Fuze Ffv-64 C Filling & Assy. 84 Mm Illu.

FUZE FFV 64 C 84 MM ILLUMINATING FUZE FILLING & ASSEMBLY

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84mm RCL GUN • 84mm RCL GUN

Introduction The 84 mm RCL Rocket Launcher is a recoilless gun which is intended primarily as an antitank Weapon but is also well suited for other roles such as attacking armoured personnel carriers, pillboxes, machine gun posts and troops in the open

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84 mm ILLUMINATING FFV 545

GENERAL : This ammunition is fired from Gun 84 mm RCL Carl Gustaf from the shoulder. The cartridge combines some of the characteristics of Rocket and Artillery ammunition in its design. The ammunition is of Swedish design. The illuminating round has been designed to meet the requirement for a very quick illumination of target areas, offering facilities for all types of direct fired weapons and guided anti-tank weapons to engage, Armoured fighting vehicles, support weapons etc. The illuminating round is also intended to facilitate for the sub-units of the battalion, supply of their own illumination of battle field, even continuous, when required. The ammunition is of the fixed type. The design of the ammunition parts and functioning are like Artillery components excepting that the rear end of the cartridge case is closed by a plastic blow out disc (base plate), which allows rearward escape of the propellant gas so as to make the weapon recoilless and the ignition of the propellant is by a side-located percussion cap and an igniter composition. 3

84 mm ILLUMINATING FFV 545 • The cartridge case is made of light aluminum alloy drawn to specification BS-1470 Grade 6082 TF or IS 736 Grade 64430 WP. At the rear of the cartridge case, it is formed with a flange which is cut away over a length to take a guide while loading the round in the gun. At about 90 degrees from the cut away flange a hole with two diameters is provided on the body of the cartridge case to take the percussion cap. The shell body is made of light aluminum alloy to specification BS 1474 Grade 2014A or IS 736 Grade 64430 WP. 4

84 mm ILLUMINATING FFV 545 • The shell body accommodates the canister illuminating candle and the parachute assembly. The shell also accommodates the time combustion fuze FFV 64C, at the nose. The shell base is made up of light alloy with six equispaced circumferential holes to fix the base plate and body together with fixing screws. The shell is spin established. Propellant NGB 204 is a ballistite propellant. This ammunition is manufactured to Government of India, Ministry of Defence Specification No. CQA 3815 and drawing number F1301-055361 K.

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84 mm ILLUMINATING FFV 545 •

PHYSICAL CHARACTERISTICS :

• • • • • •

Total length of ammunition 450 mm Total mass of ammunition 3.1 kgs Mass of projectile 2.2 kgs Propellant (ACM) 0.4 kg Mass of Illuminating composition 0.5 kg Explosive filling in primer (cap) (Composition VH 2 & Zirconium) 0.13 gm • Explosive filling in Igniter (Composition Z47B & NC 110) 15.0 gms • Explosive filling in fuze 17.68 gms • Net explosive content 932.81 gms

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84 mm ILLUMINATING FFV 545 PERFORMANCE CHARACTERISTICS :

• • • • • • •

Muzzle velocity 260 m/s Range of burst 300 to 2100 m Height of burst 200 m (approx) Illuminated area, diameter 400- 500 m Rate of descent 5 m/s (approx) Candle power 6,50,000 candela Burning time 30 ± 5 sec 7

84 mm ILLUMINATING FFV 545 • SPECIAL FEATURES : The weapon is of recoilless type and can be fired from the shoulder. The ammunition can be effectively used at any range between 300 m to 2100 m by elevating the gun to 20 degrees or 25 degrees. • SAFETY : The fuze is provided with a rubber hood and a safety pin. The rubber is for protection against atmospheric condition during storage and transport. Before firing, both the rubber hood and the safety pin is removed and the fuze is set.

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84 mm ILLUMINATING FFV 545 • RELIABILITY : Due to its sound design and careful manufacture, the ammunition is very reliable for use in combat field environment. • SHELF LIFE : The shelf life of the ammunition is 10 years PACKING : Two rounds are packed in twin containers made up of injection moulded tube of high density polyethylene. Three such twin containers (total 6 rounds) are packed in one wooden crate. 9

84 mm ILLUMINATING FFV 545 • STOWAGE DIMENSION : • Packing box size660 mm x 463 mm x 356 mm • Gross weight 40.0 kgs • Net weight24.6 kgs • Volume0.108 cu.m 10

84 mm ILLUMINATING FFV 545 • HAZARD CLASSIFICATION :Compatibility groupG • Hazard division1.2 • Fire fighting class 2

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FUZE FFV 64 C For 84mm Illuminating

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• •

A. ASSEMBLY OF DETONATOR IN HAMMER. B. ASSEMBLY OF BROAD CLOTH WASHER AND PELLETS IN TIME TRAIN RING AND FUZE BODY. • C. ASSEMBLY OF FIRING PIN IN FUZE BODY. • D. SETTING TORQUE AND DRILLING HOLE. • E. FILLING GUN POWDER AND CIRCLIP ASSEMBLY.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• PROCESS/OPERATIOAN INSTRUCTION :PART-I

• PRELIMINARY PREPARATION • ( Receipt of empty and filled components & Gun powder)

• 1. Receive empty components in container/trays and keep at their respective places. 14

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY •

( Receipt of empty and filled components & Gun powder)

• 2. Receive Detonator/ pellets duly packed in felt lined FQ 396 containers inside safety carrying box from magazine and keep at the assigned place on the table. Not more than 50 Nos. in one container. Open the box, remove the tin containers and place it on the table. Remove the carrying box. • 3. Receive Gun Powder G-12 in P.M. dubba and keep at respective place on the table and transfer a small quantity (250g) of Gun Powder in to the container. Close the P.M. dubba with lid. 15

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 4. Ensure that the tools and equipments are properly earthed. • A ASSEMBLY OF DETONATOR IN HAMMER. • 5. Receive hammer and safety plate in containers and keep on the table. • 6. Take one container containing filled detonator and open the lid gently. Remove 20 detonators behind the safety shield and keep in another container and close the lid and keep the bulk at a proper place. 16

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• A • 7.

ASSEMBLY OF DETONATOR IN HAMMER.

Take one hammer and carefully remove one detonator at a time with the help of a kit stick wax and insert in the detonator cavity of hammer with its face upward.( This operation should be done behind safety shield provided.) • 8. Keep the hammer assembled with detonator in the stacking fixture fitted on the press. Stack the assembly by operating the press at 3.50 kg. cm. Take out the unit from the fixture (Stacking to be done behind the safety shield). • 9. Gauge and inspect the unit for proper stacking. 17

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 10. Take the accepted hammer one at a time and assemble safety plate on the unit using the fixture and hand tool provided (care is to be taken while assembling safety plate otherwise the plate may get damaged). Pack the filled hammer in proper containers and pass to the next operation. • B ASSEMBLY OF BROAD CLOTH WASHER AND PELLETS IN FUZE BODY. • 11. Take a fuze body and place in the assembly fixture provided. Take a protective sleeve and fit it on the fuze body. 18

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • B ASSEMBLY OF BROAD CLOTH WASHER AND PELLETS IN FUZE BODY. • 12 Apply a thin coat of shellac varnish on the flange of the body leaving approx. 3 mm free surface around the 2 holes on fuze body by means of brush provided. • 13. Take a pellet large (perforated) and insert it in the flash hole of fuze body and check its fitting. Take a broad cloth washer (large) and insert a pellet (small) in to the small hole of the washer. Assemble the broad cloth washer on the body flange keeping the small pellet in the washer over the pellet assembled in the body and big hole of washer coinciding with the hole meant for spring and ball. Press the broad cloth washer in such a way

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

B ASSEMBLY OF BROAD CLOTH WASHER AND PELLETS IN FUZE BODY. that an effective attachment is obtained in the small layer. Check the position of small pellets.

• 14. Take a Time Train Ring (T.T.R.) filled and apply a thin coat of shellac varnish on the grooved surface with a brush. Take a broad cloth washer (small) and affix it on the surface of T.T.R. uniformly with hand. 20

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• B ASSEMBLY OF BROAD CLOTH WASHER AND PELLETS IN FUZE BODY. • 15. Receive fuze body assembled with pellets and broad cloth washer and fit it in the fixture provided. Take a T.T.R. and fit it on fuze body placed in the fixture and turn the T.T.R. in such a way that its key hole will be just in front of locking pin of the fixture, push the unit into stop where by the T.T.R. shall be blocked. Take a pressing nut and screw it on to body over T.T.R. and tighten it with torque wrench to 2.8 kg/cm torque. Take out the unit from the fixture and keep the unit under pressure for over night. 21

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• UNSCREWING PRESSING NUT AND DISASSEMBLY OF PARTS. • 16. Receive the pressed unit and clamp one unit at a time in the fixture and unscrew the pressing nut from the unit with the help of the tool provided. Remove T.T.R. and protective washer and take out fuze body in respective trays. Clean the parts if necessary to remove flown out shellac varnish and convey for further operations. 22

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• C ASSEMBLY OF FIRING PIN. • 17. Take one fuze body and assemble in the fixture of marking machine provided. Operate the machine and stamp filling details on the fuze body. Take out the fuze body from the machine and check for correct and legible marking of details on fuze body. 23

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• C ASSEMBLY OF FIRING PIN. • 18. Take fuze and a firing pin/striker and position the firing pin in the centre cavity of fuze body with point upwards. Take a locking pin and insert it into the small hole provided on the neck of the fuze body and fit it properly with the help of a mandrill so that the inside end of pin locks the firing pin in the fuze body correctly. • 19. Gauge the assembly with the gauge provided. 24

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • D SETTING TORQUE AND DRILLING HOLES • 20. Take the passed assembly and assemble T.T.R. and apply grease on the entrance threads of the body. Take a nose and apply a thin layer of talc on the nose base by rubbing it on a felt with talc powder and thread on the nose to the fuze body till it stops. Pass on the assembly to the next operations. Place the assembly in the fixture provided and tighten the nose with torque wrench provided to a torque of 28 -32 kg./cm. Insert a center punch through the hole of the nose and make a punch mark on the fuze body. Unscrew the nose and remove T.T.R. from the body and place the fuze body on the fixture under the drilling m/c. Drill a hole on the punch mark by operating the drilling m/c. Suck off the metal chips and take out the drilled body from the fixture.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • 21 Check the hole size with the gauge provided. • ASSEMBLY OF THE FUZE. • 22. Bring Fuze body with T.T.R. and nose. Check that the pellet and firing pin are in correct position in the body. Take a spring and ball and assemble in the drilled hole of the body one over the other. Place T.T.R. on the fuze body so that the position "S" mark on time ring is exactly above the ball and spring assembled on the fuze body and press the time ring on the fuze body. Position the assembly in the jig provided and clamp. Take a cylindrical pin and fit it into the transversal hole in the body by means of the pin provided. Remove the fuze from the jig and fit 2 pins vertically in the two holes of the time ring if necessary by means of a plastic hammer. Pass on the assembly to the next operator. Remove fuze and thread on the nose some turn and pass on.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • ASSEMBLY OF THE FUZE. • 23. Take a unit and remove nose and place the fuze in the fixture provided. Take a spring and insert in the body hole around the firing pin /striker. Take a hammer assembly and check the assembly for presence of detonator. Place the hammer assembly in the center hole of the nose. Assemble nose with hammer to fuze body and tighten the nose till the drilled hole on the fuze body comes concentric with the hole of the nose by means of wrench and fixing pin provided. Take a screw and lay down it in the hole and drive it to stop with the screw driver. After tightening the screw fully, unscrew it 1/4th turn and gauge the depth for 4.1 mm. Set the fuze to "S" position by rotating time train ring to the line mark on fuze body. Pass on the completed job to the next operator.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • ASSEMBLY OF THE FUZE. • 24. Take a fuze and clamp it in the fork shaped tool and lock the same in the torque setting fixture. Rotate the base wheel of the fixture clockwise one round and note the reading on the torque meter to 18 to 36 kg. cm. The start and the point where the ball locks ( at 6,11,17 ) are not counted. Fit the passed item in the fixture provided and rotate the T.T.R. till it stops. Then reverse and set the T.T.R. and make sure that the ball locks are indexing at fuze setting 6,11,17 and a normal stop is achieved when passing the "S" mark. Take out the fuze from fixture and set "S" position. Inspect the fuze visually for proper setting and pass on to next operation.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• E FILLING GUN POWDER AND CIRCLIP ASSEMBLY • 25. Take a fuze and check for presence of pellet large and place it in fixture. Fit "O" ring in the groove. Scoop approx 7 g. of G-12 gun powder and fill in the fuze cavity and level it by gentle tapping. Take care that no grain comes on to the "O" ring. 29

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • E

FILLING GUN POWDER AND CIRCLIP ASSEMBLY

• 26. Take one disc and gauge the thickness of it in the gauge fitted to ensure assembly of single disc and place the disc over the "O" ring in fuze. Place the perforated base plate on top and assemble circlip by hand. Place the unit in the fixture of the press and press the circlip home by operating the press. Take out the fuze from the press and pass on for gauging. • 27. Gauge the pressing of circlip with gauges provided.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY • E

FILLING GUN POWDER AND CIRCLIP ASSEMBLY

• 28. Take a fuze and place on the table. Take "O" ring applied with french chalk and assemble to the safety pin. Assemble the safety pin into nose. Apply cement /APC 210 on the grub screw hole /Cut out approx. 190 mm length tape and fix it up around after setting the safety pin downwards. • 29. Weigh the fuzes for specified weight 336 +/-2 g. and inspect the fuzes for proper marking and graduation visually.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 30. Pack the fuzes in boxes.(40 Nos. per box).

• PROCESS/OPERATIONAL INSTRUCTIONS PART-II • 31. The floor, machineries, work table etc. should be cleaned and mopped daily before commencement of work on day to day basis. Cleaning/sweeping operation shall be carried out at frequent intervals. 32

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 32. Sweeping, waste explosives so collected should be kept immersed under oil/water in waste explosive bucket and disposed off daily by sending to EDG. • 33. L.P. testing and earthing bonding of stacking m/c, pressing m/c (hydraulic & pneumatic) & working table shell be carried out by EE section periodically and record maintained. • 34. The relative humidity, required ( 40 to 60% ) to be maintained during the process shall be stipulated for strict compliance. 33

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 35. The log book/record book giving details of all work carried out in the building shall be maintained by staff incharge. • 36. All static earthing arrangements will be tested by electric section for conductivity once in a month and the record of the same will be maintained. • 37. Rejected filled components will be placed under oil in respective containers and disposed off by sending to Explosive Disposal Ground. 34

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 38. The shop instructions, Special Precautions and Specials Danger to be avoided will be read and explained in Hindi/Vernacular language to all persons concerned before they commence work and till such time they are fully conversant with the job and at least once in a month there after. • 39. These General Safety Directives must be strictly followed and no deviation of any kind will be permitted without written authority of danger building officer/JGM/CSO/GM Under intimation to QAO /QAE (ME) Khamaria. 35

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 40. These shop Instruction, Special Precautions and Special danger to be avoided are to be interpreted as additional to the Standing instruction/Rules and Regulation for Danger Area. • (i) SPECIAL SAFETY PRECAUTIONS (Dos') • 41. The work benches, hatches way and floor will be cleaned at the close of work. 36

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 42. The metal portion of the brushes should be covered with chamois leather. • 43. Always maintain Relative Humidity of the building and room 40 to 60% and record maintained. • 44. Ensure that First Aid Box and fire fighting equipments are available for building and approach to the equipment is clear/easily accessible. • 45. In case of any abnormality observed during the explosive process inform the staff-in-charge and HOS.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 46. Ensure that all antistatic precautions are taken and strictly observed during the explosive processing. • 47. Assembly of detonator to hammer and stacking of detonator in the hammer will be carried out behind safety shield provided. • 48. Filled hammer assembly should be handled with great care and any kind of rough handling, shock or friction should be avoided all together. • 49. Ensure that explosives kept in the place allotted and non compatible materials are not kept together.

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FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 50. Persons engaged on the job must wear DB dress, DB shoes and safety goggles. • 51. Operations which are to be performed behind safety shield must be carried out behind safety shield only and no short cut should be adopted. • 52. Amm. Packages should never be dragged or sharply put down.They should be lifted from place to place carefully. 39

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• (ii) SPECIAL HAZARDS TO BE AVOIDED (DON'TS) • 53. Avoid undue haste in all operation and always handle the explosive with great care. • 54. The detonators are sensitive to shock, friction and static charge and hence should be handled with great care and haste of any kind should be avoided. • 55. Do not allow any operator to use any type of synthetic fibre cloths and foot wear other then specified for danger area. 40

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 56. Do not use defective tools machine equipments and not perform any filling assembly and inspection operation in any place not approved and should be carried out behind safety shield. • 57. Do not start any operation when staff member is not present. • 58. Do not block the free passage for movement of working people. • 59. Do not try to set things right on your own. Ask staff-incharge. 41

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 60. The explosives used in the process is very sensitive to friction and impact, Do not allow explosives to get nipped between hard surfaces and always avoid undue friction to explosives. • 61. Detonators are extremely sensitive to shock and friction and must, therefore, be handled with great care. Container/carrying boxes with detonators must not be dropped dragged or sharply put down and should be lifted clear from place to place. • 62. Not more than one tin container containing 50 detonators shall be kept in front of operators assembling detonators. 42

FUZE FFV 64 C 84 MM ILLUMINATING FUZE

FILLING & ASSEMBLY

• 63. Not more then 20 detonators at a time should be taken out from container for assembly. • 64. Not more then 20 filled hammer assemblies will be kept exposed in front of hammer assembly operator. • 65. Fuzes loose in work trays will not be allowed to be dropped or other wise roughly handled. Work trays containing filled fuzes will not be dragged, pushed, slid or sharply put down. They will be lifted clear from place to place. • 66. Not more than 250 g of Gun Powder G-12 shall be kept in front of the operator. 43

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