T.B. #5 - SYSTEMA Revolution Burst Modification

Technical Bulletin 2009.01.08: How to fix Convert Revolution from full-auto to Burst

IMPORTANT DISCLAIMER:

1. This procedure is considered a "hack". It is not supported by SYSTEMA, nor ZShot.com - we only post it here for educational / reference purposes. In fact it is not even acknowledge by SYSTEMA. ONLY APPLY AT YOUR OWN RISK!

2. This procedure involves removing, and modifying the main circuit. It requires a very high level of skill, as well as the correct equipment. If you do not have any "surface mount" experience, DO NOT ATTEMPT. If you have to ask what "surface mount" is, DO NOT ATTEMPT. If you cannot risk $200+ for a replacement circuit (yes... that damn chip is expensive), DO NOT ATTEMPT. If you have ANY doubt what-so-ever (e.g. say one of the picture doesn't match up), DO NOT ATTEMPT.

3. Performing this modification definitely and positively void your warranty (if available in your country). For example, in U.S., if your Revolution is installed by a factory certified armorer it will come with a 90 days warranty. However if you modify the circuit (in fact, if you remove the gearbox from the receiver or even open it) your warranty is void. Only consider applying this procedure if you understand the ramification.

With all the disclaimers out of the way, lets look at how to make the Revolution fire Burst (instead of Auto). The procedure itself is really simple - remove the main control circuit (ECU, or Electronic Control Unit) from the gearbox, and solder two jumper connections together. The two pins you needed to solder is shown at the picture, which is clickable. Click here for a slightly larger version if you have a high resolution monitor. Just keep in mind that in reality its much harder then it looks.

There are a couple tricks on opening the Revolution. First of all, the cylinder head bumper will wedge itself fairly tight in the gearbox shell. It is not uncommon that it requires a bit of convincing (especially around the nozzle) for the gearbox to open. Just make sure you did remove all the screws first (the position of the longer screws that holds the two half of the shell is slightly different from traditional TM gearboxes). Secondly, always open the gearbox shell with the word "Revolution" facing you. This way the motor / battery wiring won't fall out on you. Thirdly, as you get the gearbox to split open, apply some pressure at both the cylinder and spring guide while lifting the right-half gearbox shell. The cylinder is easy, just press it down as you try to pull the shell up. On the spring guide, apply pressure through the opening behind the piston. Technically you will be pressing the spring that surrounds the spring guide, but the end result is the same. Unlike TM gearboxes, the Revolution's internal components will stay put (even under tension) and remain relatively stable even without the right-side gearbox shell. Thus, when you open the Revolution, if you make sure all components remain "seated" in their respective slot on the left-half of the shell while you lift the right half away, it will not "explode" in every direction like a TM gearbox.

Now, once you have the Revolution open, pay VERY CAREFUL attention on how the wires are routed - especially the small signal wires around the control unit. When you re-assemble the gearbox, if some of these wires are not placed correctly, it will get pinched and sometimes cut. The resulting short circuit could permanently damage your ECU. I would suggest take several pictures of the circuit / wiring for future reference, before you remove the circuit.

Finally, when you are ready to re-assemble the Revolution, make sure the Main Sector Gear (the last gear that pulls the piston) is positioned correctly. Basically, there are 15 teeth on the Main Sector Gear that will contact (and pull) the piston. THEY NEED TO BE FACING THE 6 O'CLOCK POSITION. This is, of course, assuming you are looking at the Revolution right-side-up (i.e. piston/cylinder/spring is on top, the hole where the motor shaft comes in at the bottom). Although the Revolution will automatically "time" itself after the first shot (even if the Main Sector Gear is in the wrong position - the Revolution's "timing" is fully automatic), there is still a risk that during the first shot it would smash with the piston rack gear and cause damage.

I hope you will find this bulliten informational. The following are some FAQ which we will attempt to update as needed.

Q.	Can I modify the Revolution for a 4-position trigger (S/E/3/F) like the TW5?
A.	No, unfortunately not at this moment. If you solder those two jumbers together, it will have a S/E/3 trigger group. Without them soldered, it will have a S/E/F trigger group.

Q.	Can I send the Revolution in to be modified?
A.	Sorry we currently do not offer modification services, however you may want to check with one of our official dealers. Some of the more experienced gunsmith may be willing to perform the modification for a fee.

Q.	Does SYSTEMA offer a Revolution in "Burst Mode" out of the box?
A.	Currently all Revolution have a S/E/F trigger group, and "burst" is not available at the moment. However, we do not rule out the possibility that SYSTEMA will offer a Burst Revolution in the future.

Q.	Is it safe to perform this modification?
A.	It depends on your definition of "Safe" - we suspect that SYSTEMA did not introduce the Burst mode initially (even though the circuit seems fully capable of doing such) due to insufficient internal testing. SYSTEMA traditionally perform very strenuous tests on all their products before they are released, and they might've felt that they haven't done enough testing on the Burst functional to comfortably conclude that the Revolution's Burst function meet their high standard of performance and durability. Although it is unlikely, we cannot guarantee the conversion to Burst will not adversely affect the circuit's life or performance. We have several units converted to Burst in-house and will be testing those ourselves.

Q.	Are there any catches to converting to Burst?
A.	The only one we can think of right now is the potentially shorter motor brush life. Similar to the PTW, the Revolution apply "brake" to the motor (by sending a short pulse of reversed current) when it finishes a firing cycle. If you fire in semi-auto, the motor will have to brake after each round. If you fire in full-auto, the motor will have to brake after you let off the trigger. If you fire in Burst, the motor will have to brake after 3 rounds. This, for the average user who fire in full-auto regularly, the frequency of the motor "braking" is typically higher when you use the burst mode. Since braking can cause spark/arc between the motor brush and commutator, it accelerates brush wear and occasionally wore down the commutator as well. Oh I guess another catch is that you may be buying less SYSTEMA BBs... Majority of our players reported that by switching from full-auto to burst in their PTW, they cut their ammo usage significantly because they forced themselves to have better trigger control. (Same reason why the U.S. Military introduced 3-round Burst M16.) But that's more a catch for us, then for you...

Q.	I have more questions. Where do I ask?
A.	If your question is in relation to the Burst mode conversion, I am afraid there isn't any more we can tell you. All necessary information is posted here. However, if it is related to the Revolution (or other SYSTEMA products) in general, please e-mail Sales@ZShot.com and we will try to answer them for you.