508XT Technical Manual

XT
508
Technical Manual
Ref. – 10030284 AF 28 September 2020

Warnings, Cautions, Important Notices, and Notes
Warnings, Cautions, and Important notices throughout this manual guide you to avoid injury, prevent
equipment damage, and determine equipment use when varying components or configurations exist.
Notes provide tips or additional information.
SERCEL is not responsible for damages or injuries that result from failure to observe the information
provided.
Warnings and Cautions
WARNING
When a Warning or Caution appears with a lightning-bolt icon, as
shown in this example, this is to indicate a potential hazard that may
lead to bodily injury or even death.
CAUTION
When a Warning or Caution appears with an exclamation-point icon,
as shown in this example, this is to indicate possible equipment
damage or potential risk of misuse and incorrect operation.
Important Notices
IMPORTANT
Important notices appear in the manual to highlight information that
does not affect the risk of bodily injury, death, or equipment damage,
but is nevertheless important. These notices appear with a stop-sign
icon, as shown in this example.
Notes
Note Notes provide tips or peripheral facts and may guide you to other sources of
information.
2 508XT Technical Maintenance Manual

Europe
Nantes, France
Sales; Customer Support; North America
Manufacturing & Repair. Houston, Texas, USA
B.P. 30439, 16 rue de Bel Air Sales; Customer Support;
Manufacturing & Repair;
44474 Carquefou Cedex Tel: +1 281 492 66 88, Fax: +1 281 579 75 05
Hot-Line: +1 281 492 66 88
Tel: +33 2 40 30 11 81, Fax: +33 2 40 30 19 48 E-mail:
sales.houston@sercel.com
Hot-Line: Land: +33 2 40 30 58 88 HOU_Customer.Support@sercel.com
Marine: +33 2 40 30 59 59 HOU_Training@sercel.com
Navigation: +33 2 40 30 69 87 HOU_Customer.Repair@sercel.com
E-mail:
sales.nantes@sercel.com Tulsa, Oklahoma, USA
customersupport.land@sercel.com Tel: +1 918 834 96 00, Fax: +1 918 838 88 46
customersupport.marine@sercel.com E-mail:
customersupport.navigation@sercel.com support@sercel-grc.com
repair.france@sercel.com sales@sercel-grc.com
streamer.repair@sercel.com
www.sercel.com
Calgary, Alberta, Canada
St Gaudens, France Sales; Customer Support; Manufacturing.
Vibrator & VSP Customer Support; Tel: +1 403 275 3544, Fax: +1 403 295 1805
Vibrator Manufacturing & Repair; E-mail:
Streamer Manufacturing & Repair. Cal_Customer.Support@sercel.com
Tel: +33 5 61 89 90 00, Fax: +33 5 61 89 90 33
Hot Line: (Vib) +33 5 61 89 90 91 Middle East
(VSP) +33 5 61 89 91 00
Dubai, U. A. E.
E-mail:
Sales, Customer Support, Repair.
customersupport.vib@sercel.com Tel: +971 4 8832142, Fax: +971 4 8832143
customersupport.vsp@sercel.com Hot Line: +971 50 6451752
E-mail:
Brest, France dubai@sercel.com
Sales; Customer Support repair.dubai@sercel.com
Tel: +33 2 98 05 29 05; Fax: +33 2 98 05 52 41
E-mail: sales.nantes@sercel.com
Toulouse, France
Far East
Sales; Customer Support
Tel: +33 5 61 34 80 74; Fax:+33 5 61 34 80 66 Beijing, P. R. of China
E-mail: R & D.
support@metrolog.com Tel: +86 106 43 76 710, Fax: +86 106 43 76 367
sales@metrolog.com info@metrolog.com E-mail:
support.china@geo-mail.com
Dortmund, Germany repair.china@geo-mail.com
Manufacturing.
DE REGT Tel: +49 2 31 65 55 64 11.
Xian, P. R. of China
Manufacturing & Repair.
Russia
Tel / Fax: +86 29 8222 9504
Customer Support; Repair.
Moscow, Russia Xushui, P. R. of China
Tel: +7 495 644 08 05, Fax: +7 495 644 08 04 Manufacturing & Repair.
E-mail: Tel:+86 312 8648355, Fax:+86 312 8648441
repair.cis@geo-mail.org
support.cis@geo-mail.org Singapore
Streamer Manufacturing & Repair;
Surgut, Russia Customer Support.
Tel: +7 3462 28 92 50 Tel:+65 64 17 70 00, Fax:+65 6 545 1418
28 September 2020 3
License Agreement
By downloading, installing, copying or otherwise using the present software and its associated parts or
items (« Software »), you, as licensee (“Licensee”) agree without signature to the terms and conditions
of the present software license agreement (“Agreement”) issued by us (“Licensor”) governed and
judged by the French Laws and French Courts in case of dispute resulting from its enforcement.
License.
The Software is copyrighted and licensed but not sold.
The license (“License”) is a non-exclusive, non-transferable, revocable license (with no right to sub-
licence) to use the object code version of the Software solely for the Licensee’s own internal use for an
indefinite period of time or during the term indicated by the Licensor, if any.
The Licence allows copy for back up purposes only and does not authorise the Licensee or anyone else
to:
(a) Copy, reproduce, translate, adapt, vary, enhance or modify, merge, reverse engineer, reverse
assemble, decompile, or disassemble the Software or use the Software parts or items separately;
(b) Remove from the Software any labels or notices (including copyright notices) as to the Licensor’s
ownership of the Software or any other intellectual property rights;
(c) Distribute, publish, transfer, licence, sublicense, sell, rent, lease, lend or make directly or indirectly
the Software or program documentation in whole or in part (including but not limited to object code,
source code and source program listings) available to other organisations, entities or persons;
(d) Use or exploit the Software commercially or for the benefit of others;
(e) Create or attempt to create derivative works from the Software;
(f) Use the Software to violate the terms and conditions of any other software licensing agreement
between the Licensee and any third parties.
If Licensee is located in a country which requires a specific export licence or registration of software
licenses with government authorities, Licensee shall be responsible at its own cost for meeting all
requirement of such registration.
Import and Export.
Licensee is solely responsible for obtaining the necessary import licenses and any other official
authorizations and to carry out all customs formalities necessary and for paying all associated costs,
taxes and duties.
Licensee acknowledges that Software and any related services and technology, including technical
information supplied by Licensor or contained in the Software or associated documents (collectively

“Items”), is or may be subject to export controls of any government or community including but not
limited to the U.S. government or E.U. Community ( collectively “Controls”). The export controls
may ban or restrict or require licenses for the export or re-export of Items from the United States or
E.U. or any other countries. As a consequence any delivery schedule and performance of any of
Licensor’s obligation are subject to the enforcement of any Controls and the obtaining of any licence if
any, and Licensor shall not be liable to Licensee for any damage and loss resulting thereof. The Parties
agree to provide each other with any reasonable assistance, in particular for the issue of any document
that may be required by relevant administration, to comply with the obligations of this Agreement and
the Controls and for this purpose the Licensee will complete the end user statement submitted by the
Licensor.
28 September 2020 5
Revision History
Chapters
Date of Manual
or pages Description of revision or reason for
revision Version
affected change
Feb. 2016 AA Initial Document Release
Jul. 2016 AB p. 79 - Modified strain relief process in fiber-splicing

section.
p. 126 - Added maintenance section for CX-508.
Oct. 2016 AC p. 18 - Added Spare Parts list for FDU and DSU kits.
p. 55
p. 63
Apr. 2017 AD p. 21 - added details on FM4-508 anchoring

p. 79 - added TFOI-508 part number change and
anchoring evolution
p. 155 - added Land cable-508 splicing procedure
Dec. 2017 AE p. 142 - added WTU508
Sept. 2020 AF p. 15 - added LEAK TEST BY IMMERSION

p. 166 - added LAND CABLE-508 cold splicing
procedure
p. 192 - added TZ NODES repair procedure
p. 217 - added TZ FM4-508 repair procedure

TABLE OF CONTENTS
MAINTENANCE GENERAL GUIDELINES......................................................................................................... 10

WARRANTY WARNING ...................................................................................................................................... 11
ELECTROSTATIC DISCHARGE ............................................................................................................................. 11
SAFETY EQUIPMENT FOR FIBER OPTICS ........................................................................................................... 12
CHEMICAL PRODUCT WARNING ....................................................................................................................... 12
MISCELLANEOUS RECOMMENDATIONS ........................................................................................................... 13
O-RING GREASING ............................................................................................................................................ 13
PRODUCT CLEANING ......................................................................................................................................... 14
LEAK TEST BY IMMERSION IN HOT WATER ........................................................................................................ 15
LINK-508 REPAIR PROCEDURE ..................................................................................................................... 16
OVERVIEW ........................................................................................................................................................ 17
SPARE PARTS ..................................................................................................................................................... 18
TOOLS SET ......................................................................................................................................................... 18
REPAIR INSTRUCTIONS...................................................................................................................................... 19
Base cable disassembly ................................................................................................................................ 19
Base cable re-assembly ................................................................................................................................ 21
FM4-508 PLUG REPAIR PROCEDURE ............................................................................................................ 24
SPARE PARTS ..................................................................................................................................................... 25

TOOLS SET ......................................................................................................................................................... 27
FM4-508 plug disassembly ........................................................................................................................... 30
Cable anchoring repair ................................................................................................................................. 33
Contact holder repair ................................................................................................................................... 37
Connector final assembly ............................................................................................................................. 46
Cap replacing ................................................................................................................................................ 50
FDU-508 REPAIR PROCEDURE ..................................................................................................................... 54

SPARE PARTS ..................................................................................................................................................... 55
TOOLS SET ......................................................................................................................................................... 57
Disassembly procedure................................................................................................................................. 58
Re-assembly procedure ................................................................................................................................ 60
DSU1-508 REPAIR PROCEDURE ................................................................................................................... 62
SPARE PARTS ..................................................................................................................................................... 63
TOOLS SET ......................................................................................................................................................... 64
Strap disassembly ......................................................................................................................................... 65
Spike assembly ............................................................................................................................................. 68
Disassembly procedure................................................................................................................................. 70
Re-assembly procedure ................................................................................................................................ 71
FIBER OPTICS SPLICING PROCEDURE ............................................................................................................ 73
28 September 2020 7
ALLOWABLE LOSS ............................................................................................................................................. 74
FIBER SPLICING PARTS KIT ................................................................................................................................. 75
CONSUMABLE LIST ............................................................................................................................................ 76
TOOLS SET ......................................................................................................................................................... 77
Overview....................................................................................................................................................... 79
Cable anchoring preparation........................................................................................................................ 79
Fiber optic preparation ................................................................................................................................. 84
Fiber optic fusion .......................................................................................................................................... 87
Final assembly .............................................................................................................................................. 89
TFOI-508 REPAIR PROCEDURE ..................................................................................................................... 92
SPARE PARTS ..................................................................................................................................................... 93

Electronic AND Mechanical spare parts kit .................................................................................................. 93
Mechanical Only spare parts kit ................................................................................................................... 94
Cap replacement spare parts kit .................................................................................................................. 95
TOOLS SET ......................................................................................................................................................... 96
Anchoring repair V2...................................................................................................................................... 99
Anchoring repair V1.................................................................................................................................... 106
Fiber optic connector fusion ....................................................................................................................... 112
Electronic sub-assembly replacement ........................................................................................................ 116
Final Assembly ............................................................................................................................................ 118
Cap replacement ........................................................................................................................................ 122
Splicing Machine Description of use and advised checks ........................................................................... 122
Arc test ....................................................................................................................................................... 124
CX-508 REPAIR PROCEDURE ...................................................................................................................... 126

SPARE PARTS ................................................................................................................................................... 127
TOOLS SET ....................................................................................................................................................... 129
CONSUMABLE ................................................................................................................................................. 130
REPAIR INSTRUCTIONS.................................................................................................................................... 132
CX-508 disassembly .................................................................................................................................... 132
Sandwich electronic boards replacement ................................................................................................... 134
CXAB electronic board replacement ........................................................................................................... 137
Protective cap replacement ........................................................................................................................ 139
Circular connectors replacement ................................................................................................................ 140
LINE connectors replacement ..................................................................................................................... 145
RFID and desiccant capsule replacement ................................................................................................... 149
CX-508 re-assembly .................................................................................................................................... 151
Sacrificial anode replacement .................................................................................................................... 153
LAND CABLE-508 WARM SPLICING PROCEDURE ......................................................................................... 155
TOOLS SET ....................................................................................................................................................... 156
CONSUMABLE LIST .......................................................................................................................................... 158
Splicing preparing ....................................................................................................................................... 159
Overmolding ............................................................................................................................................... 165

LAND CABLE-508 COLD SPLICING PROCEDURE............................................................................................ 166
TOOLS SET ....................................................................................................................................................... 167
CONSUMABLE LIST .......................................................................................................................................... 168
Splicing preparation ................................................................................................................................... 169
Overmolding ............................................................................................................................................... 169
WTU-508 REPAIR PROCEDURE .................................................................................................................. 171
OVERVIEW ...................................................................................................................................................... 172

SPARE PARTS ................................................................................................................................................... 173
TOOLS SET ....................................................................................................................................................... 175
SAFETY PRECAUTION .................................................................................................................................. 176
WTU-508 main disassembly ....................................................................................................................... 177
WTU-508 desiccant replacement ............................................................................................................... 179
WTU-508 bottom case disassembly ........................................................................................................... 180
WTU-508 top case disassembly .................................................................................................................. 184
WTU-508 connector protective cap replacement....................................................................................... 188
WTU-508 SD CARD access .......................................................................................................................... 189
WTU-508 bottom case re-assembly ........................................................................................................... 190
WTU-508 top case re-assembly .................................................................................................................. 190
WTU-508 re-assembly ................................................................................................................................ 191
TZ NODE-508 REPAIR PROCEDURE ............................................................................................................. 192
SPARE PARTS ................................................................................................................................................... 193

TOOLS SET ....................................................................................................................................................... 195
FDU-508 PRE-ASSEMBLY replacement ....................................................................................................... 196
HALF-LINK replacement .............................................................................................................................. 201
TZ FM4-508 REPAIR PROCEDURE ............................................................................................................... 217
SPARE PARTS ................................................................................................................................................... 218

TOOLS SET ....................................................................................................................................................... 220
TZ FM4-508 disassembly ............................................................................................................................ 221
TZ FM4-508 re-assembly ............................................................................................................................ 223
Contact holder replacement ....................................................................................................................... 229
Locking pin replacement ............................................................................................................................ 231
Locking flange replacement ....................................................................................................................... 234
28 September 2020 9
Chapter
MAINTENANCE
1 General Guidelines
This chapter includes the following sections

 WARRANTY WARNING
 ELECTROSTATIC DISCHARGE
 SAFETY EQUIPMENT FOR FIBER OPTICS
 CHEMICAL PRODUCT WARNING
 MISCELLANEOUS RECOMMENDATIONS
 O-RING GREASING
 PRODUCT CLEANING
 LEAK TEST BY IMMERSION IN HOT WATER

WARRANTY WARNING
WARNING
Warranty is void if the product shows evidence of being damaged as a result of
disassembly by anyone other than a technician authorized by SERCEL.
ELECTROSTATIC DISCHARGE
Use the following guidelines to provide a static-free repair station that will preclude any ESD-related
damage to electronic circuits:
All spare parts (circuit boards and ESD sensitive devices) should be stored and transported in static-
shielding bags.
Unless the repair station rests on a conductive floor, chairs or stools should rest on a grounded, rigid-
type, static-dissipative floor mat.
Use a static-dissipative tablemat.
Wear a static-control wrist strap or foot grounder.
Provide common-point grounding for all conductive items (including personnel and soldering iron
tip).
To control the discharge rate and protect workers from electric shocks, both the tablemat and wrist
strap should be grounded through a 1-M resistor. The mat should be connected to the same earth
ground point as the wrist strap.
Wear static-dissipative garments.
28 September 2020 11
SAFETY EQUIPMENT FOR FIBER OPTICS
Fiber optic scrap is thin and rigid and could be dangerous for eyes and hand. Be careful to wear
protection gloves and safety glasses.
Fiber optics tools and repair is HIGLY sensible to the area air quality. Work in a clean
and ventilated area; protect your equipment and tools from any dust, water, sand...
CHEMICAL PRODUCT WARNING

The following procedure includes the use the chemical product. Chemical products can have the
following health effects:
Inhalation: May cause respiratory tract irritation.
Skin contact: May cause allergic skin reaction. May cause skin irritation.
Eye contact: Contact with eyes will cause irritation.
To wear gloves to avoid skin contact, safety glasses and work in a well-ventilated area when you use
chemical products
WARNING:
This procedure contain chemical product (Loctite, epoxy glue, one use wipe…). Read
carefully the chemical product warning chapter. Use of of chemical product is marked
with:

MISCELLANEOUS RECOMMENDATIONS
Stray metal chips should be banned from the work surface. Tools should remain absolutely clean.
Special attention is required when removing screws from a metal housing, as metal chips may come
out of the holes. It is advisable to apply grease on the side and bottom of each screw hole in order to
preclude any such problem.
Take care not to bring in any contaminants throughout disassembly, repair and re-assembly operations.
It is recommended to wear clean-room gloves or finger cots. Food, drink or tobacco products should
be banned from the assembly area. Clean your area before, during and after disassembly, repair and re-
assembly.
Do not attempt to use traditional probe tips to pick up signals on the leads of VLSI circuits. A probe
tip may tear off tin chips that visual inspection without a magnifier will fail to reveal. The space
between adjacent leads is so small that tiny metal fragments may cause accidental shorts.
Use a dedicated soldering/de-soldering station equipped with an appropriate tip whenever required.
O-RING GREASING
The o-ring greasing can be done with this procedure:
- Place the O-ring with aqualub on it in a plastic bag
- Rub the oring in the bag to distribute the grease. The oring must not have grease packet on it.
PRODUCT CLEANING
A soft brush (nylon, NON METALLIC) can be used to clean the outside part of the product,
including external side of the connectors. It must NOT be used to clean inside the connectors.
Drown product in clear water, preferably warm and not calcareous, and shake them during a few
seconds. Brush dirt areas if needed, except inside of connector.
Chemicals products such as soap or alcohol must not be used.
Vaporize with clean water inside the connectors using a spray, and shake the product to remove excess
water.
Dry the connectors and caps with either:
- compressed air holding the nozzle at least 15cm of the plug
- a dry air spray with a refillable aerosol LOCTITE 1412504 (SERCEL PN 10009545) or equivalent.

LEAK TEST BY IMMERSION IN HOT WATER
Strictly complying to the instructions described in this manual when re-assembling a unit normally
ensures correct sealing. However, Sercel recommends to use the leak test procedure described below
to check the correct sealing of the product.
Test equipment required
- Water tub
- Heating resistor controlled by a thermostat
Test conditions
- Water temperature: 65°C

- Water should be transparent. Surface of the product to be tested should be free of any
substance that should bias the test
- Immersion for 3 minutes
Test procedure
- Turn on the heating resistor and wait until the temperature of the water is about 65° C.
- Dip the unit into the water: No very big bubbles should be seen right after the unit is fully
immersed.
- Leave the unit fully immersed for 3 minutes: At the end of 30 seconds, no recurrent bubble
stream should be seen.
- Take out the unit and dry it up with compressed air
Chapter
LINK-508
2 Repair Procedure
This chapter includes the following sections,

 OVERVIEW
 TOOLS SET
 REPAIR INSTRUCTIONS
 Base cable disassembly

 Base cable re-assembly

OVERVIEW
This procedure explains how to disassemble and re-assemble base-cable termination 508XT to field
units 508XT (same procedure for FDU-508 and DSU1-508).
O-RING 18,64 x 3,53

SCREW 50 x 24 SECURITY 25IPR
BASE CABLE
TERMINATION
FDU-508 DUSTCAP
PRE-ASSEMBLY LID of FDU-508
Exploded view of LINK-508 (FDU-508 version)
O-RING 18,64 x 3,53

BASE CABLE TERMINATION
SCREW 50 x 24 SECURITY 25IPR
DSU1-508 STRAP
PRE-ASSEMBLY LID of NODE-508 (FDU-508)
Exploded view of LINK-508 (DSU1-508 version)
SPARE PARTS
Note: spare parts are subject to minimum quantity order
Items Part No. Comments
SCREW 50 x 24 SECURITY 25IPR 10014254 FDU-508 and DSU1-508
O-RING 18,64 x 3,53 10003432 FDU-508 and DSU1-508
FDU-508 DUSTCAP 711082917A FDU-508 only
TOOLS SET
Supplied
Tools and materials required Tool picture Part No.
in kit No.
Electrical screwdriver 1,8Nm 10027772
Insert Bit TORX PLUS security 25IPR

10022316
- short
10027859

10017871
- long
NODE-508 holding feature 10021139

REPAIR INSTRUCTIONS
This repair procedure is applicable for all references of 508XT field units (FDU-508, DSU1-508,…).
Base cable disassembly
- Place unit on the holding feature and clamp it using the spring clip.
FDU-508 DSU1-508
- Locate the 2 screws which attach the bases cables.
- Untighten the two SCREWS 50 x 24 (screw head type : TORX 25IPR).
- De-clamp the node from the feature. The two base cable terminations can be removed.

Base cable re-assembly
- For a FDU-508 unit, insert the cap ring (P/N: 711082917A) on the pin of the PRE-
ASSEMBLY.
- Clean the O-ring groove and place a new O-ring greased with the RED AQUALUBE grease
on each BASE CABLE.
- Clean the connector areas on each side of the pre-assembly also.
- Put both BASE CABLES on a PRE-ASSEMBLY.
- Install the 2 base cable terminations and the FDU-508 pre-assembly inside the feature.
- Clamp the unit using the spring clip.
FDU-508 DSU1-508
- Tighten the 2 screw using the torque screwdriver set up inside the range 1,8Nm±0,09 and at
560rpm.

IMPORTANT : use of an electrical screwdriver is mandatory if the BASE CABLE ENDINGS are
new and have never been screwed with FDU-508 (or DSU1-508) pre-assembly. Rotation speed
of the electrical screwdriver will ensure the correct creation of the thread.
- De-clamp the unit from the feature.
Chapter
FM4-508 Plug
3 Repair Procedure

 SPARE PARTS
 TOOLS SET
 FM4-508 plug disassembly

 Cable anchoring repair
 Contact holder repair
 Connector final assembly
 Cap replacing

SPARE PARTS
BENDING RESTRICTOR
NUT WITH CAP
SLEEVE FM4-508 for REPAIR
WASHER GLAND SLEEVE
WASHER GROMMET
CONTACT HOLDER
CONTACT HOLDER PAD SCREW 3.0x8.0CBLX

3.0x6.5
GLAND SLEEVE
6mm
WIRING SPACER
PROTECTION SLEEVES
FLAT WASHER M6
refer to
§ Cable anchoring repair
S/E PLUG+LOCKING RING+O-RING
for details
All parts shown are available in FM4-508 spare parts kit (P/N: 10023949SPR).
Items Part No. Supplied in kit No.

SCREW CBLX 3.0x8.0 10032348
BENDING RESTRICTOR NUT WITH CAP 10030536
SLEEVE FM4-508 for REPAIR 410050844
CONTACT HOLDER PAD 10003785
FM4-508 CONTACT HOLDER 10016954
10023949SPR
WASHER GLAND SLEEVE 410050774
GLAND SLEEVE 6mm 410050784
WASHER GROMMET 410050794
WIRING SPACER 410023813
S/E PLUG+LOCKING RING+O-RING 10026564
PROTECTION SLEEVE 355202001
FLAT WASHER M6 217141060

TOOLS SET
Tools and materials Supplied in

Tool picture Part No.
required kit No.
Vario-torque Screwdriver
(0.4 - 1.0 Nm adjustable 10006678
using TORQUE SETTER
provided in TOOLS SET)
Screwdriver bit Torx8 10027863
Torque wrench 258310012
Open-End wrench tip 699123632
FM4 support and 10028826

disassembly tool
10027858
Cable cutters 0060132
Manual crimping tool 10025081

for pliers 35mm²
Crimping pliers 35mm² 10020116
Cable stripper 257341006
Tools and materials Supplied in
Tool picture Part No.
required kit No.
Wire stripper 257300025
Soldering iron 0020117
Tip width 1.2mm for 0220065

soldering iron (x5)
A=1.2mm
Tip width 2.4mm for 0220068 10027858

soldering iron (x5)
A=2.4mm
Power supply wiring for 0220050

Soldering iron
Solder 135110009
Crimping pliers tool 6mm² 257300035

OPTION
Electrical crimping pliers 10020019 N/A
tool 35mm² kit
(electrical version)
REPAIR INSTRUCTIONS
FM4-508 plug disassembly
- Put in place the FM4-508 plug on a holding feature (possibility to use a concentrator CX-508
to maintain the FM4-508 plug, or to use another FM4-508 plug held in a feature – see picture
below, for example).
- Turn the LOCKING RING (orange part) until the screw is visible, then unscrew it (screw head
type: TORX 8).
- Unscrew BENDING RESTRICTOR NUT WITH CAP with open-end torque wrench and slide
it backward.

- Insert FM4-508 on support and push bottomward to unlock contacts.
- Gently pull back contacts by rotating in order to move out the slack inside the plug.
Cable anchoring repair
- Cut wire as close as possible from the anchoring, in a cable area no damage.
Note: when disassembly, anchoring design of FM4-508 may be either with crimped sleeve, either with
overmolding. See next step for more details.
IMPORTANT :
WASHER GLAND SLEEVE (orange color in case n°2) must
not be re-used. For repair, use only WASHER GLAND
SLEEVE (PN410050774 black color)
WARNING
Due to product design change on BENDING RESTRICTOR WITH CAP, there may
have 2 cases for FM4-508 re-assembly :
Look in this area the

BENDING RESTRICTOR NUT WITH CAP
that will be used
CASE n°1 CASE n°2
4 ribs inside the nut no rib inside the nut
CASE n°1 CASE n°2
insert the BENDING RESTRICTOR insert the BENDING RESTRICTOR

WITH CAP only WITH CAP + FLAT WASHER M6-U
before starting the crimping process (PN 217141060) before starting
the crimping process
For the rest of the procedure, the instructions to follow are the same for both cases.
- Place new sleeve (P/N : 410050844) at 95mm of wire end as shown on scheme and make a
marking on cable to ensure sleeve position.
-
95mm +/- 1mm
- Crimp the sleeve in 2 steps. First crimping must be done on cable marking side to control to
right sleeve position. Second crimping must be done on the other side keeping few millimeters
in the middle not crimped.

- Check visually that the crimping is well done (9mm height between 2 opposite flat areas).
- Remove cable jacket on a length of 56, 5 mm ± 0,5 mm from cable end using cable stripper.
- Cut the 4 strength members with cutters.
56,5mm +/- 0.5
56,5mm +/- 0.5 16mm +/- 0.5
FLAT WASHER M6-U is located here

for CASE n° 2 (refer to § Cable
Note: strength members length < 5mm anchoring repair)

Contact holder repair
- Remove PROTECTION SLEEVE and CONTACT HOLDER PAD.
- Place CONTACT HOLDER on support.
- Remove wires upwards touching side of contact with soldering iron.
- Strip the 4 wires on a length of 6mm ±0.5 with the wire stripper. Check that the stripping is
OK.
6mm +/- 0.5
- Apply tin on the 6mm stripped of the 4 wires.
- Add WASHER GLAND SLEEVE, then GLAND SLEEVE 6mm towards SLEEVE. The
cable jacket must be flush with GLAND SLEEVE 6mm (in any case, the cable jacket over-
flush must not exceed 1mm).

NOTE : SERCEL recommends using new WASHER GLAND SLEEVE, GLAND SLEEVE
6mm, and WASHER GROMMET for every repair.
WARNING
For repair in both CASES n°1 and n°2, only WASHER GLAND SLEEVE
(PN410050774 - black color) must be used. WASHER GLAND SLEEVE orange color in
case n°2 must not be re-used.
- Slip the wires through the WASHER GROMMET
(bore of WASHER GROMMET on SLEEVE side)
WARNING: Slip the WASHER GROMMET on the 4 wires without twisting or crossing them
- Add WIRING SPACER (small hole opening on SLEEVE SIDE)
- Replace protection sleeve on each wire (P/N : 355202001)

WARNING: Respect wiring diagram between wire color and contact id.
A : BROWN WIRE
B : GREY WIRE
C : BLUE WIRE
D : YELLOW
- If the pins are not pre-tinned (new CONTACT HOLDER), tin them by filling in up to the hole
on the side of barrels.
- Control that the 4 pins are well tinned.

- Put a little bit of tin on the soldering tip.
- Heat the barrel on the side or back as shown below.
WARNING: Do not heat directly tin or front of barrel.
- Push the wire all the way to the end and towards the back of barrel as soon as the tin is
liquefied.
- Repeat process for the remaining wires/pins.
- Place the sleeves over the solders on each contact.
No burn mark on side of contacts
- Remove contact holder from holding feature and place the CONTACT HOLDER PAD, make
sure to align the slots.
the 2 bumps of the CONTACT
HOLDER PAD associated with
the 2 smallest pins
NOTE: SERCEL recommends using new CONTACT HOLDER PAD for every repair
- Push the WASHER GLAND SLEEVE, GLAND SLEEVE 6mm WASHER GROMMET
and WIRING SPACER against the sleeve.
- Turn the CONTACT HOLDER one turn anticlockwise (¾ turn minimum) to place the cable
slack within the WIRING SPACER.
WARNING: All the cable slack must be placed within the spacer. Take care not to pinch wire(s)
between other parts (GLAND SLEEVE, WASHER,…).
- Align the 3 slots (WIRING SPACER, CONTACT HOLDER & CONTACT HOLDER PAD)

Connector final assembly
- Insert the contact holder in the sub-assembly S/E PLUG+LOCKING RING+O-RING by

aligning the keyway and slots.
- Push the contact holder all the way into the body
- Slightly tighten the bend restrictor nut on the sub-assembly S/E PLUG+LOCKING RING+O-
RING.
WARNING: The bend restrictor is tightened on the sub-assembly – the sub-assembly must not
rotate.

- Open the locking ring.
- Connect the FM4-508 plug and lock it with the ¼ locking ring on the rig using the holding
feature.
- Tighten the bend restrictor nut at 10Nm±0.5 using the dynamometer wrench.
- If needed rotate the locking ring to get access to the hole for the anti-rotation screw.
-Tighten the screw using the torque screwdriver set up at 1.0Nm.

-Check that this anti-rotation screw is well located in its housing:
o Screw head in contact
o Locking ring rotates without any collision with the screw
Note: in case the screw head is not in contact, it can be required to increase (using the torque-setter)
the nominal torque of the screwdriver in order to guarantee a correct screwing.
- Control that the connector seal is present.

- Pull on the cable to check that the sleeve is correctly crimped within the bend restrictor nut

- Shut the FM4-508 plug with the CAP and lock the locking ring
Cap replacing
The following FM4-508 cap repair kit PN 10014872SPR contains:
CAP
CRIMPING SLEEVE
WIRE
Items Part No. Supplied in kit No.

CAP 410050822 + 10010287
CRIMPING SLEEVE (qty : 2) 355100001 10014872SPR
WIRE (~ 0.4m) 354800042
REPAIR PROCEDURE
- Cut the damaged wire in place on cap or on the nut with cutting pliers

- Cut the wire PN 354800042 at length 250 mm ± 2 mm
- Insert one crimping sleeve réf 355100001on wire
- Insert the extremity of wire inside FM4 cap
- Insert again the wire in the crimping sleeve and let it exceed from 1 to 3 mm from the sleeve.
The loop measurement is around 25 mm ± 5 mm
- Crimp with the tool 257300035 in the central position (blue mark 1,5 to 2,5 mm² ) , check
visually that the crimp is flat
- Insert one crimping sleeve réf 355100001 on wire and the extremity of wire inside the hole of
FM4 nut
- Insert again the wire in the crimping sleeve and let it exceed from 1 to 3 mm from the sleeve.
The loop measurement is around 25 mm ± 5 mm
- Crimp with the tool 257300035 in the central position (blue mark 1,5 to 2,5 mm² ), check
visually that the crimp is flat

- Test the cable by manual traction on both extremities
Chapter
FDU-508
4 Repair Procedure

 SPARE PARTS
 TOOLS SET

SPARE PARTS
SCREW 40 x 16 20IP
COVER O-RING
TAG RFID
FDU-508 ELECTRONIC BOARD COVER

(sold only in pre-assembly)
LID
Exploded view of FDU-508 pre-assembly
FDU-508 SPARE PARTS KIT FOR 50 10019872 contains all mechanical parts -
FDU-508 electronic board excluded
FDU-508 PRE-ASSEMBLY 10014476SPR Pre-assembly with electronic board
(sold by multiple of 10 units)
FDU-508 SPARE PARTS KIT FOR 50 (PN 10019872) contains following parts and quantities :
Items Part No. Qty Comments
LID (WITHOUT SERIAL NUMBER) 10020740 50
COVER 10014681 50
SCREW 40 x 16 20IP 410052294 300
COVER O-RING 410052263 50
TAG RFID 10001838 50
SCREW 50 x 24 SECURITY 25IPR 10014254 100 refer to § LINK-508 / SPARE PARTS
FDU-508 DUSTCAP 711082917A 50 refer to § LINK-508 / SPARE PARTS
O-RING 18,64 x 3,53 10003432 100 refer to § LINK-508 / SPARE PARTS

TOOLS SET
Supplied
in kit No.
(0.5 - 2.0 Nm adjustable using
10034626
TORQUE SETTER provided in
TOOLS SET)
Torque screwdriver fix 1,4Nm 10021742
Universal bit holder 10006699
10021683
Insert bit TORX T20 0020113
Insert Bit TORX PLUS security

10022316
25IPR - short
Screwdriver bit TORX T20 10025062
REPAIR INSTRUCTIONS
Disassembly procedure
- Remove the 6 screws with the TORX T20 screwdriver.
- Save the 6 screws for reassembly.
- Do not put your finger on the components to extract the board : extract the board by pulling on the
sides
WARNING: Keep the lid and cover together! Do not mix them.
WARNING: in order to avoid mixing of RFID tags and lid, open only 1 FDU-508 unit at a time.

- If possible, do not extract the gray RFID tad, leave it in the lid. Otherwise, refer to pictures below
for RFID tag handling.
Re-assembly procedure
- Inset gently the RFID tag following handling precaution (see §0) in the same way as shown below
:
- Insert gently the electronic board by pulling on the sides and pull on top to ensure contact locking.
Warning: be very careful with the

contacts on each side of the board,
in order to not twist them.

- Clean the O-ring groove and place a new O-ring greased with the RED AQUALUBE grease.
- Place cover on lid and tighten the 6 screw using the torque screwdriver set up inside the range
1,4Nm±10% and at max 600rpm respecting the following sequence from 1 to 6 :
- Apply a second screwing at 1,4Nm
- IMPORTANT : to inscribe the serial number of the board on the new cover in the area
Chapter
DSU1-508
5 Repair Procedure

 SPARE PARTS
 TOOLS SET
 Strap disassembly
 Spike assembly
 Disassembly procedure
 Re-assembly procedure

SPARE PARTS
SCREW 40 x 16 20IP
SCREW 50 x 24 SECURITY 25IPR COVER O-RING
SPIKE O-RING
TAG RFID
COVER
DSU1-508 ELECTRONIC BOARD

SPIKE (sold only in pre-assembly)
LID
STRAP
Exploded view of DSU1-508 pre-assembly

DSU1-508 SPARE PARTS KIT contains all mechanical parts -
10027621
FOR 50 FDU-508 electronic board excluded
Pre-assembly with electronic board
DSU1-508 PRE-ASSEMBLY 10019064SPR
(sold by multiple of 10 units)
DSU1-508 SPARE PARTS KIT FOR 50 (PN 10027261) contains following parts and quantities :
Items Part No. Qty Comments
LID 410054121 50
COVER (WITHOUT SERIAL NUMBER) 10027632 50
SCREW 40 x 16 20IP 410052294 300
COVER O-RING 410052263 50
TAG RFID 10001838 50
SPIKE 10017610 50
SPIKE O-RING 10022117 50
STRAP 410054132 50
SCREW 50 x 24 SECURITY 25IPR 10014254 150 refer to § LINK-508 / SPARE PARTS
O-RING 18,64 x 3,53 10003432 100 refer to § LINK-508 / SPARE PARTS
Note : spare parts are subject to minimum quantity order
TOOLS SET
Supplied in
kit No.
Torque screwdriver 0.8-2NM
adjustable
(to be set up @ 1.8NM using 10034626
TORQUE SETTER provided in
TOOLS SET)
Torque screwdriver fix 2,0Nm 10006685
Insert bit TORX T20 0020113 10021684
Insert Bit TORX PLUS security

10022316
25IPR - short
Screwdriver bit TORX T20 10025062
Hinged hook and pin wrench 257260013

REPAIR INSTRUCTIONS
Strap disassembly
- Locate the 2 strap attachment areas:
- To remove the strap from attachment in location A, proceed as follows :
push the strap extremity upwards strap extremity is out

of its cavity. Keep pushing.
when round section

shape is at the hook
level, make a half
turn
pull the strap extremity backwards
raise up the strap extremity to strap extremity is now
remove it from the hook shape out of the hook shape
- To remove the strap from attachment in location B, proceed as follows :
strap extremity is out

of its cavity. Keep pushing.
push the strap

extremity upwards
take advantage of the Configuration must be as shown.

flexibility of strap to push it
till the second flat shape area
second flat
shape area

raise up the strap extremity
to remove it from the hook
shape
strap extremity is now

out of the hook shape
- To make strap assembly, follow instructions in opposite way. Final assembly and position of
strap regarding NODE must be similar to picture shown in first step of this procedure.
Spike assembly
- Place the O-RING 18,64 x 3,53 inside the location on the top of the SPIKE.
- Take PRE-ASSEMBLY DSU1-508 in one hand and spike in the other hand and take care of
orientation before insertion with the arrow of SPIKE in front of arrow of PRE-ASSEMBLY
DSU1-508.
the 2 arrows
must be
aligned during
insertion

- Lock the spike by hand rotation of about ¼ turn clockwise of the spike until it becomes hard,
then finalize the locking the spike with the pin wrench to align the screwing holes.
- Place a screw and fix it with the screwdriver with torque value at 1,8± 0,1N.m (screw head
type: TORX PLUS security 25IPR).
WARNING: When the screwing is done with new parts (SPIKE and/or LID of PRE-ASSEMBLY
DSU1-508), it is mandatory to use an electrical screwdriver.
- To make spike disassembly, follow instructions in opposite way.
Disassembly procedure
- Remove the 6 screws with the TORX T20 screwdriver.
- Save the 6 screws for reassembly.
- Do not put your finger on the components to extract the board : Extract the board by pulling on the
sides.
WARNING: Keep the lid and cover together! Do not mix them.
WARNING: in order to avoid mixing of RFID tags and lid, open only 1 FDU-508 unit at a time.
- If possible, do not extract the gray RFID tad, leave it in the lid. Otherwise, refer to pictures below
for RFID tag handling.

Re-assembly procedure
- Inset gently the RFID tag following handling precaution (see §0) in the same way as shown below
:
- Insert gently the electronic board by pulling on the sides and pull on top to ensure contact locking.
Warning: be very careful with the

contacts on each side of the board,
in order to not twist them.
- Clean the O-ring groove and place a new O-ring greased with the RED AQUALUBE grease.
- Place cover on lid and tighten the 6 screw using the torque screwdriver set up inside the range 2,0
Nm±10% and at max 600rpm respecting the following sequence from 1 to 6:
6
1 4
3 2
5
- Apply a second screwing at 2,0Nm.
IMPORTANT: to inscribe the serial number of the board on the new cover in the area

Chapter
Fiber Optics Splicing
6 Procedure

• ALLOWABLE LOSS
• FIBER SPLICING PARTS KIT
• CONSUMABLE LIST
• TOOLS SET
• REPAIR INSTRUCTIONS
 Cable anchoring preparation

 Fiber optic preparation
 Fiber optic fusion
 Final assembly
ALLOWABLE LOSS
Use the tables below to check the performance of a fiber optic cable after replacing a connector or
splicing a damaged cable, or to determine the maximum allowable number of splices. The type of fiber
used appears on the outer jacket of the cable.
Optical fiber specifications G.657

Fiber 9/125 μm
Outer coating 900 μm
Characteristics Single, monomode.
Bend-optimized.
Attenuation < 0.42 dB/km @ 1310 nm
< 0.38 dB/km @ 1490 nm
Optical IOR 1.466 @ 1310 nm
1.467 @ 1490 nm
Cable specifications Max allowable

number of splices
Max length Max loss (fusion splicer)
2 km 8 dB 4
10 km 8 dB 4
The total loss in the cable should not exceed the “Max loss” figure given in the above table.
The table below details the allowable loss figure for each element.
Max allowable loss in

Fiber Type
Max loss
G.657 1 dB 1 dB
For loss tests, use an Optical Time Domain Reflectometer. The above figures are for the following test
conditions:
- FITEL LBT-101 single mode fiber mini-OTDR 1610nm for distance ≤ 2.5km or
equivalent reflectometer
- ANRITSU MT9090A-MU909011A mini-OTDR 1550nm for distance ≤ 10km or

equivalent reflectometer
- these two reflectometers integrate lunch fiber.

FIBER SPLICING PARTS KIT
The parts kit PN 10033537 contains the necessary equipment to splice one 508 fiber optic cable :
article Comment and display Part No. quantity
External conical ring 10011455 2
Internal conic sleeve 10013942 2
410047983 2
Stain relief anchor
flexible 279001008 1
Bend limiter 355209001 2
oring 237401303 2
Heat shrink sleeve 355300070 3
Cleaner sachet 256900014 1
CONSUMABLE LIST
The consumable list contains the necessary chemical products to splice up to 10 fiber optic 508 or
repair up to 10 TFOI-508. These products can be found on local market or order to Sercel with the
proper PN.

Loctite 480 8030081 1
Aqualube grease 8060015 1
Wipe single use only, 10020527 1

quantity 500 per box
Loctite 382 + Loctite 186100016 1

7455 (activator)
Loctite 242 8010031 1

TOOLS SET
The following tool list PN 512600050 contains:

17/19 mm open-end 257211701 1
wrench
24/27 mm open-end 257211703 2

wrench
Automatic stripping 257300015 1

pliers
Fusion splicer + 10028241 1
One-action precision
cleaver
900 μm fiber clamp right 257410008 1

and left side
Epoxy dispenser 257671005 1
Ring locker 699121677 1
1
Crimping pliers tool
10025879
6mm²

Cable cutters 257370005 1
Kevlar scissors 257420002 1
Stripper tool for outer jacket 257341006 1
Stripper tool for inner jacket 10021044 1

Reflectometer Fitel LBT-101 512500267 1
(*)
(*) Another tool kit (P/N 512600052) is available that includes the same tools with reflectometer.

REPAIR INSTRUCTIONS
Overview
This section describes how to splice a damaged fiber optic cable, using the fusion splicer tool kit
(PN 512600052) and fusion splicer parts kit (PN 10033537). See ALLOWABLE LOSS for the
maximum allowable number of splices.
Outer jacket Kevlar Fiber optic jacket Fiber optic
Inner jacket Fiber optic protection

Fiber optic cable
Cable anchoring preparation
- To make disassembly of TFOI-508 in order to have access to Fibre optic connector (refer to §
TFOI-508
Repair )
- Locate the damaged portion of cable as follows: connect one end of the fiber optic cable to the
reflectometer and read the length, and then connect the reflectometer to the other end and read
again the length. The sum of the two readings should equal the total length of the cable (unless
it is broken at two or more points).
Note : the fiber optic cable has marks every meter, which help to locate the fiber optic break position.
- Cut the cable 1 m (± 10 cm) apart the broken point. In case of multiple break located closely,
you can short the Fiber optic. Use the scissor PN 257420002
1 m (±10 cm) 1 m (±10 cm)
Break point
1 m (±10 cm) 1 m (±10 cm)
- Insert O-ring PN 237401303 on cable gland delivered with spiral bend restrictor PN
355209001
- Push each cable end through the spiral bend restrictor and equipped cable gland, strain-relief
anchor PN 410047983. Do not tighten the compression nut
cable gland
spiral bend
equipped with
restrictor
o-ring
strain relief
anchor
- On one end, insert the cable into the flexible protector PN 279001008. Be sure an O-ring PN
237401303 is fitted at either end of the flex splice protector.

O-ring - see note
next page
Note : flexible protector PN 279001008 includes the 2 o-rings PN 237401303 under the
yellow protective caps.
WARNING :
it is mandatory to follow the defined length to not damage the cable during the repair
operation
- Prepare each end as follows:

 Use a stripping splice PN 257341006 to remove the outer jacket so as to cut it 18 cm
from the end of the cable.
 Place adhesive tape at the end in order to make it easier to insert it into the ferrule.
15 cm
18cm
Tape
- Clean external conical ring PN 10011455 and internal conic sleeve PN 10013942 using
isopropyl alcohol
internal conical sleeve
external conical ring
- Pass the cable end through the external conical ring up to outer jacket

- Remove tape, arrange remaining Kevlar around the external conical jacket and pass the inner
cable core through the internal conical sleeve
- Place the cable end on support PN 10025163 and apply glue LOCTITE 382 all around the
middle of the internal conical sleeve.
- put tool PN 10025163 in contact with the sleeve and hit on the tool using the hammer to lock
the internal conical sleeve. Pay attention to not damage the fiber optic cable
- Spray the area using the glue activator LOCTITE7455.
- Organize the Kevlar yarns back to the anchoring and to cut the extra part.
Fiber optic preparation
- Cut the inner jacket 1 cm from the end the anchoring. Use the 2-3mm mark of the stripping
tool PN 10021044
1cm
- using scissor PN 257420002; cut end of optical fiber to have 13cm length after the end of the
inner jacket
1cm 1cm
13cm
- Push one end cable through the 40-mm heat-shrink sleeve PN 355300070 provided
WARNING : the 40-mm heat-shrink sleeve must be only on one end.

- Using a stripping splice to remove the fiber optic coating jacket 20 mm (±1mm) from the end
of the fiber optic. Use the 250µm mark of the stripping tool PN 10021044.
20mm
- clean the fiber optic with isopropyl alcohol (one use only)
WARNING : the fiber optic must be clean up to the fiber optic jackets
- Place the fiber in the 900 μm fiber clamp as shown below so as to have the end of the fiber’s
inner jacket very slightly protrude from the clamp. Then carefully close the clamp, being sure
not to move the fiber inside the clamp.
end of optical fiber jacket protection
- Open the top lid of the FITEL S326 precision fiber cleaver to cut the fiber. (at delivery, FITEL
S326 cleaver might by supplied with a support in place. If so, remove it with the hexagonal
key supplied in the cleaver packaging)
- Set the clamp and fiber onto the cleaver as shown below.
- Close the top lid. Press the cleaver button to cut the bare fiber, while holding the lid.
- Release the button. Open the lid.
WARNING
After positioning and cutting the fiber, keep it securely in place in the clamp.
- Clean and cleave the other bare fiber using the other fiber clamp. No heat shrink sleeve
required for the other side.

Fiber optic fusion
- Open the FITEL NINJA fusion splicer. Set each fiber clamp onto the fusion splicer so as to
place each fiber in its V-groove shoe. Be sure the fiber does not touch anything. If it does,
strip off, clean and cleave the fiber again.
heat shrink sleeve

only on one side
- Close the lid of the fusion splicer.
- Check for precise positioning of the fiber ends on the display panel.
- Press the green button to start the soldering process (Fusion splicer can run automatically the
soldering process depending autorun parameters of the machine).
- After splicing is complete, check the estimated loss displayed in the upper right corner of the
screen (should be less than 0.3 dB).
Check loss
- Lift the lid open and wait until a “beep” is heard, meaning that the splicer is performing a
pulling strength test.
- Slide the heat-shrink sleeve so as to place it around the splice.
- Place the splice and heat-shrink sleeve inside the oven of the fusion splicer. Be sure the sleeve
is centered inside the oven.

- Flip down the lid to close the oven.
- Make sure an oven program for a 40-mm sleeve is selected
- Press the yellow button to start shrinking the sleeve
- After shrinking the sleeve, wait for the cooling fan to stop.
- Open the oven, and then take out the splice.
Final assembly
- Thread the fiber optic cable in such a way the 2 cables anchoring are inside flexible protector
PN 279001008
Warning : inside the flexible protector, make sure the optical fiber has great curvature on both side of
the 40-mm heat-shrink sleeve PN 355300070.
Curvature as high as possible = good
Low curvature = risk of high signal attenuation
- Apply a drop of LOCTITE 480 at the beginning of the thread
- Screw strain-relief anchor by hand into the flex splice protector, without rotating the fiber.
Torque to 8 N.m ± 0.5 N.m using a torque wrench on the strain relief anchor and the key PN
257211703 to maintain the flex splice protector.
- repeat same operation on the other side of the flex splice protector

- pull on cable on both side to make sure cable anchoring is well located into strain-relief
anchor
- Apply a drop of LOCTITE 480 at the beginning of the thread
WARNING : no glue in contact with the o-ring of the gland sleeve
- Screw gland sleeve by hand into the strain-relief anchor, without rotating the fiber. Torque to
3.5 N.m ± 0.1 N.m using a torque wrench on the strain relief anchor and the key PN
257211701 to maintain the flex splice protector.
- Repeat same operation on the other side of the flex splice protector
- Screw bend restictor by hand into the gland sleeve on both side
- Again, check the spliced cable for signal loss with the reflectometer.
Chapter
TFOI-508
7 Repair Procedure

• SPARE PARTS
• TOOLS SET
 Anchoring repair V2
 Anchoring repair V1
 Fiber optic connector fusion
 Electronic sub-assembly replacement
 Final Assembly
 Cap replacement
 Splicing Machine Description of use and advised checks
 Arc test

SPARE PARTS
Electronic AND Mechanical spare parts kit
The following spare parts kit PN 10026496 contains:
Items Comment and display Part No. quantity
Torx screw 3x8 Delta 10014336 12
O-ring 39x2.5 10001810 2
TFOI 508 board only

available in 2
(red and green) complete kit
RFID Tag
10001838 2
TFOI 508 craddle
10003635 2
Transceiver belt +
10029441 2
Thermal foam
10029436 2
Screw Torx delta
10011907 12
Desiccant
10034401 2
Tie-wrap
6520160 4
TFOI 508 body and cap

10020399 2
Mechanical Only spare parts kit
The following spare parts kit PN 10026346 contains:
Items Comment and display Part No. quantity

Torx screw 3x8 10014336 16
Delta
O-ring 39x2.5 10001810 2
508 TFOI body 10020399 2
Red cap 10014737 1
Green cap 10014039 1
Bend restrictor 6820090 2
External conical 10011455 2

ring
Internal conical 10013942 2

ring
Diamon 10001804 2
connector

Cap replacement spare parts kit
The following spare parts kit PN 10026351 contains the parts to replace 10 caps, as follows:
article Part No quantity Comment and display

508 Sleeve 355100001 10
TFOI
including
cap cable 354800042 10 x 0.4m
Cap 512210051 10
sleeve 355100001 10
TOOLS SET
The following tool list PN 10026350 contains:
Article Comment and display Part No quantity
o-ring extractor 0060182 1
Kevlar locker 10012221 1
Ferule positioning tool 10025163 1
Diamond connector 10042010 1

support
Assembly tool F-3000 10021803 1
Support diamond 10042011 1

F3000 for NJ001
Hammer 257530005 1
Torque screwdriver 0.4- 10006678 1

1NM adjustable
(to be set up @
0,44NM using
TORQUE SETTER
provided in TOOLS
SET)
tip Torx T10 10027773 1

Dynamometric 10026729 1
screwdriver 0,25 Nm
Tip Torx T6 10006692 1
REPAIR INSTRUCTIONS
Two versions of TFOI-508 anchoring (optical fiber cable termination) exist:
ANCHORING V1: plastic bending restrictor
ANCHORING V2: metallic bending restrictor

Anchoring repair V2
This part describes how to change/repair the cover repair. You will need the mechanical kit PN
10026346 or 10026496.
- If needed (example of repair case : optical fiber broken after anchoring), cut the fiber optic
close to the bend limiter
- Add 2 drops at 180° of LOCTITE 242 in the thread of the cap and screw by hand the nut of
the bend restrictor
- Tighten the nut with an appropriate tool at 4N.m
- Insert the other parts of the bend restrictor along the fiber optic cable as shown
- Remove the red outer jacket using Stripper tool for outer jacket (PN 257341006) at 240mm
+/-5 from extremity. Fix the Kelvar yarns at the extremity using an adhesive tape in order to
make the next step easier.

240mm +/- 5mm
Kevlar yarns
adhesive tape
- Degrease the external conical ring (PN 10011455) and the internal conical ring (PN
10013942) using isopropyl alcohol and make to dry them.

- Insert the external conical ring on the cable end in such a way
Kevlar yarns
- place the assembly on the “Ferule positioning tool” PN 10025163
- Remove tape, arrange remaining Kevlar around the external conical jacket and pass the inner
cable core through the internal conical sleeve

- Place the cable end on support PN 10025163 and apply glue LOCTITE 382 all around the
middle of the internal conical sleeve.
- put tool PN 10025163 in contact with the sleeve and hit on the tool using the hammer to lock
the internal conical sleeve. Pay attention to not damage the fiber optic cable
- Spray the area using the glue activator LOCTITE7455.
- Organize the Kevlar yarns back to the anchoring and to cut the extra part.
- strip the white inner jacket carefully keeping 30mm ±1 mm from the anchoring using the
Stripper tool for inner jacket (PN 10021044)

30mm +/- 1mm
- Remove carefully the white inner jacket pulling in the axis of the fiber (shall be remove in
several time/cut)
- cut the kevlar yarns at the end of the white inner jacket Kevlar scissors (PN 257420002) -pay
attention to not damage the optical fiber
- Grease with RED AQUALUBE the 2 o-rings 2.06 x 2.62 (PN 10013757)
- Insert these 2 o-ring along the fiber until contact with the anchoring
2x
O-rings 2.06x2.62
- Grease with RED AQUALUBE the o-ring 14 x 2(PN 7910227)

- Set up the o-ring in the groove of the waterproofness support

O-ring 14x2
- Insert waterproofness support along the fiber and place it inside the cap
- Tighten the 2 screw 3x8 (PN 10014336) at torque 0,44Nm
- Tighten the bend restrictor at 3.5Nm
- Next step : refer to § Fiber optic connector fusion

Anchoring repair V1
- Place the fiber optic in the cover equipped with its bend limiter
- Remove the fiber optic red jacket 210 mm ± 5 mm from the end of the fiber optic, using the
stripper tool PN 257341006. You can place a part of tape at the end of the fiber optic, it could
help for next steps.
210 mm ± 5 mm
- Degrease the mooring cones (male and female) PN 10009969 and PN 10009968. To do so,
you can place them in a cup fill with isopropyl alcohol.

- Place the female mooring cone PN 10009969 on the red jacket, and place the mooring cone
and the fibre optic in the tool PN 10025163. Place the smaller part of the mooring cone in
contact with the red jacket stop.
WARNING : there is two end on the toll PN 10025163. Use the one fitting with your
mooring cone.

WARNING : the mooring cone bottom MUST stay in contact with the red jacket stop.
- Place the male mooring cone on the inner fiber optic jacket.
TOP (end of iber optic side)
BOTTOM (female mooring cone side)
- Place the Kevlar all around the female mooring cone
WARNING : no Kevlar strand must overlap each other.

- You can use the tool PN 10012221 to fix the Kevlar strands. You can do it by yourself too, if
you take care to maintain the Kevlar strand in place.
- Place a strip of the Loctite 382 PN 10021044 all around the male mooring cone bottom
- Place the male mooring cone in the middle of the Kevlar strands and use the hammer PN
257530005 and the second part of the tool PN 10025163 to lock it.

WARNING: be careful to not pinch the fiber optic
- Place a spray of Loctite 7455 (activator) PN 10021044 to finalize the mooring cones
placement.
- Cut the Kevlar brand as close as possible of fiber optic using the scissor PN 257420002
- Remove the inner jacket using the stripper tool PN 10021044, place on the 2-3mm mark. You
must remove the jacket 5 mm ± 1 mm from the mooring cones.
5 mm ± 1 mm

- Cut the Kevlar strands as close as possible the inner jacket, using the scissor PN 257420002
- Place the cones in contact with the cap. Screw the second part of the bend limiter PN
355209001. Use the key PN 10025672 with the TIP 10025675 setup at 4 Nm on the bend
limiter and the key PN 257211701 to maintain the first part of the bend limiter.

Fiber optic connector fusion
You can do up to 2 connectors splicing close to the connector. For more splices, you will need to
make a new anchoring.
Warning : the fiber optic is highly sensible to dust and grease. Do not touch the fiber
ending with your fingers and work in a clean place.
- Place the nut on the fiber optic ending PN 10001804
- Use the stripper PN 10021044 to remove 30mm ± 1 mm of the fiber optic jacket. Use the
250µm mark on the tool.
30 mm (±1 mm)
- Clean the fiber optic with isopropyl alcohol.
- Place the fiber optic in the RIGHT clamp as shown in the picture
Around
5mm
End of fiber optic protection jeacket

- Place the fiber optic in the cleaver and cut it
- Place the clamp with the fiber optic in the splicer
- Place the fiber in the 900 μm fiber clamp to have the end of the fiber’s inner jacket around
5mm from the clamp. The position of the inner jacket in the cleaver is the reference.
508 fiber optic

jacket limit
WARNING : the fiber optic must be clean up to the fiber optic jackets
- Place the connector PN 10001804 in the dedicated clamp PN 10021802 and place the
connector jacket.
- Place the connector and its clamp in the splicer

- Splice it (see the Fiber optic )
- Place the tool PN 10021802 on the splicer
- Place the spliced connector in the tool and fix it with the clamp’s tool.
clamp
- Remove the adhesive protection of the connector

- Close carefully the connector’s jacket
- Place the other parts of the connector

- Place the mounted connector in the tool PN 10021803
- Press the tool to fix the connector. The tool must be totally closed. If you cannot close it, it
means the connector is not well placed.
- Fix the nut. Place carefully the connector cap to protect the fiber optic from any dust.
You can break the fiber optic if you close the cap hardly

Electronic sub-assembly replacement
You must have the fiber optic cover in good condition and placed a connector on the fiber optic
It is possible to use the kit PN 10026346 for mechanical parts only, if electronics is still in good
condition, or kit PN 10026496 for mechanics and electronics part.
Be careful when you manipulate the RFID tag. You can break it if you don’t take it
properly.
- Place the RFID PN 10001838 in the cradle PN 10003635 if necessary.

- Place the desiccant PN 10016957 in the cradle and tied it with the cable PN 6520160.
- Be careful to place properly the cable head inside the cradle.
- Setup the RFID. See user508 manual.
- Screw the appropriate board PN 10013439 (red or green) and the transceiver belt PN
10009977 on the cradle with a torque of 0.22Nm. Use the screws torx 2,2x7 PN 10011907
with the dynamometric screwdriver PN 10026729 and the tip PN 10006692.
- You must screw in staggered row

Final Assembly
You must have a TFOI cap and a TFOI cradle available, with the same color (green or
red).
- Grease the o-ring PN 10001810.
- Place the o-ring on the TFOI cover
- Remove the cap of the fiber optic ending if any and connect the fiber optic ending on the
TFOI board. A “click” will confirm the proper connection of the fiber connector.

- The cradle will be placed in the 3 holes you can see inside the connector body PN 10013295
- Place the TFOI cradle PN 10001498 carefully in the connector TFOI 508 body. If you need to
push hard it means the cradle is not properly placed in the holes of the connector. The cradle
must be placed 3mm from the inner border.

- Use the o-ring extractor PN 0060182 to place properly the fiber optic inside the connector.
Be careful to not pinch the fiber.
- Place the cover on the connector body.
Be careful to correctly place the fiber optic.

- Screw the cover using the dynamometric screwdriver with a of 0.4 Nm. Use the screws torx
M3x8 PN 10014336 and the dynamometric screwdriver PN 10026726 equipped with the tip
PN 10027773. You must screw in staggered row

Cap replacement
When you change the cap, lock the cable with the sleeve. Use the plier PN 10025879.
Splicing Machine Description of use and advised checks

cover
Fiber clamp holder
Button for opening

and/or actuating
the cleaver
Oven
Fusion
chamber
Arrows keys Display

used to select
menu items
Start button
Turn on oven
On/Off
Warning
If this is the first use of the day, an arc test must be done. See arc test chapter

Arc test
If this is the first splicer use of the day, an arc test must be done. The fiber optic used for the test will
cannot be reused without preparation. It is highly advised to use scrap pieces of fiber optic to proceed.
- Prepare right and left clamp with fiber optic inside. See cutting fiber optic chapter
- Use the arrows to select the arc test item
- Use the arrows to validate
- Check the result:
 If result is ok, you can proceed to the fiber optic splicing.
 If result is not ok, clean the arc nozzles and fiber optic support with brush provide
with the splicer. Prepare new fiber optic to redo the arc test.
WARNING
Do not use alcohol or air gun to clean the machine

Chapter
CX-508
8 Repair Procedure

• SPARE PARTS
• TOOLS SET
• CONSUMABLE
 CX-508 disassembly
 Sandwich electronic boards replacement
 CXAB electronic board replacementProtective cap replacement
 Circular connectors replacement
 LINE connectors replacement
 RFID and desiccant capsule replacement
 CX-508 re-assembly
 Sacrificial anode replacement

SPARE PARTS
PROTECTIVE CAPS ASSEMBLY ON LID CXAB BOARD ASSEMBLY ON LID
CONNECTORS ASSEMBLY ON LID CX-508 GENERAL ASSEMBLY

(Note : wiring not shown for easier display)

SPARE PART PICTURE PART Nbr COMMENTS
Seal and screws

CX-508 SANDWICH SPARE KIT 10005429SPR
included
Ribbon cable, seal

CX-508 CXAB BOARD SPARE KIT 10005529SPR and screws
included
CX-508 LID ASSEMBLY SPARE KIT 10019902
Sacrificial anode,
CX508 BOTTOM CASE ASSY SPARE 10019714SPR seal and screws
included
SEAL 10005694
SACRIFICIAL ANODE 10000640

WAVE WASHER 9920026
NUT M6 10005665
WING NUT M6 9840020
RFID TAG 10001838
SCREW L10 TORX20 10011231
DESHYDR.CAPSULE C015100 8090011 50 units per bag
CX-508 LOW LINE CONNECTOR SPARE 10020038
CX-508 HIGH LINE CONNECTOR SPARE 10020039
CX-508 LEFT TRANSVERSE

10020030
CONNECTOR (XL1) SPARE
CX-508 RIGHT TRANSVERSE

10020033
CONNECTOR (XL2) SPARE
CX-508 BLASTER XDP CONNECTOR

10020036
SPARE
CX-508 12VDCA / 12VDCB BATTERY

10020037
CONNECTOR SPARE
PROTECTIVE CAP FOR LOW AND

410052612
HIGHT CONNECTORS
PROTECTIVE CAP FOR BATTERY

711083023B
CONNECTORS
PROTECTIVE CAP FOR TRANSVERSE

711083548A
AND XDP CONNECTORS
SCREW FOR PROTECTIVE CAP 10011231

TOOLS SET
Supplied
in kit No.
Screwdriver bit TORX10 10027773
Fix torque screwdriver 1,0Nm 10027862

+ Screwdriver bit TORX20

+ Screwdriver bit POZIDRIV PZ2 10027776

+ Screwdriver bit TORX20 (*)
10006691

+ Screwdriver bit TORX20 10006691
Straight-jaw pliers 0060174
10042273 10021402
Torque tool
+ adapter blade 258310007
+ Long-reach metric 6-point socket 10022053
Open-end wrench bit 756081356A
Socket T24 700077111A
Socket T20 732078688A
Torque spanner 15Nm 10042271

+ adapter 1/4 - 3/8 10027769
adapter 1/2 - 3/8 10031365
Click torque wrench 10Nm 0010209

(*) Note: Electrical screwdriver 2,5Nm also available for CX-508 disassembly as an option (P/N :
10030333).
OVERVIEW OF CX-508 TOOLS SET
CONSUMABLE
The chemical products needed to repair CX-508 are listed below. These products can be found on the
local market (preferably) or ordered from Sercel.
Materials required Tool picture Part No.
Loctite 480 8030081
Aqualube red grease 8060015
Cotton bud, wood stick, box/200 8910009

Degreasing agent ( Pure Isopropyl
(local sourcing)
Alcohol)

REPAIR INSTRUCTIONS
CX-508 disassembly
- Set up the CX-508 up-side down in order to have access to the screws.
- Untighten and remove the 14 screws using fix torque screwdriver + screwdriver bit TORX T20.
- It is possible also to use an electrical screwdriver (P/N : 10030333).
- Open the CX-508 raising the BOTTOM CASE.

- Untighten the screws used for GROUND link and remove this link before to completely put the BOTTOM
CASE aside.

Sandwich electronic boards replacement
- Identify and locate the 7 connectors (including the ribbon cable connector).
LOW LINE HIGH LINE XL2 XL1
XDP
CXAB
(ribbon cable POWER
connector) SUPPLY
- for connectors LOW LINE, HIGH LINE, XL2, XL1 and XDP, pull up connector after having pressed on the
central locking clip (see red arrow below).
- be carefully during connector extraction in order to not damage them.

- for connectors POWER SUPPLY, pull up connector after having pressed at the same time on the 2 clip on
each side of the connector.
- for ribbon cable connector (connected to CXAB board), follow the procedure as described below :
- 1 - - 2 - - 3 -
insert a small flat screwdriver (not raise the side of the black cover once the side of the black coveris
provided in TOOLS KIT) or unclipped, rotate it in order to declip
equivalent under the black cover the other side
leaning on the screw aside
- 4 - - 5 - - 6 -
push the 2 side rib to extract the raise up the ribbon cable connector the ribbon cable connector is removed
connector

- Once all connectors are removed, raise up the sandwich board keeping the 2 side bumpers.

CXAB electronic board replacement
- Remove ribbon cable connector of the CXAB electronic board in the same way as explained in
§ Sandwich electronic boards replacement.
- Untighten and remove the 4 screws:
- remove the CXAB board and insert a new one at the same location and orientation.
- tighten the 4 screws at torque 1,5Nm using fix torque screwdriver 1,5Nm + Screwdriver bit TORX20
following the screwing sequence as shown below :
1 3
4 2
- Insert the ribbon cable inside the connector of the CXAB board and make sure the 2 side locking feature are
folded.
- Pay attention to ribbon cable orientation, red color marked cable towards the top of the board (see picture).

Red color marking
on the ribbon cable
- -Do not forget to add the black cover, pressing on it.
- Be sure the ribbon cable goes towards outside of cover passing under both cabling LOW LINE and HIGH
LINE as shown.

Protective cap replacement
- There are 3 different reference of protective cap car CX-508. Following table is indicating the location of
the different caps.
REP Item Picture Part No. Location
PROTECTIVE CAP FOR 1A
1B
1A LOW AND HIGH LINES 410052612
CONNECTORS
PROTECTIVE CAP FOR 1C 1C

1B 711083023B
BATTERY CONNECTORS
PROTECTIVE CAP FOR

1B 1C
1C TRANSVERSE AND XDP 711083548A 1A
CONNECTORS
- whatever the cap reference, the assembly is similar.

- tighten the screw at torque 1,5Nm using fix torque screwdriver 1,5Nm + Screwdriver bit TORX20
following the screwing sequence as shown below :
- for all caps 711083023B and 711083548A, make a half turn to fix by turning the cap, the assembly is the same.
- for caps 410052612, insert it into the plug.

Circular connectors replacement
- There are 4 different references of pre-assembly connector. Following table is indicating the location of the
different references.
CX-508 LEFT
TRANSVERSE
2C 10020030
CONNECTOR (XL1)
SPARE 2F
CX-508 RIGHT
TRANSVERSE
2D 10020033
CONNECTOR (XL2)
SPARE 2C 2D
CX-508 BLASTER
2E XDP CONNECTOR 10020036
SPARE
2F 2E
CX-508 12VDCA /
2F 12VDCB BATTERY 10020037
CONNECTOR SPARE
Circular connectors disassembly
Note: illustration is done with connector 2E but procedure is similar for all circular connectors.
- Note the 2 holes in the top and the bottom of the connector
- Make a V-cut in the direction of the hole in the top of the connector using the cable cutters

- Make a V-cut in the direction of the hole in the bottom of the connector using the cable cutters
- After make the 2 V-cut, the connector must be as shown in above picture :
- Press on each side of the connector using the straight-jaw pliers in order to crack the glue and to make the
connector disassembly easier.

- Unscrew the nut using the straight-jaw pliers
- It is also possible to unscrew the nut using a standard ratchet or drive tee (both not included in Sercel Tool
set) associated with the socket T20 or T24 depending of the connector reference :
 T24 is for TRANSVERSE and XDP connectors
 T20 is for both BATTERY connectors.
Note: in case of use of standard ratchet or drive tee with socket T20 or T24, adaptor 1/2” - 3/8” or adaptor 1/4” -
3/8” provided in tool set may be required
or
adaptor 1/2”-3/8” or 1/4”-3/8” example of standard
ratchet or drive tee (both
not included in Sercel Tool
set) to be locked on
adaptor
- remove the nut and the connector from the lid

Circular connectors re-assembly
- Clean the seal area using isopropyl alcohol on both sides.
- Grease the o-ring seal with AQUALUB RED grease and make sure to locate it correctly in the groove of the
connector
WARNING : in order to avoid to put some grease on connector thread, it is recommended to protect thread
before o-ring setting with an adhesive tape (type 3M TEMFLEX® 1500 or Scotch® Performance Masking
Tape 2364) as shown on the following pictures. Remove adhesive tape after o-ring setting and clean thread
with isopropyl alcohol.

- Insert the new connector in its location.
IMPORTANT: make sure the rib of LID is well located inside the nick of the connector
- Apply 4 drops of glue LOCTITE 480 (90° apart) on the first thread of the nut welcome
- Tighten the nut with the tool at torque 15Nm.
IMPORTANT: in case of Battery connector replacement, make sure to insert fuse box in the groove.
Loop link downward

LINE connectors replacement
- There are 2 references of pre-assembly connector. Following table is indicating the location of the different
references.
2A
CX-508 LOW LINE
2A 10020038
CONNECTOR SPARE
CX-508 HIGH LINE

2B 10020039
CONNECTOR SPARE 2B
LINE connectors disassembly
- For LINE connectors 2A or 2B disassembly, proceed as follows :
- Prepare the tool Click torque wrench (10Nm) associated with the Open-end wrench bit.
- Untighten the nut.

- Remove the nut backward
- push the connector frontward until the end white connector go through the hole.
LINE connectors re-assembly
- Clean the seal area using isopropyl alcohol.

- Grease the o-ring seal with AQUALUB RED grease and make sure to locate it correctly in the groove of the
connector (protect thread with adhesive tape before o-ring setting as explained in paragraph Circular
connectors replacement )
- Insert the new LINE connector in its location.

NOTE : pay attention to connector orientation thanks to the hole on one side of the connector
LOW LINE:
hole keying through this side
LINE connector hole keying
LOW LINE
HIGH LINE
HIGH LINE:
hole keying through this side
NOTE : Check the base of connector is flush with cover
- Set up 4 points of glue LOCTITE 480 (60° apart) on the first thread from the nut welcome

- Tighten the nut with the tool at torque 10Nm.

RFID and desiccant capsule replacement
- If possible, do not extract the gray RFID tag, leave it in the lid. Otherwise, refer to pictures below for RFID
tag handling.
- Set up the RFID tag in the LID. Pay attention to RFID tag orientation (see pictures below)
- RIFD tag shall be stick on the cover thanks to the adhesive.
- Caution: do not press in the area of the RFID chip as shown. Do not press in this area
- Set up the desiccant capsule in the LID on the top of the RFID tag
- Pay attention to desiccant capsule orientation (see pictures below)

- Tighten the 2 screws at 1N.m using Fix torque screwdriver 1,0Nm with Screwdriver bit TORX20
Caution:
The time between the desiccant capsules removed from its packaging and the closing the CX-508
should be less than 12 hours. Beyond that, it is necessary to regenerate the capsule in oven at 100 ° C
for 1 hour.

CX-508 re-assembly
- Place the SANDWICH BAORD inside the LID ASSEMBLY
Bumpers
Note : Sandwich board bumpers must be oriented as illustrated
- On LID ASSEMBLY, clean the groove using isopropyl alcohol and cotton bud
- Place a new o-ring lightly greased with the RED AQUALUBE
- On BOTTOM CASE, clean the 10mm width area using isopropyl alcohol (this area is the contact of the o-
ring)
10mm

- Connect the GROUND LINK between the SANDWICH BOARD and the BOTTOM CASE.
- On both extremity of the GROUND LINK, tighten the screw at torque 2,1Nm using fix torque screwdriver
2,1Nm + Screwdriver bit POZIDRIV PZ2
GROUND LINK
- Close the CX-508 raising the BOTTOM CASE..
- Tighten the 14 screws at torque 2,5Nm using fix torque screwdriver 2,5Nm + Screwdriver bit TORX T20.
- It is possible also to use an electrical screwdriver set up at 2,5Nm and 600rpm (P/N : 10030333).
10 6 2 4 8
12 13
14 11
9 5 1 3 7

Sacrificial anode replacement
- Set up the CX-508 vertically
- Locate the Sacrificial anode area
- Install the sacrificial anode (pay attention to orientation)
OK not OK

- Place the wave washer Ø6
- Tighten the nut HM M6 at 8Nm using torque tool + adapter blade + long-reach metric 6-point socket
- Add the wing nut and tighten by hand

Chapter
LAND CABLE-508
9 WARM Splicing Procedure

 TOOLS SET
 CONSUMABLE LIST

TOOLS SET
Supplied
in kit No.
508 cable splicing - 10016794 10016794

overmolding mold
Power supply wiring for Soldering 0220050

iron
10027874
Tip width 1.2mm for soldering iron

0220065
(x5)
A=1.2mm
Tip width 2.4mm for soldering iron 0220068

(x5)
A=2.4mm
Solder 135110009
Cable stripper 257341006

Hot air heat gun 10027878

CONSUMABLE LIST
Materials required Picture Part No. Supplied in kit No.
Sealant tape 186300025
Protection gloves 253100068
Syringue 50mL 256900010
Surface cleaner wipe (x100 unit) 256900014
Abrasive paper, grit 150 257400011 512600049
Heatshrink sleeve 355300052
Potting shells 410048062
Cable cord (1 m) 410049184
D-P-RESINE FM-103 ORANGE

186200026
100GR - set
Cable tie 25 MX 316070031

REPAIR INSTRUCTIONS
Splicing preparing
- At each cut end of the damaged cable, strip off 85 mm of outer jacket using the cable stripper
without cutting the Kevlar strengther yarns.
- Cut the conductors 70 mm from the end of the outer jacket. Keep the strength members yarns at
85mm length
- Place a heat-shrink on Kevlar’s end (Heat it + Press it with plier)

It will be easier to make the knots
- Soldering STEP 1 Strip each wire on 5 mm , tin each wire end

- Soldering STEP 2: Insert a heat-shrink length 20 mm± 1mm with glue inside on each wire
- Soldering STEP 3: solder wire to wire respecting color

- WELDING STEP 4 : Add some grey tape around welded area (sealant tape)
- WELDING STEP 5 : Make sure that splice is centered in heat-shrink sleeve and heat it

- WELDING STEP 6 : Heat the heat-shrink sleeve and press with a plier both ends without
damaging the wire

- At this point, assembly should appear like this
- Make a loop in order to get the size of 60mm. Keep the loop in place using 3 cable tie wraps
(manual tightened)
- Take up the excess length of yarns into a double loop and tighten the knot. Then make a second
knot ant tighten again.

- On both ends, add an additional knot

- Cut the remaining Kevlar 5mm away from the knot. Remove tie wraps
- Put the potting shells in place so that the splice is in the middle.
- Close the potting shells.
- Take sandpaper, sand the cable on 30mm on both side of orange shelves. Clean with wipe of
isopropyl alcohol.
- Install foam ends on both sides for molding.

Overmolding
- Open the mold. Using a brush, spread out the inside surface with release agent and let it dry.
- Connect the mold to the AC power grid and wait 20 minutes to heat it up.
- Open the mold. Place the potting shell assembly in the middle.
- Close the mold.
- Put on protective gloves. Pour potting resin into a plastic cup and draw it up into a syringe.
- Inject potting resin through the mold’s inlet until resin extrudes from the two vent holes.
- Allow the potting resin to cure for at least 1 hour.
- Open the mold.

Chapter
LAND CABLE-508
10 COLD Splicing Procedure

 TOOLS SET
 CONSUMABLE LIST
 Splicing preparation
 Overmolding

TOOLS SET
Supplied in
Tools required Tool picture Part No. kit no
Cable Cutters 0060132
Power supply wiring for soldering iron 0220050
0220065
Tip width 1.2mm for soldering iron (x5) 10027874
0220068
Tip width 2.4mm for soldering iron (x5)
257341006
Cable stripper
10027878
Hot air heat gun
257350003
Spanner

CONSUMABLE LIST
Materials required Picture Part No. Supplied in kit No.
Sealant tape
186300025
Protection gloves
253100068
Surface cleaner wipe (100x unit)

256900014
Abrasive paper, grit 150

257400011
10044080
(1 set allows to make
10 splicing)
Heat-shrink sleeve 355300052
Potting shells 410048062
Solder 135800001
SCOTCHCASTTM resin kit 3M

10043537
(ref. 92-NBA 0)
Cable tie 25 MX 316070031

REPAIR INSTRUCTIONS
Splicing preparation
Same instructions as §9 LAND CABLE-508

COLD Splicing Procedure / Splicing preparation
Overmolding
- Install the 2 potting half shelves (orange color) without pinching the wires
- Using sandpaper, sand the cable.

Sand 30mm on both side of orange shelves. Clean with alcohol. Then, install foam ends on
both sides for the molding.
- Install the 2 potting half shelves in 3M plastic mold. Make sure that large opening of the
orange shelves is oriented vertically

- Close 3M shelves with filling hole oriented to the top (vertically)
- Follow the instruction manual of SCOTCHCAST resin kit 3M (ref. 92-NBA 0) for resin
potting - extract below :
Section 3 : Mix properly both components

Section 4 : Press from corner to center to maximize mixing
Section 5 : When you feel slight heat generation go to section 6.
- Allow the resin to cure for at least 1 hour at room temperature (20°C +/- 5 °C).
- After molding you can :

 Opt1 : Keep as it is with 3M shelves on
Or
 Opt2 : Unmold & remove both foam end
- Make sure that all products & waste are disposed following local regulation.

Chapter
WTU-508
11 Repair Procedure

 OVERVIEW
 SPARE PARTS
 TOOLS SET
 WTU-508 main disassembly

 WTU-508 desiccant replacement
 WTU-508 bottom case disassembly
 WTU-508 top case disassembly
 WTU-508 connector protective cap replacement
 WTU-508 SD CARD access
 WTU-508 bottom case re-assembly
 WTU-508 top case re-assembly
 WTU-508 re-assembly

OVERVIEW
This procedure explains how to disassemble and re-assemble WTU-508 units.
TOP CASE ASSEMBLY
MAIN ELECTRONIC BOARD ASSEMBLY
SYNCHRO-WLAN ELECTRONIC BOARD

ASSEMBLY + SCREWS
SHOCKS ABSORBERS
SCREWS
(BOTTOM CASE) MAIN O-RING SEAL
DESSICANT BRIDGING METAL SHEET

CAPSULE
BATTERY SHOCKS ABSORBER FOAM TOP
MAIN O-RING SEAL
BATTERY SHOCKS ABSORBER FOAM BOTTOM
BOTTOM CASE
SAFETY SCREW + O-RING
SCREWS CASE ASSEMBLY
Exploded view of WTU-508

SPARE PARTS
SPARE PART PICTURE PART N° COMMENTS
WTU-508 MAIN ELECTRONIC BOARD

10023007SPR
ASSEMBLY
WTU-508 SYNCHRO-WLAN ELECTRONIC

10017327SPR
BOARD ASSEMBLY
10005663
10011412
WTU-508 BOTTOM CASE PARTS

SCREW
BRIDGING METAL SHEET 10011474
BATTERY SHOCKS ABSORBER FOAM TOP
BATTERY SHOCKS ABSORBER FOAM BOTTOM
BOTTOM CASE
10013154
10013153
WTU-508 TOP CASE ASSEMBLY 10038080
MAIN O-RING SEAL 10013951
DESHYDR.CAPSULE C015100 8090011 50 units per bag

SPARE PART PICTURE PART N° COMMENTS
Connector
BATTERY PACK 10009227
included
SCREW CASE ASSEMBLY 10014212
SCREW BOARD ASSEMBLY 10013531
10011515 (left)
SHOCKS ABSORBER pair
10014418 (right)
SAFETY SCREW 10014257

O-RING 7910234
PROTECTIVE CAP
711087967C
for 8C CONNECTOR
PROTECTIVE CAP
711082917A
for 2C INPUT CONNECTOR
same reference
SCREW for PROTECTIVE CAPS 10011231 screw for both
caps
EXTERNAL SILICONE SEAL

5083083
for 8C CONNECTOR

TOOLS SET
Supplied
in kit No.

+ Screwdriver bit T20 10006691
(0.4Nm <-> 1Nm) 10006678
(set up at 0.7Nm)
Screwdriver bit T8 10027863 10038315
Fix torque screwdriver 2 Nm 10006685

+ universal holder 10006699
+ screwdriver bit flat 10005835

REPAIR INSTRUCTIONS
SAFETY PRECAUTION
WARNING :
WTU-508 contains Li-ion battery.
In order to prevent any over pressure (in case of battery failure) during product
disassembly, it is highly recommended to carefully untighten and remove the SAFETY
SCREW with its O-RING before to disassemble the WTU-508 product.

WTU-508 main disassembly
- Set up the WTU-508 upside down in order to have access to the screws.
- It is possible also to use an electrical screwdriver (P/N : 10030333).
- Open the WTU-508 raising the BOTTOM CASE.

- pull up battery connector after having pressed on the central locking clip (see red arrow below).
- Once battery connector are removed, find hereunder the product breakdown :
TOP CASE sub-assembly
MAIN O-RING SEAL (PN 10013951)
TOP CASE sub-assembly
SCREWS (PN 10014212) x8

WTU-508 desiccant replacement
- Remove the desiccant capsule (PN 8090011) from the bottom case sub-assembly.
- See caution note below, depending if you have to replace or re-use the desiccant capsule
Caution:
The time between the desiccant capsules removed from its packaging and the closing the WTU-
508 should be less than 12 hours. Beyond that, it is necessary to regenerate the capsule in oven at
100 ° C for 1 hour.

WTU-508 bottom case disassembly
Exploded overview of WTU-508 bottom case parts

- After having removed BRIDGING METAL SHEET, remove the BATTERY SHOCKS ABSORBER
FOAM TOP

- remove the BATTERY PACK

- remove the BATTERY SHOCKS ABSORBER FOAM BOTTOM

WTU-508 top case disassembly
Exploded overview of WTU-508 top case parts
- pull up both connector after having pressed on the central locking clip (see red arrows below).

- pull up complete electronic board, pushing on each side on the area marked below by red arrows
- at this stage, do not touch electronic board with hands.
- remove complete electronic board from WTU-508 TOP CASE ASSEMBLY

- SHOCKS ABSORBER left and right side can be removed

- Untighten and remove the 4 screws of the WTU-508 SYNCHRO-WLAN ELECTRONIC BOARD ASSEMBLY,
using vario-torque screwdriver + screwdriver bit TORX T8
- remove carefully the WTU-508 SYNCHRO-WLAN ELECTRONIC BOARD ASSEMBLY

WTU-508 connector protective cap replacement
- both connector protective caps are fixed on WTU-508 TOP CASE with the same reference screw (PN :
10011231)
- use fix torque screwdriver 2 Nm+ universal holder + screwdriver bit flat to make caps replacement
- torque to be used for tightening : 2 Nm

WTU-508 SD CARD access
- locate SD card on MAIN ELECTRONIC BOARD ASSEMBLY
- locate locking feature screw on MAIN ELECTRONIC BOARD ASSEMBLY
- untighten and remove the screw using vario-torque screwdriver + screwdriver bit TORX T8
- remove the locking feature in order to be able to extract SD card from its connector (push-in/push-out
system)
- for SD card re-assembly : follow instructions in opposite way.

- to tighten the screw, use vario-torque screwdriver + screwdriver bit TORX T8 set up at torque 0.7N.m

WTU-508 bottom case re-assembly
- follow instructions explained in WTU-508 bottom case disassembly in opposite way
- to tighten the 4 screws of the BRIDGING METAL SHEET, use fix-torque screwdriver + screwdriver
bit TORX T20 at torque 1.5N.m
WTU-508 top case re-assembly
- follow instructions explained in WTU-508 top case disassembly in opposite way
- to tighten the 4 screws of the WTU-508 SYNCHRO-WLAN ELECTRONIC BOARD ASSEMBLY ,

use vario-torque screwdriver + screwdriver bit TORX T8 at torque 0.7N.m
- before to insert the complete electronic board in the TOP CASE, please make sure the parts are
correctly assembled as shown in picture below :

WTU-508 re-assembly
- follow instructions explained in Base cable disassembly in opposite way
- to tighten the 8 screws, use fix-torque screwdriver + screwdriver bit TORX T20 at torque 1.5N.m
- pay attention to re-install correctly the MAIN O-RING SEAL (PN 10013951), after having greased it
(refer to § O-RING GREASING)
- pay attention to not forget the SAFETY SCREW with its o-ring (refer to § SAFETY PRECAUTION)

Chapter
TZ NODE-508
12 Repair Procedure

 SPARE PARTS
 TOOLS SET
 FDU-508 PRE-ASSEMBLY replacement
 HALF-LINK replacement

SPARE PARTS
This procedure explains how to disassemble and re-assemble specific TZ stress-relief systems on field
units 508XT (FDU-508).
NUT “NYLSTOP” M6
SIDE FLANGE (x2)
FDU-508
(not included in
spare part kit 10042434SPR)
SCREW CHC M6x35
SCREW 40x16
BOTTOM FLANGE
LOOP STRESS RELIEF SYSTEM (x2)
BEND RESTRICTOR (x2)

All parts shown are available in MECHANICAL SPARE PARTS KIT - NODE 508TZ (P/N:
10042434SPR).
Items Part No. Supplied in kit n°

SIDE FLANGE 10021566
BEND RESTRICTOR 10001834
BOTTOM FLANGE 10021563
TY RAP TY 25 MX 316070031 10042434SPR
SCREW PT 40x16 410052294
NUT NYLSTOP M6 216466060
SCREW CHC M6x35 10022669
LOOP STRESS RELIEF SYSTEM 10034301
For FDU-508 PRE-ASSEMBLY replacement only, spare parts are :
Pre-assembly with electronic board

FDU-508 PRE-ASSEMBLY 10014476SPR (sold by multiple of 10 units)

TOOLS SET
Supplied in
kit n°
TZ NODE-508 assembly feature 10049703
Electrical screwdriver 1,8Nm 10027772
Insert Bit TORX PLUS T20 - long 257590017
Insert Bit HEXAGONAL 5mm - long 10046166

10017871
- long
Insert Bit TORX PLUS security 25IPR 10046163

10022316
- short
(TZ NODE-
508 TOOLS
Cable cutters 0060132 SET)
Manual TY RAP cutter tool 257300016
Spanner 257350003
Torque screwdriver
(0.5 - 2.0 Nm adjustable using
10034626
TORQUE SETTER provided in TOOLS
SET)
Hexagonal key – 5mm 10046164

REPAIR INSTRUCTIONS
FDU-508 PRE-ASSEMBLY replacement
It is possible to replace the FDU-508 PRE-ASSEMBLY unit avoiding a complete TZ NODE-508

disassembly.
STEP 1 – opening
- Untighten the 10 SCREWS 40x16 (screw head type : TORX PLUS T20) on the BOTTOM
FLANGE
- Untighten the 4 SCREWS CHC M6x35 (screw head type: HEXAGONAL 5mm) on the SIDE
FLANGES

- Remove both SIDE FLANGES
- Untighten the 2 SCREWS 50 x 24 (screw head type : TORX 25IPR).
- Using a FLAT NOSE SCREWDRIVER (not provided in TOOLS SET), remove the two base
cable terminations

- Remove NODE-508, final assembly should appear like this
STEP 2 – new FDU-508 PRE-ASSEMBLY replacement

- For a FDU-508 unit, insert the cap ring on the pin of the PREASSEMBLY.
- Replace the O-ring by a new one on each base cable, ensure the new O-ring has been
greased properly (refer to § O-RING GREASING)

- Close the base cable terminations, and tighten the SCREWS 50 x 24 (screw head type : TORX
25IPR, torque 1,8N.m)
- Place both SIDE FLANGES, ensure the DUST CAP is not trapped in between the two parts
- Check the orientation of the Dust cap. It must be identical to the FDU replaced!
- Otherwise, the cable to the sensor could be too short or have a bad routing!
- Tighten the 4 SCREWS CHC M6x35 (screw head type: 6points socket 5mm, torque 1,8N.m)
on the SIDE FLANGES

- Tighten the 10 SCREWS 40x16 (screw head type : TORX PLUS T20, torque 1,8Nm).

HALF-LINK replacement
This procedure describe the procedure to repair TZ NODE-508 in the following cases :
 TZ NODE-508 stress relief broken

 replacement of intermed section between 2 TZ NODES-508
 replacement of end section between TZ NODE-508 and TZ FM4-508 termination
STEP 1 – TZ NODE-508 assembly feature presentation
POSITIONNING SYSTEM PLATE

THREE-ARM KNOBS
BALL
LOCK PIN STRETCHING
TZ NODE-508
EXTERNAL STRESS RELIEF SYSTEM WRENCH
ADJUSTABLE POSITIONNING SYSTEM
WARNING
The use of this assembly feature is mandatory during re-assembly. By not using this tool,
it can result poor mechanical performance and can heavily damage TZ NODE-508.

STEP 2 - Stress relief system disassembly
- Place unit on a holding feature and clamp it dust cap facing down.
- Using the cable cutters, cut the tie wraps holding the cable (position of tie wrap is shown
below). Be careful not to damage the cable!
- Untighten the 10 SCREWS 40x16 (screw head type : TORX PLUS T20).

- Untighten the 2 SCREWS CHC M6x35 on the BOTTOM FLANGE side (screw head type :
HEXAGONAL socket 5mm).
- Remove the BOTTOM FLANGE.
- Release cable from the LOOP STRESS RELIEF SYSTEMS by giving some slack to the cable
around it

- Remove unit from the holding feature

- Untighten the two SCREWS CHC M6x35 from the SIDE FLANGES on the DUST CAP side
(screw head type : 6points socket 5mm).
- Release unit from both SIDE FLANGES

- Release cable from the BEND RESTRICTORS. Use spanner to enlarge opening and to make
the operation easier.

STEP 3 : Stress relief system re-assembly
- Place both SIDE FLANGES on the unit
- Tighten the two SCREWS CHC M6x35 on the SIDE FLANGES on the DUST CAP side
(screw head type: 6points socket 5mm, torque 1,8Nm)

- Put a BEND RESTRICTOR on the cable on each side of unit. Use spanner to open up the
BEND RESTRICTOR and slide the cable inside of it
- Cross the cables and pass each side in the others BEND RESTRICTOR (see below).
- Place unit on the ADJUSTABLE POSITIONNING SYSTEM, DUST CAP facing down.

- Put the BEND RESTRICTORS in the bottom of the SIDE FLANGES in the dedicated area
- On each side, place a LOOP STRESS RELIEF SYSTEM. Tighten the cable manually to
adjust it to the LOOP STRESS RELIEF SYSTEM, then anchor the two together using a tie
wrap.

- Place the BOTTOM FLANGE on TZ NODE-508 and then, put the POSITIONNING
SYSTEM CAP on it. Lock it using the 4 THREE ARM KNOBS but don’t tighten it.
- On both sides, insert the cable into an EXTERNAL STRESS RELIEF SYSTEM (orange color
– delivered with TZ PACK CX-508) starting near the BEND RESTRICTORS.
(Bend restrictor side)

- Make 3 turns clockwise before letting the wire out on the other side of the reel
(Bend restrictor side)
- Close the reel EXTERNAL STRESS RELIEF SYSTEM by screwing its cap.
- Using a pin, block EXTERNAL STRESS RELIEF SYSTEM into TZ NODE-508 assembly
feature

- Using the wrench of the ADJUSTABLE POSITIONING SYSTEM, tension the cable
according to Tension indicator becomes partially visible (see below).

- Now tighten the 4 THREE-ARMS KNOBS until BOTTOM FLANGE is flush with SIDE
FLANGES.
- Using the electrical screwdriver 1,8Nm, tighten the ten SCREWS 40x16 (screw head type :
TORX PLUS T20) on the BOTTOM FLANGE.

- Tighten the two SCREWS CHC M6x35 on the SIDE FLANGES on the BOTTOM FLANGE
side (screw head type: HEXAGONAL socket 5mm, torque 1,8Nm)
- Place TY RAP on each side at following positions

- Release TZ NODE-508 from ADJUSTABLE POSITIONING SYSTEM
- Remove the 2 EXTERNAL STRESS RELIEF SYSTEM on both side

Chapter
TZ FM4-508
13 Repair Procedure

 SPARE PARTS
 TOOLS SET
 TZ FM4-508 disassembly
 TZ FM4-508 re-assembly
 Contact holder replacement
 Locking pin replacement
 Locking flange replacement

SPARE PARTS
This procedure explains how to disassemble and re-assemble specific TZ stress-relief systems on TZ
LINK-508 connectors (TZ FM4-508).
HALF FLANGE FOR LOCKING PART
HALF CLAMP BEND RESTRICTOR
CORD
LOCKING PIN
SHIM FOR
LOCKING PART SCREW PT 3x8
FM4-508
SCREW PT 40x16 (x8)
LOCKING FLANGE
HALF CLAMP
HALF FLANGE FOR SCREW
SCREW PT 50x24

All parts shown are available in MECHANICAL SPARE PARTS KIT - FM4 TZ
(P/N: 10042435SPR).
Materials required Part No. Supplied in kit n°

HALF FLANGE FOR LOCKING PART 10018751
HALF FLANGE FOR SCREW 10018701
HALF CLAMP 10016894
SHIM FOR LOCKING PART 10040718
SCREW PT 3x8 10032348
10042435SPR
SCREW PT 40x16 410052294
BEND RESTRICTOR 317504001
LOCKING FLANGE 10019839
SCREW PT 50x24 10014254
LOCKING PIN 10042021
CORD Dia.1,5mm 10042092
For FM4-508 spare parts kit, please refer to §3. FM4-508 Plug
Repair Procedure

TOOLS SET
Supplied in
Tools and materials required Tool picture Part No. kit n°
410051111
Connector support FM4 NEW
Vario-torque screwdriver
(0.5 - 2.0 Nm adjustable using 10034626
SET)
10027863 10049600
Screwdriver bit TORX T8
TZ FM4-508
Vario-torque screwdriver TOOLS SET
(2.0 - 7.0 Nm adjustable using 10049602
SET)
10025062
Screwdriver bit TORX T20
10006699
Universal bit holder
Insert Bit TORX PLUS security 25IPR 10022316

- short

REPAIR INSTRUCTIONS
TZ FM4-508 disassembly
- Place the base on a holding feature
- Place the TZ FM4-508 to disassemble on the CONNECTOR SUPPORT and lock it making a
half-turn clockwise
- Untighten the SCREW PT 3x8 TORX 8 from the BEND RESTRICTOR, and remove this part
along the cable by making half a turn with it then pulling it off.
- Untighten all 8 SCREW PT 40x16 along the body of the TZ FM4-508 (see below for their
locations, 4 on each side)

- Remove the HALF FLANGES, then the HALF CLAMPS
- Final assembly should appear like this

TZ FM4-508 re-assembly
- Place the base on a holding feature
- Place the FM4 to be equipped with specific stress relief system

on the base, and lock it.
- Use the molded form marked below, and the markings on the cable, to pre-position the two
HALF CLAMPS

- Using the Vario-torque screwdriver (2.0 – 7.0 Nm) with screwdriver Bit TORX T20, tighten
the 4 SCREWS PT 40x16 as shown below (TORQUE 2.8Nm)

- At this stage, assembly should appear like this
- Locate a rectangular-shaped hole on the nut of FDU-508
- Place one of the HALF FLANGE accordingly (the rectangular edge on the inside of the HALF
FLANGE should mate with the hole)

- Place the other HALF FLANGE
CAUTION
Make sure you used one HALF FLANGE equipped with a LOCKING BIT, and one
HALF FLANGE equipped with a SCREW PT 50x24.
- Using the Vario-torque screwdriver (2.0 – 7.0 Nm) with screwdriver Bit TORX T20, tighten
the 4 SCREWS PT 40x16 (TORQUE 2.8Nm) - see above, 2 on each side)

- Place the BEND RESTRICTOR on the plug

- Tighten the SCREW PT 3x8 using Vario-torque screwdriver at torque 1,1Nm

Contact holder replacement
WARNING
To complete this procedure, TOOLS SET PN 10027858 (found in 508XT Technical

manual, section FM4 TOOLS SET) is required.
- Follow the instructions to disassemble TZ FM4-508
- In case the SCREW PT 3x8 on the plug is not visible, turn the locking ring until you can see it
- Untighten the SCREW PT 3x8 using Vario-torque screwdriver and Screwdriver bit TORX 8
- Using the Open end torque wrench, untighten the MARSH NUT and slide it along the cable

- Gently pull the cable to take the contact holder out of the body
- refer to REPAIR INSTRUCTIONS Contact holder repair to replace the contact holder
NOTE : SERCEL recommends using new CONTACT HOLDER PAD, WASHER GLAND
SLEEVE, GLAND SLEEVE 6mm, and WASHER GROMMET for every repair.

Locking pin replacement
- Untighten SCREW PT 3x8 (screw head type: TORX 8) and remove the blocking part, and the
LOCKING PIN to be replaced
Blocking part
- On the CORD, make a 8-shaped knot and tighten it

- Cut the remaining length after the knot
- Measure 15cm of cord on the other side of the knot, and cut the CORD there
- Burn both sides slightly
- Pass the CORD in the new LOCKING PIN, starting by the straight side
- Pull the cord until the knot is trapped in the LOCKING PIN

- Insert the new LOCKING PIN in the HALF FLANGE FOR LOCKING PART
- Place the blocking part and tighten the SCREW PT 3x8 (screw head type: TORX 8; torque: 1
Nm)

Locking flange replacement
- Place TZ FM4-508 in a holding feature
- Untighten SCREW PT 50x24 (screw head type: TORX 25IPR)

- Place a new LOCKING FLANGE in position.
NOK
OK
Screw axis
Female connectors
axis
- Tighten SCREW PT 50x24 (screw head type: TORX 25IPR; torque: 2,8Nm)

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Ref. – 10030284 AF 28 September 2020

Warnings and Cautions

2 508XT Technical Maintenance Manual

The Software is copyrighted and licensed but not sold.

(e) Create or attempt to create derivative works from the Software;

Import and Export.

4 508XT Technical Maintenance Manual

Feb. 2016 AA Initial Document Release

Jul. 2016 AB p. 79 - Modified strain relief process in fiber-splicing

Apr. 2017 AD p. 21 - added details on FM4-508 anchoring

Dec. 2017 AE p. 142 - added WTU508

Sept. 2020 AF p. 15 - added LEAK TEST BY IMMERSION

6 508XT Technical Maintenance Manual

MAINTENANCE GENERAL GUIDELINES......................................................................................................... 10

SPARE PARTS ..................................................................................................................................................... 25

FDU-508 REPAIR PROCEDURE ..................................................................................................................... 54

FIBER OPTICS SPLICING PROCEDURE ............................................................................................................ 73

SPARE PARTS ..................................................................................................................................................... 93

CX-508 REPAIR PROCEDURE ...................................................................................................................... 126

8 508XT Technical Maintenance Manual

OVERVIEW ...................................................................................................................................................... 172

TZ NODE-508 REPAIR PROCEDURE ............................................................................................................. 192

SPARE PARTS ................................................................................................................................................... 193

TZ FM4-508 REPAIR PROCEDURE ............................................................................................................... 217

SPARE PARTS ................................................................................................................................................... 218

This chapter includes the following sections

10 508XT Technical Maintenance Manual

Use a static-dissipative tablemat.

Wear a static-control wrist strap or foot grounder.

Wear static-dissipative garments.

CHEMICAL PRODUCT WARNING

Inhalation: May cause respiratory tract irritation.

Eye contact: Contact with eyes will cause irritation.

12 508XT Technical Maintenance Manual

- Place the O-ring with aqualub on it in a plastic bag

Chemicals products such as soap or alcohol must not be used.

Dry the connectors and caps with either:

- compressed air holding the nozzle at least 15cm of the plug

14 508XT Technical Maintenance Manual

Test equipment required

- Water temperature: 65°C

This chapter includes the following sections,

 Base cable disassembly

16 508XT Technical Maintenance Manual

O-RING 18,64 x 3,53

Exploded view of LINK-508 (FDU-508 version)

O-RING 18,64 x 3,53

PRE-ASSEMBLY LID of NODE-508 (FDU-508)

Exploded view of LINK-508 (DSU1-508 version)

Items Part No. Comments

SCREW 50 x 24 SECURITY 25IPR 10014254 FDU-508 and DSU1-508

O-RING 18,64 x 3,53 10003432 FDU-508 and DSU1-508

FDU-508 DUSTCAP 711082917A FDU-508 only

Electrical screwdriver 1,8Nm 10027772

Insert Bit TORX PLUS security 25IPR

Insert Bit TORX PLUS security 25IPR

NODE-508 holding feature 10021139

18 508XT Technical Maintenance Manual

Base cable disassembly

- Locate the 2 screws which attach the bases cables.

20 508XT Technical Maintenance Manual

- Put both BASE CABLES on a PRE-ASSEMBLY.

- Clamp the unit using the spring clip.