CMM 29-10-60R03 Elec Hyd Pump

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL
PART NO 971533 REVISION NO. 3 DATED 15 NOVEMBER 2008 HIGHLIGHTS Revised pages are outlined below together with the highlights of the revision. Please delete the affected pages and add new pages. Enter date revised on the Record of Revision Sheet and initial. Chapter/Section and Page No. All Pages: Title Page: Record of Revisions: Record of Temporary Revisions: Service Bulletin List Chronological Service Eng.Change Record List of Effective Pages Page 101 Page 102 Page 122 Page 127 Page 401 Page 402 Page 601 Page 604 Page 610 Page 701 Page 802 Page 1002 Page 1003 Page 1010 Description of Change Added new page header to reflect Eaton Aerospace Changed copyright date Added Revision 3. Added Temporary Revision 29-3. Added Service bulletin 971533-29-02 (Eaton Ref: 910386-2) Add Modification letter B Reliability Improvement
Added revision date of Nov. 15/08 for all applicable Revision 3 change pages. Changed paragraph reference to 7 and removed space Added Optional to Electric Motor SA test Added Optional to Electric Motor SA test record Corrected reference in paragraph 7.A and 7.B Removed Trichloroethane (O-T-620) and added SkyKleen 1000 Removed Trichloroethane (O-T-620) and added SkyKleen 1000 Removed outdated materials Corrected typing error Added Corrosion Reduction-Filter Box Repair Corrected typing error Changed Item 2-110 Overall Thickness to .266 inches Corrected Eaton address Changed Nut AN345-416 to MS35650-3252 Corrected part number Item 45 to 342211 Corrected part number Item 55 to 331495
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PART NO 971533 Chapter/Section and Page No. Page 1012 Page 1017 Page 1018 Page 1019 Page 1020 Description of Change Corrected items 45 & 55 Added Eaton part numbers Added Eaton part numbers Added Eaton part numbers Added Eaton part numbers
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COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST
DC ELECTRIC MOTORPUMP ASSEMBLY PART NUMBER 971533 MODEL NUMBER MPEV3-008-6
Original Date July 30, 1996
EATON CORPORATION -CONFIDENTIAL AND PROPRIETARY NOTICE TO PERSONS RECEIVING THIS DOCUMENT AND/OR TECHNICAL INFORMATION This document, (which includes the drawings and information contained there on), is confidential and the exclusive property of Eaton Corporation, and is merely on loan for evaluation, inspection, or configuration control purposes and subject to recall by Eaton at any time.Disclosure of this data to the designated recipient is expressly conditioned upon the recipients consent that the use is limited to said use only within the recipients company. By taking possession of this document, the recipient acknowledges and agrees that the document cannot be used in anymanner adverse to the interests of Eaton,and that any other use, including (1) reproduction, either in part or in whole, by any means; (2) release to a third party; (3) dissemination for competitive reprocurement; (4) manufacturing purposes; or (5) for use in obtaining parts manufacturing authority (PMA) is strictly prohibited without prior written consent of Eaton Corporation. In the case of conflicting contractual provisions, this notice shall govern the status of this document.
Eaton Reference Only 910386
COPY RIGHT 2008 Eaton Aerospace All Rights Reserved
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PART NO 971533 RECORD OF REVISION REV ISSUE DATE REV ISSUE DATE REV ISSUE DATE BY BY BY NO DATE INSERTED NO DATE INSERTED NO DATE INSERTED 1 7/15/99 2 11/15/04 3 11/15/08
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PART NO 971533 RECORD OF TEMPORARY REVISION TEMPORARY REV NO 29-3 PAGE NUMBER 1015-1018 ISSUE DATE Oct 15/05 DATE REMOVED Nov 15/08
BY Eaton
BY Eaton
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PART NO 971533 SERVICE BULLETIN LIST SERVICE BULLETIN NUMBER ATA CONTROL NO. 971533-29-01 971533-29-02 VICKERS CONTROL NO 910386-1 910386-2 REVISION NUMBER DATE BULLETIN INCORPORATED INTO MANUAL Jul 15/99 Nov 15/08
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PART NO 971533 CHRONOLOGICAL SERVICE ENGINEERING CHANGE RECORD Sequential serial numbers are stamped on the identification plate of each unit at time of manufacture. Modification letters are added to these serial numbers or recorded on a separate record plate to denote engineering changes made to the unit subsequent to its initial release.The following service bulletins and/or change letter assignments apply. Identification Modification Effective Letter Date A 1 Sept 98 B 12 July 07
Service Bulletin 971533-29-01 971533-29-02
Description Motor Bearing Product Improvement Reliability Improvement
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PART NO 971533 LIST OF EFFECTIVE PAGES
SUBJECT
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Title Page Record of Revisions Record of Temporary Revisions Service Bulletin List Chronological Service Engineering Change Record List of Effective Pages
TP-1 ROR-1 ROR-2 RTR-1 RTR-2 SBL-1 SBL-2 SECR-1 SECR-2
Testing and Trouble Shooting
LEP-1 LEP-2 LEP-3 LEP-4 TOC-1 TOC-2 INTRO-1 INTRO-2 1 2 3 4 5 6 7 8
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Table of Contents Introduction Description and Operation
101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130
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SUBJECT PAGE
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Disassembly
301 302 303 304 305 306 307 308 309 310 311 312 401 402 403 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520
Repair
601 602 603 604 605 606 607 608 609 610 611 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 717 718 719 720 721
Assembly
Cleaning
Check
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SUBJECT PAGE
DATE Nov 15/04 Nov 15/08 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Blank Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Nov 15/04 Blank
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Fits and Clearances
801 802 803 804 805 806 807 808 809 810 811 901 902 903 904 905 906
llustrated Parts List
Special Tools,Fixtures and Equipment
1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021
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PART NO 971533 TABLE OF CONTENTS
SUBJECT PAGE
Description and Operation Testing and Fault Isolation (Not applicable) Disassembly Cleaning Check Repair Assembly Fits and Clearances Special Tools, Fixtures and Equipment Illustrated Parts List
1 101 201 301 401 501 601 701 801 901 1001
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PART NO 971533
INTRODUCTION This publication is issued as a Component Maintenance Manual for Hydraulic Motorpump Assembly, Part Number 971533 (Model Number MPEV3-008-6) manufactured by Eaton Aerospace, Hydraulics Systems Division, Jackson, Mississippi 39206. Throughout the remainder of this manual, this assembly will be referred to as a motorpump assembly. This publication establishes the requirements for acceptance testing, disassembly, cleaning, checking, repair and assembly of this hydraulic motorpump assembly. An illustrated parts list is also included to provide a part number identification of assembly components.This publication contains data converting U.S. Standard system of measurements to the metric system.Throughout this publication, metric equivalents (in parentheses) follow the U.S.Standard measurements. The maintenance and test procedures contained in this publication have been verified in actual shop practices at Eaton. These procedures should be used as a guide to develop the necessary skills for proper expedient maintenance of these hydraulic motorpump assemblies. However some degree of flexibility is permissible since user experience will result in equally acceptable procedures to accomplish the same end. The assembly and test areas assigned for the repair and maintenance of these hydraulic motorpump assemblies should be isolated from particle generating equipment such as grinders, lapping machines, paint spray booths and sandblasting machines. Adequate ventilation and good housekeeping practices should be maintained at all times to assure minimum contamination. Verification: Testing/Fault Isolation: Disassembly: Assembly: Sep 94 Sep 94 Sep 94
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PART NO 971533 DESCRIPTION AND OPERATION 1. Description. The hydraulic motorpump assembly consists of a DC electric motor driven variable displacement, hydraulic pump. The motorpump supplies fluid flow, as required, for operation of aircraft hydraulic system components. Normal functions of the motorpump, in an aircraft hydraulic system, is to provide auxiliary standby power during flight and for system checkouts on the ground. See Fig. 1. The pump section of the motorpump assembly consists of the following major component parts; a cylinder block (1, Fig. 2), nine piston and shoe subassemblies(2), valve block(3),yoke (4), yoke control springs (5), pressure compensator valve(6), shaft seal subassembly (7), mating ring (8), mounting flange (9), ball bearing (10), pump housing (11) and drive shaft (12). The drive shaft (12) is supported in the pump by bearings (10 and 19). The cylinder block is splined to the drive shaft and driven in rotation by the motor driven shaft. The cylinderblock(1) is held against the valve block (3) valving face by the action of spring(13).
Figure 1. Variable Displacement Hydraulic Motorpump Assembly
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PART NO 971533 Yoke (4) is supported in the mounting flange by two pintle bearings (14). The yoke swivels through an arc from 0 to maximum yoke angle. Yoke angle is controlled bymetered outlet fluid pressure acting on yoke control piston (15) and by yoke control springs (5) which oppose the metered outlet pressure. The piston and shoe subassemblies (2) are retained in the yoke by retainer (16), piston shoes retaining plate (17) and screws, and ride on the shoe bearing late (18) during drive shaft rotation. Valve block (3), which contains the inlet and outlet ports, provides valving action to direct fluid flow to and from the cylinder block (1). The valve block also contains the pressure compensator valve (6), pressure adjusting screw (20) and needle bearing(19). The mounting flange contains the yoke (4), seepage and case drain ports, shaft ball bearing (10), shaft seal subassembly (7) and mating ring (8). The electric motor is a four-pole, compound-field dc motor designed specifically to drive the motorpump hydraulic pump. The motor is cooled internally by means of a cooling fan directly driven by the motor shaft. Intake air is pulled through an opening equipped with a flame arrestor screen, and exhausted through a one inch (25.4 mm) O.D. port connected to outside air. Power is supplied to the motor through a RFI filter on the negative and positive leads. The purpose of the filter is to suppress radio frequency noise that may try to escape from the motor into the system. 2. Operation. Operation is fully automatic. The pump is designed to build up and maintain pressure without manual control. The pressure is maintained within a pre-adjusted range and is ready for instant use in the amount required within this range. With electric motor operating, hydraulic fluid flows through the pump inlet port and valve block (3, Fig. 2) valving slots, then into piston bores in cylinder block (1). The cylinder block is driven by the drive shaft (12) in a rotary motion and the nine piston and shoe subassemblies (2) are in turn driven by the cylinder block. At any outlet pressure less than pressure adjustment setting, the yoke is moved to maximum displacement position by yoke control springs (5). In this position, the angle between yoke and centerline of the drive shaft creates a reciprocating movement of the pistons within the cylinder block bores during drive shaft rotation. Inlet fluid enters the bores of the cylinder block on the outward stroke of the pistons and is discharged through the outlet port on the inward stroke of pistons. This action provides acontinuous, non-pulsating flow of fluid to the hydraulic system.
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PART NO 971533
Figure 2. Hydraulic Pump Cutaway
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PART NO 971533
Figure 3. Compensator Operation Operation of the compensator valve is shown on Figure 3. With no load on the pump the yoke will be at maximum angle. As load increases, outlet pressure (Ps) increases. When (Ps) is sufficient to overcome the force of the compensator spring, the compensator valve spool moves downward, metering increasing control pressure (Pc) to the yoke actuator piston. This causes the yoke angle to decrease. Decreased yoke angle shortens the stroke of the pistons within the cylinder block bores and reduces outlet flow. As outlet pressure (Ps) continues to increase, yoke angle and pump output flow continues to decrease. At or near maximum pressure, outlet fluid flow continues to be metered through the pressure compensator to yoke actuator piston, until extension of actuator piston moves the yoke to the zero flow position. The yoke remains in the zero flow position until aircraft system demand for flow is initiated. Upon demand, outlet pressure decreases to a value that allows the yoke control springs to override metered fluid pressure (Pc) to the yoke actuator piston, this allows yoke angle and flow to increase as necessary to satisfy system demand.
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PART NO 971533 3. Leading Particulars: Motorpump mounting positions Motorpump must be mounted inverted.Pump case drain connection must be connected directly to the reservoir in such a manner that the pump housing remains filled with hydraulic fluid during all operations. Pump internal parts depend on this fluid for lubrication. Mounting position must also be such that seep drain connection is at or near the 6 oclock position. Pump case must be completely filled with fluid before operation. Provide a drain from seep drain connection Do not return seepage fluid to hydraulic system 0.4375-20 UNJF-3B thread (Per Specification MS33649-4) 0.5625-18 UNJF-3B thread (Per Specification MS33649-6) 0.4375-20 UNJF-3B thread (Per Specification MS33649-4) 0.4375-20 UNJF-3B thread (Per Specification MS33649-4)
Motorpump connections Seep drain Inlet Outlet Case drain Electrical connectors Motor Thermal switch Hydraulic Pump Characteristics:
MS3459L24-12P mates with MS3459L24-12S MS3470L833P mates with MS3476L833S
Rated output flow (min) with 40 psia (276 kPa) (absolute) inlet pressure and 2750 psig (18 960 kPa) outlet pressure. Theoretical displacement Rated pressure at zero flow 1.5 gpm (5.7 l/m) 0.050 cu. in/rev. (0.82 ml/rev) 2925 psig (20167 kPa)
Pressure rise as displacement 150 psig (1034 kPa) is reduced to zero
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PART NO 971533 Pressure at which displacement begins to reduce Rated inlet pressure (min) Rated SpeedFull flow Zero flow Filtration requirements Fluid temperature range Number of pistons Direction of rotation (when viewed from motor end) Coupling shaft spline data Motor mating end 2775 to 2825 psig (19133 to 19478 kPa) 35 psia (241 kPa) (absolute) 7950 rpm 9300 rpm 10 micro (nominal) -65F to + 275F (-54C to +135C) 9 Counter clockwise
12 teeth, external involute, flat root, side fit, 32/64 pitch, 0.3750 pitch diameter, 30 pressure angle. 0.3960/ 0.3930 major diameter, 0.3335/0.3255 minor diameter. 12 teeth, external involute, flat root, side fit,32/64 pitch, 0.3750 pitch diameter, 30 pressure angle. 0.3960/ 0.3930 major diameter 0.3335/0.3255 minor diameter.
Pump mating end
Electric motor characteristics: Direction of rotation (Viewing drive end) Cooling Input voltageVDC rated VDC operating Weight (motor only) Mounting pad Drive spline data Clockwise Internal fan 28 20-32 15.0 lbs. (8.2 kg) AND 20000 12 teeth, internal involute, flat root, side fit, 32/64 pitch, 0.3750 pitch diameter, 30 pressure angle, 0.4143/0.4063 major diameter, 0.3496/0.3466 min or diameter
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PART NO 971533
Explosion proof Terminal designationsPower connector Thermal switch.
With shroud connected to outside air.
Pin A of MS3459L-12P requires 28 VDC with pin C being ground. Pins B,D and E are not used. Indirect acting normally closed thermal switch connected to pins A and B of connector MS3470L833P. 18.7 lbs (8.5 kg) max SL to 35,000 ft (SL to 10 668 M) Alkyl Phosphate Ester Base
Total dry weight of motorpump Operating altitude Fluid medium
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PART NO 971533
THIS PAGE LEFT BLANK INTENTIONALLY
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PART NO 971533 TESTING AND FAULT ISOLATION 1. Receiving Check. WARNING: USE CLEANING SOLVENTS IN WELL VENTILATED AREA TO PREVENT INJURY. AVOID PROLONGED BREATHING OF FUMES. KEEP SOLVENTS AWAY FROM OPEN FLAME. A. With all ports plugged, clean exterior of hydraulic motorpump assembly using dry cleaning solvent P-D-680 (or equivalent) and a stiff bristle brush to remove any contaminant that may have accumulated. Do not allow solvent to enter electric motor. Air blow unit dry. B. Visually check exterior for evidence of damage. If damage is noted and if damage is such that it will impair unit operation, refer to applicable paragraphs of overhaul sections for repair. If no external damage is noted, proceed with receiving check. C. Remove case drain plug and drain unit. Collect discharged contents and check for metal particles. Presence of metal particles will not necessary mean deterioration of unit but should be a warning to thoroughly check it before subjecting it to performance tests. D. If unit appears to be satisfactory after performing these preliminary procedures, perform as many operational tests as possible beginning with tests called for in paragraph 7. If it will pass all tests, return unit for a continuation of its time between overhaul period. If it will not, refer to Table 101 for repair procedures before tagging unit for complete overhaul. 2. Special Tools. Refer to SPECIAL TOOL, FIXTURES AND EQUIPMENT for a complete listing of special tools and test equipment recommended for maintenance of these motorpump assemblies and a description of their function. Tooling and test equipment other than herein specified may be used provided they perform the required operation. Refer to the following table for tools and/or fixtures recommended for testing:
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PART NO 971533 Special Tools T-233247 T-442698 T-302537 Local Manufacture (Refer to Description and Operation (Leading Particulars) for motor spline data) Flushing Set Test Plate A Frame Test Stand Coupling Adapter(Adapt Dynamometer to Motor)
3. Test Electric Motor Subassembly (Optional). A. Test equipment shall include a 28 vdc power supply capable of 500 amperes starting surge and regulated operation at 130 amperes sustained. B. A precision dynamometer capable of operation at 25 pound inches (2.8 Nm) torque and at 7,950 rpm is required to load motor for test. A mating spline and coupling is also required to adapt motor to dynamometer. C. The test stand shall be equipped with suitable instrumentation to measure torque, speed, voltage and current. All equipment shall be certified to industry standards. 4. Test Conditions. A. Motor brushes shall be seated 100% in the direction of rotation and 90% in the axial direction. B. The test load shall not be maintained for more than twenty (20) seconds with out allowing the motor to cool to room temperature. CAUTION: DO NOT HI-POT FINAL MOTOR SUBASSEMBLY. INTERNAL DAMAGE WILL OCCUR TO RFI FILTER CAPACITORS. C. Direction of motor rotation shall be clockwise when viewed from drive end. 5. Acceptance Test. The motor shall meet the following minimum performance criteria: A. Load (Pound Inches/Nm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.0 (2.8) B. RPM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7,950 500 C. Current (Max. Amps., Continuous Operation) . . . . . . . . . . . . . 130 D. Voltage, VDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Page 102 Nov 15/08
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PART NO 971533 6. Test Hydraulic Pump Subassembly (Optional). A. Test Conditions. (1) Use test equipment providing the arrangement shown in Fig. 101. (2) Use a hydraulic test stand capable of supplying the following: (a) Drive rotation, counterclockwise. (b) Variable speed drive capable of developing a minimum of 20 horsepower (15 kw). (c) Capable of measuring output speed to a maximum of 12,000 rpm. (d) Capable of recording outlet pressure to a maximum of 4000 psig (27 579 kPa) and flow from zero to 2 gpm (7.6 L/m). (e) Capable of providing inlet supercharge pressure of 25 psig (172 kPa). (f) Capable of filtering test circuit fluid to a maximum of ten micron absolute. (g) Capable of controlling inlet fluid temperatures of 160 10F (71 6C). (3) Maintain test conditions as follows, unless otherwise stated in the test instructions: (a) Maintain inlet fluid temperature at 160 10F (71 6C). (b) Maintain inlet pressure of 25 5 psig (172 34 kPa). (c) Maintain case pressure of 15 5 psig (103 34 kPa) above inlet pressure B. External Leakage. (1) Shaft Seal. Shaft seal shall not exceed two (2) drops per minute during all phases of testing.One drop is equal to approximately 1/20 ml. (2) External Leakage. External leakage other than a slight wetting insufficient to form a drop,through any seal or gasket (except shaft seal) shall be cause for rejection. C. Preliminary Tests.
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PART NO 971533 NOTE: Conduct the following tests prior to installing the pump in the test circuit. (1) Binding. Rotate drive shaft of test unit manually to check for binding. There shall be no evidence of bind. If binding is noted, disassemble pump and correct the trouble before proceeding. (2) Proof Test. Plug inlet and outlet ports and apply 150 psig (1034 kPa) to the case drain connection for two minutes. There shall be no evidence of external leakage except at the drive shaft seal. Shaft seal leakage shall not exceed ten drops in five minutes. (3) Flush Operation. Using flushing set T-233247, thoroughly flush the test unit through the case drain connection for two minutes. Do not allow case pressure to exceed 150 psig (1034 kPa). D. Test Circuit. Connect the test unit in a hydraulic test circuit as illustrated in Fig. 101. Make certain test unit and test circuit are completely full of clean alkyl phosphate ester hydraulic fluid. E. Preliminary Compensator Adjustment. Prior to starting test unit in operation, be sure that adjusting screw (35, IPL Fig. 2) is turned in sufficiently to allow full flow and 1500 psig (10 342 kPa) from outlet portwhen test unit is started up in the following run-in test. Do not run test unit below 1500 psig (10 342 kPa). F. Run-In. NOTE: This test is necessary only after the replacement of rotating group parts. NOTE: During any of the following tests, external leakage shall be as specified in paragraph 4B. (1) With load valve (2, Fig. 101) open, start hydraulic supercharge source and power drive to drive test unit at 3600 rpm for five minutes.
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PART NO 971533
Pump Schematic Test Setup Figure 101 (Sheet 1 of 2)
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PART NO 971533 INDEX NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
NOMENCLATURE Flow meter Load Valve Relief Valve Filter High Pressure Pressure Gage Pressure Gage Load Valve Relief Valve Shutoff Valve Beaker 2000 cc Capacity Filter Low Pressure Pressure Gage Temperature Gage Filter Low Pressure Supercharge Source Pump Test Stand Frequency (RPM) Power Drive
DESCRIPTION 0 to 2.0 gpm (0 to 7.6 L/m) Manual Control (high pressure) Adjustable, Set at 3100 psig (21 374 kPa) 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 4000 psig (0 to 27 579 kPa) 0 to 100 psig (o to 689 kPa) Manual Control (low pressure) Adjustable, set at 50 psig (345 kPa Manual Control (low pressure) Graduated in 25 cc increments 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 100 psig (0 to 689 kPa) 32 to 200F (0 to 93C) Range 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 50 psig (0 to 345 kPa) at 3 gpm (11.4 L/m) capacity 10 gal. (37.9 l) capacity Reservoir 0 to 12,000 rpm range Counter 20 horsepower (15 kw), variable to 12,000 rpm
Pump Schematic Test Setup Figure 101 (Sheet 2 of 2)
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PART NO 971533 (2) Adjust supercharge pump (15) to provide inlet pressure of 25 5 psig (172 34 kPa) as indicated on inlet pressure gage (12). (3) Close load valve (7) and adjust relief valve (8) to provide a case pressure of 15 5 psig (103 34 kPa) above inlet pressure as indicated on case pressure gage (6). (4) Gradually close load valve (2) to increase outlet pressure, as shown on pressure gage (5), from 1500 psig (10 342 kPa) to 2950 psig (20 340 kPa) and zero flow on flow meter (1) during the first five minutes. (5) During the next five minutes, gradually increase speed to 9350 50 rpm. Continue at this speed and zero flow for five minutes. During this run-in, open shutoff valve (9) and measure case drain flow in beaker (10). NOTE: Case drain flow at 9350 rpm and 2950 psig (20340 kPa) outlet pressure shall not exceed 0.47 gpm (1780 cc/min.).
(6) During run-in observe unit for unusual noise or chatter. Stop test and investigate trouble observed. G. Compensator Adjustment. (1) With unit operating at 9350 25 rpm and load valve (2) closed (zero flow), adjust compensator adjusting screw (35, IPL Fig. 2) to obtain 2900 + 50, - 0 psig (19995 + 345, -0 kPa). Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches(4.0 to 4.5Nm). NOTE: Make all pressure compensator settings on rising pressure. (2) Alternately open and close load valve (2, Fig. 101) rapidly. This will purge any air that may have become trapped in the compensator. After this operation, repeat step(1). H. Pressure Shift. (1) With unit operating at 9350 rpm, adjust load valve (2) to cycle from zero flow (2900 + 50, - 0 psig (19 995 + 345, -0 kPa) to 2700 + 50, -0 psig (19 995 + 345,-0kPa) to 2700 50 psig (18 616 + 345, - 0 kPa) five times. (2) Operate unit for three minutes at 9350 25 rpm with zero delivery. Outlet pressure, as shown on pressure gage (5), shall not shift more than 25 psig (172 kPa) above or below pressure assumed at the time of shutoff. I. Stability Check. NOTE: During the following check, minimum time for the sweep shall be 60 seconds from maximum to minimum speed and 60 seconds from minimum to maximum speed.
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PART NO 3032682-000 While operating test unit at zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa), vary pump speed from 9350 rpm to 6000 rpm and back to 9350 rpm. There shall be no indications of any persistent oscillations lasting more than one second. J. Delivery Check. (1) Reduce test unit speed to 7950 25 rpm. (2) Adjust load valve (2) as necessary to obtain 2700 50 psig (18 616 345 kPa) on outlet pressure gage (5). Delivery of the pump shall not be less than 1.32 gpm(5.0 L/m) or greater than 1.72 gpm (5.5 L/m) as shown on flowmeter (1). K. Case Flow Check. (1) Continue to operate test unit at conditions established in paragraph 4J. Open shutoff valve (9) and measure case drain flow. Flow shall not exceed 0.22 gpm(835 cc/min). (2) Operate test unit at 9350 25 rpm and 2900 + 50, - 0 psig (19 995 + 345, - 0 kPa) outlet pressure (zero flow). Measure case drain flow. Flow shall not exceed 0.47 gpm (1780 cc/min.). L. Cylinder Block Lift Test. NOTE: During the following tests monitor case drain leakage (flow) and outlet flow (delivery) to ascertain that cylinder block lift does not occur during acceleration and steady state conditions. Cylinder block lift will be indicated by high case drain leakage, low outlet flow (pump delivery) and pressure oscillations. (1) Operate test unit at 9350 25 rpm and reduce outlet pressure as low as possible (full flow).Record pressure for reference during test. Decelerate unit to zero rpm. (2) Uniformly accelerate test unit to 10,300 rpm within two seconds. Continue to operate at low pressure and high speed for thirty seconds. There shall be no evidence of cylinder block lift. M. Friction Test. (1) After test unit has successfully passed all tests specified in this paragraph, hand torque required to turn pump drive shaft shall be measured. Breakaway torque shall not exceed 7.0 pound inches (0.8 Nm) and turning torque shall not exceed 4.0 pound inches (0.45 Nm).
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PART NO 971533 7. Test Motorpump Assembly. CAUTION: A LIGHT SHALL BE INSTALLED (SEE FIG. 102) TO ALERT OPERATING PERSONNEL OF OVERTEMPERATURE CONDITION IN BRUSH AREA. IF OVERTEMPERATURE CONDITION IS EXPERIENCED THE TESTS SHALL BE DISCONTINUED UNTIL THE MOTOR HAS HAD ADEQUATE TIME TO COOL. THE THERMAL PROTECTION DEVICE FOR THE MOTOR IS LOCATED IN THE BRUSH AREA. THIS DEVICE IS NORMALLY CLOSED; THEREFORE,OVERTEMPERATURE CONDITION WILL BE INDICATED WHEN PILOT LIGHT GOES OFF DURING OPERATION. CAUTION: ELECTRIC MOTOR IS NOT RATED FOR CONTINUOUS-DUTY AT FULL-FLOW (MAXIMUM CURRENT DRAW) CONDITIONS. MOTOR PUMP SHALL NOT BE OPERATED CONTINUOUSLY IN FULL FLOW FOR MORE THAN ONE (1) MINUTE. A. Test Conditions. Refer to paragraphs 3B and 4A. External leakage shall be as specified in paragraph 4B. B. Test Equipment. (1) Test equipment shall include a 28 vdc power supply capable of 500 amperes starting surge and 130 amperes sustaining. (2) Test stand shall be equipped with suitable instrumentation to measure voltage and current, and pump test setup as shown in Fig. 102. (3) MS3476L833S or equivalent connector to couple thermal switch and light to 28vdc power supply. MS3459L24-12S or equivalent connector is required for motor power supply. (4) The motorpump is oriented in an inverted position in the aircraft installation. If required, a fixture shall be locally manufactured to mount motorpump as shown in Fig. 102. The motor base mounting dimensions are shown in Fig. 103. C. Test Circuit. Connect test unit into a test circuit as illustrated in Fig. 102. Be sure hydraulic pump and test circuit are completely full of clean alkyl phosphate ester hydraulic fluid.
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PART NO 971533
NOTE: Shock mounts shall not be installed on motor during test. Refer to DISASSEMBLY, paragraph 3B(3) for shock mount removal and to ASSEMBLY, paragraph 5A for reinstallation after test. D. Break-In. (1) Set power supply voltage at 28 vdc. (2) Open load valve (2, Fig. 102), start hydraulic supercharge source (15) and adjust supercharged inlet pressure as shown on pressure gage (12) to 25 5 psig (172 34 kPa). (3) Close load valve (7) and adjust relief valve (8) to provide a case drain pressure of 15 5 psig (103 34 kPa) above inlet pressure. (4) Operate test unit for three minutes with load valve (2) adjusted to provide 0.3 gpm (1.1 L/m) as indicated on flowmeter (1). During this period, observe, motorpump for any unusual noise or indication of possible malfunction. (5) Uniformly adjust load valve (2) to increase flow on flow meter (1) to obtain full flow pressure, (2700 50 psig (18616 345 kPa)) over a thirty second period. Operate at full flow for one minute. E. Outlet Pressure Check. (1) With test unit operating at 28 vdc, adjust load valve (2) for zero delivery (outlet flow) and check outlet pressure on gage (5). If pressure is not within 2900 + 50,-0 psig (19 995 + 345, - 0 kPa), adjust compensator adjusting screw (35, IPL Fig.2) as necessary to obtain zero delivery outlet pressure. (2) Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches (4.0 to 4.5 Nm) and secure with lockwire MS20995C32.
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PART NO 971533
Motorpump Schematic Test Setup Figure 102 (Sheet 1 of 2)
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PART NO 971533 INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
NOMENCLATURE Flow meter Load Valve Relief Valve Filter High Pressure Pressure Gage Pressure Gage Load Valve Relief Valve Shutoff Valve Beaker 2000 cc Filter Low Pressure Pressure Gage Pressure Gage Filter Low Pressure Supercharge Source Pump Reservoir
DESCRIPTION 0 to 2.0 gpm (0 to 7.6 L/m) Manual Control (high pressure) Adjustable, Set at 3100 psig (21 374 kPa) 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 4000 psig (0 to 27 579 kPa) 0 to 100 psig (0 to 689 kPa) Manual Control (low pressure) Adjustable, set at 50 psig(345 kPa) Manual Control (low pressure) Graduated in 25 cc increments 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 100 psig (0 to 689 kPa) 32 to 200F (0 to 93C) 10 micron (absolute), 3 gpm (11.4 L/m) capacity 0 to 50 psig (0 to 345 kPa) at 3 gpm (11. 4 L/m) capacity 10 gal. (37.9 l) capacity
Motorpump Schematic Test Setup Figure 102 (Sheet 2 of 2)
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PART NO 971533
Motorpump Mounting Dimensions Figure 103 F. Current Draw. (1) With test unit operating at voltages, pressures and/or flows as specified in the following steps, measure parameters listed as follows: (a) Amperage (b) Outlet pressure (c) Case drain flow (d) Delivery (outlet flow) (e) Inlet pressure (2) Zero flow check- operate test unit at 28 vdc and zero flow (2900 + 50, -0 psig (19 995 + 345, - 0 kPa). Maximum current draw shall not exceed 65 amperes. Case flow shall not exceed 0.47 gpm (1780 cc/min.).
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PART NO 971533 (3) Full flow check-operate test unit at 28 vdc and full flow (2700 50 psig (18 616 345 kPa). Full flow delivery shall not be less than 1.32 gpm (5.0 L/m) or greater than 1.72 gpm (6.5 L/m). Maximum current draw shall not exceed 130 amperes. Case drain flow shall not exceed 0.22 gpm (835 cc/min.). G. Test Completion. After satisfactory testing, proceed as follows: (1) Remove test unit from test setup. (2) Drain pump of test fluid and flush unit. NOTE: Pump must be filled with fluid for corrosion prevention. Fluid from test stand can be used if cleanliness exceeds SAE AS4059, Class 7 level. If.teststand fluid cleanliness levels are not maintained, flush and fill with clean fluid. (3) Be sure sealing screws (20, IPL Fig. 2) and locking nut (30) are secured with lockwire. (4) Prepare motorpump for shipment or storage as instructed in ASSEMBLY,paragraph 6. 8. Fault Isolation. The following fault isolation chart, Table101, has been prepared to assist personnel in locating cause for malfunction of the unit. It lists troubles, probable cause of each, and the necessary remedial steps.
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PART NO 971533 ITEM NO. TROUBLE 1 Electric motor inoperative 2 Pump not delivering (with electric motor operating
REMEDY Provide required input power to electric motor connector. Refer to TESTING Inlet to test unit blocked or Remove restriction from hydraulic insufficient fluid in hydraulic lines. Maintain correct fluid level in circuit. reservoir. Inlet pressure to test unit too Provide required inlet pressure test low. unit. Refer to TESTING. Yoke stuck in minimum flow Remove pump housing (135, IPL position. Fig. 2) and check movement of control piston (140). Piston shall move freely in pump housing. Correct any malfunction and reassemble unit. Electric motor not wired for Check correct wiring of electric proper rotation. motor. Refer to Fig. 702. Electric Insufficient heat dissipation in Assure inlet fluid temperature does motor hydraulic circuit not exceed value specified in overheating TESTING. or drawing Insufficient electric power to Provide required electrical power current in motor. input to motor connector specified in excess of TESTING. 130 amps. Insufficient clearance for pis- Disassemble pump components ton and shoe subassemblies check piston and shoe clearance (210, IPL Fig. 2). Refer to ASSEMBLY. Correct malfunction and re-assemble unit. Fault Isolation and Repair Procedure Chart Table 101 (Sheet 1 of 6)
PROBABLE CAUSE No electric input.
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PART NO 971533 ITEM NO. 3 (Contd)
TROUBLE
PROBABLE CAUSE Damaged drive shaft (Cont'd) bearing (285, IPL Fig. 2)and/ or (245 and 265, IPL Fig. 3). Compensator adjustment screw (35, IPL Fig. 2) improperly Fig. 2) improperly Insufficient end play for cylinder block (180, IPL.Fig. 2).
REMEDY Tag unit for complete overhaul.
Electric motor drive shaft binding.
Readjust compensator adjusting screw (35, IPL Fig. 2) as required. Refer to TESTING Disassemble pump components and check cylinder block end play specified in ASSEMBLY Correct malfunction and re--assemble unit. Brushes are not properly Check electric motor brushes as seated. specified in TESTING Excessive preload on bear- Check bearing preload as outlined ing (245 and 265, IPL Fig. 3). in ASSEMBLY.
5 6
Interference between fan and end bell. Thermostat Switch remains closed at switch room temperature Shaft seal Sealing faces of shaft leakage Seal element (125, IPL exceeds Fig. 2) and/or mating ring limits (320) are worn or specified in damaged. TESTING.
Check fan (180, IPL Fig. 3) for proper installation. Check switch as specified in Fig.501 Remove shaft sealing element (125) and mating ring (110). Lap sealing faces of each part as described in REPAIR. Reassemble and test unit.
Fault Isolation and Repair Procedure Chart Table 101 (Sheet 2)
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PART NO 971533 ITEM NO. 6 (Contd)
TROUBLE
Low outlet flow
PROBABLE CAUSE REMEDY Shaft seal wave spring (145, Remove wave spring and test part IPL Fig. 2) compression as specified in Fig. 501 and 801. relaxed. Correct malfunction and reassemble unit Insufficient electrical power Provide proper electrical power to trical power to input. Refer to TESTING Pressure control not properly Readjust pressure compensator as set, allowing yoke to move to specified in TESTING. zero flow position before full volume and pressure develops. Spool (70,IPL Fig. 2) not operating freely in valve block (60). Remove pilot valve and check for freedom of movement in valve bore.If necessary, lap as specified in Fig. 501. Reassemble unit after correction of malfunction. Remove pump housing (155, IPL Fig. 2) and check for freedom of movement of actuator piston. Refer to Fig. 801 for clearance requirement. Correct malfunction and reassemble unit
Actuator piston (175, IPL Fig.2)not operating freely in housing bores
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PART NO 971533 ITEM NO. 7 (Contd) Low outlet flow (contd)
TROUBLE
PROBABLE CAUSE Bowed or broken Bowed or broken control springs (265 and 260, IPL Fig. 2).
REMEDY Remove pump housing (155, IPL Fig. 2) and check springs as specified in Fig. 501. Replace damaged springs and reassemble unit. Excessive clearance Remove pump housing (155, IPL Fig. 2). between piston and shoe Refer to Figs. 501 and 801 for fit of pissubassemblies (225, IPL Fig. ton to bore.Replace piston and shoe 2) and piston bores in cylin- subassemblies as necessary, being sure der block (180). to preserve matched fit of all piston shoes, and reassemble unit. Scored valving faces of valve Remove pump housing (155, IPL Fig. 2). block (60, IPL Fig. 2) and/or Inspect sealing surfaces of valve block cylinder block (180). and cylinder block for requirements specified in Figs 501 and 801. If necessary, lap damaged face of each part as described in REPAIR Cylinder block (180, IPL Remove pump housing (155, IPL Fig. 2). Fig. 2)partially lifting from Inspect sealing surfaces of valve block valve block(60). and cylinder block for requirements specified in Figs 501 and 801. If necessary, lap dam aged face of part as described in REPAIR Fault Isolation and Repair Procedure Chart Table 101 (Sheet 4)
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PART NO 971533 ITEM NO. TROUBLE PROBABLE CAUSE 8 Pressure Trapped air in test circuit and/ creeps or pressure compensator more than Sticky operation of actuator 25 psig ( piston (175,IPL Fig. 2). 172 kPa) with yoke zero flow (2900 psig (19 995 Case drain pressure varies kPa)). during test period 9 Excessive Excessive clearance internal between piston and shoe leakage. subassemblies (225, IPL Fig. (Case flow 2) and piston bores in cylinexceeds der block (180). limits specified in test). Scored valving faces of valve block (60, IPL Fig. 2) and/or cylinder block(180)
REMEDY Bleed all air from test circuit and test unit. Remove pump housing (155, IPL Fig. 2) and check for freedom of movement of actuator piston. Refer to Figs. 501 and 801 for clearance requirements. Correct malfunction and reassemble unit. Maintain constant case drain pressure during test period. Remove pump housing (155, IPL Fig. 2). Refer to Figs. 501 and 801 for fit of piston to bore. Replace piston and shoe subassemblies as necessary, being sure to preserve match fit of all piston shoes, and reassemble unit Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve plate and cylinder block for requirements specified in Figs 501 and 801. If necessary, lap damaged face of each part as described in REPAIR
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PART NO 971533 ITEM NO. 9 (contd)
TROUBLE
10
Outlet pressure fluctuation.
PROBABLE CAUSE REMEDY Cylinder block (180, IPL Fig. Remove pump housing (155, IPL 2)partially lifting from valve Fig. 2). Inspect sealing surfaces of block (60) valve block and cylinder block for requirements specified in Figs.501 and 801. If necessary, lap dam aged face of part as described in REPAIR Trapped air in test circuit and/ Bleed trapped air. Refer to TEST. or pressure control Foreign matter in pressure Disassemble pressure compensator compensator. and clean parts. Refer to CLEANING. Burr on spool (70, IPL Fig. 2) Disassemble pressure compensator and remove burrs. and/or valve block(60). Sticky actuator piston (175, Remove control piston and check IPL Fig.2) for clearance and surface finish as specified in Figs. 501 and 801. Cylinder block (180, IPL Remove pump housing (155, IPL Fig. 2) partially lifting rom Fig. 2). Inspect sealing surfaces of valve block(60) valve block and cylinder block for requirements specified in Figs.. 501 and 801. If necessary, lap dam aged face of part as described in REPAIR. Fault Isolation and Repair Procedure Chart Table 101 (Sheet 6)
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PART NO 971533 9. Test Record. Remove test record pages and make a copy of the pages, replace originals into manual. Initial or record information as requested. Attach completed record to pump and place a copy of completed test record in the history file of the pump.
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PART NO 971533 TEST RECORD Assembly No.: Test Operator Fluid Used: Test Stand No.: Q.A. Acceptance: Limits Actual Data
Date: Model: Model Name: Serial No.: Customer No.: Work Order: Para Test Performed 3 Test Electric Motor Subassembly (Optional) 3.A., B&C Test setup, see Para 3. Test Conditions,see Para 4. 4
_______Comply _______Comply
CAUTION: DO NOT HI-POT FINAL MOTOR SUBASSEMBLY. INTERNAL DAMAGE WILL OCCUR TO RFI FILTER CAPACITORS Acceptance Test: The motor shall meet the following minimum RPM: Performance criteria: Test hydraulic Pump Subassembly (Optional). Test Conditions. See para 6A (1) thru (3) External Leakage. Shaft Seal. Shaft Seal shall not exceed ______Accept two (2) drops per minute during all phases of testing. One drop is equal to approximately 1/20 ml. External leakage other than ______Accept a slight wetting insufficient to form a drop, through andy seal or gasket (except shaft seal) shall be cause for rejection. Test Record Table 102 (Sheet 1 of 8) ______Comply Load: 25.0 lbs. in. (2.8 N.m)7,950 500 Current: 130 amps max. Voltage: 20 vdc _______Accept _______Accept _______Accept _______Accept
5 6 6.A. 6.B. 6.B.(1)
6.B.(2)
External Leakage.
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PART NO 971533
Para 6.C
Test Performed
Limits
Actual Data
Preliminary Tests. NOTE: Conduct the following tests prior to installing the pump in the test circuit. Binding. Rotate drive shaft of test unit manually to psig (1034 kPa) to the case drain connection for two minutes. Proof Test. Plug inlet and outlet ports and apply 150 psig (1034 kPa) to the case drain connection for two minutes. Test Circuit. Connect the test unit in a hydraulic test circuit as illustrated in Fig. 101. Make certain test unit and test circuit are completely full of clean phosphate ester hydraulic fluid or equivalent Preliminary Compensator Adjustment. Prior to starting test unit in operation, be sure that adjusting screw (35, IPL Fig.2) is turned in sufficiently to allow: Full flow and 1500 psig (10 342 kPa) from outlet port when test unit is started up in the following run-in test. Do not run test unit below 1500 psig (10 342 kPa) If binding is noted, disassemble pump and correct the trouble before proceeding There shall be no evidence of external leakage except at the drive shaft seal. Shaft seal leakage shall not exceed ten drops in five minutes. ____Accept
6.C(1)
6.C(2)
____Accept
6.C(3) 6.D
____Accept ___ Comply
6.E
____Accept
Test Record Table 102 (Sheet 2)
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PART NO 971533
Para 6.F
Test Performed
Limits
Actual Data
Run-In. NOTE: During any of the following tests, external leakage shall be as specified in paragraph 4B With load valve (2, Fig. 101) open, start hydraulic supercharge source and power drive to drive test unit at: Adjust supercharge pup (15) to provide inlet pressure Close load valve (7) and adjust relief valve (8) to provide a case pressure of: Gradually close load valve (2) to increase outlet pressure, as shown on pressure gage (5), from: During the next five minutes, gradually increase speed to 9350 50 rpm. Continue at this speed and zero flow for five minutes 3600 rpm for five minutes. ___Comply
6.F(1)
6.F(2)
25 5 psig (172 34 kPa) as indicated on inlet pressure gage (12). 15 5 psig (103 34 kPa) above inlet pressure as indicated on case pressure gage (6). 1500 psig (10 342 kPa) to 2950 psig (20 340 kPa) and zero flow on flowmeter (1) during the first five minutes During this run-in, open shutoff valve (9) and measure case drain flow in beaker (10).
___Comply
6.F(3)
___Comply
6.F(4)
___Comply
___Comply
6.F(5)
NOTE: Case drain flow at 9350 rpm and 2950 psig (20340 kPa) outlet pressure shall not exceed 0.47 gpm (1780 cc/min.). 6.F(6) 6.G 6.G(1) During run-in observe unit for unusual noise or chatter Compensator Adjustment. With unit operating at 9350 25 rpm and load valve (2) closed (zero flow), adjust compensator adjusting screw (35, IPL Fig. 2) to obtain: 2900 + 50, - 0 psig (19 995 + 345, - 0 kPa). Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches (4.0 to 4.5 Nm). ___Comply Stop test and investigate trouble observed. ___Comply
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PART NO 971533
Para 6.G(2)
Test Performed Alternately open and close load valve (2, Fig. 101 rapidly. in the compensator. After this operation, repeat step 4.G(1) Pressure Shift. With unit operating at 9350 rpm, adjust load valve (2) to cycle from: to 2700 + 50, Operate unit for three minutes at 9350 25 rpm with zero delivery. not shift more than 25 psig
Limits This will purge any air that may have become trapped
Actual Data ___Comply
6.H 6.H(1)
Zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa to) 18 616 + 345, - 0 kPa) five times. Outlet pressure, as shown on pressure gage (5), shall (172 kPa) above or below pressure assumed at the time of shutoff
___Comply
6.H(2)
____Accept
6.I
Stability Check. NOTE: During the following check, minimum time for the sweep shall be 60 seconds from maximum to minimum speed and 60 seconds from minimum to maximum speed. While operating test unit at zero flow (2900 + 50, - 0 psig (19995 + 345, - 0kPa), vary pump speed from 9350 rpm to 6000 rpm and back to 9350 rpm. There shall be no indications of any persistent oscillations lasting more than one second. __Accept
6.J 6.J(1) 6.J(2)
Delivery Check. Reduce test unit speed to: Adjust load valve (2) as necessary to obtain 2700 50 psig (18 616 345 kPa) 7950 25 rpm. Delivery of the pump shall not be less than 1.32 gpm (5.0 L/ m) or greater than 1.72 gpm (5.5 L/m) as shown on flowmeter (1). ___Comply ____Accept
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PART NO 971533
Para 6.K 6.K(1)
Test Performed Case Flow Check. Continue to operate test unit at conditions established in paragraph 4.J. Open shutoff valve (9) and measure case drain flow. Operate test unit at 9350 25 rpm and 2900 + 50, - 0 psig (19 995 + 345, - 0 kPa) gpm.outlet pressure (zero flow).
Limits
Actual Data ____Accept
Flow shall not exceed 0.22 gpm (835 cc/min).
____Accept
6.K(2)
____Accept
6.L
Cylinder Block Lift Test. NOTE: During the following tests monitor case drain leakage (flow) and outlet flow (delivery) to ascertain that cylinder block lift does not occur during acceleration and steady state conditions. Cylinder block lift will be indicated by high case drain leakage, low outlet flow (pump delivery) and pressure oscillations. Operate test unit at 9350 25 rpm and reduce outlet pressure as low as possible (full flow). Uniformly accelerate test unit to 10,300 rpm within two seconds. Continue to operate at low pressure and high speed for thirty seconds. Friction Test. After test unit has passed all tests specified in this paragraph, hand torque required to turn pump drive shaft shall be measured Record pressure for reference during test Decelerate unit to zero rpm. There shall be no evidence of cylinder block lift. ___Comply
6.L(1)
6.L(2)
____Accept
6.M
Breakaway torque shall not exceed 7.0 pound inches (0.8 Nm) and turning torque shall not exceed 4.0 pound inches (0.45 Nm).
____Accept
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PART NO 971533
Para 7.
Test Performed
Limits
Actual Data
Test Motorpump Assembly. CAUTION: A LIGHT SHALL BE INSTALLED (SEE FIG. 102) TO ALERT OPERATING PERSONNEL OF OVERTEM PERATURE CONDITION IN BRUSH AREA. IF OVERTEMPERATURE CONDITION IS EXPERIENCED THE TESTS SHALL BE DISCONTINUED UNTIL THE MOTOR HAS HAD ADEQUATE TIME TO COOL. THE THERMAL PROTECTION DEVICE FOR THE MOTOR IS LOCATED IN THE BRUSH AREA. THIS DEVICE IS NORMALLY CLOSED; THEREFORE, OVERTEMPERATURE CONDITION WILL BE INDICATED WHEN PILOT LIGHT GOES OFF DURING OPERATION. CAUTION: ELECTRIC MOTOR IS NOT RATED FOR CONTINUOUS- DUTY AT FULL-FLOW (MAXIMUM CURRENT DRAW) CONDITIONS. MOTOR-PUMP SHALL NOT BE OPERATED CONTINUOUSLY IN FULL-FLOW FOR MORE THAN ONE (1) MINUTE.
7.A
Test Conditions. Refer to paragraphs 3B and 4A. External leakage shall be as specified in paragraph 6.B Test Equipment. Refer to paragraph 7.B Test Circuit. Connect test unit into a test circuit as illustrated in Fig.102. Be sure hydraulic pump and test circuit are completely full of clean phosphate ester hydraulic fluid
___Comply
7.B
___Comply
7.C
___Comply
NOTE: Shock mounts shall not be installed on motor during test. Refer to DISASSEMBLY, paragraph 3B(3) for shock mount removal and to ASSEMBLY, paragraph 5A for reinstallation after test. Test Record Table 102 (Sheet 6)
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PART NO 971533
Para 7.D 7.D(1) 7.D(2)
Test Performed Break-In. Set power supply voltage at: Open valve (2, Fig. 102),start hydraulic supercharge source (15) and adjust supercharged inlet pressure as shown on pressure gage (12) to: Close load valve (7) and adjust relief valve (8) to provide a case drain pressure of: Operate test unit for three minutes with load valve (2) adjusted to provide 0.3 gpm (1.1 L/m) as indicated on flowmeter (1). Uniformly adjust load valve (2) to increase flow on flowmeter (1) to obtain full flow pressure, (2700 50 psig (18 616 345 kPa)) over a thirty second period Outlet Pressure Check. With test unit operating a 28 vdc, adjust load valve (2) for zero delivery (outlet flow) and check outlet pressure on gage (5).
Limits
Actual Data
28 vdc. 25 5 psig (172 34 kPa).
___Comply ___Comply
7.D(3)
15 5 psig (103 34 kPa) above inlet pressure. During this period, observe motorpump for any unusual noise or indication of possible malfunction Operate at full flow for one minute.
___Comply
7.D(4)
___Accept
7.D(5)
___Comply
7.E 7.E(1)
If pressure is not within 2900 + 50, -0 psig (19 995 + 345,-0 kPa), adjust compensator adjusting screw (35, IPL Fig2) as necessary to obtain zero delivery outlet pressure. 35 to 40 pound inches (4.0
____Accept
7.E(2)
Torque locking nut (30, IPL Fig. 2). to 4.5 Nm).Secure with lockwire MS20995C32.
___Comply ___Comply
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PART NO 971533
Para 7.F 7.F(1)
Test Performed Current Draw. With test unit operating at voltages, pressures and/or flows as specified in the following steps, measure parameters listed as follows Zero flow check-operate test unit at 28 vdc and zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa). Full flow check- operate test unit at 28 vdc and full flow (2700 50 psig (18 616 345 kPa).
Limits
Actual Data
(a) Amperage (b) Outlet pressure (c) Case drain flow (d) Delivery (outlet flow) (e) Inlet pressure Maximum current draw shall not exceed 65 amperes. Case flow shall not exceed 0.47 gpm (1780 cc/min.). Full flow delivery shall not be less than 1.32 gpm (5.0 L/m) or greater than 1.72 gpm(5.5L/m) Maximum current draw shall not exceed 130 amperes. Case drain flow shall not exceed 0.22 gpm (835cc/ min.). ___Accept ___Accept ___Accept
7.F(2) 7.F(3)
____Accept ____Accept
7.G
Test Completion. After satisfactory testing, proceed as follows:
(1) Remove test unit from test setup and install shock mounts as instructed in ASSEMBLY paragraph 5A. (2) Drain pump of test fluid and flush unit (3) Be sure sealing screws (20, IPL Fig. 2) and locking nut (30) are secured with lockwire. (4) Prepare motorpump for shipment or storage as instructed in ASSEMBLY, paragraph 6. Test Record Table 102 (Sheet 8)
___Comply
___Comply ___Comply
___Comply
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PART NO 971533
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PART NO 971533
DISASSEMBLY
1. General. See TESTING AND FAULT ISOLATION for operational test and fault isolation to establish the condition of the unit or the most probable cause of malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the unit. 2. Special Tools. See SPECIAL TOOLS, FIXTURES AND EQUIPMENT for a complete list of special tools and test equipment recommended for maintenance of these hydraulic motorpump assemblies and a description of their function. Tooling and test equipment other than herein specified may be used provided they perform the required operations. Refer to following table for special tools recommended for disassembly. T-300664 T-304103 T-304104 T-304105 T-304106 T-304165 T-443364 T-443827 Mechanical Positioner Adapter Bearing Removal Plate Bearing Driver Bearing Puller Holding Clamp Bearing Puller Assembly Fixture Spring Compressing Tool List of Special Tools Table 301 NOTE: Always use the proper tool for the job. Be sure wrenches fit properly on nutsor bolt heads. Do not use pliers to remove nuts or bolts. Do not use screwdrivers to separate mating parts. Use a soft faced rod or mallet for tapping around binding area. 3. Disassemble Motorpump Assembly. NOTE: The abbreviation IPL refers to the ILLUSTRATED PARTS LIST of this manual.Refer to IPL Fig. 1 for disassembly of hydraulic motorpump assembly. NOTE: Discard all packings and backup rings removed during disassembly operations.
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PART NO 971533 A. Prepare for Disassembly. WARNING: CARE SHALL BE TAKEN IN THE REMOVAL OF LOCKWIRE. FORCEFULLY PULLING WIRE OUT OF RETAINED PARTS MAY CAUSE PERSONAL INJURY. (1) Remove external lockwire. (2) Remove outlet plug (325, IPL Fig. 2), seep plug (335) and case drain plug (345) and packings (330, 340 and 350). (3) Remove inlet plug (355) and packing (360). Drain all hydraulic fluid from pump. B. Disassembly. (1) Remove nuts (10, IPL Fig. 1) and washers (15) securing hydraulic pump (5) to electric motor (50). (2) Carefully separate pump from motor and remove gasket (20). CAUTION: DURING REMOVAL OF SHOCK MOUNT SUBASSEMBLIES (25), HOLD MOUNT (45) BY WRENCHING FLATS TO PREVENT INTERNAL DAMAGETO SHOCK MOUNT. (3) Remove nuts (30) and washers (35) securing shock mount subassemblies to motor footing. (4) Do not disassemble shock mount subassemblies (25) unless replacement stud (40) or shock (45) is necessary. (5) Do not remove identification plate (55) unless replacement is necessary. If replacement is necessary, refer to REPAIR. 4. Disassemble Hydraulic Pump Subassembly. NOTE:Refer to IPL Fig. 2 for disassembly of hydraulic pump. A. Remove Coupling Shaft. (1) Grasp coupling shaft (5, IPL Fig. 2) and pull straight out. (2) Remove packing (10) and retaining ring (15) from coupling shaft. B. Remove Pressure Compensator. (1) Attach mechanical positioner adapter T-300664 to power arm (Wilton Model 801, or equivalent).
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PART NO 971533
Figure 301. Pump/Power Arm Assembly (2) Remove sealing screws (20, IPL Fig. 2) from pump and remove packings (25) from sealing screws. (3) Remove locking nut (30) from adjusting screw (35). (4) Remove adjusting screw (35) from pump and remove packing (40) from adjusting screw. (5) Disassemble spring seat (45), compensator spring (50), and spring guide (55) from valve block (60). C. Remove Valve Block and Spool Subassembly. (1) Remove screws (65) securing valve block and spool subassembly (60) to housing and insert subassembly (155). (2) Carefully separate valve block and spool subassembly (60) from housing and insert subassembly (155) and remove spool (70). (3) Secure mounting flange of pump to adapter as shown in Fig. 301 to facilitate disassembly.
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PART NO 971533 (4) Using bearing puller T-304105 and assembly fixture T-443364 as shown in Figure 302, remove needle bearing (80, IPL Fig. 2) from valve block (60). (5) Do not remove alignment pin (85) unless loose or damaged. (6) Remove packings (90 and 95) from valve block and housing, respectively. (7) Place valve block in a protective container to prevent damage to valving face. D. Remove Shaft Seal Subassembly and Associated Parts (1) Remove four screws (105, IPL Fig. 2) and remove retaining plate (100). CAUTION: USE CARE WHEN HANDLING MATING RING (110). THIS PART HAS A LAPPED FACE THAT MATES WITH SHAFT SEAL ELEMENT (125). (2) Remove mating ring (110) and disassemble preformed packing (115). CAUTION: USE CARE WHEN HANDLING SHAFT SEAL ELEMENT (125). THIS PART HAS A LAPPED FACE THAT MATES WITH MATING RING (110).
Figure 302. Removal of Needle Bearing
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PART NO 971533 (3) Remove shaft seal element (125), grommet (130), garter spring (135), shaft seal spacer (140) and wave washer (145) from drive shaft (290). (4) Carefully remove retainer (150) from drive shaft (290) by lifting a tongue of the retainer (two places 180 degrees apart) out of a drilled hole in the drive shaft. Do not scratch the surface of the drive shaft when removing the retainer. E. Remove Housing Subassembly. CAUTION: IN THE FOLLOWING OPERATION, DO NOT ALLOW CYLINDER BLOCK (180) TO SEPARATE FROM PISTON AND SHOE SUBASSEMBLIES (225). DAMAGE TO PISTON AND SHOE SUBASSEMBLIES MAY RESULT. CAUTION: IN THE FOLLOWING OPERATION, DO NOT ALLOW ACTUATOR PISTON(175) TO FALLOUT OF HOUSING BORE DURING HOUSING REMOVAL. DAMAGE TO PISTON MAY RESULT. (1) Remove screws (160, IPL Fig. 2) and washers (165) securing housing and inserts subassembly (155) to mounting flange subassembly (295). (2) Place finger over hydraulic fluid passageway in housing, to retain actuator piston,and carefully remove housing (155). (3) Remove actuator piston (175). (4) Do not remove inserts (170) unless loose or damaged. F. Remove and Disassemble Cylinder Block CAUTION: IN THE FOLLOWING OPERATION, USE CAUTION WHEN REMOVING CYLINDER BLOCKS (180 IPL FIG. 2) TO PREVENT DAMAGE TO PISTON AND SHOE SUBASSEMBLIES (225) AND TO VALVING FACE OF CYLINDER BLOCK. (1) Carefully separate cylinder block (180, IPL Fig. 2) from piston and shoe subassemblies (225) while removing cylinder block from drive shaft (290). (2) Using spring compressing tool T-443827 as shown in Fig. 303, compress cylinder block spring (195) sufficiently to remove retaining ring (185). (3) Remove retaining ring (185) from cylinder block and remove cylinder block from spring compressing tool. (4) Remove retainer (190), cylinder block spring (195) and seat (200) from cylinder block Page 305 Nov 15/04
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PART NO 971533 (5) Place cylinder block in a protective container. G. Remove Piston and Shoe Subassemblies. (1) Remove screws (205, IPL Fig. 2) and washers (210) securing piston and shoe subassemblies to yoke, ball and pin subassembly (240). CAUTION: IN THE FOLLOWING STEPS, USE CAUTION TOPREVENT DAMAGE TO PISTON AND SHOE SUBASSEMBLIES (225). DO NOT ALLOW THE SUBASSEMBLIES TO STRIKE ONE ANOTHER OR OTHER METAL SURFACES. (2) Carefully disassemble retainer (215), piston shoe retaining plate (220), piston and shoe subassemblies (225) and shoe bearing plate (230) from yoke, ball and pin subassembly (240). (3) Place piston and shoe subassemblies in a protective container. H. Remove Yoke, Ball and Pin Subassembly. (1) Remove mounting flange (295, IPL Fig. 2) from mechanical positioner adapter. (2) Using holding clamp T-304106 as shown in Fig. 304, compress yoke control springs (260) and (265) until yoke is free of spring load.
Fig. 303. Removal of Retaining Ring.
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PART NO 971533
Fig. 304. Compressing Control Springs. (3) Using bearing puller T-304165, remove pintle bearings (235, IPL Fig. 2). NOTE: It may be necessary to lift up on drive shaft to allow room for yoke removal. (4) Carefully remove yoke (240) from mounting flange (295). (5) Release holding clamp tension on control springs and disassemble spring guide (255), outer spring (260), inner spring (265) and control spring seat (270). (6) Do not remove locating pin (245) nor inserts (250) unless replacements are necessary. I. Remove and Disassemble Drive Shaft and Components. (1) Carefully remove shaft and bearing subassembly (280, IPL Fig. 2) from mounting flange (295). (2) Using bearing driver T-304104 and bearing removal plate T-304103 as shown in Fig. 305, press drive shaft (290) out of ball bearing (285).
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PART NO 971533 J. Disassemble Mounting Flange Subassembly. Do not remove aligning pin (300, IPL Fig. 2) nor inserts (305 and 310) from mounting flange unless replacements are necessary. K. Remove Data Plates. Do not remove rotation plate (315) nor instruction plate (320) unless replacement is necessary. If replacement is necessary, refer to REPAIR.
Fig. 305. Removing Drive Shaft. 5. Disassemble Electric Motor Subassembly. NOTE: Refer to IPL Fig. 3 for disassembly of electric motor. A. Remove Filter, Conduit and Connector Assembly. (1) Remove cap plugs (5, IPL Fig. 3), nuts (10A), lock washers (15) and detach electrical terminals (20), lead wires (25) and sleevings (30), from filter assembly (40A). Do not remove terminals sleevings or grommets (35A) unless replacement is required. (2) Remove filter assembly (40A) from cover (135) by removing screws (45) and lock washers (50).
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PART NO 971533 NOTE: Disassembly of filter, conduit (65, IPL Fig 3) and connector(70) is not necessary unless replacement is required. If disassembly is necessary, proceed as applicable. (3) Remove conduit (65, IPL Fig. 3) by disconnecting connector adapter (55) from electrical connector (70) and female adapter (60) from bulkhead adapter (85). Pull pins from connector (70). Remove conduit (65). NOTE: Electrical connector tool set is required to pull pins from connector (70) NOTE: If conduit (65) becomes damaged replacement is necessary,. (4) If replacement of thermostat (75) becomes necessary, remove sleeving (80), and remove thermostat from electrical leads. Remove lead wires only if necessary. (5) Do not remove bulkhead adapter (85) or lead wires (90 or 95) unless replacement is required. If required, remove nuts (100A) and lockwashers (105), and remove lead wires from filter posts. Do not remove terminals (110), sleeving (115), and contact bushing (315) unless required. (6) Remove bulkhead adapter (85) mounting nut and remove adapter from filter (40A). B. Remove Front Shroud and Cover Assembly. (1) Remove screws (125, IPL Fig. 3) and lockwashers (130), and carefully separate shroud (120) from drive end bell (250). (2) Remove screws (140) and lockwashers (145) and separate cover assembly (135) from commutator end bell (230). (3) Do not remove insulator (150) from cover unless damaged or necessary. C. Remove Fan. (1) Loosen screw (155, IPL Fig. 3) sufficiently to allow removal of fan (160). Carefully remove fan from armature (235) drive shaft.
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PART NO 971533 D. Disassemble Electric Motor. CAUTION: TO PREVENT DAMAGE TO BRUSHES,DO NOT USE SHUNT LEADS TO PULL BRUSHES OUT OF HOLDERS. USE A HOOK TO PULL BRUSH RETENTION SPRINGS BACK SO THAT BRUSHES SLIDE OUT FREELY. CAUTION: IF BRUSHES ARE TO BE RE-USED, IDENTIFY BRUSHES WITH HOLDERS. BRUSHES MUST BE RE-INSTALLED INTO SAME HOLDERS. (1) Remove locknuts (165, IPL Fig. 3) and washers (170) securing brush leads to holder posts. Detach terminals (175 and 180) from brush holders (190) and remove brushes (185) from holders assemblies. (2) Remove retaining ring (195) and shims (200, 205 and 210) from commutator end bell (230). Retain shims for re-use at assembly. NOTE: Commutator end bell (230), field housing (240) and drive end bell (250) must be aligned at the same positions during reassembly. (3) Scribe alignment marks on commutator end bell, field housing and drive end bell to assure correct alignment of these components during re-assembly. (4) Remove bolts (215) and lockwashers (220) securing commutator end bell, field housing and drive end bell together. (5) Carefully separate commutator end bell (230) from rear ball bearing (225) and armature assembly (235). (6) Remove armature (235) from field housing (240). (7) Remove front ball bearing (245A) and rear ball bearing (225A) from armature (235). (8) Remove drive end bell (250) from field housing (240). Do not remove set screws (255) unless replacement is necessary. (9) Do not remove mounting base (260), unless damaged or necessary. If necessary, remove screws (265A), lockwashers (270A) and flat wash (271). (10) Do not disassemble field housing (240). (11) Disassembly of commutator end bell (230), brush holder assemblies (190), or associated parts, screws (275), lockwashers (280), washers (285), jumper (lead) wires(290), and terminals (295) is not required unless individual parts require replacement.
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PART NO 971533 (12) Do not remove name plate (300, IPL Fig. 3) or warning placard (305) unless replacement is necessary. Refer to REPAIR.
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PART NO 971533
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PART NO 971533
CLEANING
1. Cleaning of Hydraulic Pump. A. The consumable materials listed in Table 401 are required during cleaning operations. Equivalent substitutes may be used.
MATERIAL Cleaner, Ultrasonic Containers, Parts, Sealable Solvent, Dry cleaning (P-D-680) Skykleen 1000 Wipers, Cotton Fluid, Hydraulic (Alkyl Phosphate Ester) Cleaning Materials Table 401
AVAILABILITY Commercially available Commercially available Commercially available Solution, St. Louis, MO Commercially available Commercially available
B. After lapping operations, thoroughly brush lapped surface of part with a bristle brush in a soap and water solution. Follow this operation cleaning part in a sonic or ultrasonic cleaner. WARNING: USE CLEANING SOLVENTS IN WELL VENTILATED AREA TOPREVENT INJURY. AVOID PROLONGED BREATHING OF FUMES.KEEP SOLVENTS AWAY FROM OPEN FLAME. CAUTION: DO NOT APPLY SONIC OR ULTRASONIC CLEANING OPERATIONSTO PARTS THAT CONTAIN OR ARE COMPOSED OF NON-METALLIC MATERIAL. CAUTION: DO NOT IMMERSE HYDRAULIC MOTORPUMP ASSEMBLY IN CLEANING FLUID. MAKE CERTAIN ALL PORTS ARE PLUGGED DURING CLEANING OPERATION. NOTE: Steel parts may require demagnetizing.
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PART NO 971533 C. Use Skykleen 1000 or equivalent in ultrasonic cleaning equipment to clean all metal parts, except parts that contain or are composed of non-metallic material. Pay particular attention to fluid passages in valve plate housing and mounting flange to make certain they are clean and free from obstructions. D. Wipe non-metallic parts with clean, lint-free toweling moistened with dry-cleaning solvent, Federal Specification P-D-680, Type ll. 2. Lubrication of Hydraulic Pump Parts. Lubricate cleaned parts with clean alkyl phosphate ester hydraulic fluid and place in heat sealable polyethylene bags or other suitable contaminant free sealable containers if parts are not to be used immediately. NOTE: A good practice is to reclean and oil parts just prior to assembly if they have been placed in storage after initial cleaning. 3. Cleaning of Electric Motor. WARNING: USE CLEANING SOLVENTS IN WELL VENTILATED AREA TO PREVENT INJURY. AVOID PROLONGED BREATHING OF FUMES. KEEP SOLVENTS AWAY FROM OPEN FLAME. A. All parts except the armature (255, IPL Fig. 3), field housing assembly (260), brushes (205), bearings (245 and 265), and filter assembly (40),may be cleaned by washing in cleaning solvent (Federal Specification P-D-680, Type l or Type ll). B. After cleaning and rinsing in solvent, blow all parts dry with low-pressure filtered compressed air 5 to 10 psig (34 to 70 kPa). C. Remove brush dust and all other foreign matter from the armature assembly (255) and field housing assembly (260) with low-pressure filtered compressed air 25 to 30 psig (172 to 207 kPa). Wipe both assemblies with a soft cloth moistened in cleaning solvent. Use a soft-bristle brush to clean between the slots on the commutator, and hard to reach areas of the stator assembly. D. After cleaning the stator and armature assembly (255), dry in an oven for approximately two hours at 225 F (107 C). E. Clean brushes (205) with a dry clean cloth only. Do not use a solvent.
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PART NO 971533
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PART NO 971533
CHECK
1. General. In most cases a visual parts check will disclose damage necessitating repair or replacement. However, because of very close tolerances that must be maintained between certain parts, the checks covered in Fig. 501 are supplemented by those outlined in Fits and Clearances Table, Fig. 801. 2. Special Tools. See SPECIAL TOOLS, FIXTURES AND EQUIPMENT for a complete list of all special tools recommended for maintenance and a description of their function. However, tooling and test equipment, other than those specified, may be used providing they perform the required operation. Refer to the following table for special tools recommended for checks. T-108684 T-219352 T-415408 T-441647 Air Gage Master Ring Air Gage Master Ring Air Gage Spindle End Play Checking Tool
3. Detailed. A. In addition to a visual check, a magnetic particle check of all steel parts shall be made in accordance with Specification ASTM E 1444. Use the wet continuous process, with either longitudinal or circular magnetization, and a current magnitude of 800 to 1200 amperes per inch of part. Any evidence of cracks that will destroy the soundness of the part is cause for rejection. Parts that have passed this check shall be passed through a demagnetizing field then cleaned as instructed in CLEANING. NOTE: Small cracks or inclusions may be removed providing the metal removed will not affect the integrity of the part. B. All non-steel metal parts shall be fluorescent penetrant checked as instructed in Specification ASTM E 1417. Any evidence of cracks that will destroy the soundness of the part is cause for parts rejection. After this, thoroughly clean part as instructed in CLEANING.
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PART NO 971533 NOTE: Small cracks or inclusions may be removed providing the metal removed will not affect the integrity of the part. C. Use optical flats and monochromatic light when checking flatness of lapping operations called for in REPAIR. NOTE: A typical flatness measurement which depicts flatness to three helium light bands is illustrated in Fig. 502. CAUTION: BE SURE VALVING FACES OF VALVE BLOCK (60, IPL FIG. 2) AND CYLINDER BLOCK (180) ARE AS FLAT AS POSSIBLE. REFER TO FIG. 501. D. Use a standard electronic amplifier (Profilometer, or equivalent) to measure surface roughness. Make certain surfaces are thoroughly cleaned before checking and part so mounted that the instrument will not pick up extraneous vibrations which will furnish a false reading on the micro inch scale. E. Use precision checking equipment (standard visual amplifiers) such as Sheffield Precisionaire Column and Sheffield Comparator as shown in Figs. 503 and 504 respectively when checking ID and OD of parts. F. Use equipment as illustrated in Fig. 505 to check end play of piston and shoe subassemblies (225, IPL Fig. 2). G. Use plating thickness tester (Magnegage, or equivalent) when measuring thickness of bronze plating on steel back parts. H. Use spring load testers such as Link Testing Devices (or equivalent) when checking springs for their performance characteristics. I. Use Nital etch process to detect localized tempering (metallurgical burn) of hardened steel valve block (60, IPL Fig. 2) and shoe bearing plate (230). Tempered area will appear darker than the unaffected portion of the part. Proceed as follows: WARNING: NITRIC ACID BURNS. BE VERY CAREFUL WHEN MIXING THE FOLLOWING SOLUTION TO PREVENT PERSONAL INJURY. WASH IMMEDIATELY WITH WATER IF ACID COMES IN CONTACT WITH SKIN. CAUTION: ACID ETCHING PRODUCES A SMALL DIMENSIONAL CHANGE IN PARTS. DO NOT ALLOW SOLUTION TO REMAIN ON SURFACE ANY LONGER THAN SPECIFIED. WASH WITH WATER TO NEUTRALIZE.
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PART NO 971533 (1) Prepare etching and neutralizing solutions as follows: WARNING: IN MAKING UP ETCHING SOLUTION, ALWAYS ADD ACID TO ALCOHOL. POUR ABOUT ONE HALF THE AMOUNT OF ALCOHOL NEEDED INTO A GRADUATE, ADD THE REQUIRED AMOUNT OF ACID BY POURING SLOWLY DOWN THE SIDE OF THE GRADUATE. STIR, AND THEN ADD ADDITIONAL ALCOHOL TO OBTAIN THE REQUIRED DILUTION. (a) Etching Solution Mix 4 ml of nitric acid and 50 ml of alcohol (ethyl or methyl) in a graduate, stir, and add additional alcohol to bring volume to 100 ml. Mix thoroughly.Maintain solution temperature between 70 -80F (21 -27C). (b) Neutralizing Solution Mix 10% (by weight) of trisodium phosphate to water or other suitable neutralizer. (2) Clean part as called for in CLEANING. (3) Immerse or swab surface to be checked with etching solution. Allow part to be exposed to this solution for 15 to 20 seconds. (4) Rinse in cold water to remove etching solution. (5) Immerse part in neutralizing solution. (6) Rinse in water to remove neutralizing solution. (7) Rinse in alcohol to remove water. (8) Dry with stream of clean, warm, dry air. (9) Check part for softened (tempered) areas which will appear darker than the unaffected portion of the part.
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PART NO 971533
PART Shock Mount, Subassembly (25, IPL Fig. 1)
CHECK Stud (40) threads. Shock mount (45) core for damage. Packing groove. Cracks. Splines for wear or damage. Visual.
METHOD
REQUIREMENT No stripped or crossed threads permitted. Repair to serviceability or replace. Replace shock mount if damaged. No nicks or burrs permitted. No cracks permitted Refer to paragraph 3B. Replace coupling shaft if it cannot meet dimensions specified in Fig 801. If damaged, replace part.
Visual.
Coupling Shaft (5,IPL Fig. 2)
Visual. Fluorescent penetrant. Visual and measured over standard over standard 0.0600 inch (1.524 mm) diameter pins Visual.
Adjusting Screw (35,IPL Fig. 2)
Check for damaged threads or packing groove Check for damaged threads or packing groove.
Visual.
Visual.
Compensator Spring (50,IPL Fig. 2)
Check spring for distortion tortion
Spring load tester Refer to paragraph 3H
Replace spring if it cannot pass test called for in Fig. 801.
General Check Requirements Figure 501 (Sheet 1 of 14)
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PART NO 971533
PART Valve Block and Spool Subassembly (60, IPL Fig. 2).
CHECK
METHOD
REQUIREMENT
NOTE: This subassembly consists of spool (70) and valve block (60) which are matched at initial assembly to very close tolerances. Do not intermix these parts with like parts of other subassemblies. Check for is wear on ID block (60) and OD of spool (70). Standard visual amplifier and surface finish analyzer. Refer to paragraphs 3D and 3E. Replace subassembly if clearance is greater than that specified in Fig. 801.of valve Surface shall not exceed 4 micro inch (0.1 micron). There shall be no evidence of sticking or rough operation. If necessary, perform a light lapping operation using jewelers rouge. Do not destroy close tolerance fit specified in Fig. 801 Thoroughly clean parts after lapping. Replace valve block if it cannot pass this check. Replace valve block if hole or groove is damaged.
Check opera- Visual. tion of spool in valve block
Valve Block and Bearing Subassem bly (75, IPL Fig. 2)
Cracks. Check for damaged locating pin hole and/or sealing groove.
Magnetic particle. Refer to paragraph 3A Visual.
General Check Requirements Figure 501 (Sheet 2)
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PART NO 971533
PART Valve Block and Bearing Subassembly (75, IPLFig. 2)
CHECK Check for wear and damage on valving surface that mates with cylinder.block (185Fig. 2)
METHOD Surface flatness tester and surface finish analyzer. Refer to paragraphs 3C and 3D.
REQUIREMENT Surfaces shall be flat within three helium light bands and have a surface finish not exceeding four micro inch (0.1 micron Lap face as instructed in REPAIR. After lapping part shall meet dime sions specified in Fig. 801. Remove any evidence of bronze smearing by lapping as instructed in REPAIR. Nital etch surface as called for in CHECK paragraph 3I to assure that localized annealing has not occurred. If annealing has occurred, additional lapping will be required to remove discolored area. Replace part if it cannot meet requirements specified in Fig.801. Replace part if it fails this check.
Check for bronze smearing on mates with cylinder block (185).
Visual.
Mating Ring (110, IPL Fig. 2)
Cracks.
Magnetic particle. Refer to paragraph 3A.
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PART NO 971533
PART Mating Ring(110, IPLFig.2) (Contd)
CHECK Check for wear or damage on sealing face that mates with seal element (125)
METHOD Surface flatness tester and surface finish analyzer. Refer to paragraphs 3C and 3D.
REQUIREMENT Surface shall be flat within four helium light bands and have a surface finish not exceeding four micro inch (0.1 micron) If necessary, lap part as instructed in REPAIR. After lapping, part shall meet dimensions specified in Fig. 801. Replace or grind spacer (300) to obtain dimension specified in Fig. 801. Refer to ASSEMBLY, paragraph 4F Replace part if it cannot pass this check. Replace part if it cannot meet requirements specified in Fig801 Cracks that destroy soundness of part will require replace unless it can be repaired as called for in REPAIR.
Shaft Seal Subassembly (120,IPL Fig. 2) Seal Element (125, IPL Fig. 2)
Check for proper height of assembled subassembly under load. Cracks.
Spring load tester. Refer to paragraph 3H.
Fluorescent penetrant. Refer to paragraph 3B. wave Spring load tester. Ref to for paragraph 3H.
Wave Check Spring spring (145, IPL fatigue Fig. 2) Housing and Inserts Subassembly (155,IPL Fig. 2) Cracks.
Fluorescent penetrant.Refer to paragraph 3B
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PART NO 971533
PART Housing and Inserts Subassembly (155 IPLFig.2) (contd) Actuator Piston (175,IPL Fig. 2) Cylinder Block (180IPL Fig. 2)
CHECK Check for piston (175) wear in bore ID for actuator.
METHOD Surface finish analyzer and standard visual amplifier.
REQUIREMENT Bore shall be free of abrasions and have a surface finish of 32 micro inch (0.8 micron).Replace housing if ID dimensions specified in Fig. 801 cannot be met Surface finish shall not exceed eight micro inch (0.2 micron).Replace part if it cannot meet dimensions specified in Fig. 801 Replace part if it fails to pass this check. Replace cylinder block if piston bores cannot meet dimensions specified in Fig. 801.
Check piston for wear and scoring.
Surface finish analyzer and standard visual amplifier. Refer to paragraphs 3D and 3E. Fluorescent penetrant Refer to paragraph 3B. Use air gage spindle T415408 and air gage rings T-108684 and T-219352. See Fig. 503 and refer to paragraph 3E. Surface flatness tester and surface finish analyzer. Refer to paragraphs 3C and 3E
Cracks. Check piston bore ID for wear.
Check for we ar or damage on valving face that mates with valve block(60)
Surface shall be flat within four helium light bands and have a surface finish not exceeding 4 micro inch (0.1 micron). Lap face as instructed in REPAIR paragraph 8A. After lapping part shall meet dimensions specified in Fig. 801
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PART NO 971533
PART Cylinder Block (180, IPL Fig. 2) (contd) Spring (195,IPL Fig. 2) Retainer Plate (215,IPL Fig. 2)
CHECK Check for wear on internal splines. Check spring for distortion and fatigue. Cracks.
METHOD Use standard 0.0540 inch (1.372 mm) diameter pin gages and standard gage blocks. Spring load tester. Refer to paragraph 3H. Fluorescent penetrant.Refer to paragraph 3B. Surface flatness tester and surface finish analyzer. Refer to paragraphs 3C and 3E
REQUIREMENT Replace cylinder block if not within limits specified in Fig 801. Replace spring if it cannot meet limits specified in Fig. 80l. Replace part if it fails to pass this check. Surface shall be flat within 0.001 inch (0.03 mm) and have surface finish not exceeding 16 micro inches (0.4 micron). Lap face as instructed in REPAIR After lapping, part shall meet dimensions specified in Fig. 801 Plate thickness shall not be less than 0.005 inch (0.13 mm). Replace part if it cannot pass this check.
Check for wear or damage on bronze face
Bronze plate thickness. Piston Shoe Retaining Plate (220,IPL Fig. 2) Cracks.
Plating thickness tester Refer to paragraph 3G Magnetic particle. Refer to paragraph 3A
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PART NO 971533
PART Piston Shoe Retaining Plate (220, IPL Fig.2) (Contd)
CHECK Check for flatness and finish on both sides.
METHOD Surface flatness tester and surface finish analyzer. Refer to paragraphs 3C and 3E.
REQUIREMENT Both surfaces shall be flat within 0.0002 inch (0.005 mm) and finish shall not exceed 16 micro inch (0.4 micron). If necessary lap part as instructed in REPAIR After lapping, part shall meet dimensions specified in Fig. 801. Refer to ASSEMBLY for selection of part thickness. Piston surface finish shall not exceed eight micro inch (0.2 micron). Replace piston and shoe subassembly if it can not meet tolerances specified in Fig. 801. Surface finish shall not exceed eight micro inch (0.2 micron). If necessary, lap surface as instructed in REPAIR.After lapping, be sure all piston and shoe subassemblies meet tolerances specified in Fig. 801.
Piston and Shoe Subassembly (225,IPL Fig. 2)
Check for scoring and wear on piston OD
Surface finish analyzer and standard visual amplifier Refer to paragraphs 3D and 3E. Surface finish analyzer Refer to paragraph 3D.
Check piston shoe surface that mates with shoe bearing plate (230) for finish and wear.
Check end play between piston and shoe.
End play checking tool End play shall not exceed T-441647. See Fig. 505. tolerance dimensions specified in Fig. 801. If tolerances are exceeded, replace subassembly
NOTE: When replacing individual piston and shoe subassemblies, observe shoe thickness as specified in REPAIR General Check Requirements Figure 501 (Sheet 7)
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PART NO 971533
PART Shoe Bearing Plate (230,IPL Fig. 2)
CHECK Cracks.
METHOD Magnetic particle. Refer
REQUIREMENT Replace part if it cannot meet this check to paragraph 3A.
Check for flatness and wear on face that mates with piston and shoe subassemblies.
Surface finish analyzer. Refer to paragraph 3D.
Surface shall be flat within four helium light bands, parallel with back side within 0.0002 inch (0.005mm) and have a surface finish not exceeding four micro inch (0.1 micron). If necessary, lap part as instructed in REPAIR. After lapping, part shall meet dimensions specified in Fig. 801. Replace part if it cannot pass this check. OD of trunnions shall meet tolerance dimensions specified in Fig. 801. Surface finish shall not exceed 32 micro inch (0.8 micron) as specified in 801.Fig. 801. Ball shall be secure in yoke.
Yoke, Ball and Pin Subassembly (240,IPL Fig. 2)
Cracks Check wear and surface finish on trunnions for pintle bearings (235) Check security of ball that mates with spring guide (255).
Magnetic particle. Refer to paragraph 3A. Surface finish analyzer and standard visual amplifier.Refer to paragraphs 3D and 3E
Visual.
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PART NO 971533
PART Yoke, Ball and Pin Subassembly (240, IPLFig. 2)(Contd) Outer Yoke Spring (260,IPL Fig. 2) Inner Yoke Spring (265,IPL Fig. 2) Drive Shaft (290, IPLFig. 2)
CHECK Check locating pin extension and shoe bearing plate (230) parallelism. Check spring for distortion and fatigue. Check spring for distortion and fatigue. Cracks. Check internal splines for wear. Check external splines for wear Visual.
METHOD
REQUIREMENT Measurements shall meet tolerance dimensions specified in Fig. 801.
Spring load tester. Refer to paragraph 3H.
Replace part if it fails check specified in Fig. 801
Spring load tester. Refer to paragraph 3H
Replace part if it fails check specified in Fig. 801.
Magnetic particle. Refer to paragraph 3A. Use standard 0.05774 inch (1.466 mm) diameter pin gages and standard gage blocks. Use standard 0.0600 inch (1.524 mm) diameter pin gages
Replace part if it cannot pass this check. Replace drive shaft if dimensions between pins exceed limits specified in Fig. 801. Replace drive shaft if dimensions over pins, is less than limits specified in Fig. 801.
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PART NO 971533
PART Drive Shaft (290, IPL Fig. 2) (Contd)
CHECK Check diameter of surface that mates with needle bearing (90). Check diameter of surface that mates with ball bearing (275) and 3E.
METHOD Surface finish analyzer and standard visual amplifier.Refer to paragraphs 3D and 3E Surface finish analyzer and standard visual amplifier Refer to paragraphs 3D Fluorescent penetrant Refer to paragraph 3B.
REQUIREMENT Replace drive shaft if surface finish exceeds eight micro inches (0.2 micron) or diameter is less than limit specified in Fig. 801. Replace drive shaft if surface finish exceeds 16 micro inches (0.41 micron) and/or diameter is less than limit specified in Fig. 801. Replace part if it cannot pass this check.
Mounting Flange Subassembly (295, IPLFig. 2)
Cracks.
Check for loose or damaged inserts. Check for worn or damaged bores for pintle bearings
Visual.
Replace loose or damaged inserts.Refer to REPAIR. Replace part if it cannot meet dimensions specified in Fig. 801.
Standard bore gage
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PART NO 971533
PART Mounting Flange Subassembly (295,IPLFig.2) (Contd)
CHECK Check surface finish of mating ring (110) bore. Check for damage in seal groove area. Check for damaged case, connector or terminals
METHOD Surface finish analyzer.Refer to paragraph 3D Visual.
REQUIREMENT Replace part if it cannot meet dimensions specified in Fig.801 Replace part if damage cannot be repaired without affecting sealing ability. Replace filter if defective.
RFI Filter (40,IPL Fig. 3)
Visual.
CAUTION: DO NOT HI-POT FILTER, INTERNAL RFI FILTER CAPACITORS WILL BE DAMAGED Thermostat (75, IPLFig. 3) Check for physical damage and continuity. Check for dents, cracks or broken welds Check for dents, cracks or broken welds. Visual and ohmmeter. Replace thermostat if defective Thermostat is normally closed Replace shroud if defective
Shroud (120, IPL Fig. 3)
Visual.
Cover (135, IPLFig 3)
Visual.
Replace cover if defective.
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PART NO 971533
PART Fan (160,IPL Fig. 3)
CHECK Check for chipped, cracked or broken blades. Check for cracks or discoloration Brush guides for damage. Spring tension.
METHOD Visual and fluorescent penetrant. Refer to para graph 3B.
REQUIREMENT Replace fan if defective.
Brush Holders (190, IPL Fig. 3)
Visual.
Replace part if cracked or discolored Replace part if damage is noted Replace spring if spring tension is not within 28 to 35 ounces (794 to 992 gm).
Visual. Spring scale.
NOTE: To check springs, connect a scale to spring and pull straight out until contact point of spring is in line with top of brush guide Commutat or End Bell (230, IPL Fig. 3) Check for cracks or other damage Check bore ID of bear ing (225A) for wear Check for worn, pitted or burned commutator bars Visual. Replace end bell if defective. Replace part if bore exceeds limits specified in Fig. 801 Replace part if it cannot be repaired as outlined in REPAIR paragraph 10. Must meet requirements specified in Fig. 801 after repair.
Micrometer.
Armature (235, IPL Fig. 3)
Visual.
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PART NO 971533
PART Armature (235, IPL Fig. 3) (Contd)
CHECK Check for damage to windings, banding material or shaft. Visual.
METHOD
REQUIREMENT Replace part if damage is noted.
(1) Check armature for shorted turns, using a growler. Hold a piece of steel (such as hacksaw blade) loosely on core of armature,move it slowly all the way around core while growler is energized. Turn armature as required. If piece of steel is attracted to any point in armature, there is a short circuit, replace armature. (2) Hi-pot armature between commutator and shaft with 600 VAC RMS, 60Hz for 1.0 second. If armature fails this test replace armature. Field Housing Assembly (240, IPLFig. 3) Check for cracks, burned or damaged Check for loose pole shoes, damaged coils and frayed wires. Visual. Replace part if damage is noted.
Visual.
Replace part if It is defective.
NOTE: If above checks are satisfactory, perform the following electrical check: Hi-Pot field coils from No.10 AWG white wire to field housing with 600 VAC RMS, 60 Hz for 1.0 second. Replace field housing if it fails this check. General Check Requirements Figure 501 (Sheet 13)
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PART NO 971533
PART Drive End Bell (250, IPL Fig. 3)
CHECK Check for cracks or other damaged. Check bore ID for bearing (245A) for wear. Visual.
METHOD
REQUIREMENT Replace end bell if defective,except studs which may be replaced individually if dam aged. Replace end bell if bore exceeds limits specified in Fig. 801.
Micrometer.
Measurement of Light Bands Figure 502
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PART NO 971533
Measuring Cylinder Block Bores Figure 503
Measuring Piston Size Figure 504
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PART NO 971533
Measuring Piston and Shoe End Play Figure 505
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PART NO 971533
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PART NO 971533
REPAIR
1. General. A. The consumable materials listed in tabular form in Table 601 are required during repair operations called for in this manual. Equivalent substitutes may be used. TYPE OR GRADE 9 micron
MATERIAL Polishing Paper Alodine (MIL-A-8625) Lapping powder (Aluminum oxide) Onion Skin Paper Lapmaster powder Lubricant Loctite
AVAILABILITY Commercially available Commercially available Commercially available Commercially available Lapmaster InternationalInc.Morton Grove, Illinois Commercially available Loctite Aerospace 2850 Willow Pass Road P. O. Box 312, Bay Point, CA 94565-0031 Beacon Chemical Co. Mt. Vernon, N.J. Beacon Chemical Co. Mt. Vernon, N.J. Commercially available Ablap Corp., Franklin, PA Abrasive Diamond Tool Co.Madison Heights, M Commercially available
12.5 micron grit 25% Cotton Fiber 1800 MIL-L-17672 A
Epoxy resin Curing Agent Solvent, Dry cleaning Lapping Plate Diamond Lapping Compound EPO Dynaweight Balancing Compound
Magna-Tac M-611 CH-16 P-D-680 Diamond Matrix (3000 Mesh) USBS #6
Repair Material Table 601
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PART NO 971533 B. Parts which fail to meet requirements as specified in CHECK shall be repaired or replaced. Damaged or worn parts which cannot be restored to serviceability following the instructions in this section, shall be replaced. C. Parts which have been repaired must conform to dimensional requirements of Table 801 after repair. 2. Special Tools. Tooling and test equipment other than those herein specified may be used provided they perform the required operations. Table 602 is a list of special tools, fixtures and equipment used during repair. T-443826 8DL-3000 Mesh 5-005-2-0015 Gang Lap Fixture Three Cornered Scrapper Ablap Lapping Plate Lapping Machine Ceramic Polishing Plate Arkansas Stone List of Special Tools, Fixtures and Equipment Table 602 NOTE: Always use the proper tool for the job. Be sure wrenches fit properly on nuts or bolt heads. Do not use pliers to remove nuts or bolts. Do not use screwdrivers to separate mating parts. Use a soft faced rod or mallet for tapping around binding areas. 3. Use of Polishing Paper. CAUTION: WHEN POLISHING PAPER IS USED, DO NOT POLISH NON-STEEL METAL PARTS ON PAPER THAT HAS BEEN USED FOR STEEL BECAUSE STEEL PARTICLES RETAINED IN THE PAPER WILL DAMAGE A NON-STEEL SURFACE. Dress down minor scratches or burrs on operating parts with polishing paper 9micron, or equivalent, or Arkansas stone. 4. Welding. CAUTION: THIS PROCESS MAY CAUSE SIGNIFICANT DISTORTION TO CASTINGS. A. Repair of aluminum alloy castings may be made by aluminum welding per Specification SAE AMS-STD-2219 and finishing to size.
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PART NO 971533 B. Check all machined surfaces before and after welding for possible distortion caused by the welding operation. C. Refer to CHECK, paragraph 3B for fluorescent penetrant procedures to follow after a welding operation has been performed. D. Refer to paragraph 5 for protective finishing of exposed metal surfaces. 5. Protective Finish. WARNING: TO AVOID INJURY, OPERATORS SHOULD WEAR PROTECTIVE CLOTHING TO AVOID CONTACT WITH ALODINE SOLUTION. A. Refinish aluminum surfaces that have had their protective coatings removed by applying alodine solution. B. Proceed as follows: (1) Clean repaired area with cleaning solvent. (Ref. CLEANING). (2) Rinse thoroughly with water to remove solvent. WARNING: EQUIPMENT USED TOAPPLY ALODINE SOLUTION SHOULD NOT BE ALLOWED TO DRY OUT. IF ALLOWED TO DRY, THEY MAY CONSTITUTE A FIRE HAZARD. (3) Apply alodine solution with brush, sponge or rag. (4) Allow solution to remain on surface from one to five minutes to allow color to match adjacent areas. (5) Remove excess solution by flushing with clean water. (6) Allow a minimum of one hour to dry before handling repaired surface. 6. Repair of Inserts. A. Do not remove inserts unless loose or damaged. If removal is necessary, a standard Helicoil kit provides the necessary means for insert removal. If such a kit is not available, inserts may be removed as follows: (1) Insert proper sized, three-cornered scraper into insert. (2) After getting a good solid fit, turn insert out of housing. (3) Air blow bore.
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PART NO 971533 7. Lap Steel Parts as Follows: A. Mating Ring (110, IPL Fig. 1) (1) If surface is badly scored or worn and sufficient surface stock is available, lightly grind it before lapping. (2) If part is to be lapped by hand, use a grooved lapping plate. If it is to be lapped on a lapping machine, use a lapping plate without grooves. (3) The lapping compound consists of one (1) U.S. pound of 12.5 micron grit aluminum oxide, Lapmaster powder #1800 (product #0006), Lapmaster International-Inc. or equivalent and one (1) gallon of lubricant (MIL-L-17672). (4) Apply a small amount of compound to surface, and using a circular motion, lap it in such a manner that the whole working face of lapping plate is used. CAUTION: EXCESSIVE POLISHING WILL ERODE OUTER EDGES OF PART AND MAY DESTROY HYDRAULIC BALANCE BY REDUCING EFFECTIVE SEALING AREA. NOTE: When lapping parts on a lapping plate and using lapping compound, the lapped surface will become impregnated with the compound. After lapping, thoroughly brush lapped surface using a soft bristle brush in a soap and water solution. Rinse off soap solution and dry part. Follow this operation by cleaning part in a sonic or ultrasonic cleaner. (5) Clean and finish polish the part on 9 micron polishing paper tightly drawn over a surface plate. (6) After polishing, thoroughly clean part as instructed in CLEANING and check flatness and surface finish of lapping operations as instructed in CHECK. After this, check edges of lands or other openings in lapped face for possible burrs or feather edges raised by lapping operation. Remove these burrs but leave edge square. Clean again after this operation. 8. Lap Non-Steel Parts as Follows: A. Shaft Seal Element (125, IPL Fig. 2). NOTE: Lapping of non-steel parts on a lapping machine with lapping compound, the same as for steel parts as specified in paragraphs 7C and 7D, is acceptable. However, special attention shall be given to cleaning the part after lapping operation. (1) If needed, lap part on a lapping machine as called for in paragraphs 7C and 7D,except limit time on the machine to four or five cycles. Clean part per CLEANING section.
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PART NO 971533 (2) Touch lap sealing element on a diamond matrix (Ablap) polishing plate (3000 mesh) to restore flatness and remove the residual aluminum oxide contamination. (3) Finish polish part on a flat, clean ceramic polishing plate or 9 micron polishing paper. Use a circular motion and change hand hold on part every few circles. Use a ceramic polishing plate manufactured by Lapmaster International, Morton Grove, Illinois, their number 5-005-2-0015 (or equivalent). CAUTION: DO NOT POLISH THE PART ON A STONE OR PAPER THAT HAS BEEN USED FOR METAL PARTS. THE METAL PARTICLES RETAINED IN SUCH A STONE OR PAPER WILL DAMAGE THE PART. (4) After polishing part, clean it as instructed in CLEANING. Check for possible burrs or feather edges raised by the lapping and polishing operation. Remove these burrs. Check accuracy of lapping operation as instructed in CHECK. Clean part again after this operation. B. Cylinder Block (180, IPL Fig. 2) and Retainer Plate (210). (1) If needed, lap part on a lapping plate as called for in paragraphs 7C and 7D. NOTE: Lapping of non-steel parts on a lapping machine with lapping compound, the same as for steel parts as specified in paragraph 7 is acceptable.However, special attention shall be given to cleaning the part after lapping operation. (2) Thoroughly clean the part as instructed in CLEANING. CAUTION: DO NOT POLISH NON-STEEL METAL PARTS ON PAPER THAT HAS BEEN USED FOR STEEL. STEEL PARTICLES RETAINED IN THE PAPER WILL DAMAGE A NON-STEELSURFACE. IN ADDITION, EXCESSIVE POLISHING WILL ERODE THE OUTER EDGES OF THE PART AND MAY DESTROY HYDRAULIC BALANCE BY REDUCING THE EFFECTIVE SEALING AREA. (3) Finish polish parts on 9 micron polishing paper, tightly drawn over a surface plate. (4) Measure thickness of bronze plating on retainer plate (180) as called for in CHECK. Plating thickness shall not be less than 0.005 inch (0.13 mm). (5) Check surface flatness and finish as called for in CHECK. Surface must conform to requirements specified in Figs. 501 and 801.
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PART NO 971533 C. Shoes of Piston and Shoe Subassemblies (225, IPL Fig. 2). CAUTION: GANG LAP FIXTURE T-443826 MUST BE USED WITH ITS GUIDE RING TO ENSURE THAT PARALLELISM OF SHOE FACE IS MAINTAINED. (1) Use gang lap fixture T-443826 as shown in Fig. 601 and a lapping plate. Refer to paragraph 7C and 7D for lapping. NOTE: All nine piston shoes must be lapped as a set to maintain their tolerancethickness (that area between shoe retainer plate (220, IPL Fig.2) and shoe bearing plate (230) of 0.0004 inch (0.010 mm) of each other. (2) After this operation, thoroughly clean part as instructed in CLEANING. (3) Finish polish part on 9micron polishing paper, tightly drawn over a surface plate.Again, clean the part.
Gang Lap of Piston Shoes Figure 601
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PART NO 971533 9. Replace Bonded Plates. A. If identification plate (55, IPL Fig. 1) or modification plate (60), rotation plate (315, IPL Fig. 2), instruction plate (320) or name plate (300, IPL Fig. 3) requires replacement, proceed as follows: B. If plates must be removed, place housing (not a complete motorpump assembly) in an electric oven preheated to 280 - 300 F (138 - 149 C) or maximum of 225 F (107C) for field housing (260, IPL Fig. 3) and heat part for a sufficient length of time to loosen the epoxy bond. Peel off plate. NOTE: Retain removed identification plate (55, IPL Fig. 1) so that data information can be transferred to new plate. C. After part has cooled, thoroughly clean area to receive new plate to remove residue bonding epoxy resin. If necessary, form plates to contoured surface prior to bonding. D. Use epoxy resin (Magna-Tac, M-611) and curing agent (CH-16), manufactured by Beacon Chemical Company, Mt. Vernon, NY 10550 (or equivalent) to bond new plates as follows: (1) Surfaces which have been painted (except those painted with epoxy paints) must be completely stripped. Thoroughly clean the surface to which plate is to be secured using a lint-free toweling moistened with dry-cleaning solvent (PD-680 or equivalent). Refer to any additional information supplied by the adhesive manufacturer to ensure a good bond. (2) Combine 100 parts by weight of epoxy resin with 32 parts by weight of Curing Agent CH-16 and thoroughly mix. (3) The components shall be weighed to an accuracy of 5 percent. (4) Apply adhesive to each of the surfaces to be bonded using a sufficient amount to fill the space between the parts after assembly. (5) Bring faying surfaces together and apply only sufficient pressure to cause adhesive to squeeze out around edges of plate. Maintain pressure until the adhesive is cured. (6) Remove excessive adhesive before curing by using a lint-free towel moistened with toluene, acetone, ketone, or equivalent solvent. (7) Cure adhesive-bonded joint at 150 F (65.5 C) for 60 minutes or allow to cure overnight at room temperature. (8) Exposed joints shall show a complete fillet line or ring of adhesive between component parts.
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PART NO 971533 10. Repair of Armature. A. Rough-Cut Commutator. (1) If inspection reveals that the commutator is rough, pitted, scored, or burned, refinish in a lathe that is accurately setup and adjusted. It is preferable to use a lathe that supports the armature on its bearing journals to ensure proper concentricity. Concentricity is extremely important for proper operation and life. (2) Remove only the material necessary to clean and true-up the commutator surface. Use a carbide tool to remove all grooves, pits, and other surface damage.After finishing the rough cut, check the commutator diameter to be sure it is not less than the minimum diameter of 1.900 inches (48.26 mm). If the commutator diameter is less than 1.900 inches (48.26 mm), it should be replaced. B. Undercutting Mica. Once the commutator has been rough cut, and is still larger than the minimum allowable diameter of 1.900 inches (48.26 mm), the mica should be undercut to a depth of 0.035/0.030 X 0.030 inch (0.89/0.76 X 0.76 mm) wide, following the original undercutting slots. C. Final Cut Commutator. The final cut is made with a diamond head cutting tool. The cutting point of the tool must be on the exact centerline of the commutator to a maximum of 0.002 inch (0.05 mm) below centerline (never above centerline). Use a light airflow to keep the chips off the commutator while it is being cut. Check concentricities and minimum allowable commutator diameter. Do not touch or otherwise contaminate the commutator after the final cut has been made. Cover with a clean oil-free paper until ready to reassemble. D. Balancing. After the commutator has been refinished, check the armature for proper balance, which should be within five-grain inches at each end. If balancing is required, add EPO Dynaweight Balancing Compound as required. 11. Repair of Field Housing. Other than repairing minor damage to insulation or tightening loose terminations, the field housing assembly must be replaced if defective.
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PART NO 971533 12. Replacement of Brushes. NOTE: New brushes must be properly seated on the commutator surface before starting performance testing. Proper brush seating is obtained when 100% contact is obtained in the direction of rotation and at least 90% in the axial direction. Motor run-in at reduced voltage, with a fan for cooling, will obtain brush seating in approximately ten hours at 12 VDC. 13. Sealing Kit PN 914926. The Sealing Kit contents for model MPEV3-008-6 (PN 971533) are listed in Table 603.
SEALING KIT - PN 914926

PART NUMBER 271085 271087 271128 271131 271135 271147 271157 283606 371687 971680 NOMENCLATURE PACKING,PREFORMED NAS1612-4 PACKING, PREFORMED NAS1612-6A PACKING, PREFORMED NAS1611-008 PACKING, PREFORMED NAS1611-011 PACKING, PREFORMED NAS1611-015 PACKING, PREFORMED NAAS1611-027 PACKING, PREFORMED NAS1611-118 GASKET GROMMET SEAL, MOLDED TABLE 603 IPL NUMBER 2-330, 2-340, 2-350 2-360 2-25 2-95, 2-10 2-40 2-90 2-115 1-20 2-130 2-275
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PART NO 971533 14. Overhaul Kit PN 914927. The Overhaul Kit contents for model MPEV3-008-6 (PN 971533) are listed in Table 604.
OVERHAUL KIT - PN 914927

PART NUMBER 211753 297009 332539 332956 342047 342245 571537 571538 622342 211753 NOMENCLATURE BEARING, BALL BEARING, ROLLER BEARING, ROLLER-NEEDLE WASHER, WAVE SPRING, HELICAL SPRING, HELICAL SPRING, HELICAL SPRING, HELICAL SPRING, HELICAL BEARING, BALL TABLE 604 15. Corrosion Reduction- Filter Box IPL NUMBER 2-285 2-235 2-80 2-145 2-135 2-50 2-265 2-260 2-195 2-285
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PART NO 971533
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PART NO 971533
ASSEMBLY
1. General. A. The consumable materials listed in Table 701 are required during assembly operations.Equivalent substitutes may be used. MATERIAL Fluid, Hydraulic, Skydrol 500-B4 Lockwire, Corrosion Resistant Round Steel Wire, Type 302, MS20995C20 and MS20995C32 Grease, Molybdenum Disulfide, MIL-G-21164 Dry, Cleaning Solvent, P-D-680 Retaining Compound (Loctite 242) Solder, Resin Core (60/40) PR-1440 B-2 (Sealant) AVAILABILITY Commercially available Commercially available
Commercially available
Commercially available Loctite Aerospace Bay Point, CA 94565-0031 USA Commercially available Products Research and Chemical Corp. Glendale, CA 91203 Assembly Materials Table 701
B. Use all new packings, backup rings, gaskets and bearings (if bearings were removed from their mountings). Lubricate packings and backup rings with hydraulic fluid before installation. C. Clean and lubricate all hydraulic pump parts in clean alkyl phosphate ester base hydraulic fluid just prior to assembly to provide initial pump lubrication. Also, in the case of screws, to assure more accurate torque readings. Refer to Table 801 for applicable torque values. D. The assembly area should be void of materials and equipment not directly associated with the assembly of these units. Normal room temperature and humidity conditions should prevail. Ventilation should be such that outside small particle debris is not allowed to settle in the area. The area should be isolated or removed from particle generating equipment such as grinders, lapping machines paint spray booths, sand blasting machines, etc. Good house keeping practices that assure minimum contamination should be maintained at all times.
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PART NO 971533 2. Special Tools, Fixtures and Equipment. Tooling and test equipment other than those herein specified may be used provided they perform the required operations. Table 702 is a list of special tools, fixtures and equipment used during assembly. T-300664 T-304106 T-304108 T-420868 T-424768 T-439664 T-443364 T-443827 Mechanical Positioner Adapter Holding Clamp Shaft Holder Grommet Guide Valve Plate Bearing Driver Assembly Fixture (Shaft Bearing) Assembly Fixture (Valve Block Bearing) Spring Compressing Tool List of Special Tools Table 702 NOTE: Always use the proper tool for the job. Be sure wrenches fit properly on nuts or bolt heads. Do not use pliers to remove nuts or bolts. Do not use screw drivers to separate mating parts. Use a soft faced rod or mallet for tapping around binding areas. 3. Assemble DC Electric Motor Subassembly. NOTE: The abbreviation IPL refers to ILLUSTRATED PARTS LIST of this manual. Refer to IPL Fig. 3 for parts identification during assembly of electric motor. A. Assemble Electric Motor. (1) Install front ball bearing (245A, IPL Fig. 3) and rear ball bearing (225A) on armature assembly (235). Use an arbor press and bearing press tool that applies pressure to bearing inner race only. (2) If removed, install new name plate (300) and/or warning placard (305). Refer to REPAIR. NOTE: Solder all terminals on electric wires using 60/40 resin core solder. (3) If removed, install terminals (295) on jumper wires (290) as required. (4) If removed, assemble brush holder assemblies (190) on commutator end bell (230) and secure with screws (275), lockwashers (280) and washers (285).
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PART NO 971533 5) If replacement of lead wires (25) is required, assemble grommet (35A), sleevings (30) and terminals (180 and 175) on lead wires, install lead wires and grommet into commutator end bell (230). NOTE: During installation, grommets (35A) are to be oriented so that they are not trapped under lip of assembly filter (40A). (6) Assemble brushes (185) shunts and terminals (175 and 180) on brush holder posts, and secure with locknuts (165) and washers (170). Do not install brushes into brush holders at this time. (7) Assemble commutator end bell (230) on field housing assembly (240). (8) Carefully install armature assembly (235) into field housing (240) and commutator end bell (230). (9) Install drive end bell (250), align with field housing (240) and commutator end bell (230) with scribe marks made during disassembly, and secure with bolts (215) and washers (220). Torque bolts to 30 to 35 pound inches (3.4 to 4.0 Nm). (10) Install shims (200, 205 and 210) and retaining ring (195) in commutator end bearing bore. Place motor between centers and check armature (235) end play with a dial gage. Add or remove shims to obtain 0.008 to 0.010 inch (0.20 to 0.25 mm) end play. NOTE: If same brushes (185) are to be re-used, be sure they are reinstalled in the same brush holder from which removed during disassembly. (11) Hold brush springs back with a hook, slide brushes into place in brush holders (190) and slowly release springs. NOTE: Be sure brush shunts and springs are positioned so they are clear andfree to move with brush wear and that all fasteners are secure. (12) If removed, install new set screws (255). B. Install Fan. (1) Carefully position fan (160) on armature (235) shaft, facing as shown in IPL Fig. 3. (2) Apply Loctite 242 to setscrew (155) threads and secure fan on armature shaft with setscrew. C. Install Front Shroud and Rear Cover Assembly. (1) If insulator (150, IPL Fig. 3) was removed, install new insulator in cover assembly (135) and secure with tape.
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PART NO 971533 (2) Position rear cover assembly (135) on commutator end bell (230) and secure with screws (140) and lockwashers (145). (3) Apply sealant, PR-1440 B-2, around screws (140) and lockwashers (145). (4) Carefully install front shroud (120 or 120A) on drive end bell (250) and secure with screws (125) and lockwashers (130). Torque screws 303 in lbs (3.4.34 Nm) Secure all four (4) screws together using lockwire (325) per MS33540. NOTE: Be sure mounting base is positioned parallel to hydraulic pump pad set screws (255). (5) Install mounting base (260) on electric motor and secure with screws (265A) lockwashers (270A) and flat washer (271). (6) Secure all four (4) screws together using lockwire (325) per MS33540. D. Install RFI Filter, Conduit and Connector Assembly. (1) If new lead wires (90 or 95, IPL Fig. 3) are to be installed, assemble new sleevings (115), terminals (110), contact bushings (315) and connector pins on new wires. (2) If removed, install lead wires (90 and/or 95) connector pins in bulkhead adapter (85). (3) Install bulkhead adapter (85) into filter (40A) and secure with adapter nut. (4) Install lead wires (90 and 95) on filter (40A) posts and secure with nuts (100A) and lockwashers (105). (5) If removed, solder thermostat (75) wires to connector pins using WRMAP-3 Sn 60,0.031 diameter solder. Use heatshrink (80) on solder connection for strain relief. Install a new thermostat (75) and secure with sleeving (80). See Fig. 701 for connector wiring diagram. (6) Install conduit (65) on electrical power leads sliding conduit over leads as shown in IPL Fig. 3 and connect female adapter (60) to bulkhead adapter (85). NOTE: Electrical connector tool set is required to insert pins in connectors. (7) Insert power lead connector pins into electrical connector (70).
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PART NO 971533 (8) Install RFI filter (40A) on cover assembly (135) and secure with screws (45) and lockwashers (50). (9) Apply sealant, PR-1440 B-2, to sealing area between RFI filter (40A) and cover assembly (135) and around screws (45) and lockwashers (50). (10) Install lead wires (25) on filter (40A) and secure with nuts (10A) and lockwashers (15). Install cap plugs (5) on nuts (10A). (11) Turn armature shaft slowly by hand. Armature shall rotate freely and smoothly. There shall be no evidence binding or roughness.
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PART NO 971533
Wiring Diagram Figure 701
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Page 706 Nov 15/04

PART NO 971533 4. Assemble Hydraulic Pump Subassembly. NOTE: The abbreviation IPL refers to ILLUSTRATED PARTS LIST of this manual. NOTE: Figure 702 provides a cross section view of the hydraulic pump subassembly. Use this figure for parts location and IPL Fig. 2 for parts identification. A. Assemble Mounting Flange Subassembly. (1) If rotation plate (315, IPL Fig. 2) and/or instruction plate (320) was removed or damaged, install a new plate to mounting flange (295) as instructed in REPAIR. (2) If removed, install two new aligning pins (300) in mounting flange. Be sure pins bottom in holes. (3) If removed, install new inserts (305 and 310) in mounting flange in accordance with MS33537 and remove tangs. B. Assemble Drive Shaft and Bearing Subassembly. (1) Place ball bearing (285, IPL Fig. 2) in an oven preheated to 275 F (135 C) maximum. Heat bearing for one hour. WARNING: TO PREVENT PERSONAL INJURY, USE PROTECTIVE GLOVES WHEN HANDLING HEATED PARTS. CAUTION: BE SURE BEARING SEATS FLUSH AGAINST SHOULDER ON DRIVE SHAFT. BEARING THRUST FACE SHALL BE AS SHOWN IN FIG. 702. (2) After ball bearing has attained the desired temperature, use bearing assembly fixture T-439664 mounted on an arbor press as shown in Figure 703 to seat drive shaft (290) into ball bearing (285). NOTE: Use of arbor press is only to assure proper seating of bearing. Do not force assembly of bearing to the shaft.
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PART NO 971533
Hydraulic Pump Cross Section View Figure 702 (Sheet 1 of 2)
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PART NO 971533 5. Coupling Shaft 10. Packing 15. Retaining Ring 20. Sealing Screw 25. Packing, Preformed 30. Nut, Locking 35. Adjusting Screw 40. Packing, Preformed 45. Guide, Spring 50. Spring 55. Seat, Spring 60. Valve Block and Spool 65. Screw Subassembly 70. Spool 80. Needle Bearing 85. Alignment Pin 90. Packing, Preformed 95. Packing, Preformed 100. Plate, Retainer 105. Screw 110. Ring, Mating 115. Packing, Preformed 125. Element, Shaft Seal 130. Grommet 135. Spring, Garter 140. Spacer, Shaft Seal 145. Spring, Wave 150. Retainer 155. Housing and Inserts Subassembly 160. Screw 165. Washer 170. Inserts 175. Piston, Actuator 180. Block, Cylinder 185. Ring, Retaining 190. Retainer 195. Spring 200. Seat 205. Screw 210. Washer 215. Retainer 220. Plate, Piston Shoe Retaining 225. Piston and Shoe Subassembly 230. Plate, Shoe Bearing 235. Bearing, Pintle 240. Yoke, Ball and Pin Subassembly 245. Pin, Locating 250. Insert 255. Guide, Spring 260. Spring, Outer 265. Spring, Inner 270. Seat, Control Spring 275. Packing, Preformed 285. Bearing, Ball 290. Shaft, Drive 295. Mounting Flange Subassembly 300. Pin, Aligning 305. Insert 310. Insert 315. Plate, Rotation 320. Plate, Instruction
Hydraulic Pump Cross Section View Figure 702 (Sheet 2 of 2) (3) After completing the assembly, allow parts to cool. Clean parts thoroughly in dry cleaning solvent P-D-680. Lubricate the ball bearing in clean hydraulic fluid. Slowly rotate the outer race of the bearing to assure it was not damaged during assembly. C. Calculate Cylinder Block End Play. (1) Attach mounting flange (295, IPL Fig. 2) to mechanical positioner adapter T-300664 (attached to power arm), position with mounting flange face horizontal and yoke ears Up. (2) Position drive shaft (290), with ball bearing (285) installed, in mounting flange (295) as shown in Fig. 703. CAUTION: IN THE FOLLOWING STEPS, USE CAUTION TO PREVENT DMAGE TO VALVING FACES OF VALVE BLOCK (60) AND CYLINDER BLOCK (180). Page 709 Nov 15/04
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PART NO 971533
Installing Drive Shaft Ball Bearing Figure 703 (3) Temporarily assemble retainer (190) and retaining ring (185) in cylinder block (180). Install these assembled parts down over drive shaft (290). Be sure retainer (190) is seated on drive shaft shoulder. (4) Temporarily assemble housing (155) onto mounting flange (2955). Secure with several screws (160) and washers (165). (5) Takemeasurements A and B (Fig. 704) in several locations to obtain an average difference between the two dimensions A and B). Use this difference to grind sufficient stock from spring side (flat side) of retainer (190) to provide 0.006 to 0.010 inch (0.15 to 0.25 mm) clearance between face of valve block (60) and cylinder block (180). Thickness of retainer (100) = B - A0.006 to 0.010 inch (0.15 to 0.25 mm). (6) Demagnetize and deburr retainer after grinding. Clean retainer as instructed in CLEANING. Tag retainer for subsequent use. (7) Disassemble housing (155), cylinder block (180) and drive shaft (290) from mounting flange.
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PART NO 971533
NOTE: Index numbers are the same as those shown on IPL Fig. 2. 60. Valve Block 155. Housing 180. Cylinder Block 185. Retaining Ring 190. Retainer 290. Drive Shaft 295. Mounting Flange
Cylinder Block End Play Measurements Figure 704
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PART NO 971533 D. Calculate Piston and Shoe Subassembly End Play. (1) If at parts inspection, it was found necessary to lap piston shoes, ensure the nine individual shoes were lapped within 0.0004 inch (0.010 mm) of each other. Refer to REPAIR for the lapping of piston shoes. (2) If locating pin (245, IPL Fig. 2) was removed from yoke (240) install a new pin ensuring pin extension from yoke face is 0.024 to 0.029 inch (0.61 to 0.73 mm). (3) Assemble bearing plate (230) into yoke, ensure recess on face of plate engages locating pin in yoke. (4) Test this assembly by pressing down on shoe bearing plate. If plate does not seat properly, recheck extension of location pin (245). (5)Takemeasurements X and Y, Fig. 705. Subtract Y from X, less 0.0015 to 0.0034 inch (0.038 to 0.086 mm). The resultant dimension will be used to determine the selection of shoe retaining plate (220) NOTE: index numbers are the same as those shown on IPL Fig. 2.
225. Piston & Shoe Subassembly 230. Bearing Plate 240. Yoke Measurements to Determine Piston Shoe Clearance Figure 705
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PART NO 971533 NOTE: Shoe retaining plates (220, IPL FIG. 2 through 220D) are graduated in thicknesses from standard through four oversizes (0.003, 0.005, 0.007 and 0.010 inch) (0.08, 0.13, 0.18 and 0.25 mm). Select the proper thickness of retaining plate that will provide piston shoe end play of 0.0015 to 0.0034 inch (0.038 to 0.086 mm) between bearing plate (215) and shoe retaining plate (185). (6) Tag shoe retainer plate (220, IPL Fig. 2) having the correct thickness for use in assembly. E. Assemble Yoke Subassembly and Associated Parts. (1) Assemble in order, control spring seat (270, IPL Fig. 2), inner and outer springs (265 and 260) and spring guide (255) in mounting flange (295) a shown in Fig.702. (2) Position yoke (240) in mounting flange with pivot ball seated in spring guide (255) recess. (3) Place assembled parts in holding clamp T-304106 as shown in Fig. 304. (4) Compress yoke springs (260 and 265) sufficiently to install pintle bearings (235). Install pintle bearing with thin edge on outer race facing the yoke and lip on inner race facing outward. (5) Remove from holding clamp and reinstall assembled parts on mechanical Positioner adapter and power arm. F. Assemble Piston and Shoe Subassembly. CAUTION: IN THE FOLLOWING OPERATIONS, USE CAUTION TO PREVENT DAMAGE TO PISTON AND SHOE SUBASSEMBLIES. DO NOT ALLOW PISTON TO STRIKE ONE ANOTHER OR OTHER METAL SURFACES. (1) Carefully assemble in yoke (240, IPL Fig. 2), shoe bearing plate (230), nine piston and shoe subassemblies (225), piston shoe retaining plate (220)(selected in paragraph 4D) and retainer (215) (with bronze face against yoke), and secure finger tight with screws (205) and washers (210). (2) Using a criss-cross method, torque screws (205) first to 10 to 12 pound inches (1.1 to 1.4 Nm) and then to 24 to 28 pound inches (2.7 to 3.2 Nm). G. Assemble and Install Cylinder Block. CAUTION: IN THE FOLLOWING STEPS,USE CAUTION TO PREVENT DAMAGE TO VALVING FACE OF CYLINDER BLOCK AND TO PISTON AND SHOE SUBASSEMBLIES.
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PART NO 971533 (1) Assemble in order, seat (200, IPL Fig. 2), cylinder block spring (195) and retainer (190) in cylinder block (180). NOTE: A retainer (190) of proper thickness was obtained in paragraph 4C, use this retainer in this assembly. (2) Using spring compressor T-443827 as shown in Fig. 303, compress spring (195) sufficiently to allow installation of retaining ring (185). Install retaining ring and remove cylinder block from spring compressor. (3) Carefully install cylinder block (180, IPL Fig. 2) with assembled parts on drive shaft (290) and piston and shoe subassemblies (225). (4) Test assembly by alternately pulling up and pushing down on cylinder block several times. Also rotate cylinder block. There shall be no evidence of binding or roughness. H. Assembly and Install Housing Subassembly and Associated Parts. (1) If removed, install new inserts (170, IPL Fig. 2) in housing in accordance with MS33537 and remove tangs. (2) Install actuator piston (175, IPL Fig. 2) in piston bore of housing (155). (3) Place finger over hydraulic passageway in housing, to retain actuator piston in housing, and carefully position housing on mounting flange (295). (4) Secure housing to mounting flange with screws (160) and washers (165) finger tight. (5) Using a criss-cross method, torque screws (160) first to 30 - 35 pound inches (3.4-4.0 Nm) and then 60 - 65 pound inches (6.8 - 7.3 Nm). (6) Install packing (95) in groove in housing. I. Install Valve Block and Spool Subassembly. (1) If removed, install a new alignment pin (85, IPL Fig. 2) in valve block (60). CAUTION: USE EXTREME CARE IN THE FOLLOWING STEP TO PREVENT DAMAGE TO VALVING FACE OF VALVE BLOCK. (2) Using assembly fixture T-443364 and bearing driver T-424758 as shown in Fig.706, install needle bearing (80) in valve block (60). Press needle bearing in flush or up to 0.010 inch (0.25 mm) below valving face. Do not bottom bearing in bore.
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PART NO 971533
Installation of Roller Bearing Figure 706 (3) Install packing (90) in groove in valve block pilot. (4) Install valve block (60) on housing (155) and secure with screws (65) finger tight. (5) Using a criss -cross method, torque screws (75) first to 30 - 35 pound inches (3.4 - 4.0 Nm) and then 60 - 65 pound inches (6.8 - 7.3 Nm). (6) Install spool (70) in valve block pressure compensator bore. J. Assemble Shaft Seal Subassembly. NOTE: Fig. 707 provides a cross section view of shaft seal subassembly. See this figure for parts location and IPL Fig. 2 of parts identification. CAUTION: USE CARE NOT TO SCORE SEALING DIAMETEROF DRIVE SHAFT IN THE FOLLOWING STEPS. (1) Measure depth of shaft seal cavity, dimension A, as shown in Fig. 707. (2) Subtract thickness of mating ring (110, IPL Fig. 2), dimension B, from depth of shaft seal cavity, dimension A, to obtain shaft seal working cavity, dimension C.
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PART NO 971533
100. Retaining Plate 110. Mating Ring 115. Preformed Packing 125. Shaft Seal Element
130. Grommet 135. Garter Spring 140. Shaft Seal Spacer 145. Wave Spring
150. Retainer 285. Bearing 290. Drive Shaft
Shaft Seal Subassembly, Cross Section View Figure 707 (3) Remove stock from shaft seal spacer (140) to obtain a shaft seal load of 8.0 -10.0 lbs. (3.63 - 4.53 kg) in the shaft seal working cavity dimension C. (4) Carefully install retainer (150) on end of shaft and bearing subassembly (280). Be sure tongue of retainer engage drilled holes in drive shaft properly. (5) Insert wave washer (145) and shaft seal spacer (140) into retainer (150). CAUTION: USE CARE WHEN HANDLING SHAFT SEAL ELEMENT (125). THIS PART HAS A LAPPED FACE THAT MATES WITH MATING RING (110). (6) Install garter spring (135) on grommet (130). Using shaft seal guide, T-420868, install grommet and spring on shaft. Remove seal guide from shaft and install shaft seal element (125) in retainer (150) on drive shaft. (7) Carefully install shaft seal element (1255) on shaft.
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PART NO 971533 CAUTION: USE CARE WHEN HANDLING MATINGRING (110). THIS PART HAS A LAPPED FACE THAT MATES WITH SHAFT SEAL ELEMENT (125). (8) Assemble preformed packing (115) on mating ring (110) and carefully install mating ring with chamfered OD against shaft seal element (125). (9) Install retainer plate (100) and secure with screws (105). Torque screws (105) to 14 - 15 pound inches (1.58 - 1.7 Nm). K. Assemble Pressure Compensator. (1) Assemble in order, spring seat (45, IPL Fig. 2), spring (50) and spring guide(45) in valve block (60) pressure compensator bore. (2) Install packing (40) on adjusting screw (35) and install adjusting screw in valve block. (3) Install locking nut (30) on adjusting screw. Torquing of locking nut and lockwiring will be performed in testing. (4) Install packings (25) on two sealing screws (20) and install screws in valve block.Torque screws 15 - 20 pound inches (1.7-2.3 Nm) and secure with lockwire (320)per MS33540. (5) Remove hydraulic pump from mechanical positioner adapter. L. Install Coupling Shaft. (1) Install packing (10, IPL Fig. 2) and retaining ring (15) on coupling shaft (5). (2) Fill drive shaft (290) coupling chamber one third full and coat coupling shaft splines with Royco C-201 grease. (3) Insert coupling shaft into drive shaft. Be sure retaining ring secures coupling shaft in place. M. Check Drive Shaft Rotation. (1) After completing the assembly of pump and before plugging inlet and outlet ports, test the assembly for freedom of drive shaft rotating. Shaft shall turn relatively free without an indication of binding at any point. (2) Plug outlet, seep drain, case drain and inlet ports with plugs (325, IPL Fig. 2, 335, 345 and 355) and packings (330, 340, 350 and 360).
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PART NO 971533 NOTE: If hydraulic pump is to be placed in storage for any length of time before testing and/or mating with electric motor, refer to paragraph 6. 5. Assemble Motorpump Assembly. NOTE: The abbreviation IPL refer to the ILLUSTRATED PARTS LIST of this manual. Refer to IPL Fig. 1 for assembly of hydraulic motorpump assembly. A. Assemble Shock Mount Subassemblies. CAUTION: DURING ASSEMBLY OF SHOCK MOUNT SUBASSEMBLIES (25), HOLD SHOCK MOUNT (45) WRENCHING FLATS TO PREVENT DAMAGE TO SHOCK MOUNT. (1) If shock mount subassemblies (25, IPL Fig. 1) were disassembled, thread stud (40) into shock mount (45) while holding mount by wrenching flats. (2) Torque studs 100 - 105 pound inches (11.3 - 11.9 Nm). Be sure to hold shock mounts by wrenching flats. (3) Install shock mount subassemblies on electric motor (50) footings and secure with nuts (30) and washers (35). Torque nuts 72 - 76 pound inches (8.1 - 8.6 Nm). Be sure to hold shock mounts by wrenching flats. B. Assemble Hydraulic Pump to Electric Motor. (1) Install gasket (20, IPL Fig. 1) on electric motor (50) mounting flange. (2) Fill electric motor drive shaft coupling chamber one third full and coat mating coupling shaft spline of pump (5) with grease MIL-G-21164. (3) Install hydraulic pump (5) on electric motor (50) mounting flange and secure with nuts (10) and washers (15). Torque nuts 72 - 76 pound inches (8.1 - 8.6 Nm).
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PART NO 971533 6. Storage After Assembly. A. Preservation. The following table lists items necessary for adequate storage of these hydraulic motorpump assemblies after repair and test. In addition to these items, each user will have established his own procedures for storage/shipment functions as they relate to his respective operations. PART NUMBER 186104 NAS1612-4 186104 NAS1612-4 186104 NAS1612-4 212662 NAS1612-6 Hydraulic Fluid NAME Plug, Outlet (Shipping) Packing, Preformed (Shipping) Plug, Seep (Shipping) Packing, Preformed (Shipping) Plug, Case Drain (Shipping) Packing, Preformed (Shipping) Plug, Inlet (Shipping) Packing, Preformed (Shipping) Alkyl Phosphate Ester Base Storage Material Table 703 B. Procedure. Fill to 90% capacity with recommended clean hydraulic fluid. Plug and cap all port openings. NOTE: Pump must be filled with fluid for corrosion prevention. Fluid from teststand can be used if cleanliness exceeds SAE AS4059, Class 7 level. If teststand fluid cleanliness levels are not maintained, flush and fill with clean fluid. C. Long Term Storage. The following recommendation outlines the steps necessary to provide satisfactory storage of units for periods of up to five years. Generally, replacement of synthetic rubber parts is not required during the storage period when these recommendations are followed. As a precautionary measure, seals should be changed in any units stored in excess of five years. QTY 1 1 1 1 1 1 1 1 AR
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PART NO 971533 (1) Newly cleaned and flushed units shall be filled to 90% capacity with fresh fluid. Fluid pressure shall be approximately at ambient. (2) Secure all plugs and caps. (3) Package to provide protection from routine handling and contamination. (4) Identify as necessary. Note date of storage and date for fluid renewal. (5) Each 60 months throughout the storage period, the fluid shall be drained, units flushed and refilled with new fluid. (6) As with any material containing synthetic rubber, storage conditions can be critical to the service life. Conditions to be avoided are: (a) Temperatures in excess of 75 F (24 C). (b) Excessive ozone-usually present in the vicinity of electric motors, welding equipment, etc. (c) Excessive sunlight and air circulation.
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PART NO 971533
THIS PAGE LEFT BLANK INTENTIONALL
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PART NO 971533
FITS AND CLEARANCES

1. Service Wear Limits. Table 801 lists all critical fits and clearances that must be maintained among the various parts during assembly of the hydraulic pump assembly. Illustrations (Fig. 801) are provided where necessary to clarify the location of the itemized dimension Fig. 801 Ref. Ltr. IPL Figure and Item No. 2-5
In-Service Wear Limits Name Coupling Shaft Both ends measured over standard 0.600 inch (1.524 mm) diameter pin gages: Compensator Spring Load at compressed height of: Load at compressed height of: Inches Millimeters
0.459 min. 1.008 inch at 37.0 1.9 lb.
11.66 min. 25.60 mm at 16.78 0.86kg.
2-50
23.75 mm at 0.935 inch 51.66 2.6 lb. 23.43 1.18 kg.
2-60 A
Valve Block and Spool Subassembly Diametral clearance between valve block bore and spool (70):
B C D
0.0004 max. 0.0014 to 0.0016
0.010 max. 0.036 to 0.041 0.10 micron
Surface finish on mating valving block bore and spool 4 micro inch OD: Surface finish of valving 4 micro inch face: 3 helium light Flatness of valving face: bands max. 0.5007 max. Needle bearing bore ID: Fits and Clearances Table Table 801 (Sheet 1 of 6)
0.1 micron 3 helium light bands max. 12.718 max.
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PART NO 971533 Fig. 801 Ref. Ltr. F G H I 2-120 IPL Figure and Item No. 2-110
In-Service Wear Limits Name Mating Ring Overall Thickness Sealing face flatness: Inches 0.266 min. 2 helium light bands max. Millimeters 6.76 min, 2 helium light bands max. 0.013 max. 0.05 micron
Sealing face parallel with 0.0005 max. back face within: Surface finish on sealing face: 2 micro inch Shaft Seal Subassembly Load at compressed height of 0.321 inch (8.15mm): (See Fig. 707 and refer to ASSEMBLY). Shaft Seal Element Sealing face extension: Sealing face surface finish: Overall thickness: Back face flatness within: Sealing face flatness: Surface finish on backface: 2-145 Spring Wave Washer Load at compressed height of 0.050 inch (1.27 mm):
Do not compress below:
9.0 1.0 lb.
4.08 0.45 kg.
2-125 J K L M N O
0.005 min. 4 micro inch 0.155 min. 0.0005 max. 3 helium light bands max. 16 micro inch
0.13 min. 0.1 micron 3.94 min. 0.013 max. 3 helium light bands max. 0.4 micron
9.0 1.0 lb. 0.041
4.08 0.45 kg. 1.04
2-155 P Q
Housing Subassembly Surface finish of actuator piston (175) bore: Clearance between piston bore ID and actuator piston (175) OD:
32 micro inch
0.8 micron
0.0013 max.
0.033 max.
Fits and Clearances Table Table 801 (Sheet 2)
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PART NO 971533 Fig. IPL 801 Figure Ref. and Ltr. Item No. 2-175 R S 2-120
In-Service Wear Limits Name Actuator Piston Surface finish of piston OD: Clearance between piston OD and housing bore ID: Cylinder Block (Measure piston bore size as shown in Fig. 503 (9 places)): Clearance between bore ID and piston OD: Center recess depth: Valving face flatness: Inches 8 micro inch 0.0013 max. Millimeters 0.2 micron 0.033 max.
T U V W X
0.0010 max. 0.005 min. 4 helium light bands max. 4 micro inch 0.3317 max. between 0.0540 diameter pins 0.450 inch at 30 3.0 lbs. 0.001 max. 16 micro inch 0.005 min.
0.025 max. 0.13 min. 4 helium light bands max. 0.1 micron 8.425 max. between 1.372 diameter pins 11.43 mm at 13.6 1.4 kg. 0.03 max. 0.4 micron 0.13 min.
Surface finish of valving face: Internal splines measured between standard diameter gage pins:
2-195
Spring (Cylinder Block) Load at compressed height of: Retainer Plate Surface flatness on bronze face: Surface finish on bronze face: Thickness of bronze plating: Piston Shoe Retaining Plate Both faces flat within: Surface finish (both faces): Fits and Clearances Table Table 801 (Sheet 3)
2-215 Y Z AA 2-220
0.0002 max. 16 micro inch
0.005 max. 0.4 micron
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PART NO 971533 Fig. IPL 801 Figure Ref. and Ltr. Item No. 2-225 AB AC AD AE AF AG AH
In-Service Wear Limits Name Piston and Shoe Subassembly Clearance between piston OD and ID bore of cylinder block: Surface finish on OD of piston: Piston-to-shoe end play: Surface finish on shoe bearing face: Surface finish on shoe to retainer plate (220) mating surfaces: Depth of shoe counter bore: Thickness of all shoes in one set within: Inches Millimeters
0.0010 max. 8 micro inch 0.005 max. 8 micro inch
0.025 max 0.2 micron 0.13 max. 0.2 micron
16 micro inch 0.005 min. 0.0004 max.
0.4 micron 0.13 min. 0.010 max.
2-230 AI AJ AK 2-240 AL AM AN
Shoe Bearing Plate Surface finish on shoe mating face: Flatness of shoe mating face: Surface parallel within: Overall thickness: Yoke, Ball and Pin SubassemblySurface finish on yoke trunnions: Diametral clearance between ID of pintle bearing (235) and OD of trunnion: Extension of locating pin (245): Fits and Clearances Table Table 801 (Sheet 4)
4 micro inch 4 helium light bands max. 0.0002 max. 0.057 min.
0.1 micron 4 helium light bands max. 0.005 max. 1.45 min.
32 micro inch
0.8 micron
0.0010 max.
0.025 max.
0.024 to 0.029 0.61 to 0.74
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PART NO 971533 Fig. IPL 801 Figure Ref. and Ltr. Item No. 2-260
In-Service Wear Limits Name Outer Yoke Control Spring Load at compressed height of 0.743 inches (18.87mm): Load at compressed height of 1.075 inches (27.31mm): Inner Yoke Control Spring Load at compressed height of 0.673 inches (17.09mm): Load at compressed height of 1.005 inches (25.53mm): Drive Shaft Internal splines measured between 0.0574 inch (1.4666 mm) pin gages: External splines measured over 0.0600 inch (1.524 mm) pin gages: AQ OD for needle bearing: AR OD for ball bearing: Mounting Flange Subassembly Diametral clearance between ID of mounting flange and OD of pintle bearings (220) Surface finish of mating ring (320) bore OD: Diametral clearance between ID of mounting flange and OD of shaft bearing (275) Commutator End Bell Bearing (225A) bore ID: Fits and Clearances Table Table 801 (Sheet 5) Inches Millimeters
28 2.8 lb. 8.0 0.8 lb.
12.7 1.3 kg. 3.63 0.36 kg.
2-265
7.0 0.7 lb. 2.0 0.2 lb.
3.17 0.32 kg. 0.91 0.09 kg.
2-290 AO
0.2896 max.
7.356 max.
AP AQ AR 2-295 AS AT AU
0.4836 min. 0.3118 min. 0.5905 min.
12.283 min. 7.920 min. 14.999 min.
0.0010 max. 32 micro inch
0. 025 max. 0.8 micron
0.0010 max. 1.2610 max.
0.025 max. 32.029 max.
3-230
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PART NO 971533 Fig. IPL 801 Figure Ref. and Ltr. Item No. 3-235
In-Service Wear Limits Name Armature Bar-to-bar concentricity within: Commutator-to-shaft concentricity within: Commutator diameter Drive End Bell Bearing (245A) bore ID: Fits and Clearances Table Table 801 (Sheet 6) Inches 0.0002 max. 0.0008 max. 1.900 min. Millimeters 0.005 max. 0.020 max. 48.25 min.
3-250
1.2610 max.
32.029 max.
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PART NO 971533
Fits and Clearances Figure 802 (Sheet 1 of 3)
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PART NO 971533
Fits and Clearances Figure 802 (Sheet 2)
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PART NO 971533
Fits and Clearances Figure 802 (Sheet 3)
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PART NO 971533 2. Torque Values. Table 802 lists all torque values that must be obtained to assure proper security of attaching parts during assembly of the motorpump assembly. NOTE: Lubricating threads of attaching parts with clean alkyl phosphate ester hydraulic fluid will assure a more accurate torque reading. IPL Fig. and Item No. 1-10 1-30 1-40 2-20 2-35 2-65 2-160 2-205 3-215 Nut Nut Stud, Shock Screw Screw, Compensator Adj. Screw Screw Screw Bolt Mounting Torque Item (Pound/Inch) 72 to 76 72 to 76 100 to 105 15 to 20 35 to 40 60 to 65 60 to 65 24 to 28 30 to 35 Torque Values Table 802 Newton Meters 8.1 to 8.6 8.1 to 8.6 11.3 to 11.9 1.7 to 2.3 4.0 to 45 6.8 to 7.3 6.8 to 73 2.7 to 3.2 3.4 to 4.0
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PART NO 971533
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PART NO 971533
SPECIAL TOOLS, FIXTURES AND EQUIPMENT

1. General. The following special tools and test equipment (Fig. 901) are recommended for the repair and test of this equipment. However, tooling and test equipment other than those listed may be used provided they perform the required operations. See Fig.902 for identification of tools
TOOL NO. NAME APPLICATION T-108684 Master Ring, Air Used with spindle T-415408 to check cylinder Gage block bores for wear. This ring calibrates low limit reading of air gage.See Fig. 503. T-219352 Master Ring, Air Gage Set, Flushing Adapter, Mechanical Positioner A Frame Test Stand Plate, Bearing Removal Driver, Bearing Used with spindle T-415408 to check cylinder block bores for wear. This ring calibrates low limit reading of air gage. See Fig. 503. Used to flush hydraulic pump before and after testing. Used with Power Arm to support hydraulic pump during ASSEMBLY and DISASSEMBLY. See Fig. 301. Used to secure unit during TESTING. Used with T-304104 driver to remove ball bearing (285) from pump drive shaft. See Fig. 305. Used with bearing removal plate T-304103 to remove ball bearing (285) from pump drive shaft. See Fig. 305. Used to remove needle bearing (80) from pump valve block. See Fig. 302. Used to compress control springs (260 and 265) to remove pintle bearings (235). See Fig. 304.
T-233247 T-300664
T-302537 T-304103
T-304104
T-304105 T-304106
Puller, Bearing Clamp, Holding
Special Tools, Fixtures and Equipment Table Figure 901 (Sheet 1 of 2)
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PART NO 971533
TOOL NO. T-304108 T-304165 T-330664
NAME Holder, Shaft Puller, Bearing
APPLICATION Used to hold drive shaft (290) while assembling shaft seal subassembly (120). See Fig. 708. Used to remove pintle bearings (235). See Fig. 302.
Adapter, Mechanical Used with Power Arm to support hydraulic pump Positioner during ASSEMBLY and DISASSEMBLY. See Fig. 301. Spindle, Air Gage Guide, Grommet Driver, Valve Plate Bearing Fixture, Assembly Fixture, End Play Check Test Plate Wrench, Spanner Fixture, Assembly Fixture, Gang Lap Outspreading Compression Used with air gage rings T-108684 and T-219352 to check bores in cylinder block (180). See Fig. 503. Used to install shaft seal grommet (130) on pump drive shaft. See Fig. 708. Use with assembly fixture T-443364 to install needle bearing (80) in valve block (60). See Fig. 709. Used with arbor press to install ball bearing (285) on pump drive shaft (290).See Fig. 704. Used to check end play of piston and shoe subassemblies (225). See Fig. 505. Used with T-302537 to secure unit during TESTING. Used to remove mounting feet. Used with bearing driver T-24768 to install needle bearing (80) into valve block (60). See Fig. 709. Used to lap shoes of piston and shoe subassemblies (225). See Fig. 602. Used to remove and install cylinder block spring (195) and retaining ring (185). SeeFig. 303.
T-415408 T-420868 T-424768 T-439664 T-441647 T-442698 T-442754 T-443364 T-443826 T-443827
Special Tools, Fixtures and Equipment Table Figure 901 (Sheet 2)
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PART NO 971533
Special Tools and Test Equipment Figure 902 (Sheet 1 of 3)
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PART NO 971533
Special Tools and Test Equipment Figure 902 (Sheet 2)
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PART NO 971533
Special Tools and Test Equipment Figure 902 (Sheet 3)
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PART NO 971533
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PART NO 971533
ILLUSTRATED PARTS LIST

1. Introduction. A. General. This Illustrated Parts List is applicable to the Variable Displacement Hydraulic Motor-pump Assembly, Part Number 971533 (Model Number MPEV3-008-6). The purpose of this list is to itemize the parts that comprise and are necessary for the support of these assemblies. It is intended for use in provisioning, requisitioning, storing and issuing replaceable parts. B. Detail Parts List. The Detail Parts List has been compiled in accordance with accepted procedure. In general, parts are listed in their order of disassembly and are indented to show their relationship to the next higher assembly. C. Part Numbering System. There is no relationship among Eaton-Vickers part numbers since they are assigned as referenced drawings are completed. A given subassembly, for instance, will not necessarily consist of numbers in sequence or in related groups. Numbers shown in the part number column are Vickers numbers, with the exception of AN, MS,NAS and Vendor supplied parts. When AN, MS or NAS numbers are shown in the part number column, Vickers equivalent numbers appear in the nomenclature column in parentheses, preceded by Vickers Code 62983. Vendor part numbers are identified by the vendors code (preceded by the letter V) immediately following the nomenclature when available. This, in turn, is followed by Vickers Code 62983 and the Vickers part number.
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PART NO 971533 D. Manufacturers Code and Name. The following list of codes arranged in numerical sequence reflects the names and addresses of manufacturers supplying items for the equipment in this publication. Vendors Code 54395 Vendors Name and Address Electromech Technologies 2600 South Custer Wichita, Kansas 62217 Eaton Aerospace Hydraulic Systems Div. 5353 Highland Drive Jackson, Mississippi 39206
62983
E. Explanation of Symbols and Abbreviations The abbreviation REF is used in the UNITS PER ASSEMBLY column in lieu of unit quantity. For the total quantity of the item (and all components of the item) refer to the first listing of the item. The abbreviation AR is used in the UNITS PER ASSY column to indicate the quantity of parts to use is As Required. The abbreviation NP is used in the Units Per Assembly column to indicate the parts are not procurable. 2. Numerical Index. The following numerical index is provided to assist the user in locating part numbers in the Detail Parts List. The index is compiled in accordance with accepted procedure.
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PART NO 971533 AIRLINE PART NO.
PART NUMBER AN3-54A MS35360-3252 AN363-428 AN565DC428H24 AN960-8 BPF-5/8 C004AA1420AC C007DX1420AC C120AA2420AC F2010A00 MIL-W-22759/41-6-9 MS16998-28 MS21083-N08 MS21209F0-620 MS21209F1-15 MS3456L24-12P MS3470L833P MS35206-245 MS35265-14 MS35265-27 MS35266-78 MS35275-215 MS35333-37 MS35333-39 MS35333-40
FIG. ITEM 3-215 3-10 3-100 1-10 1-30 3-255 3-170 3-285 3-5 3-60 3-85 3-55 3-65 3-90 3-95 2-65 2-160 3-165 2-250 2-310 2-170 2-305 3-70 3-51 3-275 3-52 3-45 3-140 3-265 3-52A 3-50 3-145 3-130 3-15A
TTL REQ. 4 2 2 4 4 4 4 4 2 1 1 1 1 1 1 4 8 4 8 4 4 8 1 NP 4 NP 2 4 5 NP 2 4 4 2
29-10-60
Page 1003 Nov 15/08

PART NUMBER MS35338-42 MS35338-43 MS35338-44 MS35489-93 MS35650-3252
FIG. ITEM 3-280 3-220 3-15 3-105 3-270 3-35 3-10A 3-100A 3-155 3-195 2-105 2-25 2-95 2-10 2-40 2-90 2-115 2-330 2-340 2-350 2-360 3-40 3-35A 3-40A 3-120 3-125 3-135 3-150 3-160 3-190 3-230 3-235 3-240
TTL REQ. 4 4 2 2 5 2 2 2 1 1 4 2 1 1 1 1 1 1 1 1 1 1 2 1 1 4 1 1 1 4 1 1 1
MS51964-49 N5000-125MD NAS1101E06-6 NAS1611-008/-008A NAS1611-011/-011A NAS1611-015/-015A NAS1611-027/-027A NAS1611-118/-118A NAS1612-4/-4A
NAS1612-6/-6A 48-11-7000-1 48-17-1001-1 48-18-7000-1 48-5-1009-2 48-5-1010 48-5-1001 48-1-1032 48-5-1005 48-5-3000 48-5-6001 48-5-2000 48-5-5000-1
29-10-60
Page 1004 Nov 15/04

PART NUMBER 48-5-4000 48-5-1006 55-14-3003-1 414-66 1250-1000-3 1250-1000-5 1250-1000-20 3100-1-065 7000 7017-02-10 7017-06-10 7022-10-00 7022-12-00 7028-02-1 7028-6-1 9000-17 9000-96 9000-18 9000-97 32994 33461 33465 34108 122658 152048 162442 186104
FIG. ITEM 3-250 3-260 3-185 3-305 3-200 3-205 3-210 3-75 3-300 3-30 3-115 3-25 3-290 3-80 3-310 3-225 3-225A 3-245 3-245A 3-175 3-295 3-20 3-110 3-180 2-205 2-15 2-185 2-325 2-335 2-345 2-285
TTL REQ. 1 1 4 1 AR AR AR 1 1 AR AR 1 2 AR 1 1 1 1 1 4 1 1 3 2 8 1 1 1 1 1 1
186159 See MS21209F1-15 211753
29-10-60
Page 1005 Nov 15/04

PART NUMBER 212662 217438 See MS21209F0-620 224946 See MS16998-28 248774 271085 See NAS1612-4 271087 See NAS1612-6 271128 See NAS1611-008 271131 See NAS1611-011 271135 See NAS1611-015 271147 See NAS1611-027 271157 See NAS1611-118 279326 283606 297009 312468 331495 331753 332539 332566 332956 342047 342211 342245 344947 344952
FIG. ITEM 2-355
TTL REQ. 1
2-85 2-300
1 2
2-30 1-20 2-235 2-70 2-45 2-20 2-80 2-150 2-145 2-135 2-55 2-50 2-315 2-320
1 1 2 NP 1 2 1 1 1 1 1 1 1 1
29-10-60
Page 1006 Nov 15/04

PART NUMBER 371687 388159 406746 417355 417355 570794 571500 571503 571509 571528 571529 571534 571537 571538 571588 622119 622137 622181 622182 622183 622184 622185 622186 622187 622262 622342 622556 623980 623981
FIG. ITEM 2-130 1-60 2-35 1-15 1-35 2-125 1-55 2-180 2-225 2-200 2-190 2-230 2-265 2-260 2-245 2-210 1-40 2-155 2-280 2-60 2-175 2-240 2-290 2-75 2-5 2-195 2-215 2-270 2-255
TTL REQ. 1 1 1 4 4 1 1 1 9 1 1 1 1 1 1 8 4 1 1 1 1 1 1 NP 1 1 1 1 1
29-10-60
Page 1007 Nov 15/04

PART NUMBER 624057 624058 624059 624060 624061 628040 914926 914927 971533 971676
FIG. ITEM 2-220 2-220A 2-220B 2-220C 2-220D 2-165 2-365 2-370 1-1 1-5 2-1 1-50 3-1 2-120 2-140 2-275 2-295 2-110 2-100 1-45 1-25
TTL REQ. 1 AR AR AR AR 8 AR AR REF 1 REF 1 REF 1 1 1 1 1 1 4 4
971677 971678 971679 971680 971681 971686 971687 972206 972209
29-10-60
Page 1008 Nov 15/04

PART NO 971533
Hydraulic Motorpump Assembly, Exploded View Figure 1
29-10-60
Page 1009 Nov 15/04

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 MOTORPUMP, D.C. ELECTRIC MOTOR DRIVEN HYDRAULIC PUMP ASSEMBLY (MODEL MPEV3-008-6) . HYDRAULIC PUMP SUBASSEMBLY (SEE IPL FIG. 2 FOR DETAILS) (ATTACHING PARTS) . NUT (62983 138116) . WASHER -- -- -- * * * -- -- -. GASKET . SHOCK MOUNT SUBASSEMBLY (ATTACHING PARTS) . NUT (62983 138116) . WASHER -- -- -- * * * -- -- -. STUD . MOUNT, SHOCK . MOTOR, SUBASSEMBLY, D.C. ELECTRIC (SEE IPL FIG. 3 FOR DETAILS) . PLATE, IDENTIFICATION . PLATE, MODIFICATION POST SB 971533-29-01 UNITS EFFECT PER CODE ASSY REF
FIG. PART ITEM NUMBER 11 971533
971676
10 15 20 -25
AN363-428 417355 283606 972209
4 4 1 4
30 35 40 45 50
AN363-428 417355 622137 342211 971677
4 4 4 4 1
55 60
331495 388159
1 1
- ITEM NOT ILLUSTRATED
29-10-60
Page 1010 Nov 15/08

PART NO 971533
Hydraulic Pump Subassembly, Exploded View Figure 2
29-10-60
Page 1011 Nov 15/04

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 PUMP, HYDRAULIC VARIABLE DELIVERY SUBASSEMBLY (SEE ITEM 5, IPL FIG. 1) . SHAFT, COUPLING . PACKING, PREFORMED (62983 271131) . RING, RETAINING . SCREW, SEALING . PACKING, PREFORMED (62983 271128) . NUT, LOCKING . SCREW, ADJUSTING . PACKING, PREFORMED (62983 271135) . GUIDE, SPRING . SPRING . SEAT, SPRING . VALVE BLOCK AND SPOOL SUBASSEMBLY (ATTACHING PARTS) . SCREW (62983 224946)
-- -- -- * * * -- -- --.
FIG. PART ITEM NUMBER 21 971676
UNITS EFFECT PER CODE ASSY REF
5 10 15 20 25 30 35 40 45 50 55 60
622262 NAS1611-011/ 011A 152048 331753 NAS1611-008/ 008A 279326 406746 NAS1611-015/ 015A 342211 342245 331495 622183
1 1 1 2 2 1 1 1 1 1 1 1
65 70 75 80 85 90 95 100 105
MS16998-28 312468 622187 332539 248774 NAS1611-027/ 027A NAS1611-011/ 011A 971687 NAS1101E06-6
4 NP NP 1 1 1 1 1 4
. . SPOOL . . VALVE BLOCK AND BEARING SUBASSEMBLY . . BEARING, NEEDLE . . PIN, ALIGNMENT . PACKING, PREFORMED (62983 271147) . PACKING, PREFORMED (62983 271131) . PLATE, RETAINER (ATTACHING PARTS) . SCREW (62983 971554)
29-10-60
Page 1012 Nov 15/08

PART NO 971533 AIRLINE PART NO. UNITS PER ASSY
FIG. PART ITEM NUMBER 2110 115 -120 125 130 135 140 145 150 155 971686 NAS1611-118/ -118A 971678 570794 371687 342047 971679 332956 332566 622181
NOMENCLATURE 1234567
-- -- -- * * * -- -- --
EFFECT CODE
160 165 170 175 180 185 190 195 200 205 210 215
MS16998-28 628040 MS21209F1-15 622184 571503 162442 571529 622342 571528 122658 622119 622556
.RING, MATING .PACKING, PREFORMED (62983 271157) . SHAFT SEAL SUBASSEMBLY . . ELEMENT, SHAFT SEAL . . GROMMET . . SPRING, GARTER . . SPACER, SHAFT SEAL . . SPRING, WAVE . . RETAINER . HOUSING AND INSERTS SUBASSEMBLY (ATTACHING PARTS) . SCREW (62983 224946) . WASHER
-- -- -- * * * -- -- --
1 1 1 1 1 1 1 1 1 1
8 8 4 1 1 1 1 1 1 8 8 1 1 AR
624057 220 -220A 624058
. .INSERT (62983 186159) .PISTON, ACTUATOR .CYLINDER BLOCK .RING, RETAINING .RETAINER .SPRING .SEAT .SCREW .WASHER .RETAINER .PLATE, PISTON SHOE RETAINING .PLATE, PISTON SHOE RETAINING (0.003 (0.08 MM) OVERSIZE)
29-10-60
Page 1013 Nov 15/04

PART NO 971533 AIRLINE PART NO. UNITS PER ASSY AR
FIG. ITEM 2-
PART NUMBER
NOMENCLATURE 1234567 .PLATE, PISTON SHOE RETAINING (0.005 (0.13MM) OVERSIZE) .PLATE, PISTON SHOE RETAINING (0.007 (0.18MM) OVERSIZE) .PLATE, PISTON SHOE RETAINING (0.010 (0.25MM) OVERSIZE) .PISTON AND SHOE SUBASSEMBLY .PLATE, SHOE BEARING .BEARING, PINTLE .YOKE, BALL, AND PIN SUBASSEMBLY . .PIN, LOCATING . .INSERT (62983 217438) .GUIDE, SPRING .SPRING, OUTER .SPRING, INNER .SEAT, CONTROL SPRING .PACKING, PREFORMED .SHAFT AND BEARING SUBASSEMBLY .. BEARING, BALL ..SHAFT, DRIVE .MOUNTING, FLANGE SUBASSEMBLY . .PIN, ALIGNING . .INSERT (62983 186159) . .INSERT (62983 217438) .PLATE, ROTATION .PLATE, INSTRUCTION .PLUG, OUTLET
EFFECT CODE
-220B 624059
-220C 624060
AR
-220D 624061
AR
225 230 235 240 245 250 255 260 265 270 275 -280 285 290 -295 300 305 310 315 320 -325
571509 571534 297009 622185 571588 MS21209F0620 623981 571538 571537 623980 971680 622182 211753 622186 971681 248774 MS21209F1-15 MS21209F0620 344947 344952 186104
9 1 2 1 1 8 1 1 1 1 1 1 1 1 1
2 8 4 1 1 1
29-10-60
Page 1014 Nov 15/04

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 .PACKING. PREFORMED (62983 271085) .PLUG, SEEP .PACKING, PREFORMED (62983 271085) .PLUG, CASE DRAIN .PACKING, PREFORMED (62983 271085) .PLUG, INLET .PACKING, PREFORMED (62983 271087) .KIT, SEALING .KIT, OVERHAUL UNITS EFFECT PER CODE ASSY 1 1 1 1 1 1 1 AR AR
FIG. PART ITEM NUMBER 2-330 -335 -340 -345 -350 -355 -360 -365 -370 NAS1612-4/ -4A 186104 NAS1612-4/ -4A 186104 NAS1612-4/ -4A 212662 NAS1612-6/ -6A 914926 914927
29-10-60
Page 1015 Nov 15/04

PART NO 971533
Electric Motor Subassembly, Exploded View Figure 3
29-10-60
Page 1016 Nov 15/04

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 MOTOR SUBASSEMBLY, D.C. ELECTRIC (SEE ITEM 50, IPL FIG. 1) (V54395 971677) . CAP PLUG (V54395 BPF-5/8) . NUT SUPSD BY ITEM 10A . NUT SUPSDS ITEM 10 . LOCKWASHER . TERMINAL (V54395 33461) . WIRE, LEAD (10--GAUGE BLK, 30 IN. (762 MM) LONG) (V54395 7022-10-00) . SLEEVING, NO. 2 (V54395 7017-02-10) . BUSHING, RUBBER SUPSD BY ITEM 35A . GROMMET (V54395 48-171001-1) SUPSDS ITEM 35 . FILTER ASSEMBLY (V54395 48-11-7000-1) SUPSD BY ITEM 40A . FILTER ASSEMBLY (V54395 48-18-7000-1) SUPSDS ITEM 40 (ATTACHING PARTS) . SCREW . LOCKWASHER -- -- -- * * * -- -- -. . CONNECTOR, ELECTRICAL . . SCREW SUPSD BY ITEM 52A . . SCREW SUPSDS ITEM 52 . ADAPTER, CONNECTOR (V54395 C120AA2420AC) UNITS EFFECT PER CODE ASSY REF
FIG. PART ITEM NUMBER 3 1 971677
5 10
3032681-300 AN345-416
2 2 2 2 1 1
10A MS35650-3252 15 20 25 MS35338-44 3032681-301 3032681-302
30 35
3032681-303 MS35489-93
AR 2 2 1
35A 3032681-304 40 3032681-305
40A 3032681-306
45 50 51 52
MS35265-27 MS35333-37 MS3470L833P MS35265-14
2 2 NP NP NP 1
52A MS35275-215 55 3032681-307
29-10-60
Page 1017 Nov 15/08

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 . ADAPTER, FEMALE (V54395 C004AA1420AC) . CONDUIT (V54395 F2010A00) . CONNECTOR . THERMOSTAT (V54395 3100-1-065) . HEATSHRINK (V54395 7028-02-1) . ADAPTER, BULKHEAD (V54395 C007DX1420AC) . WIRE, LEAD WHITE 30 IN. (762 mm) LONG) (P/N CORRECTION) . WIRE, LEAD WHITE 30 IN. (762 mm) LONG) (P/N CORRECTION) . NUT SUPSD BY ITEM 100A . NUT SUPSDS ITEM 100 . LOCKWASHER . TERMINAL (V54395 33465) . SLEEVING, NO. 6 (V54395 7017-06-10) . SHROUD, ASSEMBLY (V54395 48-5-1009-2) (ATTACHING PARTS) . SCREW (V54395 48-5-1010) . LOCKWASHER -- -- -- * * * -- -- -. COVER ASSEMBLY (V54395 48-5-1001) (ATTACHING PARTS) . SCREW . LOCKWASHER
. SETSCREW
FIG. PART ITEM NUMBER 3 60 65 70 75 80 85 90 3032681-308 3032681-309 MS3456L24-12P 3032681-310 3032681-311 3032681-312 MIL-W-22759/ 41-6-9 MIL-W-22759/ 41-6-9 AN345-416
UNITS EFFECT PER CODE ASSY 1 1 1 1 AR 1 1
95
100
2 2 2 3 AR 1
100A MS35650-3252 105 110 115 120 MS35338-44 3032681-313 3032681-314 3032681-315
125 130 135
3032681-316 MS35333-39 3032681-317
4 4 1
140 145 155
MS35265-27 MS35333-37
MS51964-49
4 4
1
29-10-60
Page 1018 Nov 15/08

PART NO 971533 FIG. PART ITEM NUMBER 3 160 165 170 175 180 185 190 195 3032681-324 200 205 210 215 220 -225 3032681-325 3032681-326 3032681-327 AN3-54A MS35338-43 3032681-328 MS51964-49 3032681-319 MS21083-N08 AN960-8 3032681-320 3032681-321 3032681-322 3032681-323 AIRLINE PART NOMENCLATURE NO. 1234567 . FAN (V54395 48-5-1005) . LOCKNUT . WASHER . TERMINAL (V54395 32994) . TERMINAL (V54395 34108) . BRUSH (V54395 55-14-3003-1) . ASSEMBLY, BRUSH HOLDER (V54395 48-5-3000) . RING, RETAINING (V54395 N5000-125MD) . SHIM (V54395 1250-1000-3) . SHIM (V54395 1250-1000-5) . SHIM (V54395 1250-1000-20) . BOLT . LOCKWASHER . BEARING, BALL (REAR) (V54395 9000-17) (SUPSD BY ITEM 3-245A) (PRE SB 971533-29-01) . BEARING, BALL (REAR) (V54395 9000-96) (SUPSDS ITEM 3-245) (PRE SB 971533-29-01) . END BELL, COMMUTATOR (V54395 48-5-6001) . ARMATURE ASSEMBLY (V54395 48-5-2000) . FIELD HOUSING ASSEMBLY (V54395 48-5-5000-1) . BEARING, BALL (FRONT) (V54395 9000-18) (SUPSD BY ITEM 3-245A) (PRE SB 971533-29-01) . BEARING, BALL (FRONT) (V54395 9000-97) (SUPSDS ITEM 3-245) (POST SB 971533-29-01) UNITS EFFECT PER CODE ASSY 1 1 4 4 4 2 4 4 1 AR AR AR 4 4 1
225A 3032681-329
230 235 240 245
3032681-330 3032681-331 3032681-332 3032681-333
1 1 1 1
245A 3032681-334
29-10-60
Page 1019 Nov 15/08

PART NO 971533 AIRLINE PART NOMENCLATURE NO. 1234567 . DRIVE END BELL ASSEMBLY (V54395 48-5-4000) . . BOLT . BASE, MOUNTING (V54395 485-1006) ATTACHING PARTS . SCREW SUPSD BY ITEM 265A . SCREW SUPSDS ITEM 265 . LOCKWASHER SUPSD BY ITEM 270A . LOCKWASHER SUPSDS ITEM 270 . WASHER, FLAT -- -- -- * * * -- -- -. SCREW . LOCKWASHER . WASHER . WIRE (12-GAUGE, BLACK (V54395 7022-12-00) 7 IN. (178 mm) LONG) . TERMINAL (V54395 32994) . DELETE . PLACARD, WARNING (V54395 414-66) . HEATSHRINK (.5) (V54395 7028-6-1) . BUSHING, CONTACT . WIRE, SAFETY . WIRE, SAFETY UNITS EFFECT PER CODE ASSY 1 4 1 5 5 5 5 5 4 4 4 2
FIG. PART ITEM NUMBER 3 250 255 260 265 3032681-335

AN565DC428H24
3032681-336 MS35266-78
265A MS35266-77 270 MS35338-44
270A MS35338-40 271 275 280 285 290 AN960-416L MS35206-245 MS35338-42 AN960-8 3032681-337
295 300 305 310 315 320 325
3032681-320 7000 3032681-340 3032681-341 MS3348-4-6 MS20995C32 MS20995C20
1 1 1 1 2 AR AR
29-10-60
Page 1020 Nov 15/08

PART NO 971533
29-10-60
Page 1021 Nov 15/04

CMM 29-10-60R03 Elec Hyd Pump

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CMM 29-10-60R03 Elec Hyd Pump

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Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Highlights, Page 1 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Highlights, Page 1 Nov 15/08

COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST

DC ELECTRIC MOTORPUMP ASSEMBLY PART NUMBER 971533 MODEL NUMBER MPEV3-008-6

Original Date July 30, 1996

Eaton Reference Only 910386

COPY RIGHT 2008 Eaton Aerospace All Rights Reserved

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page RR-1/RR-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page RTR-1/RTR-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page SBL-1/SBL-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Service Bulletin 971533-29-01 971533-29-02

Description Motor Bearing Product Improvement Reliability Improvement

Page SECR-1/SECR-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

TP-1 ROR-1 ROR-2 RTR-1 RTR-2 SBL-1 SBL-2 SECR-1 SECR-2

Testing and Trouble Shooting

LEP-1 LEP-2 LEP-3 LEP-4 TOC-1 TOC-2 INTRO-1 INTRO-2 1 2 3 4 5 6 7 8

Table of Contents Introduction Description and Operation

LEP-1 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

LEP-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Fits and Clearances

llustrated Parts List

Special Tools,Fixtures and Equipment

LEP-3 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page TC--1/TC--2 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page INTRO-1/INTRO-2 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Figure 1. Variable Displacement Hydraulic Motorpump Assembly

Page 1 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page 2 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Figure 2. Hydraulic Pump Cutaway

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page 4 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

MS3459L24-12P mates with MS3459L24-12S MS3470L833P mates with MS3476L833S

Pressure rise as displacement 150 psig (1034 kPa) is reduced to zero

Page 5 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Pump mating end

Page 6 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Explosion proof Terminal designationsPower connector Thermal switch.

With shroud connected to outside air.

Total dry weight of motorpump Operating altitude Fluid medium

Page 7 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

THIS PAGE LEFT BLANK INTENTIONALLY

Page 8 Nov 15/04

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

Page 101 Nov 15/08

Aerospace Operations Hydraulic Systems COMPONENT MAINTENANCE MANUAL

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