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COMPONENT MAINTENANCE MANUAL

COMPONENT MAINTENANCE MANUAL


WITH
ILLUSTRATED PARTS LIST

Position Pick-off Unit

Part Number
9028A0004-01

LIEBHERR-AEROSPACE LINDENBERG GmbH


(D9893)
Customer Service
P.O. Box 1363
88153 LINDENBERG
GERMANY
Fax: +49 (0)8381 46-4103
E-Mail: techpub.lindenberg@liebherr.com
SITA Code: FDHLEXD

TP1
49CC000092-04
Initial Issue: Feb 29/88 27-09-16 Revision No. 4
Sep 15/10
COMPONENT MAINTENANCE MANUAL

Copyright © 1988 Liebherr-Aerospace Lindenberg GmbH. All rights reserved.

This document is given in confidence and may not be reproduced, stored in a retrieval system, or
transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise,
without the prior written permission of Liebherr-Aerospace Lindenberg GmbH.

Unless Liebherr-Aerospace Lindenberg GmbH (the company) has accepted a contractual obligation in
respect of the information and data contained herein, such information and data is provided without
responsibility and the company disclaims all liability arising from its use.

TP2
49CC000092-04
Initial Issue: Feb 29/88 27-09-16 Revision No. 4
Sep 15/10
COMPONENT MAINTENANCE MANUAL
9028A0004

LIEBHERR-AEROSPACE LINDENBERG GmbH


(D9893)
Customer Service
P.O. Box 1363
88153 LINDENBERG
GERMANY
Fax: +49 (0)8381 46-4103
E-Mail: techpub.lindenberg@liebherr.com
SITA Code: FDHLEXD
CAGE CODE D9893

REVISION TRANSMITTAL LETTER

To

Holders of Component Maintenance Manual (CMM) 27-09-16, Revision No. 3, date Jul 01/10.

General

This Revision Transmittal Letter is attached to the Revision No. 4 of the Component Maintenance Manual
(CMM) 27-09-16, date Sep 15/10.

Minor text or layout changes were not marked with a change bar.

Instructions

The pages which have changed with this revision are shown on the List of Effective Pages. The type of the
change is given in the list below.

– R = This page is changed (replace)


– D = This page is deleted (remove)
– N = This page is new (put in the CMM).

Make sure that the pages of the CMM are the same as in the List of Effective Pages.

Write the details on the Record of Revision page.

File this Revision Transmittal Letter after the Title Page.

Reason for the Revision

– Test values updated


– The attached highlights give instructions of the revision changes included in this reissue.

TL

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HIGHLIGHTS

Revision No.4 - Sep 15/10

Pages which have been added, revised or deleted are outlined below together with the Highlights of the
Revision.

LOCATIONS DESIGNATION DESCRIPTION OF CHANGE

TITLE PAGE R

SERVICE BULLETIN LIST R

LIST OF EFFECTIVE PAGES R

TESTING AND FAULT ISOLATION


SUBTASK 27-09-16-700-006-A01 R Values updated

SUBTASK 27-09-16-700-007-A01 R Subtast updated

HLTS

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RECORD OF REVISIONS

INSERTED INSERTED
REV. ISSUE REV. ISSUE
No. DATE DATE BY No. DATE DATE BY

ROR

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RECORD OF TEMPORARY REVISIONS

INSERTED REMOVED
TEMP REV. ISSUE PAGE No.
No. DATE DATE BY DATE BY

RTR

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SERVICE BULLETIN LIST

SERVICE BULLETIN INCORPORATION INTO CMM TITLE

Number Rev Date Rev

SBL

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

TITLE PAGE 6 Jul 01/10


1 R Sep 15/10 7 Jul 01/10
2 R Sep 15/10 8 Jul 01/10
9 Jul 01/10
RECORD OF REVISIONS 10 Blank Jul 01/10
1 Feb 29/88
2 Blank Feb 29/88 TESTING AND FAULT ISOLATION
1001 R Sep 15/10
RECORD OF TEMPORARY REVISIONS 1002 R Sep 15/10
1 Nov 30/04 1003 R Sep 15/10
2 Blank Nov 30/04 1004 R Sep 15/10
1005 R Sep 15/10
SERVICE BULLETIN LIST 1006 R Sep 15/10
1 R Sep 15/10 1007 R Sep 15/10
2 Blank Sep 15/10 1008 R Sep 15/10
1009 R Sep 15/10
LIST OF EFFECTIVE PAGES 1010 R Sep 15/10
1 R Sep 15/10 1011 R Sep 15/10
2 R Sep 15/10 1012 R Sep 15/10
1013 R Sep 15/10
TABLE OF CONTENTS 1014 R Sep 15/10
1 R Sep 15/10 1015 R Sep 15/10
2 R Sep 15/10 1016 R Sep 15/10
3 R Sep 15/10
DISASSEMBLY
4 R Sep 15/10
3001 Jul 01/10
LIST OF ILLUSTRATIONS 3002 Jul 01/10
1 R Sep 15/10 3003 Jul 01/10
2 Blank Sep 15/10 3004 Blank Jul 01/10

LIST OF TABLES CLEANING


1 R Sep 15/10 4001 Nov 30/04
2 Blank Sep 15/10 4002 Nov 30/04
4003 Nov 30/04
INTRODUCTION 4004 Nov 30/04
1 Jul 01/10
INSPECTION/CHECK
2 Jul 01/10
3 Jul 01/10 5001 Nov 30/04
4 Jul 01/10 5002 Nov 30/04
5 Jul 01/10 5003 Nov 30/04
6 Jul 01/10 5004 Blank Nov 30/04

DESCRIPTION AND OPERATION REPAIR


1 Jul 01/10 6001 Jul 01/10
2 Jul 01/10 6002 Jul 01/10
3 Jul 01/10
ASSEMBLY
4 Jul 01/10
5 Jul 01/10 7001 Jul 01/10

LEP

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LIST OF EFFECTIVE PAGES (Continued)

SUBJECT PAGE DATE SUBJECT PAGE DATE

7002 Jul 01/10 10011 Jul 01/10


7003 Jul 01/10 10012 Jul 01/10
7004 Jul 01/10
7005 Jul 01/10 OPTIONAL VENDOR INDEX
7006 Jul 01/10 10013 Jul 01/10
7007 Jul 01/10 10014 Blank Jul 01/10
7008 Jul 01/10
7009 Jul 01/10 DETAILED PARTS LIST
7010 Jul 01/10 10015 Jul 01/10
7011 Jul 01/10 10016 Jul 01/10
7012 Blank Jul 01/10 10017 Jul 01/10
10018 Jul 01/10
FITS AND CLEARANCES 10019 Jul 01/10
8001 Nov 30/04 10020 Jul 01/10
8002 Nov 30/04 10021 Jul 01/10
8003 Nov 30/04 10022 Jul 01/10
8004 Nov 30/04

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND


CONSUMABLES
9001 Jul 01/10
9002 Jul 01/10
9003 Jul 01/10
9004 Jul 01/10
9005 Jul 01/10
9006 Jul 01/10

STORAGE (INCLUDING TRANSPORTATION)


15001 Jul 01/10
15002 Jul 01/10
15003 Jul 01/10
15004 Jul 01/10

ILLUSTRATED PARTS LIST (IPL)


10001 Jul 01/10
10002 Blank Jul 01/10

INTRO IPL
10003 Jul 01/10
10004 Jul 01/10
10005 Jul 01/10
10006 Jul 01/10
10007 Jul 01/10
10008 Blank Jul 01/10

ALPHA/NUMERIC INDEX
10009 Jul 01/10
10010 Jul 01/10

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TABLE OF CONTENTS
PAGE

INTRODUCTION .............................................................................................................................. INTRO 1


1. General ..................................................................................................................................... INTRO 1
A. Purpose and Scope ........................................................................................................... INTRO 1
B. Applicable Publications ...................................................................................................... INTRO 3
C. Shop Verification of Page Blocks in the CMM .................................................................... INTRO 3
D. Approved Repair Stations .................................................................................................. INTRO 3
2. Abbreviations and Terminology ................................................................................................. INTRO 5
A. Units of Measure ................................................................................................................ INTRO 5
B. Abbreviations ..................................................................................................................... INTRO 6

DESCRIPTION AND OPERATION .................................................................................................. 1


1. Description ................................................................................................................................ 1
A. General .............................................................................................................................. 1
B. Unit Description .................................................................................................................. 1
2. Operation .................................................................................................................................. 6
A. General .............................................................................................................................. 6
3. Technical Data ........................................................................................................................... 8
A. Dimensions ........................................................................................................................ 8
B. Operation Data ................................................................................................................... 8
C. Synchro Assembly Type I (400 Hz) .................................................................................... 8
D. Synchro Assembly Type II (2500 Hz) ................................................................................. 9

TESTING AND FAULT ISOLATION ................................................................................................. 1001


1. Testing ....................................................................................................................................... 1001
A. Reason for the Job ............................................................................................................. 1001
B. Job Set-up Information ....................................................................................................... 1001
C. Job Set-up .......................................................................................................................... 1002
(1) General ....................................................................................................................... 1002
D. Procedure .......................................................................................................................... 1002
(1) Visual Inspection ......................................................................................................... 1002
(2) Breakout Torque Test .................................................................................................. 1002
(3) Bonding Test ............................................................................................................... 1003
(4) Mechanical Zero Setting Adjustment .......................................................................... 1003
(5) Adjustment of the Synchro Assemblies ...................................................................... 1005
(6) Electrical Zero Position Adjustment ............................................................................ 1006
(7) Error Curve Examination ............................................................................................ 1008
(8) Alternative Test ........................................................................................................... 1012
(9) End Procedure ............................................................................................................ 1013
(10) Isolation Resistance Test ............................................................................................ 1014
(11) Dielectric Strength Test ............................................................................................... 1014
2. Fault Isolation ............................................................................................................................ 1015
A. Reason for the Job ............................................................................................................. 1015
B. Job Set-up Information ....................................................................................................... 1015
C. Job Set-up .......................................................................................................................... 1015
D. Procedure .......................................................................................................................... 1015
(1) Fault Isolation ............................................................................................................. 1015

SCHEMATIC AND WIRING DIAGRAMS ........................................................................ NOT APPLICABLE

TOC

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TABLE OF CONTENTS (Continued)


PAGE

DISASSEMBLY ................................................................................................................................ 3001


1. Disassembly of the Unit ............................................................................................................ 3001
A. Reason for the Job ............................................................................................................. 3001
B. Job Set-up Information ....................................................................................................... 3001
C. Job Set-up .......................................................................................................................... 3001
(1) General ....................................................................................................................... 3001
D. Procedure .......................................................................................................................... 3001
(1) Removal of the Synchro Assemblies .......................................................................... 3001
(2) Removal of the Cover Assembly (1-60) and Harmonic Drive Assembly (1-140) ........ 3002
(3) Disassembly of Assembled Parts ............................................................................... 3003

CLEANING ....................................................................................................................................... 4001


1. Cold Cleaning ............................................................................................................................ 4001
A. Reason for the Job ............................................................................................................. 4001
B. Job Set-up Information ....................................................................................................... 4001
C. Job Set-up .......................................................................................................................... 4001
(1) General ....................................................................................................................... 4001
D. Procedure .......................................................................................................................... 4001
(1) Cleaning of Parts ........................................................................................................ 4002
(2) Cleaning of Ball Bearings ........................................................................................... 4002
(3) Cleaning of new Parts ................................................................................................. 4002
E. Close-up ............................................................................................................................. 4002
(1) Protection .................................................................................................................... 4002
2. Ultrasonic Cleaning ................................................................................................................... 4003
A. Reason for the Job ............................................................................................................. 4003
B. Job Set-up Information ....................................................................................................... 4003
C. Job Set-up .......................................................................................................................... 4003
(1) General ....................................................................................................................... 4003
D. Procedure .......................................................................................................................... 4003
(1) Cleaning ...................................................................................................................... 4003
E. Close-up ............................................................................................................................. 4004
(1) Protection .................................................................................................................... 4004

INSPECTION/CHECK ...................................................................................................................... 5001


1. Inspection and Check ................................................................................................................ 5001
A. Reason for the Job ............................................................................................................. 5001
B. Job Set-up Information ....................................................................................................... 5001
C. Job Set-up .......................................................................................................................... 5001
(1) General ....................................................................................................................... 5001
D. Procedure .......................................................................................................................... 5001
(1) Visual Inspection ......................................................................................................... 5001
(2) Dimensional Check ..................................................................................................... 5002
(3) Spring Check .............................................................................................................. 5002
(4) Feel Check .................................................................................................................. 5002
(5) Crack Test - Fluorescent-Penetrant Method ............................................................... 5002
(6) Crack Test - Magnetic-Particle Method ....................................................................... 5002
E. Close-up ............................................................................................................................. 5003
(1) Part Categories ........................................................................................................... 5003

TOC

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TABLE OF CONTENTS (Continued)


PAGE

REPAIR ............................................................................................................................................ 6001


1. General Repairs ........................................................................................................................ 6001
A. Reason for the Job ............................................................................................................. 6001
B. Job Set-up Information ....................................................................................................... 6001
C. Job Set-up .......................................................................................................................... 6001
D. Procedure .......................................................................................................................... 6001
(1) Removal of Corrosion ................................................................................................. 6001
(2) Surface Treatment ...................................................................................................... 6001
(3) Replacement of the Coil Inserts .................................................................................. 6001

ASSEMBLY ...................................................................................................................................... 7001


1. Assembly of the Unit ................................................................................................................. 7001
A. Reason for the Job ............................................................................................................. 7001
B. Job Set-up Information ....................................................................................................... 7001
C. Job Set-up .......................................................................................................................... 7001
(1) Preparation ................................................................................................................. 7001
D. Procedure .......................................................................................................................... 7002
(1) Assembly of the Housing ............................................................................................ 7002
(2) Assembly of the Cover ................................................................................................ 7004
(3) Truth of Turn Check of the Synchro Assemblies ......................................................... 7005
(4) Installation of the Synchro Assemblies and Connector Block ..................................... 7006
(5) Installation of the Connectors ..................................................................................... 7009
(6) Assembly of the Housing and Cover .......................................................................... 7009
(7) Installation of the Frame ............................................................................................. 7011
(8) End Procedure ............................................................................................................ 7011

FITS AND CLEARANCES ................................................................................................................ 8001


1. Fits and Clearances .................................................................................................................. 8001
A. How to use the Fits and Clearances Table ........................................................................ 8001
B. Fits and Clearances Table ................................................................................................. 8001
2. Spring Properties ...................................................................................................................... 8003
A. General .............................................................................................................................. 8003
B. Spring Properties Table ...................................................................................................... 8003
3. Torque Values ........................................................................................................................... 8004
A. General .............................................................................................................................. 8004
B. Torque Values Table ........................................................................................................... 8004

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES ............................................. 9001


1. Special Tools, Fixtures and Equipment ..................................................................................... 9001
A. List of Special Tools, Fixtures and Equipment ................................................................... 9001
2. Consumables ............................................................................................................................ 9005
A. List of Consumables .......................................................................................................... 9005

SPECIAL PROCEDURES ............................................................................................... NOT APPLICABLE

REMOVAL ....................................................................................................................... NOT APPLICABLE

INSTALLATION ............................................................................................................... NOT APPLICABLE

TOC

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TABLE OF CONTENTS (Continued)


PAGE

SERVICING ..................................................................................................................... NOT APPLICABLE

STORAGE (INCLUDING TRANSPORTATION) ............................................................................... 15001


1. Storage of the Unit .................................................................................................................... 15001
A. Reason for the Job ............................................................................................................. 15001
B. Job Set-up Information ....................................................................................................... 15001
C. Job Set-up .......................................................................................................................... 15001
D. Procedure .......................................................................................................................... 15001
(1) Installation of the Storage Parts .................................................................................. 15001
(2) Packing ....................................................................................................................... 15003
(3) Storage ....................................................................................................................... 15003
(4) Removal from Storage ................................................................................................ 15004

REWORK (SERVICE BULLETIN ACCOMPLISHMENT PROCEDURES) ...................... NOT APPLICABLE

ILLUSTRATED PARTS LIST (IPL) ................................................................................................... 10001


1. Introduction ............................................................................................................................... 10003
A. General .............................................................................................................................. 10003
B. How to Use the IPL ............................................................................................................ 10003
C. Vendors List ....................................................................................................................... 10003
D. Numerical Index ................................................................................................................. 10003
E. Detailed Part List ................................................................................................................ 10004
F. Effectivity Code .................................................................................................................. 10004
G. Symbols and Abbreviations ............................................................................................... 10004

VENDOR LIST .......................................................................................................................... 10007

Alpha/Numeric Index ................................................................................................................. 10009

Optional Vendor Index ............................................................................................................... 10013

Detailed Parts List ..................................................................................................................... 10015

TOC

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LIST OF ILLUSTRATIONS

FIGURE TITLE PAGE

INTRO-1 MTOSS Code .............................................................................................................. INTRO-2


1 Position Pick-off Unit - General View .......................................................................... 3
2 Position Pick-off Unit - Sectional View ........................................................................ 4
3 Harmonic Drive Assembly (1-140) .............................................................................. 5
4 Wiring diagram ............................................................................................................ 7
1001 Alignment Data ........................................................................................................... 1004
1002 Manual Zero Setting ................................................................................................... 1005
1003 Wiring Arrangement .................................................................................................... 1010
1004 Test Set-up .................................................................................................................. 1011
1005 Schematic Test Set-up ................................................................................................ 1011
1006 Examples of the Error Curve ...................................................................................... 1012
3001 Harmonic Drive Assembly .......................................................................................... 3003
7001 Installation of the Plate (1-370) ................................................................................... 7003
7002 Assembly Measurement ............................................................................................. 7003
7003 Harmonic Drive Assembly (1-140) with Assembled Items .......................................... 7005
7004 Truth of Turn Check of the Synchro Assemblies ......................................................... 7006
7005 Arrangement of the Synchro Assemblies in the Zero Position ................................... 7008
7006 Assembly Details ........................................................................................................ 7010
8001 Fits and Clearances - Locations ................................................................................. 8002
9001 Special Tools, Fixtures and Equipment ....................................................................... 9002
15001 Storage Parts .............................................................................................................. 15002

Detailed Parts List

1 Position Pick-off Unit ................................................................................................... 10016


2 Synchro Housing ........................................................................................................ 10020

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LIST OF TABLES

TABLE TITLE PAGE

1001 Values of the Error Curve ............................................................................................ 1008


1002 Fault Isolation ............................................................................................................. 1015
15001 Storage Parts .............................................................................................................. 15001

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INTRODUCTION

TASK 27-09-16-871-801-A01
1. General

A. Purpose and Scope

(1) This Component Maintenance Manual (CMM) agrees with the Air Transport Association
(ATA) iSpec 2200 and is written in Simplified Technical English (AeroSpace and Defence,
Specification: ASD-STE100).

(2) Maintenance Task Oriented Support System (MTOSS) identification is used in this CMM (refer
to Figure INTRO-1). The tasks, subtasks and other data have MTOSS identification for the use
of electronic data processing (EDP). The user of this CMM can ignore the MTOSS identification.

(3) This CMM gives all the necessary information to understand the function of the unit.

(4) This CMM will be revised as and when necessary to show new information or include
modifications.

(5) The maintenance procedures given in this CMM are only for approved persons with the
necessary skills.

(6) This CMM contains:

– Description and operation of the unit


– Test procedures of the unit
– Maintenance and repair procedures of the unit
– Illustrated parts list (IPL).

(7) Read and obey all WARNINGS, CAUTIONS and NOTES in this CMM.

(a) Warnings tell technicians about the use of materials, procedures, or limits which must be
followed accurately to prevent injury to persons.

(b) Cautions tell technicians about the procedures which must be followed to prevent damage
to equipment.

(c) Notes tell technicians about the procedures which make the job easier.

INTRO

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MTOSS Code
Figure INTRO-1
INTRO

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B. Applicable Publications

Nomenclature Part Number Publication Number Type


Not applicable

C. Shop Verification of Page Blocks in the CMM

(1) The shop verification makes sure that the procedures in the Page Blocks in the table given
below are correct.

Page Block Method Date


TESTING AND FAULT ISOLATION Verified by review Sep 15/10
DISASSEMBLY Verified by review Sep 15/10
ASSEMBLY Verified by review Sep 15/10

D. Approved Repair Stations

Company Name Address Notes


LIEBHERR-AEROSPACE LINDENBERG Postfach 1363
GMBH 88153 Lindenberg
Germany
Phone: +49 (0)8381 460
Fax: +49 (0)8381 46 4103
Hotline: +49 (0)171 852 7304
LIEBHERR-AEROSPACE TOULOUSE 408 Av des Etats-Units
S.A. BP 2010
31016 Toulouse
Cedex 2
France
Phone: +33 (0)5 61 35 28 28
Fax: +33 (0)5 61 35 28 00
Forwarding agent: SDV Toulouse
Phone: +33 (0)5 62 74 22 45
LIEBHERR-AEROSPACE SALINE 1465 Woodland Drive
MI 48176 –1259
U.S.A.
Phone: +1 73 44 29 72 25
Fax: +1 73 44 29 53 57
AOG: +1 31 35 80 72 62
Sita: DTWLACR

INTRO

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Company Name Address Notes


LIEBHERR-AEROSPACE SINGAPORE 8 Pandan Avenue
Singapore 609384
Singapore
Phone: +65 62 65 23 05
Fax: +65 62 65 26 57
LIEBHERR-AEROSPACE SHANGHAI Factory No. 28
Fu Te Dong Er Lu Waigaoqiao
Free Trade Zone
Shanghai 200 131
P.R. China
Phone: +86 21 50 46 19 88
Fax: +86 21 50 46 19 89

INTRO

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TASK 27-09-16-871-802-A01
2. Abbreviations and Terminology

A. Units of Measure

(1) General

(a) The dimensions given in this manual are from original manufacturing drawings.

(b) All values in this manual are in S.I. units or subdivisions of these units. Imperial units are
given in parenthesis immediately after the S.I. units.

(2) Units of Measure and Conversion Factors

A Ampere

g Kilogram 0.002205 lb

Hz Hertz

kPa Kilopascal 0.145 psi

mm Millimeter 0.03937 in.

N Newton 0.2248 lbf

Nm Newton meter 8.851 lbf.in.

rpm Turns per minute

VAC Volt alternating current

VDC Volt direct current

VRMS Volt root mean square

W Watt

° Degree

’ Minute (angle)

°C Degree Celsius 0.556 (°F -32)

°F Degree Fahrenheit 1.8 °C +32

Ω Ohm

(3) Signs

> More than

≥ More than or the same as

< Less than

≤ Less than or the same as


INTRO

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± Plus or minus

B. Abbreviations

ASD AeroSpace and Defence

assy Assembly

ATA Air Transport Association

CCW Counter-clockwise

CMM Component Maintenance Manual

CW Clockwise

dia. Diameter

DTI Dial Test Indicator

EDP Electronic Data Processing

Fig. Figure

ID Inner Diameter

INTRO Introduction

IPL Illustrated Parts List

Max. Maximum

Min. Minimum

MTOSS Maintenance Task Oriented Support System

N.A. Not applicable

No. Number

Nom. Nominal

OD Outer Diameter

PPU Position Pick-off Unit

PN Part Number

QTY Quantity

ref. Refer to

SADC Synchro Analog/Digital Converter

INTRO

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DESCRIPTION AND OPERATION

TASK 27-09-16-872-801-A01
1. Description

A. General

(1) The Position Pick-off Units (PPU) are self-contained Line Replacement Units installed in the
aircraft flap/slat system. The PPU monitors the flap/slat system for symmetrical operation and
feedback of flight surface position.

(2) The primary components of PPU are as follows:

– Housing Assembly
– Two Synchro Assemblies
– Harmonic Drive Assembly.

(3) The power supply for the PPU is from 26 VAC at 400 Hz and 21 VAC at 2.5 kHz aircraft system.

B. Unit Description

(1) Housing Assembly (Refer to Figure 1)

(a) The housing assembly is a sealed metal case which contains the two synchro assemblies
and the harmonic drive assembly.

(b) Four lugs, which are part of the cover assembly, attach the PPU to the aircraft. One side
of the housing has the identification plate and an inspection window. The window is used
to make sure that the mechanical zero marks are aligned during assembly and installation
(refer to pageblock TESTING AND FAULT ISOLATION).

(c) The rear of the housing has two electrical connectors, identified as 'A' and 'B', which
connect the PPU synchro assemblies to the aircraft electrical system. The front part of the
housing contains the harmonic drive assembly and input shaft.

(d) The front part of the housing has a codification hole. The reason for the codification hole
is to prevent the PPU from being used in an incorrect location. The hole engages with
a pin on the unit to which it is attached.

(2) Synchro Assemblies (Refer to Figure 2)

(a) The two synchro assemblies (parallel configuration) change the mechanical input to a
three-phase output-signal which is transmitted to the aircraft system.

(b) The synchro assembly is a brushless type which contains a transformer and a synchro.
The turning transformer has two parts, the primary winding (stator) connected to the
aircraft supply, and the secondary winding internally connected to the synchro rotor.
The synchro-stator is a 'Y' wound type. Each synchro is independently attached to an
external connector.

(c) The input shaft of each synchro has an anti-backlash gear to remove any play between
the synchro assembly and the harmonic drive. One of the anti-backlash gear has a range
zero indicator segment.

27-09-16 Page 1
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

(3) Harmonic Drive (Refer to Figure 3)

(a) The harmonic drive assembly is a reduction gear assembly which lets a high
gear-reduction occur in the minimum space. The reduction between the input to the
PPU and the synchro assembly is 140:1. Thus when the input shaft turns 140 times the
synchro assembly turns 360° (one turn).

(b) The harmonic drive has four primary components as follows:

– Wave Generator
– Circular Spline
– Dynamic Spline
– Flexspline.

(c) The splined input shaft is attached to an elliptical wave-generator. A bearing in the housing
holds the input shaft. The wave-generator is installed in a set of ball bearings, and together
are installed in the flexspline. The flexspline is a flexible ring-gear with external gear teeth.

(d) Thus, the flexspline keeps the same shape of the wave-generator as the wave-generator
turns. The flexspline is installed in a fixed circular-spline and a dynamic-spline that turns.
These are also ring gears but have internal gear-teeth. The circular spline has two gear
teeth more than the dynamic and flexspline.

(e) The dynamic spline has a splined shaft that connects to the anti-backlash gears of the
synchro assemblies. The circular and dynamic spline gear-teeth mesh with that part of the
flexspline which is adjacent to the larger diameter of the wave-generator.

(f) Thus, the difference in gear-teeth gives a reduction ratio between the input shaft and the
dynamic-spline output-shaft of 70:1. A reduction ratio of 2:1 between the dynamic-spline
output-shaft and the synchro anti-backlash drive gears gives a total reduction ratio of
140:1.

(g) The spring-tensioned locking plate engages with the input-shaft splines when the PPU is
removed from the aircraft. This locking-plate locks the harmonic drive and the synchro
assemblies mechanically.

27-09-16 Page 2
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

ELECTRICAL
IDENTIFICATION PLATE CONNECTORS

INSPECTION WINDOW

ATTACHING LUG

SYNCHRO
COVER

LOCKING PLATE

INPUT SHAFT
HOUSING ASSEMBLY

COVER
FLANGE

CABLE TIE
LLI1-270916-00001-01-01.CGM

(TEMPORARY LOCKING DEVICE)

Position Pick-off Unit - General View


Figure 1

27-09-16 Page 3
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

SYNCHRO
ASSEMBLIES

SYNCHRO
ANTI-BACKLASH GEAR

HARMONIC DRIVE ASSEMBLY

INPUT SHAFT BEARING


LLI1-270916-00002-01-01.CGM

Position Pick-off Unit - Sectional View


Figure 2

27-09-16 Page 4
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

DYNAMIC SPLINE ZERO INDICATOR SEGMENT


SYNCHRO 'A' DRIVE GEAR

BEARING

SYNCHRO ASSEMBLY 'A'


INPUT SHAFT

SYNCHRO ASSEMBLY 'B'


WAVE GENERATOR

FLEXSPLINE

FIXED CIRCULAR SPLINE SYNCHRO B DRIVE GEAR


(FIXED TO HOUSING)
OUTPUT SHAFT

FIXED CIRCULAR SPLINE


(FIXED TO HOUSING)
OUTPUT SHAFT
(HARMONIC DRIVE)
FLEXSPLINE

WAVE GENERATOR

INPUT SHAFT
LLI1-270916-00003-01-01.CGM

BEARING DYNAMIC SPLINE

Harmonic Drive Assembly (1-140)


Figure 3

27-09-16 Page 5
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

TASK 27-09-16-873-801-A01
2. Operation
(Refer to Figure 4)

A. General

(1) When the PPU is installed in the aircraft and the electrical system is energized, the power supply
of, 26 VAC, 400 Hz or 21 VAC, 2500 Hz is given to the synchro assemblies at pins 'A' and 'B'.
This energizes the primary coil of the rotating transformer (stator). The energized primary coil
induces a voltage in the secondary coil of the transformer (rotor). As a result of this, a voltage is
also induced in each of the three phase-coils (S1, S2 and S3) of the synchro-generator (stator).

(2) Thus, given voltage amplitude and phase values from the synchro-generator are made available
at pins 'C', 'D' and 'E'. These output values do not change unless the secondary winding of the
transformer (rotor) is moved. Pin 'F' of the connector is connected to the case ground.

(3) Any movement in the flap/slat system is transmitted to the input shaft of the PPU. This
movement is decreased (140:1) through the harmonic drive that turns the synchro input-shaft
and the secondary coil of the transformer. The secondary coil voltage changes continuously
in phase and results in the change of the voltage amplitude and phase values of the
synchro-generator, in proportion to the movement of the secondary coil.

27-09-16 Page 6
Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

CONNECTORS
IDENTIFICATION
MASTER
SPLINE
B A

A A
F B F B
ROTATING TRANSFORMER
E DC E DC
PRIMARY SECONDARY
WINDING WINDING
(STATOR) (ROTOR)
MECHANICAL INPUT
SYNCHRO
STATOR
POSITION PICK-OFF UNIT
REDUCTION
140:1

SYNCHRO SYNCHRO
ASSEMBLY B ASSEMBLY A

S1 S3 S1 S3
R2 R2

R1 S2 R1 S2

X Z Y X Z Y SYNCHRO
Q P Q P
ROTOR
RED-WHT

RED-WHT
BLK-WHT

BLK-WHT
COPPER

COPPER
BLU

BLK

BLU

BLK
YEL

YEL

B A C E D F B A C E D F
CONNECTOR 'B' CONNECTOR 'A'
LLI1-270916-00004-01-01.CGM

LEGEND
BLK - BLACK
WHT - WHITE
BLU - BLUE
YEL - YELLOW

Wiring diagram
Figure 4

27-09-16 Page 7
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COMPONENT MAINTENANCE MANUAL
9028A0004

TASK 27-09-16-872-802-A01
3. Technical Data

A. Dimensions

Parameter Value
Length ≤122.75 mm (≤4.83 in.)
Width ≤80.2 mm (≤3.16 in.)
Height ≤80.5 mm (≤3.17 in.)
Mass ≤955 g (≤2.11 lb)

B. Operation Data

Parameter Value
Operating temperature -55 to 90 °C (-67 to 194 °F)
Operating speed input 600 rpm
Maximum input speed 3000 rpm
Reduction ratio 140:1
Precision at zero position ±15’ at 2.5 kHz
Precision at all other positions ±25’ at 2.5 kHz
Precision at zero position ±45’ at 400 Hz
Precision at all other positions ±80’ at 400 Hz
Mismatch between the two synchro assemblies ≤30’
Lubrication:
Grease Grease Isoflex Alltime SL1 (M313)

C. Synchro Assembly Type I (400 Hz)

(1) Exitation

Parameter Value
Voltage 23 to 28 VRMS (26 VRMS Nom.)
Frequency 380 to 420 Hz (at 400 Hz Nom.)
Current (no load) 200 mA Max.
Power Consumption (no load) 1.8 W Nom.

(2) Signal Output

Parameter Value
Voltage (no load) ≤11.8 VRMS
Stator Impedance 41.5 Ω
Sensitivity 0.206 V/°

27-09-16 Page 8
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COMPONENT MAINTENANCE MANUAL
9028A0004

Parameter Value
Zero Voltage ≤40 mV
Phase Shift 11° Nom.

D. Synchro Assembly Type II (2500 Hz)

(1) Exitation

Parameter Value
Voltage 20 to 26 VRMS (21 VRMS Nom.)
Frequency 2 to 3 kHz (2.5 kHz Nom.)
Current (no load) ≤35 mA
Power Consumption (no load) 0.3 W Nom.

(2) Signal Output

Parameter Value
Voltage (no load) 9.98 VRMS Max.
Stator Impedance 230 Ω
Sensitivity 0.174 V/°
Zero Voltage ≤40 mV
Phase shift 0° Nom.

NOTE: There is no physical difference between Type I and Type II synchro assemblies. The
different types are given to show the alternative operation frequencies.

NOTE: On the aircraft the synchro assemblies operate with the two frequencies 400 Hz and
2.5 kHz. In shop test operation, 400 Hz is used.

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COMPONENT MAINTENANCE MANUAL
9028A0004

TESTING AND FAULT ISOLATION

TASK 27-09-16-700-801-A01
1. Testing

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Special Tools

Name and Part Number Used for


To do the mechanical and electrical zero position
Mounting Plate (55947S0001)
adjustment
To do the mechanical and electrical zero position
Adjustment Mandrel (55947S0100)
adjustment
Connector Assembly (55947S0300) To do the electrical zero position adjustment
Coarse/Fine Selector (52173A0000-01) To do the electrical zero position adjustment
Connection Cables (52261A0000-01) To do the electrical zero position adjustment
Connection Cables (52268A0000-01) To do the electrical zero position adjustment
Mechanical Test-Set (52182A0000-01) To do the test on the unit
Control Box (52183A0000-01) To do the test on the unit
Test Rig 230 V (60550A0000-01) To do the test on the unit

NOTE: More data is shown in Special Tools, Fixtures and Equipment,


task-27-09-16-940-801-a01.

(2) Consumables

Name and Material Number Group


Loctite 675 (M029) Safety Lacquer

NOTE: More data of the consumables shown in Consumables,


task-27-09-16-941-801-a01.

(3) Measuring Instruments

Unit and min.


Name Reference Properties Precision
Test Range
Bonding Test, subtask-27-09-16-
Ohmmeter Resistance 0 to 100 mΩ ±2 %
750-001-a01

27-09-16 Page 1001


Sep 15/10
COMPONENT MAINTENANCE MANUAL
9028A0004

Unit and min.


Name Reference Properties Precision
Test Range
Dielectric Strength Test,
Ohmmeter Resistance 0 to 50 MΩ ±2 %
subtask-27-09-16-700-009-a01
Spring Balance
Breakout Torque Test, Break-out 0 to 0.1 Nm ±0.001 Nm
with Pulley
subtask-27-09-16-700-002-a01 Torque (0 to 0.9 lbf.in.) (±0.009 lbf.in.)
Wheel

(4) Ambient Conditions

Parameter Value
Ambient Temperature 17 to 27 °C (63 to 80 °F)
Relative Humidity ≤85 %

(5) Additional Equipment necessary are as follows:

– Function Generator of 26 VRMS at 400 Hz


– Synchro Analog/Digital Converter (SADC) with display of 26 VRMS at 400 Hz.

C. Job Set-up

SUBTASK 27-09-16-700-001-A01
(1) General

(a) Make sure that all special tools, fixtures and equipment are serviceable and, where
necessary, correctly calibrated before you use them.

(b) Do the test in the sequence as given in this procedure.

(c) Refer to the ILLUSTRATED PARTS LIST (IPL) for the figure/item numbers.

D. Procedure

SUBTASK 27-09-16-220-001-A01
(1) Visual Inspection

(a) Visually examine the unit and make sure that:

– It is clean
– It has all items
– There are no signs of external damage
– The data given on the identification plate are correct
– The identification plate has the correct position on the unit.

SUBTASK 27-09-16-700-002-A01
(2) Breakout Torque Test

(a) Measure the breakout torque of the drive shaft of the harmonic drive assembly (1-140)
in CW and CCW direction. Make sure that the breakout torque in CW and CCW is
≤0.05 Nm (0.44 lbf.in.).

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COMPONENT MAINTENANCE MANUAL
9028A0004

SUBTASK 27-09-16-750-001-A01
(3) Bonding Test

(a) Measure the resistances between the earth-point and flange of the housing and the pin
'F' of the connector 'A'.

(b) Measure the resistances between the earth-point and flange of the housing and the pin
'F' of the connector 'B'.

(c) Make sure that the resistances are ≤20 mΩ.

SUBTASK 27-09-16-700-004-A01
(4) Mechanical Zero Setting Adjustment

(a) Look through the inspection window for the zero marks (refer to Figure 1001).

(b) If the zero marks are not aligned, do the steps that follow:

1 Attach the PPU to the Mounting Plate (55947S0001) with the two screws.

2 Push the Adjustment Mandrel (55947S0100) on to the input shaft of the harmonic
drive assembly (1-140). Make sure that the input shaft turns freely.

3 Install the Mounting Plate (55947S0001) in a vise or equivalent alternative.

4 Turn the input shaft to zero. Make sure that the gear zero mark and the orange zero
indicator aligns with the fixed pointers in the inspection window of the PPU.

5 Remove the Adjustment Mandrel (55947S0100) and make sure that the zero mark
on the input shaft aligns with the fixed zero mark. If the marks do not align, turn the
input shaft until the marks are aligned.

6 If mechanical zero marks are missing, engrave the marks.

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COMPONENT MAINTENANCE MANUAL
9028A0004

ORANGE ZERO INDICATOR


DRIVE GEAR ZERO MARK

FIXED POINTER

VIEW ON INSPECTION WINDOW

INPUT SHAFT ZERO MARK

LLI1-270916-01001-01-01.CGM

FIXED ZERO MARK

VIEW ON THE DRIVE SHAFT

Alignment Data
Figure 1001

27-09-16 Page 1004


Sep 15/10
COMPONENT MAINTENANCE MANUAL
9028A0004

SCREW

LOCATION DOWEL

LOCATION DOWEL
ADJUSTMENT MANDREL

SCREW

LLI1-270916-01002-01-01.CGM
MOUNTING PLATE

Manual Zero Setting


Figure 1002

SUBTASK 27-09-16-820-001-A01
(5) Adjustment of the Synchro Assemblies

NOTE: You can use the Test Rig (60550A0000-01) as alternative, refer to Alternative Test,
subtask-27-09-16-700-007-a01.

(a) Do this procedure not while the receipt test.

(b) Make sure that all mechanical zero marks are aligned (refer to Figure 1001). If mechanical
zero marks are missing, engrave the marks.

(c) Do the Electrical Zero Adjustment of Synchro Assembly 'A' as follows:

1 Connect the wires of synchro assembly 'A' to the test set-up (Control
Box (52183A0000-01), Connection Cables (52261A0000-01) and Mechanical Test
Set (52182A0000-01)) (refer to Figure 1004).

2 Set the selector switch to COARSE 'A'. Supply the PPU with 26 VRMS, 400 Hz at
2 VA and set the power supply to ON.

3 Loosen the screws (2-170) at the synchro assembly 'A' (refer to Figure 7006).

4 Carefully turn the housing of the synchro assembly 'A', until the maximum voltage of
30 mV is shown on the voltmeter.

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COMPONENT MAINTENANCE MANUAL
9028A0004

5 Set the selector switch to FINE 'A'. Turn the housing of the synchro assembly 'A' until
the voltmeter shows a voltage of approximately zero. Make sure that the maximum
voltage is ≤40 mV.

6 Apply Loctite 675 (M029) to the threads of the screws (2-170) and install them to
the plate (2-180) of the synchro assembly 'A'. Torque the screws between 1.0 and
1.5 Nm (9 and 13 lbf.in.).

7 Disconnect the wires of the synchro assembly 'A' from the wiring configuration.

(d) Do the Electrical Zero Adjustment of Synchro Assembly 'B' as follows:

1 Connect the wires of synchro assembly 'B' to the test set-up (Control
Box (52183A0000-01), Connection Cables (52261A0000-01) and Mechanical Test
Set (52182A0000-01)) (refer to Figure 1004).

2 Set the selector switch to COARSE 'B'. Supply the PPU with 26 VRMS, 400 Hz at
2 VA and set the power supply to ON.

3 Loosen the screws (2-170) at the synchro assembly 'B' (refer to Figure 7006).

4 Carefully turn the housing of the synchro assembly 'B', until the maximum voltage of
30 mV is shown on the voltmeter.

5 Set the selector switch to FINE 'B'. Turn the housing of the synchro assembly 'B' until
the voltmeter shows a voltage of approximately zero. Make sure that the maximum
voltage is ≤40 mV.

6 Apply Loctite 675 (M029) to the thread of the screw (2-170) and install the terminal of
the grounding lead (2-200) to the plate (2-180) of the housing (1-350) (refer to Figure
7006). Torque the screw between 1.0 and 1.5 Nm (9 and 13 lbf.in.).

7 Disconnect the wires of the synchro assembly 'B' from the wiring configuration.

SUBTASK 27-09-16-700-005-A01
(6) Electrical Zero Position Adjustment

NOTE: You can use the Test Rig (60550A0000-01) as alternative, refer to Alternative Test,
subtask-27-09-16-700-007-a01.

(a) General

1 Do the test with one of these as follows:

– The Wiring circuit with the Connector Assembly (55947S0300)


– The Coarse/Fine Selector (52173A0000-01) and the associated Connection
Cables (52268A0000-01)
– The Control Box (52183A0000-01) with the Connection Cables (52268A0000-01)
and the SADC.

NOTE: Only the zero set procedure using the circuit diagram is related to the schematic
diagram (refer to Figure 1004).

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COMPONENT MAINTENANCE MANUAL
9028A0004

2 If the zero position can be seen or is known to be near, perform the manual procedure
with the Coarse/Fine Selector (52173A0000-01) together with the Mounting
Plate (55947S0001) and the Adjustment Mandrel (55947S0100).

NOTE: The zero set procedure with the Coarse/Fine Selector (52173A0000-01) is
described in the dedicated Test Equipment Manual.

3 If the zero position is not visible, is unknown or is fully out of adjustment, do the
motor-drive zero reset procedure with Control Box (52183A0000-01).

NOTE: The zero set procedure using the Control Box (52183A0000-01) is
described in the dedicated Test Equipment Manual.

(b) Procedure

NOTE: This test gives data to align the electrical zero position of the synchro assemblies
and the mechanical zero.

1 Attach the PPU to the Mounting Plate (55947S0001) and turn the input shaft with
Adjustment Mandrel (55947S0100). Make sure that the shaft turns freely.

CAUTION: SET THE POWER SUPPLY TO OFF BEFORE YOU CONNECT THE
COARSE/FINE SELECTOR CIRCUIT.

2 Connect the wiring to connectors 'A' and 'B' (2-10) (refer to Figure 1003).

3 Set the selector switch to the COARSE 'A' position and supply the PPU with 26 VRMS,
400 Hz. Set the power supply to ON.

4 Turn the input shaft in the direction of zero until the voltmeter shows the maximum
voltage indication (in the range of approximately 36 mV). Make sure that the driving
gear zero mark and orange zero indicator aligns with the fixed pointers in the window
of the PPU.

5 Set the selector switch to the FINE 'A' position. Turn the input shaft until the voltmeter
shows the minimum voltage indication. Make sure that the minimum voltage is
<40 mV. This is the electrical zero position.

6 Remove the Adjustment Mandrel (55947S0100) and make sure that the zero marks
on the input shaft align. If not, turn the input shaft and align the zero marks to get the
mechanical zero position (refer to Figure 1001).

7 The voltmeter indicates the offset voltage of the mechanical zero position to the
electrical zero position. Read the voltmeter reading and make sure that the voltage is
<195 mV.

NOTE: The voltage is the maximum allowed electrical zero position voltage of 40 mV
added to the maximum zero position tolerance of ±60' (155 mV) at 400 Hz.

8 Move the selector switch to the FINE 'B' position. Make sure that the voltage is
≤100 mV.

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COMPONENT MAINTENANCE MANUAL
9028A0004

9 Set the power supply to OFF to disconnect the Test Set-up. Make sure that the
deviation of the zero mark of the input shaft of the harmonic drive assembly (1-140) is
≤45°.

SUBTASK 27-09-16-700-006-A01
(7) Error Curve Examination

NOTE: You can use the Test Rig (60550A0000-01) as alternative, refer to Alternative Test,
subtask-27-09-16-700-007-a01.

(a) General

1 Use the Control Box (52183A0000-01), Test Set (52182A0000-01) and applicable
cables with a SADC and a power supply of 26 VRMS at 400 Hz (refer to Figure 1004).

NOTE: This procedure gives the electrical deviation curve of the synchro assemblies
related to 360°. This is 140 turns of the input shaft.

2 For alternative equipment, refer to Figure 1005.

(b) Procedure

1 Make sure that the PPU is in the mechanical zero (refer to Mechanical Zero Setting
Adjustment, subtask-27-09-16-700-004-a01).

2 Record the error curve in increments of four turns at the input shaft.

NOTE: The revolutions of the input shaft in relation to the synchro assembly turns is
given in Table 1001.

3 Examine the recorded diagram and find the deviations. Include the precision of the
SADC to the deviations and make sure that:

– The deviation for curves A and B from the nominal value is between ±30' (±0.5°) at
the zero position
– The deviation for curves A and B at all other positions is ±60' (±1.0°)
– The total value of the deviation curve between Synchro 'A' and 'B' is ≤30' (±0.5°).

NOTE: For an example of error curve, refer to Figure 1006.

4 If the deviation and the total values are within the values, set the electrical/mechanical
zero position.

Values of the Error Curve


Table 1001

Turns of Input Shaft Movement of Synchro-Output Shaft (°)


0 0
4 10.286
8 20.571
12 30.857
16 41.143

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COMPONENT MAINTENANCE MANUAL
9028A0004

Values of the Error Curve


Table 1001 (continued)

Turns of Input Shaft Movement of Synchro-Output Shaft (°)


20 51.429
24 61.714
28 72.000
32 82.286
36 92.571
40 102.857
44 113.143
48 123.429
52 133.714
56 144.000
60 154.286
64 164.571
68 174.857
72 185.143
76 195.429
80 205.714
84 216.000
88 226.286
92 236.571
96 246.857
100 257.143
104 267.429
108 277.714
112 288.000
116 298.286
120 308.571
124 318.857
128 329.143
132 339.429
136 349.714
140 360.000

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COMPONENT MAINTENANCE MANUAL
9028A0004

A
B 100 kΩ

C
R2 S1 S3 D
MEASURING
100 kΩ RANGE OF
V VOLTMETER
200 mV
R1 S2
E

A
COARSE 'A':
B 1 kΩ COARSE 'B':
C FINE 'A':
SELECTOR
R2 S1 S3 D 1 kΩ
FINE 'B': SWITCH

R1 1 kΩ
S2 E

F
1 kΩ
26 VRMS
400 Hz 26 VRMS MAX
2 VA HI LO
400 Hz V

100 Ω 1 kΩ 1 kΩ
100 kΩ S3
C S1 D
WIRING LAYOUT
R2
B

A
R1 S2
COMMON
E
COARSE SETTING
LEGEND
CONNECTION FOR SYNCHRO 'A'
26 VRMS
CONNECTION FOR SYNCHRO 'B' 400 Hz MIN
HI LO
LLI1-270916-01003-01-01.CGM

NOTE V
Measurement Requirements:
C S1 S3 D
Coarse A: Adjustments to max.
Coarse B: Voltage approx. 30 mV R2
B

Fine A: Adjustments to min. A


Voltage indication R1 S2
Fine B:
40 mV max.
COMMON
Tolerance between Fine 'A' and E
Fine B max. 100 mV FINE SETTING

Wiring Arrangement
Figure 1003

27-09-16 Page 1010


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COMPONENT MAINTENANCE MANUAL
9028A0004

CONTROL BOX
A

LLI1-270916-01004-01-01.CGM
SETTING
MARKS A

HANDWHEEL

Test Set-up
Figure 1004

SADC DISPLAY

UNIT UNDER TEST


A
MOTOR PPU
B

LLI1-270916-01005-01-01.CGM

REVOLUTION COUNTER
WITH EXACT ZERO POSITION
26 VRMS
400 Hz
2 VA

Schematic Test Set-up


Figure 1005

27-09-16 Page 1011


Sep 15/10
COMPONENT MAINTENANCE MANUAL
9028A0004

DEVIATION FROM
NOMINAL VALUE

+60'
CURVE DIFFERENCE
TURNS OF
+30' SYNCHRO-OUTPUT
(DEGREES)
360°
0

LLI1-270916-01006-01-01.CGM
-30'

-60'

LEGEND
ERROR CURVE OF SYNCHRO ASSEMBLY:
A
B

Examples of the Error Curve


Figure 1006

SUBTASK 27-09-16-700-007-A01
(8) Alternative Test

NOTE: This test replaces the:

– Adjustment of the synchro assemblies, refer to Adjustment of the Synchro Assemblies,


subtask-27-09-16-820-001-a01
– Electrical zero position adjustment, refer to Electrical Zero Position Adjustment,
subtask-27-09-16-700-005-a01
– Error curve examination, refer to Error Curve Examination, subtask-27-09-16-700-006-a01.

(a) Install the PPU to the Test Rig (60550A0000-01).

(b) Do the running-in procedure as follows:

NOTE: This procedure is only necessary when the harmonic drive or gears have been
changed.

1 Operate the PPU CW for 15 minutes.

2 Operate the PPU in CCW for 15 minutes.

(c) Remove the PPU from the Test Rig (60550A0000-01) and make sure that all mechanical
zero marks are aligned (refer to Figure 1001).

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COMPONENT MAINTENANCE MANUAL
9028A0004

(d) If mechanical zero marks are not aligned do the mechanical zero setting check (refer to
Mechanical Zero Setting Adjustment, subtask-27-09-16-700-004-a01). If mechanical
zero marks are missing, engrave the marks.

(e) Install the PPU to the Test Rig (60550A0000-01).

(f) Adjust the synchro assemblies as follows:

NOTE: This procedure is not necessary when the error curves are within the allowed
tolerances. This test must be done when the Syncros, harmonic drive or gears
have been removed.

1 Turn the housing of the synchro assembly 'A' and record the COARSE and FINE
voltages. Make sure that the COARSE voltage is between 32 to 36 mV and the FINE
voltage is as small as possible and ≤40 mV.

2 Apply Loctite 675 (M029) to the threads of the screws (2-170) and install them to
the plate (2-180) of the synchro assembly 'A'. Torque the screws to between 1.0
and 1.5 Nm (9 and 13 lbf.in.).

3 Loosen the screws (2-170) at the synchro assembly 'B' (refer to Figure 7006).

4 Turn the housing of the synchro assembly 'B' carefully and record the COARSE and
FINE voltages. Make sure that the COARSE voltage is between 32 to 36 mV and the
FINE voltage is so near as possible to the FINE voltage of the synchro assembly 'A'
and ≤40 mV.

5 Apply Loctite 675 (M029) to the thread of the other screw (2-170) and install it to the
plate (2-180) of the synchro assembly 'B' and housing. Torque the screw between 1.0
and 1.5 Nm (9 and 13 lbf.in.).

(g) Record the error curve.

(h) Examine the recorded diagram and find the deviations. Include the precision of the SADC
to the deviations. Make sure that:

– The deviation for curves A and B from the nominal value is between ±30' (±0.5°) at the
zero position
– The deviation for curves A and B at all other positions is ±60' (±1.0°)
– The total value of the deviation curve between Synchro 'A' and 'B' is ≤30' (±0.5°).

NOTE: For an example of an error curve, refer to Figure 1006.

(i) Remove the PPU from the Test Rig (60550A0000-01).

(j) Make sure that the deviation of the zero mark of the input shaft of the harmonic drive
assembly (1-140) is ≤45°.

SUBTASK 27-09-16-420-001-A01
(9) End Procedure

NOTE: This procedure is not necessary while the receipt test.

(a) Install the cover (2-120) to the housing (1-350).

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(b) Install the screws (2-130) and seals (2-140) to the cover. Torque the screws between
0.9 and 1.0 Nm (7 and 9 lbf.in.).

(c) Install the identification plate (2-100) and screws (2-110) to the connector block assembly
(2-70). Tighten the screws carefully.

SUBTASK 27-09-16-700-008-A01
(10) Isolation Resistance Test

(a) Measure the resistances at 45 to 50 VDC between the pins of the connector 'A' and points
as follows:

– Pin 'A' and housing


– Pin 'C' and housing
– Pin 'A' and Pin 'C'.

(b) Measure the resistances at 45 to 50 VDC between the pins of the connector 'B' and points
as follows:

– Pin 'A' and housing


– Pin 'C' and housing
– Pin 'A' and Pin 'C'.

(c) Make sure that the resistances are ≥10 MΩ.

SUBTASK 27-09-16-700-009-A01
(11) Dielectric Strength Test

CAUTION: DECREASE THE PROOF VOLTAGE FOR EACH NEXT TEST BY 20 % TO


REDUCE THE RISK OF DAMAGE TO THE PPU. THE PROOF VOLTAGE FOR
THE FIRST TEST AFTER A REPAIR IS 400 VDC.

(a) Do the test for a period of one minute between the pins of the connector 'A' and points
as follows:

– Pin 'A' and housing


– Pin 'C' and housing.

(b) Do the test for a period of one minute between the pins of the connector 'B' and points
as follows:

– Pin 'A' and housing


– Pin 'C' and housing.

(c) Do the test for a period of one minute between the pins as follows:

– Pin 'A' of the connector 'A' and Pin 'A' of the connector 'B'
– Pin 'A' of the connector 'A' and Pin 'C' of the connector 'B'
– Pin 'C' of the connector 'A' and Pin 'A' of the connector 'B'
– Pin 'C' of the connector 'A' and Pin 'C' of the connector 'B'.

Dielectric breakdown is not permitted.

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TASK 27-09-16-810-801-A01
2. Fault Isolation

A. Reason for the Job

Self explanatory

B. Job Set-up Information

Not applicable

C. Job Set-up

Not applicable

D. Procedure

SUBTASK 27-09-16-810-001-A01
(1) Fault Isolation

Fault Isolation
Table 1002

Problem Possible Cause Correction


Breakout Torque Test, subtask-27-09-16-700-002-a01
Replace harmonic drive assembly
Harmonic drive assembly (1-140)
(1-140), bush (1-190), seal (1-200)
defective
and bearing (1-220)
The brake-out torque too high
Friction of seal (1-200) too high Replace bush (1-190), seal (1-200)
Bearing (1-220) defective and bearing (1-220)
Bonding Test, subtask-27-09-16-750-001-a01
Internal ground connection at the Disassemble the PPU and make the
PPU housing is not sufficient contact better
Resistance too high
Connector pin 'F' connection is not Disassemble connector and make
sufficient pin 'F' connection better
Electrical Zero Position Adjustment, subtask-27-09-16-700-005-a01
Synchro assembly 'A' defective Replace the synchro assembly 'A'
Voltage >195 mV when zero
mark of the input shaft aligns Synchro assembly 'A' position to
with fixed zero mark the mechanical zero position out of Adjust the synchro assembly
adjustment
Synchro assembly 'B' defective Replace the synchro assembly 'B'

Voltage >100 mV (PPU in


mechanical zero position, Synchro assembly 'B' zero position
Voltage between Fine A and to the mechanical or to the synchro
Adjust the synchro assembly
Fine B position) assembly 'A' zero position out of
adjustment

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Fault Isolation
Table 1002 (continued)

Problem Possible Cause Correction


Error Curve Examination, subtask-27-09-16-700-006-a01
Make an inspection of wheel and
Wheel (1-280) and/or spindle
compare with table of fits and
(1-310) worn
clearances. Replace if necessary
Error Curve out of tolerance
Synchro assembly 'A' (2-150)
or synchro assembly 'B' (2-160) Replace defective synchro assembly
defective
Dielectric Strength Test, subtask-27-09-16-700-009-a01
Current measured in High Make an inspection of wiring
Defective insulation
Voltage Test too high installation
Synchro assembly defective - Replace synchro assembly
Connector defective - Replace Connector

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DISASSEMBLY

TASK 27-09-16-000-801-A01
1. Disassembly of the Unit

A. Reason for the Job

Self explanatory

B. Job Set-up Information

Not Applicable

C. Job Set-up

SUBTASK 27-09-16-000-001-A01
(1) General

(a) Full disassembly is not usually necessary. To find the necessary replacement or repair of
a component (refer to Fault Isolation, task-27-09-16-810-801-a01).

(b) Disassemble in a dry, bright, clean room.

(c) Keep all parts of each sub-unit in a clean tray.

(d) Discard the parts on removal that follow:

– Bonded seals
– Gaskets
– Circlips
– Shim (1-210).

(e) Refer to the ILLUSTRATED PARTS LIST (IPL) for the figure/item numbers.

D. Procedure

SUBTASK 27-09-16-020-001-A01
(1) Removal of the Synchro Assemblies

(a) Remove the protective caps (20) (refer to Table 15001) from the connectors (2-10).

(b) Remove the screws (2-130), seals (2-140) and cover (2-120) from the housing.

(c) Remove the screws (2-20) and washers (2-30) from the connectors (2-10) and connector
block assembly (2-70).

(d) Remove the locking rings (2-60) from the connectors (2-10).

(e) Remove the wires with the reducing sleeves (2-40) and pins (2-190) from the connectors
(2-10).

NOTE: The special tool included with each connector is color coded. Red for pin
insertion and white for pin extraction.

(f) Carefully remove the gaskets (2-50) from the connectors (2-10).

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(g) Remove the screws (1-390), washers (1-400), frame (1-380), transparent plate (1-410)
and gasket (1-420) from the housing (1-350).

(h) Remove the screws (1-440) and washers (1-450) from the connector block assembly
(2-70).

(i) Remove the block assembly (2-70) and gasket (1-460) from the housing.

(j) Cut the pins (2-190) from the wires. Remove the screws (2-170) from the plates (2-180).

(k) Remove the synchro assemblies (2-150) and (2-160) with the plates (2-180) from the
housing.

(l) Remove the polyester tape from the synchro assemblies.

(m) Remove the tube (2-210) from the wires.

SUBTASK 27-09-16-020-002-A01
(2) Removal of the Cover Assembly (1-60) and Harmonic Drive Assembly (1-140)

(a) Remove the cable tie (10) (refer to Table 15001) from the cover assembly (1-60).

(b) Remove the screws (1-20) and washers (1-30) from the flange (1-10) and cover assembly.

(c) Remove the flange (1-10), locking plate (1-40) and springs (1-50) from the cover assembly.

(d) Remove the screws (1-70) and washers (1-80) from the cover.

NOTE: Safety the screws (1-70) with adhesive. During disassembly the screw heads
can break off. If the screw heads break off, remove the remaining parts of the
screws and replace the coil inserts (1-330) (refer to pageblock REPAIR).

(e) Remove the cover assembly from the housing (1-350).

NOTE: The dynamic spline remains in the housing (1-350) together with the wheel
(1-280) (refer to Figure 3001).

(f) Remove the circlip (1-170), shim (1-180) from the harmonic drive assembly (1-140).

(g) Push out the drive shaft, wave generator and flexispline of the harmonic drive assembly
(1-140) from the cover assembly (1-60) (refer to Figure 3001).

(h) Loosen the screws (1-150) enough to push the screws and thus remove the circular
spline from the housing.

(i) Remove the pins (1-130) from the cover assembly.

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DYNAMIC SPLINE
CIRCULAR SPLINE

FLEXSPLINE

WAVE GENERATOR

LLI1-270916-03001-01-01.CGM
DRIVE SHAFT

Harmonic Drive Assembly


Figure 3001

SUBTASK 27-09-16-030-001-A01
(3) Disassembly of Assembled Parts

(a) Remove the circlip (1-240) from the cover (1-90).

(b) Remove the bush (1-190), seal (1-200), shim (1-210), bearing (1-220) and shim (1-230)
from the cover.

(c) Remove the screws (1-150) and washers (1-160) from the cover (1-90).

(d) Remove the circular spline from the cover.

(e) Remove the shim (1-260), (1-270) and wheel (1-280) from the spindle (1-310).

(f) Remove the screw (1-290) from the wheel (1-280).

(g) Remove the dynamic spline from the wheel.

(h) Remove the screw (1-320) and spindle (1-310) from the housing (1-350).

(i) Remove the plate (1-370) from the housing.

(j) Remove the screws (2-110) and identification plate (2-100) from the connector block
assembly (2-70).

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CLEANING

TASK 27-09-16-100-801-A01
1. Cold Cleaning

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Consumables

Name and Material Number Group


Turco Solv LO (M201) Cleaning Agent
Ethyl Alcohol (M202) Cleaning Agent
Lint-free Cloth (M204) Cloth
Scotch Brite (M804) Abrasive Pad

NOTE: More data is shown in Consumables, task-27-09-16-941-801-a01.

C. Job Set-up

SUBTASK 27-09-16-100-001-A01
(1) General

(a) Do the cleaning procedures in a clean area with good airflow.

D. Procedure

WARNING: OBEY ALL THE SAFETY AND HEALTH PRECAUTIONS DURING THE CLEANING
PROCEDURES.

WARNING: ONLY USE APPROVED TOOLS, MATERIALS, EQUIPMENT AND PROCEDURES.


READ AND OBEY THE MANUFACTURERS INSTRUCTIONS AND THE LOCAL
HEALTH AND SAFETY REGULATIONS. THIS WILL HELP TO PREVENT INJURIES
TO PERSONNEL AND/OR DAMAGE TO PROPERTY.

WARNING: DO NOT GET CLEANING AGENTS ON YOUR SKIN, IN YOUR EYES, OR IN YOUR
MOUTH. DO NOT BREATHE THE FUMES. PUT ON APPROVED PROTECTION.
CLEANING AGENTS ARE POISONOUS.

WARNING: ONLY USE CLEANING AGENTS IN AN AREA AWAY FROM HEAT SOURCES AND
WITH A GOOD AIRFLOW. CLEANING AGENTS ARE FLAMMABLE.

WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR. DO NOT POINT
COMPRESSED AIR AT PERSONNEL. COMPRESSED AIR IS DANGEROUS AND
CAN CAUSE INJURY.

CAUTION: DO NOT TOUCH CLEAN PARTS WITH YOUR BARE HANDS. NATURAL OILS IN
YOUR SKIN CAN CAUSE CORROSION.

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SUBTASK 27-09-16-140-001-A01
(1) Cleaning of Parts

CAUTION: DO NOT USE TURCO SOLV LO FOR CLEANING PARTS WITH SEALS. THE
CLEANING AGENT CAN DAMAGE SEALS. USE ETHYL ALCOHOL TO CLEAN
SEALS AND PARTS WITH INSTALLED SEALS.

(a) Remove the heavy contamination from all metal parts with an abrasive pad Scotch
Brite (M804) and Turco Solv LO (M201) or Ethyl Alcohol (M202).

(b) Clean the metal parts (but not the bearing (1-220)) with the ultrasonic equipment
(refer to Ultrasonic Cleaning, task-27-09-16-130-801-a01) or hand clean with Turco
Solv LO (M201) and a soft bristle brush.

NOTE: The time necessary, is in relation to the quantity of contamination.

(c) Remove the contamination from the electrical components with a soft bristle brush or a
Lint-free Cloth (M204) and a small quantity of Ethyl Alcohol (M202).

WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR. DO NOT POINT
COMPRESSED AIR AT PERSONNEL. COMPRESSED AIR IS DANGEROUS
AND CAN CAUSE INJURY.

(d) Dry the parts with a Lint-free Cloth (M204) or clean, dry compressed air at a maximum
of 140 kPa (20 psi).

SUBTASK 27-09-16-100-002-A01
(2) Cleaning of Ball Bearings

CAUTION: DO NOT USE FLUIDS TO CLEAN THE BALL BEARINGS.

(a) Clean the bearing (1-220) with a Lint-free Cloth (M204) and remove dirt or grease from
the external surface.

SUBTASK 27-09-16-130-001-A01
(3) Cleaning of new Parts

(a) Fully clean the new parts and remove all preservation material.

(b) Make sure that the holes and the connections are clean and clear.

E. Close-up

SUBTASK 27-09-16-160-001-A01
(1) Protection

NOTE: The protection of the cleaned parts is only necessary, if the parts are not examined
directly after cleaning.

(a) Make sure that the parts are clean.

(b) Apply an applicable protection to the parts to prevent contamination, damage and
corrosion.

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TASK 27-09-16-130-801-A01
2. Ultrasonic Cleaning

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Consumables

Name and Material Number Group


Lint-free Cloth (M204) Cloth

NOTE: More data is shown in Consumables, task-27-09-16-941-801-a01.

(2) Equipment

Name Reference Properties Range Precision


Ultrasonic Cleaning Equipment Ultrasonic N. A. N. A. N. A.
Cleaning,
task-27-09-16-
130-801-a01

C. Job Set-up

SUBTASK 27-09-16-100-003-A01
(1) General

(a) Make sure that the heavy surface contamination of the components is removed.

D. Procedure

WARNING: ONLY USE APPROVED TOOLS, MATERIALS, EQUIPMENT AND PROCEDURES.


READ AND OBEY THE MANUFACTURERS INSTRUCTIONS AND THE LOCAL
HEALTH AND SAFETY REGULATIONS. THIS WILL HELP TO PREVENT INJURIES
TO PERSONNEL AND/OR DAMAGE TO PROPERTY.

SUBTASK 27-09-16-130-002-A01
(1) Cleaning

CAUTION: DO NOT TOUCH CLEAN PARTS WITH YOUR BARE HANDS. NATURAL OILS IN
YOUR SKIN CAN CAUSE CORROSION.

(a) Put each metal part fully in the ultrasonic bath and operate the ultrasonic cleaning
equipment.

NOTE: The time necessary is in relation to the contamination of the part.

(b) Stop the ultrasonic cleaning equipment.

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WARNING: USE GLOVES THAT GIVE PROTECTION WHEN YOU REMOVE THE PARTS
FROM THE ULTRASONIC CLEANING EQUIPMENT. THE PARTS ARE VERY
HOT AND CAN BURN YOUR SKIN.

(c) Remove the parts from the ultrasonic cleaning equipment.

(d) Do the ultrasonic cleaning again, if the parts are not clean.

(e) Let the parts cool down to ambient temperature.

WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR. DO NOT POINT
COMPRESSED AIR AT PERSONNEL. COMPRESSED AIR IS DANGEROUS
AND CAN CAUSE INJURY.

(f) Dry the parts with a Lint-free Cloth (M204) or clean, dry compressed air at a maximum
of 140 kPa (20 psi).

E. Close-up

SUBTASK 27-09-16-160-002-A01
(1) Protection

NOTE: The protection of the cleaned parts is only necessary, if the parts are not examined
directly after cleaning.

(a) Make sure that the parts are clean.

(b) Apply an applicable protection to the parts to prevent damage and corrosion.

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INSPECTION/CHECK

TASK 27-09-16-200-001-A01
1. Inspection and Check

A. Reason for the Job

Self explanatory

B. Job Set-up Information

Not applicable

C. Job Set-up

SUBTASK 27-09-16-200-001-A01
(1) General

(a) Examine the parts in a clean area with good light.

(b) Refer to the ILLUSTRATED PARTS LIST (IPL) to find the changed or superseded parts.

D. Procedure

SUBTASK 27-09-16-220-002-A01
(1) Visual Inspection

(a) Examine the surfaces of all parts for corrosion (depth and location).

(b) Examine all parts for:

– Cracks
– Scratches
– Abrasion
– Distortion.

(c) Examine all sealing surfaces and seal seats for:

– Scratches
– Nicks
– Indentations.

(d) Examine all threads for:

– Indentations
– Breaks
– Scoring.

(e) Examine all coil inserts for:

– Damage
– Tightness
– Correct insertion-depth.

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(f) Examine all gears and splined parts for:

– Fretting
– Damage
– Wear.

NOTE: Polished wear marks are only permitted, if there are no steps at the outer edges of
worn area.

(g) Make sure that the ball bearings turn freely.

(h) Examine the identification plate for correct data.

SUBTASK 27-09-16-220-003-A01
(2) Dimensional Check

(a) Do a check for correct dimensions of the parts (refer to Fits and Clearances,
task-27-09-16-220-801-a01).

SUBTASK 27-09-16-220-004-A01
(3) Spring Check

(a) Do a check for correct spring properties (refer to Spring Properties,


task-27-09-16-220-802-a01).

SUBTASK 27-09-16-210-003-A01
(4) Feel Check

(a) Do the feel check on the bearing (1-220).

(b) Hold the inner race and slowly turn the outer race.

(c) Discard the bearing if it is loose or does not turn smooth.

SUBTASK 27-09-16-230-001-A01
(5) Crack Test - Fluorescent-Penetrant Method

(a) If you think there is a crack, do a crack test to the fluorescent-penetrant method
(ASTM-E1417 or approved alternative) on the parts that follow:

– Cover (1-90)
– Cover (2-120)
– Housing (1-350).

Cracks are not permitted.

SUBTASK 27-09-16-240-001-A01
(6) Crack Test - Magnetic-Particle Method

(a) If you think there is a crack, do a crack test to the magnetic-particle method (ASTM-E-1444
or approved alternative) on the steel parts.

Cracks are not permitted.

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E. Close-up

SUBTASK 27-09-16-210-001-A01
(1) Part Categories

(a) After inspection/check, put the parts into one of these groups:

– Serviceable
– For repair
– Discard and replace.

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REPAIR

TASK 27-09-16-350-801-A01
1. General Repairs

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Consumables

Name and Material Number Group


Deoxidine 624 (M103) Pickling Agent
Molykote DX (M302) Corrosion Protection

NOTE: More data is shown in Consumables, task-27-09-16-941-801-a01.

C. Job Set-up

Not Applicable

D. Procedure

SUBTASK 27-09-16-350-001-A01
(1) Removal of Corrosion

(a) Remove the light corrosion with an abrasive stone or glass fibre brush.

(b) Make sure that the dimensions are correct (refer to Fits and Clearances,
task-27-09-16-220-801-a01).

SUBTASK 27-09-16-380-001-A01
(2) Surface Treatment

WARNING: OBEY ALL HEALTH AND SAFETY PRECAUTIONS. THE MATERIAL IS


POISONOUS AND ACIDIC. IT CAN CAUSE INJURY TO PERSONNEL AND/OR
DAMAGE TO THE PARTS.

(a) Repair small damage to the anodic-oxidized surfaces of the aluminium alloy parts with
Alodine 1200 (M104), refer to MIL-DTL-5541.

SUBTASK 27-09-16-350-002-A01
(3) Replacement of the Coil Inserts

(a) Remove the setscrew (1-100) from the coil insert (1-110).

(b) Remove the coil inserts (1-110), (1-120), (1-330), (1-340), (1-360) and (2-80) with a
removal tool.

(c) Clean the threaded holes of the related damaged coil inserts with Ethyl Alcohol (M202).

(d) Apply a thin layer of Molykote DX (M302) to the threads of the coil inserts.

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(e) At none countersunk holes, install the inserts to between 1/4 and 1/2 of a turn below the
surface of the holes with an insertion tool.

(f) Carefully break off and remove the fitting tang.

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ASSEMBLY

TASK 27-09-16-400-801-A01
1. Assembly of the Unit

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Special Tools

Name and Part Number Used for


To install the bush (1-190) to the drive shaft of the
Mandrel (58540-0002)
harmonic drive assembly (1-140)
Mandrel (58540-0003) To install the seal (1-200) to the housing (1-90)

NOTE: More data is shown in Special Tools, Fixtures and Equipment,


task-27-09-16-940-801-a01.

(2) Consumables

Name and Material Number Group


Araldite 2011 (M001) Adhesive
Loctite 675 (M029) Safety Lacquer
Sicomet 8300 (M030) Adhesive
Ardrox 3140 (M122) Corrosion Preventive
Molykote DX (M302) Corrosion Protection
Grease Isoflex Alltime SL1 (M313) Grease
PR1826B2ALO (M704) Sealing Compound
Lockwire 0.63 (M819) Lockwire

NOTE: More data is shown in Consumables, task-27-09-16-941-801-a01.

C. Job Set-up

SUBTASK 27-09-16-400-001-A01
(1) Preparation

(a) Refer to the ILLUSTRATED PARTS LIST (IPL) for the figure/item numbers.

(b) If necessary, remove the parts from their applicable storage containers.

(c) Examine the parts for the correct part number and make sure that they are serviceable.

(d) Make sure that all parts are clean and all preservation material used during storage is
removed.

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(e) Make sure that the shelf life and the cure date of the seals have not expired.

(f) Make sure that all special tools, fixtures and equipment are serviceable and, where
necessary, correctly calibrated before you use them.

D. Procedure

SUBTASK 27-09-16-440-001-A01
(1) Assembly of the Housing

(a) Apply Araldite 2011 (M001) to the plate (1-370).

(b) Install the plate in the slot of the housing. Make sure that the end of the plate is between
7.9 and 8.5 mm (0.31 and 0.33 in.) from the end of the slot (refer to Figure 7001).

(c) Install the spindle (1-310) to the housing.

(d) Apply Loctite 675 (M029) to the threads of the screws (1-320) and install the screws to the
spindle and housing. Torque the screws between 0.8 and 1.2 Nm (7 and 10 lbf.in.).

(e) Examine the truth of turn of the bore of the housing (refer to Figure 7002). Make sure that
the truth of turn is ≤0.04 mm (0.0016 in.).

CAUTION: IF REPLACEMENT IS NECESSARY, REPLACE THE FULL HARMONIC DRIVE


ASSEMBLY (1-140). MAKE SURE THAT THE PN OF ALL PARTS OF THE
HARMONIC DRIVE ASSEMBLY IS SAME.

(f) Install the dynamic spline of the harmonic drive assembly (1-140) to the wheel (1-280)
(refer to Figure 3001).

(g) Apply Loctite 675 (M029) to the threads of the screws (1-290). Install the screws to the
wheel (1-280). Torque the screws between 0.8 and 1.2 Nm (7 and 10 lbf.in.).

(h) Apply Grease Isoflex Alltime SL1 (M313) to the threads of the wheel, dynamic spline
and spindle.

(i) Push the wheel (1-280), shim (1-270), shim (1-260) and circlip (1-250) to the spindle
(1-310). Make sure that the axial play between the wheel and the spindle is 0.02 to
0.08 mm (0.001 to 0.003 in.) (refer to Figure 7003).

(j) Adjust the thickness of the shim (1-270) to give the correct axial play. If necessary, use
one or more shims (1-270) for correct adjustment.

(k) Turn the wheel in CW and CCW direction with your hand and make sure that it turns freely.

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COMPONENT MAINTENANCE MANUAL
9028A0004

HOUSING (1-350)

LLI1-270916-07001-01-01.CGM
PLATE (1-370)

Installation of the Plate (1-370)


Figure 7001

SUPPORT FOR
MEASURING THE
TRUTH OF TURN

SPINDLE (1-310)

POINT OF MEASUREMENT
LLI1-270916-07002-01-01.CGM

HOUSING (1-350)

Assembly Measurement
Figure 7002

27-09-16 Page 7003


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COMPONENT MAINTENANCE MANUAL
9028A0004

SUBTASK 27-09-16-420-002-A01
(2) Assembly of the Cover

(a) Apply Loctite 675 (M029) to the small diameter of the pins (1-130).

(b) Install the pins in the holes of the cover (1-90). Make sure that the distance between the
centres of the two pins is 25.4 mm (1.00 in.) and the pins are in position.

(c) Install the circular spline of the harmonic drive assembly (1-140) to the cover (1-90) (refer
to Figure 3001).

(d) Apply Loctite 675 (M029) to the threads of the screws (1-150). Install the screws and the
washers (1-160) to the cover. Torque the screws between 0.8 and 1.0 Nm (7 and 9 lbf.in.).

(e) Install seal (1-200) into housing (1-90) using Mandrel (58540-0003).

(f) Install the shim (1-210), bearing (1-220), shim (1-230) and circlip (1-240) to the cover
(1-90). Make sure that the axial play of the bearing (1-220) is ≤0.12 mm (0.0047 in).
If necessary, use one or more shims (1-230) or remove the shim (1-210) for correct
adjustment.

(g) Apply Grease Isoflex Alltime SL1 (M313) to the teeth of the circular spline.

(h) Apply Grease Isoflex Alltime SL1 (M313) to the shaft, bearing and flexspline of the
harmonic drive assembly (1-140). Install the flexspline to the bearing.

(i) Push the drive shaft with the bearing of the harmonic drive assembly into the cover (1-90).

(j) Turn the drive shaft in CW and CCW direction with your hand and make sure that it
turns freely.

CAUTION: MAKE SURE THAT THE CHAMFER SIDE OF THE BUSH (1-190) IS
INSTALLED AGAINST THE BEARING (1-220). THIS WILL HELP TO PREVENT
MALFUNCTION OF THE PPU.

(k) Push the bush (1-190) to the drive shaft of the harmonic drive assembly (1-140) with the
Mandrel (58540-0002) (refer to Figure 7003).

(l) Push the shim (1-180) and the circlip (1-170) to the drive shaft of the harmonic drive
assembly (1-140) (refer to Figure 7003).

NOTE: Replace the shim (1-180) if the circlip (1-170) is not correctly installed in the
groove.

(m) Install the springs (1-50) to the pins (1-130).

CAUTION: MAKE SURE THAT THE CHAMFER SIDE OF THE LOCKING PLATE (1-40) IS
INSTALLED AGAINST THE COVER (1-90). THIS WILL HELP TO PREVENT
MALFUNCTION OF THE PPU.

CAUTION: IF YOU USE THE OLD PARTS, MAKE SURE THAT THE MARKS OF THE
LOCKING PLATE (1-40) AND THE INPUT SHAFT OF THE HARMONIC DRIVE
ASSEMBLY (1-140) ARE ALIGNED.

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COMPONENT MAINTENANCE MANUAL
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CAUTION: MAKE SURE THAT THE MARKS OF THE LOCKING PLATE (1-40) IS IN THE
CORRECT DIRECTION (REFER TO FIGURE 1001).

(n) Install the locking plate (1-40) to the springs and pins.

NOTE: If you use new parts the marks must be put while the adjustment of the synchro
assemblies to the locking plate (1-40) and/or the input shaft of the harmonic
drive assembly (1-140) (refer to Adjustment of the Synchro Assemblies,
subtask-27-09-16-820-001-a01).

(o) Install the flange (1-10) to the cover. Install the screws (1-20) and washers (1-30) to the
flange and cover. Torque the screws between 0.8 and 1.0 Nm (7 and 9 lbf.in.).

SEAL (1-200)**
CIRCLIP (1-240)
BUSH (1-190)* BEARING (1-220)

CIRCLIP (1-170)

SPINDLE
(1-310)

LLI1-270916-07003-01-01.CGM
SPACER (1-230) SHIM
SHIM (1-180) (1-270)
INPUT SHAFT OF HARMONIC
DRIVE ASSEMBLY (1-140) SHIM (1-210)
SHIM (1-260)

LEGEND CIRCLIP (1-250)


* INSTALL WITH MANDREL (58540-0002)
* * INSTALL WITH MANDREL (58540-0003)
Harmonic Drive Assembly (1-140) with Assembled Items
Figure 7003

SUBTASK 27-09-16-210-002-A01
(3) Truth of Turn Check of the Synchro Assemblies

NOTE: The truth of turn check is necessary only if one or the two synchro assemblies are
replaced.

(a) Align the holes of the drive gear of the synchro assembly 'A' (2-150) and make it spring
loaded. Install an applicable pin into the alignment holes of the gear.

NOTE: This will keep the gear spring-loaded.

(b) Put the synchro assembly 'A' in a vee-block or alternative support. Make sure that the
gear reference mark points towards the DTI.

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COMPONENT MAINTENANCE MANUAL
9028A0004

(c) Attach a flat shaped tip to the DTI. Position the DTI on the gear at the 0° position with a
suitable support (refer to Figure 7004). Set the DTI to zero.

(d) Turn the shaft of the synchro assembly CCW and record the deviation at 90°, 180°, 270°
and 360° of shaft turn. Obey the direction of the deviation.

(e) Do a check of the synchro assembly 'B' (2-160).

(f) Calculate the difference of the deviations of the synchro assemblies at 90°, 180°, 270°
and 360° of shaft turn.

(g) Make sure that all differences are ≤25 µm (0.001 in.).

DIAL TEST INDICATOR

REFERENCE MARK 0°
OF SYNCHRO HOUSING

BACKLASH GEAR GEAR REFERENCE MARK


(FIXED SPROCKET)
REFERENCE MARK
0° ON SHAFT

LLI1-270916-07004-01-01.CGM
DIRECTION OF
TURN

V-BLOCK

Truth of Turn Check of the Synchro Assemblies


Figure 7004

SUBTASK 27-09-16-420-003-A01
(4) Installation of the Synchro Assemblies and Connector Block

(a) Install applicable pins into the alignment holes of the gears of the synchro assemblies
(2-150) and (2-160).

NOTE: This will keep the gears spring-loaded.

(b) Turn the wheel (1-280) in the housing (1-350) until the drive gear zero mark is aligned with
the fixed pointer in the inspection window (refer to Figure 1001). Hold the wheel in position.

(c) Install the synchro assemblies (2-150) and (2-160) to the housing (1-350), so that the
applicable pins align with the center point of the spindle (1-310). Hold the wheel of the
harmonic drive in position during this procedure (refer to Figure 7005).

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COMPONENT MAINTENANCE MANUAL
9028A0004

(d) Set the wire bundles in the correct position (refer to Figure 7006). Lock the synchro
assemblies with the plates (2-180) and the screws (2-170). Torque the screws between
0.8 and 1.2 Nm (7 and 10 lbf.in.).

(e) Push the wires of the synchro assemblies and grounding lead (2-200) through the tube
(2-210).

(f) Push the tube (2-210) into the channel of housing (1-350).

NOTE: The channel is below the plate (1-370).

(g) Remove the pins.

(h) Remove an applicable screw (2-170) and install the grounding lead (2-200) to the plate
(2-180). Torque the screw (2-170) between 0.8 and 1.2 Nm (7 and 10 lbf.in.).

CAUTION: MAKE SURE THAT THE POSITION OF THE KNOTS ARE AS FAR AS POSSIBLE
FROM THE COVER (2-120).

(i) Attach the wires of synchro assembly 'A' and the ground lead together with the polyester
tape. Safety the tape with a knot and attach to synchro assembly 'A' (2-150) with Sicomet
8300 (M030) (refer to Figure 7006).

(j) Attach the wires of synchro assembly 'B' together with polyester tape. Safety the tape with
a knot and attach to synchro assembly 'B' with Sicomet 8300 (M030) (refer to Figure 7006).

(k) Install the gasket (1-460) to the housing.

(l) Apply Molykote DX (M302) in holes of the screws of the connector block assembly (2-70).

(m) Push the wires of synchro assemblies and the grounding lead (2-200) through the
connector block assembly (2-70).

(n) Install the connector block assembly to the housing (1-350).

(o) Install the screws (1-440) and washers (1-450) to the connector block assembly and
housing. Torque the screws to between 0.8 and 1.0 Nm (7 and 9 lbf.in.).

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COMPONENT MAINTENANCE MANUAL
9028A0004

POSITION OF PINS
SYNCHRO ASSEMBLY 'B'
(2-160)

SYNCHRO ASSEMBLY 'A'


(2-150)

LLI1-270916-07005-01-01.CGM

Arrangement of the Synchro Assemblies in the Zero Position


Figure 7005

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Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

SUBTASK 27-09-16-420-004-A01
(5) Installation of the Connectors

(a) Remove 5 mm (0.2 in.) of the insulation from the end of the wires with the wire-stripper.

CAUTION: FOR THE GROUNDING LEAD WIRE DO NOT USE A REDUCING SLEEVE (2-40).

(b) Put the wires of the synchro assemblies (2-150) and (2-160) through the holes of the
reducing sleeves (2-40).

(c) Install the pins (2-190) to the ends of the wires of the synchro assemblies and sleeves.

(d) Crimp the pins with a crimp tool. Put the wires of the synchro assemblies through the
holes of the locking ring (2-60).

(e) Put the wires of the synchro assemblies through the holes of the gaskets (2-50).

(f) Install the pins into the connector (2-10) with the applicable insertion tool (refer to Figure 4).

NOTE: The special tool included with each connector is color coded. Red for pin
insertion and white for pin extraction.

(g) Install the locking rings (2-60) to the connector (2-10).

(h) Install the connectors (2-10) and the gaskets (2-50) to the connector block assembly.

(i) Apply Molykote DX (M302) in holes of the screws of the connector block assembly.

(j) Make sure that the master splines of the connectors are in the correct position (refer
to Figure 7006). Install the screws (2-20) and washers (2-30) to the connectors and
connector block assembly. Torque the screws between 0.45 and 0.55 Nm (4 and 5 lbf.in.).

SUBTASK 27-09-16-420-005-A01
(6) Assembly of the Housing and Cover

(a) Clean the attachment faces of the cover (1-90) and the housing (1-350).

(b) Apply sealing compound PR1826B2ALO (M704) to the attachment face of the housing
(1-350) and let it dry for 5 to 10 minutes.

(c) Attach the cover (1-90) to the housing (1-350). Make sure that the flexspline aligns
correctly with the circular dynamic splines.

(d) Install the screws (1-70) and washers (1-80) to the cover and housing. Torque the screws
between 0.8 and 1.2 Nm (7 and 10 lbf.in.).

(e) Install the setscrew (1-100) into the cover (1-90) if removed during disassembly. Make
sure that the setscrew head is between 0.7 and 1.3 mm (0.03 and 0.05 in.) above the
surface of the cover.

(f) Make sure that all the mechanical zero marks are correctly aligned (refer to Figure 1001).

(g) Turn the input shaft with your hand and make sure that it turns freely.

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COMPONENT MAINTENANCE MANUAL
9028A0004

SYNCHRO ASSEMBLY 'B'


POLYESTER BAND
GROUNDING LEAD (2-200) (2-160)

GROUND CABLE

KNOT
WIRE BUNDLE
SCREW (2-170)
KNOT

POLYESTER BAND
A

SYNCHRO ASSEMBLY 'A'


TUBE (2-210)
(2-150)

CONNECTOR 'A' (2-10)

MASTER SPLINES
CONNECTOR 'B' (2-10)

APPLY SEALING COMPOUND


PR1776A2AS (M702)
LLI1-270916-07006-01-01.CGM

Assembly Details
Figure 7006

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COMPONENT MAINTENANCE MANUAL
9028A0004

SUBTASK 27-09-16-420-006-A01
(7) Installation of the Frame

(a) Safety the screws (1-440) with Lockwire 0.63 (M819) as per NASM 33540.

(b) Install the frame (1-380), transparent plate (1-410) and gasket (1-420) to the housing
(1-350).

(c) Install the screws (1-390) and washers (1-400) to the frame and housing. Torque the
screws between 0.8 and 1.0 Nm (7 and 9 lbf.in.).

(d) Apply Ardrox 3140 (M122) to the washers (1-400) and the heads of the screws (1-390).

SUBTASK 27-09-16-440-002-A01
(8) End Procedure

(a) Do the test (refer to Testing, task-27-09-16-700-801-a01).

(b) Torque all applicable exposed screws, (refer to Torque Values,


task-27-09-16-210-801-a01).

(c) Safety all applicable bolts, screws and nuts with Lockwire 0.63 (M819) as per NASM
33540.

(d) Apply Ardrox 3140 (M122) to all exposed nuts and screw heads.

(e) Make sure that all open holes and bores are filled with sealing compound
PR1826B2ALO (M704).

(f) Make sure that the input shaft is in the zero position.

(g) Install the cable tie (10) (refer to Table 15001) and lock the locking plate (1-40), refer to
Figure 1.

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COMPONENT MAINTENANCE MANUAL
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COMPONENT MAINTENANCE MANUAL
9028A0004

FITS AND CLEARANCES

TASK 27-09-16-220-801-A01
1. Fits and Clearances

A. How to use the Fits and Clearances Table

(1) Identifiers in column “Mating IPL Figure and Item No.” identify the parts in the IPL.

(2) The column “Original Manufacturer Limits” gives the original manufacturing limits and
clearances.

(3) The column “In-Service Wear Limits”:

(a) The maximum limits are maximum wear limits. If a part is in these limits then it is
serviceable.

(b) You must repair or replace parts with more wear than the permitted limits (refer to
REPAIR).

B. Fits and Clearances Table

Original Manufacturer Limits In-Service Wear Limits


Mating
Figure IPL Permitted
Dimension Dimension Dimension
8001 Figure Clearance
mm (in.) mm (in.) mm (in.)
Ref. No. and mm (in.)
Item No.
Min. Max. Min. Max. Min. Max. Max.
OD (1-140)
over two
measuring
6.507 6.557 6.500 6.557
1 pins of - - -
(0.2562) (0.2581) (0.2560) (0.2581)
0.430 mm
(0.0169 in.)
dia.
6.986 6.995 6.986 6.995
OD (1-140)
(0.2750) (0.2754) -0.024 -0.006 (0.2750) (0.2754) -0.006
2
6.971 6.980 (-0.001) (-0.0002) 6.971 6.980 (-0.0002)
ID (1-190)
(0.2744) (0.2748) (0.2744) (0.2748)
6.986 6.995 6.986 6.995
OD (1-140)
(0.2750) (0.2754) 0.000 0.014 (0.2750) (0.2754) 0.014
3
6.995 7.000 (0.000) (0.0006) 6.995 7.000 (0.0006)
ID (1-220)
(0.2754) (0.2756) (0.2754) (0.2756)
16.995 17.000 16.995 17.000
OD (1-220)
(0.6691) (0.6693) 0.001 0.019 (0.6691) (0.6693) 0.022
4
17.001 17.014 (0.00004) (0.0007) 17.001 17.017 (0.0008)
ID (1-90)
(0.6693) (0.6698) (0.6693) (0.6699)

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COMPONENT MAINTENANCE MANUAL
9028A0004

Original Manufacturer Limits In-Service Wear Limits


Mating
Figure IPL Permitted
Dimension Dimension Dimension
8001 Figure Clearance
mm (in.) mm (in.) mm (in.)
Ref. No. and mm (in.)
Item No.
Min. Max. Min. Max. Min. Max. Max.
4.994 5.000 4.992 5.000
OD (1-310)
(0.1966) (0.1968) 0.004 0.018 (0.1965) (0.1968) 0.022
5
5.004 5.012 (0.0001) (0.0007) 5.004 5.014 (0.0009)
ID (1-280)
(0.1970) (0.1973) (0.1970) (0.1974)

LLI1-270916-08001-01-01.CGM
2 3 4 5
1

INPUT SHAFT OF HARMONIC


DRIVE ASSEMBLY (1-140)

Fits and Clearances - Locations


Figure 8001

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COMPONENT MAINTENANCE MANUAL
9028A0004

TASK 27-09-16-220-802-A01
2. Spring Properties

A. General

(1) The parts are identified by the IPL figure and item number.

B. Spring Properties Table

IPL Fig. and Item Length of Spring Test Length of Spring Test Spring Force
No. mm (in.) mm (in.) N (lbf)
15.2 (0.598) 7.6 to 10.4 (1.71 to 2.34)
(1-50) 21.4 (0.843)
10.7 (0.421) 14.0 to 17.0 (3.15 to 3.82)

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COMPONENT MAINTENANCE MANUAL
9028A0004

TASK 27-09-16-210-801-A01
3. Torque Values

A. General

(1) The parts are identified by the IPL figure and item number.

B. Torque Values Table

Torque
IPL Fig. and Item No. Name
Nm (lbf.in.)
(1-20) Screw 0.8 to 1.0 (7 to 9)
(1-70) Screw 0.8 to 1.2 (7 to 10)
(1-150) Screw 0.8 to 1.0 (7 to 9)
(1-290) Screw 0.8 to 1.2 (7 to 10)
(1-320) Screw 0.8 to 1.2 (7 to 10)
(1-390) Screw 0.8 to 1.0 (7 to 9)
(1-440) Screw 0.8 to 1.0 (7 to 9)
(2-20) Screw 0.45 to 0.55 (4 to 5)
(2-130) Screw 0.8 to 1.0 (7 to 9)
(2-170) Screw 0.8 to 1.2 (7 to 10)

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COMPONENT MAINTENANCE MANUAL
9028A0004

SPECIAL TOOLS, FIXTURES, EQUIPMENT AND CONSUMABLES

TASK 27-09-16-940-801-A01
1. Special Tools, Fixtures and Equipment

A. List of Special Tools, Fixtures and Equipment

NOTE: You can use equivalent alternatives.

Figure 9001 Vendor Code and Used in


Name and Part Number
Ref. No. Address Page Block
1 Coarse/Fine Selector (52173A0000-01) D9893 1000
2 Connection Cables (52268A0000-01) D9893 1000
3 Test Set Assembly (55947S0000)
3.1 Mounting Plate (55947S0001)
D9893 1000
3.2 Adjustment Mandrel (55947S0100)
3.3 Connector Assembly (55947S0300)
4 Mechanical Test Set (52182A0000-01) D9893 1000
5 Control Box (52183A0000-01) D9893 1000
6 Connection Cables (52261A0000-01) D9893 1000
7 Mandrel (58540-0002) D9893 7000
8 Mandrel (58540-0003) D9893 7000
-9 Test Rig 230 V (60550A0000-01) D9893 1000
- ITEM NOT ILLUSTRATED

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Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

3 3.3

3.2
3.1

LLI1-270916-09001-01-01.CGM

Special Tools, Fixtures and Equipment


(Sheet 1 of 3)
Figure 9001

27-09-16 Page 9002


Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

SENSOR

POWER SUPPLY
5
CABLE

MEASUREMENT LINE

6*

LLI1-270916-09001-02-01.CGM

LEGEND
* INDICATES CONNECTION CABLES ONLY FOR PPU A310

Special Tools, Fixtures and Equipment


(Sheet 2 of 3)
Figure 9001

27-09-16 Page 9003


Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

LLI1-270916-09001-03-00.CGM

Special Tools, Fixtures and Equipment


(Sheet 3 of 3)
Figure 9001

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COMPONENT MAINTENANCE MANUAL
9028A0004

TASK 27-09-16-941-801-A01
2. Consumables

A. List of Consumables

NOTE: You can use approved alternatives.

Name and Material Used in Page


Group Specification Vendor Code and Address
Number Block
D8274
3M DEUTSCHLAND GmbH
Araldite 2011 (M001) Adhesive Carl-Schurz-Strasse 1 7000
41453 Neuss
Germany
D2617
LOCTITE DEUTSCHLAND
GmbH 1000
Loctite 675 (M029) Safety Lacquer
Postfach 81 05 80 7000
81905 Muenchen
Germany
D2065
Henkel KGAA
Sicomet 8300 (M030) Adhesive Sichel Str.1 7000
30453 Hannover
Germany
F2865
CFPI INDUSTRIES
S.A.
Deoxidine 624 (M103) Pickling Agent 6000
28 Blvd Camelinat
92233 Gennevilliers
France
D1940
Aerospatial PQ CHEMETALL GmbH
Corrosion
Ardrox 3140 (M122) 816.0 Norme Air Trakehner Str. 3 7000
Preventive
0011 60487 Frankfurt a.M.
Germany
D8908
HENKEL SURFACE
TECHNOLOGIES
Turco Solv LO (M201) Cleaning Agent 4000
Henkelstrasse 67
40589 Duesseldorf
Germany
O-E-00760 Type 4000
Ethyl Alcohol (M202) Cleaning Agent Local purchase
III 15000
DEF 1410-1 A
Lint-free Cloth (M204) Cloth Local purchase 4000
A59323

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COMPONENT MAINTENANCE MANUAL
9028A0004

Name and Material Used in Page


Group Specification Vendor Code and Address
Number Block
D8367
DOW CORNING GmbH
Corrosion 6000
Molykote DX (M302) Rheingaustrasse 34
Protection 7000
65201 Wiesbaden
Germany
Grease MIL-PRF-
Grease MIL-PRF-81322 Local purchase 15000
81322 (M304)
D8375
KLUEBER LUBRICATION
DEUTSCHLAND KG
Grease Isoflex Alltime Geisenhausenerstrasse 7
Grease 7000
SL1 (M313) 81379 Muenchen
Postfach 701047
81310 Muenchen
Germany
F0229
JOINT FRANCAIS (Le)
Sealing GROUPE HUTCHINSON
PR1826B2ALO (M704) 7000
Compound 2 Rue de Balzac
75008 Paris
France
Scotch Brite (M804) Abrasive Pad Local purchase 4000
Lockwire 0.63 (M819) Lockwire Local purchase 7000

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COMPONENT MAINTENANCE MANUAL
9028A0004

STORAGE (INCLUDING TRANSPORTATION)

TASK 27-09-16-550-801-A01
1. Storage of the Unit

A. Reason for the Job

Self explanatory

B. Job Set-up Information

(1) Consumables

Name and Material Number Group


Ethyl Alcohol (M202) Cleaning Agent
Grease MIL-PRF-81322 (M304) Grease

NOTE: More data is shown in Consumables, task-27-09-16-941-801-a01.

C. Job Set-up

Not applicable

D. Procedure

SUBTASK 27-09-16-530-001-A01
(1) Installation of the Storage Parts
(Refer to Figure 15001)
(Refer to Table 15001)

(a) Attach the cable tie (10) and caps (20) to the PPU.

(b) Attach the screws (30) and washers (40) in a plastic bag to the PPU.

Storage Parts
Table 15001

Fig.15001 Vendor Code and


Part Number Name Quantity
Ref. No. Address
10 V23403Z359A3 Cable Tie VD9893 1
VF0225
9 R PORTE DE BUC,
20 8500-5586A Protective Cap 2
78000 VERSAILLES,
FRANCE
30 NAS1351C4-12P Screw V80205 4
40 MS20002-4 Washer V96906 4

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COMPONENT MAINTENANCE MANUAL
9028A0004

POSITION PICK-OFF UNIT 20

30 x4

10
LLI1-270916-15001-01-00.CGM

40 x4

Storage Parts
Figure 15001

27-09-16 Page 15002


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COMPONENT MAINTENANCE MANUAL
9028A0004

SUBTASK 27-09-16-530-002-A01
(2) Packing

(a) Clean the unit externally and remove all finger marks with Ethyl Alcohol (M202).

(b) Apply a thin layer of Grease MIL-PRF-81322 (M304) to all the steel parts that do not
have protection.

(c) Put protective material on all projections and sharp edges.

(d) Wind shock absorbent material around the unit and then wind waxed-paper around the
shock absorbent material.

CAUTION: SEAL THE POLYETHYLENE BAG AS QUICKLY AS POSSIBLE, THE DESICCANT


BAGS ABSORB WATER QUICKLY.

(e) Put sealed bags of desiccant along the length of the unit.

(f) Put the unit into a polyethylene bag which has a minimum thickness of 0.2 mm (0.008 in.).
Make sure that there is sufficient material to seal the bag three times.

(g) Put an identification label into the bag and make sure that it can be read externally.

(h) Put a humidity indicator into the bag and make sure that it can be seen externally.

(i) Remove as much air as possible from the bag, then use heat to seal it.

(j) Attach the labels that follow to the outer side of the bag:

– A label that shows the packing date and that a desiccant is used
– A label identified, 'DO NOT OPEN UNLESS IT IS NECESSARY'.

(k) Put the unit into an ATA 300 container and make sure it cannot move in the container.

(l) Close the container and attach the labels that follow:

– Item identification
– Desiccant label.

(m) Apply a layer of clear varnish to the labels (refer to ATA 300 for the label data).

SUBTASK 27-09-16-550-001-A01
(3) Storage

(a) Do not keep the unit near a source of fluids that can cause corrosion, heat or ozone.

(b) Make sure that you can read the identification and humidity indication labels easily.

(c) Keep the packaged unit in a sequence of date.

(d) Keep the unit in its original packing. If stacked-storage is used, be careful to prevent
damage caused by too much weight (refer to Technical Data, task-27-09-16-872-802-a01).

(e) Keep the unit in a clean, dry room or building.

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COMPONENT MAINTENANCE MANUAL
9028A0004

(f) Make sure that the temperature is between 18 and 28 °C (64 and 82 °F) and the relative
humidity is between 25 and 65 %.

SUBTASK 27-09-16-540-001-A01
(4) Removal from Storage

(a) Remove the unit with the oldest date from storage first.

(b) Remove the unit from the container and polyethylene bag.

(c) Remove the packing materials and clean off corrosion protection.

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COMPONENT MAINTENANCE MANUAL
9028A0004

ILLUSTRATED PARTS LIST (IPL)

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TASK 27-09-16-871-803-A01
1. Introduction

A. General

(1) The Illustrated Parts List (IPL) gives data for the identification of the replacement parts for
this unit. The item numbers are given in the sequence of disassembly. The IPL includes the
sections that follows:

Introduction (INTRO)
Equipment Designator Index (EDI)
Vendors List (VL)
Numerical Index (NI)
Detailed Parts List (DPL).

B. How to Use the IPL

(1) Part Number known

(a) When a PN is known, refer to the numerical index.

(b) The NI will give you the figure and index number for the part.

(c) Use the figure and index number to refer to the data about the part in the applicable
illustration or DPL.

(2) Part Number unknown

(a) When PN is unknown, find the illustration that shows the applicable part.

(b) Use the item number given in the illustration to refer to data about the part in the DPL.

C. Vendors List

(1) Vendor codes, which have the capital letter "V" in front of them, are given in the nomenclature
column of the DPL.

(2) The vendor code show the source of procurement of vendor items.

(3) These codes and the address of the vendors are given in Vendor List.

(4) When no code is given, the item is a LIEBHERR-AEROSPACE LINDENBERG part or a


standard part.

D. Numerical Index

(1) The NI shows all of the part numbers given in the detailed parts list in an alpha-numeric
sequence.

(2) The “Part Number” column contains all part numbers included in the DPL.

(3) The “Total Required” column shows the total quantity necessary for each figure and item
number of the PN.

(4) A column is given for airline use and optional PNs.

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COMPONENT MAINTENANCE MANUAL
9028A0004

(5) Part numbers that have deleted or superseded in the DPL are shown in the NI and identified
as deleted or superseded.

E. Detailed Part List

(1) The DPL gives part numbers and their related illustrations.

(2) The indenture system which shows the relation of the data, is given below.

1234567
Assembly
Attaching parts for assembly
• Detailed parts for assembly
• Sub-assembly
• Attaching parts for sub-assembly
• • Detailed parts for sub-assembly
• • Sub-sub-assembly
• • Attaching parts for sub-sub-assembly
• • • Detailed parts for sub-sub-assembly

(3) You find the attaching parts directly after the part which they attach. They are given in the same
indenture as the item they attach and are identified as "Attaching Parts" followed with asterisks.

NOTE: A dash (-) in front of the item number in the "Figure and Item" column identifies items
that are not illustrated.

(4) A column is given for airline use.

(5) Vendor Codes have the prefix "V" and are given in brackets.

F. Effectivity Code

(1) A letter (A, B and so on) shows a variant of the item, assembly or sub-assembly and their
relation to the next higher assembly where applicable.

G. Symbols and Abbreviations

ALT TO part Alternative to part number, This identifies an alternative


number MADE PN specified as a part that
BY has the same function and
is physically interchangeable
after re-work. and modification
or requires additional part to
install it.

AMDT Amendment

AR As Required This shows that the part is used


in a quantity as necessary.

DELETED Deleted part

DET Detail

DPL Detailed Parts List

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COMPONENT MAINTENANCE MANUAL
9028A0004

EDI Equipment Designator Index

IPL Illustrated Parts List

LH OR RH Left hand or right hand This shows a left hand or right


hand part.

LM A part made from raw


materials, such as seals,
hinge strips, extrusions and so
on.

MFR Manufacturer Manufacturer or Optional


Manufacturer in the DPL.

NHA Next higher assembly

NP Not procurable You cannot send an order for


this part.

OPT TO PN Optional to part number This shows an "optional" PN


that is fully interchangeable
with the part in the part-number
column.

OPT SEE TABLE See optional table

ORDER Order overlength part number This shows a PN more than 15


OVERLGTH PN figures long which is too large
for the part number column.

OVERSIZE/ This shows an oversize or


UNDERSIZE undersize part.

PN Part number

POST SB Post Service Bulletin This shows the Service Bulletin


which has an effect on the
item shown in the part number
column.

PRE SB Pre Service Bulletin Before modification shown by


a Service Bulletin.

RF For reference This shows an item given for


reference data.

SEE CMM See Component Maintenance Manual

SEE FIG FOR See figure for details This shows the IPL location
DET where detail-breakdown
locations of a sub-assembly
are shown.

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COMPONENT MAINTENANCE MANUAL
9028A0004

SEE FIG FOR See figure for next higher assembly This shows the IPL location
NHA where the next highest
assembly is shown.

SEL FROM Selected from This shows the part which


must be selected as necessary
from a group of parts with a
basic PN.

SUPSD BY Superseded by xxx Identifies a part superseded


or replaced in the unit or
assembly and is referenced to
the new part.

SUPSDS Supersedes xxx Identifies the new part used


in the unit or assembly and
is referenced to the part it
superseded or replaced.

VL Vendors List

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COMPONENT MAINTENANCE MANUAL
9028A0004

VENDOR LIST

CODE NAME ADDRESS

VD1371 ITT CANNON GMBH CANNONSTR. 1-3


P.O.BOX 1120
71384 WEINSTADT
GERMANY

VD9893 LIEBHERR-AEROSPACE P.O. BOX 1363


LINDENBERG GMBH 88153 LINDENBERG
GERMANY

VF0225 SOURIAU 9 R PORTE DE BUC


78000 VERSAILLES
FRANCE

VF5442 AEROSPATIALE MATRA 37 BD MONTMORENCY


NORMALISATION STANDARD 75016 PARIS
ASN FRANCE

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COMPONENT MAINTENANCE MANUAL
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ALPHA/NUMERIC INDEX

PART NUMBER AIRLINE FIGURE ITEM TOTAL


STOCK NUMBER NUMBER REQ'D
NUMBER

C23121Z10C21 001 –271A AR

C23121Z10C22 001 –272A AR

C23123Z3C2 002 140A 4

C23211A1C12 001 370A 1

C23211A1C29 002 120A 1

C23211A1C31 002 180A 2

C23211A1C34 001 290A 3

C23211A1C35 002 130A 4

C23211A1C36 001 020A 2

C23211A1C48 001 040A 1

C23211A1C7 001 010A 1

C23211A2A1-1 001 430A 1

C23211A2B10
(superseded by 070B) 002 070A 1

C23211A2B14
(supersedes 300A) 001 –300B 1

C23211A2C10 001 420A 1

C23211A2C12 001 380A 1

C23211A2C16
(supersedes 070A) 002 –70B 1

C23211A2C18 001 –350B 1

C23211A2C6 001 280A 1

C23211A2C8 002 090A 1

C23334Z3C7
(supersedes 010A) 002 –10B 2

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

PART NUMBER AIRLINE FIGURE ITEM TOTAL


STOCK NUMBER NUMBER REQ’D
NUMBER

IS04762M3X8A4
(same as IS04762M3X8A4-70) 002 170A 4

LN9499-01045 001 120A 2

LN9499-02060 001 340A 4

MS21209C0420 002 080A 12

NAS1351C06H8 001 390A 2

NAS1352C04H8 001 440A 4

PVW0R10-6PWC57
(optional, see basic P/N C23334Z3C6) 002 010A 2

SP127A 001 030A 2


002 030A 8

V23401E3001L103
(supersedes 150A) 002 –150B 1

V23401E3001L104
(superseded by 150B) 002 150A 1

V23401E3001L203
(supersedes 160A) 002 –160B 1

V23401E3001L204
(superseded by 160B) 002 160A 1

V23443L359A1 002 200A 1

Z23403A10 002 100A 1

852-01R10
(optional, see basic P/N C23334Z3C2) 002 060A 2

8522-2142 002 040A 12

8525-10N10B6PWH
(optional, see basic P/N C23334Z3C7) 002 –10B 2

8525-10R10B6PWH
(optional, see basic P/N C23334Z3C6) 002 010A 2

8525-1425
(optional, see basic P/N C23334Z3C3) 002 050A 2

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

PART NUMBER AIRLINE FIGURE ITEM TOTAL


STOCK NUMBER NUMBER REQ’D
NUMBER

8526-1348 002 190A 12

9028A0004-01 001 –1A RF

ASNE0053N10B6PWE
(optional, see basic P/N C23334Z3C7) 002 –10B 2

C23121Z10C19 001 180A AR

C23121Z10C20 001 270A 1

C23121Z4C12 001 250A 1

C23121Z4C14 001 170A 1

C23121Z4C5 001 240A 1

C23123Z3C1 001 200A 1

C23211A1B4 001 –60A 1

C23211A1C26 001 190A 1

C23211A1C27 001 130A 2

C23211A1C4 001 090A 1

C23211A1C43 002 210A 1

C23211A1C49 001 050A 2

C23211A2A1-1 002 –1A RF

C23211A2B11 001 140A 1

C23211A2B9
(superseded by 300B) 001 –300A 1

C23211A2C1 001 350A 1

C23211A2C11 001 410A 1

C23211A2C21 001 260A 1

C23211A2C22 001 230A 1

C23211A2C23 001 210A 1

C23211A2C7 001 310A 1

– ITEM NOT ILLUSTRATED

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Jul 01/10
COMPONENT MAINTENANCE MANUAL
9028A0004

PART NUMBER AIRLINE FIGURE ITEM TOTAL


STOCK NUMBER NUMBER REQ’D
NUMBER

C23211A2C9 001 460A 1

C23221Z23C1 001 220B 1

C23334Z3C2 002 060A 2

C23334Z3C3 002 050A 2

C23334Z3C6
(superseded by 010B) 002 010A 2

D137A30R60 001 080A 4


160A 4

IS04762M3X12A2
(same as IS04762M3X12A2-70) 001 070A 4
150A 4

IS04762M3X6A4
(same as IS04762M3X6A4-70) 001 320A 2

LN9499-01045 001 330A 10

MS21209C0815 001 110A 1

MS21209F0610 001 360A 2

MS24630-2 002 110A 4

MS51021-32 001 100A 1

NAS1352C04H6 002 020A 8

SP127A 001 450A 4

SP127B 001 400A 2

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

OPTIONAL VENDOR INDEX

OPTIONAL PART NUMBER


PART NUMBER VENDOR
CODE PART NUMBER VENDOR
CODE

C23334Z3C2 VD9893 852-01R10 VF0225

C23334Z3C3 VD9893 8525-1425 VF0225

C23334Z3C6 VNP 8525-10R10B6PWH VF0225


PVW0R10-6PWC57 VD1371

C23334Z3C7 VD9893 8525-10N10B6PWH VF0225


ASNE0053N10B6PWE VF5442

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COMPONENT MAINTENANCE MANUAL
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DETAILED PARTS LIST

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COMPONENT MAINTENANCE MANUAL
9028A0004

80 x4
70 x4
160 x4
150 x4
290 x3

90
130 x2 280
50 x2

110
190
180 100
170 260

120 x2
270 430
40
10 250
30 x2
20 x2

140

240
230
340 x4
220
210
350
200

330 x4
330 x4

370
310
460
LLI1-270916-10001-01-01.CGM

330 x2
420

410 360 x2
320 x2
450 x4
400 x2
440 x4

380 390 x2

Position Pick-off Unit


Figure 1

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COMPONENT MAINTENANCE MANUAL
9028A0004

FIG. ITEM PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS


STOCK 1234567 CODE PER
NUMBER ASSY

1 – 1A 9028A0004-01 POSITION PICK-OFF UNIT RF

10A C23211A1C7 . FLANGE 1

ATTACHING PARTS

20A C23211A1C36 . SCREW 2

30A SP127A . WASHER 2

***

40A C23211A1C48 . PLATE, LOCKING 1

50A C23211A1C49 . SPRING 2

– 60A C23211A1B4 . COVER ASSY 1

ATTACHING PARTS

70A IS04762M3X12A2 . SCREW, CAP, SOCKET HEAD 4


ORDER OVERLGTH PN
IS04762M3X12A2-70

80A D137A30R60 . WASHER 4

***

90A C23211A1C4 . . COVER 1

100A MS51021-32 . . SETSCREW 1

110A MS21209C0815 . . INSERT, COIL 1

120A LN9499-01045 . . INSERT, COIL 2

130A C23211A1C27 . . PIN 2

140A C23211A2B11 . DRIVE ASSY, HARMONIC 1

ATTACHING PARTS

150A IS04762M3X12A2 . SCREW, CAP, SOCKET HEAD 4


ORDER OVERLGTH PN
IS04762M3X12A2-70

160A D137A30R60 . WASHER 4

***

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

FIG. ITEM PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS


STOCK 1234567 CODE PER
NUMBER ASSY

1 170A C23121Z4C14 . CIRCLIP 1

180A C23121Z10C19 . SHIM, THICKNESS 0.12 MM AR

190A C23211A1C26 . BUSH 1

200A C23123Z3C1 . SEAL 1

210A C23211A2C23 . SHIM 1

220B C23221Z23C1 . BEARING 1

230A C23211A2C22 . SHIM 1

240A C23121Z4C5 . CIRCLIP 1

250A C23121Z4C12 . CIRCLIP 1

260A C23211A2C21 . SHIM 1

270A C23121Z10C20 . SHIM, THICKNESS 0.10 MM 1


(SELECT FROM 270A TO 272A)

– 271A C23121Z10C21 . SHIM, THICKNESS 0.12 MM AR

– 272A C23121Z10C22 . SHIM, THICKNESS 0.15 MM AR

280A C23211A2C6 . WHEEL 1

ATTACHING PARTS

290A C23211A1C34 . SCREW, CAP, SOCKET HEAD 3

***

– 300A C23211A2B9 . HOUSING ASSY NP 1


SUPSD BY 300B

– 300B C23211A2B14 . HOUSING ASSY 1


SUPSDS 300A

310A C23211A2C7 . . SPINDLE 1

ATTACHING PARTS

320A IS04762M3X6A4 . . SCREW, CAP, SOCKET HEAD 2


ORDER OVERLGTH PN
IS04762M3X6A4-70

***

330A LN9499-01045 . . INSERT, COIL 10


– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

FIG. ITEM PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS


STOCK 1234567 CODE PER
NUMBER ASSY

1 340A LN9499-02060 . . INSERT, COIL 4

350A C23211A2C1 . . HOUSING NP 300A 1

– 350B C23211A2C18 . . HOUSING 300B 1

360A MS21209F0610 . . INSERT, COIL 2

370A C23211A1C12 . . PLATE 1

380A C23211A2C12 . FRAME 1

ATTACHING PARTS

390A NAS1351C06H8 . SCREW, CAP, SOCKET HEAD 2

400A SP127B . WASHER 2

***

410A C23211A2C11 . PLATE, TRANSPARENT 1

420A C23211A2C10 . GASKET 1

430A C23211A2A1-1 . HOUSING, SYNCHRO NP 1


SEE 27-09-16-02 FOR DET

ATTACHING PARTS

440A NAS1352C04H8 . SCREW, CAP, SOCKET HEAD 4

450A SP127A . WASHER 4

***

460A C23211A2C9 . GASKET 1

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

170 x4 130 x4

200 140 x4

180
160

120

20 x4
30 x4

180 210 40 x12


150
190 x12

70

90 80 x4

10

50

60
LLI1-270916-10002-01-01.CGM

80 x4

100

110 x4

Synchro Housing
Figure 2

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COMPONENT MAINTENANCE MANUAL
9028A0004

FIG. ITEM PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS


STOCK 1234567 CODE PER
NUMBER ASSY

2 – 1A C23211A2A1-1 HOUSING, SYNCHRO NP RF


SEE 27-09-16-01 FOR NHA

10A C23334Z3C6 . CONNECTOR NP 2


OPT TO 8525-10R10B6PWH MADE
BY (VF0225)
OPT TO PVW0R10-6PWC57 MADE
BY (VD1371)
SUPSD BY 010B

– 10B C23334Z3C7 . CONNECTOR 2


OPT TO 8525-10N10B6PWH MADE
BY (VF0225)
OPT TO ASNE0053N10B6PWE
MADE BY (VF5442)
SUPSDS 010A

ATTACHING PARTS

20A NAS1352C04H6 . SCREW, CAP, SOCKET HEAD 8

30A SP127A . WASHER 8

***

40A 8522-2142 . SLEEVE, REDUCING (VF0225) 12

50A C23334Z3C3 . GASKET 2


OPT TO 8525-1425 MADE BY
(VF0225)

60A C23334Z3C2 . RING, LOCKING 2


OPT TO 852-01R10 MADE BY
(VF0225)

70A C23211A2B10 . BLOCK, CONNECTOR, ASSY NP 1


SUPSD BY 070B

– 70B C23211A2C16 . BLOCK, CONNECTOR, ASSY 1


SUPSDS 070A

80A MS21209C0420 . . INSERT, COIL 070A 12

90A C23211A2C8 . . BLOCK NP 070A 1


(USE ONLY WITH ITEM 080A)

100A Z23403A10 . PLATE, IDENTIFICATION 1

– ITEM NOT ILLUSTRATED

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COMPONENT MAINTENANCE MANUAL
9028A0004

FIG. ITEM PART NUMBER AIRLINE NOMENCLATURE EFFECT UNITS


STOCK 1234567 CODE PER
NUMBER ASSY

2 ATTACHING PARTS

110A MS24630-2 . SCREW, SELF TAPPING 4

***

120A C23211A1C29 . COVER 1

ATTACHING PARTS

130A C23211A1C35 . SCREW 4

140A C23123Z3C2 . U-SEAL 4

***

150A V23401E3001L104 . SYNCHRO, ASSY, LOCK A NP 1


SUPSD BY 150B

– 150B V23401E3001L103 . SYNCHRO, ASSY, LOCK A 1


SUPSDS 150A

160A V23401E3001L204 . SYNCHRO, ASSY, LOCK B NP 1


SUPSD BY 160B

– 160B V23401E3001L203 . SYNCHRO, ASSY, LOCK B 1


SUPSDS 160A

ATTACHING PARTS

170A IS04762M3X8A4 . SCREW, CAP, SOCKET HEAD 4


ORDER OVERLGTH PN
IS04762M3X8A4-70

180A C23211A1C31 . PLATE 2

***

190A 8526-1348 . PIN (VF0225) 12

200A V23443L359A1 . LEAD, GROUNDING 1

210A C23211A1C43 . TUBE, PTFE, 36.0 MM LONG 1

– ITEM NOT ILLUSTRATED

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Jul 01/10