MAINTENANCE AND REPAIR

INSTRUCTIONS

SUBJECT OF THE DOCUMENT

ANTENNA MODULE FOR INDRA

PRIMARY SURVEILLANCE RADAR
R736 500N

DOCUMENT NO. FORMAT SHEET

R730 916X A4 1/19

REV. INDEX - A B C D
 SHEET OF REVISIONS AND SIGNATURES
REVISION INDEX DESCRIPTION OF REVISION

A Clutch implementation (chap.2.6, 2.7, fig.3)

B Specifikacion of the recommended speed for switching of the clutch (chap.2.6.2)

Update of the chapter 2.6.2 – using of the blocking screw.

C Update of the figures from no.3 to 7.

D Update of the MS 1 periodicity

Index/Date - / 28.6.2011 A/ 24.4.2012 B/ 24.5.2012 C/10.9.2012 D/ 17.9.2013 E/

Prepared by P.FIŠER P.FIŠER P.FIŠER P.FIŠER P.FIŠER

Reviewed by Z.KŘIVÁK Z.KŘIVÁK Z.KŘIVÁK Z.KŘIVÁK Z.KŘIVÁK

Approved by V.VENCEL V.VENCEL V.VENCEL V.VENCEL V.VENCEL

Authorized by L. MITÁŠ L. MITÁŠ L. MITÁŠ L. MITÁŠ L. MITÁŠ

DOCUMENT NO. FORMAT SHEET

R730 916X A4 2/19

REV. INDEX - A B C D
 CONTENTS

1. MAINTENANCE INSTRUCTIONS.................................................................................... 4

2. LIST OF TREATMENT TECHNOLOGICAL CARD.......................................................... 6

3. REPAIR INSTRUCTIONS .............................................................................................. 18

4. LIFE TIME, RELIABILITY AND WARRANTY ................................................................ 19

DOCUMENT NO. FORMAT SHEET

R730 916X A4 3/19

REV. INDEX - A B C D
1. MAINTENANCE INSTRUCTIONS

1.1 Maintenance of the INDRA PSR antenna unit must be carried out in the following cases:

- preventively, based on a plan of maintenance service prepared in advance

- during the operation
- to remedy faults and failures of assembly groups and sub-groups

The following types of maintenance service are to be performed:

Maint. Maint. To be
Name of the Maintenance
type No. performed by
operating
MS 1 1 Maintenance service No. 1 – yearly treatment
personnel
operating
personnel,
specialists,
MS 2 2 Maintenance service No. 2 – yearly treatment
customer
service of the
Manufacturer

1.2 MAINTENANCE SERVICE No. 1

To be performed Time
Action: Job Description: Note:
by: [min]
operating Removal of dirt Removal of any rough dirt, deposits, 30 As per TTC 6
personnel snow and icing.
operating Treatment of parts Varnished surfaces are to be treated only 60 As per TTC 1
personnel surfaces. in spots where damaged.
Non-varnished metal surfaces are to be 30 As per TTC 2
treated over the whole area. Apply a
small amount of grease, or, if need be, oil
on functional lubricated friction areas.
Treat non-metallic materials. 10 As per TTC 4

operating Treatment of earth Demounting and maintenance of earth 70 As per TTC 3,

personnel terminals and terminals on ground, earth and TTC 5
conductor surfaces. connecting wires.
operating Checking oil level and Replenishment of oil or grease into 120 As per
personnel lubricating points. lubricating points. Removal of excess R730 914X
grease or oil.
operating Check for completeness Before starting the operation, the feeds, 30 As per
personnel and intactness. the antenna, the antenna holder, the R730 913X,
conductors and waveguides are to be R730 964X
checked for completeness and intactness.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 4/19

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1.3 MAINTENANCE SERVICE No. 2

Maintenance service No. 2 is advisable to be carried out best at the end of the year (turn of winter). The
maintenance service No. 2 is to be performed by the operating personnel and specialists (customer
service of the Manufacturer). Within the maintenance service No. 2 the following operations are to be
carried out:

- Checking condition of the accompanying and operating documentation supplied along with the
product.
- Checking separate parts for their function and condition.
- Checking oil level in the antenna drive mechanism box.
- Checking oil level in gearboxes.
- Checking functionality of reversal of feed polarization.
- Checking all limit switches for their functionality.
- Checking earth terminals for their condition. The earth terminals must be free from traces of painting
and rust.
- Checking connectors and connecting cables for their condition. If damaged, they have to be replaced.
- Checking all bolted connections, split pins etc.; those loosened should be tightened, the missing ones
replaced.
- Checking painted surfaces and protective coatings. Repair of painted surfaces..
- Checking indicating elements.

Caution:
• Service and maintenance must only be carried out by properly trained and authorized personnel. Only
genuine parts can be used for servicing and maintenance.

• All inspection, maintenance, and repair work must be carried out with care by trained personnel only.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 5/19

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 2. LIST OF TREATMENT TECHNOLOGICAL CARD

TTC 1 TREATMENT OF VARNISHED SURFACES

TTC 2 TREATMENT OF NON-VARNISHED METAL SURFACES
TTC 3 TREATMENT OF EARTH TERMINALS
TTC 4 TREATMENT OF NON-METALLIC MATERIALS
TTC 5 REMOVAL OF DIRT
TTC 6 CHANGE OF ELECTRIC MOTOR
TTC 7 CHANGE OF GEARBOX

2.1 TTC 1 TREATMENT OF VARNISHED SURFACES

Materials Fine emery paper, rags, benzine, U2066 top paint, U 7001 hardener, U6002 thinner, U 2008
needed: Axapur Primer ground paint, brush, vessel.
Procedure: 1.Using a fine emery paper, carefully clean the damaged spot. Be careful not to remove the
protective metal coating.
2. Degrease the spot with a cloth dampened with the cleaning benzine or directly with the
thinner.
3. Apply the ground paint by brush and allow it to dry (in accordance with the instructions
of the producer).
4. Brush the top paint (in accordance with the instructions of the producer).

Note: If small spots of top paint are damaged, adhere to the procedure as per points 2 and 4.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 6/19

REV. INDEX - A B C D
 2.2 TTC 2 TREATMENT OF NON-VARNISHED METAL SURFACES

Materials WD-40 oil, rags, collecting vessel for petroleum waste.

needed:

Procedure: 1. Apply a small amount of the WD-40 oil on the surface and allow it to act for two minutes.
2. Using a cloth, thoroughly soak off the dissolved rust, impurities and the pushed up water.
3. Onto the clean surface apply again a small amount of WD-40 and allow it to soak into the
surface for a period of one minute. Wipe off the excess oil with a clean rag.

Note
The above procedure may be repeated until the time when no more impurities can be wiped
off the surface.

2.3 TTC 3 TREATMENT OF EARTH TERMINALS

Materials Open double-ended wrench 13-17, WD-40 oil, brush, rags, collecting vessel for petroleum
needed: waste.

Procedure: 1. Apply a small amount of the WD-40 oil on the earth terminals and all non-protected metal
components and allow it to act for two minutes.
2. Using a dry cloth, soak off the impurities and the water pushed up.
3. Using the wrench 13, tighten loose nuts of the earth terminals.

CAUTION
Before treating the earth terminals on the operated antenna system, make sure to switch off
the electric switchboard. This job must not be carried out during a storm !

DOCUMENT NO. FORMAT SHEET

R730 916X A4 7/19

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 2.4 TTC 4 TREATMENT OF NON-METALLIC MATERIALS

Materials Bucket with water and detergent, fine plastic brush, cloth, suitable place for drying.
needed:
Procedure: 1. By knocking and with use of the brush, remove rough impurities off the components.
2. Wash them, or clean with a damp cloth or the brush in water.
3. Dry up with air-flow, or in the sun..
4. Upon drying, examine the surface; if a damage is found out hindering further use of the
component, consider repair or replacement.

2.5 TTC 5 REMOVAL OF DIRT

Materials Plastic (scrubbing) brush, wooden spatula (self-made), bucket (small tub), washing agent and
needed: desinfectant (JAR, PUR or similar detergent…), water, WD-40 oil, brush, rags.
Procedure: 1. Using the brush and the wooden spatula, remove rough dirt.
2. Dampen deposits in inaccessible spots with the washing agent and the desinfectant and
allow to act for at least 10 minutes. Dirt from shipping packing is to be emptied after its
release. If icing is involved, apply warm water, or a flow of warm air.
3. Dry the whole surface with rags.
4. Treat the lubricating points as per R730 914X.

CAUTION
Do not perform the maintenance in case of storm !

DOCUMENT NO. FORMAT SHEET

R730 916X A4 8/19

REV. INDEX - A B C D
 2.6 TTC 6 CHANGE OF ELECTRIC MOTOR

2.6.1 WITH THE SYSTEM OUT OF OPERATION

Materials One spanner No.18, inbus wrenches 4 and 8 mm, an anti-seize agent (Orelube Anti-seize 1),
needed: two mechanicians
Procedure: 1. Switch off the electric supply to the motors.
2. Demount the supply cables from the terminal board of the electric motor.
3. Release (do not disassemble!) the four M12 bolted joints on the flange of the electric
motor and the clutch.
4. Demount the four M12 bolted joints. While demounting the screws, it is necessary to hold
the motor all the time – two mechanicians are needed! Except these 4 bolts, there are no
other elements securing the motor in its position! After removel of the screws the motor is
to be placed on the floor.
5. Coat the shaft and the key of the new motor with the anti-seize agent.
6. Flange-mount the shaft of the electric motor onto the opening in the clutch.
7. Lock the motor with the clutch by means of four M12 bolted joints.
8. Mount the supply electric cables.
9. Switch the power supply on.

CAUTION
Danger of burns due to hot parts. Do not touch the motor without protection.
Be careful not to axially distort the motor shaft when flange-mounting the motor.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 9/19

REV. INDEX - A B C D
 2.6.2 CHANGE OF ELECTRIC MOTOR WITH THE SYSTEM RUNNING - (ONLY ONE
ELECTRIC MOTOR)

Materials One spanner No.10 and 18, inbus wrenches 4 and 8 mm, M6x44 blocking screw, an anti-seize
needed: agent (Orelube Anti-seize 1), two mechanicians
Procedure: 1. Switch off the electric supply to the demounted motor.
2. Unscrew the locking screw M6 of the clutch control lever.
3. Bring the clutch control lever over to „OFF“ position (see Fig.4).
Note: the clutch transfers a slight torque (2 N.m max.) even after this disconnection. Such
torque is a result of a mutual friction of clutch plates through their own weight.
4. Secure the clutch control lever in this position with the locking screw M6.
5. Demount the supply cables from the terminal board of the electric motor.
6. Release (do not disassemble!) the four M12 bolted joints on the flange of the electric
motor and the clutch.
7. Apply the built-in mechanical friction brake controlled with M6x44 blocking screw
provided with a pin and brake the drive half of the clutch (see Fig.4). The transfer of the
clutch slight torque will be eliminated.
Note: The brake screw will slowly screw up into the tapped hole after the safety screw,
arresting the control lever in ON position. When the screw is screwed in into a depth of
approximately 30 mm, the brake will get activated – a resistance of the screw being
screwed can be felt and in this way braking itself takes place (braked condition can be
watched on the free end of the shaft in ventilator cover).
The clutch under this mode can be operated for maximum 45 minutes only!
8. Demount the four M12 bolted joints. While demounting the screws, it is necessary to hold
the motor all the time – two mechanicians are needed! Except these 4 bolts, there are no
other elements securing the motor in its position! After removel of the screws the motor is
to be placed on the floor (see Fig.5).
9. After finishing of the motor demounting, release the brake by screwing out the M6x44
blocking screw (see Fig.4).
10. Coat the shaft and the key of the new motor with the anti-seize agent.
11. Apply the built-in mechanical friction brake controlled with M6x44 blocking screw
provided with a pin and brake the drive half of the clutch (see Fig.4). The transfer of the
clutch slight torque will be eliminated.
Note: The clutch under this mode can be operated for maximum 45 minutes only!
12. Flange-mount the shaft of the electric motor onto the opening in the clutch.
13. Lock the motor with the clutch by means of four M12 bolted joints.
14. After finishing of the motor mounting, release the brake by screwing out the M6x44
blocking screw (see Fig.4).
15. Mount the supply electric cables.
16. Switch the power supply on.
17. Unscrew the locking screw M6 of the clutch control lever.
18. Bring the clutch control lever over to „ON“ position – always to be done under nominal
speed (11,6 rpm) only!
19. Secure the clutch control lever in this position with the locking screw M6.

CAUTION

See next page.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 10/19

REV. INDEX - A B C D
CAUTION

Danger of burns due to hot parts. Do not touch the motor without protection.
Be careful not to axially distort the motor shaft when flange-mounting the motor.
Do not exceed the nominal speed (11,6 rpm) by switching clutch control lever over to „ON“
position – there is a risk of clutch discs damaging.
Upon disconnecting the clutch, the motor will keep a big moment of inertia, therefore, before
performing any further activity, it is necessary to wait for some 3 to 5 minutes until the motor
speed gets decreased spontaneously (the motor speed reduction can be monitored on the free
end of the shaft in ventilator cover).
The clutch with braked side from the motor and rotating side from the gearbox, can be
operated for maximum 45 minutes because the inner plates will get heated; after elapse of
such time, the brake of the lower part of the clutch must be released and the mechanism let
cooled down prior to further application of the brake.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 11/19

REV. INDEX - A B C D
 2.7 TTC 7 CHANGE OF CLUTCH OR GEARBOX

Materials Two spanners No.18, inbus wrench 4, 5 and 8 mm, hammer, an anti-seize agent (Orelube
needed: Anti-seize 1), two mechanicians
Procedure: 1. Before demounting the gearbox, it is necessary to demount the electric motor – to be
performed as per TTC 6.
2. Remove the gearbox mounting plugs 502 and 503 (see Fig.1).
3. Turn the drive shaft 515 and clamping ring 560 of the gearbox to align them with the
mounting holes for the mounting plugs 502 and 503 (see Fig.2).
4. Release the hexagon socket-head screw 561.
5. Release the grub screw 564
6. Release (do not disassemble!) the four M12 screws on the flange of the clutch and the
gerbox (see Fig.3).
7. Demount the four M12 screws. While demounting the screws, it is necessary to hold the
clutch all the time – two mechanicians are needed! Except these 4 bolts, there are no other
elements securing the clutch in its position! After removel of the screws the clutch is to be
placed on the floor.
8. Release (do not disassemble!) the four M12 bolted joints fixing the gearbox on the flange
of the connecting cylinder of the antenna drive mechanism (see Fig. 6).
9. Demount the four M12 bolted joints. While demounting the screws, it is necessary to hold
the gearbox all the time – two mechanicians are needed! Except these 4 bolts, there are no
other elements securing the gearbox in its position, it is only slipped over in the BKN
clutch! After removel of the joints the gearbox is to be placed on the floor.
10. Before mounting the new gearbox, coat its shaft with the anti-seize agent.
11. Demount the half of the BKN clutch out of the original gearbox shaft. Mount it and
secure it by using grub screw on the new gearbox shaft (see Fig. 7).
12. Put the shaft of the gearbox into the second half of the BKN clutch and secure it on the
flange with the four M12 bolts with nuts and safety washers Nord-Lock.
13. Coat the shaft and the key of the clutch with the anti-seize agent.
14. Remove the mounting plugs 502 and 503 (see Fig.1).
15. Turn the drive shaft 515 and clamping ring 560 of the gearbox to align them with the
mounting holes for the mounting plugs 502 and 503(see Fig.2).
16. Apply adhesive (medium strength, e.g. Loctite 243) to the grub screw 564, hexagon
socket-head screw 561 and bolts 505.
17. Secure the clamping ring 560.
18. Flange-mount the clutch to the short coupling lantern and secure it with the bolts 505.
19. Screw the grub screw 564 to the featherkey 563 until a slight resistance is felt, then turn
the grub screw 564 half a turn back.
20. Insert the socket wrench into the grub screw 564 through the hole for the mounting plugs
503. This prevents the shaft from twisting.
21. Tighten the hexagon socket-head screw 561.
22. Tighten the grub screw 564.
23. Seal the mounting holes with the mounting plugs 502 and 503.
24. Remount the electric motor as per TTC 6.
25. Refill the oil charge into the gearbow as per the Lubrication Chart R730 914X.

CAUTION
Danger of burns due to hot parts. Do not touch the gearbox without protection.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 12/19

REV. INDEX - A B C D
Fig. 1 - Short coupling lantern with clamp connection

Fig. 2 - Short coupling lantern with clamp connection

DOCUMENT NO. FORMAT SHEET

R730 916X A4 13/19

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Fig. 3 - Electric motors with clutches (switched ON) and gearboxes

DOCUMENT NO. FORMAT SHEET

R730 916X A4 14/19

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CONTROL
LEVER

BLOCKING
SCREW

Fig. 4 -The clutch is switched OFF, the blocking screw is applied

DOCUMENT NO. FORMAT SHEET

R730 916X A4 15/19

REV. INDEX - A B C D
Fig. 5 - Driving mechanism after demounting of the electric motor (the clutch is switched OFF)

DOCUMENT NO. FORMAT SHEET

R730 916X A4 16/19

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Fig. 6 – Driving mechanism after demounting of the electric motor and the clutch

Fig. 7 – New gearbox equipped by one half of the BKN clutch

DOCUMENT NO. FORMAT SHEET

R730 916X A4 17/19

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3. REPAIR INSTRUCTIONS

3.1 The INDRA PSR antenna unit is a repairable product. Repairs of the system by replacing worn-out and
damaged parts should be left to the Manufacturer. The electrical parts are repaired exclusively by the
Manufacturer.

3.2 The following procedure should be followed by the user in case warranty and after-warranty repairs are
requested: the user will find out the name and number of the drawing (nomenclature) of the part
requiring repair. The user will send the „Fault Report“ to the Manufacturer and will agree with him the
date and place where the repair will be performed, and, if need be, the way of passing over the damaged
part and the new (repaired) one.

3.3 Warranty repairs are requested to be submitted in writing and are to be passed over to the Manufacturer
along with the defective part.

3.4 In case of an after-warranty repair to be performed by the the Manufacturer, the user will pass over,
along with the defective part, also the filled slip guiding the defective part. At the same time, the user
will send to the Manufacturer a confirmed order for repair, or, as the case may be, an order for delivery
of new parts as per the agreement, see article 3.2.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 18/19

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4. LIFE TIME, RELIABILITY AND WARRANTY

4.1 The life time of the INDRA PSR antenna unit is 15 years.

4.2 Warranty conditions:

The Manufacturer provides 24 months of warranty which start running from the date of selling the
system. During the warranty period any defects, that have provably arisen during the manufacture or
due to a defective material, shall be remedied free of charge. The user is requested to follow the
warranty-repair procedure as per the article. 3.2 and 3.3 herein.

4.3 The warranty period shall be extended by the period during which the system was out of operation due
to a pending claim.

4.4 The warranty shall not apply to defects due to:

- improper attendance and maintenance
- unsuitable storing
- violent damage
- natural disaster
- intervention by unauthorized personnel
- common wear.

DOCUMENT NO. FORMAT SHEET

R730 916X A4 19/19

REV. INDEX - A B C D