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EFA STORES MANAGEMENT SYSTEM: TANK EJECTOR UNIT (TRAINING NOTES)

EUROFIGHTER TYPHOON AIRCRAFT

TRAINING NOTES

“Airborne Equipment Test, MAINTENANCE & REPAIR to Level 3 forCustomer Service Instructor Personnel”, including familiarisation

for training on:

TANK EJECTOR UNIT(EFA STORES MANAGEMENT SYSTEM)

LCN: X943212, SPE-J-943-M-7022

Prepared and printed by:

Compañía Española de Sistemas Aeronáuticos

Pº. John Lennon, s/n. 28996 Madrid (Spain)

Note: Unmaintained Publication. No amendments possible.

© Compañía Española de Sistemas AeronáuticosPº. John Lennon, s/n. 28996 Madrid (Spain)

Prepared by: A. Consuegra Issue 4 - Date: 11/07/2008 of 162


I. CONTENTSPage

I. CONTENTS............................................................................................................................2

II. INTRODUCTION...................................................................................................................4

III. GENERAL DATA..................................................................................................................5

Technical Data...............................................................................................................5

General Warnings, Cautions and Related Safety Data..............................................6

IV. AEROSPACE GROUND EQUIPMENT (AGE) AND TOOLS..............................................7

V. LIST OF CONSUMABLES..................................................................................................11

SECTION I – TANK EJECTOR UNIT......................................................................................12

CHAPTER 1 DESCRIPTION OF HOW IS MADE & ITS FUNCTION..........................13

CHAPTER 2 REMOVAL PROCEDURE FROM TANK...............................................20

CHAPTER 3 GENERAL FAULT ISOLATION PROCEDURES....................................22

CHAPTER 4 CLEAN AND APPLY SURFACE PROTECTION....................................24

CHAPTER 5 VISUAL EXAMINATIONS.......................................................................25

CHAPTER 6 DISASSEMBLE OF MODULES.............................................................29

CHAPTER 7 ASSEMBLE PROCEDURES..................................................................33

CHAPTER 8 FUNCTIONAL TESTS.............................................................................41

CHAPTER 10 INSTALL PROCEDURE (TEU IN THE FUEL TANK)..........................60

CHAPTER 11 STORAGE PROCEDURES AND DATA...............................................62

SECTION II – BLOCK & BARREL.........................................................................................65

CHAPTER 1 DISSASEMBLE BLOCK AND BARREL ASSY......................................66

CHAPTER 2 – BLOK & BARREL REPAIR PROCEDURE.........................................81

CHAPTER 3 – ASSEMBLE BLOCK & BARREL ASSY..............................................82

SECTION III – BREECH & ELECTRICAL ASSY..................................................................102

CHAPTER 1 – DISSASSEMBLE BREECH & ELECTRICAL ASSY........................103

CHAPTER 2 - ISOLATION UNIT ASSY, REPAIR PROCEDURE..............................107

CHAPTER 3 – ASSEMBLE BREECH & ELECTRICAL ASSY.................................108

SECTION IV – CAM ASSEMBLY..........................................................................................112

CHAPTER 1 - DISASSEMBLE CAM ASSEMBLY.....................................................113

CHAPTER 2 - ASSEMBLE CAM ASSEMBLY...........................................................115

SECTION V – SAFETY KINEMATIC ASSY..........................................................................117

CHAPTER 1 - REMOVE FROM BLOCK AND BARREL ASSY................................118




CHAPTER 2 - SAFETY KINEMATIC ASSY, REPAIR PROCEDURE.......................121

CHAPTER 3 - INSTALL ON BLOCK AND BARREL ASSY......................................122

CHAPTER 4 - REMOVE FROM BREECH AND ELECTRIC ASSY..........................127

CHAPTER 5 - INSTALL ON BREECH AND ELECTRIC ASSY................................134

SECTION VI – BREECH UNIT ASSY...................................................................................148

CHAPTER 1 - DISASSEMBLE BREECH UNIT ASSY..............................................149

CHAPTER 2 - BREECH UNIT ASSY - REPAIR PROCEDURE................................153

CHAPTER 3 - ASSEMBLE BREECH UNIT ASSEMBLY..........................................154




II. INTRODUCTION

These Training Notes give the 3rd level maintenance procedures for the equipment described

on the Title Page.

Training Notes are used as an aid during the training course and can be kept by those

attending the course. However you must not use these Training Notes to perform

maintenance procedures. Only the approved maintenance data documents shall be used.




III. GENERAL DATA

Technical Data

TEU EJECTION SYSTEM:

Type.................................................................... Ram operated (ram included in spigot bolt) .......

Minimum ram area............................................. 490 mm2 .............................................................

Number of cartridges.......................................... 2.........................................................................

Type of cartridge................................................. ARD446..............................................................

NECESSARY POWER FOR THE TEU:

Supply voltage.................................................... between 16 and 30,5 VDC.................................

Fire supply current.............................................. 12,0 A for 50 ms max.........................................

Isolation relay current......................................... 200 mA max each isolation relay .......................

TEU DIMENSIONS:

Length................................................................ 316,3 mm...........................................................

Width.................................................................. 120 mm (without operating handles)..................

Height................................................................. 193,1 mm (without the spigot bolt).....................

Mass................................................................... 20,3 ± 0,1 kg ......................................................

SPIGOT BOLT DIMENSIONS:

Height................................................................. 152 mm..............................................................

Base diameter.................................................... 86 mm................................................................




General Warnings, Cautions and Related Safety Data

++WARNING++

THE TWO GAS CARTRIDGES OF THE TANK EJECTOR UNIT (TEU) BREECH AND

ELECTRICAL ASSEMBLY ARE EXPLOSIVE DEVICES. BEFORE YOU DO WORK ON

THE TEU, REMOVE THE TWO CARTRIDGES.

++WARNING++

THE CARTRIDGE HOLDERS LET YOU SEE IF A CARTRIDGE IS LOADED OR NOT

BY A RED RING AROUND THE CARTRIDGE HOLDER. AN APPROXIMATELY 1MM

BROAD RING INDICATES THAT THE HOLDER IS EMPTY (SAFE CONDITION).

AN APPROXIMATELY 5MM BROAD RING INDICATES THAT THERE IS A

CARTRIDGE INSIDE THE HOLDER — REMOVE CARTRIDGE IMMEDIATELY.

+CAUTION+

MAKE SURE THAT BLANKING CAPS ARE ATTACHED TO THE ELECTRICAL

CONNECTORS IN ORDER TO AVOID DAMAGE OF THE CONNECTORS.

+CAUTION+

DISCARD O-RINGS AFTER REMOVAL AND ALWAYS USE NEW O-RINGS FOR

INSTALLATION.

+CAUTION+

DO A VISUAL EXAMINATION OF EVERY COMPONENT BEFORE INSTALLATION.

MAKE SURE THAT THE COMPONENTS FOR INSTALLATION ARE CLEAN AND

SERVICEABLE.




IV. AEROSPACE GROUND EQUIPMENT (AGE) AND TOOLS

DESCRIPTION:

1. Tank Ejector Unit, Center Fuselage Pylon – List of Tools.

For the list of tools for the Tank Ejector Unit (TEU), refer to Table 1.

EF2000 -List of Tools and Equipment for Equipment Maintenance Part Number Alphanumerical Index

AGERD No. NOMENCLATURE PART NUMBER/ MANUFACTURING DRAWING

AGE DATA SHEET (DMC)/ MANUFAC TURING INFO

Brush 5001–001 -

Caliper (slice gauge)

5003–001 or 5003–002

-

Gauge feelers 5033–002 -

Hammer, soft faced

5039–004 -

Handle Speedbrace

5043–003 -

Circlip Pliers 5062–011 -

Pliers, wiretwisting

5063–001 -

Punch Drift 8 mm 5066–015 -

Screw Driver Bit Holder square/hex drive

5077–001 -

Screwdriver Bit Torque—Set No .1

5080–002 -

Screwdriver Bit Torque—Set No. 2

5080–003 -

Screw driver, flat point

5082–005 -

Screw driver, flat point

5082–013 -

Sliding T-Bar 5089–005 -







Socket Wrench Adapter

5090–002 -

Socket Wrench Adapter

5090–003 -

Hexagonal Plug Socket

5091–005 -

Standard Socket, 6.3mm square, 8 mmbi-hex.

5095–009 -

Standard Socket, 12.5mm square, 17 mm bi-hex.

5097–008 -

Standard Socket, 12.5mm square, 23mm bi-hex.

5097–014 -

Thread Cutting Tap Wrench

5110–006 -

Thread Cutting Tap M3

5111–003 -


5111–009 -


5111–013 -


5111–016 -

Torque Driver 1–13.5Nm

5112–004 -

Ring Spanner 8 mm (for 5165 –002)

5115–084 -

Torque Wrench 20–215 Nm

5119–005 -

Wrench, combination8 mm

5129–006 -


5129–007 -


5129–010 -








5129–012 -

Wrench, combination, 15 mm

5129–013 -

Wrench, combination, 22 mm

5129–020 -


5129–025 -

Crowfoot, 15 mm open end, lock on 10 mm square drive

5135–003 -

Hexagonal key “L”–Type 10 mm

5141–014 -

Wrench Peg Spanner 5147–001 - Wrench (Hand) 6 mm 5149–002 - Torque Handle (for 5115–084)

5165–002 -

Scriber, Engineers (beryllium copper)

5187-002 -

Heat Application Tool 5449–001 - Drip Tray 5710-001 - Power Supply 0–40 VDC -5A

5820–004 -

Enercap Tool 594–02501–160–190

-

Apex Hexagonal Bit Screwdriver Handle 6.3 mm

Local Supply -

Filling Strips (for grooves on the block/barrel cylinder)

TBD -

Insertion/ extraction tool set (for bushes)

X94322120101 Dowel

Mechanic Pressurization Test Set

MC1251 1B1943A0096-00A-066A-A

Metal Strip, approximately 10 * 200 * 0.1 mm

Local Supply -







Electrical Tester, ERU

RX00528 1B-A-AA-0201-00A-066-A

Screw, machine, M4 * (30 to 50)

Local Supply -

Socket Hexagonal Plug

Facom Ent.312

TEU Test Fixture 10002-01 1B-A-AJ-3831-00A-066A-A

Weighing scales Local Supply -




V. LIST OF CONSUMABLES

List of consumables for the tank ejector unit (TEU):

REF. ITEM LCM No.

MATERIAL AND PACKING

MANUFACTURERS REFERENCE AND/OR SPECIFICATION

NATIONAL STOCK No.

SUPP. CODE

SHELF LIFE

SAFETY REMARKS

04–001 Grease, Synthetic

G-353 9150–99– 942–5139

G1000 24 mon DM

04–002 Grease, Graphite

G-355 9150–99– 910–0517

U1553 24 mon DM

04–004 Grease, Multi-Purpose

G-395 9150–99– 224–1797

K6231 24 mon DM

05–002 Nitrogen, Technical

BB-N-411 6830–00– 782–2643

81348 — DM

08–004 Locking Compound

Loctite 270–10ML 8030–99– 224–8707

U0406 12 mon DM

Loctite 270–50ML 8030–99– 224–9318

U0406 12 mon DM

270–10ZN331 8030–12– 182–4878

D3393 12 mon DM

08–021 or

Locking Compound

Loctite 241–50ml or 8030–99– 224–8992

U0406 12 mon DM

08–023 Loctite 242–50ml 8030–99– 225–0248

U0406 12 mon DM

08–043 Adhesive Loctite 638–50ml 8040–99–792–7208U0406

12 mon DM

09-010 Compound, Sealing

PR-1770-A2 8030–99– 747–4318

K0113 9 mon DM

11-032 Isopropyl, Alcohol

IPA or IPA400H

6180-99-450–2886 or 6150-99-830–2856

K6835 or K2337

— —

DM DM

18-060 Lint-free Cloth, White

DEF 1410-1 7920–99– 120–4367

K0851 —

Local Supply

Corrosion Prevention Oil

Dinitrol AV 25 8030–12– 305–8329

C7223 — DM

Local Supply

Wire, Locking 0.711mm

MS20995C32 9505–00– 847–1663

—




SECTION I – TANK EJECTOR UNIT




CHAPTER 1 DESCRIPTION OF HOW IS MADE & ITS FUNCTION

1. General

The Tank Ejector Unit (TEU) (Figure 1) is a subassembly of the Supersonic Fuel Tank

(SFT). The TEU is an ejector unit operated by two cartridges; It can carry and eject an

external fuel tank with a capacity of 1000 liters.

The main components of the TEU are the:

- Block and Barrel Assembly

- Safety Mechanism (Kinematic Assembly)

- Crutching Mechanism

- Breech Assembly

- Electrical Assembly (Isolation Unit and Harness)

1.1 Block and Barrel Assembly

This assembly provides an attachment for the complete unit and a location for the

crutching mechanisms. The ejector piston (9, Figure 2) with its ground safety lock in

the cam (10) are in the Block and Barrel Assembly. The latching element (located in

slots at the upper end of the barrel) is used to latch and keep the tank to the spigot

housing on the aircraft. This is done when the latching element catches between a

groove in the aircraft fitting and a surface on the head of the ejector piston. An

attachment with four bolts attaches the Block and Barrel Assembly to the fuel tank.

1.2 Safety Mechanisms

The Safety Mechanisms has the cam system and a kinematics assembly. The

kinematics joins the cam system to the three-position operating lever (safety handle).

The safety handles have the following three positions:

- SPIGOT UNLOCK

- SAFE

- ARMED




When the safety handle is in the “SPIGOT UNLOCK” position, a cam inside the Block

and Barrel Assembly is rotated to move the piston upwards for manual release.

In the “SAFE” position, the safety mechanisms physically prevents movement of the

release/eject piston. It also interrupts electrically the firing lines.

In the “ARMED” position all the safety is removed and the TEU is ready to be ejected.

1.3 Crutching Mechanism

The Crutching Mechanism has a conical engagement ring which moves upwards to

engage with the spigot housing for the aircraft. The ring moves on a crutching collar

which is located around the barrel. The crutching collar rotates on the barrel and is

operated by a worm-and-wheel gearbox, located on the main mounting block.

1.4 Breech Assembly

Two cartridge holder assemblies (1, Figure 2), an expansion chamber and a

“cartridge-fired” indicator (3, Figure 2) are in the Breech Assembly (7). The firing pins

for the cartridges base in the back of the breech and interface with the electrical

system.

If the cartridges are fired, gas exits through the gas channel (2) from the breech

through the cut-off valve (6). Then the gas passes into the gas channel (4) of the Block

and Barrel Assembly to the base of the ejector piston through a gas tube which

houses a force-control orifice throttle (5, Figure 2).

1.5 Electrical Assembly

The Electrical Assembly has an isolation unit (with the cartridge firing circuitry) on the

back of the breech, a safety switch (operated by the safety handle) and the harness.

The isolation unit has dual redundant firing circuits, each with a connector, surge

limiter, current-limiting resistors, low-pass filter and two relays. The firing connections

are made by sliding connector pins which engage in the backs of the breech firing

pins.




2. Operation

The TEU main operational modes are as following:

- Supersonic Fuel Tank (SFT) Loading

- In-Flight SFT Release

- SFT Off-Loading

On ground, the TEU is operated mechanically through operation points. They are

identified with labels on the SFT aircraft fairing (Figure 3). The labels show the

meaning of the operation points and their positions.

1.6 SFT Loading

For SFT load operation the ground crew must set the safety handle to “SPIGOT

UNLOCK” position.

Then the SFT with the TEU must be moved up towards the carriage position. The SFT

must be moved up until the latching element engages with the groove of the aircraft

fitting. Thus, during automatic latching, the safety kinematic “snaps” into a locked

state. At this moment, the ground safety handle automatically turns into a position

between “SPIGOT UNLOCK STEP2” and the “SAFE” position.

The ground crew must set the safety handle fully into the “SAFE” position. Then a tool

must be inserted into the “SPIGOT PRELOAD” hole (pre-load operating point). With

this tool, the worm of the wormgear of the crutching mechanism can be rotated. When

the worm of the crutching mechanisms is rotated, the gear rotates the crutching collar

to move the conical ring vertically. The worm must be rotated clockwise.

As a consequence, the collar moves vertically downwards compressing a set of disc

springs located under the collar. This compression generates a pre-load force in the

barrel and the safety interlock is unlocked by the disc springs (this interlock is invisible

that means it is different from the mechanical INTERLOCK left above the safety

handle axle).

With the safety interlock unlocked, the safety handle can be turned from the “SAFE” to

the “ARMED” position and back. The “SAFE” position is used on ground, whereas

the “ARMED” position must be selected for flight.




1.7 In-Flight SFT Release

The ejection of the SFT is done by gas pressure from the breech which has two

cartridges (ARD 446). When fired the rapidly expanding gases are transmitted to an

actuator piston which unlocks the latching system and moves the SFT downwards by

the ram (included in the spigot bolt of the piston). To avoid any accidental release on

ground, a dedicated safety handle is available to mechanically and electrically inhibit

the release if turned into the “SAFE” position.

1.8 SFT Off-Loading

For the Off-load operation the safety handle must be set from “ARMED” to “SAFE”

position, then you can remove the pre-load from the crutching system by turning the

SPIGOT PRELOAD counterclockwise.

The tank is now ready to be removed after the mechanical interlock (left, above of the

safety handle axle) is unlocked and the safety handle is turned into the “SPIGOT

UNLOCK” position.




1 Latching Element2 Conical Ring3 Stop Sleeve4 Preload Operating Point5 Cartridge Cap6 Isolation Unit7 Electrical Connector8 Breech Assembly9 Safety Handle10 Mechanical Interlock11 Cartridge Fired Indicator12 Safety Kinematic Assembly13 Gas Channel14 4 Bolt Attachment to SFT15 Safety Interlock16 Block and Barrel Assembly




1 Cartridge Holder Assembly 2 Gas Channel 3 “Cartridge-Fired-Indicator” and Expansion Chamber 4 Gas Channel 5 Orifice Throttle 6 Cut-Off Valve 7 Breech Assembly 8 Block and Barrel Assembly, Cylinder 9 Piston with spring10 Cam Assembly




CHAPTER 2 REMOVAL PROCEDURE FROM TANK

1. PROCEDURE:

1.1 Disconnect the two electrical connectors from the receptacles.

1.2 Remove the two safety handles from the TEU (2). Refer to Figure 1.

1.2.1 Hold the rear safety handle (1, R/H side) and use an allen key to remove the grub

screw (9) from the front safety handle (8, L/H side).

1.2.2 Remove the front safety handle (8) and the front bushing (7).

1.2.3 Remove the rear safety handle (1) and the rear bushing with spring, spring stop and

bar.

1.3 Remove the four bolts (4) that attach the TEU locking plates (3). Remove the locking

plates (3) from the tank.

1.4 Remove the four female bolts (5) and the four washers (4) that attach the TEU (2) to

the tank.

1.5 Remove the four male bolts (10) from the tank.

+CAUTION+

YOU MUST TAKE CARE TO PREVENT ANY DAMAGE TO THE SEAL GROOVE ON THE

TEU SPIGOT.

1.6 Remove the TEU (2) from the tank.

CLOSE UP

1. Install suitable blanking caps on the electrical connectors.




CHAPTER 3 GENERAL FAULT ISOLATION PROCEDURES

1. General

The Tank Ejector Unit (TEU) has mechanic, pneumatic and electric components. If the

failure is already known, it is possible to isolate the failure by doing the associated test

only.

If failure is unknown or if the failure free operation of the TEU has to be tested, do the

complete function test. “Complete” means that the following 3 tests (visual

examinations, leakage test and function test) have to be done in any sequence:

- Visual Examinations,

- Leakage Test,

- Function Test.

1.1 Visual Examinations

This is the simplest of all TEU tests. It tests the mechanic function of the safety

kinematic assembly in the positions “SPIGOT UNLOCK” and “SAFE”, but not in

“ARMED”. It does not test the function of any electrical parts or any pneumatic parts,

either. The visual examinations test should be done on an already tested TEU

immediately before it is installed into the fuel tank pylon.

1.2 Leakage Test

This test tests the pneumatic functions of the TEU in the positions “SAFE” and

“ARMED”. The ejection function itself cannot be tested, because the test works on

reduced pressure and after ejection the TEU is split into parts. But the chance is very

small that a TEU will not eject although it has passed all the leakage test (including

insertion and extraction from the test fixture), the electric test and the visual

examination.

The leakage test must be performed after a TEU has been assembled out of the two

main parts Block and Barrel Assembly and the Breech and Electric Assembly.




1.3 Function Test

This test tests the electric function of the TEU in the positions “SAFE” and “ARMED”. It

tests most of the functions of the TEU, but not the leakage. The TEU must be inserted

into the test fixture during this test. Therefore nearly all mechanical functions are

tested in this test.

Do the function test after repair on electric parts of the TEU. You should do the

function test as first test for troubleshooting, because this test finds most of the TEU

failures.




CHAPTER 4 CLEAN AND APPLY SURFACE PROTECTION

++WARNING++

DRY CLEANING SOLVENT ISOPROPANOL IS A DANGEROUS MATERIAL AND CAN

CAUSE DAMAGE TO YOUR HEALTH. BEFORE YOU USE IT, MAKE SURE YOU KNOW

THE SAFETY PRECAUTIONS AND FIRST AID INSTRUCTION ON:

• THE LABEL OF THE CONTAINER.

• ITS MATERIAL SAFETY DATA SHEET.

• YOUR LOCAL REGULATIONS.

AFTER CONTACT WITH SKIN OR EYES, WASH IMMEDIATELY WITH PLENTY SOAP AND

FLUSH WATER.

++WARNING++

USE CLEANING SOLVENT IN A WELL VENTILATED AREA AND AVOID PROLONGED

BREATHING OF FUMES AND KEEP SOLVENT AWAY FROM OPEN FLAMES.

USE SUITABLE PROTECTIVE CLOTHING DURING ALL CLEANING OPERATIONS.

1. Clean all threaded holes with threat cutting tap wrench (Supp.Equip 5110-006) and

threat cutting tap:

- Supp.Equip Local Supply for M3 holes.




NOTE: Use drip tray (Supp.Equip Local Supply) to wash TEU or TEU parts.

2. Carefully clean non-painted surfaces with brush (Supp.Equip Local Supply).

3. Carefully clean threads of e.g. access plates, ring nuts, cover plates and the piston

head with scriber, engineers (Supp.Equip Local Supply).

4. Clean the tank ejector unit.

1.1 Clean all metal parts with a lint-free cloth (Supply Local Supply) made moist with

isopropanol (Supply Local Supply).

1.2 Dry with a clean lint-free cloth (Supply Local Supply).




5. Overpaint damaged surface parts as necessary.

CHAPTER 5 VISUAL EXAMINATIONS

PROCEDURE:

1. Examine the tank ejector unit for signs of damage (bent/broken control rods, scratches).

2. Examine the cartridge-fired indicator pin (11, Figure 1) to make sure that it is in the

retracted position.

NOTE: If the cartridge-fired indicator pin is extended, manually press it back to the retracted

position.

3. Make sure that the safety handles are in the 7 o’ clock position (SAFE position,

Figure2).

NOTE: If the safety handles are in the 6 o’ clock position, turn them into the 7 o’ clock

position as explained in Step 7.

If the safety handles are in the 9 o’ clock position, the TEU is defective and must be

completely disassembled, and assembled.

4. Make sure that you cannot turn the safety handle (9, Figure 1) into the 6 o’ clock

position (SPIGOT UNLOCK STEP2 position, Figure 2).

5. Make sure that you cannot turn the safety handle (9, Figure 1) into the 9 o’ clock

position (ARMED position, Figure 2).

6. Use a screwdriver (Supp.Equip Local Supply) to turn the mechanical interlock (10,

Figure 1) counterclockwise (approx. 30 degrees). Hold the mechanical interlock (10) in

this position and turn the safety handle to the 6 o’ clock position (SPIGOT UNLOCK

STEP2 position, Figure 2).

NOTE: The piston spring pin at the top of the TEU needs a very high force to insert it. Use

your both hands and for example an aluminium plate to insert the pin. It is also possible to




hold the TEU with your hands and press the piston spring pin against the working plate to

insert it.

7. Depress the piston spring pin until the safety handles move to a position at between 6 o’

clock and 7 o’ clock.

Turn the safety handles into the 7 o’ clock position.




1 Latching Element2 Conical Ring3 Stop Sleeve4 Preload Operating Point5 Cartridge Cap6 Isolation Unit7 Electrical Connector8 Breech Assembly9 Safety Handle10 Mechanical Interlock11 Cartridge Fired Indicator12 Safety Kinematic Assembly13 Gas Channel14 4 Bolt Attachment to SFT15 Safety Interlock16 Block and Barrel Assembly




CHAPTER 6 DISASSEMBLE OF MODULES

NOTE: The position of the safety handles (6, Figure 1) is not important for the disassembly

of the TEU.

1. Use screwdriver Supp.Equip Local Supply to remove the two screws (2 and 7, Figure

1) and the safety kinematic interlink rod (3) between them.

2. Install the two screws (2 and 7) back into their holes and manually tighten only.

NOTE: The safety kinematic interlink rod (3, Figure 1) between the Block and Barrel

Assembly and the Breech and Electric Assembly is not part of the two TEU subassemblies.

Store the interlink rod separately.

3. Use combination wrench Supp.Equip Local Supply to remove the four 6 point bolts (6,

Figure 2) and washers (5).

4. Remove the four 12 point screws (3 and 10, Figure 2) and special washers (4 and 9)

with combination wrench Supp.Equip Local Supply.

NOTE: If necessary, use hammer, soft faced (Supp.Equip Local Supply) to separate the

Block and Barrel Assembly (1) from the Breech and Electric Assembly (7).

5. Remove the Block and Barrel Assembly from the Breech and Electric Assembly.

6. Remove the gas tube orifice throttle (4, Figure 3 ) from the Block and Barrel assembly

gas channel.

7. Remove the O-ring (5, Figure 3 ) from the Block and Barrel assembly gas channel.

8. If the Block and Barrel Assembly must be completely disassembled, remove the safety

kinematic assembly.

9. If the Breech and Electric Assembly must be completely disassembled, remove safety

kinematic assembly.




1 Block and Barrel Assembly2 Screw3 Safety Kinematic Interlink Rod4 Mechanical Interlock5 Breech and Electric Assembly6 Safety Handle

7 Screw




1 Block and Barrel Assembly2 Contact surface3 12 Point Screw (2x, gas channel)4 Special Washer (2x, gas channel)5 Washer (4x)6 6 Point Bolt (4x)7 Breech and Electric Assembly8 gas channel sealing surface9 Special Washer (2x, gas channel)10 12 Point Screw (2x, gas channel)




1 Spring Slide, short version2 Front Cam3 Spring Slide, long version4 Gas Tube Orifice Throttle5 O-Ring




CHAPTER 7 ASSEMBLE PROCEDURES

++WARNING++

LOCTITE IS A DANGEROUS MATERIAL. MAKE SURE THAT YOU

KNOW THE SAFETY PRECAUTIONS AND FIRST AID INSTRUCTIONS

+CAUTION+

MAKE SURE THAT THE WORK AREA IS CLEAN.

+CAUTION+

MAKE SURE THAT ALL PARTS AND TOOLS ARE CLEAN AND SERVICEABLE.

+CAUTION+

BLANKING CAPS AND PROTECTION MUST BE INSTALLED TO THE HOLES AND

THREADS.

1. On the Breech and Electric Assembly, make sure that the safety kinematic (1 to 3,

Figure 1) including the safety handles is installed.

NOTE

If the safety kinematic is not installed, then refer to SECTION V CHAPTER 5.

2. On the Block and Barrel Assembly, make sure that the safety kinematic (1 to 3, Figure

2) is installed on both sides.

NOTE

If the safety kinematic is not installed, then refer to SECTION V CHAPTER 3

3. On the gas channel of the Block and Barrel Assembly, make sure that the gas tube

orifice throttle (4, Figure 2) (Spare) is installed.




4. On the gas channel of the Block and Barrel Assembly, install an O-Ring (5, Figure 2)

(Spare) with Grease, multi purpose (Supp.Equip Local Supply).

5. Remove both cartridge holder caps from the breech and electric assembly with10 mm

hexagon screw key (Supp.Equip Local Supply).

6. Hold the breech and electric assembly such that the two electrical connectors (left side

on Figure 1) face downward and the opening of the gas channel to the block and barrel

assembly faces upward. This position makes sure that Dinitrol AV 25 (Supply Local

Supply) does not flow into the cut off valve.

NOTEOnly apply a very small amount of Dinitrol AV 25.

Only apply a very small amount of Dinitrol AV 25.

7. Spray Dinitrol AV 25 (Supply Local Supply) into the gas openings of both cartridge

chambers of the breech and electric assembly.

8. Clean the openings from unwanted AV 25 with lint-free cloth (Supply Local Supply).

9. Install the two cartridge holders and cartridge holder caps into the breech assembly

(hand tight only).

10.Make sure that the four 6 point bolts (6, Figure 3) and the four 12 point screws (3 and

10, Figure 3 for fixing the Block and Barrel Assembly to the Breech and Electric

Assembly are removed.

11. Apply PR1770 (Supply Local Supply) on both sides of the 4 washers (5, Figure 3) and

apply Loctite 270 (Supply Local Supply) on the threads of the four 6 point bolts (6).

12.Fix the Block and Barrel Assembly (1, Figure 3) to the Breech and Electric Assembly (7)

with the four 6 point bolts (6) and four washers (5) and manually tighten only.

13.Apply PR1770 (Supply Local Supply) on both sides of the 4 special washers (4, 9,

Figure 3).

14.Apply Loctite 270 (Supply Local Supply) on the threads of the 4 screws (3, 10 Figure 3).




15.Fix block and barrel assembly (1, Figure 3) to breech and electric assembly (7) with the

four 12 point screws (3, 10) and four special washers (4, 9). Do not (yet) torque the

screws and bolts.

16.Make sure the torque handle (Supp.Equip Local Supply) is adjusted to 9.0Nm - 10.0

Nm.

17.Put together torque handle (Supp.Equip Local Supply) and ring spanner (Supp.Equip

Local Supply).

18.Torque the four 12 point screws (3,10, Figure 3) of the gas channel to 9.0Nm - 10.0 Nm.

19.Make sure the torque handle (Supp.Equip Local Supply) is adjusted to 5.5Nm - 6.5 Nm.

20.Torque the four 6 point bolts (6, Figure 3) to 5.5Nm - 6,5 Nm.

21.On the Block and Barrel Assembly, surround the sealing surface of the gas channel (8,

Figure 3) with a 2 mm broad stripe of PR 1770 (Supply Local Supply). Do not

completely cover the sealing surface

NOTE

Contact areas are bonding areas and have to be free of sealing compound (referto Block

and Barrel and Breech and Electrical Assy areas).

22.Apply a 2 mm broad stripe of PR1770 (Supply Local Supply) over the gaps at joints

between Block and Barrel Assembly and Breech e.g. around gas tube and around upper

contact surface.

NOTE

Install the safety kinematic interlink rod (3, Figure 4) such that the flat side becomes the

inner side.

23.With a Supp.Equip Local Supply, remove the two screws (2 and 7, Figure 4).

24.




25.With the screw (2, Figure 4), fix the safety kinematic interlink rod (Spare ) to the Block

and Barrel Assembly. Use Supp.Equip Local Supply together with Supp.Equip Local

Supply and Supp.Equip Local Supply to torque the screw to a value between 2,8 Nm

and 4,0 Nm.

26.

27. If necessary, release the mechanical interlock (4, Figure 4) by turning and holding it

counterclockwise and turn the safety handle (6) such that the second screw (7) of the

safety kinematic interlink rod can be inserted.

28.With the screw (2, Figure 4), fix the safety kinematic interlink rod (Spare ) to the Breech

and Electric Assembly. Use Supp.Equip Local Supply together with Supp.Equip Local

Supply and Supp.Equip Local Supply to torque the screw to a value between 2,8 Nm

and 4,0 Nm.

29.Do the visual examinations.

30.Do the leakage test.




1 Operating Body

2 Safety Kinematic Rod and Actuator

3 Countersunk Screw

Figure 1 Safety Kinematic on the Breech and Electric Assembly (Handles removed)




1 Spring Slide, short version

2 Front Cam

3 Spring Slide, long version

4 Gas Tube Orifice Throttle

5 O-Ring

Figure 2 Safety Kinematic on the Block and Barrel Assembly.




1 Block and Barrel Assembly2 Contact surface3 12 Point Screw (2x, gas channel)4 Special Washer (2x, gas channel)5 Washer (4x)6 6 Point Bolt (4x)7 Breech and Electric Assembly8 Gas channel sealing surface9 Special Washer (2x, gas channel)10 12 Point Screw (2x, gas channel)

Figure 3 Connection between the Block & Barrel Assy. and the Breech and Electric Assy.




1 Block and Barrel Assembly2 Screw3 Safety Kinematic Interlink Rod4 Mechanical Interlock5 Breech and Electric Assembly6 Safety Handle7 Screw

Figure 4 Installation of Safety Kinematic Interlink Rod.




CHAPTER 8 FUNCTIONAL TESTS

SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

PROCEDURE:

NOTE

Directions “clockwise” and “counter-clockwise” are only correct when you face the cartridge

holder caps (5, Figure 1).

1. On tank ejector unit (Figure 1), make sure, that the safety handle (9) is turned into the 6

o’clock position (UNLOCKED).

NOTE

If the safety handle is not in the vertical position, use a screwdriver (Supp.Equip Local

Supply) to turn the mechanical interlock (10, Figure 1) counterclockwise to release safety

mechanism, hold it in this position and then turn the safety handle (9) into 6 o’clock;

(UNLOCKED) position.

2. Push the TEU into the test fixture (Supp.Equip) until the safety handle turns into the 7 o’

clock SAFE position.




3. Turn the safety handles clockwise until the mechanical interlock locks. Make sure that

the safety handle cannot be turned back into the 6 o’ clock position and cannot be

turned into the 9 o’ clock position.

NOTE

If the safety handle can be turned into the 6 o’ clock position or 9 o’ clock position, the TEU

is defective.

4. On a sheet of paper, draw a table with four columns and 25 lines. On the top of the

page note the Assembly part number of the block and barrel assembly

(J94330030–.......), the serial number and the date. On the left column, write the

numbers 1 to 25 into each line. On the next column, write “without pre-load” as header.

On the next column write “with pre-load” and on the right column write “pin travel” as

header. Put your signature at the bottom of the list.

5. Use a caliper (slice gauge) (Supp.Equip Local Supply) to measure the distance between

the end of the safety interlock pin (15, Figure 1) and the top access plate of the block

and barrel assembly. Record this distance (unit: millimeter) into column “without pre-

load” of line 1 of the table.

6. Put the socket hexagonal plug 12mm (Supp.Equip Facom Ent.312) with handle

speedbrace (Supp.Equip Local supply) into the preload operating point (wormgear

hexagonal socket) (4, Figure 1).

7. Turn the preload operating point (wormgear) clockwise until the torque increases

significantly.

++WARNING++

DO NOT EXCEED A TORQUE OF 100 NM IN THE TEST FIXTURE

8. Take the torque wrench dial indicator (Supp.Equip Local suppy) instead of the handle

speedbrace and torque the wormgear of the crutching mechanism to 45 Nm.




9. Make sure the safety handle cannot be turned into the 9 o’ clock position (if it can be

turned, the TEU is defective).

10.Torque the wormgear to 80+10Nm (maximum required pre-load application).

11. Make sure the safety handle can be turned into the 9 o’clock position (if cannot be

turned, the TEU is defective).

12.Measure the distance between the end of the safety interlock pin (15, Figure 1) and the

top access plate of the block and barrel assembly. Record this distance (unit: millimeter)

into column “with pre-load” of line 1 of the table.

13.Calculate the difference between the value for “without pre-load” and “with pre-load” and

record this difference into column “pin travel”.

14.At the preload operation point (4, Figure 1), release the crutching mechanism by turning

the wormgear counterclockwise with the torque wrench dial indicator (Supp.Equip Local

supply) until the torque decreases significantly.

++WARNING++

THE CRUTCHING MECHANISM IS NOT RESISTANT AGAINST EXTREME

OVERWINDING IN THE COUNTERCLOCK DIRECTION. THUS, MAKE SURE THE TEU

COMES LOOSE INSIDE THE TEST FIXTURE AND STOP TO ROTATE THE HANDLE

SPEEDBRACE AS SOON AS THE TEU IS LOOSE.

15.Take the handle speedbrace (Supp.Equip Local supply) instead of the wrench dial

indicator and turn wormgear counterclockwise until the TEU comes loose inside the test

fixture (“loose” does not mean that the TEU can already be taken out of the test fixture).

Do not overwind.

16.Repeat Step 5 to Step 15 four times (which means a total of 5). Record the distances

into the appropriate columns in lines 2 to 5 of the table.

16.1 If one of the recorded values for “pin travel” is less than 2 mm, the functional test

has failed. The block and barrel assembly has to be disassembled completely and

re-assembled again. Continue with Step 27.




16.2 If all 5 values recorded for “pin travel” are at least 3,2 mm, the mechanical part of

TEU functional test is successful. Continue with Step 18.

16.3 If Step 16.2 was not successful, continue with Step 17.

17.Repeat Step 5to Step 15 at maximum 20 times and record the values into lines 6 to 25

of the table until the following success/fail criteria are fulfilled:

17.1 If one of the values recorded for “pin travel” is less than 2mm, TEU functional test

has failed. Block and barrel assembly has to be disassembled completely and re-

assembled again. Continue with Step 27.

17.2 If the values for pin travel of three consecutive cycles are at least 3,2 mm AND (!)

the total number of cycles (step 5 to step 15) is less than 26, the mechanical part of

the TEU functional test is successful. Continue with Step 18.

17.3 If the number of cycles (step 5 to step 15) exceeds 25, TEU functional test has

failed. The Block and barrel assembly has to be disassembled completely and re-

assembled again Continue with Step 27.

18.Remove both cartridge holder caps (5, Figure 1) from the TEU with 10mm hexagon

socket screw key (Supp.Equip Local supply).

NOTE

Process for Electrical Tester in customer sites is described hereunder; CESA uses its own

production test tools for student’s comprehensive didactical purposes.

19.From the Electrical Tester, ERU (Supp.Equip ) transport case, take the TEU/ALDERU

dummy cartridge assembly A (red) and install it into the lower breech of the TEU. Take

the TEU/ALDERU dummy cartridge assembly B (green), and install it in the upper

breech of the TEU. Observe all clearances.

20.Take the TEU test loom assembly from the storage box and connect it to the TEU

connections and the dummy cartridge connectors. Make sure the electrical interface is

correct.




21.Connect the TEU Test Loom to the ET (Figure 2), and make sure that all shorting plugs

are installed (for detailed information on the Electrical Tester, ERU.

22.Perform the TEU Loom Test as follows:

22.1 Apply the 230 VAC, 50 Hz or alternatively the 28 VDC electrical supply to the ET,

and set the POWER switch to the selected voltage. One of the power indication

lamps (LP1 or LP2) comes on and the ET performs its self-test routine.

22.2 With the arrow-keys on the keypad select TEU LOOM CON TEST from the menu

OPTION , and press the ENTER key.

22.3 Follow the instructions on the screen to complete the test.

22.4 Set the POWER switch to OFF.

23. Perform the TEU LRI Electrical Test as follows:

23.1 Connect the TEU Test Cable to the ET and to the electrical interface points on the

unit under test (UUT) and the dummy cartridges.

23.2 Apply the 230 VAC, 50 Hz or alternatively the 28 VDC electrical supply to the ET,

and set the POWER switch to the selected voltage. One of the power indication

lamps (LP1 or LP2) comes on and the ET performs its self-test routine.

23.3 With the arrow-keys on the keypad select TEU TEST MENU OPTION, and press

the ENTER key.

23.4 Follow the instructions on the screen to complete the test.

23.5 Set the POWER switch to OFF.

23.6 Remove the TEU dummy test breeches from the ejector chambers of the UUT, and

put them into the ET transport case.

24. Put both cartridge holders and cartridge holder caps into the TEU (hand-tight only).




25. At the pre-load operating point (4, Figure 1) turn the wormgear counterclockwise with

the torque wrench dial indicator (Supp.Equip Local supply) until the torque is

approximately zero, to release the crutching mechanism.

++WARNING++

THE CRUTCHING MECHANISM IS NOT RESISTANT AGAINST EXTREME

OVERWINDING IN THE COUNTERCLOCK DIRECTION. THUS, MAKE SURE THE TEU

COMES LOOSE INSIDE THE TEST FIXTURE AND STOP TO ROTATE THE HANDLE

SPEEDBRACE AS SOON AS THE TEU IS LOOSE.

26. Take the handle speedbrace (Supp.Equip Local supply) instead of the wrench dial

indicator and turn the wormgear counterclockwise, until the TEU comes loose inside the

test fixture (“loose” does not mean that the TEU can already be taken out of the test

fixture). Do not overwind.

27. Turn and hold mechanical interlock (19, Figure 1) counterclockwise and turn the safety

handle (9) into vertical direction (6 o’clock position). The TEU will be released from the test

fixture.

28. Remove the TEU from the text fixture.




Figure 1 TEU, Main Components




CHAPTER 9 LEAKAGE TESTS

SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

PROCEDURE:

1. On tank ejector unit (Figure 1), make sure that the safety handles (9) are turned into the

vertical position (6 o’clock; “SPIGOT UNLOCKED”).

NOTE: If the safety handles are not in the vertical position, use screwdriver Supp.Equip

Local Supply) to turn the mechanical interlock (10, Figure 1) counterclockwise to

release safety mechanism, hold it in this position and then turn safety handles into

vertical position (6 o’clock; “SPIGOT UNLOCKED”).

2. Push tank ejector unit (TEU) (11, Figure 2) into the test fixture (1, Supp.Equip BM-J

2813196–401) until the safety handles turn into the 7 o’ clock position.

3. Turn the safety handles clockwise until the mechanical interlock (8, Figure 2) locks.

Make sure that the handles cannot be turned back into the 6 o’ clock position and

cannot be turned into the 9 o’ clock position.

NOTE: If the safety handles can be turned into the 6 o’ clock position or 9 o’ clock

position, the TEU is defective.




4. If this leakage test is done after the TEU function test, the next steps shall be skipped

and the test shall continue with Step 19. If only this leakage test is done alone, continue

with Step 5.

5. On a sheet of paper, draw a table with four columns and 25 lines. On the top of the

page note the Assembly part number of the block and barrel assembly

(J94330030–.......), the serial number and the date. On the left column, write the

numbers 1 to 25 into each line. On the next column, write “without pre-load” as header.

On the next column write “with pre-load” and on the right column write “pin travel” as

header. Put your signature at the bottom of the list.

6. Using a caliper (slice gauge) (Supp.Equip Local Supply), measure the distance between

the end of the safety interlock pin (15, Figure 1) and the top access plate of the block

and barrel assembly. Record this distance (unit: millimeter) into column “without pre-

load” of line 1 of the table.

7. Put the socket hexagonal plug (Supp.Equip Facom Ent.312) with handle speedbrace

(Supp.Equip Local Supply) into preload operating point (wormgear hexagonal socket)

(4, Figure 1) hexagonal socket.

8. Turn the preload operating point (wormgear) clockwise until the torque becomes

significantly greater.

++WARNING++

UNDER NO CIRCUMSTANCES EXCEED A TORQUE OF 100 NM IN THE TEST

FIXTURE

9. Take the torque wrench dial indicator (Supp.Equip Local Supply) instead of the handle

speedbrace and torque the wormgear of the crutching mechanism to 45 Nm.

10. Make sure the safety handle cannot be turned into the 9 o’ clock position (if it can, the

TEU is defective).

11. Torque the crutching mechanism (wormgear) to 80Nm (maximum required pre-load

application).




12. Make sure the safety handle can be turned into the 9 o’clock position.

13. Measure the distance between the end of the safety interlock pin (15, Figure 1) and the

top access plate of the block and barrel assembly. Record this distance (unit: millimetre)

into column “with pre-load” of line 1 of the table.

14. Calculate the difference between the value for “without pre-load” and “with pre-load”

and record this difference into column “pin travel”.


the wormgear counterclockwise with the torque wrench dial indicator (Supp.Equip Local

Supply) until the torque decreases significantly.

++WARNING++

THE CRUTCHING MECHANISM IS NOT RESISTENT AGAINST EXTREME

OVERWINDING IN THE COUNTERCLOCK DIRECTION. THEREFORE CHECK TEU

TO BECOME LOOSE INSIDE THE TEST FIXTURE AND STOP ROTATING THE

HANDLE SPEEDBRACE AS SOON AS THE TEU IS LOOSE.

16.Take the handle speedbrace (Supp.Equip Local Supply) instead of the wrench dial

indicator and turn wormgear counterclock wise until the TEU becomes loose inside the



17. Repeat Step 6 to Step 16 four times (that means 5 times total). Record the distances

into the appropriate columns in lines 2 to 5 of the table.

17.1 If one of the values recorded for “pin travel” is less than 2 mm, functional test has

failed. Block and barrel assembly has to be disassembled completely and re-

assembled again. Goto Step 50.

17.2 If all 5 values recorded for “pin travel” are at least 3,2 mm, the mechanical part of


17.3 If Step 17.2 was not successful, continue with Step 18.




18.Repeat Step 6 to Step 16 at maximum 20 times and record the values into lines 6 to 25

of the table until the following success/fail criteria are fulfilled:

18.1 If one of the values recorded for “pin travel” is less than 2mm, TEU functional test

has failed. Block and barrel assembly has to be disassembled completely and re-


18.2 If the pin travel values of three consecutive cycles are at least 3,2 mm AND (!) the

total number of cycles (step 5 to step 15) is less than 26, the mechanical part of the


18.3 If the number of cycles from step 5 to step 15 exceeds 25, TEU functional test has

failed. Block and barrel assembly has to be disassembled completely and re-


19.Put the socket hexagonal plug (Supp. Equip Facom Ent.312) with handle speedbrace

(Supp. Equip Local Supply) into preload operating point (wormgear hexagonal socket)

(4, Figure 1) hexagonal socket

20.Turn the preload operating point (wormgear) clockwise until the torque becomes

significantly greater.

++WARNING++

UNDER NO CIRCUMSTANCES EXCEED A TORQUE OF 100 NM IN THE TEST FIXTURE

21.Take the torque wrench dial indicator (Supp.Equip Local Supply) instead of the handle

speedbrace and torque the wormgear of the crutching mechanism to 80 Nm (maximum

required pre-load application).

22.Remove the grub screw of the upper safety handle and remove the upper safety handle.

Only the axle (7, Figure 2) with the second safety handle shall remain.

23.Remove both cartridge (holder) caps (5, Figure 1) from the TEU with 10mm hexagon

socket screw key (Supp. Equip Local Supply).




24.From mechanic pressurization test set (Supp. Equip Local Supply), put the blanking

plug into one breech (6, Figure 2).

25.Put the drilled plug into the other breech (3, Figure 2).

26.From mechanic pressurization test set (Supp. Equip Local Supply), connect the inlet of

the pressure regulator to the 150 bar nitrogen bottle (Local Supply).

27.From mechanic pressurization test set (Supp. Equip Local Supply), connect the outlet of

the pressure regulator to one end of the flexible hose.

28.Connect valve (5, Figure 2) and manometer (4) to the other side of the flexible hose.

29.Connect valve (5) and manometer (4) to the drilled plug (3).

30.Make sure that the (remaining) safety handle is in the 7 o’clock (SAFE) position (if it is

not, turn counterclockwise until it stops due to mechanical interlock (8); the position of

the safety kinematics must now be as shown in figure Figure 1).

31.Ensure the pin of the fired indicator (9, Figure 2) is retracted. If it is not, press down the

pin of fired indicator until it is retracted.

32.Turn off (turn counterclockwise until mechanical limit) the regulating valve on the

pressure regulator in order to minimize nitrogen pressure.

33.Slowly open the valve on the nitrogen bottle and adjust the regulating valve to 10 bar on

the low pressure manometer on the nitrogen bottle armature.

34.Open valve (5, Figure 2) for 3 to 5 seconds and make sure that the manometer (4)

indicates 10 bar and the fired indicator (9) extends or is extended.

35.Close valve (5), wait 5 minutes and during that time watch the pressure descending.

36.When the 5 minutes have passed, note the residual pressure. 1 bar leakage is

allowable.

37.Ensure the (remaining) safety handle is in the 9 o’ clock (ARMED) position (turn

clockwise until it stops).




38.Repeat steps Step 34 to Step 36. The pressure leakage must be smaller now because

in ARMED position the cut-off valve to the block and barrel assembly is open which

means that the size of the volume under pressure is now greater than with cut-off valve

in closed (7 o’ clock = SAFE) position.

39.Close the valve of the 150 bar nitrogen bottle.

40.Turn off (turn counterclockwise until mechanical limit) the regulating valve on the

pressure regulator.

41.Open valve to release nitrogen from the flexible hose; If there is no such valve, carefully

(system might still be under pressure) remove flexible hose from the pressure regulator.

42.Open valve (5, Figure 2) until manometer (4) indicates zero pressure in the TEU, then

close again.

43.Disassemble mechanic pressurization test set into its origin parts.

44.Remove the drilled plug (3, Figure 2) and blanking plug (6) from the breeches.

45.Press down fired indicator pin (9, Figure 2) until it is retracted

46. Install the both cartridge (holder) caps (5, Figure 1) into the TEU

47. Install safety handle (9) with bushing and grub screw such that the grub screw head

looks to the right, down side of Figure 1.


the wormgear counterclockwise with the torque wrench dial indicator (Supp. Equip Local

Supply) until the torque is approximately zero.




++WARNING++

THE CRUTCHING MECHANISM IS NOT RESISTENT AGAINST EXTREME

OVERWINDING IN THE COUNTERCLOCK DIRECTION. THEREFORE CHECK

TEU TO BECOME LOOSE INSIDE THE TEST FIXTURE AND STOP ROTATING

THE HANDLE SPEEDBRACE AS SOON AS THE TEU IS LOOSE.

49.Take the handle speedbrace (Supp. Equip Local Supply) instead of the wrench dial

indicator and turn wormgear counterclockwise until the TEU becomes loose inside the



50.Turn and hold mechanical interlock (10, Figure 1) counterclockwise and turn safety

handles into vertical direction (6 o’ clock position). The TEU will release from the test

fixture.

51.Remove the TEU from the text fixture.




Figure 1 TEU, Main Components




Legend

1 Latching Element

2 Conical Ring

3 Stop Sleeve

4 Preload Operating Point

5 Cartridge Cap

6 Isolation Unit

7 Electrical Connector

8 Breech Assembly

9 Safety Handle

10 Mechanical Interlock

11 Cartridge Fired Indicator

12 Safety Kinematics Assembly

13 Gas Channel

14 4 Bolt Attachment

15 Safety Interlock

16 Block and Barrel Assembly




Figure 2 TEU, inserted into test fixture, with Mechanic Pressurization Test Set




Legend

1 Test Fixture

2 Preload Operating Point

3 Drilled Plug

4 Manometer

5 Valve

6 Blanking Plug

7 Axle (of Safety Handle)

8 Mechanical Interlock

9 Fired Indicator

10 Safety Pin

11 Tank Ejector Unit (TEU)




CHAPTER 10 INSTALL PROCEDURE (TEU IN THE FUEL TANK)

1. Remove the blanking caps from the electrical connectors.

+CAUTION+

YOU MUST TAKE CARE TO PREVENT DAMAGE ANY DAMAGE TO THE SEAL

GROOVE ON THE TEU SPIGOT.

2. Put the TEU (2, Spare J281CMOD200 ) in position in the tank. Refer to Figure 1 .

3. Use four male bolts (10, Spare A2810115-001 ), four female bolts (5, Spare A2810116-

001 ) and four washers (4, Spare A2810267-001 ) to attach the TEU (2) to the tank.

Tighten the bolts with a torque wrench (Supp. Equip 5121-004 ) to make sure that the

torque is 55,4 NM.

4. Put the locking plate (3, Spare A2810261-001 ) in position. Use four bolts (6, Spare

JN0032-04012T ) to attach the plate to the tank. Tighten the bolts with a torque driver

(Supp. Equip 5112-003 ) to make sure that the torque is between 2,0 and 2,5 NM.

5. Install the two safety handles.

5.1 Put the safety handles (1 and 8), the bushings (7), the spring stud the spring stop

and the operating shaft in position.

5.2. Install the shaft into the TEU with the R/H safety handle vertical and the grub screw (9)

looking backwards.

5.3. Install the L/H safety handle vertical with the grub screw (9) looking backwards.

5.4. Use a torque wrench (Supp. Equip 5119-001 ) to make sure that the torque of the grub

screw (Spare DIN916-M3X5-45H ) is between 1,3 and 1,7 NM.

6. Connect the two electrical connectors to the TEU.

CLOSE UP

1. Install the tank/aircraft seal.




Figure 1 Tank Ejector Unit - Installation




CHAPTER 11 STORAGE PROCEDURES AND DATA

PROCEDURE:

1. Packing.

1.1 Make sure the protective caps are installed on the electrical connectors.

1.2 Put the Tank Ejector Unit (TEU) into a PVC bag (Supply Local Purchase).

1.3 Put dehydrating agent (Supply DIN55473) into the PVC bag.

1.4 Close the bag hermetically.

1.5 Attach an identification label to the packing.

1.6 Position the TEU in the transportation container Supp.Equip Local Purchase. Attach

the cradle straps to hold the TEU and close the transportation container.

2. Storage Conditions.

2.1 Keep the TEU in a dry place at an average temperature of 15 C with a relative air

humidity of 55%.

2.2 After 12,5 years of storage, remove the TEU from storage and do the following

procedures:

a. Replace cut-off valve retaining ring and sealing ring as follows:

- Disassemble Breech and Electric Assembly, but only as much as it is

necessary to remove the cut-off valve body.

- Take off and discard all sealing rings e.g. retaining ring, sealing ring and filler

support ring.

- Reassemble Breech and Electric Assembly again with new sealing rings e.g.

retaining ring, sealing ring and filler support ring.

b. Apply a very small amount of Dinitrol AV 25 (Supply Local Supply) as follows:




- Remove both cartridge holder caps from the TEU with 10 mm hexagon

screw key (Supp.Equip Local Supply).

- Hold the TEU such that the two electrical connectors face downward and the

Block and Barrel Assembly faces upward. This position makes sure that

Dinitrol AV 25 does not flow into the cut-off valve.

- Spray small amounts of Dinitrol AV 25 (Supply Local Supply) into the gas

openings of both cartridge chambers.

- Clean the openings from unwanted AV 25 with lint-free cloth (Supply Local

Supply).

- Install the two cartridge holders and cartridge holder caps into the breech

assembly (hand tight only).

c. Replace the O-ring in the gas channel between Block and Barrel Assembly and

Breech and Electric Assembly by disassembling and reassembling the TEU.

d. Replace the sealing ring and scraper ring from the piston and the O-rings from

the cam assembly (and the access plates) from the Block and Barrel Assembly as

follows:

- Disassemble Block and Barrel Assembly, but only as much as it is necessary

to remove the cam and the piston. The top access plate needs not to be

removed.

- Take off and discard all sealing rings e.g. sealing ring and scraper ring from

the piston and O-rings from the cam assembly.

- Reassemble Block and Barrel Assembly again.

e. Do the function test.

f. Do the leakage test.

Put the TEU back into storage.




3. Remove from Storage.

3.1 Open the transportation container lid, remove the cradle straps and remove the

TEU with the PVC bag.

3.2 Remove the TEU from the PVC bag.




SECTION II – BLOCK & BARREL




CHAPTER 1 DISSASEMBLE BLOCK AND BARREL ASSY.

SAFETY CONDITIONS:

++WARNING++

OBEY THE WARNINGS AND CAUTIONS, REFER TO “III GENERAL DATA”

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

NOTE

Make sure that the work area is free from tools and other equipment.

PROCEDURE:

1. Make sure that the Breech and Electric Assembly is disassembled from the Block and

Barrel Assembly.

2. Make sure that the safety kinematics assembly is removed from the Block and Barrel

assembly.

3. Pull out all latching element cams (6, 5, 4, 2, Figure 1) (and those that are not visible in

Figure 1) using a screwdriver and secure the cams with a metal strip (Supp. Equip Local

Supply).

4. Use protective glove (Supply Local Supply) to remove latching element (1, Figure 2).




NOTE

The Block and Barrel Assembly cannot be latched into the test fixture because the latching

element is missing. The test fixture is only helpful to prevent the Block and Barrel Assembly

from turning around when screws are removed.

5. Install the Block and Barrel Assembly (5, Figure 2) into the test fixture (Supp.Equip

1B1943M3831) in a position that the spigot preload operating point (wormgear) (6) is

positioned up.

6. Attach the Block and Barrel Assembly to the test fixture with a screw and a washer (part

of the test fixture) such that the cylinder (4, Figure 2) is nearly half inserted into the test

fixture.

7. Put the socket hexagonal plug 12mm (Supp.Equip Facom Ent.312) with handle speed-

brace (Supp.Equip Local Supply) into the spigot preload operating point (wormgear

hexagonal socket) (6, Figure 2).

8. Turn the wormgear clockwise until the conical ring (2, Figure 2) separates.

9. Remove the Block and Barrel Assembly from the test fixture.

10.Remove the conical ring (2, Figure 2) and the stop sleeve (3, Figure 2).

11. Use combination wrench (Supp.Equip Local Supply) to remove the four screws (1,

Figure 3) and washers (2) from the top access plate (3).

12.Remove the top access plate (3, Figure 3) from the Block and Barrel Assembly (4).

13.Remove the crutching collar (2, Figure 4) from the Block and Barrel Assembly.

14.Remove the inner O-ring (3, Figure 4) and the outer O-ring (1) from the crutching collar

(2).

15.Remove the worm gear (4, Figure 4) from the Block and Barrel Assembly.




16.Remove the four screws (1, Figure 5) and washers (2) from the Block and Barrel

Assembly (7).

17.Remove the worm cover plate (3, Figure 5) from the Block and Barrel Assembly.

18.Remove the worm (5, Figure 5) from the Block and Barrel Assembly.

19.Remove the O-rings (4 and 6, Figure 5) from the worm.

NOTE

The bushes (6 resp. 7, Figure 6) need only be removed if they are worn out or

damaged. In all other cases, the next step needs not to be performed.

20. If the bushes (6 resp. 7, Figure 6) of the worm gear shall be removed, use extraction

tool set (Supp.Equip X94322120101) and drive out the bush(es) with hammer, soft

faced (Supp.Equip Local Supply).

21.Turn the Block and Barrel Assembly (9, Figure 7) upside down and stamp it carefully

onto the working plate to make the following parts come out:

- 23 cup springs (3 to 7, Figure 7) in two different versions (with and without slotted

guide (2)

- 1 preload indicator pin (1) with O-Ring (6, Figure 6)

- 1 cup-shaped spring holder (8, Figure 7)

22.Remove O-Ring (10, Figure 7) from the preload indicator (1, Figure 7).

23. Insert Block and Barrel Assembly (6, Figure 8) into test fixture such that side access

plate (1) and bottom access plate (8) are accessible and fix the Block and Barrel

Assembly to the test fixture with a screw.

24.With heat application tool (Supp.Equip Local Supply), warm up the body around the side

access plate (1, Figure 8) to resolve loctite.

25.Remove side access plate (1, Figure 8) with wrench, combination (Supp.Equip Local

Supply).




26.Remove O-ring (2, Figure 8) from side access plate.

27.Remove cam assembly (4, Figure 8).

28.Remove O-rings (3 and 5, Figure 8) from cam assembly.

29.With heat application tool (Supp.Equip Local Supply), warm up the body around the

bottom access plate (8, Figure 8) to resolve loctite.

30.Remove bottom access plate (8, Figure 8) with wrench, combination (Supp.Equip Local

Supply).

31.Remove O-ring (7, Figure 8) from bottom access plate.

32.Change the position of the Block and Barrel Assembly in the test fixture such that the

top and the bottom of the assembly are free and fix the assembly with a screw.

33.Through the bottom access, drive up the piston assembly (2, Figure 9) with hammer,

soft faced (Supp.Equip Local Supply) and punch drift (Supp.Equip Local Supply), until it

reaches a limit stop (Figure 9).

34.Hold the piston (1, Figure 9) with wrench, combination (Supp.Equip Local Supply) (5,

Figure 9).

NOTE

Brass grows more than steel if heat is applied which means that it might become more

difficult to unscrew the piston head if it is very hot. Therefore heat head for some seconds

only and cool down head with water if it becomes too hot. Repeat this procedure until it is

possible to remove the head.

Once the piston head is loose, always turn the head clockwise and counterclockwise until

the resistance of loctite ceases.

34bis CESA alternative

NOTE




This procedure must be applied if wrench (5, Fig 9) is not available (proceed after steep 23,

Cut-off Valve installed)

Turn the Cam Assy (4, Fig 8) in order to raise the Piston Assy enough to loose the piston

head.

35.With repeated use of heat application tool (Supp.Equip Local Supply) resolve loctite and

unscrew the piston head (1, Figure 9) with wrench peg spanner (Supp.Equip Local

Supply).

36.Remove the piston assembly (2, Figure 9) by pushing it down through the opening of

the Block and Barrel bottom access plate.

37.Remove the scraper ring (10, Figure 10) and sealing ring (8, Figure 10) from the piston

assembly.

38.Disassemble the piston assembly into its parts (3 to 7, Figure 10).

39.Remove the O-ring (2, Figure 10) from the spring pin (3, Figure 10).




Figure 1 Securing the latching element cams with a metal strip

1 Metal Strip2 Latching Element Cam3 Block and Barrel Assembly4 Latching Element Cam5 Latching Element Cam6 Latching Element Cam




Figure 2 Removal of latching element and conical ring

1 Latching Element2 Conical Ring3 Stop Sleeve4 Cylinder5 Block and Barrel Assembly6 Spigot Preload Operating Point (Wormgear)




Figure 3 Removal of the top access plate

1 Screw2 Washer3 Top Access Plate4 Block and Barrel Assembly




Figure 4 Removal of crutching collar and wormgear

1 O-Ring2 Crutching Collar3 O-Ring4 Wormgear5 Block and Barrel Assembly

Figure 5 Removal of the worm

1 Screw

2 Washer




3 Worm Cover Plate

4 O-Ring

5 Worm

6 O-Ring





Figure 6 Bushes for cam assembly and worm gear

1 Side Access Plate2 Bush, Side Access Plate3 Bush, Block and Barrel Housing, Cam4 Hole for Bush, Worm5 Block and Barrel Housing6 Bush, Block and Barrel Housing, Worm7 Bush, Worm Cover Plate8 Worm Cover Plate9 Hole for Bush, Cam

1 Preload Indicator Pin

2 Slotted Guide

3 Cup Spring (13x)

4 Cup Spring with Slotted Guide (2x)

5 Cup Spring (2x)

6 Cup Spring with Slotted Guide (2x)

7 Cup Spring (4x)

8 Spring Holder


10 O-Ring




Figure 7 Arrangement of cup springs in the Block and Barrel Assembly




Figure 8 Cam assembly with access plates

1 Side Access Plate2 O-Ring3 O-Ring4 Cam Assembly5 O-Ring6 Block and Barrel Assembly7 O-Ring8 Bottom Access Plate

Figure 9 Removal of the Piston Head




1 Piston Head2 Piston Assembly3 Slot for Combination Wrench4 Block and Barrel Assembly5 Combination Wrench 27mm6 Peg Spanner




Figure 10 Disassembly of the Piston Assembly1 Piston Head2 O-Ring3 Spring Pin4 Spring5 Washer6 Shim Washer7 Spring Stop8 Sealing Ring9 Piston (body)10 Scraper Ring

CHAPTER 2 – BLOK & BARREL REPAIR PROCEDURE

SAFETY CONDITIONS:+CAUTION+


+CAUTION+

BLANKING CAPS AND PROTECTION MUST BE INSTALLED TO THE HOLES AND THREADS.

NOTETo repair the Block and Barrel Assembly, first locate the defective part.

PROCEDURE:

1. Replace the defective part.

NOTE:

Do not disassemble the Block and Barrel Assembly more than necessary.

2. Depending on the kind of repair, do the following tests after complete assembly (Block

and Barrel Assembly, Breech and Electric Assembly and Safety Kinematic) of the TEU:

- If only a simple mechanic part of the Block and Barrel Assembly has been affected

(e.g. removal of the latching element), do the visual examinations,

- If any part of the gas channel has been affected (e.g. due to removal of any access

plate), do the leakage test.




- In case of doubt or if the Block and Barrel Assembly has been separated from the

Breech and Electric Assembly, do all above tests including the function test, refer to

ensure a successful repair of the Block and Barrel Assembly.

CHAPTER 3 – ASSEMBLE BLOCK & BARREL ASSY.

SAFETY CONDITIONS:

++WARNING++

LOCTITE IS A DANGEROUS MATERIAL. MAKE SURE THAT YOU KNOW THE SAFETY

PRECAUTIONS AND FIRST AID INSTRUCTIONS,

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

PROCEDURE

NOTE:

Do not use grease or oil yet. The threads of the piston head (6, fig.1) must be clean for a

later use of loctite.

1. Make sure there are no O-rings fitted to any part.




2. Make sure that there is a bush (2, Figure 1) fitted in the side access plate (1, Figure 1)

of the Block and Barrel housing (5). If there is no bush fitted, insert a bush (Spare

J94330105–001) with insertion/extraction tool (Supp.Equip X94322120101) and

hammer, soft faced (Supp.Equip Local supply). The bush must be inserted from the

inner side of the side access plate to the outside direction.

3. Make sure that there is a bush (3, Figure 1) fitted in the hole (9, Figure 1) of the Block

and Barrel housing (5). If there is no bush fitted, insert a bush (Spare J94330107–001)

with insertion/extraction tool (Supp.Equip X94322120101) and hammer, soft faced

(Supp.Equip Local supply). The bush must be inserted from inside the Block and Barrel

Assembly in the outside direction.

4. Make sure that there is a bush (7, Figure 1) fitted in the worm cover plate (8,Figure 1) of

the Block and Barrel housing (5). If there is no bush fitted, insert a bush (Spare

J94330075–001) with insertion/extraction tool (Supp.Equip X94322120101) and

hammer, soft faced (Supp.Equip Local supply). The bush must be inserted from the

inner side of the worm cover plate in the outside direction.

5. Make sure that there is a bush (6, Figure 1) fitted in the hole (4, Figure 1) of the Block

and Barrel housing (5). If there is no bush fitted, insert a bush (Spare J94330075–001)

with insertion/extraction tool (Supp.Equip X94322120101) and hammer, soft faced

(Supp.Equip Local supply). The bush must be inserted from inside the Block and Barrel

Assembly in outside direction.

6. Assemble all parts of the piston assembly, as shown in Figure 2, but without sealing ring

(8), scraper ring (11) and O-ring (2). Torque the piston head (1) manually only.

7. Press the piston assembly top down onto a weighing scales (Supp.Equip Local Supply)

until the spring pin (3, Figure 2) begins to retract and read the value of the force.

8. The force when the spring pin begins to retract shall be 214N (21,82Kg) +/- 5%

- In case the force is less then 203,3N (20,79Kg), disassemble the piston assembly,

put in one more shim washer (6, Spare LN65045–14) and restart with Step 6.

- In case the force is within 214N (21,82Kg) +/- 5%, continue with Step 9.




- In case the force is more then 224,7N (22,91Kg), disassemble the piston assembly,

put out one shim washer (6, Spare LN65045–14) and restart with Step 6.

9. Disassemble the piston assembly again.

10. Install O-Rings with multi-purpose grease (Supply 04–004) onto the piston assembly

parts as follows:

- O-Ring Spare 07.10–1.60 72NBR (2, Figure 2) onto the spring pin (3).

- Sealing ring from kit Spare 592–12400–964–01 (8, Figure 2) onto the bottom part

of the piston (9).

- Sealing ring from kit Spare 592–12400–964–01 (11, Figure 2) onto the middle part

of the piston (9).

11. Put the two scraper rings (8 and 11, Figure 12) from kit Spare 592–12400–964–01 into

hot water of 90 ºC + 10º C for a maximum of 10 minutes. After that, cool them in the air

for at least 10 minutes, before you install the scraper rings over the sealing rings.

12.Fix the Block and Barrel Assembly housing (4, Figure 3) on the test fixture (3, Figure 3)

with a screw (5, Figure 3) (DIN 65442-16 120 and washer DIN 125-ST-A17, included in

TEU test fixture set) such that the bottom and the top of the barrel are accessible and

that the hole for the side access plate is up.

13.Apply grease, synthetic (Supply Local supply) to the scraper ring (11, Figure 2), the

sealing ring (8) and the bottom of the piston body (10).

14.Make sure that the piston is turned exactly like shown in Figure 2 (the guide leader pin

(9) at the bottom of the piston will have to catch into the cam assembly when the cam

assembly will be installed).

15. Install/slide the piston — open end first — into the Block and Barrel Assembly housing

through the bottom access plate hole until the sealing ring (8, Figure 2) is inside the

cylinder.




16.Through the bottom access hole, drive up the piston assembly with hammer, soft faced

(Supp.Equip Local supply) and punch drift (Supp.Equip 5066–015),until it reaches a

limit stop (Figure 3).

NOTE:

Do not put grease onto the threads (1, Figure 3) for the piston head. The threads must be

clean for a later use of loctite. Put a paper roll inside the piston top to protect the threads

from grease.

17.Apply grease, synthetic (Supply Local supply) to the spring stop (7, Figure 2), the spring

(4) and the spring pin (3) and assemble piston as follows,

- Install the spring stop (7).

- Install the amount of shim washers (6) that guarantee a preload of 214N (21,82Kg)

+/- 5% (refer to Step 8).

- Install the washer (5).

- Install the spring (4).

18.Make sure the spring pin with the O-ring (3 and 2, Figure 2) is inserted into the piston

head (1).

+CAUTION+

DO NOT PUT LOCTITE ON MORE THAN THE LAST TWO THREADS (THOSE THREADS

THAT WILL GO IN LAST IF THE PISTON HEAD IS SCREWED ONTO THE PISTON) OF

THE PISTON HEAD. TOO MUCH LOCTITE WILL MAKE IT IMPOSSIBLE TO REMOVE

THE PISTON HEAD DURING FUTURE MAINTENANCE.

19.Apply loctite 241 or 242 (Supply 08–021/023) to the last two threads of the piston head.

20.Screw the piston head including spring pin onto the piston.

21.Hold the piston assembly (2, Figure 4) with 27mm wrench, combination (Supp.Equip

5129–025) (5, Figure 4).




21 bis CESA alternative for piston holding

NOTE

This procedure must be applied if wrench (5, Fig 9) is not available (proceed after steep 23,

Cut-off Valve installed)

Proced with previous installation of Cam assy and Side access plate (steps 29 to 32) Turn

the Cam Assy (4, Fig 8) in order to raise the Piston Assy enough to loose the piston head.

22.Torque the piston head (1, Figure 4) with wrench peg spanner (Supp.Equip Local

supply) (6) to make sure it is fully tightened.

23.Put O-ring (Spare BS4518–0371–16) (8, Figure 5) with multi-purpose grease (Supply

04–004) onto the bottom access plate (9, Figure 5).

24.Apply loctite 241 or 242 (Supply Loctite 241/242) to the threads of the bottom access

plate (9, Figure 5).

25. Install bottom access plate and tighten with combination wrench, 14mm(Supp.Equip

Local supply).

26. Install O-ring (Spare 10,00–1,50S72NBR) (3 and 5, Figure 5) with multi-purpose grease

(Supply Grease, Multi Purpose) into the fullering on both ends of the axle of the cam

assembly (4, Figure 5).

27.Apply grease, synthetic (Supply Grease, Synthetic) to all parts of the cam assembly

excluding the area outside the O-rings.

28.Push back the piston into the cylinder until the piston head (not the spring pin) flushes

with the upper end of the cylinder.

29. Install the cam assembly (4, Figure 5) into the Block and Barrel Assembly housing (6,

Figure 5) and turn the cam with hand wrench 6mm (Supp.Equip Local supply) until the

guide leader pin (7, Figure 5) snaps into the guide of the cam and then push the cam

assembly down.




30. Install O-ring (Spare JN01754A0412) (2, Figure 5) with multi-purpose grease (Supply

04–004) onto the side access plate (1).

31.Apply loctite 241 or 242 (Supply Loctite 241/242) to the threads of the side access plate

(1).

32. Install side access plate and tighten with combination wrench 27mm (Supp.Equip Local

supply).

33.Looking at the side access plate, turn the hexagon axle counterclockwise with hand

wrench 6mm (Supp.Equip 5149–002) until it reaches a stop limit (ARMED position). Do

not overwind.

34.Press the piston back into the cylinder once and then turn the hexagon axle clockwise

until it reaches a limit stop. Watch for the following things to happen:

- The axle (the cam assembly) allows to turn for approximately 150 degrees.

- On the last 30 degrees, the piston moves up for approximately 1 cm.

35.Take the Block and Barrel Assembly out of the test fixture.

36.

37.

38.

39. Install an O-ring (Spare JN 0175A0170) (10, Figure 7) with multi-purpose grease (Supply

Grease, Multi Purpose) onto both sides of the worn (5, Figure 7)

40.Apply grease, synthetic (Supply Grease, Synthetic) to the rings (3 to 7, Figure 7), and

the worm (8, Figure 7) of the locking device assembly.

41.From the insertion/extraction tool set (Supp.Equip X94322120101), put the insertion tool

(7, Figure 7) into the back hole of the worm (5, Figure 7).




42. Install/slide the worm including the insertion tool into the Block and Barrel Assembly (8,

Figure 7) and remove insertion tool as soon as the worm is fully inserted.

43. Install the insertion tool into the front hole (12 mm hexagon) of the worm.

44. Install the worm cover plate (3, Figure 7) over the insertion tool and the worm until it

rests in the Block and Barrel Assembly.

45. Remove the insertion tool from the worm.

46. Apply loctite 270 (Supply Loctite 270) to the threads of the four screws (1, Figure 7).

47. Fix the worm cover plate (3, Figure 7) onto the Block and Barrel Assembly (8, Figure 7)

with four washers (2, Figure 7) and four screws (1, Figure 7).

48. Put together torque driver (Supp.Equip Local Supply) and standard socket, 8mm

(Supp.Equip Local Supply).

49. Torque the four screws (1, Figure 7) to 6,5 Nm.

50. Install an O-ring (Spare JN 0175A0170) (10, Figure 8) with multi-purpose grease

(Supply Grease, Multi-Purpose) onto the preload indicator pin (1).

51. Apply grease, synthetic (Supply Grease, Synthetic) onto all cup springs (3 to 7, Figure

8), onto the spring holder (8, Figure 8) and onto the preload indicator pin (1, Figure 8).

NOTE

All cup springs (3 to 7, Figure 8) must be positioned inner side up as shown in section

A-A of Figure 8.

52. Install 4 cup springs without slotted guide (7, Figure 8) into the spring holder (8, Figure

8).

53. Install 2 cup springs (6, Figure 8) with slotted guide (2, Figure 8) into the spring holder

(8, Figure 8) such that the guides reach through the opening of the spring holder,

orientation downwards.




54. Install 2 cup springs (5, Figure 8) without slotted guide, then 2 cup springs (4, Figure 8)

with slotted guide and then 13 cup springs (3, Figure 8) without slotted guides into the

spring holder.

NOTE

The preload indicator pin (1, Figure 8) is built asymmetrically. Insert the indicator pin such

into the slotted guide as shown in section A-A. Only this position ensures that the

indicator pin will fully retract when the correct preload is applied.

55. Insert/install the preload indicator pin into the slotted guide of the lower cup springs (6,

Figure 8) and ensure it is fixed there with grease, synthetic (Supply Grease, Synthetic)

Install the worm cover plate (3, Figure 7) over the insertion tool and the worm until it


56. Install the spring holder (8, Figure 8) with all the springs and the preload indicator pin

over the cylinder into the Block and Barrel Assembly (9, Figure 8) such that the indicator

pin inserts into the appropriate hole. The end of the pin must become visible outside if

correctly assembled.

57. Slightly turn and move the spring holder (8, Figure 8) left and right until it snaps into the

right position (there must be a positioning pin in the block and barrel housing that fits

into a hole at the bottom of the spring holder). When the positioning pin has caught the

hole of the spring holder, the spring holder cannot be turned or moved any more.

58. Install an O-ring (Spare JN 0175A0170) (4 and 6, Figure 7) with multi-purpose grease

(Supply Grease, Multi-Purpose) onto both sides of the worm (5).

59. Apply grease, synthetic (Supply Grease, Synthetic) to the O-rings (4 and 6, Figure 7)

and the worm (5, Figure 7) of the locking device assembly.

60.From the insertion/extraction tool set (Supp.Equip X94322120101), put the insertion tool

(7, Figure 7) into the back hole of the worm (5, Figure 7).

61. Install/slide the worm including the insertion tool into the Block and Barrel Assembly (8,

Figure 7) and remove insertion tool as soon as the worm is fully inserted.




62. Install the insertion tool into the front hole (12 mm hexagon) of the worm.

63. Wet-assemble the worm cover plate face to the Block and Barrel with PR1770A2

(Supply PR1770A2).

64. Install the worm cover plate (3, Figure 7) over the insertion tool and the worm until it


65. Remove the insertion tool from the worm.

66. Apply PR1770A2 (Supply PR1770A2) on the screw heads (1, Figure 7) and washers

(2, Figure 7).

67. Apply loctite 270 (Supply Loctite 270) to the threads of the four screws (1, Figure 7).

68. Fix the worm cover plate (3, Figure 7) onto the Block and Barrel Assembly (8, Figure 7)

with four washers (2, Figure 7) and four screws (1, Figure 7).

69. Put together torque driver (Supp.Equip Local Supply) and standard socket, 8mm


70. Torque the four screws (1, Figure 7) to 6.5Nm.

71. Apply grease, synthetic (Supply Grease, Synthetic) to the wormgear (4, Figure 9),

especially the lower side.

72. Slide/install the wormgear into the Block and Barrel Assembly (6, Figure 9). If

necessary, turn wormgear left and right and press it down until it is flush with the upper

end of the Block and Barrel Assembly housing. Apply grease, synthetic (Supply Grease,

Synthetic) to the cylinder (7, Figure 9) of the Block and Barrel Assembly (6, Figure 9).

73. Apply grease, synthetic to the cylinder (7, Figure 9) of the Block and Barrel Assembly

(6, Figure 9).

74. Install filling strips (5, Figure 9) (Supp.Equip Local supply) into both grooves of the

cylinder and fix the strips with grease, synthetic (Supp.Equip Grease, Synthetic).




75. Install O-Ring (Spare 60,00–1,50572NBR) (3, Figure 9) with multi-purpose grease

(Supply Grease, Multi-Purpose) into the crutching collar (2, Figure 9).

76. Install O-Ring (Spare JN 0175A0670) (1, Figure 9) with multi-purpose grease (Supply

Grease,Multi-Purpose) around the crutching collar (2, Figure 9) into the groove above

the toothwheel.

77. Apply grease, synthetic (Supply Grease, Synthetic) to the crutching collar inner and

outer side.

78. Slide the crutching collar, side with the threads at the top, over the cylinder (7, Figure 9)

into the Block and Barrel Assembly (6). If necessary, turn it left and right and press it

down until the toothwheel fully inserts into its counterpart inside the wormgear

79. Remove the filling strips (5, Figure 18) (Supp.Equip Local supply) from both grooves of

the cylinder.

80. Wet-assemble the top access plate face to the Block and Barrel with PR1770A2

(Supply PR1770A2).

81. Install top access plate (3, Figure 19) onto the Block and Barrel Assembly (4, Figure

19) and position such that the holes for the screws and the shape of the plate matches

to the Block and Barrel Assembly housing.

82.Apply Loctite 270 (Supply Loctite 270) to the threads of the four screws (1, Figure 19).

83. Fix the top access plate (3, Figure 19) onto the Block and Barrel Assembly (4, Figure

19) with four washers (2, Figure 19) and four screws (1, Figure 19) and torque to 6,5

Nm.

84. Apply grease, synthetic (Supply Grease, Synthetic) to the threads of the conical ring (2,

Figure 20).

85. Install the stop sleeve (3, Figure 20) over the cylinder (4, Figure 20) of the Block and

Barrel Assembly (5, Figure 20).




86. Install the conical ring (2, Figure 20) at the cylinder (4, Figure 20) of the Block and

Barrel Assembly (5, Figure 20). If necessary, turn it left and right until the conical ring

slides into the grooves of the cylinder.

87. Install the socket hexagonal plug 12mm (Supp.Equip Facom Ent.312) with handle

speedbrace (Supp.Equip Local Supply) into the wormgear hexagonal socket that means

the spigot preload operating point (6, Figure 20).

88. Carefully turn the handle, speedbrace counterclockwise and let the threads of the

conical ring join into the threads of the crutching collar. Turn until the conical ring

presses slightly against the stop sleeve. Do not overwind.

89. Turn the handle, speedbrace clockwise for approximately one turn.

90. Use protective glove (Supply Local Supply) to install the latching element (1, Figure 20)

onto the top of the cylinder (3, Figure 20) and turn latching element until the cams of the

latching element snap into the grooves of the cylinder.Install 4 cup springs without

slotted guide (7, Figure 7) into the spring holder (8, Figure 7).

91.

92.

93.

94.

95. .




Figure 1 Bushes for cam assembly and worm gear




Figure 2 Assembly of the Piston Assembly




Figure 3 Installation of piston body




Figure 4 Installations of the Piston Head




Figure 5 Cam assembly with access plates




Figure 6 Installation of the worm




Figure 7 Arrangement of cup springs in the Block and Barrel assembly




Figure 8 Installation of wormgear and crutching collar




Figure 9 Installation of the top access plate




Figure 10 Installation of the conical ring and the latching element




SECTION III – BREECH & ELECTRICAL ASSY.

CHAPTER 1 – DISSASSEMBLE BREECH & ELECTRICAL ASSY




SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

NOTE:

When you do the procedure, Make sure that the work area is free from tools and other

equipment.

PROCEDURE:

1. Make sure that the Block and Barrel Assembly is disassembled from the Breech and

Electric Assembly.

2. Make sure that the safety kinematic assembly is removed from the Breech and Electric

Assembly.

3. Remove the nut and washer (12, Figure 1) from the switch (7, Figure 1)

4. Remove the switch (7,Figure 1) from Bracket Switch (13, Figure 1)

5. Put together apex hexagonal bit screwdriver handle (Supp.Equip Local Supply) and

torque-set bit (Supp.Equip Local Supply).

6. Remove the switch (7, Figure 1) from the bracket switch (13, Figure 1).

7. Reinstall nut and washer (12, Figure 1)and tighten by hand.




8. Put together bit screwdriver handle (Supp.Equip Local Supply) and torque-set bit (Supp.

Equip Local Supply).

9. Remove the three screws (1, Figure 1) and washers (2).

10.Remove the two screws (6) and washers (5).

11. Separate Isolation Unit (3) from the Breech Assembly (4).

There is no maintenance planned on the isolation unit. In case that this unit is defective,

it must be completely replaced by a spare.

12.Remove both sealing rings (3, Figure 2) from the cartridge contact holes (2) in the

electric isolation unit (1).




Figure 1 Disassembly of the Breech and Electric Assembly

1 Screws (3x)

2 Washers (3x)

3 Isolation Unit

4 Breech Unit

5 Screws (2x)

7 Switch

8 Connector with Captive Screws

9 Washers (2x)

10 Screws (2x)



13

12


11 Socket

12 Nut & Washer (2x+2x)

13 Bracket Switch

Figure 2 Sealing Rings between Breech Assembly and Isolation Unit




1 Isolation Unit

2 Cartridge Contact Holes

3 Sealing Rings (2x)

CHAPTER 2 - ISOLATION UNIT ASSY, REPAIR PROCEDURE

SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


THREADS.

NOTE

There is no repair for the isolation unit assembly. If this unit is defective, it has to be

replaced completely.

PROCEDURE

1. Replace Isolation Unit Assembly.




CHAPTER 3 – ASSEMBLE BREECH & ELECTRICAL ASSY

SAFETY CONDITIONS

++WARNING++


PRECAUTIONS AND FIRST AID INSTRUCTIONS,

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

PROCEDURE:

1. Apply grease, synthetic (Supply Local Supply) on both O-rings (Spare 100–019–1109)

(3, Figure 2).

2. Install the O-rings (3, Figure 2) into the cartridge contact holes (2, Figure 2) of the

isolation unit (1, Figure 2).

3. Apply Sealant PR1770 (Supply Local Supply) over the contact surface between

Isolation Unit and Breech assembly.

4. Apply loctite 270 (Supply Local Supply) to the threads of all screws (1, 6 and 10, Figure

1).




5. Put the isolation unit (3, Figure 1) onto the breech assembly (4, Figure 1) and fix it with

three screws (1, Figure 1) and washers (2, Figure 1). Do not yet torque the screws.

6. Install the two screws (6, Figure 1) and washers (5, Figure 1). Do not yet torque the

screws.

7. Put together torque driver (Supp.Equip Local Supply), bit holder (Supp.Equip Local

Supply) and torque-set bit no. 2 (Supp.Equip Local Supply).

8. Torque the two screws (6, Figure 2) to 2.8 – 4.0 Nm.

9. Torque the three screws (1, Figure 2) to 2.8 – 4.0 Nm.

10.Put together torque driver (Supp.Equip Local Supply), bit holder (Supp.Equip Local

Supply) and torque-set bit no. 1 (Supp.Equip Local Supply).

11. Remove nut & washer (12, Figure 1)

NOTE

The switch needs to be adjusted. This will be done when the safety kinematic assembly is

installed on the Breech and Electric Assembly.

12. Install electrical switch (7, Figure 1) in the Bracket Switch (13, Fig 1) and install washer

and but (12, Figure 1).

13.



13

12


Figure 1 Disassembly of the Breech and Electric Assembly

1 Screws (3x)

2 Washers (3x)

3 Isolation Unit

4 Breech Unit




5 Screws (2x)

7 Switch

8 Connector with Captive Screws

9 Washers (2x)

10 Screws (2x)

11 Socket

12 Nut & Washer (2x+2x)

13 Bracket Switch




Figure 2 Sealing Rings between Breech Assembly and Isolation Unit

1 Isolation Unit

2 Cartridge Contact Holes

3 Sealing Rings (2x)

SECTION IV – CAM ASSEMBLY




CHAPTER 1 - DISASSEMBLE CAM ASSEMBLY

SAFETY CONDITIONS

++WARNING++

OBEY THE WARNINGS AND CAUTIONS.

NOTE:

When you do the procedure. Make sure that the work area is free from tools and other

equipment.

PROCEDURE:

1. Remove the circlip (3, Figure 1) with circlip pliers (Supp.Equip Local Supply).

2. Remove pin (1) and sleeve (4).

3. Make sure all O-rings are removed.




1 Pin

2 Cam

3 Circlip

4 Sleeve Assembly (with bush)

CHAPTER 2 - ASSEMBLE CAM ASSEMBLY

SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


PROCEDURE:

1. Apply grease, synthetic (Supply Local Supply) to the pin (1, Figure 1).

2. Slide/insert pin (1, Figure 1) into the cam (2, Figure 1) and through the sleeve

assembly (4, Figure 1).

3. Use circlip pliers (Supp.Equip Local Supply) to install circlip (Spare DIN 471–6 x 0.7

phr) (3, Figure 1) into the fullering of the pin (1, Figure 1).

NOTE

The O-rings are not yet fitted to the cam assembly; this will be done during assembly of

Block and Barrel Assembly, refer to 1B-B-94-32-12-01A-710A-C

4. Apply grease, synthetic (Supply Local Supply) to all parts of the cam assembly.




1 Pin

2 Cam

3 Circlip

4 Sleeve Assembly (with Bush)




SECTION V – SAFETY KINEMATIC ASSY




CHAPTER 1 - REMOVE FROM BLOCK AND BARREL ASSY

PROCEDURE:

1. Make sure that the work area is free from tools and other equipment.

NOTE

The following step makes sure that the Block and Barrel Assembly is in the “SAFE”

position.

The piston spring pin at the top of the Block and Barrel Assembly needs a very high force to

insert it. Use your both hands and for example an aluminium plate to insert the pin. It is also

possible to hold the Block and Barrel Assembly with your hands and press the piston spring

pin against the working plate to insert it.

2. Make sure that the actuator, front cam (12, Figure 1) is turned into the position shown in

Figure 1.

NOTE

If the actuator, front cam (12) is not in the position shown in Figure 1, depress the spring

pin on top of the block and barrel cylinder until the actuator, front cam reaches a 1 o’ clock

position, then turn manually into the 2 o’ clock position (maximum clockwise position). On

block and barrel assembly, left side, remove the four screws (1, 14 Figure 1) with flat point

screwdriver Supp.Equip Local Supply.

3. Remove the two spring sliders (2, 13, Figure 1) the spacers (5), washers (7) and nuts

(8).

4. Put together screwdriver handle (Supp.Equip Local Supply) with bit (Supp.Equip Local

Supply).

5. Remove the screw (3).

6. Remove the actuator, front cam (12).




NOTE

The safety kinematic on right (rear) side is mounted in the same way as on the left

(front) side, but mirror-inverted.

7. Turn around Block and Barrel Assembly and remove safety kinematic from the right

(rear) side the same way as it was for the left (front) side.




Figure 1 TEU, Safety Kinematic Assembly on Block and Barrel Assembly, left (front) side

1 Screws (long) (2x) 8 Nut (2x)2 Spring slide (short) 9 Block and Barrel Assembly3 Screw 10 Spring Slide (long), rear side4 Washer 11 Axle of Cam Assembly5 Spacer (2x) 12 Front Cam Actuator6 Hole for Screws (long) (2x) 13 Spring Slide (long)




7 Washer (2x) 14 Screws (short) (2x)

CHAPTER 2 - SAFETY KINEMATIC ASSY, REPAIR PROCEDURE

SAFETY CONDITIONS:

+CAUTION+


+CAUTION+


NOTE:

To repair the safety kinematic assembly, replace the defective part.

PROCEDURE:

1. Remove the defective part of the safety kinematic assembly:

- For safety kinematic on Block and Barrel Assembly.- For safety kinematic on Breech and Electric Assembly.

2. Install the spare part of the safety kinematic assembly:

- For safety kinematic on Block and Barrel Assembly.- For safety kinematic on Breech and Electric Assembly.

NOTE:

Do not remove more parts of the Safety Kinematic Assembly than necessary.

3. Depending on the kind of repair, do the following tests after complete assembly (Block and Barrel Assembly, Breech and Electric Assembly and Safety Kinematic) of the TEU:- If only a simple mechanic part of the safety kinematic has been affected (e.g. removal of a spring slide), do the visual examinations.- If any part of the electric part of the TEU has been affected (e.g. removal of the switch), do the function test.- If any part of the gas channel has been affected (e.g. due to removal of operating body), do the leakage test.- In case of doubt or if the Block and Barrel Assembly has been separated from the Breech and Electric Assembly, do all above tests to ensure a successful repair of thesafety kinematic assembly.




CHAPTER 3 - INSTALL ON BLOCK AND BARREL ASSY

SAFETY CONDITIONS

++WARNING++


PRECAUTIONS AND FIRST AID INSTRUCTIONS.

+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

PROCEDURE

NOTE

The following three steps make sure that the Block and Barrel Assembly is in the “SAFE”

position.

The piston spring pin at the top of the Block and Barrel Assembly needs a very high force to

insert it. Use your both hands and for example an aluminium plate to insert the pin. It is also

possible to hold the Block and Barrel Assembly with both hands and press the piston spring

pin against the working plate to insert it.

1. Make sure that the piston spring pin and the piston at the top of the block and barrel

assembly (9, Figure 1) are retracted. If not, depress the spring pin until pin and piston

are retracted (in Figure 1, the spring pin and piston are not retracted).




2. Put together hexagonal bit screwdriver (Supp.Equip Local Supply) and torque set bit no.

1 (Supp.Equip Local Supply).

3. Install the actuator, front cam (12, Figure 1) onto the axle of the cam assembly (11) as

shown in Figure 1 (2 o’ clock position) and fix it (torque hand tighten only) with the screw

(3).

NOTE

Because of the hexagon shape of the axle it is possible to mount the safety kinematic

assembly in a wrong position. Therefore the following step must be performed very

carefully.

4. Try to turn the front cam actuator (12, Figure 1) clockwise as much as possible until it

reaches a stop. Do not overwind the mechanism.

5. Remove the screw (3, Figure 1) and, if necessary, remove the front cam (12) and put it

back onto the hexagon axle (11) as shown in Figure 1 (2 o’ clock position).

6. Apply Loctite 270 (Supply Local Supply) on the threads of the screw (3, Figure 1).

7. Fix the front cam actuator to the Block and Barrel Assembly with the screw (3, Figure 1)

and a washer (4).

NOTE

The spring slides comprise two main parts:

- (main) part with the spring; long version for the aft spring slide and short version for

the forward spring slide.

- stud male aft (long stud) for the long spring slide or stud male forward (short stud) for

the short spring slide.

The main part with the spring shall not be disassembled. In case the mainpart is

assembled from spare parts, secure the threads of the main partscrews with loctite 241

or 242 (Supply Local Supply).




8. Apply grease, graphite (Supply Local Supply) onto the studs and into the holes of the

spring slides (2 and 13, Figure 1).

9. Assemble one complete long spring slide (13, Figure 1) and one complete short spring

slide (2) by inserting the male studs into the main part with the spring.

10. Install the short spring slide (2, Figure 1) to the Block and Barrel Assembly such that the

side with the stud is next to the actuator (12).

11. Take screwdriver (Supp.Equip Local Supply) to fix the short stud of the short spring slide

(2, Figure 1) to the front cam actuator (12) with one of the two short screws (14).

12. Install the long spring slide (13, Figure 1) to the Block and Barrel Assembly such that

the side with the stud is next to the actuator (12).

13.Fix the long stud of the long spring slide (13, Figure 1) to the front cam actuator (12)

with the second of the two short screws (14).

14. Install one of the long screws (1, Figure 1) through the hole in the main part of the short

spring slide (2), through the spacer (5) and then through the hole (6) of the Block and

Barrel Assembly (9).

15.Fix the screw (1, Figure 1) with washer (7) and nut (8).

16.Fix the long spring slide (13, Figure 1) in the same way.

17.Make sure that the front cam actuator still is in the 2 o’ clock position.

NOTE

The safety kinematic on right (rear) side must be installed in the same way as on the left

(front) side, but mirror-inverted that means the rear spring slide (10, Figure 1) is the same

long version as the front spring slide (13).

18.Turn around Block and Barrel Assembly and put the actuator, rear cam onto the

hexagon axle in the 10 o’ clock position.




19. Apply Loctite 270 (Supply Local Supply) to the threads of the screw similar to (3, Figure

1).

20.Fix the rear cam actuator to the rear axle of the cam assembly with the screw and

washer.

21. Install the long and short spring slides in the same way (but mirror-inverted)

as on the left (front) side.




Figure 1 Safety Kinematic installation (Block and Barrel)

1 Screws (long) (2x) 8 Nut (2x)2 Spring slide (short) 9 Block and Barrel Assembly3 Screw 10 Spring Slide (long), rear side4 Washer 11 Axle of Cam Assembly5 Spacer (2x) 12 Front Cam Actuator6 Hole for Screws (long) (2x) 13 Spring Slide (long)




7 Washer (2x) 14 Screws (short) (2x)

CHAPTER 4 - REMOVE FROM BREECH AND ELECTRIC ASSY

SAFETY CONDITIONS

++WARNING++


+CAUTION+


+CAUTION+


+CAUTION+


THREADS.

NOTE

When you do the procedure, make sure that the work area is free from tools and other

equipment.

PROCEDURE

1. Put together hexagonal bit screwdriver handle (Supp.Equip Local Supply) together with

torque set bit no. 1 (Supp.Equip Local Supply).

2. Hold the rear safety handle (4, Figure 1) against the Breech and Electric Assembly (3) in

order to compensate the force of the spring (6) inside the spring stop (7).

3. On the front side (cartridge side) of the Breech and Electric Assembly (3, Figure 1),

remove the grub screw (9) from the safety handle (1).

4. Remove the safety handle (1, Figure 1) and the front bushing (2).




5. Remove the rear safety handle (4, Figure 1) and the rear bushing (5) with spring (6),

spring stop (7) and bar (8).

6. Remove the split pin (4, Figure 2) and remove the washing damper (washer with steel

and plastic side).

7. Remove the circlip (1, Figure 2) with the circlip pliers (Supp.Equip Local Supply) and

remove the washer.

8. Remove the countersunk screw (7, Figure 2).

9. Remove the cam (6, Figure 2) and the rod (5).

10. If the rod (5, Figure 2) and the cam (6) have to be put into parts, remove the flat point

screw (not visible in Figure 2) that attaches the rod to the cam with flat point screwdriver


11. Turn Breech and Electric Assembly upside down.

12.Remove the mechanical interlock (4, Figure 3) together with the spring.

NOTE

The grub screws (3 and 5, Figure 3) and the actuator (1) are mounted

with loctite. If necessary, warm up the actuator with heat application tool

(Supp.Equip Local Supply) in order to resolve loctite.

13.Remove the grub screw (3, Figure 3) with the hexagon socket screw key.

NOTE

The grub screw (5, Figure 3) is mounted such that the hexagon head looks to the left side

(inner side of the actuator).

The grub screw (5, Figure 3) has to be removed in “reverse direction” that means by

screwing the grub screw back into the inner side of the actuator (1).




14. Insert hexagon socket screw key through the opening of the removed grub screw (3,

Figure 3) and turn the grub screw (5) counterclockwise until the grub screw is free in the

middle of the actuator.

15.Pull out hexagon socket screw key and if necessary, shake the Breech and Electric

Assembly until the grub screw falls out.

16.Remove actuator (1, Figure 3).

NOTE

The grub screw (2, Figure 3) is part of the safety kinematic, but it is recommended to

remove this screw only if it is really necessary.

17. If the Breech and Electric Assembly must be completely disassembled, remove the grub

screw (2, Figure 3).

18.Remove the operating body (1, Figure 4) from the Breech and Electric Assembly (2,

Figure 4).




Figure 1 TEU, Safety Handles on Breech and Electric Assy

1 Safety Handle (front)2 Bushing (front)3 Breech and Electric Assembly4 Safety Handle (rear)5 Bushing (rear)6 Spring7 Spring Stop8 Bar9 Grub Screw




Figure 2 TEU, Safety Kinematic Assy on Breech and Electric Assy, electric assy side

1 Washer and Circlip2 Breech and Electric Assembly3 Operating Body4 Washing Damper and Split Pin5 Rod6 Cam7 Countersunk Screw




Figure 3 TEU, Safety Kinematic Assembly on Breech and Electric Assembly, breech assembly side

1 Actuator2 Grub Screw with Spring Loaded Pin (Do not exist in current configuration)3 Grub Screw (not visible)4 Mechanical Interlock5 Grub Screw




Figure 4 TEU, Safety Kinematic Assy on Breech and Electric Assy, removal of operating body

1 Operating Body2 Breech and Electric Assembly




CHAPTER 5 - INSTALL ON BREECH AND ELECTRIC ASSY

SAFETY CONDITIONS:

++WARNING++

LOCTITE IS A DANGEROUS MATERIAL. MAKE SURE THAT YOU KNOW THE SAFETY PRECAUTIONS AND FIRST AID INSTRUCTIONS.

+CAUTION+


+CAUTION+


+CAUTION+

BLANKING CAPS AND PROTECTION MUST BE INSTALLED TO THE HOLES AND THREADS TO PREVENT DAMAGE.

PROCEDURE:

NOTEIn case that the grub screw (3, Figure 11) has already been mounted and adjusted before this procedure has been started, it might be impossible to fully slide/insert the operating body (1, Figure 12) because the spring loaded pin is extracted. In this case, push back the spring-loaded pin (2, Figure 11) into the grub screw, hold it back and then install the operating body.

1.

2. Apply grease, graphite (Supply Local Supply) onto the slide faces of the operating body (1, Figure 2) and slide the operating body into the breech and electric assembly (2).

NOTE




The grub screw (3, Figure 2) with the spring loaded pin latches the movement of the operating body (1, Figure 3) in three positions (“ARMED”, “SAFE” and “SPIGOT UNLOCKED”). In case the grub screw is not installed deep enough, the operating body can be turned without force and there is no latching at any position; in case the grub screw is installed too deep, the operating body cannot be turned at all. The following step will define the correct position. The following step is only necessary if a grub screw has not already been installed and adjusted before this procedure has been started.

3. In case a new grub screw is inserted in this procedure, turn the operating body and turn the grub screw clockwise until the operating body cannot be turned any more. After that turn the grub screw counterclockwise for approx. 1/2 turn.

4. Turn the operating body into the position shown in figure Figure 4. Slightly turn the operating body left or right until it latches (“SPIGOT UNLOCK” position).

5. Apply loctite 270 (Supply Local Supply) into the hole (5, Figure 5) for the right grub screw

6. Apply loctite 638 (Supply Local Supply) to those parts of the actuator (6, Figure 4) that will get into contact with the operating body (1, Figure 2).

7. Set the actuator (6, Figure 4) in the position as shown in Figure 4 (“SPIGOT UNLOCK”) onto the operating body.

8. Insert the grub screw (3, Figure 4) from the left side. Continue to turn the grub screwwith the hexagon socket screw key (1, Figure 4) until the grub screw passes throughthe middle of the operating body into the threaded hole (5, Figure 4). Turn the grub screw until it mates with the surface of the hole (5).

9. Apply loctite 270 (Supply 08–004) to the grub screw (2, Figure 4).

10. Insert the grub screw (2, Figure 4) again from the left side. Continue to turn the grub screw with the hexagon socket screw key until the grub screw mates with the surface of its hole.

11. If not already assembled, take flat point screwdriver (Supp. Equip Local Supply) and connect cam (1, Figure 5) and flat end of the rod (2) with a flat point screw (screw head not visible in Figure 5).

NOTE:

The axle of the shut off valve is shaped such that the safety kinematic assembly can only be mounted in the correct position. If the kinematic assembly does not fit onto the axle of the shut off valve, it must be turned left or right until the correct position isreached.




12.Stick the cam (1, Figure 5) onto the hexagon axle of the cut off valve as shown in Figure 5. Make sure that the rod (2, Figure 5) is not connected to the pin (3, Figure 5) of the operation body.

13. If necessary, turn the axle of the shut off valve body with the axle of the safety handles until the position is as shown in Figure 5.

14.Take the cam (1, Figure 5) off and put it back again on the hexagon axle such that it is positioned as shown in Figure 5. Make sure that the hole of the rod (2, Figure 5) catches the pin (3, Figure 5) of the operation body. If necessary, turn cam (1, Figure 5) a little bit left or right.

15.Connect hexagonal bit screwdriver handle (Supp. Equip Local Supply) together with screwdriver bit torque set no. 1 (Supp. Equip Local Supply).

16.Fix the cam to the cut off valve with the countersunk screw (8, Figure 6).

17. Install washer (Spare EN2138–05010) (1, Figure 6) onto the rod.

18.Use circlip pliers (Supp. Local Supply) and secure washer with a circlip (Spare LN471–5B).

19.Use gauge feelers (Supp. Local Supply) to measure the gap (7, Figure 6) between the switch (6) and the actuator (4).

20. If the gap (7, Figure 6) has a width of 0.5 mm, continue with Step 21. If not:

- remove locking wire from the nuts of the switch. - adjust gap width (7, Figure 6) with the two nuts (5, Figure 6) to 0.5 mm draw up the

nuts with combination wrenches (Supp.Equip Local Supply) - secure nuts with lock wire Supply MS20995C32 twist the wire with wiretwisting pliers


21.Apply grease. graphite (Supply Local Supply) onto the mechanical interlock (8, Figure 7).

NOTE

Early versions of TEU can have an mechanical interlock (8, Figure 7) with a groove around the hole for the split pin (7). Newer versions do not have this groove. The groove is not important. Both versions of the mechanical interlock may be used as well. However, if the mechanical interlock needs to be replaced, only the ungrooved version is available as spare part.

22. Install the mechanical interlock (8, Figure 7) together with the spring (6) into the Breech and Electric Assembly (2). Wind up the spring such that the lever (9) is spring loaded clockwise (the lever (9) will lock into the gap (1) of the actuator (5) as soon as the actuator is turned clockwise).




23.On the backside of the Breech and Electric Assembly, install the washing damper (Spare J94330265–401) (2, Figure 8) onto the mechanical interlock axle with plastic side down and the steel side visible.

24.Put the split pin (Spare EN2367–18012) (1, Figure 8) into the hole of the mechanicalinterlock.

25.Position the safety handles (1, 4, Figure 9) including bushings (2), spring stud (6), spring stop (7) and operating shaft (8) as shown in Figure 9.

26.Make sure that one safety handle (4, Figure 9) is fixed to the right end of the operating shaft (8) with the grub screw (5).

27. Install/slide the bushing (2, Figure 9), the spring stud (6) and the spring stop (7) ontothe operating shaft (8).

28. Install/slide the operating shaft into the Breech and Electric Assembly (3, Figure 9) such that the safety handle (4) is vertical with the countersunk screw (5) looking backwards.

29. Install the left safety handle (1, Figure 9) such that the safety handle is vertical (as the right safety handle) and the grub screw (5) looks backwards.

30.Check that the safety handles (3, Figure 10) are almost parallel to the actuator (4).

31.Turn and hold the mechanical interlock (8, Figure 7) counterclockwise. Turn the safety handle (1, 4, Figure 9) to the horizontal and vertical position and check the safety kinematic for smooth operation and for latching in the 6 o’clock (vertical), 7 o’clock (45 deg.) and 9 o’clock (horizontal) position.

32.Turn the safety handle into the 9 o’clock position (vertical position; spigot unlocked) and release the mechanical interlock.

33.Turn the safety handle into the 7 o’clock position (45 deg.; safe) and check the mechanical interlock locks (safety handles cannot be turned back into the 9 o’clock position).




Figure 1 TEU-Breech Housing; Grub Screw with spring loaded pin

1 Breech Housing2 Spring loaded Pin3 Grub Screw




Figure 2 TEU, Safety Kinematic Assy on Breech and Elec.Assy, insertion of operating body

1 Operating Body2 Breech and Electric Assembly

Figure 3 TEU, Safety Kinematic Assembly on Breech and Electric Assembly; position of operating body1 Operating Body2 Breech and Electric Assembly




Figure 4 TEU, Safety Kinematic Assy on Breech & Electric Assy, adjustment of the actuator

1 Hexagon socket screw key2 Grub Screw3 Grub Screw4 Breech and Electric Assembly5 Threaded Hole for Grub Screw (3)6 Actuator




Figure 5 TEU, Safety Kinematic Assy on Breech & Electric Assy, adjustment of cut off valve

1 Cam2 Rod3 Operating Body Pin4 Breech and Electric Assembly




Figure 6 TEU, Safety Kinematic Assy on Breech & Electric Assy, installation of cam and rod

1 Washer and Circlip2 Breech and Electric Assembly3 Operating Body4 Cam and Rod5 Nuts6 Switch7 Gap8 Countersunk Screw




Figure 7 Safety Kinematic Assy on Breech & Electric Assy, insertion of mechanical interlock

1 Gap on Actuator2 Breech and Electric Assembly3 Washing Damper4 Split Pin5 Actuator6 Spring7 Hole for Split Pin8 Mechanical Interlock9 Lever




Figure 8 TEU, washing damper and split pin on mechanical interlock

1 Split Pin2 Washing Damper




Figure 9 TEU, Installation of safety handles

1 Safety Handle, left2 Bushings (2x)3 Breech and Electric Assembly4 Safety Handle, right5 Grub Screw (2x)6 Spring Stud7 Spring Stop8 Operating Shaft




Figure 10 TEU, Orientation of the safety handles

1 Breech and Electric Assembly2 Grub Screws (2x)3 Safety Handles (2x)4 Actuator




SECTION VI – BREECH UNIT ASSY




CHAPTER 1 - DISASSEMBLE BREECH UNIT ASSY

SAFETY CONDITIONS:

++WARNING++


+CAUTION+


+CAUTION+


+CAUTION+


NOTE:

When you do the procedure, Make sure that the work area is free from tools and other equipment.

PROCEDURE:

1. Make sure that the breech unit assembly is disassembled from the electric unit.

NOTE:

The expansion chamber (2, Figure 1) is only a hollow screw; therefore there is no maintenance necessary on this item.

2. In case the expansion chamber shall be removed, use heat application tool (Supp. Equip Local Supply) to resolve loctite and 22 mmspanner to remove the expansion chamber.

3. With heat application tool (Supp. Equip Local Supply), warm up ring nut (10, Figure 1) to resolve loctite.




4. Remove ring nut (10) with 22mm combination wrench (Supp. Equip Local Supply).

5. Remove O-ring (11, Figure 1).

6. Use Scriber, engineers (Supp. Equip Local Supply) to remove the two ring nut plugs (9, Figure 1) from the ring nut (10, Figure 1).

7. Install the extractor screw (Supp. Equip Local Supply) (7, Figure 1) at the axle of the cut-off valve body (6, Figure 1).

8. Pull the cut-off valve body out of the breech assembly (1, Figure 1).

9. Remove the two bearings (3, Figure 1).

10.Remove the two retaining rings (4, Figure 1) and sealing rings (5, Figure 1) from the cut off valve body (6, Figure 1).

NOTE:

There is no maintenance planned on the cartridge holder caps. In case that a cartridgeholder cap is defective, it must be completely replaced by a spare.There is no maintenance planned on the firing pin system (electric contact to the cartridge). In case that the firing pin system is defective, the breech unit assembly must be replaced by a spare.There is no maintenance planned on the fired indicator (3, Figure 2) . In case thatthe fired indicator is defective, it must be completely replaced by a spare.

11. In case the fired indicator has to be removed, use heat application tool (Supp. Equip Local Supply), warm up region around fired indicator to resolve loctite and use 15mm spanner to remove the fired indicator assembly together with the breech adaptor (2, Figure 2).

12.The breech adaptor (4, Figure 2) should not be removed from the fired indicator (3, Figure 2) because it is difficult to clean the threads of the fired indicator from loctite. In case the breech adaptor (4, Figure 2) has to be removed from the fired indicator (3, Figure 2), proceed as follows:

Use heat application tool (Supp. Equip Local Supply) to warm up region around fired indicator to resolve loctite.Use two 15mm spanners to remove the breech adaptor from the fired indicator assembly.




Figure 1 Disassembly of breech assembly

1 Breech Assembly2 Expansion Chamber3 Bearing (2x)4 Retaining Ring (2x)5 Sealing Ring (U-Ring) (2x)6 Cut-Off Valve Body7 Extractor Screw M48 Sealing Ring9 Ring Nut Plug (Stopper)10 Ring Nut




11 O-Ring

Figure 2 Removal of the fired indicator

1 Breech Assembly2 Fired Indicator with Breech Adaptor3 Fired Indicator4 Breech Adaptor




CHAPTER 2 - BREECH UNIT ASSY - REPAIR PROCEDURE

SAFETY CONDITIONS:+CAUTION+


+CAUTION+


NOTE:

To repair the Breech Unit Assembly, replace the defective part.

PROCEDURE:

1. Replace the defective part.

NOTE:

Do not disassemble the Breech Unit Assembly more than necessary.

2. Depending on the kind of repair, do the following tests after complete assembly (Block and Barrel Assembly, Breech and Electric Assembly and Safety Kinematic) of the TEU:

- If any part of the electric part of the TEU has been affected (e.g. removal of the electricisolation unit), do the function test, - If any part of the gas channel has been affected (e.g. due to removal of the cut off valve), do the leakage test, - In case of doubt or if the Breech and Electric Assembly has been separated from the Block and Barrel Assembly, do all above tests including the visual examination, refer to ensure a successful repair of the Breech Unit Assembly.




CHAPTER 3 - ASSEMBLE BREECH UNIT ASSEMBLY

SAFETY CONDITIONS:++WARNING++

LOCTITE IS A DANGEROUS MATERIAL. MAKE SURE THAT YOUKNOW THE SAFETY PRECAUTIONS AND FIRST AID INSTRUCTIONS.

+CAUTION+


+CAUTION+


+CAUTION+


PROCEDURE:

1. Apply multi-purpose grease (Supply Grease, Multi-Purpose) on the two sealing rings(U-rings) (3, Figure 2) (Spare 139685) and on the two retaining (backup) rings (2, Figure 2) (Spare 138686) for the cut off valve body.

2. Install the two sealing rings (3, 4, Figure 2) at the cut off valve body (1, Figure 2) as shown in Figure 2.

3. Install the two retaining (backup) rings (2, 5, Figure 2) at the cut off valve body (1, Figure 2) at the outer (back) side of the two sealing rings as shown in Figure 2.

4. Slide/insert the cut off valve body with the rings into the enercap tool (Supp.Equip 594–02501–160–190) and leave it there.

NOTE:

The expansion chamber (2, Figure 1) is usually already installed to the breech housing.

The expansion chamber threads are sealed with loctite 270 (Supply Local Supply)and the expansion chamber is torqued to 100Nm +/- 5 Nm.

5. Make sure that the expansion chamber (2, Figure 1) is installed on the breech assembly (1, Figure 1).




6. Make sure that the fired indicator (2, Figure 3) is installed in the breech assembly (1,Figure 3).

NOTE:

If the fired indicator (2, Figure 3) is installed, continue with Step 15, if not continue with next step(s).

7. Make sure that the breech adaptor (4, Figure 3) and the fired indicator (3, Figure 3) are assembled to one unit (2, Figure 3).

NOTE:

If the breech adaptor is mounted to the fired indicator, continue with Step 12, if not continue with next step(s).

8. Put together torque driver (Supp.Equip Local supply), socket wrench adapter (Supp.Equip Local supply) and crowfoot (Supp.Equip Local supply).

9. Apply Loctite 270 (Supply Loctite 270) on the threads of the breech adaptor (4, Figure 3) (Spare J94330189–001) that will be screwed into the fired indicator.

10.Screw the breech adaptor (4, Figure 3) into the fired indicator (3, Figure 3).

11. Hold the breech adaptor with combination wrench 15mm (Supp.Equip Local supply) and torque on the other end to 7,5Nm +/- 1,5 Nm.

12.Apply loctite 270 (Supply Loctite 270) on the threads of the fired indicator with breech adaptor (2, Figure 3).

13.Put together torque wrench (Supp.Equip Local supply), socket wrench adapter (Supp.Equip Local supply) and crowfoot (Supp.Equip Local supply).

+CAUTION+

DO NOT TORQUE AT THE FIRED INDICATOR (3, Figure 3), BUT AT THE BREECHADAPTOR (4, Figure 3), BECAUSE THE TORQUE BETWEEN FIRED INDICATORAND BREECH ADAPTOR MUST NOT BE MORE THAN 9 NM.

14. Install the fired indicator with breech adaptor (2, Figure 3) and torque at the breech adaptor to 20Nm +/- 2 Nm.

+CAUTION+

• WHEN YOU APPLY GREASE, ALWAYS MAKE SURE IT IS UNCONTAMINATED!• CHECK FOR FOREIGN PARTICLES IN THE REGION OF THE CUT OFFVALVE BODY AND ITS BREECH BORE. CONTAMINANTS THERE CANLEAD TO A JAM OF THE CUT OFF VALVE.

15.Apply grease, multi purpose (Supply Local Supply) onto one bearing (3, Figure 1).




NOTE

Take care not to put grease onto the threads of the hole (11, Figure 1) where the ring nut (9, Figure 1) will be screwed in.

16. Install the bearing (3, Figure 1) into the hole (11) for the cut off valve.

17.Take the cut off valve body with the rings out of the enercap tool (Supp.Equip 594–02501–160–190).

18.On the breech assembly, put grease, multi purpose (Supply Local Supply) into the hole (11, Figure 1) for the cut off valve.

NOTE

The position of the cut off valve body will be exactly determined when the safety kinematic assembly will be installed on the Breech and Electric Assembly.

Turn the cut off valve body (6, Figure 1) such that one gas flow opening of the cut off valve body is to the right side and the other opening is down. Put the cut off valve body in this position into the hole in the breech assembly.

19.Apply grease, multi purpose (Supply Local Supply) onto the second bearing (3, Figure 1).

20. Install the bearing upon the cut off valve body.

21. Install the two ring nut plugs (8, Figure 1) (Spare J94330271–001) with the hole on the outside into the appropriate holes of the ring nut (9, Figure 1) as deep as possible.

22.Apply multi-purpose grease (Supply Grease, Multi-Purpose) onto the sealing ring (7, Figure 1) (Spare ASOB10–18–4–7–88NBR101).

23. Install sealing ring (7, Figure 1) into the ring nut (9, Figure 1).

24.Apply Loctite 241 or 242 (Supply Loctite 241 or 242) onto the threads of the ring nut (9, Figure 1).

25. Install filler support ring (Spare GTK00231) (10, Figure 1) into the hole (11,Figure 1).

26.With combination wrench 22mm (Supp.Equip Local supply), carefully screw the ring nut (9, Figure 1) into its hole (11, Figure 1) , and apply a torque of 10 Nm+.2 Nm to it

27.Make sure that the break-out torque of the cut-off valve is lower than 3 Nm and full movement is lower than 1,5Nm. If both requirements are not OK, perform Step 28.

28.Unscrew the ring nut (9, Figure 1) for 5º and repeat Step 27.




29.Verify that the ring nut plugs (8, Figure 1) stop the ring nut (9, Figure 4) from turning into any direction until loctite is hard.

Figure 1 Assembly of breech assembly




Figure 2 Installation of sealing rings and retaining rings on cut off valve body




Figure 3 Installation of the fired indicator



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