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NOTICE OFCANCELLATIONINCH-POUNDMIL-HDBK1023/4NOTICE 115 December 2006SUPERSEDINGMIL-HDBK-1023/415 May 1991DEPARTMENT OF DEFENSEHANDBOOKMAINTENANCE OF VISUAL AIR NAVIGATION FACILITIESMIL-HDBK-1023/4 dated 30 November 1998 is hereby canceled. For future designcriteria refer to MIL-STD-3007, “STANDARD PRACTICE FOR UNIFIEDFACILITIES CRITERIA AND UNIFIED FACILITIES GUIDE SPECIFICATIONS”.Custodian:Army - CENavy – YDAir Force - 50Preparing Activity:Navy – YD(Project FACR-2007-023)NOTE: The activities listed above were interested in this document as of thedate of this document. Since organizations and responsibilities change, you should verifythe currency of the information above using the ASSIST Online database athttp://assist.daps.dla.mil/.AMSC N/AFACR
INCH-POUNDMIL-HDBK-1023/430 NOVEMBER 1998DEPARTMENT OF DEFENSEHANDBOOKMAINTENANCE OF VISUALAIR NAVIGATION FACILITIESAMSC N/AAREA FACRDISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.
MIL-HDBK-1023/4FOREWORDThis handbook is approved for use by all departments and agencies of the Department ofDefense (DOD).Beneficial comments (recommendations, additions, deletions) and any pertinent data which maybe of use in improving this document should be addressed to: Commander, Naval FacilitiesEngineering Command (NAVFAC), Criteria Office, 1510 Gilbert Street, Norfolk, VA23511-2699, telephone commercial (757) 322-4200, by using the Standardization DocumentImprovement Proposal (DD Form 1426) appearing at the end of this document, or by letter. TheAir Force point of contact is HQ AFCESA/CESE, 139 Barnes Drive, Suite 1, Tyndall AFB, FL32403-5319, telephone commercial (850) 283-6352. The Army point of contact is USACE,CPW, 7701 Telegraph Road, Ft. Belvoir, VA 22060-5580, telephone commercial(703) 806-5163.This handbook was prepared by NAVFAC Criteria Office, Norfolk, VA. The contents weretaken from Federal Aviation Administration (FAA) documents and inputs from variousdepartments of the U.S. Navy, U.S. Army, and the U.S. Air Force. A special thanks toCrouse-Hinds Airport Lighting, Windsor, CT, Mr. Phil Rakowski, who supplied many of thetroubleshooting procedure write-ups and figures.Do not use this handbook as a reference in a procurement document for facilities construction. Itis to be used in the purchase and preparation of facilities planning and engineering studies anddesign documents used for the procurement of facilities construction (scope, basis of design,technical requirements, plans, specifications, cost estimates, request for proposals, and invitationfor bids). Do not reference it in military or federal specifications or other procurementdocuments.ii
MIL-HDBK-1023/4ABSTRACTThis handbook provides recommended guidelines for maintenance of airport, heliport, andhelipad lighted navigational aid facilities. Since the function of such facilities is to assist in thesafe and efficient movement of aircraft during landing, takeoff, and taxiing maneuvers, it isessential that a high degree of operating reliability be maintained. To achieve this, it is necessaryto establish and maintain an effective preventive maintenance program. This handbook providessuggestions for establishing such a program but, due to the varying complexities of airfields andfacilities provided, such a program must be tailored to suit each individual airfield’s particularneeds. Since corrective and preventive maintenance procedures for specific equipment areadequately covered in manuals supplied with the equipment, this handbook addressesmaintenance topics of a more general nature.iii
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MIL-HDBK-1023/4CONTENTSPAGESection 11.11.21.3INTRODUCTIONGeneral .1Scope.1Other Systems.2Section 42.62.72.82.92.102.112.122.132.142.15SAFETYGeneral .8Causes of Accidents.8Safety Procedures and Guidelines .8Two Basic Rules .8Safety Practices.9Personal Safety Precautions .9Safety Boards.10Safety Warning Signs/Danger Tags.11“Danger - High-Voltage” Sign .11“Danger” Tag.12“Danger” Tag Control.12Locks and Padlocks.13Safety Board Inspection .13Safety Checklist.13Electric Shock.13Soldering Safety.14Lightning .15Toxic Agents and Solvents.16Fire Extinguishers .16Grounding.17First Aid.17Safety Training .17Section NTENANCE MANAGEMENTMaintenance Philosophy .18Maintenance Schedule .18Maintenance Records.18Preventive Maintenance Program.19Installation and Material.19Personnel .19Tools and Test Equipment.19Inspection Program .19Preventive Maintenance Inspection (PMI) Schedule.19Record Retention .20Reference Library .20Equipment Technical Manuals .20v
MIL-HDBK-1023/43.7.23.7.33.7.43.83.8.13.8.2PAGEFAA Advisory Circulars (ACs).20Other Technical Data .20As-built Drawings.20Spare Part Provisioning.20Choosing Spare Parts .21Part Identification .21Section 4.11.2ELECTRICAL TEST EQUIPMENTGeneral .22Volt-Ohm-Milliammeter .22General .22Safety .22High-Voltage Measurements.22Switch Settings .22Case Insulation .22Insulation Resistance Tester.23General .23Safety .24High-Resistance Fault Locator.24General .24Safety .25Clamp-on Ammeter .25General .25Safety .26Cable Route Tracer .26General .26Safety .26Impulse Generator/Proof Tester .27General .27Safety .27Acoustic Detector .28General .28Directional Detector.30General .30Safety .31Portable Oil Tester.32General .32Operation.32Ground Resistance Tester .33General .33Safety .33Section 55.15.2PREVENTIVE MAINTENANCEGeneral .35Rotating Beacons Airfield, Helipads, and Heliports .35vi
15.155.15.15.15.25.13Section 66.16.26.36.3.16.46.4.16.56.5.16.6PAGEPreventive Maintenance Inspection (PMI) Procedures.35Wind Cone Assemblies .38Preventive Maintenance Inspection Procedures.38Airport Lighting Vault .40Preventive Maintenance Inspection Procedures.40Recommended Vault Procedures.44Runway and Taxiway Edge Lighting Systems.45Preventive Maintenance Inspection Procedures.45Maintenance Procedures .46Constant Current Regulators .50Preventive Maintenance Inspection Procedures.51Centerline and Touchdown Zone Lighting Systems.53Preventive Maintenance Inspection Procedures.53Maintenance Procedures .56Precision Approach Path Indicator System (PAPI/CHAPI) .59Preventive Maintenance Inspection Procedures.59Maintenance Procedures .61Visual Approach Slope Indicator (VASI).62Airfield Beacons and Obstruction Lights.62Preventive Maintenance Inspection Procedures.62Runway End Identification Lights (REIL).64Preventive Maintenance Inspection Procedures.64Medium Intensity Approach Lighting Systems (MALSR).68Preventive Maintenance Inspection Procedures.68Standby Engine Generator Plants .71Preventive Maintenance Inspection Procedures.71Maintenance Procedures .75High Intensity Approach Lighting Systems (ALSF-1/ALSF-2) .76Illuminated Signs .78Preventive Maintenance Inspection Procedures.78Control Systems.79Energizing and Brightness Control.79Lighting System Control Points .80Maintenance Responsibility .80TROUBLESHOOTING PROCEDURES FOR SERIES LIGHTING CIRCUITSGeneral .81Safety Warning .81Initial Fault Isolation.81Initial Fault Isolation Procedure .81Locating Grounds in the Field Circuit .83Troubleshooting Underground Circuits .83Locating Ungrounded Shorts in Field circuits.95Isolating Ungrounded Shorts.95Locating Opens in Field Circuits.102vii
MIL-HDBK-1023/46.6.16.76.7.16.86.8.1PAGEIsolating Open Circuits .102Overloads in Series Circuits .112Isolating Overloads in Series Circuits.112Input Power Circuits .113Input Power Circuit Fault Isolation .113APPENDIXAPPENDIX A Standards and Tolerances.116FIGURESFigure 0Danger High-Voltage Sign.11Danger Tag .12Typical Volt-Ohm-Milliammeters.23Insulation Resistance Tester (Typical).24Typical High-Resistance Fault Locator .25Typical Ammeters and Current Clamp Probe .26Cable Route Tracer .27Typical Impulse Generator/Proof Tester.28Typical Acoustic Detector.29Use of the Acoustic Detector.30Typical Directional Detector .31Typical Portable Oil Tester .32Typical Ground Resistance Tester.34Cleaning Centerline and Touchdown Zone Lights.57PAPI Configuration .60REIL Layout.66REIL Aiming .67MALSR Configuration.71ALSF-1 Block Diagram .76ALSF-2 Block Diagram .77Typical Load Circuit With S1 Cutout - No Faults.84Typical Load Circuit With S1 Cutout - Single Ground on Load .85Typical Load Circuit With S1 Cutout - Two Grounds on Load.86Regulator Connected to Typical S1 Cutout and IntentionalGround Switch With Ground Current Indicating Circuit.87Single Ground on Load Circuit - Intentional Ground.88Two Grounds on Load Circuit Intentional Ground Method .89Regulator Connected to Typical S1 Cutout and Ground ReturnSwitch With Ground Current Indicating Circuit .91Single Ground on Load Circuit – Ground Return Method .92Two Grounds on Load Circuit – Ground Return Method.93Sectional Isolation Method – Megger Tests.94viii
ectional Isolation Method – Megger Tests Locate GroundedSection of Load.95Single Short on Load .97Single Load-to-Load Short.98Single Load-to-Load Short Circuit Integration Method .99Two Load-to-Load Shorts .100Two Load-to-Load Shorts - Circuit Integration Method .101Grounded Open on Load Circuit - Intentional Ground Method.103Grounded Open on Load Circuit Ground Return Method .104Ungrounded Open on Load Circuit Manual – Ground MethodFirst Test.106Ungrounded Open on Load Circuit – Manual Ground MethodSecond Test .107Ungrounded Open on Load Circuit Manual – Ground MethodThird Test .108Ungrounded Open on Load Circuit Manual – Ground TestFourth Test .109Sectional Isolation Method - Megger Confirms Open onLoad Circuit.110Sectional Isolation Method - Megger Confirms ContinuityBetween L2 and Inserted Ground .111Sectional Isolation Method - Megger Confirms Open BetweenL1 and Inserted Ground .112TABLESTable 12345678910111213List of Standards and Specifications.2List of FAA ACs.3List of Department of Defense (DOD) Publications.5Additional Reference Documents.7Types of Fire Extinguishers .16Preventive Maintenance Inspection Schedule for Rotating Beacons38Preventive Maintenance Inspection Schedule for Wind Cones .40Preventive Maintenance Inspection Schedule for Airport LightingVault.43Table of Initial Resistance Values Versus Circuit Length .43Table of Insulation-Resistance Test Values for Field Circuits.44Preventive Maintenance Inspection Schedule for Runway andTaxiway Edge Lighting Systems .47Preventive Maintenance Inspection Schedule for ConstantCurrent Regulators.53Preventive Maintenance Inspection Schedule for Centerline andTouchdown Zone Lighting Systems .56ix
A-8.Preventive Maintenance Inspection Schedule for PrecisionApproach Path Indicator (PAPI) System .Preventive Maintenance Inspection Schedule for Hazard Beaconsand Obstruction Lights.Preventive Maintenance Inspection Schedule for Runway EndIdentifier Lights (REIL) .Preventive Maintenance Inspection Schedule for Medium IntensityApproach Lighting Systems (MALSR) .Preventive Maintenance Inspection Schedule for Standby EngineGenerator Plants.Preventive Maintenance Inspection Schedule for High-IntensityApproach Systems (ALSF-1/ALSF-2).Preventive Maintenance Inspection Schedule for Illuminated Signs .Beacons .Medium Intensity Approach Lighting Systems With Flashers(MALSR).High Intensity Approach Lighting Systems With Flashers(ALSF-1/ALSF-2) .Runway End Identifier Lights (REIL) .Precision Approach Path Indicator (PAPI)/Chase Helicopter Approach Path Indicator (CHAPI) Systems .Runway and Taxiway Lighting Systems.Photoelectric Devices.Standby Engine Generators.GLOSSARY .xPAGE61646870757880117117118119120121122123124
MIL-HDBK-1023/4Section 1: INTRODUCTION1.1General. This handbook provides the recommended minimum guidance, to be used inconjunction with information available in instruction books, advisory circulars, and otherhandbooks, for the maintenance of lighted navigational aids. Additional information is availablein FAA Advisory Circular AC 150/5340-26, Maintenance of Airport Visual Aid Facilities, andFAA Order 6850.5, Maintenance of Lighted Navigational Aids.1.2Scope. This handbook provides system maintenance information and establishes amaintenance program for lighted navigational aids. The information provided covers thefollowing systems, subsystems, or components:a) Airport and heliport beaconsb) Wind cone assembliesc) Airfield lighting vaultsd) Constant current regulatorse) Isolation transformersf) Runway and taxiway light systems(1) Elevated fixtures(2) In pavement fixturesg) Runway centerline and touchdown lighting systemsh) Precision approach path indicator (PAPI) and chase helicopter approach pathindicator (CHAPI) systemsi) Obstruction lightsj) Runway end identifier lights (REIL)k) Medium intensity approach light system with flashers (MALSR)l) Approach light system with sequence flashers (ALSF-1/ALSF-2)m) Standby engine generator plants1.3Other Systems. There are a number of DOD lighted navigational aids that have theirown maintenance and troubleshooting procedure manuals, which are not included in thishandbook, such as: Mirror Optical Visual Landing Aid System (MOVLAS) USN, Fresnel LensOptical Landing System (FLOLS) USN, and Emergency Airfield Lighting System (EALS)1
MIL-HDBK-1023/4USAF. Tables 1, 2, 3, and 4 list documents where additional guidance may be found for themaintenance of lighted navigational aids.a) A complete listing of FAA advisory circulars, including those referenced in Table 2as well as other airport planning documents, can be found on the world wide web (www) homepage menu located at: http://www.faa.gov, and choose “airports” from the menu. For otherFAA publications, write to the Department of Transportation, Distribution Unit, Washington, DC20590.b) For Navy publications, including those referenced in Table 3, write to:Commanding Officer, Naval Air Technical Services Facility, 700 Robbins Ave., Philadelphia,PA 19111-5097.c) Air Force documents, including those referenced in Tables 3 and 4, are located inthe Air Force Electronic Publishing Library, which is located at: ) For Army documents, including those referenced in Table 3, write to: Commander,USACE Publications Depot, ATTN: CEIM-IM-PD, 2803 52nd Avenue, Hyattsville, MD 207811102.e) Additional DOD publication resources are located at:http://www.defenselink.mil/pubs/.DOCUMENT FAA-E-2756FAA Drawing C-6046AFAA Drawing C-6076FAA Drawing D-6155Table 1List of Standards and SpecificationsTITLEStructural SteelPAR 56 Lamp HolderLight Base and Transformer HousingRunway End Identifier Lighting System (REIL)Medium Intensity Approach Light System with Alignment IndicatorLightsApproach Light, Semi-flush, Steady BurningSequenced Flashing Lighting System Elevated and Semi-flush withDimming and MonitoringDual Mode High Intensity Approach Lighting System (ALSF-2/SSALR)Low Impact Resistant StructuresFour Box PAPIFrangible Coupling Type 1 and Type 1A, DetailsALSF-2 Approach Lighting System 6’-0” to 128’-0” Low ImpactResistant (LIR) StructuresALSF-2, 6’ to 128’ and MALS, 40’ to 128’ LIR Structures2
MIL-HDBK-1023/4Table 2List of FAA ACsDOCUMENT NO.AC 70/7460-1AC 150/5200-18AC 150/5210-5AC 150/5300-13AC 150/5340-18AC 150/5340-26AC 150/5345-3AC 150/5345-5AC 150/5345-7AC 150/5345-10AC 150/5345-12AC 150/5345-13AC 150/5345-26AC 150/5345-27TITLE AND DESCRIPTIONObstruction Marking and Lighting. Describes the FAA standards formarking and lighting structures to promote safety.Airport Safety Self-Inspection. Provides information to airport operations onself-inspection programsPainting, Marking, and Lighting of Vehicles Used on an Airport. Providesguidance, specifications and standards in the interest of airport personnelsafety and operational efficiency, for painting, marking and lighting ofvehicles.Airport Design. Contains the FAA standards for airport design.Standards for Airport Sign Systems. Contains standards for siting andinstallation of runway and taxiway signs.Maintenance of Airport Visual Aid Facilities. Provides recommendedguidelines for maintenance of airport visual aid facilities.Specification for L-821 Panels for Remote Control of Airport Lighting.Contains the specification requirements for panels used for remotecontrol of airport lighting systems.Circuit Selector Switch. This advisory circular contains a specification for acircuit selector switch for use in airport lighting circuits.Specification for L-824 Underground Electrical Cable for Airport LightingCircuits. Describes the specification requirements for L-824 electricalcables.Specification for L-828 Constant Current Regulators Regulator Monitors.Contains a specification for constant current regulators, used on airportlighting circuits, and for a monitor that reports on the status of theregulator.Specification for Airport and Heliport Beacon. Contains equipmentspecifications for light beacons which are used to locate and identify civilairports, seaplane bases, and heliports.Specification for L-841 Auxiliary Relay Cabinet Assembly for Pilot Controlof Airport Lighting Circuits. Contains the specification requirements fora relay cabinet used to control airfield lighting circuits. The L-841consists of an enclosure containing a DC power supply, control circuitprotection and 20 pilot relays.Specification for L-823 Plug and Receptacle, Cable Connectors. Describesthe subject specification requirements.Specification for Wind Cone Assemblies. This advisory circular contains aspecification for wind cone assemblies to be used to provide windinformation to pilots of aircraft.3
MIL-HDBK-1023/4Table 2List of FAA ACs (Continued)DOCUMENT NO.AC 150/5345-28AC 150/5345-42AC 150/5345-43AC 150/5345-44AC 150/5345-45AC 150/5345-46AC 150/5345-47AC 150/5345-49AC 150/
Crouse -Hinds Airport Lighting, Windsor, CT, Mr. Phil Rakowski , who supplied many of the troubleshooting procedure write-ups and figures. Do not use this handbook as a reference in a procurement document for facilities construction. It is to be used in the purchase and prepa
