from the actuating handle See figure 2b c Remove Tensiometer from the cable by returning the actuating handle to the latched position The black line opposite the position on the cable size gage indicates the cable diameter See figure 2c Warning When re latching actuating handle verify that the latch is positioned in the detent socket before releasing the handle If this is not done the handle will be allowed to snap open with possible personal injury SOP TN 002 Rev Q T60 Operations and Service Manual 4 4 TAKING C
Download Pdf Manuals
Related Search