FIXTURE STRUT THSA (GIM - GSE Instruction Manual)

P/N:
98D27403003002 GSE/Tool User Guide

ORIGINAL VERSION (ENGLISH LANGUAGE)
FIXTURE STRUT THSA

98D27403003002
CE DIRECTIVES ARE NOT

APPLICABLE ON THIS GSE
REACH Compliant
Doc. issue: A FIXTURE STRUT THSA Page 1 of 28

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Released on 06 July 2020

P/N:
Document Validation
Company Department Date

EXCENT
Made by 16/06/2020
FRANCE
Checked by AIRBUS
Validated by AIRBUS SEMSD
Record of Revisions
Reference of the
Issue Date Affected Page(s) Reason for revision
document used
A 16/06/2020 All

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P/N:
Table of Contents
Document Validation ...............................................................................................2

Record of Revisions ................................................................................................2
1 Prerequisites .....................................................................................................4
1.1 General information .......................................................................................4
1.2 Warning and caution .....................................................................................4
2 GSE/Tool setup .................................................................................................6
2.1 Before use.....................................................................................................6
2.2 Customer checklist ........................................................................................6
2.3 Packing checklist ...........................................................................................7
2.4 Zone of use (aircraft location) ........................................................................8
3 GSE/Tool usage.................................................................................................9
3.1 GSE/Tool description ....................................................................................9
3.2 Personal protective equipment ....................................................................10
3.3 Conditions of use ........................................................................................10
3.4 Assembly procedure....................................................................................11
3.4.1 Hydraulic Assembly ..................................................................................11
3.4.2 Mechanical Assembly ...............................................................................14
3.4.3 Assembly of the 2 recording devices ......................................................17
3.4.4 Tool Utilization ..........................................................................................20
3.5 GSE/Tool usage during maintenance task ..................................................23
3.6 Disassembly procedure ...............................................................................23
3.7 Trouble shooting .........................................................................................23
3.7.1 Trouble shooting with pressure loss .........................................................23
3.7.2 Trouble shooting with pump .....................................................................24
3.7.3 Trouble shooting with standards parts......................................................24
4 Test & Maintenance.........................................................................................25
4.1 Calibration ...................................................................................................25
4.2 Periodical Test ............................................................................................26
5 Handling / Storage ..........................................................................................27
6 End of life.........................................................................................................27
7 Glossary...........................................................................................................28

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1 Prerequisites
1.1 General information
All following instructions are only applicable for GSE/Tool P/N 98D27403003002.
This GSE/Tool User Guide must be read in conjunction with the appropriate Aircraft
documentation.
In case of conflicting documents please contact AIRBUS.
Before using or mounting the GSE/Tool, read this GSE/Tool User Guide carefully and
ensure that all content is well understood. Non-compliance with the instructions can
lead to personal injury or material damage and excludes any warranty.
The GSE/Tool is delivered by the manufacturer ready for assembly.

Before GSE/Tool assembly, a visual inspection and crosscheck with tool packing list
(see Chapter 2.3) shall be performed to ensure there are no missing or damaged parts.
During GSE/Tool life cycle, follow the maintenance intervals set out in the maintenance
instructions (see Chapter 4), except where:
- Visual inspection calls for immediate action;
- Unforeseen conditions necessitate more frequent servicing.
1.2 Warning and caution

A. General
The GSE/Tool P/N 98D27403003002 is designed to meet specific conditions of use
and to fulfil a defined function (described into this user guide). Any other use / action
than that given in this user guide will be under users / operators responsibility (except
in case of specific request coming from Airbus).

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B. Icons
WARNING
Climbing, standing or riding on this equipment is prohibited
WARNING
Finger pinch point when lowering and aligning
CAUTION
25 kg
C. Safety precautions
Ensure safe working practices when handling the GSE/Tool.
GSE/Tool shall be used only by an authorized and competent person who fully
understands the content of this user guide.
Always follow the procedures described in this user guide and the related Airbus
maintenance tasks.
The user shall ensure that:

 The GSE/Tool is only used for the function it has been designed for, as described
in this user guide;
 The GSE/Tool is in proper working conditions and that the applicable safety de-
vices are checked for functional reliability;
 Required personal protective equipment (PPE) for the GSE/Tool users are avail-
able and being used;
 Only qualified personnel is in charge of handling, operating, maintaining and re-
pairing the GSE/Tool;
 All attached safety and warning notices will not be removed and are legible.
Before use, the user shall ensure that GSE/Tool is in conformity with local legislation
if used outside of the EU.

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2 GSE/Tool setup
2.1 Before use
 Before using the equipment, you must, to ensure safe use of the tool and its
efficiency, read these instructions for use and comply with all
recommendations given.
 The instructions for use are not a training manual.
 These instructions for use must be placed at the disposal of all operators.
 Read and keep legible the instructions given on the tool. Do not use the tool if
the markings are not legible.
 Before each use, check that the machine is in good condition.
 Never use the tool if it is visibly not in good condition.
 The tool can be used only by capable, trained and competent operators
 Check the validity of the last conformity inspection.
2.2 Customer checklist

 Before using the GSE/Tool, be sure that you have:
☐_____a certificate of conformity,

☐_____a GSE User Guide,
Documents
☐_____periodical test results,

☐_____AMM, SB, SRM and/or TSM task relevant to the use of the GSE/Tool.
 A manufacturer's plate shall be placed on the GSE/Tool. It must include:
☐_____the name and country of the manufacturer,

On GSE/Tool
☐_____the GSE/Tool part and serial numbers,

☐_____the weight of the GSE/Tool,
☐_____the M.L. of the GSE/Tool,
☐_____the design issue of the GSE/Tool,

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P/N:
2.3 Packing checklist
062
058
044
042
060
Item Description P/N Quantity

042 RECORDING DEVICE 98D27403003042 1
044 RECORDING DEVICE 2 98D27403003044 1
058 HYDRAULIC ASSY 98D27403003058 1
060 ASSEMBLY PUMP 98D27403003060 1
062 STORAGE 98D27403003062 1

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P/N:
2.4 Zone of use (aircraft location)
All Aircraft except A340-500/600

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P/N:
3 GSE/Tool usage
3.1 GSE/Tool description
FIXTURE STRUT THSA
P/N 98D27403003002
Name of manufacturer
Address
Manufacturer name
Year of construction XXXX
Essential function This tool is used to control damage on THSA
Secondary function N/A
GSE/Tool weight
45 kg
Unit: kg
GSE/Tool dimensions
(Length x Width x Height) 330 x 420 x 1160 mm
Unit: mm
M.L.
850 kg
Unit: kg
Type of energy used by this GSE/Tool Manual
Number of persons required to use this GSE/Tool 2
The tool will be used for a maintenance task in

Working environment
an environment provided for this purpose.
GSE/Tool storage box

P/N 98D27403003062
GSE/Tool storage box dimensions
(Length x Width x Height) 330 x 420 x 1160 mm
Unit: mm

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3.2 Personal protective equipment

Note that PPEs to be used for GSE/Tool handling have to be consistent with the
working environment and associated requirements (some of them can be missing in
this chapter).
Mandatory head Mandatory body

protection protection
Mandatory foot Mandatory hand

protection protection
3.3 Conditions of use
Condition Details / Limits

Environment of use Inside …
External power needed? NO …
Operating temperature range -0°C / + 40°C …
 Check that the various parts of the tool are in good condition.
 Check the validity of the last conformity inspection.
 Read the installation instructions given below.

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3.4 Assembly procedure
3.4.1 Hydraulic Assembly

 Remove from the storage box the following items required:
o ASSEMBLY PUMP (060)
o HYDRAULIC ASSY (058) including:
 HYDRAULIC SYSTEM (114)
 CLEVIS ASSY (102)
 BAR 2 (210)
 BAR 3 (212)
 Install the hydraulic system (114) on the Aircraft fitting with ball lock pin.
Hydraulic
system (114)
Bush
Ball lock pins
 Screw totally the bush of the hydraulic system
OK NOK

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 Use the correct extension (in accordance with aircraft configuration)

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 Screw the good extension on the hydraulic system (114)
Extension
Couplers
Hydraulic
system (114)
 Connect the hydraulic system (114) to the hydraulic pump (060) with
couplers.

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3.4.2 Mechanical Assembly

Next steps consist to connect the tool to the upper fitting of the aircraft. To do that,
it’s necessary to adjust the tool length to be able to connect the ball lock pin to the
upper fitting.
Ball lock pin

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1st adjustment: Adjustment with hydraulic system
 Open the valves 1 & 2

 Put the selector of the manual pump on "compression" or “traction” (See
§3.4.4) and pump to adjust the length of the tool in order to align the green
groove of the extension with the green face of the Hydraulic Assy
Valve 1
Selector
Valve 2
Manual pump
Alignment of the
green groove
 Put the selector of the manual pump on "neutral" (See §3.4.4)

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2ndadjustment: Adjustment with the knurled bush.
Knurled Bush
Caution:
Adjustment system is used to adjust the length with a simple color control.
The length adjustment is OK if no red marking appear.
If red marking appear, do not use the tool.
NOK
 Adjust the length of the tool with the knurled bush until you are able to make
the connection with the fitting and to insert the ball lock pin
Ball lock pin

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3.4.3 Assembly of the 2 recording devices

 To check the correct operation of the THSA system, the installation of 2
recording devices is necessary
3.4.3.1 Assembly of Tie Bar Comparator
 Choose the assembly in accordance with the Aircraft.
98D27403003112 98D27403003110
- -
SA LR
 Install the comparator on the comparator system
Comparator

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 Screw the recording device on the Tie Bar System until the recording device
is stable. Do not compress the spring totally.
Tie bar
Recording devices
 Adjust the comparator to 0.

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3.4.3.2 Assembly of Ballscrew Comparator
System ballscrew Axis
Positioning of the comparator
 To install the system, unscrew both knurled nut to open it (See below),
Axis
Knurled nut + free axis
 Once opened, put the system around the ballscrew,

 Close the system and clamp it by screwing both knurled nut,
 Adjust the comparator.

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3.4.4 Tool Utilization

This tool is used to apply a load on the THSA system and to verify that there are no
defects.
Selector Valve 1 Traction Manometer
Traction
Line
-- Neutral
Compression
Line
Valve 2
Compression Manometer
Follow the step below before each utilization (traction or compression):
 Valves 1 & 2 opened, action the selector from traction to compression or

inversely and check there is no pressure in the system using manometers.
Traction Compression
Manometer Manometer
 Close valves 1 & 2 , and re-open them by half a turn only
 Refer to AMM procedure to apply the hydraulic pressure needed to perform

the task.
Note: Manometers can take a few seconds to react

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3.4.4.1 Tool Utilization in compression

Selector Valve 1
Compression
Line
Valve 2
Compression Manometer
Note: There is a risk for the safety valve to trigger if this procedure is not respected.
 Put the selector of the manual pump on "compression"
 To apply the hydraulic pressure needed, press the pump lever slowly about
once each 5 seconds until 120 bars and once each 10 seconds after 120
bars, until the required pressure is reached
Note: If the safety valve is triggered, restart

the hydraulic test from the beginning 3.4.4
Tool Utilization
 When you reach the pressure required, close valve 2 (compression valve).
Note: Closing the valve can slightly increase the pressure
 Read the displacement value of THSA system on the 2 recording devices
To uncharge the THSA, the pressure has to drop slowly. Change

the selector position from Compression to Traction and open
the valve 2 very slowly
Note: If you have difficulties to apply the pressure needed, refer to 3.7 Trouble
shooting

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3.4.4.2 Tool Utilization in traction
Selector Valve 1 Traction Manometer
Traction
Line
Valve 2
Note: There is a risk for the safety valve to trigger if this procedure is not respected.
 Put the selector of the manual pump on "traction"
 To apply the hydraulic pressure needed, press the pump lever slowly about
once each 5 seconds until 380 bars and once each 10 seconds after 380
bars, until the required pressure is reached
Note: If the safety valve is triggered, restart

the hydraulic test from the beginning 3.4.4
Tool Utilization
 When you reach the pressure required, close valve 1 (traction valve).
Note: Closing the valve can slightly increase the pressure
 Read the displacement value of THSA system on the 2 recording devices
To uncharge the THSA, the pressure has to drop slowly. Change

the selector position from Traction to Compression and open
the valve 1 very slowly
Note: If you have difficulties to apply the pressure needed, refer to 3.7 Trouble
shooting

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P/N:
3.5 GSE/Tool usage during maintenance task

N/A
3.6 Disassembly procedure

 Valves 1 & 2 opened, action the selector from traction to compression or
inversely and check there is no pressure in the system using manometers
 Proceed in reverse order of the installation steps.
3.7 Trouble shooting

3.7.1 Trouble shooting with pressure loss
A slight pressure loss can occur during utilization, if not exceed 10 bars in 5 min,
there is no trouble. If exceed, see trouble shooting bellow:
If there is a loss of pressure when using the hydraulic system, this may be caused
by:
 The safety valve was triggered because the applied pressure was too strong
 In that case, put the selector of the manual pump on “compression”

and “traction” to release the pressure in the system.
 Then, test again the system from the beginning 3.4.4 Tool Utilization
Note: For information, the safety valve can be triggered from 443 bars in traction and
from 158 bars in compression
 The safety valve is not corectly set (this can happen after several triggers)
 Note: Valve setting must be done by an agreemented company

 Anyway, setting the valves can be done following procedure in
paragraph 4.1 Calibration
 The manometers are not working properly and do not indicate the correct
value
 Connect a precise calibrated manometer on the hydraulic tool system

(see procedure in paragraph 4.1 Calibration)
 Control the values indicated by each manometers
 Change the manometers if necessary
 Oil leak in the hydraulic system
 Check that there is no oil leakage at the hydraulic connections

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3.7.2 Trouble shooting with pump
If you use the pump and the pressure does not increase in the system, it is possible
there is a lack of oil in the pump.
 Follow the procedure bellow:
- Warning: Be sure there is no pressure inside the system

- Unscrew “Nut 1” with appropriate Hex Key
- Clean the hydraulic connection at “Nut 1” position
- Fill the pump with mineral hydraulic oil (ref HF95 from ENERPAC or
Equivalent) (the “pipe” is directly connected to the pump)
- Clean the hydraulic connection at “Nut 1” position
- Screw back “Nut 1” by using hydraulic thread sealant / Teflon
- Connect the actuator to the hydraulic Pump
- Bleed the system by folding / unfolding 5 times the actuator.
Nut 1
Pipe
3.7.3 Trouble shooting with standards parts

In case of problems with standard parts (commercial of the shelf) refer to operating
instruction of standard part manufacturer.
In case of any GSE/Tool issues, please contact:
Maintenance Planning &GSE Services
Customer Service
Airbus S.A.S
1 rond point Maurice Bellonte
31707 Blagnac Cedex
France
maint.gsetools@airbus.com

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4 Test & Maintenance

4.1 Calibration
As GSE & Tools manufacturer, Airbus recommends calibration tests during tool
life cycle. Those recommendations should include a load test factor and a
periodicity defined here after.
Safety valve Calibration:
Periodicity: 12 months
Procedure:
 Connect a precise calibrated manometer on the THSA Hydraulic system

(For the connection, a standard coupler AZ3120 or AZ3140 from Larzep or
equivalent is needed)
Precise Calibrated
Manometer
Male and Female
Standard Coupler
Safety
Valves
THSA
Manometers Hydraulic
system
 Remove the protective cap
 Unlock the nut with appropriate fork wrench

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 Set the safety valve with appropriate hex key (closkwise for increase the
pressure limit)
 Trigger value of the safety valves:

 Traction: 458 bars +/- 3% (6640 psi)
 Compression: 164 bars +/- 3% (2378 psi)
Protective cap Nut Do not disassemble

this nut
Hex wrench size 6
 Control the trigger value of each safety valve with the calibrated manometer
Note: for safety valve calibration, pump identically as for tool utilization paragraph 3.4.4
Tool Utilization
 Once set, tighten the nut and instal the protective cap.
 During safety valve calibration, check the correct operation of the manometers
1&2
4.2 Periodical Test

As GSE & Tools manufacturer, Airbus recommends periodical tests during tool life
cycle. Those recommendations should include a load test factor and a periodicity
defined here after.
 For hydraulic GSE Tool:

Periodical pressure test has to be performed every year as follow:
- Performed leakage test at operating pressure during 2mn
- The GSE is equiped with 2 safety valves. For both valves, realise calibration (If
needed, follow procedure 3.7.1 Issue with pressure loss to set the safety
valves)
- Manometer check (can be realised during safety valve calibration procedure)

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A. Servicing &Maintenance
Servicing and maintenance must be done before each use, with the GSE/Tool
uninstalled and in a rest configuration.
Servicing and maintenance shall consist of:
- Verifying the proper conditions of working of the GSE/Tool.
- Checking periodic tests have been performed
- Checking calibration has been performed
- Cleaning parts
B. Maintenance Schedule
Perfom calibration and periodical test (see §4.1 and §4.2)
C. Specific maintenance
- See calibration and periodical test (see §4.1 and §4.2)
- Grease all threaded areas if needed
- Worn components must be replaced with original parts, not repaired. Parts of
inferior quality could damage the tools and be a risk to safety.
- Clean tool with appropriate cleaning agent
- Follow hydraulic pump & cylinder manuals for their preventive maintenance
actions needed.
5 Handling / Storage
A. Handling
- GSE storage box with stored GSE inside can be handled by hand.
- All items can be handled by hand through one or more people
B. Storage
- Before storing, refer to ‘Packing checklist’ (chapter 2.3) in order to verify the
availability of all items which shall be part of the GSE/Tool P/N 98D27403003002.
6 End of life
WARNING
To be compliant with regulation 2012/19/EC - Do not dispose Electric
and Electronic Equipment waste and collect them separately

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7 Glossary
A/C Aircraft
AMM Aircraft Maintenance Manual
E.g. For Example
Fig, Figs Figure, Figures
GSE Ground Support Equipment
Max Maximum
N/A Not Applicable
P/N Partnumber
M.L. Maximum Limit

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REFERENCE GIM_90034853
Distribution List
ISSUE A00 DATE 06 Jul 2020
GIM_98D27403003002
Distribution List
MANUAL DISTRIBUTION LIST

-------------------------------------------
wogse@sonovisiongroup.com
-------------------------------------------
maint.gsetools@airbus.com
-------------------------------------------
programs.gsetools@airbus.com
-------------------------------------------
Repair2@hydro.aero
-------------------------------------------
Tooling-Biberach@hydro.aero
-------------------------------------------
Tool.repair@airbus.com
-------------------------------------------
procurement.tools@airbus.com
-------------------------------------------
julio.ortiz@groupedcm.com
-------------------------------------------
contact.airbus@groupe-lpf.com
-------------------------------------------
capra.g@ecagroup.com
-------------------------------------------
gse.technic@ecagroup.com
-------------------------------------------
distribution.gse@airbus.com
-------------------------------------------
gserequest@excent.fr
© AIRBUS S.A.S. 2020. ALL RIGHTS RESERVED. CONFIDENTIAL AND PROPRIETARY DOCUMENT.

FIXTURE STRUT THSA (GIM - GSE Instruction Manual)

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P/N:

98D27403003002 GSE/Tool User Guide

FIXTURE STRUT THSA

CE DIRECTIVES ARE NOT

Doc. issue: A FIXTURE STRUT THSA Page 1 of 28

Released on 06 July 2020

Company Department Date

Validated by AIRBUS SEMSD

Doc. issue: A FIXTURE STRUT THSA Page 2 of 28

Released on 06 July 2020

Document Validation ...............................................................................................2

Doc. issue: A FIXTURE STRUT THSA Page 3 of 28

Released on 06 July 2020

The GSE/Tool is delivered by the manufacturer ready for assembly.

1.2 Warning and caution

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The user shall ensure that:

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2.2 Customer checklist

☐_____a certificate of conformity,

☐_____periodical test results,

 A manufacturer's plate shall be placed on the GSE/Tool. It must include:

☐_____the name and country of the manufacturer,

☐_____the GSE/Tool part and serial numbers,

Doc. issue: A FIXTURE STRUT THSA Page 6 of 28

Released on 06 July 2020

2.3 Packing checklist

Item Description P/N Quantity

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2.4 Zone of use (aircraft location)

All Aircraft except A340-500/600

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FIXTURE STRUT THSA

Year of construction XXXX

Essential function This tool is used to control damage on THSA

Secondary function N/A

Type of energy used by this GSE/Tool Manual

Number of persons required to use this GSE/Tool 2

The tool will be used for a maintenance task in

GSE/Tool storage box

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3.2 Personal protective equipment

Mandatory head Mandatory body

Mandatory foot Mandatory hand

3.3 Conditions of use

Condition Details / Limits

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3.4 Assembly procedure

3.4.1 Hydraulic Assembly

Ball lock pins

 Screw totally the bush of the hydraulic system

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 Use the correct extension (in accordance with aircraft configuration)

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 Screw the good extension on the hydraulic system (114)