- 1 year ago
It is one of the most popular and best fighter jets in the world: JAS 39. The so called “Gripen” is a light single-engine multirole fighter aircraft manufactured by the Swedish aerospace company Saab. At the Czech Air Force Base in Caslav, the jet gets the biggest overhaul of its lifetime!
In only 40 days, the Gripen is stripped down to its bone, everything from the ejection seat to the engine is removed and checked. The 14 Gripen of the airbase are part of the “Quick Reaction Alert” Force of the NATO. If they are not in the air, the airspace is not protected. That puts a lot of time pressure and liability to the 11 mechanics, who are responsible for the aircraft.
The machinists put the war machine to the acid test. They check the hydraulic system, all moving parts and the oil – the aircraft`s blood. It is one of the most important things of the Gripen: without it, the pilot is not able to control the jet. The ejection seat – the pilot`s life insurance. The access panel is examined painstakingly – the skin. The biggest part is the engine check: the turbine is the heart of the Gripen. In the end, the weapon system - the fist - will be disassembled, so the gun is working when it is needed in action.
Every fault they will find means a delay to the schedule. So the team has to work really concentrated and, above all properly, that the Gripen will be able to start in time.
In only 40 days, the Gripen is stripped down to its bone, everything from the ejection seat to the engine is removed and checked. The 14 Gripen of the airbase are part of the “Quick Reaction Alert” Force of the NATO. If they are not in the air, the airspace is not protected. That puts a lot of time pressure and liability to the 11 mechanics, who are responsible for the aircraft.
The machinists put the war machine to the acid test. They check the hydraulic system, all moving parts and the oil – the aircraft`s blood. It is one of the most important things of the Gripen: without it, the pilot is not able to control the jet. The ejection seat – the pilot`s life insurance. The access panel is examined painstakingly – the skin. The biggest part is the engine check: the turbine is the heart of the Gripen. In the end, the weapon system - the fist - will be disassembled, so the gun is working when it is needed in action.
Every fault they will find means a delay to the schedule. So the team has to work really concentrated and, above all properly, that the Gripen will be able to start in time.
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TVTranscript
00:01What does it take to cut a ship into two halves, to strip down and reassemble a giant plane, to overhaul the world's longest high-speed train?
00:15It takes hundreds of professionals, expertise, precision, and courage.
00:25It's never been done before.
00:27Pushing everyone to the limit.
00:29It is surely a challenging job.
00:31Now, on Mega Pitstops.
00:45It is one of the most state-of-the-art fighter jets in the world, the Saab JAS-39, known as the Gripen, or in English, Griffin.
00:53So, what is the Swedish-built jet used for?
00:56Pursuit, attack, and reconnaissance.
00:58The 35-million-euro fighter jet can fly at double the speed of sound and is renowned for its high level of reliability and versatility.
01:09It can master both the extreme cold and difficult runways.
01:15To avoid deadly accidents, every jet has to pass a Mega Pitstop after 200 flying hours.
01:25The machine has put the Gripen to the acid test.
01:27They check the hydraulic system, all moving parts, and the oil, the aircraft's blood, the ejection seat, the pilot's life insurance, the access panel, the skin.
01:41The biggest part is the engine check.
01:45The turbine is the heart of the Gripen.
01:47They also overhaul the weapon system, the fist.
01:51All of this in only eight weeks.
01:54The Czech Republic, the 21st Tactical Air Force Base in Časlav, 100 kilometers east of Prague, home to 14 Gripen's.
02:05Two of them are on call 24-7, ready to defend NATO's airspace.
02:10The fighter jet with serial number 39.238 already has 1,800 flying hours under its belt.
02:22Time for a major Mega Pitstop.
02:25Head mechanic Martin Batra will be inspecting every inch of the plane with a fine-tooth comb.
02:34Any fault could put airspace safety at risk.
02:37I have been interested in planes ever since I was little.
02:45For me, the most fascinating thing is that such heavy machines are able to lift up into the air and fly.
02:54And I am in awe of the fact that you can master these planes up there whenever you want.
03:01Sadly, I wasn't able to become a pilot myself as my hearing and sight weren't good enough.
03:07That's why I became a mechanic.
03:09It's a great job.
03:10Nowadays, every aircraft is different.
03:14Planes start to age and often reveal problems that we knew nothing about.
03:18For us, that's the biggest challenge during this pit stop.
03:25Martin's team has to be finished in 40 working days.
03:28As well as complete precision, this also means a whole lot of time pressure.
03:33His crew starts right away.
03:42The worker's first job is to take a sample of the hydraulic oil.
03:46Admittedly, it is a pretty small task.
03:49But sending it off for analysis in Sweden, a few hundred kilometers north of here, can take several weeks.
03:56And changing 20 liters of fighter jet oil requires a lot of time and effort, too.
04:07We will start the engine for 30 minutes so that we get all particles to move.
04:12We will first take the hydraulic samples, then we'll do the IP gravity spreadsheet.
04:17And after the shutdown, we will take the engine samples.
04:22Aircraft mechanic Roman Brazda starts up the plane and moves all of its wings to make sure the oil
04:28is distributed as evenly as possible throughout the plane.
04:32Then Martin siphons off the oil.
04:35Now, all that's left is to hope that the result is positive, so they don't have to replace the oil.
04:42After all, this mission has more important priorities.
04:49We have 14 aircraft stationed here.
04:52Altogether, they have to fly 2,000 hours in one year.
04:56A huge challenge we face is keeping the window for maintenance work as small as possible,
05:01so that the planes can complete their flying hours.
05:04That's why we work around the clock.
05:10Incidentally, the teams give every fighter jet a nickname, depending on its weakness.
05:15The Beast is undergoing a mega pit stop today.
05:19Its name comes from the fact that its combustion system keeps developing a life of its own.
05:24First things first, it's time to give The Beast a good wash.
05:28We are preparing the plane for cleaning.
05:33Because we use a high-pressure cleaner, there are places where water could get into the plane.
05:38That's why we have to tape up any points that aren't completely leak-proof, including the cabin.
05:44Rust is the worst thing that can happen to a plane.
05:50Cleaning is about more than just making sure the plane looks nice.
05:54It is the only way the team is able to locate any damage to the fighter jet's outer shell.
06:03Here is something small.
06:07Chipping paint is a reoccurring problem.
06:12After all, the planes are a good 14 or 15 years old.
06:16As long as we can see the silver layer, then everything is still okay.
06:23This protects the pilots from lightning.
06:26If the silver layer disappears, there will be problems during a storm.
06:30The systems could shut down if a bolt hits the plane.
06:33The access panel is a kind of harness to the aircraft.
06:41Under the special varnish, there is a rust and lightning protection.
06:46The mechanics inspect the access panel precisely.
06:50Every single scratch has to be repaired.
06:53If they find larger damages, they even replace parts.
06:56They have to be repaired.
07:04Yes, that'll be fine.
07:07I'll pass the washer jet up to you.
07:12First, the Czech army uses a special mixture to remove any larger bits of filth.
07:18Then, all the team has to do is spray down the film of dirt.
07:22We're not quite done yet. There's still work left to do.
07:28It's almost like a car wash.
07:30Just a little more hardcore than removing a few flies from the windshield.
07:38Most of the dirt is fuel.
07:40Insects, engine oil, hydraulic oil, and fine particles.
07:45Because the jet is up in the air, it also gets covered in lots of dust particles,
07:53sand from the Sahara, and animals.
07:57That's why we use stronger chemicals than in a car wash.
08:01The jet's paintwork is a lot tougher than the paint used on cars.
08:09Day two.
08:11Now the team turns their attention to the ejector seat.
08:14Every pilot's life insurance policy.
08:19Stop.
08:19Including the parachute, rocket propeller, and emergency kit, the seat weighs 120 kilograms.
08:26Over the next 15 days, it will be completely dismantled, serviced, and put back together again.
08:33This also includes a functional check and test of the pyrotechnics.
08:37The man in charge of making sure everything works when the jet's back on duty, aircraft mechanic Peter Sikora.
08:48Even the ejector seats has to be checked on a regular basis, because all materials age.
08:53We check all the seals regularly and replace anything that isn't up to standard.
09:00The same goes for the individual pyrotechnic cartridges.
09:04They age too.
09:05So, of course, they have to be replaced.
09:08Same for the belts, springs, and so on.
09:11Peter isn't daunted by this responsibility.
09:15However, he doesn't quite take the same stance when it comes to the explosives themselves.
09:24I don't feel under pressure.
09:26After all, there's plenty of equipment in the aircraft to make sure the pilot stays safe.
09:30It's more the explosives that worry me, because they are a risk to me.
09:38But it is precisely this highly explosive substance that allows the seat to work in the first place.
09:45It triggers a range of emergency measures, from launching the seat to releasing the parachute.
09:54But one thing at a time.
09:56Before the Mega Pit Stop mechanics can dismantle the seat, they have to remove the volatile explosives.
10:06There is even a special ejector seat workshop to assist.
10:11Here, the mechanics remove the nine pyrotechnic cartridges in total.
10:15These cartridges hold a total of 3.5 kilos of explosives and accelerate the pilot to 17 times
10:31his own body weight in an emergency. So, beware.
10:38Day four in the Mega Pit Stop. Now it's time to look at the fighter jet's power source.
10:45The mechanic starts screening the turbines. And that's no easy task.
10:52Including the afterburners. The engine can produce thrust of over 80 kilonewton.
10:58An Airbus A380, which weighs more than 80 times as much, achieves just four times this force.
11:07The turbine is the heart of the Gripen. Little scratches can have severe consequences.
11:12If the engine collapses, the aircraft is crashing down.
11:17In case there are damages invisible to the naked eye, the mechanics inspect everything precisely
11:23with the stethoscope. If they discover one mistake, the whole engine has to be replaced.
11:29The time has come for Roman Barsta. Wearing a special anti-static suit,
11:37he climbs inside the fighter jet's inner chamber.
11:40This is a job that most people don't like doing, because you have to climb all the way inside this very tight space.
11:53People with claustrophobia would never be able to do this job.
12:02But for me, it's the best experience there is, because I get to go inside the heart of the plane,
12:07to a place where not many people get to go. It's a definite highlight and the best feeling there is.
12:17Despite 15 years of experience in the field, even Roman has found himself trapped inside a fighter jet turbine,
12:23which resulted in a dramatic rescue. But not even that has put him off.
12:32I will start from the interspace, from the sealing rubber that separates the engine from the Griffon's part.
12:40Then I will devote myself to the first pre-stater, the blades, and then the first stage of the fan,
12:46and the second stage, including the inlet.
12:52Roman has to look out for every tiny dent, most of which are caused by stones or birds hitting the plane.
13:00If he misses just one single flaw, the entire engine could be destroyed during its next military deployment.
13:10Everything looks fine. I didn't see anything out of the ordinary.
13:16I'll carry on checking the turbine from the top now.
13:25At the same time, head mechanic Martin and his team are removing the fighter jet's outer shell,
13:31and looking for further damage.
13:36Here I've spotted something. This dark patch is just anti-rust agent.
13:42There's still enough there, so it's fine.
13:44It's fine. We only need to add a new layer when it gets too dry.
13:48The waterproofing here? No, it's fine.
13:54This involves undoing thousands of screws, each of which has its own precise location.
14:00The solution is as smart as it is simple.
14:03Every screw on the plane has its own position. Not always every bolt is the same,
14:13so to prevent the confusion of the bolts and possible damage to the aircraft,
14:18we have prepared such a Czech invention. It consists of these cartons. Each carton is marked with the
14:24number of holes and by the direction of the flight. The bolts go in exactly by this order.
14:30So now, I'll try to find the right kit.
14:34There are cables or turbine components behind every drilled hole. This means that the engineers
14:40have to adjust the length of every screw accordingly. Just one mistake would almost inevitably destroy the electronics, too.
14:49The level of damage caused could quickly reach the six-figure range.
14:53Roman uses an endoscope to check the turbine's inner workings.
14:56There are only a few people on the airfield able to perform this test, and that is precisely the problem.
15:04You need to have special training to do it, but you also need a certain flair and the right way of looking at things.
15:10We simply have to find everything. We're talking about very small parts here,
15:15which is why we need all the intuition and experience.
15:17Roman has to take a break every 90 minutes to make sure he has enough concentration to hopefully uncover every problem, like now.
15:33I can see some second-degree damage. It looks like a small dent from a stone.
15:40Later on, I'll compare the damage with the table to see how deep and wide it is.
15:44I'll take some photos now before I assess the damage. Only then can I see how bad it really is.
15:56And whether damage like this will cause the plane to crash in the near future?
16:01The consequences sound pretty dramatic.
16:07A full engine replacement, performed lovingly by hand.
16:10I am more an old-fashioned guy. It took a long time to get used to these computers.
16:17All my life I have only been working with engines. So the Gryphon is my life. All my life.
16:25After the cold zone of the turbine, Roman now turns his attention to the combustion chamber.
16:30This is where the kerosene is ignited, generating the maximum thrust needed and equally heated situations during combat.
16:37We are slowly working towards the most critical point. Now, I really have to concentrate to make sure I don't miss any faults.
16:49After all, we are in the combustion chamber here.
16:52In here, damage smaller than a hairline crack can quickly destroy the entire engine.
17:04A fighter jet known as the Gryphon belonging to the Czech army is in for a mega pit stop.
17:10It's day 8 of 40. Roman is checking the final rotary blades in the turbine.
17:16I've spotted a problem here. I need to take a closer look from another angle.
17:28No, that doesn't look good. The turbine blade is really heavily damaged. We'll have to replace the engine.
17:35Damage like this could quickly spell disaster during deployment.
17:38But the risk of a crash is too high. The turbine needs to come out, which means a delay of at least 5 days.
17:47Two days later, the fighter jet's weaponry system is now under the microscope.
17:53The Gryphon is a multi-purpose warplane. Hunt, attack and search.
17:59Therefore, it is able to carry 8 variable weapons.
18:03Always with it, the machine gun.
18:05The Akon Mauser BK-27 can fire 1,700 rounds with a 27-millimeter caliber per minute.
18:21Tomáš Smoller is the maintenance team's weapons expert.
18:25He knows that the Gryphon is more or less perfect.
18:29But even a multi-flexible fighter jet can have its weaknesses.
18:35The cannon is exceptionally important.
18:38Say, for example, if the pilot is not able to use rockets, then the cannon is the ideal solution.
18:44However, if I compare this one here to the one in the tornado, I see that it may be the same weapon,
18:50but the tornado is able to reload if it gets jammed.
18:54This plane doesn't have that option.
18:56If the shell is blocked, then we're really screwed.
18:58There is a knot here on the top. You have to loosen it and pull the crank.
19:14Tomáš tests the Gryphon's cannon again and again, after every deployment, in fact.
19:19In times apiece, he still checks it at least once a year.
19:23So, oil the barrel outside and inside, then we'll carry on.
19:33First things first, the barrel-based machine gun has to be dismantled into hundreds of separate pieces.
19:42Utmost precision is extremely important in this job.
19:45If I put something back together wrong, forget a part or fail to spot something,
19:50it could have fatal consequences for the fighter jet, complete destruction or shots fired.
19:56They follow a standard procedure. First up, washing.
20:00The soldiers carefully scrub every component.
20:03Even cleaning weapons is a dream job for Tomáš.
20:06I collect weapons and guns as a hobby. I think it's good when a job is performed by someone who enjoys doing it,
20:15as it means they'll be precise. I put my heart into my work.
20:24One week later, the replacement engine has now arrived, five days behind schedule.
20:30But this step couldn't be avoided.
20:32We could have had a case where there was not enough coolant to cool the engine.
20:38It could have set on fire.
20:41This almost certainly would have led to a catastrophe and the plane could have crashed.
20:49Luckily, it only takes an hour to change the turbine, according to the manufacturer.
20:54Roman sees that as a challenge.
20:56How are things going with you? The line is jammed. You'll have to loosen it.
21:06A critical moment. Roman releases the 1050 kilogram damaged jet engine from the plane.
21:14Okay, keep going. Yeah.
21:19That's great.
21:20It sits here at the back. Stop.
21:28Whether it's during a mega pit stop or in the tough conditions of war,
21:32an efficient replacement process is crucial.
21:37It is interesting that the whole engine actually hangs only on three points.
21:41A left and a right hinge and the back hinge hang on such a bolt.
21:56Can we? So, we go.
21:58Can I go on?
22:00Here, we hang on something.
22:02Yeah, wait here.
22:03You must go to the middle, lift the pad, the pad on the bolt and forward.
22:11Good?
22:12So, we can now.
22:27Watch out.
22:27Now lift it.
22:35We don't have any room for errors here. I need to be really careful now.
22:40Even the tiniest thing could have major consequences.
22:43A broken pipe, a damaged bracket, it could all be disastrous.
22:50Yes, keep going. Just like that.
22:52Engine expert Roman is still making good time.
22:59And he seems pretty happy.
23:03So, it's in.
23:04We had a good day today.
23:06If the holes move, you can't fit the pins in.
23:11And then you have to fiddle around a lot.
23:14Half an hour down, half an hour back up.
23:17It took us an hour, as promised.
23:18We have reached their first important milestone.
23:28In week four of the mega pit stop.
23:30However, the team is still running behind.
23:33Then they get news from Sweden.
23:35The results of the hydraulic oil test.
23:38Roman.
23:43Particles are good.
23:44It came out as class five.
23:46Low viscosity just around the section to replace the liquid.
23:50The oil is the blood of the aircraft, responsible for all moving parts.
23:56Therefore, the quality of the hydraulic oil is extremely important.
24:01Within the next two days, the mechanics will check all flaps with which the pilot steers the grip in.
24:08And they test if the landing gear opens in an emergency situation.
24:13If this doesn't happen within a time limit, they have to replace parts.
24:21So, even if we're taking it later or longer, it would not be different.
24:26Well, that means that we will print an API gravity report.
24:29We will look at it and send an API and then, hopefully, we will finish.
24:37Let's do it.
24:40Yes, I take the pump and I pump a bit there.
24:43The verdict?
24:48They have to pump out 20 liters of old hydraulic oil and replace it with fresh oil.
24:54This will also take up time that they hadn't accounted for.
24:58It's a setback that the team has to shake off.
25:01After all, it's not just a personal objective they've set for themselves.
25:06It is about making sure NATO's pilots are back in the air again as quickly as possible.
25:12It's slowly moving.
25:18Because of the purity of the fluid, it is very important to use this fluid in a closed circuit.
25:23After each use, it is necessary to rinse the tube in order to pass it over the filter,
25:28which will clean it continuously and keep the fluid in good condition.
25:35The team starts the test with fresh hydraulic oil.
25:39The plane isn't allowed to run here in the hangar.
25:42So, a generator is used to produce the pressure needed by pumping additional oil into the lines.
25:49Good?
25:49Yes, good. I set it to 28.
25:51The mechanics move all the wings.
26:00This pumps oil through all the lines, pushing out the last few air bubbles.
26:04The Gryphon can't return to the skies until it has passed this test.
26:11The hydraulic system is the most important element.
26:15The engine is what starts and powers the plane, but the wings are what control it.
26:22Any loss of fluid would require the plane to make an immediate emergency landing,
26:27because the pilot could lose control of the aircraft within seconds.
26:34Therefore, it is very important that we work accurately and don't make mistakes.
26:42On the other side, we have to look at…
26:46Uh-oh, now we've got a problem.
26:52Looks like we've got an issue with the generator.
26:55Now we have to figure out what happened.
27:03Martin and his team have to suspend testing until the generator stops its strike.
27:08And that means more valuable time down the drain.
27:13The men frantically search for the problem.
27:15Then they find out that the test has to be delayed.
27:24We can't proceed. We have to wait for our generator to shut down.
27:29At over 30 degrees Celsius, the air here in the hangar was too hot.
27:34We have to wait until it's more stable. Then we can continue working.
27:37And yet, just half an hour later, everything is running again.
27:46The team was in luck.
27:49The onboard computer now manages the entire test and moves all the wings, one after another.
27:55It measures the response time and gives the final green light, or not.
28:02Martin, everything's fine.
28:04Okay.
28:06This is, of course, the first day, the day of the hydraulic tests.
28:11And these came out well for us, so we're happy for it, of course.
28:14Just next door, in the ejector seat workshop, the pilot's guardian angel is still waiting.
28:21Should worst come to worst, this seat will shoot 80 meters into the air.
28:27The ejector seat has to be checked every two years.
28:31In an emergency situation, it is the last option for the pilot.
28:35That's why the mechanics put the seat to the acid test.
28:38After every part was maintained, the mechanics reassembled the seat and include the parachute and the survival kit.
28:48In the end, they will do a functional testing to ensure it is working properly in the event of an emergency.
28:57Aircraft mechanic Yeezy Wozniak has been servicing and testing high-tech seats like this for the past 20 years.
29:04It's a job that's very close to my heart.
29:10If we make a mistake, it could cost someone's life.
29:15For the pilots, this seat is their last chance to leave the aircraft when everything goes wrong.
29:22Of course, if you do something for a certain amount of time,
29:28there's a tendency to go into autopilot.
29:29But it's important to battle your ego and focus on following the instructions you're given.
29:37If I make a mistake, I might lose a friend and colleague, and nobody wants that.
29:44So Yeezy and his colleague take great care when checking the seat.
29:49The generator applies 42 bar of pressure to simulate one of the pyrotechnic cartridges exploding.
29:55If the pin shoots out, the seat has been released.
30:01Test passed, but that's not all.
30:06Now we simulate the ignition of the rocket engine.
30:09When it actually happens, this cable is firmly attached to the fuselage.
30:14During the firing sequence, it pulls off 80 centimeters of a cord.
30:18That activates this mechanism and pulls out the combat wedge.
30:23This activates the pyro cartridges.
30:26And gas pressure ignites the pyro cartridge in the engine and opens the isolation valve.
30:37This is where the opposite side actually release the gas pressure.
30:40With the pressure test, we check if the system is tight.
30:48Yeezy is satisfied. Everything is working.
30:53The seat belts also tighten and secure the pilot should worse come to worst.
30:59We can release the pressure.
31:00The pilot uses this yellow and black handle to activate the ejector seat.
31:09It can't be too heavy to pull, but then again, it can't be too light either.
31:14Otherwise, the pilot could find himself ejected from the plane simply because something got caught on the lever.
31:20According to requirements, exactly 27 kilos of tensile force is needed.
31:25Requirement met.
31:27The parachute returns to the seat just as it was when it arrived.
31:32This is one piece of equipment that Yeezy prefers not to touch.
31:36In fact, these parachutes are all packed in Sweden.
31:40Each layer of the parachute must be folded differently, so each stack is pressed by several tons for 24 hours.
31:47So actually, the parachute assembly itself takes, from what we know, about seven days.
31:54The final step before the explosives are returned to the seat, sorting out the large number of belts.
32:07Not a problem for a pro like Yeezy.
32:09Unlike the 3.5 kilogram explosive charge that now has to go back into the seat.
32:18The nine pyrotechnic cartridges require Yeezy's full concentration.
32:22Even after 20 years, he still treats them with utmost respect.
32:26If we work in the way that we're supposed to work, following all the documents and regulations, then almost nothing could go wrong.
32:35If I don't stick to the rules, I could put lives at risk.
32:41The emergency kit is the only thing missing now.
32:44This yellow case helps the pilot to survive, even after a crash.
32:50It is packed full of food, fishing equipment, a knife, and some tools.
32:58One day later, back in the hangar.
33:01Today, the team is testing the Gripen's gears.
33:04The special thing about these gears is their ability to cope with the toughest conditions on the ground, even during the winter.
33:11There is one thing that Martin always pays particularly close attention to.
33:20There could be problems if the landing gear does not lower at the right time.
33:24If that happens, we have to locate the problem as quickly as possible,
33:29solve it, and then replace the landing gear struts if necessary.
33:35That would be another delay.
33:41The onboard computer once again takes charge of the test.
33:49The three gears have to close and open within the space of 12 seconds.
33:56At the end, the system simulates another hydraulics failure and checks whether the gear can still lower,
34:02solely using its own weight.
34:03Another job ticked off for the mega pit stop.
34:12But it is not the last.
34:13Martin checks the hydraulic lines.
34:19The pilot is used to the aircraft responding immediately.
34:22If there isn't enough fluid, it would react later when turning.
34:30If, say, two jets were flying next to each other and one was working properly but the other one wasn't,
34:37there could be an accident because one of the jets would be slower and would react differently.
34:41A newly fitted joint attracts attention.
34:50I found traces of the old hydraulic oil here, but none of the new oil has leaked.
34:55That means everything is okay.
34:59Week seven of the mega pit stop and they are already seven days behind schedule.
35:05In the weapons workshop, Tomas Smoller has dismantled the entire cannon.
35:14Now I'm checking the hole, looking for cracks and minor damage.
35:19These issues could destroy the muzzle.
35:24And because the pressure in this area is so high,
35:27it could end up damaging the entire plane to such an extent that it would probably crash.
35:34a huge responsibility.
35:43Tomas hasn't found anything this time,
35:45but he has to be 100% sure when he signs off the cannon as fault-free.
35:54Maintenance errors are out of the question.
35:56They are just not an option.
35:58Small mistakes can cause serious problems,
36:01which can actually even culminate into the loss of the aircraft.
36:08That's why the specialist tests the weapon one last time before returning it to the Gripen.
36:14First, he performs a mechanical check to make sure nothing is obstructing the shell casing.
36:19And then, though this may look like a cartridge, it is actually an analysis device that checks the cannon's electronics.
36:31Good, we've done that, we've done that, we've done that, we've done that.
36:46When we will release the barrel, the cartridge will blast.
36:49By simulating the blast, the machine would signal any kind of problems we might have.
37:05But this cannon is functioning well.
37:11Tomas makes his decision.
37:12It's the 42nd day of work for the Gripen's mega pit stop.
37:27Actually, the fighter jet should have been finished two days ago.
37:30Instead, Peter Sikora is installing the seat today.
37:37It feels good to install a seat after it has been serviced.
37:39That's the result of all our hard work.
37:44It makes you feel proud to know that you've done a good job.
37:50Nevertheless, the men can't put their feet up yet.
37:56Maximum concentration is required right down to the last step.
38:03We can't allow ourselves to make any mistakes.
38:05That's why we work in pairs and keep an eye on each other's work.
38:10Not a single mistake is allowed.
38:12We feel confident that it will work.
38:15After all, we're professionals and we do a good job.
38:21Deep down, of course, they hope that the seat will never really work.
38:25Because they hope it never has to be activated.
38:27It's not long before the final turbine test.
38:40The Gripen's jet engine can accelerate to Mach 2.
38:43That's double the speed of sound, provided that it's working properly.
38:47If the fighter jet fails, then all their hard work would be for nothing.
38:53Martin Roman and their colleagues would have to start all over again.
38:57The test flight is scheduled for just two days from now.
39:02Inside this special hangar, Roman leaves the jet to run at full power.
39:06A dangerous moment for the plane and all the mechanics.
39:09This is the final check. I'm carrying a great deal of responsibility here.
39:21After this, there will be no more checks before the plane actually starts up.
39:27The engine runs at 1200 revolutions per minute,
39:31which means that even a tiny fault could have disastrous consequences.
39:35It could damage the machine.
39:43So, who does not have to be here?
39:46Outside will stay only Gabina or Marian with Romana.
39:50Mara is in the cabin and everyone else get in.
39:53When you sit in the plane after, I'll radio everything over to you.
39:57When we're outside in the hangar and you're in the plane,
39:59I want you to lift up your hands away from the controls.
40:06The mood is tense. The team is prepared for an emergency.
40:10The mechanic in the plane is wearing a fireproof suit.
40:15In an emergency, the team can use the crane to quickly rescue him from the cockpit.
40:21In this safety zone, 10 centimeters of armored glass separate Roman from the aircraft.
40:27He controls the test from here.
40:29It is very dangerous now. Anything can happen to the engine.
40:43It could set on fire at any time. People are at risk and they have to protect themselves at all times.
40:49This plane is a fifth generation model. It's made from CFC, a very light material.
40:59There is a risk of very loud noises and strong vibrations.
41:06The team runs through various emergency situations that could happen in the air.
41:11The engine follows along, using different settings and speeds, raising and lowering the thrust.
41:24Roman notes down the results.
41:28Then, a problem occurs.
41:31Test aborted.
41:33The measuring equipment has reported an air leak in the cooling system.
41:37Roman hopes that it's just a false alarm.
41:40He has built a special flag for cases just like this.
41:43If the cords don't move, it means there is no air leak.
41:47All clear.
41:48It was just a false alarm after all.
41:51The test continues.
41:52Now, the mechanic in the cockpit has to hit full throttle and ignite the afterburners.
42:06It doesn't get more powerful than this.
42:08A heavy load for humans and the aircraft.
42:13These tests are quite demanding because the technicians will get into that plane only twice a year.
42:19Of course, they do some preparation.
42:23But you have to try to get into the shoes of the man sitting twice a year in the plane,
42:28which is worth several billions, and he has to do the test.
42:32Because of this huge responsibility, we are constantly under pressure.
42:49I cannot be 100% sure that everything is all right, because I have not seen the data yet.
43:12But basically, it looks like, according to my experience, even if we still don't have one preliminary result,
43:20which we will have right after the engine will be turned off, we could be 90% sure that the plane is okay.
43:27So, yes, I am proud.
43:31The next morning, the maintenance team has been working through the night.
43:35The beast is ready for its test flight.
43:43We've finished. The problem with the oil is fixed.
43:49Okay.
43:52Ten days behind schedule, the mega pit stop is now on the home straight.
43:57Four major milestones have cost the team a great deal of patience.
44:01Hard work, concentration, and sweat.
44:05In the space of 50 days, the team has replaced and tested the hydraulic oil and engine.
44:11The weapons and ejector seat have been removed and serviced.
44:15Everything is done.
44:16Well, almost everything.
44:20We are always happy when a job is finished and are already looking forward to the next one.
44:25However, the aircraft still needs to be tested.
44:31We're not sure how well it will do. If it's a success, then you'll see us all cheering and celebrating.
44:40Test pilot Mikhail Danek, radio handle Marco.
44:44Hey.
44:47I'll quickly explain everything we've done.
44:55Following a complete overhaul, the Gripen's first takeoff will be in his hands.
44:59Hopefully.
45:04I'm not scared.
45:06I used to get a bit nervous when I wasn't so used to it.
45:12But now I'm experienced.
45:16Of course, you have to be careful.
45:20But I can rely on the team here and the work they do.
45:23The flight is just the last piece in the puzzle.
45:27But, of course, anything could happen.
45:35The pilot does one last visual inspection.
45:39And checks out the new engine.
45:42But ultimately, he has to rely on the maintenance team's efforts.
45:45This is the number for the new engine.
45:49Everything is ready.
45:51Good luck.
45:56The Gripen, nicknamed the Beast, makes its way to the runway.
46:01Pilot Marco is well-experienced.
46:04Nevertheless, there are still butterflies whenever the plane takes off.
46:09For everyone involved.
46:12I don't even want to think about it.
46:14But the worst thing that could happen is that the plane won't take off.
46:19However, we won't let that happen.
46:21Eventuality.
46:22I'm expecting the plane to be ready to fly and everything to run smoothly.
46:52Ready for take-off.
47:22It's taking off.
47:34We're hoping he'll arrive back safely.
47:36But it'll be fine.
47:37We're happy when the plane is in the air.
47:39That shows that we've done our job properly.
47:42It's our bread and butter.
47:4750 days of work.
47:4811 mechanics.
47:50Over 50 repairs, both large and small.
47:53Martin and his team dismantled the ejector seat, jet turbines, and revolver cannon,
47:59and put them all back together again.
48:02This was no easy mega pit stop.
48:05The Beast is ready to return to duty.
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