TEU Course Training Notes Issue 4 (11!07!2008)

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

TRAINING NOTES
Airborne Equipment Test, MAINTENANCE & REPAIR to Level 3 for
Customer 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:

Compaa Espaola de Sistemas Aeronuticos
P. John Lennon, s/n. 28996 Madrid (Spain)
Note: Unmaintained Publication. No amendments possible.

Prepared by: A. Consuegra

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I. CONTENTS
Page
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


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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


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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.


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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................................................................


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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.


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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
Brush
Caliper (slice
gauge)
Gauge feelers
Hammer, soft
faced
Handle
Speedbrace
Circlip Pliers
Pliers,
wiretwisting
Punch Drift 8 mm
PART NUMBER/
MANUFACTURING
DRAWING
AGE DATA
SHEET (DMC)/
MANUFAC
TURING INFO
5001001
5003001 or
5003002
5033002
5039004
5043003
5062011
5063001
5066015
Screw Driver Bit

Holder square/hex
drive
5077001
Screwdriver Bit
TorqueSet No .1
5080002
Screwdriver Bit
TorqueSet No. 2
5080003
5082005
5082013
5089005
Screw driver, flat

point
Screw driver, flat
point
Sliding T-Bar


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AGERD No.
NOMENCLATURE
PART NUMBER/
MANUFACTURING
DRAWING
AGE DATA
SHEET (DMC)/
MANUFAC
TURING INFO
Socket Wrench
Adapter
5090002
5090003
5091005
5095009
5097008
5097014
5110006
5111003
5111009
5111013
5111016
5112004
5115084
5119005
5129006
5129007
5129010
Socket Wrench
Adapter
Hexagonal Plug
Socket
Standard Socket,
6.3mm square, 8 mm
bi-hex.
Standard Socket,
12.5mm square, 17
mm bi-hex.
Standard Socket,
12.5mm square,
23mm bi-hex.
Thread Cutting Tap
Wrench
Thread Cutting Tap
M3
Thread Cutting Tap
M4
Thread Cutting Tap
M5
Thread Cutting Tap
M6
Torque Driver 113.5
Nm
Ring Spanner 8 mm
(for 5165 002)
Torque Wrench 20
215 Nm
Wrench, combination
8 mm
Wrench, combination
9 mm
Wrench, combination
12 mm


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AGERD No.
NOMENCLATURE
PART NUMBER/
MANUFACTURING
DRAWING
AGE DATA
SHEET (DMC)/
MANUFAC
TURING INFO
Wrench, combination
14 mm
5129012
5129013
Wrench,
combination, 15 mm
Wrench,
combination, 22 mm
Wrench, combination
27 mm
Crowfoot, 15 mm
open end, lock on 10
mm square drive
Hexagonal key L
Type 10 mm
Wrench Peg Spanner
Wrench (Hand) 6 mm
Torque Handle (for
5115084)
Scriber, Engineers
(beryllium copper)
Heat Application Tool
Drip Tray
Power Supply 040
VDC -5A
Enercap Tool
Apex Hexagonal Bit
Screwdriver Handle
6.3 mm
Filling Strips (for
grooves on the
block/barrel cylinder)
Insertion/ extraction
tool set (for bushes)
Mechanic
Pressurization Test
Set
Metal Strip,
approximately 10 *
200 * 0.1 mm
5129020
5129025
5135003
5141014
5147001
5149002
5165002
5187-002
5449001
5710-001
5820004
59402501160
190
Local Supply
TBD
X94322120101
Dowel
MC1251
1B1943A009600A-066A-A
Local Supply


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AGERD No.
NOMENCLATURE
PART NUMBER/
MANUFACTURING
DRAWING
Electrical Tester,
ERU
Screw, machine, M4
* (30 to 50)
Socket Hexagonal
Plug
TEU Test Fixture
RX00528
Weighing scales
Local Supply
Local Supply
AGE DATA
SHEET (DMC)/
MANUFAC
TURING INFO
1B-A-AA-020100A-066-A
Facom Ent.312
10002-01

1B-A-AJ-383100A-066A-A
-

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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
04001
Grease,
Synthetic
G-353
915099
9425139
G1000
24 mon
DM
G-355
915099
9100517
U1553
24 mon
DM
G-395
915099
2241797
K6231
24 mon
DM
BB-N-411
683000
7822643
81348
DM
Loctite 27010ML
803099
2248707
U0406
12 mon
DM
Loctite 27050ML
803099
2249318
U0406
12 mon
DM
27010ZN331
803012
1824878
D3393
12 mon
DM
Loctite 24150ml or
803099
2248992
U0406
12 mon
DM
Loctite 24250ml
803099
2250248
U0406
12 mon
DM
12 mon
DM
9 mon
DM
DM
DM
04002
04004
05002
08004
08021
or
Grease,
Graphite
Grease,
MultiPurpose
Nitrogen,
Technical
Locking
Compound
Locking
Compound
08023
08043
Adhesive
Loctite 63850ml
09-010
Compound,
Sealing
PR-1770-A2
11-032
18-060
Local
Supply
Local
Supply
Isopropyl,
Alcohol
Lint-free
Cloth, White
Corrosion
Prevention
Oil
Wire,
Locking
0.711mm
2
80409979 7208U0
406
803099
K0113
7474318
IPA or
IPA400H
6180-994502886
or
6150-998302856
K6835
or
K2337
DEF 1410-1
792099
1204367
K0851
Dinitrol AV 25
803012
3058329
C7223
MS20995C32
950500
8471663

DM

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SECTION I TANK EJECTOR UNIT


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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


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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.


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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.


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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.


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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 Kinematic
Assembly
13 Gas Channel
14 4 Bolt Attachment to SFT
15 Safety Interlock
16 Block and Barrel
Assembly


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1
2
3
4
5
6
7
8
9
10
Cartridge Holder Assembly

Gas Channel
Cartridge-Fired-Indicator and Expansion Chamber
Gas Channel
Orifice Throttle
Cut-Off Valve
Breech Assembly
Block and Barrel Assembly, Cylinder
Piston with spring
Cam Assembly


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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.


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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.


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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.


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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.
1.1
Clean the tank ejector unit.

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).


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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


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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.


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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
11 Cartridge Fired Indicator
12 Safety Kinematic
Assembly
13 Gas Channel
14 4 Bolt Attachment to SFT
15 Safety Interlock
16 Block and Barrel
Assembly


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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.


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1 Block and Barrel Assembly

2 Screw
3 Safety Kinematic Interlink Rod
5 Breech and Electric Assembly
6 Safety Handle
7 Screw


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2 Contact surface
3 12 Point Screw (2x, gas channel)
4 Special Washer (2x, gas channel)
5 Washer (4x)
6 6 Point Bolt (4x)
8 gas channel sealing surface
10 12 Point Screw (2x, gas
channel)


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1 Spring Slide, short version

2 Front Cam
3 Spring Slide, long version
4 Gas Tube Orifice Throttle
5 O-Ring


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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.


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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).


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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.


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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.


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1 Operating Body
2 Safety Kinematic Rod and Actuator
3 Countersunk Screw
Figure 1 Safety Kinematic on the Breech and Electric Assembly (Handles removed)


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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.


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2 Contact surface
5 Washer (4x)
6 6 Point Bolt (4x)
8 Gas channel sealing surface
Figure 3 Connection between the Block & Barrel Assy. and the Breech and Electric Assy.


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2 Screw
3 Safety Kinematic Interlink Rod
6 Safety Handle
7 Screw
Figure 4 Installation of Safety Kinematic Interlink Rod.


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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
oclock 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 oclock;
(UNLOCKED) position.
2. Push the TEU into the test fixture (Supp.Equip) until the safety handle turns into the 7 o
clock SAFE position.


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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 preload 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.


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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 oclock 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.


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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 reassembled 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 reassembled 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 students 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.


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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).


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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 oclock position). The TEU will be released from the test
fixture.
28. Remove the TEU from the text fixture.


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Figure 1 TEU, Main Components


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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 oclock; 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 oclock; SPIGOT UNLOCKED).
2. Push tank ejector unit (TEU) (11, Figure 2) into the test fixture (1, Supp.Equip BM-J
2813196401) 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.


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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 preload 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).


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12. Make sure the safety handle can be turned into the 9 oclock 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 reassembled 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.


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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 reassembled again. Goto Step 50.
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 reassembled again. Goto Step 50.
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).


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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 oclock (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).


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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.


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++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.


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Figure 1 TEU, Main Components


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Legend
1
Latching Element
Conical Ring
Stop Sleeve
Preload Operating Point
Cartridge Cap
Isolation Unit
Electrical Connector
Breech Assembly
Safety Handle
10
Mechanical Interlock
11
Cartridge Fired Indicator
12
Safety Kinematics Assembly
13
Gas Channel
14
4 Bolt Attachment
15
Safety Interlock
16


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


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Legend
Test Fixture
Preload Operating Point
Drilled Plug
Manometer
Valve
Blanking Plug
Axle (of Safety Handle)
Fired Indicator
10
Safety Pin
11
Tank Ejector Unit (TEU)


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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 A2810116001 ) 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.


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Figure 1 Tank Ejector Unit - Installation


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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:


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- 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.


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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.


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SECTION II BLOCK & BARREL


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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).


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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 speedbrace (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.


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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).


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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


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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).


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Figure 1 Securing the latching element cams with a metal strip

1
2
3
4
5
6
Metal Strip
Latching Element Cam


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Figure 2 Removal of latching element and conical ring
1
2
3
4
5
6
Latching Element
Conical Ring
Stop Sleeve
Cylinder
Spigot Preload Operating Point (Wormgear)


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Figure 3 Removal of the top access plate

1
2
3
4
Screw
Washer
Top Access Plate


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Figure 4 Removal of crutching collar and wormgear
1 O-Ring
2 Crutching Collar
3 O-Ring
4 Wormgear
Figure 5 Removal of the worm

1 Screw
2 Washer


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3 Worm Cover Plate
4 O-Ring
5 Worm
6 O-Ring


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Figure 6 Bushes for cam assembly and worm gear
1 Side Access Plate
2 Bush, Side Access Plate
3 Bush, Block and Barrel Housing, Cam
4 Hole for Bush, Worm
5 Block and Barrel Housing
6 Bush, Block and Barrel Housing, Worm
7 Bush, Worm Cover Plate
8 Worm Cover Plate
9 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


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


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Figure 8 Cam assembly with access plates
1 Side Access Plate
2 O-Ring
3 O-Ring
4 Cam Assembly
5 O-Ring
7 O-Ring
8 Bottom Access Plate
Figure 9 Removal of the Piston Head


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1 Piston Head
2 Piston Assembly
3 Slot for Combination Wrench
5 Combination Wrench 27mm
6 Peg Spanner


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Figure 10 Disassembly of the Piston Assembly
1
2
3
4
5
6
7
8
9
10
Piston Head
O-Ring
Spring Pin
Spring
Washer
Shim Washer
Spring Stop
Sealing Ring
Piston (body)
Scraper Ring
CHAPTER 2 BLOK & BARREL REPAIR PROCEDURE

SAFETY CONDITIONS:
+CAUTION+
+CAUTION+
THREADS.
NOTE
To 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.


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- 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.


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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
J94330105001) 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 J94330107001)
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
J94330075001) 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 J94330075001)
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 LN6504514) and restart with Step 6.
- In case the force is within 214N (21,82Kg) +/- 5%, continue with Step 9.


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- In case the force is more then 224,7N (22,91Kg), disassemble the piston assembly,
put out one shim washer (6, Spare LN6504514) and restart with Step 6.
9. Disassemble the piston assembly again.
10. Install O-Rings with multi-purpose grease (Supply 04004) onto the piston assembly
parts as follows:
- O-Ring Spare 07.101.60 72NBR (2, Figure 2) onto the spring pin (3).
- Sealing ring from kit Spare 5921240096401 (8, Figure 2) onto the bottom part
of the piston (9).
- Sealing ring from kit Spare 5921240096401 (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 5921240096401 into
hot water of 90 C + 10 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.


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16. Through the bottom access hole, drive up the piston assembly with hammer, soft faced
(Supp.Equip Local supply) and punch drift (Supp.Equip 5066015),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 08021/023) 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
5129025) (5, Figure 4).


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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 BS4518037116) (8, Figure 5) with multi-purpose grease (Supply
04004) 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 10,001,50S72NBR) (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.


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30. Install O-ring (Spare JN01754A0412) (2, Figure 5) with multi-purpose grease (Supply
04004) 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 5149002) 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).


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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.


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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.


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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).


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75. Install O-Ring (Spare 60,001,50572NBR) (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).


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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. .


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Figure 1 Bushes for cam assembly and worm gear


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Figure 2 Assembly of the Piston Assembly


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Figure 3 Installation of piston body


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Figure 4 Installations of the Piston Head


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Figure 5 Cam assembly with access plates


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Figure 6 Installation of the worm


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


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Figure 8 Installation of wormgear and crutching collar


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Figure 9 Installation of the top access plate


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Figure 10 Installation of the conical ring and the latching element


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SECTION III BREECH & ELECTRICAL ASSY.
CHAPTER 1 DISSASSEMBLE BREECH & ELECTRICAL ASSY


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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.


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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).


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12
Figure 1 Disassembly of the Breech and Electric Assembly
13
Screws (3x)
Washers (3x)
Isolation Unit
Breech Unit
Screws (2x)
Switch
Connector with Captive Screws
Washers (2x)
10
Screws (2x)


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11
Socket
12
Nut & Washer (2x+2x)
13
Bracket Switch
Figure 2 Sealing Rings between Breech Assembly and Isolation Unit


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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.


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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 1000191109)
(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).


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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.


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12
13
Figure 1 Disassembly of the Breech and Electric Assembly

1
Screws (3x)
Washers (3x)
Isolation Unit
Breech Unit


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5
Screws (2x)
Switch
Connector with Captive Screws
Washers (2x)
10
Screws (2x)
11
Socket
12
Nut & Washer (2x+2x)
13
Bracket Switch


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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


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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.


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1
Pin
Cam
Circlip
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
3. Use circlip pliers (Supp.Equip Local Supply) to install circlip (Spare DIN 4716 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.


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Pin
Cam
Circlip
Sleeve Assembly (with Bush)


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SECTION V SAFETY KINEMATIC ASSY


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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).


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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.


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Figure 1 TEU, Safety Kinematic Assembly on Block and Barrel Assembly, left (front) side
1
2
3
4
5
6
Screws (long) (2x)

Spring slide (short)
Screw
Washer
Spacer (2x)
Hole for Screws (long) (2x)
8
9
10
11
12
13
Nut (2x)
Spring Slide (long), rear side
Axle of Cam Assembly
Front Cam Actuator
Spring Slide (long)


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7
Washer (2x)
14
Screws (short) (2x)
CHAPTER 2 - SAFETY KINEMATIC ASSY, REPAIR PROCEDURE

SAFETY CONDITIONS:
+CAUTION+
+CAUTION+
THREADS.
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 the
safety kinematic assembly.


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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).


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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).


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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.


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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.


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Figure 1 Safety Kinematic installation (Block and Barrel)

1
2
3
4
5
6
Screws (long) (2x)

Spring slide (short)
Screw
Washer
Spacer (2x)
Hole for Screws (long) (2x)
8
9
10
11
12
13
Nut (2x)
Spring Slide (long), rear side
Axle of Cam Assembly
Front Cam Actuator
Spring Slide (long)


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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).


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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).


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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).


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Figure 1 TEU, Safety Handles on Breech and Electric Assy

1 Safety Handle (front)
2 Bushing (front)
4 Safety Handle (rear)
5 Bushing (rear)
6 Spring
7 Spring Stop
8 Bar
9 Grub Screw


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Figure 2 TEU, Safety Kinematic Assy on Breech and Electric Assy, electric assy side
1 Washer and Circlip
3 Operating Body
4 Washing Damper and Split Pin
5 Rod
6 Cam
7 Countersunk Screw


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Figure 3 TEU, Safety Kinematic Assembly on Breech and Electric Assembly, breech
assembly side
1 Actuator
2 Grub Screw with Spring Loaded Pin (Do not exist in current configuration)
3 Grub Screw (not visible)
5 Grub Screw


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Figure 4 TEU, Safety Kinematic Assy on Breech and Electric Assy, removal of operating
body
1 Operating Body


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CHAPTER 5 - INSTALL ON BREECH AND ELECTRIC ASSY
SAFETY CONDITIONS:
++WARNING++
PRECAUTIONS AND FIRST AID INSTRUCTIONS.
+CAUTION+
+CAUTION+
+CAUTION+
THREADS TO PREVENT DAMAGE.
PROCEDURE:
NOTE
In 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


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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 screw
with the hexagon socket screw key (1, Figure 4) until the grub screw passes through
the 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 08004) 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 is
reached.


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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 EN213805010) (1, Figure 6) onto the rod.
18. Use circlip pliers (Supp. Local Supply) and secure washer with a circlip (Spare
LN4715B).
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).


Issue 4 - Date: 11/07/2008
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23. On the backside of the Breech and Electric Assembly, install the washing damper
(Spare J94330265401) (2, Figure 8) onto the mechanical interlock axle with plastic
side down and the steel side visible.
24. Put the split pin (Spare EN236718012) (1, Figure 8) into the hole of the mechanical
interlock.
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) onto
the 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 oclock (vertical), 7
oclock (45 deg.) and 9 oclock (horizontal) position.
32. Turn the safety handle into the 9 oclock position (vertical position; spigot unlocked)
and release the mechanical interlock.
33. Turn the safety handle into the 7 oclock position (45 deg.; safe) and check the
mechanical interlock locks (safety handles cannot be turned back into the 9 oclock
position).


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Issue 4 - Date: 11/07/2008
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Figure 1 TEU-Breech Housing; Grub Screw with spring loaded pin

1
2
3
Breech Housing
Spring loaded Pin
Grub Screw


Issue 4 - Date: 11/07/2008
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Figure 2 TEU, Safety Kinematic Assy on Breech and Elec.Assy, insertion of operating body
1 Operating Body
Figure 3 TEU, Safety Kinematic Assembly on Breech and Electric Assembly; position of operating body
1 Operating Body


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Issue 4 - Date: 11/07/2008
Page 143 of 162

Figure 4 TEU, Safety Kinematic Assy on Breech & Electric Assy, adjustment of the actuator
1
2
3
4
5
6
Hexagon socket screw key

Grub Screw
Grub Screw
Breech and Electric Assembly
Threaded Hole for Grub Screw (3)
Actuator


Issue 4 - Date: 11/07/2008
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Figure 5 TEU, Safety Kinematic Assy on Breech & Electric Assy, adjustment of cut off valve
1
2
3
4
Cam
Rod
Operating Body Pin


Issue 4 - Date: 11/07/2008
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Figure 6 TEU, Safety Kinematic Assy on Breech & Electric Assy, installation of cam and rod
1
2
3
4
5
6
7
8
Washer and Circlip

Operating Body
Cam and Rod
Nuts
Switch
Gap
Countersunk Screw


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Figure 7 Safety Kinematic Assy on Breech & Electric Assy, insertion of mechanical interlock
1
2
3
4
5
6
7
8
9
Gap on Actuator
Washing Damper
Split Pin
Actuator
Spring
Hole for Split Pin
Lever


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Figure 8 TEU, washing damper and split pin on mechanical interlock

1
2
Split Pin
Washing Damper


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Figure 9 TEU, Installation of safety handles

1
2
3
4
5
6
7
8
Safety Handle, left

Bushings (2x)
Safety Handle, right
Grub Screw (2x)
Spring Stud
Spring Stop
Operating Shaft


Issue 4 - Date: 11/07/2008
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Figure 10 TEU, Orientation of the safety handles

1
2
3
4

Grub Screws (2x)
Safety Handles (2x)
Actuator


Issue 4 - Date: 11/07/2008
Page 150 of 162

SECTION VI BREECH UNIT ASSY


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CHAPTER 1 - DISASSEMBLE BREECH UNIT 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. 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.


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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
cartridge
holder 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 that
the 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.


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Figure 1 Disassembly of breech assembly

1
2
3
4
5
6
7
8
9
10
Breech Assembly
Expansion Chamber
Bearing (2x)
Retaining Ring (2x)
Sealing Ring (U-Ring) (2x)
Cut-Off Valve Body
Extractor Screw M4
Sealing Ring
Ring Nut Plug (Stopper)
Ring Nut


Issue 4 - Date: 11/07/2008
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11
O-Ring
Figure 2 Removal of the fired indicator

1
2
3
4
Breech Assembly
Fired Indicator with Breech Adaptor
Fired Indicator
Breech Adaptor


Issue 4 - Date: 11/07/2008
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CHAPTER 2 - BREECH UNIT ASSY - REPAIR PROCEDURE

SAFETY CONDITIONS:
+CAUTION+
+CAUTION+
THREADS.
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 electric
isolation 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.


Issue 4 - Date: 11/07/2008
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CHAPTER 3 - ASSEMBLE BREECH UNIT ASSEMBLY

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:
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
59402501160190) 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


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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 J94330189001) 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 BREECH
ADAPTOR (4, Figure 3), BECAUSE THE TORQUE BETWEEN FIRED INDICATOR
AND 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 OFF
VALVE BODY AND ITS BREECH BORE. CONTAMINANTS THERE CAN
LEAD TO A JAM OF THE CUT OFF VALVE.
15. Apply grease, multi purpose (Supply Local Supply) onto one bearing (3, Figure 1).


Issue 4 - Date: 11/07/2008
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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
02501160190).
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 J94330271001) 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 ASOB10184788NBR101).
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 5 and repeat Step 27.


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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


Issue 4 - Date: 11/07/2008
Page 160 of 162

Figure 2 Installation of sealing rings and retaining rings on cut off valve body


Issue 4 - Date: 11/07/2008
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Figure 3 Installation of the fired indicator


Issue 4 - Date: 11/07/2008
Page 162 of 162

TEU Course Training Notes Issue 4 (11!07!2008)

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EFA STORES MANAGEMENT SYSTEM:

TANK EJECTOR UNIT (TRAINING NOTES)

EUROFIGHTER TYPHOON AIRCRAFT

TANK EJECTOR UNIT

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

Prepared and printed by:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

III. GENERAL DATA

TEU EJECTION SYSTEM:

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

Minimum ram area.............................................

490 mm2 .............................................................

NECESSARY POWER FOR THE TEU:

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 .......................

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

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

20,3 0,1 kg ......................................................

SPIGOT BOLT DIMENSIONS:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

General Warnings, Cautions and Related Safety Data

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

IV. AEROSPACE GROUND EQUIPMENT (AGE) AND TOOLS

Screw Driver Bit

Screw driver, flat

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra

EFA STORES MANAGEMENT SYSTEM:

SECTION I TANK EJECTOR UNIT

Compaa Espaola de Sistemas Aeronuticos

Prepared by: A. Consuegra