SS 1593-TMM-001-C

1593-TMM-001 Commercial-in-Confidence
Issue C
CHESS DYNAMICS LTD

USER MANUAL
Doc No. 1593-TMM-001
TECHNICAL MAINTENANCE MANUAL FOR AN

IOTA ELECTRO OPTICAL DIRECTOR
AND
DIRECTOR CONTROL UNIT
Issue Date Change No. Reason for change Approved

A 14/02/07 First Issue
B 18/07/07 Maintenance details added
C 09/08/07 Tooling Number Corrected
Commercial-in-Confidence Page 1 of 39
Issue C
1 Safety and Warnings............................................................................................................4

1.1 Safety Information ..........................................................................................................4
1.2 Unpacking and Inspection ..............................................................................................4
1.3 Voltages ........................................................................................................................4
1.4 Power up .......................................................................................................................4
EOD Installation Instructions.......................................................................................................5
1.5 Tools & Consumables Required ......................................................................................5
1.6 Deck Interface Preparation .............................................................................................5
1.7 EOD Interface Preparation & Fitting ................................................................................5
2 EOD Removal Procedure ................................................................................................... 10
2.1 Tools & Consumables Required .................................................................................... 10
2.2 EOD Removal.............................................................................................................. 10
3 DCU Installation Instructions............................................................................................. 11
3.2 DCU Interface Preparation and fitting ............................................................................ 11
4 DCU Removal Procedure ................................................................................................... 13
4.2 DCU Removal.............................................................................................................. 13
5 Electrical Installation & Interfaces ..................................................................................... 14
5.1 System block diagram .................................................................................................. 14
5.2 DCU............................................................................................................................ 14
5.2.1 Power connections ................................................................................................... 14
5.2.2 Communications ...................................................................................................... 15
5.2.3 DCU-Motors ............................................................................................................ 15
5.2.4 DCU-Signals............................................................................................................ 15
5.3 EOD............................................................................................................................ 16
5.3.1 EOD – Motors .......................................................................................................... 16
5.3.2 EOD – Signals ......................................................................................................... 16
5.3.3 LRF......................................................................................................................... 16
5.3.4 Daylight TV camera.................................................................................................. 17
5.3.5 TI............................................................................................................................ 18
6 Fault finding....................................................................................................................... 19
6.1 Gyro Fault ................................................................................................................... 19
6.2 Encoder feedback error ................................................................................................ 19
6.3 Servo Drive Fault ......................................................................................................... 19
6.4 No communications possible......................................................................................... 19
7 Removal & Refitting of Rate Gyro Unit (RGU) .................................................................... 21
7.1 Tools & Consumables required ..................................................................................... 21
7.2 Rate Gyro Unit Removal............................................................................................... 21
7.3 Rate Gyro Unit Refitting................................................................................................ 23
8 Removal & Refitting of Piranha TV Camera........................................................................ 24
8.2 Removal of Piranha TV Camera.................................................................................... 24
8.3 Refitting of Piranha TV Camera..................................................................................... 26
9 Removal & Refitting of Thermal Imaging Camera .............................................................. 28
9.2 Removal of the Thermal Imaging Camera...................................................................... 28
9.3 Refitting of Thermal Imaging Camera ............................................................................ 29
10 Removal & Refitting of Laser Range Finder....................................................................... 31
10.2 Removal of the Laser Range Finder (LRF)..................................................................... 31
10.3 Refitting of the Laser Range Finder (LRF)...................................................................... 32
11 General Maintenance ......................................................................................................... 34
11.1 Preventive Maintenance / Inspection Procedures ........................................................... 34
11.1.1 Periodic Maintenance – Every 6 Months ................................................................ 34
11.1.2 Periodic Maintenance – Every Month .................................................................... 34
11.1.3 General Cleaning................................................................................................. 34
11.1.4 Azimuth Greasing Procedure ................................................................................ 35
Issue C
11.1.5 Elevation Greasing Procedure .............................................................................. 36
11.1.6 Checking and Replacement of EOD Dessicator ..................................................... 38
11.1.7 Checking and Replacement of DCU Dessicator ..................................................... 39
Definition of terms
A/F - Across Flats

DCU - Director Control Unit
EMC - Electro-Magnetic Compatibility
EOD - Electro-Optic Director
LRF - Laser Range Finder
PCB - Printed Circuit Board
RGU - Rate Gyro Unit
TI - Thermal Imager
Issue C
1 Safety and Warnings

All maintenance is to be carried in strict accordance with this document. This maintenance
manual contains annotated descriptions relating to sub-system removal and refit. This
document also contains information and specific warnings to be followed by the user to ensure
safe operation of the equipment throughout its lifecycle, and more specifically, when carrying
out necessary maintenance.
1.1 Safety Information

Throughout the document the following safety notices are given (see Terms used in this
manual). It is important to read and become familiar with these instructions before attempting
installation, operation, or maintenance. Failure to observe these instructions may possibly
result in serious bodily injury, damage to the equipment, or operational difficulties.
Terms used in this Manual
CAUTION Directs attention to general precautions, which, if not followed, could result in
personal injury and/or equipment damage.
NOTE Highlights information critical to your understanding of this equipment.
1.2 Unpacking and Inspection

On receipt of the equipment carefully remove all packaging and carryout inspection in order to
check that no damage has occurred whilst in shipment. It is essential to notify Chess
Dynamics immediately if damage to the equipment or any of its subsystems is noticed.
Note some items may be attached to the packing base. Do not dispose of shipping
packaging, crates or boxes until the packing list has been fully checked and equipment
inspected.
CAUTION Equipment is heavy. Do not move without adequate lifting devices such as fork
lift truck or pallet-pump truck. Incorrect movement of equipment may result in
personal injury and/or severe damage to the equipment itself.
NOTE Do not slide or drag equipment across the floor or work surface, as this may lead to
unnecessary damage. Particularly if any protective finish is removed, this will increase
the likelihood of corrosion damage.
1.3 Voltages
The system / equipment needs to operate from a 28 Volt DC Supply & 110 Volt AC Supply
CAUTION Check polarity of power before connecting the EOD & DCU as reverse polarity
will seriously damage the unit.
1.4 Power up
CAUTION Do not operate system without a full payload fitted as this can cause damage to
the equipment.
Issue C
EOD Installation Instructions
1.5 Tools & Consumables Required

? Isopropyl alcohol cleaner or similar cleaner
? M12 eyebolt and eyebolt extension (Tool number 1593-0100-T00)
? 24mm Open ended spanner
? Fine stone (Used for de-burring)
? Electrolytic Corrosion Inhibitor CA1000
? Loctite 222
? ½” Drive Torque Wrench – Torque range 25 to 65Nm with a 17mm open ended crow foot
spanner fitting.
? 3/8” Drive Ratchet with 13mm Socket and extension bar
1.6 Deck Interface Preparation
? Ensure mounting face of Deck is clean and free from dirt and grease. (If necessary clean the
mounting face with an appropriate cleaner/degreaser such as Isopropyl alcohol cleaner)
Check for any burrs that may cause the EOD not to sit down properly and remove with a fine
stone.
? Fit two 6mm location dowels into the deck, these dowels must be set into the deck with a
maximum of 5mm protruding above the mounting face.
1.7 EOD Interface Preparation & Fitting
? Remove packaging from around the EOD and remove any loose components from inside the
packaging crate such as cables etc.
? Fit M12 eyebolt and eyebolt extension (Tool number 1593-0100-T00) through top hole in
centre cover (See figure 1) and use a 24mm open ended spanner to tighten the eyebolt down
into position
Figure 1 – Eyebolt / Extension
CAUTION Ensure eyebolt holder is screwed fully into the platform before undertaking any
lifting operations – failure in following this instruction may result in damage or
personal injury.
Issue C
? Unscrew and remove all fixing bolts securing the platform to its packaging pedestal and
carefully lift the EOD out of its crate with an adequate lifting hoist, being careful not to damage
the EOD on the sides of the crate.
? With the EOD removed from its packaging unclip and remove both fibreglass covers to gain
better access to the underside of the EOD. (See Figure 2)
FIBREGLASS
COVERS
CLIPS
Figure 2 – EOD with covers

NEW PHOTO REQUIRED
? Using the lifting apparatus lift the EOD high enough so you can access the bottom mounting
face.
? Fit a 3mm diameter O-ring by 255mm internal diameter into the O-ring groove on the bottom
face of the EOD (See figure 3). This O-ring should be made of either NBR or silicone. If
necessary hold this O-ring in place using a small amount of grease
? Clean and degrease the mounting face of the EOD and check for burrs removing any with a
fine stone.
? Apply a smear of Electrolytic Corrosion Inhibitor CA1000 compound onto the mounting face
outside of the O-ring groove. (See figure 4)
Issue C
O RING
GROOVE
MOUNTING
FACE
Figure 3 – View of Azimuth base
SMEAR THIS FITTED

SURFACE WITH O RING
ELECTROLYTIC
CORROSION
INHIBITOR
Figure 4 – View of Azimuth base showing where

to put corrosion inhibitor
Issue C
? Slowly lower the EOD down onto the deck mounting foot, making sure that the alignment mark
on the base flange is facing towards the front of the ship as this is the zero position. (See
figure 5)
ALIGNMENT
MARK
Figure 5 – View showing alignment mark
? As the EOD is lowered down onto the location dowels make sure that the platform goes down
square to the top of the dowels. The location dowels should be a slide fit into the bottom of the
EOD so minimal force should be required to make the EOD sit firmly down onto its mounting
base.
? Using six M10 x 30 Hex Head screws with form A washers (Screw Material A4 – A70 Grade
Stainless Steel) screw the EOD down onto the deck applying a small amount of Loctite 222 to
each screw before fitting. The screws must be tightened in the following sequence as shown
below using a torque wrench fitted with an open ended 17mm crow foot spanner fitting. First
tighten the screws to 29Nm and then finally to 58Nm.
FORE
1 3
Figure 6 – screw tightening

6 5 sequence
4 2
AFT
Issue C
? Remove lifting Eyebolt and Eyebolt extension from EOD and fit the rubber blanking plug
provided into the hole in the central cover. (See Figure 7)
RUBBER
BLANKING
PLUG
Figure 7 – Blanking plug fitting
? Before fitting an Earth strap onto the side of Azimuth Base (See Figure 8) ensure that the
back nut is tightened fully down against the side wall of the Azimuth base using a 13mm
socket and wrench to trap the star washer against the Aluminium surface. Then fit an
Earth strap and lock in place with the second M8 nut provided.
EARTH
STUD
STAR
WASHER
Figure 8 – Earth Point
? Re-fit fibreglass covers and secure with the four retaining clips on both sides.
? Finally working from underneath the EOD inside the sponson area attach the five power
and communication cables to their respective connectors and tighten by hand until they
are secure.
Issue C
2 EOD Removal Procedure

? M12 eyebolt and eyebolt extension (Tool number 1593-0100-T00)
? 24mm Open ended spanner
? ½” Drive breaker bar – With a 17mm open ended crow foot spanner fitting.
? 3/8” Drive breaker bar with 13mm Socket and extension bar
? WD-40 or similar
2.2 EOD Removal
? The EOD removal procedure is basically the reverse of the installation procedure however the
following relevant points should be noted.
? Before you start any removal procedure on the EOD you must first position the elevation axis
15 degrees above its horizontal axis to gain access to the Eyebolt mounting hole.
? Once the above procedure is done remove all power to the platform and disconnect the power
and comms cables underneath the platform.
? Remove the rubber blanking plug and re-fit the eyebolt and eyebolt extension (Tool number
1593-0100-T00) using a 24mm open ended spanner to lock the eyebolt assembly in place.
CAUTION Ensure eyebolt holder is screwed fully into the platform before undertaking any
lifting operations – failure in following this instruction may result in damage or
personal injury.
? Remove the Earth Strap with a 13mm Socket and 3/8” Drive breaker bar.
? Remove Fibreglass covers.
? Loosen the M10 x 30 Hex Head screws using a ½” drive breaker bar fitted with a 17mm open
ended crow foot spanner, if these screws are tight a lubricant such as WD-40 can be used to
aid removal.
? With all the main mounting screws loose connect the lifting apparatus to the EOD and then
remove the screws completely. The EOD can now be lifted off its deck mounting and put
straight into its packaging crate.
CAUTION The EOD must be put straight into its special packaging crate as the EOD
cannot be allowed to sit down on the connector bucket as the unit will topple
over – failure in following this instruction may result in damage or personal
injury.
Issue C
3 DCU Installation Instructions

? Isopropyl alcohol cleaner or similar
? Fine stone (Used for de-burring)
? Loctite 222
? 3/8” Drive Ratchet with 13mm Socket
? Torque wrench – Torque range of 20Nm to 35Nm fitted with a 6mm A/F Hex Key
3.2 DCU Interface Preparation and fitting
? Remove packaging from around the DCU and carefully lift the DCU from the crate being
careful not to damage the mounting surfaces.
? Lift the DCU onto its side being careful of the paint work and check the two mounting faces for
burrs, if necessary remove any burrs with a fine stone and clean both faces with Isopropyl
alcohol cleaner. (Figure 9)
DCU
MOUNTING
FACES
DCU
MOUNTING
HOLES
Figure 9 – Clean & Degrease mounting faces highlighted
? Lift DCU onto its mounting position and fit in place with four M8 x 20mm long Cap Head
screws fitted with Form ‘A’ washers and a small amount of Loctite 222 applied to the
thread. (Screw Material A4 – A70 Grade Stainless Steel)
? Using a Torque Wrench fitted with a hex key 6mm A/F tighten the four screws to a torque
of 28Nm.
CAUTION If the DCU is being wall mounted two people will be required to carry out the
above fitting procedure as the DCU weighs 10Kg.
? With the DCU in place connect the five cables and tighten by hand until they are secure.
(Figure 10)
Issue C
POWER &
COMMS
CONNECTORS
Figure 10 – DCU showing connectors
? Finally attach an Earth Strap to the Earth Stud on the side of the DCU and tighten the M8
nut down using a 13mm A/F socket and wrench. (See Figure 11)
EARTH
STUD
Figure 11 – DCU Earth Stud
Issue C
4 DCU Removal Procedure

? 3/8” Drive breaker bar with 13mm Socket
? ½” Drive breaker bar fitted with a 6mm A/F Hex Key
4.2 DCU Removal
? The DCU removal procedure is the reverse of the installation procedure however the following
relevant points should be noted.
? Remove all power to the DCU and disconnect the power and comms cables.
? Remove the Earth Strap with a 13mm Socket and 3/8” Drive breaker bar.
? With one person holding the DCU loosen and remove the four M8 x 20 mounting screws with
a ½” Drive breaker bar fitted with a 6mm A/F Hex key.
? The DCU can now be lifted from its mounting and placed into its packaging crate.
CAUTION If the DCU is wall mounted two people will be required to carry out the above
fitting procedure as the DCU weighs 10Kg.
Issue C
5 Electrical Installation & Interfaces
5.1 System block diagram
Appendix A shows an electrical block diagram of the various system components, and
connecting cables. All connectors are assigned either a P or S number which will be referred to
throughout this document
5.2 DCU
5.2.1 Power connections

Figure 12 shows a labelled view of the front panel of the DCU.
P2 – RS422
COMMUNICATIONS
P18 – AC POWER
S3 – MOTOR
SIGNALS
P1 – DC POWER S4– EOD SIGNALS
Figure 12 – DCU Front Panel
The DC power connections are made through connector P1. This has the following pin-out:
In order for the IOTA system to function 24V+/-?? And 36V +/-? Must be present on the pins
indicated.
The AC (110V) power connections are made through P18. This has the following pin-out:
Issue C
The AC supply is only used for the low temperature heaters inside the DCU. For DCU
operation below 5?C the AC supply must be maintained at all times – even when the DC
supply is switched off and the IOTA platform is powered down.
5.2.2 Communications
The IOTA platform is controlled via an RS422 communications link. All platform commands are
issued via this link, and all status information is received back through this connection. The
connection is provided through connector P2 and has the following pin-out:
The RX (data receive) and TX (data transmit) references are relative to the DCU ie: TX is for
data transmitted from the DCU to the outside world. RX refers to data received into the DCU.
5.2.3 DCU-Motors
Connector S3 carries the signals for the motors. This mates with connector P3 on cable W03 –
refer to the cable drawing in appendix B for connector pin-out.
5.2.4 DCU-Signals
Connector S4 carries the feedback and control signals for the EOD. This mates with connector
S4 on cable W04 – refer to the cable drawing in appendix B for connector pin-out.
Issue C
5.3 EOD
Figure 13 shows a labelled picture of the connectors on the underneath of the EOD.
P9-TI P8-TV
P5- EOD
SIGNALS
P6- MOTORS
P7- LRF
Figure 13 – Connectors on EOD
5.3.1 EOD – Motors
Connector P6 carries the signals for the motors. This mates with connector S6 on cable W03 –
refer to the cable drawing in appendix B for connector pin-out.
5.3.2 EOD – Signals

Connector P5 carries the feedback and control signals for the EOD. This mates with connector
S5 on cable W04 – refer to the cable drawing in appendix B for connector pin-out.
5.3.3 LRF
The connection for the LRF on the EOD is made through connector P7 on the base of the
director. The pin-out for this connector is as follows:
Connector S11 on the elevation junction box, provides the connections from the EOD to the
LRF. The pin-out on S11 is identical to P7.
Issue C
5.3.4 Daylight TV camera
The connection for the daylight TV camera on the EOD is made through connector P8 on the
base of the director. The pin-out for this connector is as follows:
Connector S10 on the elevation junction box provides the connections from the EOD to the TV
camera. The pin-out on S10 is identical to P8.
Issue C
5.3.5 TI
The connection for the TI on the EOD is made through connector P9 on the base of the director.
The pin-out for this connector is as follows:
Connector S11 on the elevation junction box, provides the connections from the EOD to the TV
camera. The pin-out on S10 is identical to P9.
Issue C
6 Fault finding
The main indication of the IOTA system status is provided via the RS422 communications link to
XXXX. The following error conditions will be reported in Byte XX of the IOTA platform
communications protocol – please refer to document XXXXX for more detailed information.
1) Gyro Fault
2) Encoder Feedback Error
3) Servo Drive Fault
Procedures to be followed for each of these error conditions are detailed in the following
sections.
6.1 Gyro Fault

If a gyro fault is indicated the following procedures should be carried out in the order listed until
the fault is resolved:
? Cycle System DC power (both 36V and 24V)

? Check the security and condition of cables W01 and W04.
? Change the RGU on the EOD following maintenance procedure - if error is cured, then the
removed RGU needs to be returned to Chess for evaluation and repair.
? Replace the DCU following maintenance procedure – if error is cured then the removed
DCU needs to be returned to Chess for evaluation and repair.
? Replace the EOD following maintenance procedure – return the EOD to Chess for
evaluation and repair if this cures the fault.
6.2 Encoder feedback error

If an encoder feedback error is indicated the following procedures should be carried out in the
order listed until the fault is resolved:

? Check the security and condition of cable W04.
6.3 Servo Drive Fault

If a servo drive fault is indicated the following procedures should be carried out in the order
listed until the fault is resolved:

? Check the security and condition of cable W04.
6.4 No communications possible.
In the event that no communication is possible with the DCU via the serial link, the following
procedure should be followed:
Issue C
? Confirm correct connections to DCU communications connector, checking polarity and
continuity.
? Confirm 24V DC power is present, with correct polarity, at the DCU power connector
? Replace DCU.
If communications is re-established by replacing the DCU, then the broken unit needs to be
returned to Chess for evaluation and repair.
Issue C
7 Removal & Refitting of Rate Gyro Unit (RGU)
7.1 Tools & Consumables required

? 3mm Hex Allen Key
? Loctite 222
? Isopropyl alcohol cleaner or similar
? Torque driver fitted with a 3mm Hex bit
7.2 Rate Gyro Unit Removal
? Before removing the Gyro from the EOD you must first position the EOD so that the payload
bracket with the Gyro is facing you.
? With the EOD in the correct position remove all power to the platform.
? Remove the Fibreglass cover to gain access to the payload mounting bracket and sensors.
(See figure 14)
RATE
GYRO
UNIT
Figure 14 – Payload / Gyro side
? Disconnect the Gyro cable at the Gyro end by unscrewing the connector. (See figure 15)
Issue C
DISCONNECT
GYRO CABLE
Figure 15 – Gyro cable
? Using a 3mm Hex Allen key unscrew the four captive screws holding the Gyro in position
being careful not to drop the Gyro. (See figure 16) Once the screws have been undone a
gentle pull on the Gyro should prise the Gyro off of its location dowels. Please note the
orientation of the Gyro before removal.
Figure 16 – Unscrewing Gyro Mounting Screws
Issue C
? With the gyro removed both location dowels should still be firmly located in the payload
bracket, however if they have come away with the Gyro refit the dowels back into their
respective holes. (See figure 17)
CLEAN
MOUNTING
FACES
LOCATION
DOWELS
Figure 17 – Gyro Removal – Showing Dowels in Position
7.3 Rate Gyro Unit Refitting
? Clean & degrease the mounting faces of the Gyro and the payload bracket (See figure 17)
? Ensure the location dowels are fitted and that they are sitting no more than 4mm proud of the
payload bracket mounting face. (See figure 17)
? Apply a small amount of Loctite 222 to the thread of each captive screw and then push the
Gyro into position onto its location dowels.
? Using a torque driver fitted with a 3mm Hex bit tighten the four captive screws to a torque of
2.4Nm
? Re-connect the Gyro cable and re-fit the fibreglass cover
Issue C
8 Removal & Refitting of Piranha TV Camera

? 3mm Ball Hex Allen Key
? Loctite 222
? 3/8” Drive Torque wrench fitted with a 3mm Hex bit and an extension bar
8.2 Removal of Piranha TV Camera
? Before removing the TV Camera from the EOD you must first position the EOD so that the
payload bracket with the Camera is facing you, then rotate the elevation axis down by
approximately 20 degrees.
PIRANHA TV
CAMERA
Figure 18 – Payload Bracket / Piranha Camera side
? With the EOD in the correct position remove all power to the platform and to the sensors.
? Remove the Fibreglass cover to gain access to the payload mounting bracket and sensors.
(See figure 18)
? Disconnect the camera cable and move the cable back out of the way of the Camera.
? Using a 3mm Ball Ended Allen key loosen the two captive screws at the back of the dovetail
see figures 19 & 20 below showing the two captive screws.
Issue C
CAPTIVE
SCREWS
Figure 19 – View showing the back of Piranha camera
CENTRE
SCREW LOOSEN
THESE TWO
CAPTIVE
SCREWS
Figure 20 – View showing the two captive screws on the back of the camera that need
To be undone to remove camera
? With the two captive screws loose slowly tighten the centre screw highlighted in figure 20
above to unlock the dovetails.
? Carefully slide the camera off the dovetail and remove from the EOD (Figure 21)
Issue C
Figure 21 – Removing camera from dovetail
8.3 Refitting of Piranha TV Camera
? Refitting is basically the reverse of the removal procedure
? On the dovetail on the back of the camera check that the centre screw is not protruding out of
the rear clamp block (See figure 22) Apply Loctite 222 to the threads of the two captive
screws.
REAR
CLAMP
BLOCK
ENSURE
CENTRE
SCREW IS
RETRACTED
Figure 22 – Centre screw retracted
Issue C
? Ensure both halves of the dovetail are free from dirt and grease if not clean with an
appropriate cleaning solution.
? Slide the camera onto the dovetail until the two halves lock together. See figure 23
Figure 23 – Piranha Camera mounted in position
? Using a 3/8” Drive Torque wrench fitted with a 3mm Hex bit and an extension bar tighten the
two captive screws to a torque of 2.4Nm. Lock the centre screw by tightening with a 3mm
Allen Key.
? Reconnect the camera cable and then refit the fibreglass covers.
? Power system up and check operation of Piranha Camera.
Issue C
9 Removal & Refitting of Thermal Imaging Camera

? Loctite 222
9.2 Removal of the Thermal Imaging Camera

? Before removing the Thermal Imaging Camera from the EOD you must first position the EOD
so that the payload bracket with the Camera is facing you, then rotate the elevation axis down
by approximately 20 degrees.
THERMAL
IMAGING
CAMERA
Figure 24 – Payload Bracket / Thermal Imager Side
? With the EOD in the correct position remove all power to the platform and the sensors.
? Remove the Fibreglass cover to gain access to the payload mounting bracket and sensor.
(See figure 24)
? Disconnect the camera cable and move the cable back out of the way of the Camera.
see figures 25 below showing the two captive screws.
Issue C
CAPTIVE
SCREWS
CENTRE
SCREW
Figure 25 – Rear of Thermal Imager
? With the two captive screws loose slowly tighten the centre screw highlighted in figure 25
above to unlock the dovetails.
? Carefully slide the Thermal Imager back and at the same time lift the camera outwards
away from the dovetail and remove from the EOD.
9.3 Refitting of Thermal Imaging Camera
? On the dovetail on the back of the camera check that the centre screw is not protruding out of
the rear clamp block (See figure 26) Apply Loctite 222 to the threads of the two captive
screws.
RETRACT
SCREW SO
IT IS FLUSH
WITH REAR
CLAMP
BLOCK
Figure 26 – Thermal Imager Dovetail
Issue C
? Position the Thermal Imager over the dovetail and align the protruding screw heads with the
slots in the dovetail carrier plate. See figure 27
DOVETAIL
CARRIER
PLATE
Figure 27 – Align Screw Heads with Dovetail Carrier Plate
? Slide the Thermal Imager onto the dovetail until the two halves lock together
Allen Key.
? Reconnect the camera cable and then refit the fibreglass covers.
? Power system up and check operation of Thermal Imaging Camera.
Issue C
10 Removal & Refitting of Laser Range Finder

? Loctite 222
10.2 Removal of the Laser Range Finder (LRF)
? Before removing the Laser Range Finder from the EOD you must first position the EOD so
that the payload bracket with the sensor is facing you, then rotate the elevation axis down by
approximately 20 degrees.
? With the EOD in the correct position remove all power to the platform and the sensors.
? Remove the Fibreglass cover to gain access to the payload mounting bracket and sensor.
(See figure 28)
LASER
RANGE
LASER FINDER
RANGE CABLE
FINDER
Figure 28 – View of Payload Bracket – Laser Range Finder side
? Disconnect the LRF cable and move the cable back out of the way.
see figure 29.
? With the two captive screws loose slowly tighten the centre screw highlighted in figure 29 to
unlock the dovetails.
Issue C
CAPTIVE
SCREWS
CENTRE
SCREW
Figure 29 – View of Laser Range Finder rear clamp block
? Carefully slide the LRF back and at the same time lift outwards away from the dovetail and
remove from the EOD.
10.3 Refitting of the Laser Range Finder (LRF)
? On the dovetail on the back of the LRF check that the centre screw is not protruding out of the
rear clamp block (See figure 30) Apply Loctite 222 to the threads of the two captive screws.
RETRACT CAPTIVE
CENTRE SCREWS
SCREW
Figure 30 – LRF Dovetail
? Position the LRF over the dovetail and align the protruding screw heads with the slots in the
dovetail carrier plate (If Applicable). See figure 31
? Slide the LRF onto the dovetail until the two halves lock together.
Issue C
Figure 31 – Mounting LRF onto Dovetail
Allen Key.
? Reconnect the LRF cable and then refit the fibreglass covers.
? Power system up and check operation of the LRF and EOD.
Issue C
11 General Maintenance
11.1 Preventive Maintenance / Inspection Procedures

This section describes the recommended procedures to be followed in the event that the
system requires maintenance.
These operations are to be carried out by trained personnel with the appropriate skills.
Lists of recommended maintenance procedures follow:
11.1.1 Periodic Maintenance – Every 6 Months
1 Grease Azimuth and Elevation seals using the grease nipples provided (See procedure 12.1.4
& 12.1.5)
2 Check the condition of all external cables and tightness of their respective back-shells.
Damaged sheaths on cables may be repaired using local approved techniques, however those
that are deemed beyond economical repair should be replaced and the reason why they have
been damaged ascertained where possible.
Where bulkhead connectors are retained by jam nuts, these should be checked for tightness –
if they feel loose to the hand then they should be appropriately tightened. Bulkhead
connectors using jam nuts are located on the underside of the EOD and on the upper junction
box
11.1.2 Periodic Maintenance – Every Month
1 Check condition of the Desiccators on both the EOD & the DCU if the indicator has changed
from blue to pink replace with a new Desiccator (See procedures 12.1.6 & 12.1.7)
11.1.3 General Cleaning
Cleaning should be carried out before any maintenance procedure is undertaken to prevent ingress of
dirt and debris.
Cleaning should be carried out in two stages:
? All loose dust and dirt should be removed with a soft cloth.
? Secondly, grime should be removed using a soft cloth moistened with dilute detergent or
proprietary cleaning solution. The detergent or solution should be compatible with the
requirements of the working area. All spillages should be removed immediately.
Issue C
11.1.4 Azimuth Greasing Procedure
? To grease the Azimuth axis the EOD needs to be rotated into a position so that both grease
nipples can be easily accessed as there are two grease nipples one on either side of the
platform. (See figure 32)
? With the EOD in position remove power to the system.
GREASE
NIPPLE 1
GREASE
NIPPLE 2
Figure 32 – Azimuth Greasing Points
? Using a grease gun fitted with a conical nozzle (Part number - NSCC1) and filled with Kluber
grease PDL 300A put ONE pump of grease into each grease nipple. Clean any excess grease
off the EOD with a soft cloth. (See Figure 33)
Figure 33 – View of Grease Gun and Nozzle
? Power up the EOD and then rotate Azimuth axis five complete turns to allow the grease to
flow into the grease labyrinth and to lubricate the seal.
Issue C
11.1.5 Elevation Greasing Procedure
? To grease the Elevation axis both sides of the EOD need to be accessed, so it is suggested
that you grease one side at a time.
? Position the EOD so that it is possible to access the Payload bracket with the Thermal Imager
on and remove power to the system.
? Remove the fibreglass cover.
Figure 34 – Payload – Thermal Imager side
? Using the grease gun fitted with the conical nozzle and filled with Kluber grease PDL 300A put
ONE pump of grease into each grease nipple. Clean any excess grease off the EOD with a
soft cloth.
GREASE GREASE
NIPPLE 1 NIPPLE 2
Figure 35 – View Showing both Grease Nipples on Side 1
? Refit fibre glass cover
? Power system up and rotate Azimuth axis through 180 degrees to access second Payload
bracket. With the EOD in the correct position power down again.
Issue C
? Remove the second fibreglass cover to reveal payload.
Figure 36 – View of Payload
? For ease of access disconnect Gyro cable at the junction box end and move cable to one
side to reveal grease nipples. (See figure 37)
GREASE
NIPPLE 2
GREASE
NIPPLE 1
Figure 37 - View Showing both Grease Nipples on Side 2

With Gyro Cable Disconnected
? Using the same grease gun put ONE pump of grease into both of these grease nipples
and clean excess with a soft cloth.
? Re-fit the Gyro connector and the fibreglass cover.
? Power the system up and rotate elevation from end stop to end stop to allow the grease to
flow into the grease labyrinth and to lubricate the seal.
Issue C
11.1.6 Checking and Replacement of EOD Dessicator
? Rotate the EOD around so that you can see the Desiccator.
? Check the indicator on the front of the Desiccator if it has gone PINK then the Desiccator
should be replaced (See figure 38)
DESSICATOR
PINK SO IT
SHOULD BE
REPLACED
Figure 38 – EOD Desiccator
? Unscrew the Desiccator from the EOD and clean the sealing face.
? Remove the new Desiccator from its packaging and check there is an O-Ring fitted on the
back of the Desiccator. Screw the Desiccator into the EOD and tighten down compressing the
O-Ring onto the sealing face. (See Figure 39)
SEALING
FACE
O-RING
Figure 39 – Fitting new Desiccator
CAUTION Under no circumstances must you leave the EOD without a Desiccator fitted as
this will damage the equipment.
Issue C
11.1.7 Checking and Replacement of DCU Desiccator
? Check the indicator on the front of the Desiccator if it has gone PINK then the Desiccator
should be replaced (See figure 40)
Figure 40 – DCU Desiccator
? Unscrew the Desiccator from the DCU and clean the sealing face.
? Remove the new Desiccator from its packaging and check there is an O-Ring fitted on the
back of the Desiccator. Screw the Desiccator into the DCU and tighten down compressing the
O-Ring onto the sealing face. (See Figure 41)
SEALING
FACE
Figure 41 – Fitting new Desiccator

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1593-TMM-001 Commercial-in-Confidence

CHESS DYNAMICS LTD

TECHNICAL MAINTENANCE MANUAL FOR AN

Issue Date Change No. Reason for change Approved

1 Safety and Warnings............................................................................................................4

A/F - Across Flats

1 Safety and Warnings

1.1 Safety Information

NOTE Highlights information critical to your understanding of this equipment.

1.2 Unpacking and Inspection

EOD Installation Instructions

1.5 Tools & Consumables Required

1.6 Deck Interface Preparation

1.7 EOD Interface Preparation & Fitting

Figure 1 – Eyebolt / Extension

Figure 2 – EOD with covers

Figure 3 – View of Azimuth base

SMEAR THIS FITTED

Figure 4 – View of Azimuth base showing where

Figure 5 – View showing alignment mark

Figure 6 – screw tightening

Figure 7 – Blanking plug fitting

Figure 8 – Earth Point

2 EOD Removal Procedure

2.1 Tools & Consumables Required

2.2 EOD Removal

? Remove Fibreglass covers.

3 DCU Installation Instructions

3.1 Tools & Consumables Required

3.2 DCU Interface Preparation and fitting

Figure 9 – Clean & Degrease mounting faces highlighted

Figure 10 – DCU showing connectors

Figure 11 – DCU Earth Stud

4 DCU Removal Procedure

4.1 Tools & Consumables Required

4.2 DCU Removal

5 Electrical Installation & Interfaces

5.1 System block diagram

5.2.1 Power connections

P1 – DC POWER S4– EOD SIGNALS

Figure 12 – DCU Front Panel

Figure 13 – Connectors on EOD

5.3.1 EOD – Motors

5.3.2 EOD – Signals

6.1 Gyro Fault

? Cycle System DC power (both 36V and 24V)

6.2 Encoder feedback error

? Cycle System DC power (both 36V and 24V)

6.3 Servo Drive Fault

? Cycle System DC power (both 36V and 24V)

6.4 No communications possible.

7 Removal & Refitting of Rate Gyro Unit (RGU)

7.1 Tools & Consumables required

7.2 Rate Gyro Unit Removal

Figure 14 – Payload / Gyro side

Figure 15 – Gyro cable

Figure 16 – Unscrewing Gyro Mounting Screws

Figure 17 – Gyro Removal – Showing Dowels in Position

7.3 Rate Gyro Unit Refitting

? Re-connect the Gyro cable and re-fit the fibreglass cover