*DMWR 1-4320-271

DEPOT MAINTENANCE WORK REQUIREMENT

CONTAINING
NATIONAL MAINTENANCE REPAIR STANDARDS
for

UTILITY PUMP MODULE ASSEMBLY

PART NUMBER NATIONAL STOCK

NUMBER

70652-02300-048 4320-01-092-6724
70652-02300-049 4320-01-136-2118
70652-02300-050 4320-01-207-7228

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

THIS PUBLICATION IS NOT AVAILABLE THROUGH US ARMY PUBLICATION DISTRIBUTION

CENTERS. IT MUST BE OBTAINED FROM U.S. ARMY AVIATION AND MISSILE COMMAND,
ATTN: AMSAM-MMC-MA-NP, REDSTONE ARSENAL, AL 35898-5000.

*This DMWR supersedes DMWR 1-4320-271, dated 15 November 2000, including all
changes.

US ARMY AVIATION
AND MISSILE COMMAND
20 November 2003
 DMWR 1-4320-271

WARNING

PRECAUTIONARY DATA

Personnel performing operations, procedures, and practices which are included or implied in this work
requirement shall observe the following warnings. Disregard of these warnings and precautionary
information can cause serious injury, death, or destruction of material.

WARNING

GENERAL WARNING

Observe all cautions and warnings on containers when using consumables. When applicable, wear
necessary protective gear during handling and use. If a consumable is flammable or explosive, MAKE
CERTAIN consumable and its vapors are kept away from heat, spark, and flame. MAKE CERTAIN fire-
fighting equipment is readily available prior to use. For additional information on toxicity, flash point,
and flammability of chemicals, refer to Material Safety Data Sheet (MSDS) for specific component
information.

WARNING

CLEANING SOLVENTS

Cleaning solvents may be toxic. Use in well-ventilated areas. Avoid prolonged inhalation of fumes or
direct contact with skin. Do not use solvents near open flames or in areas where very high temperatures
prevail. Solvent with a flash point above 100°F (38°C) should be used, unless otherwise noted. However
solvents with a flash point lower than 100°F (38°C) may be specified. Consult the Material Safety Data
Sheet (MSDS) for solvent flash point. Avoid breathing solvent vapor. Do operations involving cleaning
solvent under a ventilated hood or in a well-ventilated work area. Wear a suitable mask when neces-
sary. Avoid continuous contact with a solvent. Wear goggles, gloves, and apron to prevent irritation
due to prolonged contact. Change clothing that has been saturated with solvent.

WARNING

TOXIC MATERIALS

Before handling or using any consumable materials, read and observe the instructions on the material
container. These warnings and precautionary data, if not strictly observed, may result in personnel
injury or loss of life. Recommended safety equipment will be used at all times.

WARNING

TEST EQUIPMENT OPERATION

Test equipment shall be operated by authorized personnel only.

a
DMWR 1-4320-271

WARNING

COMPRESSED AIR

Compressed air may be used for cooling, cleaning, and drying applications as long as (1) air flow is
restricted to less than 15 psi, (2) a safety nozzle is used, and (3) effective eye protection (safety glasses
with shield or safety goggles) is also used. Other less hazardous means, including vacuuming and wet
sweeping should be considered. By no means shall compressed air be used to clean ones clothing.

WARNING

NOISE

Operation and maintenance personnel shall wear ear protection devices when working near or around
an operating test stand.

WARNING

ETHYL ALCOHOL,
A-A-53880

USP alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well ventilated areas (or use ap-
proved respirator as determined by local safety/industrial hygiene personnel). Keep away from open
flames, sparks, or other sources of ignition.

WARNING

ACETONE, TECHNICAL
ASTM-D329

Acetone is flammable and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas (or use ap-
proved respirator as determined by local safety/industrial hygiene personnel). Keep away from open
flames, sparks, hot surfaces or other sources of ignition.

b
 DMWR 1-4320-271

WARNING

ALCOHOL, TECHNICAL ISOPROPYL

ASTM-D770

Isopropyl alcohol is flammable and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas (or use ap-
proved respirator as determined by local safety/industrial hygiene personnel). Keep away from open
flames, sparks, or other sources of ignition.

WARNING

DS-108

DS-108 is combustible, reactive with strong oxidizers, and toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face shield. Avoid repeated or prolonged contact. Use only in
well-ventilated areas (or use approved respirator as determined by local safety/industrial hygiene
personnel). Keep away from open flames, sparks, hot surfaces or other sources of ignition. Do not mix
or cross apply with other cleaners or chemicals.

WARNING

ELECTRON DIELECTRIC SOLVENT,

0296-06

Electron is combustible and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas. Use ap-
proved organic vapor respirator, with dust and mist filter, if exposed to vapor mist. Keep away from
open flames, sparks, or other sources of ignition.

WARNING

POSITRON DIELECTRIC SOLVENT,

060-6 GAL

Positron is combustible and toxic to eyes, skin, and respiratory tract. Wear protective gloves and
goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas. Use ap-
proved organic vapor respirator, with dust and mist filter, if exposed to vapor mist. Keep away from
open flames, sparks, or other sources of ignition.

c
DMWR 1-4320-271

WARNING

n-PROPYL BROMIDE,
0338-06

n-Propyl Bromide is toxic to eyes, skin, and respiratory tract. Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged contact. Use only in areas with adequate mechanical or local
exhaust ventilation (or use approved respirator as determined by local safety/industrial hygiene person-
nel).

WARNING

DEGREASING SOLVENT,
MIL-PRF-680, TYPE II
Degreasing solvent is combustible and toxic to eyes, skin, and respiratory tract. Wear protective gloves
and goggles/face shield. Avoid repeated or prolonged contact. Use only in well-ventilated areas (or use
approved respirator as determined by local safety/industrial hygiene personnel). Keep away from open
flames or other sources of ignition.

WARNING

HYDRAULIC FLUID,
MIL-PRF-83282

If hydraulic fluid is decomposed by heat, toxic gases are released. Prolonged contact with liquid or mist
can cause dermatitis and irritation. If there is any prolonged contact with skin, wash contacted area with
soap and water. If liquid contacts eyes, flush eyes with water immediately for 15 minutes. Remove
saturated clothing. If fluid is swallowed, do not induce vomiting. Get immediate medical attention.
When handling liquid, wear rubber gloves. Inhalation of vapors should be avoided.

WARNING

SILICONE ADHESIVE-SEALANT,
MIL-A-46146
Uncured silicone adhesive-sealant can irritate eyes, skin, nose, and throat. If contact with eyes occurs,
flush immediately with water for 15 minutes and seek medical attention. If skin contact occurs, wipe with
dry cloth then wash with soap and water. Protection: safety glasses or goggles, approved gloves,
NIOSH/MSHA approved respirator if mists or vapors exceed established limits.

WARNING

CHILLED PARTS
Wear suitable protective gloves when handling chilled parts.

d
 DMWR 1-4320-271

WARNING

SEALING COMPOUND,
AMS-S-8802

Sealing compound can irritate skin and cause burns. Avoid contact with skin, eyes, and clothing. In case
of contact, immediately flush skin or eyes with water for at least 15 minutes. Get medical attention for
eyes.

WARNING

CORROSION PREVENTIVE COMPOUND,

MIL-C-81309

Corrosion preventive compound is combustible. Keep it away from heat, sparks, and open flames. Do
not smoke when using it. Use in a well-ventilated area. Inhalation of vapors is harmful. Wear oil
impervious gloves, chemical splash proof goggles (or face shield), and protective apron. If splashed on
clothing or in eyes, remove clothing immediately and flush skin/eyes with clear water for 15 minutes. If
vapors cause light-headedness, move to fresh air. If liquid is swallowed, do not induce vomiting. Get
prompt medical attention. Use absorbent to soak up spilled solution. Dispose of absorbent in ac-
cordance with local, state, and federal regulations. Keep solution away from oxygen and strong
oxidants. Store in approved metal safety container. Keep containers closed when not in use.

WARNING

CHEMICAL CONVERSION COATINGS,

MIL-C-5541

Chemical conversion coatings are strong oxidizing agents. They may ignite combustible material such
as wood and paper or organic substances. Keep container closed; keep sparks, flames, and heat away.
Keep off skin, eyes, and clothes. May severely burn the eyes and skin on contact. Do not breathe
vapors. Breathing dusts and mists may irritate the respiratory tract. Long term overexposure by breath-
ing mists or absorption through the skin may cause cancer, kidney and liver damage, and ulceration of
the nasal septum. Protection: chemical splash proof goggles, approved gloves, forced ventilation,
NIOSH/MSHA approved respirator if mists exceed established exposure limits.

WARNING

ASSEMBLY FLUID,
NO. 1

Ultrachem assembly fluid may irritate the skin and eyes on contact. If assembly fluid contacts the eyes,
flush immediately for 15 minutes. Prolonged or repeated use without hand protection may cause der-
matitis. At normal temperatures, assembly fluid poses minimal health hazard by inhalation. If the

e
DMWR 1-4320-271

product is heated or applied as a mist, use of a NIOSH/MSHA approved respirator may be necessary.
Wash hands with soap and water after use. Protection: chemical splash proof goggles or safety glasses,
oil resistant gloves and skin protective clothing.

PURPOSE OF WARNINGS, CAUTIONS AND NOTES

WARNING

Alerts personnel to operation, procedure, practice, etc., which if not strictly observed, could result in
personnel injury or loss of life.

CAUTION

Alerts personnel to operation, procedure, practice, etc., which, if not strictly observed, could result in
damage to or destruction of equipment.

NOTE

Applies to operation, procedure, condition, etc., which it is essential to highlight.

f
 DMWR 1-4320-271

LIST OF EFFECTIVE PAGES

Insert latest changed pages; dispose of superseded pages in accordance with regulations.

Note: On changed pages, the portion of the text affected by the latest change is indicated by a vertical line in the outer
margin of the page. Changes to illustrations are indicated by vertical lines next to the figure title.

Dates of issue for original and changed pages are:

Original 0 ...................... 20 November 2003

Total number of pages in this manual is 148 consisting of the following:

Page *Change Page *Change Page *Change
No. No. No. No. No. No.
Title. . . . . . . . . . . . . . . . . . . . . . . 0 2-1 - 2-6 . . . . . . . . . . . . . . . . . 0 A-1 - A-2 . . . . . . . . . . . . . . . . 0
blank . . . . . . . . . . . . . . . . . . . . . 0 3-1 - 3-89 . . . . . . . . . . . . . . . 0 B-1 . . . . . . . . . . . . . . . . . . . . . . . 0
a - f ...................... 0 3-90 blank . . . . . . . . . . . . . . . 0 B-2 blank. . . . . . . . . . . . . . . . . 0
A ......................... 0 4-1 - 4-5 . . . . . . . . . . . . . . . . . 0 C-1 - C-4 . . . . . . . . . . . . . . . . 0
B blank . . . . . . . . . . . . . . . . . . . 0 4-6 blank . . . . . . . . . . . . . . . . 0 D-1 . . . . . . . . . . . . . . . . . . . . . . . 0
i - v. . . . . . . . . . . . . . . . . . . . . . . 0 5-1 - 5-5 . . . . . . . . . . . . . . . . . 0 D-2 blank . . . . . . . . . . . . . . . . 0
vi blank . . . . . . . . . . . . . . . . . . 0 5-6 blank . . . . . . . . . . . . . . . . 0 E-1 - E-3 . . . . . . . . . . . . . . . . . 0
1-1 - 1-5 . . . . . . . . . . . . . . . . . 0 6-1 . . . . . . . . . . . . . . . . . . . . . . . 0 E-4 blank. . . . . . . . . . . . . . . . . 0
1-6 blank . . . . . . . . . . . . . . . . 0 6-2 blank . . . . . . . . . . . . . . . . 0 F-1 - F-2 . . . . . . . . . . . . . . . . . 0

* Zero in this column indicates an original page.

A/(B blank)
 *DMWR 1-4320-271

Depot Maintenance US ARMY AVIATION

Work Requirement AND MISSILE COMMAND
No. 1-4320-271 20 November 2003

Depot Maintenance Work Requirements

Containing

National Maintenance Repair Standards

for

UTILITY PUMP MODULE ASSEMBLY

PART NATIONAL
NUMBER STOCK NUMBER

70652-02300-048 4320-01-092-6724
70652-02300-049 4320-01-136-2118
70652-02300-050 4320-01-207-7228

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can improve this manual. If you find any mistakes, or if you know of a way to
improve these procedures, please let us know. Mail your letter or DA Form 2028 (Recom-
mended Changes to Publications and Blank Forms) located in the back of this manual,
directly to: Commander, US Army Aviation and Missile Command, ATTN: AMSAM-
MMC-MA-NP, Redstone Arsenal, AL 35898-5000. A reply will be furnished to you. You
may also provide DA Form 2028 information to AMCOM via e-mail, fax, or the World
Wide Web. Our fax number is: DSN 788-6546 or Commercial 256-842-6546. Our
e-mail address is: 2028@redstone.army.mil. Instructions for sending an electronic 2028
may be found at the back of this manual immediately preceding the hard copy 2028. For
the World Wide Web use: https://amcom2028.redstone.army.mil.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

Page

CHAPTER 1 INTRODUCTION ........................................................................................ 1-1

*This DMWR supersedes DMWR 1-4320-271, dated 15 November 2000, including all changes.
i
 DMWR 1-4320-271

TABLE OF CONTENTS (Cont)

Page

Section I. General ..................................................................................................... 1-1

1-1 Scope ........................................................................................................ 1-1
1-2 Forms, Records, and Reports....................................................................... 1-1
1-3 Reporting Equipment Improvement Recommendations (EIRS) ......................... 1-1
1-4 Engineering Change Proposals (ECPS)......................................................... 1-1
1-5 Deviations and Exceptions .......................................................................... 1-1

Section II. Description, Data Plates, and Tabulated Data............................................... 1-2

1-6 Description ................................................................................................ 1-2
1-7 Data Plates ................................................................................................ 1-2
1-8 Tabulated Data .......................................................................................... 1-2
1-9 Differences Between Models ........................................................................ 1-2

CHAPTER 2 REQUIREMENTS......................................................................................... 2-1

Section I. General ..................................................................................................... 2-1

2-1 Facilities .................................................................................................... 2-1
2-2 Support Items ............................................................................................. 2-1
2-3 Expendable Materials ................................................................................. 2-3
2-4 Finite Life Items, Time Between Overhaul (TBO) Items
and Mandatory Replacement Parts .............................................................. 2-3
2-5 Repair Parts ............................................................................................... 2-6
2-6 Flight Safety Parts Program ......................................................................... 2-6

Section II. Standards .................................................................................................. 2-6

2-7 Quality of Material..................................................................................... 2-6
2-8 Labor-Hour Standards ................................................................................ 2-6

CHAPTER 3 MAINTENANCE, OVERHAUL, AND REPAIR ................................................ 3-1

Section I. General ..................................................................................................... 3-1

3-1 Arrangement.............................................................................................. 3-1

Section II. Safety........................................................................................................ 3-1

3-2 Precautions ................................................................................................ 3-1

Section III. Preshop Analysis ........................................................................................ 3-1

3-3 Purpose ..................................................................................................... 3-1
3-4 Unpacking ................................................................................................. 3-1
3-5 Tags and Forms ......................................................................................... 3-1

Section IV. Disassembly ............................................................................................... 3-2

ii
 DMWR 1-4320-271

TABLE OF CONTENTS (Cont)

Page

3-6 General ..................................................................................................... 3-2

3-7 Disassembly ............................................................................................... 3-2
3-8 Cleaning.................................................................................................... 3-19

Section V. In-Process Inspection................................................................................... 3-22

3-9 General ..................................................................................................... 3-22

Section VI. Repair ....................................................................................................... 3-71

3-10 General ..................................................................................................... 3-71
3-11 Standard Processes..................................................................................... 3-71

Section VII. Assembly ................................................................................................... 3-73

3-12 General ..................................................................................................... 3-73
3-13 Assembly Procedures .................................................................................. 3-73

CHAPTER 4 FINAL ASSEMBLY AND TESTING................................................................ 4-1

Section I. Assembly ................................................................................................... 4-1

4-1 General ..................................................................................................... 4-1

Section II. Final Performance Check ............................................................................ 4-1

4-2 General ..................................................................................................... 4-1
4-3 Test Requirements....................................................................................... 4-1
4-4 Test Procedures .......................................................................................... 4-1

CHAPTER 5 QUALITY ASSURANCE/QUALITY CONTROL REQUIREMENTS ..................... 5-1

Section I. General ..................................................................................................... 5-1

5-1 Responsibility ............................................................................................. 5-1
5-2 Quality Assurance Terms and Definitions ..................................................... 5-1
5-3 Test Measurement and Diagnostic Equipment (TMDE) ................................... 5-1
5-4 Certification of Personnel, Materials, and Processes ...................................... 5-1

Section II. Inspection Requirements.............................................................................. 5-1

5-5 General ..................................................................................................... 5-1
5-6 Product Verification Audit ........................................................................... 5-1
5-7 In-Process and Acceptance Inspections......................................................... 5-1

CHAPTER 6 PACKAGING ............................................................................................. 6-1

6-1 Preservation, Packaging, and Marking ........................................................ 6-1

APPENDIX A REFERENCES ............................................................................................. A-1

iii
 DMWR 1-4320-271

TABLE OF CONTENTS (Cont)

Page

APPENDIX B REPAIR PARTS AND SPECIAL TOOLS LIST ................................................... B-1

APPENDIX C EXPENDABLE AND DURABLE ITEMS ........................................................... C-1

Section I. Introduction................................................................................................ C-1

C-1 Scope ........................................................................................................ C-1
C-2 Explanation of Columns .............................................................................. C-1

Section II. Expendable Supplies and Materials List ....................................................... C-1

APPENDIX D DELETED.................................................................................................... D-1

APPENDIX E MODIFICATIONS ....................................................................................... E-1

E-1 Scope ........................................................................................................ E-1
E-2 Modification .............................................................................................. E-1

APPENDIX F RECAPITALIZATION REQUIREMENTS .......................................................... F-1

F-1 Recapitalization Requirements ..................................................................... F-1

iv
 DMWR 1-4320-271

LIST OF ILLUSTRATIONS

Figure Title Page

1-1 Hydraulic Flow Schematic ........................................................................... 1-3

1-2 Utility Pump Module Assembly .................................................................... 1-4
1-3 Overhaul Data Plate ................................................................................... 1-5
3-1 Preshop Analysis Data Form ....................................................................... 3-3
3-2 Utility Pump Module Assembly - Exploded View........................................... 3-4
3-3 Hanger and Piston Subassembly ................................................................. 3-14
3-4 Magnet Inspection ...................................................................................... 3-23
3-5 Optical Light Band Inspection...................................................................... 3-24
3-6 Measure Height of Carbon ......................................................................... 3-25
3-7 Hanger and Piston Subassembly - Clearances .............................................. 3-74
3-8 Shaft and Bearing Subassembly .................................................................. 3-76
3-9 Electrical Schematic .................................................................................... 3-79
3-10 Solenoid Spool and Sleeve Adjustment ........................................................ 3-80
3-11 Install O-Ring on Internal Drive Shaft........................................................... 3-85
3-12 Install O-Ring in Magnet............................................................................. 3-86
3-13 Install Magnet into Seal Retainer ................................................................. 3-87
3-14 Install Seal Case onto Magnet ..................................................................... 3-88
3-15 Install Magnetic Seal into Module Subassembly............................................ 3-89
4-1 Test Schematic ........................................................................................... 4-2

LIST OF TABLES

Table Title Page

1-1 Leading Particulars ..................................................................................... 1-2

2-1 Special Tools and Equipment ...................................................................... 2-1
2-2 Inspection and Test Equipment .................................................................... 2-2
2-3 Mandatory Replacement Parts ..................................................................... 2-3
2-4 Labor-Hour Standards ................................................................................ 2-6
4-1 Break-In..................................................................................................... 4-3
5-1 Inspection Definitions .................................................................................. 5-2
E-1 Modification of Part No. 70652-02300-048 to 70652-02300-049 .............. E-1
E-2 Modification of Part No. 70652-02300-049 to 70652-02300-050 .............. E-3
F-1 Mandatory Replacement Parts List ............................................................... F-1

v/(vi blank)

CHAPTER 1
INTRODUCTION
Section I. General
1-1. SCOPE.
1-1.1. These instructions are for use by depot/
contractor personnel. They apply to the utility pump
module assemblies, part numbers 70652-02300-048,
-049, and -050, manufactured by Abex Corporation,
Aerospace Division, 3151 West 5th Street, Oxnard, CA
93030 (CAGE 75250) for Sikorsky Aircraft Corporation,
6900 Main St., P.O. Box 9729, Stratford, CT 06615-
9129 (CAGE 78286) and, in case of conflict, take
precedence over all other documents pertinent to
maintenance of the item.
1-2. FORMS, RECORDS, AND REPORTS.
1-2.1. Department of the Army forms and procedures
used for equipment maintenance shall be those
prescribed by DA PAM 738-751.
1-3. REPORTING EQUIPMENT IMPROVEMENT
RECOMMENDATIONS (EIRS).
1-3.1. EIRs shall be submitted by anyone who is aware
of an unsatisfactory condition with the equipment design
or use. It is not necessary to show a new design or list a
better way to do a procedure. Simply tell why the design
is unfavorable or why a procedure is difficult. EIRs will be
prepared using SF Form 368, Quality Deficiency Report.
Instructions for preparing EIRs are provided in DA PAM
738-751, Functional Users Manual for The Army
Maintenance Management System (TAMMS-A). EIRs
should be mailed directly to Commander, US Army Avia-
tion and Missile Command, ATTN: AMSAM-MMC-MA-
NM, Redstone Arsenal, AL 35898-5000. A reply will be
furnished directly to you.
1-4. ENGINEERING CHANGE PROPOSALS (ECPS).
1-4.1. ECPs will be submitted using DD Form 1693
(Engineering Change Proposal) (Short Form). Completed
forms should be mailed direct to Commander, US Army
Aviation and Missile Command, ATTN: AMSAM-RD-SE-
TD-CM Redstone Arsenal, AL 35898-5000. A reply will
be furnished to you.
DMWR 1-4320-271
1-5. DEVIATIONS AND EXCEPTIONS.
1-5.1. Contractors and All Organic Activities. These
instructions apply to requests for work deviations and
exceptions and take precedence over similar procedures
specified in applicable Depot Maintenance Work
Requirement (DMWR). Care must be taken to make sure
that all active AMCOM Engineering Directives (AEDs)
relevant to the DMWR have been considered.
1-5.2. When any work segment as set forth in this
Depot Maintenance Work Requirement (DMWR) cannot
be accomplished, or can be accomplished only in a man-
ner other than specified, submit a Request for Depot
Engineering Support (AMSAT-I-M Form 1379-R-E),
located in the back of this manual, through the Contract-
ing Officer to AMSAM-MMC-VS-EC with a copy to
AMSAM-MMC-BM-D. This request for action shall state
the problems, the reason for urgency, and give the specif-
ics listed below.
a. Serial Number (SN), if applicable, Part Number
(PN), and National Stock Number (NSN) of affected
equipment.
b. Work elements which will not be completed or
which will not be accomplished as specified herein.
c. Reason for nonaccomplishment or deviation.
d. Action taken to correct the condition causing
nonaccomplishment or need for deviation.
e. Data relative to nonavailability of parts required,
if applicable.
f. Estimated labor-hours.
g. Instructions and inspection required to maintain
the integrity of the end item because of such omission or
deviation.
1-1
DMWR 1-4320-271

Section II. Description, Data Plates, and Tabulated Data

1-6. DESCRIPTION. Table 1-1. Leading Particulars

1-6.1. The utility pump module assembly is designed to

Characteristic Parameter
act as an integrated package of hydraulic components
that will provide hydraulic power for a helicopter control
Service Fluid ................ Hydraulic Fluid (item 9, App C)
system. It provides the necessary hydraulic power and is
Fluid Temperature ................................ -40°F to 250°F
designed to make sure of rapid pressure recoveries. The
Rated Speed ............................................... 7335 rpm
module will incorporate all the functional elements
Flow ........................ 6.2 gpm at 2900 psig (minimum)
required of a basic hydraulic power system. The utility
Rated Pressure .................................... 3050 psig 650
pump module assembly consists of a pressure
Rotation ............................................ Counterclockwise
compensated hydraulic pump, spring pressurized
(viewed from external
reservoir, pressure and return filters with differential pres-
drive shaft end)
sure indicators, return filter bypass, high pressure relief
Ports:
and bleed valve, electric depressurizer valve, and low
Seal Drain Port ................................. 0.250 in. Tube
level fluid indicator. Refer to Figure 1-1 for hydraulic flow
(0.4375-20UNJF-3B threads)
schematic.
Discharge Port .............................. Quick Disconnect
(Seaton-Wilson PN ZA-1452H4-8-MT8)
1-7. DATA PLATES.
Return Port .................................... Quick Disconnect
1-7.1. Equipment Data Plate. The identification plate, (Seaton-Wilson PN ZA-1452H4-8-MT8)
Ground Test Port ........................... Quick Disconnect
part No. 61415, for the utility pump module assembly, is
(Aeroquip PN TBO15519-S4-8D)
secured by adhesive compound to the endplate of the
Relief Valve .......................................... 0.375 in. hose
reservoir in the location shown in Figure 1-2.
(hose connection hitting end)
Electrical Connectors:
1-7.2. Overhaul Data Plates. The current overhaul data
Reservoir ................................. M83723-88H08036
plate (Figure 1-3) will at all times be attached to the
Solenoid ................................. M83723-88H0803N
equipment, next to the manufacturer’s data. The data
Overall Dimensions:
plate will include: RECAP month/year (two digit numbers
Height ...................................................... 10.10 in.
shall identify the month and year), initials of the facility
(includes Relief Valve)
doing the overhaul, contract number, date of overhaul,
Width ........................................................ 7.17 in.
part number, and total operating time since new, if ap-
Length ...................................................... 14.00 in.
plicable. The data will be stamped on the data plate using
1/8 inch high letters and figures per MIL-STD-130.
Stamp the required information on the data plate before 1-9. DIFFERENCES BETWEEN MODELS.
installation. When there is not enough space available on
the existing data plate to add information, the plate shall 1-9.1. A new removable sight glass with an improved
be replaced and all pertinent data transferred to the new retainer has been incorporated in the utility pump module
plate. Data shall not be stamped directly on any part, as- assembly, 70652-02300-049 and -050. In order to
sembly, or item of equipment. prevent accumulation of hydraulic fluid leaks from the
vent port, a drain line has been incorporated in the utility
1-7.3. Material. Make overhaul data plate from pump module assembly, 70652-02300-050, to join the
adhesive-backed aluminum foil (item 18, App C). shaft seal vent port with the reservoir vent port and on to
the drain manifold. A new reservoir and internal drive
1-8. TABULATED DATA. shaft have also been incorporated.

1-8.1. The major characteristics of the utility pump

module assembly are listed in Table 1-1.

1-2
 DMWR 1-4320-271

CHECK VALVE
3 PLACES
PRESS FILTER WITH
P INDICATOR
HIGH PRESS
RELIEF VALVE

GROUND
PRESSURE
PORT

DISCHARGE
PORT
(HP)

BLEED AND
RELIEF VALVE
HOSE
CONNECTION

RETURN PORT

RETURN FILTER
WITH P
INDICATOR

BLEED AND BYPASS VALVE

RELIEF VALVE (LP)

SEAL DRAIN
ELECTRICAL CASE PORT
CONNECTOR DRAIN
LOW LEVEL
INDICATOR

PUMP
RESERVOIR
LEVEL
WINDOW
ELECTRICAL
RESERVOIR CONNECTOR
INDICATOR E.D.V.

AA3824
SA

Figure 1-1. Hydraulic Flow Schematic

1-3
DMWR 1-4320-271

OVERHAUL DATA
IDENTIFICATION PLATE (FIGURE 1−3)
FLUID
IDENTIFICATION PLATE IDENTIFICATION
PLATE & LEVEL INDICATOR
GRND (2 PLACES)
PRESSURE
PRESSURE

ROTATION
PLATE

INSTRUCTION
PLATE

TEMPERATURE
TEMPILABEL MONITOR IDENTIFICATION
121C 135C 149C 163C PLATE

250F 275F 300F 325F

TEMPILABLE
RETURN (2 PLACES)

IDENTIFICATION
PLATE

AA3825
SA

Figure 1-2. Utility Pump Module Assembly

1-4
 DMWR 1-4320-271

HYDRAULIC POWER SUPPLY. VARIABLE DELIVERY

PN 70652−02300 SER NO
OVERHAULED BY DATE
CONTRACT NO

AA8881
SA

Figure 1-3. Overhaul Data Plate

1-5/(1-6 blank)
 DMWR 1-4320-271

CHAPTER 2

REQUIREMENTS
Section I. General

2-1. FACILITIES.
2-1.1. The Depot/Contractor facilities shall be
equipped to perform all phases of overhaul, repair, and
testing as specified in this DMWR.
2-2. SUPPORT ITEMS.
for items listed in Table 2-1 must be approved in ac-
cordance with paragraph 1-5.
2-2.2. Inspection and Test Equipment. Required inspec-
tion and test equipment are listed in Table 2-2. Substitu-
tions for items listed in Table 2-2 must be approved in
accordance with paragraph 1-5.

2-2.1. Special Tools and Equipment. Required special

tool and equipment are listed in Table 2-1. Substitutions

Table 2-1. Special Tools and Equipment

National Stock Number Reference Paragraph of

Nomenclature or Part No. CAGE Use

Testing Adapter Plate 53023-T200 93835 3-13.2, 4-3.4

Test Light 53023-T201 93835 3-13.2.cc

Packing Assembly Tool 53785-T200 93835 3-13.2

Tapered Fixture 55661-T200 93835 3-13.2

Barrel Assembly Tool 57913-T200 93835 3-13.2

Wrench 57919-T2 93835 3-7.3, 3-13.1

Lapping Holder 57921-T1 93835 3-13.1

Holding Fixture 57925-T1 93835 3-7.3, 3-13.1

Staking Tool 57925-T2 93835 3-13.1

Assembly Rod 61356-T201 93835 3-7.2, 3-13.2

Holding Fixture 61386-T200 93835 3-13.2

Set Block 61386-T201 93835 3-13.1

Pressing Fixture 61393-T200 93835 3-13.2

Holding Fixture (Out) 61393-T201 93835 3-7.2

Puller 61420-T200 93835 3-7.2

2-1
DMWR 1-4320-271

Table 2-1. Special Tools and Equipment (Cont)

National Stock Number Reference Paragraph of

Nomenclature or Part No. CAGE Use

Assembly Tool 93058-T1 04171 3-13.3.1.6,

3-13.3.2.6.1

Assembly Tool 62596-T200 93835 3-13.2

Assembly Tool 62596-T201 93835 3-13.2

Assembly Tool 62596-T202 93835 3-13.2

Assembly Plate 62596-T203 93835 3-7.2, 3-13.2

Freeze Tool 62596-T204 93835 3-13.2

Assembly Tool 62596-T206 93835 3-7.2, 3-13.2

Holding Fixture 62599-T200 93835 3-11.8

Filter Removal Tool 62617-T201 93835 3-7.2, 3-13.2

Holding Fixture 62696-T200 93835 3-13.2

Lapping Holder 68615-T1 93835 3-13.1

Differential Pressure 01TB0660TSE0 18350 3-13.2.bp.1

Indicator Test Block

NOTE: Equivalent tools and equipment may be used.

Table 2-2. Inspection and Test Equipment

Part No. or National Reference Paragraph of

Nomenclature Stock Number CAGE Use

Optical Flat Double Surface 62679 3-9.3, 3-11.7

Monochromatic Light 6210-00-700-7646 62679 3-11.7

Ultrasonic Cleaner LG-500 99251 3-8.2

Cold Chamber To freeze reservoir piston - 3-13.2

packing for assembly.
This unit should meet the
applicable design
requirements of MIL-S-
8512.

2-2
 DMWR 1-4320-271

Table 2-2. Inspection and Test Equipment (Cont)

Part No. or National Reference Paragraph of

Nomenclature Stock Number CAGE Use

Lapping Machine 3419-00-864-5441 71724 3-11.5

NOTE: Equivalent tools and equipment may be used.

2-3. EXPENDABLE MATERIALS. 2-4.2 Mandatory Replacement Parts. Mandatory

replacement parts will be replaced if the assembly or
2-3.1. All expendable materials are listed in Appendix subassembly in which they are found is overhauled. Refer
C. to Table 2-3 Mandatory Replacement Parts.

2-4. FINITE LIFE ITEMS, TIME BETWEEN OVERHAUL

(TBO) ITEMS AND MANDATORY REPLACEMENT PARTS.

2-4.1. Finite Life Items, Time Between Overhaul (TBO)

Items. Items with a finite life and/or TBO time are listed
in Table 2-3.

Table 2-3. Mandatory Replacement Parts

Part No. National Stock Number Description Qty

61419 Oil Seal 1

M83461/1-131 5331-01-141-1915 O-Ring 1

MS28774-027 5330-00-003-9271 Retainer, Packing 1

M83461/1-027 5331-01-107-4949 O-Ring 1

M83461/1-021 5331-01-107-1149 O-Ring 1

MS28778-8 5331-00-808-0794 O-Ring 3

M83461/1-111 5331-01-107-3121 O-Ring 2

M83461/1-014 5331-01-046-0629 O-Ring 3

7697801 5330-01-114-9266 Header Gasket 1

8004418 5331-01-115-2337 O-Ring 1

3004503 Insulation Sleeving, 1

Electrical

M23053/5-102C 5970-01-451-3999 Insulation Sleeving, 1

Electrical

2-3
DMWR 1-4320-271

Table 2-3. Mandatory Replacement Parts (Cont)

Part No. National Stock Number Description Qty

M23053/5-106C 5970-01-119-2173 Insulation Sleeving, 1

Electrical

M83461/1-119 5331-01-123-3299 O-Ring 1

M83461/1-017 5331-01-050-1538 O-Ring 2

M83461/1-012 5331-01-046-3300 O-Ring 4

6257312 5330-00-543-7090 Retainer, Packing 4

6257320 5330-01-318-6796 Retainer, Packing 2

M83461/1-019 5331-01-050-1539 O-Ring 2

M83461/1-020 5331-01-107-4950 O-Ring 2

M8815-6-8 1650-01-114-1899 Filter Element 2

M83461/1-113 5331-01-107-4951 O-Ring 1

M83461/1-011 5331-01-047-0435 O-Ring 4

8090218 5331-01-115-2336 O-Ring 1

MS16625-1075 5325-00-754-1082 Ring, Retainer 1

53855 4320-00-394-4039 Breather 1

M83461/1-016 5331-01-043-1419 O-Ring 1

S62117-2 5330-01-213-5766 Seal, Plain 1

62606 4310-01-114-3009 Ring, Piston 1

62607 4320-01-114-3010 Ring, Piston 1

MS28774-013 5330-00-843-9726 Retainer, Packing 2

M83461/1-013 5332-02-088-6108 O-Ring 1

6257311 5330-01-330-0310 Packing Backup Retainer 6

M83461/1-010 5331-01-088-5363 O-Ring 1

M83461/1-141 5331-01-115-2216 O-Ring 1

8025418 5331-01-114-9264 O-Ring 1

MS28774-028 5330-00-814-2372 Retainer, Packing 2

2-4
 DMWR 1-4320-271

Table 2-3. Mandatory Replacement Parts (Cont)

Part No. National Stock Number Description Qty

M83461/1-028 5331-01-107-4952 O-Ring 2

M83248/2-906 5331-00-165-1981 O-Ring 1

MS28774-012 530-00-543-7090 Retainer, Packing 2

027-517 (04171) O-Ring 1

021-517 (04171) 5330-01-301-0997 Seal 1

6156302 1560-01-173-9116 Closure 1

61388 4320-01-127-6909 Adaptor, Spline 1

61369 4820-01-161-3972 Valve, Relief 1

62168 4820-01-134-8371 Valve, Safety Relief 1

6980004 4820-01-169-9285 Check Valve 1

62617 2995-01-159-4423 Shutoff Valve Assembly 2

68756 3120-01-116-1244 Thrust Washer 1

68617 4320-00-403-1972 Hanger Wear Plate 1

66587 4320-01-029-0596 Shoe Retainer Plate 1

62912 5945-01-376-5196 Solenoid, Electrical 1

ZA-1452H7-8-MT8 4730-01-165-8010 Coupling Half, Quick 1

Disconnect

ZA-1452H6-8-MT8 4730-01-165-8009 Coupling Half, Quick 1

Disconnect

NOTE

Spring (52691) may be reused at overhaul provided it has not lost its spring tension. Inspect before use for free length
of 0.96875 + 0.0100 inch.

52691 5360-01-022-5478 Spring, Helical Compres- 1

sion

2-5
DMWR 1-4320-271

Table 2-3. Mandatory Replacement Parts (Cont)

Part No. National Stock Number Description Qty

NOTE

Spring (56986) may be reused at overhaul provided it has not lost its spring tension. Inspect before use for free length
of 0.8750 + 0.0100 inch.

56986 5360-01-144-0951 Spring, Helical Compres- 1

sion

2-5. REPAIR PARTS. 2-6. FLIGHT SAFETY PARTS PROGRAM.

2-5.1. Repair parts and replacement parts needed for 2-6.1. This DMWR is not impacted by the Flight Safety
overhaul appear in TM 1-1520-237-23P Series. Parts Program.

Section II. Standards

2-7. QUALITY OF MATERIAL. Table 2-4. Labor-Hour Standards

2-7.1. All parts and materials used for replacement,

repair, or modification shall meet equipment drawings Task Estimated Average
and specifications. Labor-Hours

2-8. LABOR-HOUR STANDARDS. Preshop Analysis 0.5

2-8.1. Estimated average labor-hour standards for Disassembly 4.0

performance of depot maintenance are listed in Table
2-4. Cleaning and Inspec- 1.5
tion

Assembly 4.5

Testing 2.0

2-6
 DMWR 1-4320-271

CHAPTER 3

MAINTENANCE, OVERHAUL, AND REPAIR

Section I. General

3-1. ARRANGEMENT. will be disassembled and cleaned. Next, parts shall be

inspected per the OIP. Parts that do not meet OIP require-
3-1.1. This chapter provides instructions for depot level ments shall be repaired or replaced. Finally, the utility
maintenance of the utility pump module. First, preshop pump module is assembled and tested to verify that it is
analysis will be performed. Then, the utility pump module ready in all respects for return to service.

Section II. Safety

3-2. PRECAUTIONS. from heat, spark, and flame. MAKE

WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals refer, to Material
Safety Data Sheet (MSDS) for specific
component information.
3-2.1. No special safety precautions need to be taken
for overhaul and repair of the utility pump module as-
sembly. Standard warnings, cautions, and notes are
provided where required.

Section III. Preshop Analysis

3-3. PURPOSE. 3-5. TAGS AND FORMS.

3-3.1. The purpose of the preshop analysis is to
determine the reason(s) the component was removed
from service and returned to depot for overhaul and to
verify compliance criteria is implemented on all required
forms and records for historical data.
3-4. UNPACKING.
3-4.1. Shipping containers and packing materials are
reusable. Use care during unpacking to avoid damage to
the shipping container, packing material and the utility
pump module assembly. Open the shipping container
and remove packing materials. Carefully remove the
depot repairable item from the container. Return packing
materials to the shipping container and retain the ship-
ping container for reuse. Do not remove tags or forms
from the pump module. Check the pump module for dam-
age and condition before disassembly.
a. Historical records will be reviewed to ensure cor-
rect documents are available. All historical data received
will be used for evaluation criteria.
b. Every effort will be made during processing to
maintain the integrity of the utility pump module operat-
ing history in accordance with DA PAM 738-751,
Functional Users Manual for The Army Maintenance
Management System-Aviation (TAMMS-A).
c. Examine all tags and forms attached to the utility
pump module assembly to determine the reason(s) for
removal from service, or statements describing any
malfunction or improper operation. Tags and forms shall
not be removed from the roll trim actuator assembly. If
tags and forms are missing, contact the contracting officer
or national maintenance point (AMCOM).

3-1
DMWR 1-4320-271
d. A PSA Data Form (see Fig 3-1) will be completed
on each utility pump module overhauled. When filling out
the PSA Data Form, fill in only those spaces applicable to
the utility pump module. In completing the data form
provide a qualifying statement encompassing the location
and degree of each discrepancy, defect, or failure
observed. Copies of the PSA Data Form, DA Form 2410,
DD Form 1577-2, DD Form 1577-3 and SF 368 (Quality
Section IV. Disassembly
3-6. GENERAL.
3-6.1. The following instructions assume that all lock-
wire will be removed where necessary. Parts such as
bushings, liners, staked bearings, which are removed on
condition, are classified as repairs and are covered in
repair section.
3-6.2. Control of Parts. Label all bearings, piston and
shoe subassemblies, and spool and sleeve subassemblies
that are matched parts and keep them together. During
disassembly, look for damage that could not be seen after
parts have been removed and cleaned. Bring this type of
damage to the attention of inspection personnel before
continuing with disassembly.
3-7. DISASSEMBLY.
CAUTION
Reservoir may be pressurized. Open relief
valve (84, Figure 3-2) to relieve pressure
and drain residual hydraulic fluid.
3-2
Deficiency Report) will be forwarded to the following
organization for each component processed:
U.S. Army Aviation and Missile Command
Customer Interface Branch
ATTN: AMSAM-MMC-MA-NC
Redstone Arsenal, AL 35898-5000
NOTE
Before removing any lockwire, carefully
note method of lockwiring for reference
and ease of duplication during reassembly.
3-7.1. Disassemble the utility pump module assembly
according to numerical sequence of index numbers as-
signed to the exploded view illustration (Figure 3-2) not-
ing special procedures in the following paragraphs and
using special tools required in Table 2-1.
3-7.2. Disassembly of Utility Pump Module Assembly.
NOTE
Perform steps a., b., and c. on utility pump
module assembly, 70652-02300-050,
only.
a. Remove tubing (44), tee subassembly hose (45),
and tubing (46). Discard tubing.
b. Remove retaining ring (127), elbow subassembly
(47), and packing (129) from reservoir subassembly
(115). Discard retaining ring and packing.
 DMWR 1-4320-271

PRESHOP ANALYSIS DATA

NOUN PART NO. SERIAL NO. SEQUENCE DATE PREPARED BY

DEPOT MAINTENANCE REQ. O/M /SN /SO MAG. PLUG OIL FILTER

YES NO CLEAN CONTAM CLEAN CONTAM

FIELD TAG YES NO REASON

REASON FOR RETURN

PRIME CAUSE OF FAILURE

SECONDARY FAILURE

NOUN FAILED PART SERIAL NO.

PART NO.

CONDITION / DISCREPANCY

AA8563
SA

Figure 3-1. Preshop Analysis Data Form

3-3
DMWR 1-4320-271

22

13
182
9 18

12
11
6
5 A

19
10
1

3
4

19 13 4

17
8
16
7
15
21
14

20
AA3826_1A
SA

Figure 3-2. Utility Pump Module Assembly - Exploded View (Sheet 1 of 5)

3-4
 DMWR 1-4320-271

44 29

49 47
66
30
48
31
50 33 32 70
46 69
42 64 63
34 35
45
43 40
23 35
36 41
51
39 24 65
25
26 38
52
37
27 53 38 B 61
28 54

78
179
A
79
178
80
81 181

180 60
77 74
76
75 66
61
83 73

82
59

58 68
72
57 67
71
72

56
62

55

AA3826_2B
SA

Figure 3-2. Utility Pump Module Assembly - Exploded View (Sheet 2 of 5)

3-5
DMWR 1-4320-271

144 C

91 93
88 92
143 90
86 94
87

89

96 98
95 97

99
101
104
145
105
103
100 106
84 102

85

113

112

111

110 115

116

107 114 117

109

108

AA3826_3B
SA

Figure 3-2. Utility Pump Module Assembly - Exploded View (Sheet 3 of 5)

3-6
 DMWR 1-4320-271

140

141
142
136
137
135 136
137
136

138 139

162 161

163

164

172
171

173

174

133
175 134

170
159
168 153
169
157 152
167 154 158
166 157 150
155 149 151
165 155 156 150

160

AA3826_4A
SA

Figure 3-2. Utility Pump Module Assembly - Exploded View (Sheet 4 of 5)

3-7
DMWR 1-4320-271

131
130
119
126

120
124

132
121

123

129 122 125

128

127
118

115 124

182 175 145

148

176
187

186 147
177 146

184

185
183

AA3826_5C
SA

Figure 3-2. Utility Pump Module Assembly - Exploded View (Sheet 5 of 5)

3-8
 DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

3-2- 70652-02300-048 UTILITY PUMP MODULE ASSY, (Sikorsky Source

Control DWG) (75250 Part No. 53023-3, Model No.
HPSIV-3-03)................................................................. 1 A
70652-02300-049 UTILITY PUMP MODULE ASSY, (Sikorsky Source
Control DWG) (75250 Part No. 53023-05, Model No.
HPSIV-3-06)................................................................. 1 B
70652-02300-050 UTILITY PUMP MODULE ASSY, (Sikorsky Source
Control DWG) (75250 Part No. 53023-06, Model No.
HPSIV-3-06)................................................................. 1 C
70652-02110-106 . PUMP MODULE ASSY, (Sikorsky Source Control
DWG) (75250 Part No. 53223-03)............................ 1 A
70652-02110-108 . PUMP MODULE ASSY, (Sikorsky Source Control
DWG) (75250 Part No. 53223-05)............................ 1 B
70652-02110-109 . PUMP MODULE ASSY, (Sikorsky Source Control
DWG) (75250 Part No. 53223-06)............................ 1 C
-1 61417 . . SHAFT, EXTERNAL DRIVE, (75250)................... 1
-2 66948 . . RING, RETAINING, (75250) ................................. 1
-3 69954 . . SPRING, HELICAL COMPRESSION, (75250)..... 1
-4 61420 . . SEAL AND RETAINER SUBASSY, (75250) ........ 1
-5 NAS1351-3-8P . . SCREW, /AP/ ........................................................ 4
-6 AN960C10 . . WASHER, /AP/...................................................... 4
-7 61419 . . . SEAL, OIL, (75250)............................................ 1
-8 61395 . . . RETAINER, SEAL, (75250) ............................... 1
-9 M83461/1-131 . . PACKING ............................................................... 1
-10 67745 . . PIN, STEP, (75250) .............................................. 1
-11 MS28774-027 . . RETAINER, PACKING BACKUP........................... 1
-12 M83461/1-027 . . PACKING ............................................................... 1
-13 67717 . . SEAL, PLAIN ENCASED, (75250) ....................... 1 A
20807 . . SEAL, PLAIN ENCASED, (75250) ....................... 1 B,C
-14 67727 . . . SEAL, MATING FACE, (75250) (Used on
67717 and 20807)............................................... 1
-15 67726 . . . SEAL, NOSE, (75250) (Used on 67717 and
20807) ................................................................. 1
-16 67725 . . . WASHER, FLAT, (75250) (Used on 67717 and
20807) ................................................................. 1
-17 67724 . . . WASHER, WAVY, (75250) (Used on 67717
and 20807).......................................................... 1
-18 M83461/1-021 . . PACKING ............................................................... 1
-19 61394 . . SHAFT AND BEARING SUBASSY, (75250)........ 1 A
21351 . . SHAFT AND BEARING SUBASSY, (75250)........ 1 B,C
-20 69840 . . . BEARING, BALL, (75250).................................. 1
-21 61393 . . . SHAFT, INTERNAL DRIVE, (75250)................. 1 A
21350 . . . SHAFT, INTERNAL DRIVE, (75250)................. 1 B,C
-22 61396 . . SPRING, HELICAL COMPRESSION, (75250)..... 1
-23 62666 . . DISCONNECT ASSY, RETURN, (75250) ............ 1
ZA-1452H7-8-MT8 . . DISCONNECT ASSY, RETURN, (05477) (For
correct NHA move one column to left) .................. 1
AE83175H . . DISCONNECT ASSY, RETURN, (00624)
(Alternate for ZA-1452H7-8-MT8) (For correct
NHA move one column to left) .............................. 1
-24 MS28778-8 . . PACKING ............................................................... 1
-25 M83461/1-111 . . PACKING ............................................................... 1
-26 62665 . . DISCONNECT ASSY, PRESSURE, (75250) ....... 1
ZA-1452H6-8-MT8 . . DISCONNECT ASSY, PRESSURE, (05477)
(For correct NHA move one column to left) .......... 1
AE83172H . . DISCONNECT ASSY, PRESSURE, (00624)
(Alternate for ZA-1452H6-8-MT8) (For correct
NHA move one column to left) .............................. 1
-27 MS28778-8 . . PACKING ............................................................... 1

3-9
DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

-28 MS83461/1-111 . . PACKING ............................................................... 1

-29 62656 . . COVER, DUST, (75250) ....................................... 1
AE81892H . . CAP, DUST, (00624) (For correct NHA move
one column to left) ................................................. 1 B,C
155-S7-8D . . CAP, DUST, (00624) (Alternate for AE81892H)
(For correct NHA move one column to left) .......... 1
-30 62655 . . COUPLING, (75250) ............................................. 1
TB015519-S2-8D . . COUPLING, (00624) ............................................. 1
-31 MS28778-8 . . PACKING ............................................................... 1
-32 61412 . . FITTING, PORT, (75250)...................................... 1
-33 M83461/1-119 . . PACKING ............................................................... 1
-34 61367 . . VALVE, CHECK, (75250) ..................................... 2
-35 M83461/1-017 . . PACKING ............................................................... 2
-36 61369 . . VALVE, RELIEF, HYDRAULIC, (75250) .............. 1
-37 M83461/1-012 . . PACKING ............................................................... 1
-38 MS28774-012 . . RETAINER, PACKING BACKUP........................... 2
-39 M83461/1-014 . . PACKING ............................................................... 1
-40 61368 . . VALVE, BYPASS, FILTER, (75250) ..................... 1
-41 M83461/1-014 . . PACKING ............................................................... 1
-42 20292 . . BAND, RETAINING, (75250) ................................ 2 B,C
-43 20291 . . CAP, DUST, (75250) ............................................ 2 B,C
-44 2074402 . . TUBING, (75250) .................................................. 1 C
-45 20742 . . TEE SUBASSY, HOSE (75250) ........................... 1 C
-46 2074401 . . TUBING, (75250) .................................................. 1 C
-47 20737 . . ELBOW SUBASSY, (75250)................................. 1 C
-48 AN6289D4 . . NUT, /AP/ .............................................................. 1 C
-49 20743 . . ELBOW, HOSE CONNECTOR, (75250) .............. 1 C
-50 MS28778-4 . . PACKING ............................................................... 1 C
-51 62616 . . INDICATOR, DIFFERENTIAL PRES-
SURE, (75250)...................................................... 2
-52 6257320 . . RETAINER, PACKING BACKUP, (75250) ........... 2
-53 M83461/1-020 . . PACKING ............................................................... 2
-54 M83461/1-019 . . PACKING ............................................................... 2
-55 62615 . . FILTER HOUSING ASSY, (75250)....................... 2
-56 M8815-6-8 . . ELEMENT, FILTER,............................................... 2
-57 62617 . . SHUTOFF ASSY, (75250) .................................... 2
-58 MS28774-028 . . RETAINER, PACKING BACKUP........................... 2
-59 M83461/1-028 . . PACKING ............................................................... 2
-60 62618 . . SCREW, LOCKING, (75250) ................................ 2
-61 62912 . . SOLENOID SUBASSY, (75250) ........................... 1
-62 MS9088-06 . . BOLT, /AP/ ............................................................ 2
-63 62601 . . . SOLENOID, ELECTRICAL, (75250).................. 1
-64 M83461/1-113 . . . PACKING ............................................................ 1
-65 52691 . . . SPRING, COMPRESSION, (75250).................. 1
-66 55661 . . . SPOOL AND SLEEVE SUBASSY, (75250) ...... 1
-67 55662 . . . . SPOOL, (75250) (Matched Part, Order NHA)
......................................................................... 1
-68 55623 . . . . SLEEVE, (75250) (Matched part, Order
NHA) ................................................................ 1
-69 55682 . . . . NUT, LOCK, (75250) ...................................... 1
-70 61564 . . . . WASHER, SPRING TENSION, (75250)......... 1
-71 M83461/1-012 . . PACKING ............................................................... 2
-72 6257312 . . RETAINER, PACKING, (75250) ........................... 2
-73 61475 . . NUT, CHECK, (75250).......................................... 1
-74 61474 . . SCREW, ADJUSTING, (75250)............................ 1
-75 M83461/1-011 . . PACKING ............................................................... 1
-76 56986 . . SPRING, COMPRESSION, (75250)..................... 1
-77 67895 . . RETAINER, SPRING, (75250).............................. 1
-78 62625 . . PLUG, HEX HEAD, (75250) ................................. 1

3-10
 DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

-79 8090218 . . PACKING, PREFORMED, (75250) ...................... 1

-80 62626 . . SLEEVE, COMPENSATOR, (75250) ................... 1
-81 67719 . . SPOOL, COMPENSATOR, (75250) ..................... 1
-82 AN814-6JL . . PLUG AND BLEEDER........................................... 1
-83 M83248/2-906 . . PACKING ............................................................... 1
-84 62168 . . VALVE, RELIEF, HYDRAULIC, (75250) .............. 1
-85 M83461/1-014 . . PACKING ............................................................... 1
-86 M83723-88H08036 . . CONNECTOR, ELECTRICAL................................ 1
-87 NAS1352C04H4 . . SCREW, /AP/ ........................................................ 4
-88 7697801 . . GASKET, HEADER, (75250) ................................ 1
-89 3004503 . . SLEEVING, HEAT SHRINKABLE, (75250) .......... 3 A
M23053/5-103C . . SLEEVING, HEAT SHRINKABLE ......................... AR B,C
-90 7078208 . . TUBING, STANDARD WALL, (75250) ................. 3 A
M23053/5-106C . . SLEEVING, HEAT SHRINKABLE ......................... AR C
-91 M23053/5-102C . . SLEEVING, HEAT SHRINKABLE ......................... AR C
-92 62594 . . COVER, SWITCH, (75250)................................... 1
-93 NAS1351-06-6P . . SCREW, /AP/ ........................................................ 6
-94 NAS620C6L . . WASHER, /AP/...................................................... 6
-95 8004418 . . PACKING, PREFORMED, (75250) ...................... 1
-96 62590 . . SWITCH, ELECTRIC, (75250).............................. 1
-97 MS21044C06 . . NUT, /AP/ .............................................................. 2 A
62848 . . NUT, SELF-LOCKING, (75250) /AP/ ................... 2 B,C
-98 AN960C6L . . WASHER, /AP/...................................................... 2
-99 MS9487-16 . . SCREW, /AP/ ........................................................ 2
-100 MS19065-36 . . PIN ......................................................................... 1
-101 62593 . . LEVER, SWITCH, (75250).................................... 1
-102 55675 . . SPRING, COMPRESSION, (75250)..................... 1 A
52691 . . SPRING, COMPRESSION, (75250)..................... 1 B,C
-103 62592 . . BRACKET, SWITCH, (75250) .............................. 1
-104 NAS1352-06-6P . . SCREW, /AP/ ........................................................ 4
-105 NAS620C6L . . WASHER, /AP/...................................................... 4
-106 6156302 . . CLOSURE, PROTECTIVE, (75250) ..................... 1
-107 62596 . . PISTON, RESERVOIR, (75250) ........................... 1
-108 S62117-2 . . SEAL, RADIAL PISTON, (64422)......................... 1
-109 62606 . . RING, PISTON, TOP, (75250).............................. 1
-110 62607 . . RING, PISTON, LOWER, (75250)........................ 1
-111 61426 . . SPRING, COMPRESSION, (75250)..................... 1
62728 . . SPRING, COMPRESSION, (75250) (Alternate
for 61426)............................................................... 1
-112 62153 . . GUIDE, SPRING, (75250) .................................... 1
-113 61532 . . PLATE, END, (75250)........................................... 1
-114 61415 . . PLATE, IDENTIFICATION, (75250)...................... 1
-115 62575 . . RESERVOIR SUBASSY, (75250) ........................ 1 A
21041 . . RESERVOIR SUBASSY, (75250) ........................ 1 B
21887 . . RESERVOIR SUBASSY........................................ 1 C
-116 MS16998-30 . . SCREW, /AP/ ........................................................ 8 A,B
MS16998-31 . . SCREW, /AP/ ........................................................ 2 C
MS16998-30 . . SCREW, /AP/ ........................................................ 6 C
-117 AN960C10 . . WASHER, /AP/...................................................... 8
-118 61549 . . . PLATE, INSTRUCTION, (75250)....................... 1
-119 62187 . . . PLATE, FLUID IDENTIFICATION AND FLUID
LEVEL INDICATOR, (75250)............................. 1 A
21088 . . . PLATE, FLUID IDENTIFICATION AND FLUID
LEVEL INDICATOR, (75250)............................. 1 B,C
-120 62183 . . . PLATE, FLUID IDENTIFICATION AND FLUID
LEVEL INDICATOR, (75250)............................. 1 A

3-11
DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

21089 . . . PLATE, FLUID IDENTIFICATION AND FLUID

LEVEL INDICATOR, (75250)............................. 1 B,C
-121 61423 . . . GLASS, SIGHT, (75250).................................... 2
-122 NAS1352-06-6P . . . SCREW, /AP/ ..................................................... 2 B,C
-123 NAS602C6L . . . WASHER, /AP/................................................... 2 B,C
-124 21084 . . . RETAINER SUBASSY, SIGHT
GLASS, (75250)................................................. 2 B,C
-125 20544 . . . . RETAINER, (75250)........................................ 1 B, C
-126 21042 . . . . GASKET, (75250) ........................................... 1 B,C
-127 MS16625-1075 . . . RING, RETAINING ............................................. 1 A,B
-128 53855 . . . BREATHER, (75250) ......................................... 1 A,B
-129 M83461/1-016 . . . PACKING ............................................................ 1 A,B
-130 MS21209F0610 . . . INSERT, HELICAL COIL .................................... 6
-131 MS21209C0620 . . . INSERT, HELICAL COIL .................................... 4
-132 62574 . . . RESERVOIR, (75250)........................................ 1 A
21085 . . . RESERVOIR, (75250)........................................ 1 B,C
-133 NAS1351-3-10 . . SCREW.................................................................. 13
-134 NAS620-10L . . WASHER ............................................................... 13
-135 61399 . . RETAINER, PACKING, (75250) ........................... 1
-136 6257311 . . RETAINER, PACKING, (75250) ........................... 4
-137 M83461/1-011 . . PACKING ............................................................... 2
-138 6980004 . . VALVE, CHECK, (75250) ..................................... 1
-139 M83461/1-010 . . PACKING ............................................................... 1
-140 M83461/1-141 . . PACKING ............................................................... 1
-141 8025418 . . PACKING, (75250)................................................ 1
-142 68746 . . PIN, RETAINING, (75250) .................................... 1
-143 56546 . . PLATE, ROTATION, (75250)................................ 1
-144 AN535-00-2 . . SCREW, /AP/ ........................................................ 2 A
MS21318-1 . . SCREW, /AP/ ........................................................ 2 B,C
-145 62599 . . MANIFOLD SUBASSY, (75250) ........................... 1
-146 MS21209F1-15 . . . INSERT, HELICAL COIL .................................... 27
-147 61414 . . . JET, LUBRICATION, (75250) ............................ 1
-148 62571 . . . MANIFOLD, VALVE & FILTER, (75250) ........... 1
62567 . . . MANIFOLD, VALVE & FILTER, (75250)
(Alternate Part No.)............................................. 1
-149 61400 . . PLUG, RATE PISTON, (75250)............................ 1
-150 MS28774-013 . . RETAINER, PACKING BACKUP........................... 2
-151 M83461/1-013 . . PACKING ............................................................... 1
-152 61405 . . SPRING, COMPRESSION, (75250)..................... 1
-153 61404 . . PISTON, RATE, (75250)....................................... 1
-154 62699 . . COUPLING, FLUID TRANSFER, (75250)............ 1
-155 6257311 . . RETAINER, PACKING, (75250) ........................... 2
-156 M83461/1-011 . . PACKING ............................................................... 1
-157 6257312 . . RETAINER, PACKING, (75250) ........................... 2
-158 M83461/1-012 . . PACKING ............................................................... 1
-159 62698 . . PISTON, STROKING, (75250) ............................. 1
-160 61390 . . PLATE, PORT, (75250) ........................................ 1
-161 61389 . . COVER, TRUNNION, (75250).............................. 1
-162 62283 . . SCREW, CAP, BUTTONHEAD, (75250) /AP/ ..... 4
-163 NAS620-10L . . WASHER, FLAT, /AP/........................................... 4
-164 61358 . . BEARING, TRUNNION, (75250) .......................... 1
-165 61461 . . BARREL, CYLINDER, (75250) ............................. 1
-166 67800 . . BEARING, CYLINDER BARREL, (75250)............ 1
-167 61388 . . BUSHING, SPLINE, (75250) ................................ 1
-168 57915 . . SPRING, COMPRESSION, (75250)..................... 1
-169 61398 . . SEAT, SPRING, (75250) ...................................... 1
-170 61397 . . GUIDE, SPRING, (75250) .................................... 1

3-12
 DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

-171 61387 . . HANGER AND PISTON SUBASSY, (75250)

(See Figure 3-3 for Breakdown) ............................ 1
-172 61392 . . ARM, HANGER, (75250) ...................................... 1
-173 MS24674-10 . . SCREW, /AP/ ........................................................ 2
-174 61358 . . BEARING, TRUNNION, (75250) .......................... 1
-175 62600 . . HOUSING SUBASSY, (75250)............................. 1
62706 . . HOUSING SUBASSY, (75250) (Alternate for
62600) .................................................................... 1
-176 MS21209F1-15 . . . INSERT, HELICAL COIL .................................... 4
-177 62591 . . . HOUSING, PUMP, (75250) ............................... 1
62705 . . . HOUSING, PUMP, (75250) (Alternate for
62591) ................................................................. 1
-178 SS9019-2048 . . PLATE, IDENTIFICATION, (78286) (For NHA
move one column to left) (75250)......................... 1
-179 SS9019-2049 . . PLATE, IDENTIFICATION, (78286) (For NHA
move one column to left) ....................................... 1
-180 SS9109-2050 . . PLATE, IDENTIFICATION, (78286) (For NHA
move one column to left) ....................................... 1
-181 4B-225 . . TEMPILABEL, (29907) (For correct NHA move
one column to left) ................................................. 2 B,C
HM200-300 . . TEMPILABEL, (94858) (Alternate for 4B-225)
(For correct NHA move one column to left) .......... 2 B, C
-182 93058 . MAGNETIC SEAL, (04171) (Alternate for 67717
and 20807)................................................................ 1
-183 86145-1-7 . . SPLIT SLEEVE, (04171) (Used on 93058) .......... 1
-184 021-517 . . O-RING, (04171) (Used on 93058) ...................... 1
-185 86145-1-113 . . SEAL CASE, (04171) (Used on 93058) ............... 1
-186 93058-1-2 . . MAGNET, (04171) (Used on 93058) .................... 1
-187 027-517 . . O-RING, (04171) (Used on 93058) ...................... 1

3-13
DMWR 1-4320-271

AA8880
SA

Figure 3-3. Hanger and Piston Subassembly

3-14
 DMWR 1-4320-271

QTY USABLE
FIGURE & PER ON
INDEX NO. PART NUMBER 1 2 3 4 5 6 7 DESCRIPTION ASSY CODE

3-3- 61387 HANGER AND PISTON SUBASSY, (75250) (See

Figure 3-2 for NHA) ..................................................... REF
-1 66587 . PLATE, SHOE RETAINER, (75250)........................ 1
-2 68754 . PISTON AND SHOE SUBASSY, (75250) ............... 9
-3 68617 . PLATE, WEAR, HANGER, (75250)......................... 1
-4 61375 . HANGER, (75250) ................................................... 1
-5 68756 . WASHER, THRUST, (75250) .................................. 1
-6 61386 . RETAINER, PLATE AND WASHER, (75250) ......... 1

3-15
DMWR 1-4320-271
c. Remove nut (48), packing (50), and hose con-
nector elbow (49). Discard packing.
d. Using standard needle nose pliers, compress
retaining ring (2) and remove external drive shaft (1) and
helical compression spring (3) from manifold subas-
sembly (145).
e. Remove screws (5) and washers (6) and remove
seal and retainer subassembly (4) and plain encased seal
(13) from manifold subassembly (145). Remove plain
encased seal from seal and retainer subassembly.
f. Using puller (61420-T200) separate oil seal (7)
and seal retainer (8). Remove packing (9) from seal
retainer. Discard seal and packing.
g. Remove step pin (10), packing backup retainer
(11) and packing (12) from plain encased seal (13) or
magnetic seal (182). Separate mating face seal (14),
nose seal (15), flat washer (16), wavy washer (17) and
packing (18). Discard packings and retainer. Separate
split sleeve (183), o-ring (184), seal case (185), magnet
(186), and o-ring (187). Discard o-rings.
h. Remove shaft and bearing subassembly (19) and
helical compression spring (22) from manifold subas-
sembly (145).
i. Place shaft and bearing subassembly (19) on
holding fixture (out) (61393-T201) and using the ram
drift pin inside the splined cavity of the internal drive shaft
(21), press the internal drive shaft from ball bearing (20).
j. Remove return disconnect assembly (23) with as-
sembled packings (24 and 25). Remove and discard
packings.
k. Remove pressure disconnect assembly (26) with
assembled packings (27 and 28). Remove and discard
packings.
l. Remove hydraulic relief valve (36), packings (37
and 39) and packing backup retainers (38) from
manifold subassembly. Discard packings and packing
backup retainers.
m. Remove filter bypass valve (40) with packing
(41) from manifold subassembly. Discard packing.
3-16
NOTE
Perform step n. on utility pump module as-
semblies, 70652-02300-049 and -050
only.
n. Remove retaining bands (42) and dust caps (43)
from differential pressure indicators (51).
o. Remove differential pressure indicators (51) with
packing backup retainers (52) and packings (53 and 54).
Discard packing backup retainers and packings.
p. Unscrew dust cover/cap (29) from coupling
(30).
q. Remove coupling (30) with assembled packing
(31) from manifold subassembly (145). Remove and
discard packing.
r. Remove port fitting (32) with packing (33) from
manifold subassembly (145). Discard packing.
s. Remove two check valves (34) with two packings
(35) from manifold subassembly. Remove and discard
packing.
CAUTION
Filter elements (56) are spring loaded.
t. Remove two filter housing assemblies (55) and
two filter elements (56) from manifold subassembly (145).
Discard filter elements.
u. Using filter removal tool (62617-T201) remove
shutoff assemblies (57), packing backup retainers (58)
and packings (59). Discard packing backup retainers
and packings.
v. Do not remove locking screws (60) unless dam-
aged or replacement is required.
w. Remove bolts (62) that secure electrical solenoid
(63) to manifold subassembly (145).

x. Remove solenoid (63) with assembled packing
(64) from manifold subassembly. Remove and discard
packing.
y. Remove compression spring (65) from spool
(67). Discard compression spring.
CAUTION
Spool and sleeve subassembly (66) are a
matched set. Retain or replace as a
matched set.
z. Remove spool and sleeve subassembly (66) with
assembled locknut (69), spring tension washer (70),
packings (71), and packing backup retainers (72).
aa. Remove locknut (69), spring tension washer (70),
spool (67), packings (71), and packing backup retainers
(72) from sleeve (68). Discard packings and packing
backup retainers.
ab. Loosen check nut (73) and remove adjusting
screw (74) with packing (75), compression spring (76)
and spring retainer (77) from manifold subassembly
(145). Discard packing and compression spring.
ac. Remove hex head plug (78), packing preformed
(79), compensator sleeve (80) and compensator spool
(81) from manifold subassembly (145). Discard packing.
ad. Remove plug and bleeder (82) with packing (83)
from manifold subassembly (145). Remove and discard
packing.
ae. Remove hydraulic relief valve (84) with packing
(85) from reservoir subassembly (115). Discard packing.
NOTE
Do not disassemble or unsolder lead wires
of electrical connector (86) unless dam-
aged or replacement is required.
af. Remove four screws (87) that secure electrical
connector (86) to switch cover (92).
ag. Remove heat shrinkable sleevings (89 and 91)
and standard wall tubing (90), and unsolder lead wires
from electrical connector (86).
DMWR 1-4320-271
ah. Remove electrical connector (86) and header
gasket (88). Discard header gasket.
ai. Remove screws (93) and washers (94). Lift switch
cover (92) from reservoir subassembly (115). Remove
and discard preformed packing (95).
aj. Remove nuts (97), washers (98) and screws (99).
Disassemble electric switch (96), pin (100), switch lever
(101) and compression spring (102).
ak. Remove four screws (104) and four washers
(105). Lift switch bracket (103) from reservoir subas-
sembly (115).
WARNING
Reservoir subassembly (115) is spring
loaded to 260 pounds. Observe special
instructions in removing eight attaching
screws (116).
al. Remove protective closure (106) from reservoir
subassembly (115).
am. Insert assembly tool (62596-T206) through
opening left by removal of protective closure (106) and
thread assembly tool into boss of reservoir piston (107).
an. Install assembly plate (62596-T203) over as-
sembly tool (62596-T206) and up against reservoir
subassembly (115). Install a one inch number 8 thread
nut, (commercial source) on assembly tool. Tighten nut
against assembly plate two to three complete turns to
secure reservoir piston (107) and compression spring
(111).
WARNING
Do not remove eight attaching screws
(116) until reservoir piston (107) and
compression spring (111) have been
properly secured.
ao. Remove screws (116) and washers (117) that
secure reservoir subassembly (115) to manifold subas-
sembly (145).
3-17
DMWR 1-4320-271
ap. Do not remove identification plate (114) from
end plate (113) unless there is evidence of damage,
modification of data entered on identification plate, or
change of identification plate is required.
NOTE
Perform step aq. on utility pump module
assembly, 70652-02300-048, only.
aq. Do not remove instruction plate (118), fluid
identification and fluid level indicator plates (119 and
120) or sight glass (121) from reservoir (132) unless
there is evidence of damage.
NOTE
Perform steps ar. and as. on utility pump
module assemblies, 70652-02300-049
and -050, only.
ar. Do not remove instruction plate (118), fluid
identification and fluid level indicator plates (119 and
120), sight glasses (121) and sight glass retainer subas-
semblies (124) from reservoir (132) unless there is
evidence of damage.
as. If sight glasses (121) or sight glass retainer
subassembly (124) are damaged, remove by removing
screws (122) and washers (123). If required, remove and
discard gaskets (126) and retainers (125).
at. Do not remove helical coil inserts (130 and 131)
unless there is evidence of damage. If inserts require
replacement, do not attempt removal until after disas-
sembly step as.
NOTE
Perform step au. on utility pump module
assemblies, 70652-02300-048 and -049,
only.
au. Remove retaining ring (127), breather (128),
and packing (129) from reservoir (132). Discard retain-
ing ring, breather, and packing.
WARNING
Reservoir piston (107) is spring-loaded to
260 pounds. Exercise extreme caution in
reducing compression spring force. Make
3-18
certain that assembly rod does not turn
when backing off nut.
av. Back off the one-inch number 8 nut on the as-
sembly rod (61356-T201) very slowly until all compres-
sion spring force has been relieved and compression
spring has attained normal free length of approximately
13.87 inches.
aw. Remove the one-inch nut, and assembly plate
(62596-T203) from assembly rod (61356-T201) and
unscrew assembly rod from reservoir piston (107).
ax. Remove reservoir piston (107), radial piston seal
(108), top piston ring (109), lower piston ring (110),
compression spring (111), spring guide (112) and end
plate (113) from reservoir (132). Remove and discard
piston seal, top piston ring, and lower piston ring.
ay. Remove buttonhead cap screws (162), flat wash-
ers (163), and trunnion cover (161) from housing subas-
sembly (175).
az. Remove screws (133) and washers (134) from
housing subassembly (175). Lift housing subassembly out
of manifold subassembly (145).
ba. Remove assembled packing retainers (135 and
136) and packings (137) from manifold subassembly
(145).
bb. Remove and discard four packing retainers (135
and 136) and two packings (137) from retainer.
bc. Remove check valve (138) along with packing
(139) from manifold subassembly (145). Remove packing
from check valve and discard packing.
bd. Remove packings (140 and 141) from manifold
subassembly (145). Discard packings.
be. Remove retaining pin (142) from port plate
(160).
bf. Remove rotation plate (143) and screws (144)
only if rotation plate is damaged.
bg. Remove assembled rate piston plug (149), two
packing backup retainers (150) and packing (151) from
housing subassembly (175). Remove and discard retain-
ers and packing from rate piston plug.
bh. Remove compression spring (152) and rate
piston (153) from housing subassembly (175).

bi. Remove assembled fluid transfer coupling (154),
packing retainers (155), packing (156), packing retain-
ers (157) and packing (158) from housing subassembly
(175). Remove and discard retainers, packing, retainers
and packing from fluid transfer coupling.
bj. Remove stroking piston (159) and port plate
(160) from housing subassembly (175).
bk. Lift trunnion bearing (164) out of housing subas-
sembly (175).
bl. Remove cylinder barrel (165), cylinder barrel
bearing (166), spline bushing (167), compression spring
(168), spring seat (169), and spring guide (170) out of
housing subassembly (175).
bm. Lift hanger and piston subassembly (171) out of
housing subassembly (175). Remove lockwire from
screws (173).
bn. Remove screws (173) and hanger arm (172)
from hanger and piston subassembly (171).
bo. Remove trunnion bearing (174) from housing
subassembly (175).
bp. Remove identification plates (178, 179, and
180) and tempilabel (181) only if damaged or unread-
able.
3-7.3. Disassembly of Hanger and Piston Assembly.
a. Set hanger and piston subassembly in holding
fixture (57925-T1).
b. Using wrench (57919-T2) unscrew shoe retainer
plate (1, Figure 3-3) from plate and washer retainer (6)
c. Lift shoe retainer plate and nine piston and shoe
subassemblies (2) from plate and washer retainer (6).
Separate shoe retainer plate and piston and shoe subas-
semblies.
NOTE
Retain nine piston and shoe subassemblies
(2) as a set, for further evaluation during
inspection.
d. Remove hanger wear plate (3), hanger (4) and
thrust washer (5) from plate and washer retainer (6).
DMWR 1-4320-271
3-8. CLEANING.
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
3-8.1. After utility pump module assembly has been
disassembled, clean all parts using methods in general
cleaning or specific cleaning instructions paragraphs.
3-8.2. Clean all metal parts in accordance with the fol-
lowing instructions:
WARNING
• Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
• Degreasing solvent is combustible and
toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged
contact. Use only in well-ventilated areas
(or use approved respirator as determined
3-19
DMWR 1-4320-271
by local safety/industrial hygiene person-
nel). Keep away from open flames or other
sources of ignition.
• USP alcohol is flammable and toxic to
eyes, skin, and respiratory tract. Wear
protective gloves and goggles/face shield.
Avoid repeated or prolonged contact. Use
only in well ventilated areas (or use ap-
proved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames, sparks, or other
sources of ignition.
CAUTION
• Contaminants are a major cause of wear
and pump module failure. Cover or
otherwise protect all parts after cleaning to
prevent dust and dirt from settling on them.
• Do not agitate parts more than four
minutes at any one time. Put bearings
through one cleaning cycle only to prevent
pitting.
a. If ultrasonic cleaning equipment (LG-500) is
available, clean all parts using the ultrasonic method.
Clean parts four - five minutes. Clean reservoir subas-
sembly (115, Figure 3-2) and manifold subassembly
(145) with Daraclean (item 23, App C) at a concentration
less than 10% and temperature at 120°F (49°C). All other
parts must be cleaned with degreasing solvent (item 6,
App C), Breakthrough (item 19, App C), Brulin (item 11,
App C), or USP alcohol (item 10, App C). Prior to clean-
ing, use a nonmetallic scraper to remove sealant.
b. If ultrasonic cleaning equipment is not available,
use the instructions in steps c. through e. to clean utility
pump module assembly parts. Prior to cleaning, use a
nonmetallic scraper to remove sealant.
WARNING
Degreasing solvent is combustible and
toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face
3-20
shield. Avoid repeated or prolonged
contact. Use only in well-ventilated areas
(or use approved respirator as determined
by local safety/industrial hygiene person-
nel). Keep away from open flames or other
sources of ignition.
c. Immerse all parts in degreasing solvent (item 6,
App C). Pay particular attention to interior passages and
bores. Soak parts and use a stiff-bristled brush to loosen
and remove any hardened deposits of dirt or other
contaminants. Do not use harsh abrasives or wire brushes
that might scratch, score, or mar polished surfaces.
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
d. Remove light color discoloration from bare metal
surfaces with low-lint cleaning cloth (item 22, App C)
saturated with brass metal polish (item 13, App C).
Remove discoloration by rubbing briskly. Polish with low-
lint cleaning cloth. Clean parts thoroughly after polishing.
WARNING
Compressed air may be used for cooling,
cleaning, and drying applications as long
as (1) air flow is restricted to less than 15
psi, (2) a safety nozzle is used, and (3) ef-
fective eye protection (safety glasses with
shield or safety goggles) is also used.
Other less hazardous means, including
vacuuming and wet sweeping should be
considered. By no means shall compressed
air be used to clean ones clothing.

e. Dry parts thoroughly by purging with clean, dry,
filtered compressed air of not more than 15 psig, or with
low-lint cleaning cloth (item 22, App C).
CAUTION
Do not use crocus cloth (item 5, App C) on
aluminum parts as it contains ferrous oxide
which causes rapid deterioration of
aluminum.
f. Remove corrosion from ferrous metal surfaces by
polishing with crocus cloth (item 5, App C) and polishing
in accordance with step d.
g. Remove corrosion from aluminum as follows:
(1) Clean and rinse thoroughly with water to
remove any residual solvent.
WARNING
Contact of aluminum etchant with metals
releases hazardous fumes. The liquid is
corrosive and can cause burns to exposed
body tissues on contact. If any liquid
contacts skin or eyes, immediately flush af-
fected area thoroughly with water. Inhala-
tion of mist can cause respiratory irritation,
marked by difficulty in breathing.
Protection: chemical splash proof goggles
or face shield, impervious gloves and cloth-
ing, NIOSH/MSHA approved respirator if
mists exceed established exposure limits.
DMWR 1-4320-271
(2) Remove corrosion by mechanical methods.
Treat repaired area per MIL-C-5541.
WARNING
Chemical conversion coatings are strong
oxidizing agents. They may ignite
combustible material such as wood and
paper or organic substances. Keep
container closed; keep sparks, flames, and
heat away. Keep off skin, eyes, and
clothes. May severely burn the eyes and
skin on contact. Do not breathe vapors.
Breathing dusts and mists may irritate the
respiratory tract. Long term overexposure
by breathing mists or absorption through
the skin may cause cancer, kidney and
liver damage, and ulceration of the nasal
septum. Protection: chemical splash proof
goggles, approved gloves, forced ventila-
tion, NIOSH/MSHA approved respirator if
mists exceed established exposure limits.
(3) Touch up damaged anodize in threaded
areas using chemical conversion coating (item 24, App
C) per MIL-C-5541.
3-8.3. Clean Bearing. Clean bearings per TM 55-1500-
322-24 including Attachment 6A, which replaces Section
V of manual, and Attachment 6B, which replaces
paragraphs 14-74 through 14-98 of Section XIV of
manual.
3-21
DMWR 1-4320-271
Section V. In-Process Inspection
3-9. GENERAL.
3-9.1. In-process inspection is an examination of
component parts of the disassembled (utility pump
module assembly). The inspection is basically visual or
mechanical to detect damage or wear to determine
serviceability of parts. Detailed inspection requirements
for individual parts are specified in the Overhaul Inspec-
tion Procedures (OIP) in this chapter. Inspect all parts for
any damage or condition that might affect their safe
reuse. Detail inspect parts for signs of wear and for
service tolerances specified in applicable OIP. All dimen-
sions in OIP’s are in inches unless otherwise noted.
Remove parts from service that are worn beyond allow-
able limits, or that cannot be repaired. Any component or
subassembly that is repaired shall meet requirements
specified in the applicable OIP. Used components and
refinished parts recovered as products of disassembly will
be examined 100% by the contractor to determine
serviceability. When the OIP states 9no damage allowed,9
9no nicks or burrs,9 9no corrosion allowed,9 or similar
type of restricting statement, it shall be interpreted to
mean that the part should be repaired using a good shop
practice, or a specific method which is stated in the DM-
WR repair section.
3-9.2. Visual Inspection. Magnifying glass and ampli-
fied lighting shall be used as necessary, during visual
inspection to determine cracks. Damage indicated by
visual inspection shall be verified by measurement or
gage before discarding part. When cracks are indicated,
do a magnetic particle or fluorescent penetrant inspection
check to aid the visual inspection.
3-9.3. Mechanical Inspection. Mechanical inspection
shall be done using standard micrometers and gages. A
surface table or optical flat (Table 2-2) surface shall be
used to check for distortion of parts.
3-9.4. Magnetic Particle Inspection. Ferrous parts
requiring magnetic particle inspection by an OIP shall be
inspected per ASTM-E1444.
WARNING
• n-Propyl Bromide is toxic to eyes, skin, and
respiratory tract. Wear protective gloves
and goggles/face shield. Avoid repeated
or prolonged contact. Use only in areas
3-22
with adequate mechanical or local exhaust
ventilation (or use approved respirator as
determined by local safety/industrial
hygiene personnel).
• DS-108 is combustible, reactive with strong
oxidizers, and toxic to eyes, skin, and
respiratory tract. Wear protective gloves
and goggles/face shield. Avoid repeated
or prolonged contact. Use only in well-
ventilated areas (or use approved respira-
tor as determined by local safety/industrial
hygiene personnel). Keep away from open
flames, sparks, or other sources of ignition.
Do not mix or cross-apply with other clean-
ers or chemicals.
• Electron is combustible and toxic to eyes,
skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid
repeated or prolonged contact. Use only in
well ventilated areas. Use approved
organic vapor respirator, with dust and
mist filter, if exposed to vapor mist. Keep
away from open flames, sparks, or other
sources of ignition.
• Positron is combustible and toxic to eyes,
skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid
repeated or prolonged contact. Use only in
well-ventilated areas. Use approved
organic vapor respirator, with dust and
mist filter, if exposed to vapor mist. Keep
away from open flames, sparks, or other
sources of ignition.
• Acetone is flammable and toxic to eyes,
skin, and respiratory tract. Wear protective
gloves and goggles/face shield. Avoid
repeated or prolonged contact. Use only in
well-ventilated areas (or use approved
respirator as determined by local safety/
industrial hygiene personnel). Keep away
from open flames, sparks, hot surfaces or
other sources of ignition.
• Isopropyl alcohol is flammable and toxic to
eyes, skin, and respiratory tract. Wear
protective gloves and goggles/face shield.
Avoid repeated or prolonged contact. Use

MATING FACE AREA
NOTES
1. ALL DIMENSIONS ARE IN INCHES
UNLESS OTHERWISE NOTED.
2. SYMBOLS: MAGNET
DIAMETER
Figure 3-4. Magnet Inspection
only in well-ventilated areas (or use ap-
proved respirator as determined by local
safety/industrial hygiene personnel). Keep
away from open flames, sparks, or other
sources of ignition.
3-9.5. Fluorescent Penetrant Inspection. Nonferrous
parts requiring fluorescent penetrant inspection by an OIP
shall be inspected per ASTM-E1417. Parts requiring
fluorescent penetrant inspection shall be cleaned prior to
inspection with n-propyl bromide (vapor degreasing
only) (item 27, App C), DS-108 (item 28, App C),
Electron (item 29, App C), or Positron (item 30, App C).
DS-108, Electron, or Positron must be followed by an
acetone (item 25, App C) or isopropyl alcohol (item 3,
App C) rinse or wipe; or drying until there is no visible
solvent residue left on parts.
3-9.6. Inspection of Bearings. Inspect bearings (20,
154, 166, and 174, Figure 3-2) per TM 1-1500-322-24.
3-9.7. Magnetic Seal Inspection.
3-9.7.1. Magnet Inspection.
DMWR 1-4320-271
0.970 1.108
0.277 MINIMUM
AB1353
SA
a. The magnet is made of cast Alnico; therefore,
pits and minor surface irregularities are permissible
except in mating face area. Limits are shown in Figure
3-4.
b. Visually inspect magnet under clean room condi-
tions using a strong light. Check for scratches, nicks, and
cracks. Cracked magnet is not reparable and shall be
replaced.
c. Inspect lapped sealing surface of magnet under
helium light source using an optical flat. The surface shall
be flat within two helium light bands (Figure 3-5).
d. Check packing seal groove for damage. Any
damage that extends across the three surfaces of groove
is cause for replacement. Locally polish to remove raised
or sharp edges.
e. Check both surfaces of magnet for parallelism.
Magnet thickness shall be parallel within 0.0005 inch.
3-9.7.2. Seal Case Inspection.
3-23
DMWR 1-4320-271

MAGNET
UNACCEPTABLE UNACCEPTABLE

LINES NOT SHARPLY DEFINED, SPACING UNEVEN AND CURVED

ACCEPTABLE

LINES EVENLY SPACED, SHARPLY DEFINED AND STRAIGHT

SEAL CASE CARBON

UNACCEPTABLE UNACCEPTABLE

LINES NOT SHARPLY DEFINED, SPACING UNEVEN AND CURVED

ACCEPTABLE

LINES EVENLY SPACED, SHARPLY DEFINED AND STRAIGHT

AB1354
SA

Figure 3-5. Optical Light Band Inspection

3-24
 DMWR 1-4320-271

HEIGHT OF CARBON

0.007 INCH MINIMUM

SEAL CASE AB1383

SA

Figure 3-6. Measure Height of Carbon

a. Sealing surface of carbon shall show no visible
scratches when viewed with the naked eye. Chips on seal-
ing surface of carbon are not allowed unless they are
within the following carbon seal limits:
Carbon Chip Limits
b. Using depth micrometers, measure from carbon
seal face to metal hub of seal case. This dimension shall
not be below minimum (Figure 3-6).
c. Inspect lapped carbon face under helium light
source using an optical flight. Surface shall be flat within
two helium light bands (Figure 3-5) with no visible
scratches.

Number Size d. Check packing seal groove for damage. Any

of Chips damage that extends across the three surfaces of groove
is cause for replacement. Locally polish to remove raised
1 0.031 inch or 20% of or sharp edges.
seal face width,
whichever is smaller NOTE

4 0.015 inch or 10% of Lapping of sealing surfaces is not recom-

seal face width, mended.
whichever is smaller
e. If seal case fails to meet these requirements,
No limits 5% of seal face width
replacement of carbon will be accomplished by Magnetic
Seal Corp., 365 Market Street, Warren, RI 02885.

3-25
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61417

ITEM: EXTERNAL DRIVE SHAFT REFERENCE: 3-2, 1

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine splines for burrs

and uneven wear

2 A Actual tooth thickness of Measure 0.6863 (minimum)

external splines mating with 0.6862 (replace)
internal drive shaft (21)
measured over 0.0960
diameter pins

3 Fractures and cracks Magnetic particle per para No fractures or cracks al-
3-9.4 lowed

4 B Actual tooth thickness of Measure 0.9346 (minimum)

external splines mating with 0.9345 (replace)
helicopter gear box
measured over 0.0960
diameter pins

SHEET 1

3-26
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61417

ITEM: EXTERNAL DRIVE SHAFT REFERENCE: 3-2, 1

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

AA3827
SA

SHEET 2

3-27
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61395

ITEM: SEAL RETAINER REFERENCE: 3-2, 8

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine packing groove

for nicks and burrs. Check
overall condition of face

2 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

3-9.5 lowed

SHEET 1

3-28
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 67727

ITEM: MATING FACE SEAL REFERENCE: 3-2, 14

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No nicks, burrs, or

scratches permitted on seal-
ing surface

SHEET 1

3-29
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 67726

ITEM: NOSE SEAL REFERENCE: 3-2, 15

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No nicks, burrs, or

scratches

SHEET 1

3-30
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61393, 21350

ITEM: INTERNAL DRIVE SHAFT REFERENCE: 3-2, 21

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for scratches,

grooves, or galling on neck
and bearing surfaces.
Inspect for flat spots or
uneven wear of spline
profile

2 A Actual tooth thickness of Measure 0.4630 (minimum)

external splines mating with 0.4629 (replace)
spline bushing (167)
measured over 0.0600
diameter pins

3 B Actual space width of Measure 0.4218 (maximum)

internal splines mating with 0.4219 (replace)
external drive shaft (1)
measured between 0.0864
diameter pins

4 Fractures and cracks Magnetic particle per para No fractures or cracks al-
3-9.4 lowed

AA3828
SA

SHEET 1

3-31
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61412

ITEM: PORT FITTING REFERENCE: 3-2, 32

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

SHEET 1

3-32
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61367

ITEM: VALVE, CHECK REFERENCE: 3-2, 34

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No nicks, scratches, or

burrs allowed

SHEET 1

3-33
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61369

ITEM: VALVE, RELIEF REFERENCE: 3-2, 36

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No nicks, scratches, or

burrs allowed

SHEET 1

3-34
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61368

ITEM: FILTER BYPASS VALVE REFERENCE: 3-2, 40

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Measure Check valve for 100 psi

cracking pressure

SHEET 1

3-35
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62615

ITEM: FILTER HOUSING ASSEMBLY REFERENCE: 3-2, 55

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No crossed or stripped

threads allowed

SHEET 1

3-36
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62617

ITEM: SHUTOFF ASSEMBLY REFERENCE: 3-2, 57

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No crossed or stripped

threads allowed. No broken
springs allowed

SHEET 1

3-37
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62601

ITEM: ELECTRICAL SOLENOID REFERENCE: 3-2, 63

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Pitting, corrosion, and bent Visual No pitted, corroded, or

connector pins bent connector pins allowed

2 Serviceability Measure (apply 18 vdc to Check solenoid for 6.5 lbs

connector pins) (minimum) push force

SHEET 1

3-38
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 55661

ITEM: SPOOL AND SLEEVE SUBASSEMBLY REFERENCE: 3-2, 66

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine mating surfaces of

spool (67) and sleeve (68)
for nicks and burrs; none
allowed. Must be free-
sliding fit

2 A/B Measure outside diameter Measure Clearance is 0.0002

of spool and inside (maximum)
diameter of sleeve

SHEET 1

3-39
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 55661

ITEM: SPOOL AND SLEEVE SUBASSEMBLY REFERENCE: 3-2, 66

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

SPOOL
A

SLEEVE

AA3829
SA

SHEET 2

3-40
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61474

ITEM: ADJUSTING SCREW REFERENCE: 3-2, 74

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Non-threaded areas Visual No nicks, burrs, or

scratches allowed

2 A Good thread (2 places) Gage 0.3750-24UNJF-3A thread

per SAE AS8879

AA3830
SA

SHEET 1

3-41
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 67895

ITEM: SPRING RETAINER REFERENCE: 3-2, 77

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-42
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62626

ITEM: COMPENSATOR SLEEVE REFERENCE: 3-2, 80

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Inside diameter and outside Visual No nicks, burrs, or

diameter scratches allowed

2 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-43
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 67719

ITEM: COMPENSATOR SPOOL REFERENCE: 3-2, 81

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Inside diameter and outside Visual No nicks, burrs, or

diameter scratches allowed. Spool
(81) must slide freely in
sleeve (80)

2 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-44
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62168

ITEM: VALVE, HYDRAULIC RELIEF REFERENCE: 3-2, 84

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine packing groove

for nicks, scratches, and
burrs. None allowed.

SHEET 1

3-45
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62596

ITEM: PISTON, RESERVOIR REFERENCE: 3-2, 107

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine packing groove

for nicks, scratches, and
burrs

2 A Outside diameter mating Measure 5.705 (minimum)

with reservoir (115) 5.703 (replace)

3 B Good thread Visual Thread damage

4 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

AA3831
SA

SHEET 1

3-46
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61426, 62728

ITEM: COMPRESSION SPRING REFERENCE: 3-2, 111

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual No corrosion, burrs, or

gouges allowed

2 Free length (P/N 62728) Measure 12.00 (approximately)

Loaded length (P/N 62728) Measure 5.75 at 200 - 240 lbs

3 Free length (P/N 61426) Measure 13.87

Loaded length Measure 5.75 at 234 - 286 lbs

SHEET 1

3-47
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62575, 21041,

21887

ITEM: RESERVOIR SUBASSEMBLY REFERENCE: 3-2, 115

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine mating surface

and mounting holes for
nicks, dents, and scratches
exceeding 0.030 deep
maximum. No visible burrs
allowed

2 A Inside diameter mating with Measure 5.752 (maximum)

reservoir piston (107) 5.753 (replace)

3 B Good thread Visual Thread damage

4 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

5 C Loose or damaged insert No loose or damaged insert

allowed

SHEET 1

3-48
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62575, 21041,

21887

ITEM: RESERVOIR SUBASSEMBLY REFERENCE: 3-2, 115

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

AA3832
SA

SHEET 2

3-49
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61399

ITEM: PACKING RETAINER REFERENCE: 3-2, 135

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-50
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62599

ITEM: MANIFOLD SUBASSEMBLY REFERENCE: 3-2, 145

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine mating surfaces

and mounting holes for
nicks, dents, and scratches
exceeding 0.030 deep
maximum. No visible metal
burrs allowed

2 A Outside diameter mating Measure 5.746 (minimum)

with reservoir subassembly 5.745 (replace)
(115)

3 B Inside diameter mating with Measure 1.869 (maximum)

ball bearing (20) 1.870 (replace)

4 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

5 C Good thread Visual Thread damage

6 Loose or damaged insert No loose or damaged insert

allowed

7 D Serviceability of lubrication Visual No foreign matter in hole

jet (147) passage allowed. No loose-
ness of jet allowed

SHEET 1

3-51
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62599

ITEM: MANIFOLD SUBASSEMBLY REFERENCE: 3-2, 145

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

B C

AA3833
SA

SHEET 2

3-52
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61400

ITEM: RATE PISTON PLUG REFERENCE: 3-2, 149

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-53
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61404

ITEM: RATE PISTON REFERENCE: 3-2, 153

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for nicks,

scratches, and burrs

2 A Outside diameter Measure 0.498 (minimum)

0.497 (replace)

3 Fractures and cracks Visual No fractures or cracks al-

lowed

AA3834
SA

SHEET 1

3-54
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62699

ITEM: FLUID TRANSFER COUPLING REFERENCE: 3-2, 154

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-55
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62698

ITEM: STROKING PISTON REFERENCE: 3-2, 159

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for nicks,

scratches, and burrs

2 A Outside diameter Measure 0.4837 (minimum)

0.4836 (replace)

3 Fractures and cracks Visual No fractures or cracks al-

lowed

AA3835
SA

SHEET 1

3-56
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61390

ITEM: PORT PLATE REFERENCE: 3-2, 160

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for nicks,

scratches, burrs, and corro-
sion on edges of porting
surfaces. Lap parting
surface flat within 3 helium
light bands

2 A Thickness Measure 0.198 (minimum)

0.196 (replace)

3 Fractures and cracks Magnetic particle per para No fractures or cracks al-
3-9.4 lowed

AA8879A
SA

SHEET 1

3-57
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61389

ITEM: TRUNNION COVER REFERENCE: 3-2, 161

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

SHEET 1

3-58
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61461

ITEM: CYLINDER BARREL REFERENCE: 3-2, 165

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

NOTE

Dimension 9A9 is measured using depth micrometer from the top of barrel bore to bottom of barrel bore (porting face)
then subtracting this measurement from the overall cylinder barrel length.

1 A Distance between porting Measure 0.128 (minimum)

face and top of piston bore 0.127 (replace). Lap port-
ing surface flat within 3
helium light bands

2 B Space width measured Measure 0.4789 (maximum)

between 0.1080 diameter 0.4790 (replace)
pins

3 C Inside diameter of bores Measure Individual bore diameters

mating with piston and not more than 0.3235 with
shoe subassemblies (2, accumulative total of all
Figure 3-3) (measured at nine bore diameters not
first 0.500 of each nine more than 2.9119
bores)

AA3836
SA

SHEET 1

3-59
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61388

ITEM: SPLINE BUSHING REFERENCE: 3-2, 167

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for nicks,

scratches, and burrs

2 A Tooth thickness measured Measure 0.8035 (minimum)

over 0.1200 diameter pins 0.8034 (replace)

3 B Space width of internal Measure 0.3292 (maximum)

splines measured between 0.3293 (replace)
0.0450 diameter pins

4 Fractures and cracks Magnetic particle per 3-9.4 No fractures or cracks al-
lowed

AA3837
SA

SHEET 1

3-60
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61398

ITEM: SPRING SEAT REFERENCE: 3-2, 169

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-61
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61397

ITEM: SPRING GUIDE REFERENCE: 3-2, 170

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-62
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61392

ITEM: HANGER ARM REFERENCE: 3-2, 172

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-63
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 62600, 62706

ITEM: HOUSING SUBASSEMBLY REFERENCE: 3-2, 175

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine mating surfaces

for nicks, scratches, and
burrs

2 A Inside diameter of stroking Measure 0.4848 (maximum)

piston (159) bore 0.4850 (replace)

3 B Inside diameter of rate Measure 0.501 (maximum)

piston (153) bore 0.502 (replace)

4 Fractures and cracks Fluorescent penetrant per No fractures or cracks al-

para 3-9.5 lowed

5 Loose or damaged insert Visual No loose or damaged insert

allowed

AA3838
SA

SHEET 1

3-64
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 66587

ITEM: SHOE RETAINER PLATE REFERENCE: 3-3, 1

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 A Minor thickness Measure 0.061 (minimum)

0.060 (replace)

2 B Inside diameter of nine Measure 0.335 (maximum)

holes mating with piston 0.336 (replace)
and shoe subassemblies (2)

3 Fractures and cracks Visual No fractures or cracks al-

lowed

4 C Good thread Gage 0.625-18UNF-3B thread

per SAE AS8879

AA3839
SA

SHEET 1

3-65
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 68754

ITEM: PISTON AND SHOE SUBASSEMBLY REFERENCE: 3-3, 2

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 A End play between piston Measure 0.005 (maximum)

and shoe

2 B Thickness of piston shoe Measure 0.088 (minimum)

mating with hanger wear 0.087 (replace)
plate (3)

SHEET 1

3-66
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 68754

ITEM: PISTON AND SHOE SUBASSEMBLY REFERENCE: 3-3, 2

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

AA3840
SA

SHEET 2

3-67
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 68617

ITEM: HANGER WEAR PLATE REFERENCE: 3-3, 3

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Serviceability Visual Examine for nicks,

scratches, and burrs

2 A Minor thickness mating with Measure 0.089 (minimum)

piston and shoe subas- 0.088 (replace)
semblies (2)

3 Fractures and cracks Visual No fractures or cracks al-

lowed

AA3841
SA

SHEET 1

3-68
 DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61375

ITEM: HANGER REFERENCE: 3-3, 4

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Fractures and cracks Magnetic particle per para No fractures or cracks al-
3-9.4 lowed

SHEET 1

3-69
DMWR 1-4320-271

OVERHAUL INSPECTION PROCEDURES PART NO. 61386

ITEM: PLATE AND WASHER RETAINER REFERENCE: 3-3, 6

REF
NO. LTR CHARACTERISTIC INSP METHOD REQUISITE

1 Good thread Gage 0.625-18UNF-3A thread

2 Fractures and cracks Visual No fractures or cracks al-

lowed

SHEET 1

3-70

Section VI. Repair
3-10. GENERAL.
3-10.1. Parts that fail to meet inspection requirements
listed in OIP shall be either repaired or replaced. Only
those authorized repair instructions given in this section
shall be done. When no repair is given for a part, it is
considered nonreparable and shall be replaced.
3-11. STANDARD PROCESSES.
3-11.1. Observe following repair procedures for
noncritical parts not having close wear tolerances.
CAUTION
Do not use crocus cloth (item 5, App C) on
aluminum parts as it contains ferrous oxide
which causes rapid deterioration of
aluminum.
NOTE
Minor repair to precision-machined parts
may be accomplished if fits are maintained
and reliability of the part is not affected.
3-11.2. Corroded Aluminum Parts. Remove corrosion
from aluminum parts as follows:
a. Remove corrosion by mechanical methods. Treat
repaired area per MIL-C-5541.
b. Rinse thoroughly with water. If all corrosion is
not removed, damage is considered major and part shall
be replaced.
3-11.3. Corroded Ferrous Parts. Remove minor corro-
sion indicated by discoloration on external surfaces by
polishing with crocus cloth (item 5, App C).
3-11.4. Threaded Areas. Apply chemical conversion
coating per MIL-C-5541 to exposed metal where anodize
has been damaged.
DMWR 1-4320-271
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
CAUTION
Do not attempt major repair of stripped or
crossed threads of fittings, ports or bosses
of components operating with high pres-
sure. Leakage around a loose-threaded
part or movement between bolted parts
can cause a unit failure and damage to
equipment.
3-11.5. Concentricity of Parts. Care must be taken not to
alter concentricity of any part. If rework is on a mating
surface, finish lap using lapping machine (Model 24) and
lapping compound (item 12, App C). Break all sharp
edges after lapping, using an abrasive stick (item 1, App
C). For nonferrous parts, use abrasive stick (item 1, App
C). For ferrous parts, use sharpening stone (item 17, App
C).
3-11.6. Replacement of Loose or Damaged Threaded
Inserts.
a. Use long nosed pliers to remove loose or dam-
aged inserts.
3-71
DMWR 1-4320-271
WARNING
Degreasing solvent is combustible and
toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged
contact. Use only in well-ventilated areas
(or use approved respirator as determined
by local safety/industrial hygiene person-
nel). Keep away from open flames or other
sources of ignition.
b. Clean hole from which insert was removed, us-
ing degreasing solvent (item 6, App C) and remove cor-
rosion, if present.
NOTE
To install new insert, use a suitable tool,
with the correct outside diameter to fit
inside diameter of insert, and slotted to fit
over tang of insert.
c. Install new insert, 3/4 to 1-1/2 turns below
surface of countersink. Remove tang, if applicable, using
long nose pliers or blunt tool and hammer.
3-11.7. Replacement of Mating Seal. If mating seal (14,
Figure 3-2) is to be reused, lap the porting or mating
surfaces flat in accordance with lapping instructions
contained in paragraph 3-11.5. Use monochromatic light
(C-2) and an optical flat (Table 2-2) to check that the
degree of flatness is within three helium light bands and is
free of all imperfections; if not replace part. Replace part
if the dimensions listed in Section V are exceeded.
3-11.8. Replacement of Loose or Damaged Lubricant Jet.
a. Drill old lubrication jet (147, Figure 3-2) out of
manifold subassembly (145).
b. Using holding fixture (62599-T200), press new
lubrication jet (147) into manifold subassembly bore with
arbor press.
3-11.9. Repair of Disconnects. Repair disconnect as-
semblies (23 or 26, Figure 3-2) when they show signs of
brinelling from ball bearings in the female connector as
follows:
NOTE
Check disconnect assembly for 9C9 etched
on flat of nut. Disconnect assembly with this
etching is not reparable.
3-72
a. Inspect disconnect assembly to make sure brinell
areas are not greater than 0.005 inch.
b. Grind 45° chamfer with indents to at least 0.005
inch to remove damage. Maintain surface finish equal to
or better than adjacent surfaces.
c. Etch disconnect assembly with 9C9 on flat of nut
to indicate compliance with this repair.
3-11.10. Repair of Manifold. Weld repair is limited to
damaged area of drive and reservoir mount and packing
glands/grooves of manifold subassembly (145, Figure
3-2). Weld fill repair of seal flange circumference, as
required, is acceptable.
a. V-notch cracks and blend irregular broken
surfaces.
b. Weld fill repair areas per SAE-AMS-STD-2219,
TIG method using welding rod (item 26, App C) or
equivalent.
c. Blend weld filled areas to original contour
maintaining original surface finish of adjacent area.
WARNING
Chemical conversion coatings are strong
oxidizing agents. They may ignite
combustible material such as wood and
paper or organic substances. Keep
container closed; keep sparks, flames, and
heat away. Keep off skin, eyes, and
clothes. May severely burn the eyes and
skin on contact. Do not breathe vapors.
Breathing dusts and mists may irritate the
respiratory tract. Long term overexposure
by breathing mists or absorption through
the skin may cause cancer, kidney and
liver damage, and ulceration of the nasal
septum. Protection: chemical splash proof
goggles, approved gloves, forced ventila-
tion, NIOSH/MSHA approved respirator if
mists exceed established exposure limits.
d. Apply chemical conversion coating (item 24,
App C) to exposed metal where anodize has been
removed.
e. Fluorescent penetrant inspect repair area per
paragraph 3-9.5.

Section VII. Assembly
3-12. GENERAL.
3-12.1. Assembly is essentially the reverse of disas-
sembly. The following procedural steps provide assembly
instructions for the utility pump module assembly. Refer to
Figures 3-2 and 3-3 for reference and visual identifica-
tion of components. Observe following procedures prior
to any assembly steps:
WARNING
If hydraulic fluid is decomposed by heat,
toxic gases are released. Prolonged
contact with liquid or mist can cause der-
matitis and irritation. If there is any
prolonged contact with skin, wash
contacted area with soap and water. If
liquid contacts eyes, flush eyes with water
immediately for 15 minutes. Remove
saturated clothing. If fluid is swallowed, do
not induce vomiting. Get immediate medi-
cal attention. When handling liquid, wear
rubber gloves. Inhalation of vapors should
be avoided.
CAUTION
Make certain that all seals and bearings
are adequately lubricated before as-
sembly. This preliminary lubrication will
prevent a dry seal or bearing from burning
before it obtains normal lubricant during
operation.
a. Soak all seals, packings, and bearings in
hydraulic fluid (item 9, App C) for not less than one hour
prior to installation. Wipe any excess fluid from parts
before reassembly.
b. Make sure that all parts are clean and that cor-
rosion preventive materials have been removed.
c. Replace all parts listed in mandatory replace-
ment parts (Table 2-3).
d. Torque must be within specified limit. If part is to
be lockwired, tighten to lowest recommended torque,
DMWR 1-4320-271
then advance to line up for lockwiring. Never go above
highest recommended torque. Unless specified, do not
drill a second lockwire hole in any part previously drilled.
Replace part if holes cannot be lined up.
e. Install lockwire per NASM33540.
3-13. ASSEMBLY PROCEDURES.
3-13.1. Assemble Hanger and Piston Subassembly.
a. Set plate and washer retainer (6, Figure 3-3) in
holding fixture (57925-T1).
b. Install thrust washer (5) and hanger (4) on plate
and washer retainer (6).
c. If hanger wear plate (3) is to be reused, surface
mating with thrust washer and surface mating with piston
and shoe subassemblies (2) to within 3 helium light
bands.
d. Using lapping holder (57921-T1) lap nine piston
and shoe subassemblies (2) to a uniform height not
exceeding minimum limit dimensions specified in Section
V.
e. Install nine piston and shoe subassemblies (2) in
shoe retainer plate (1). Turn assembled parts onto plate
and washer retainer.
f. Using wrench (57919-T2) tighten shoe retainer
plate to 100 - 120 inch-pounds torque.
CAUTION
Plastic is the preferred material for feeler
gages used to measure piston shoe clear-
ance. Utilizing other material (i.e. steel,
aluminum, etc.) for feeler gages requires
care not to scratch or blemish the mirror
surface.
g. Measure clearance between piston and shoe
subassemblies and hanger wear plate. It should be 0.001
- 0.003 inch. If clearance is less than 0.001 inch, disas-
semble hanger and piston subassembly and lap thrust
washer (5, Figure 3-3), using lapping holder (68615-T1)
3-73
DMWR 1-4320-271

3 5

1
4

6
A
B
C
SEE DETAIL A
DETAIL A

A: 0.001−0.003 INCH
B: 0.010−0.006 INCH
C: 0.087−0.090 INCH

NOTE
AA3842A
INDEX NUMBERS REFER TO FIGURE 3−3. SA

Figure 3-7. Hanger and Piston Subassembly - Clearances

to fit. If clearance is more than 0.003 inch, obtain thicker Remove hanger and piston subassembly from set block
thrust washer. Refer to Figure 3-7. (61386-T201).

h. After obtaining correct clearance between piston
and shoe subassemblies and hanger wear plate, be
certain hanger wear plate is tightened 100 - 120 inch-
pounds torque. Remove hanger and piston subassembly
from holding fixture, and proceed to step i.
NOTE
After staking shoe retainer plate to plate
and washer retainer, inspect threaded end
of retainer under 10 power magnification
for possible cracks. Retainer plate (6,
Figure 3-3) may be restaked, as required,
provided no cracks are visible.
3-13.2. Assembly of Utility Pump Module Assembly.
a. Install trunnion bearing (174, Figure 3-2) on
hanger and piston subassembly (171).
b. Attach hanger arm (172) on hanger and piston
subassembly (171) using screws (173). Tighten screws to
25 - 30 inch-pounds torque. Lockwire screws with lock-
wire (item 14, App C).
c. Install hanger and piston subassembly (171) in
housing subassembly (175).
NOTE

i. Position set block (61386-T201) in a suitable Make certain trunnion bearing is aligned
arbor press. Position hanger and piston subassembly on and seated in bearing recess of housing
set block. subassembly.

j. Position staking tool (57925-T2) on plate and d. Place compression spring (168) on shaft of
washer retainer. spring guide (170).

k. Apply pressure and upset plate and washer e. Position spring seat (169) in recess of spline
retainer into shoe retainer plate in two places 180° apart. bushing (167).

3-74

f. Set cylinder barrel (165), porting face down, on
a surface which will not mar nor scratch face.
g. Insert assembled spline bushing (167) and
spring seat (169) into cylinder barrel; then insert shaft
end of spring guide (170) along with spring (168) into
spring seat.
h. Slide cylinder barrel bearing (166) over cylinder
barrel (165).
i. Position trunnion bearing (164) into bore of
housing subassembly (175) and over bearing end of
hanger (4, Figure 3-3).
j. Turn housing subassembly (175) along with
hanger and piston subassembly (171) 90° and mate
holes of cylinder barrel (165) with piston and shoe subas-
semblies. Using barrel assembly tool (57913-T200) slide
housing subassembly over assembled parts.
k. Insert stroking piston (159, Figure 3-2) in hous-
ing subassembly (175).
l. Using packing assembly tool (53785-T200)
install new packings (156 and 158), and new packing
retainers (155 and 157) on fluid transfer coupling (154).
Install assembled parts into stroking piston bore of hous-
ing subassembly (175).
m. Install rate piston (153) in rate piston bore of
housing subassembly (175). Install compression spring
(152) in rate piston.
n. Using packing assembly tool (53785-T200)
install new packing (151) and two new packing backup
retainers (150) on rate piston plug (149). Install as-
sembled parts into rate piston bore of housing subas-
sembly (175).
o. Install rotation plate (143), using screws (144),
and retaining pin (142) on manifold subassembly (145) if
removed during disassembly.
p. Install new packings (141 and 140) on manifold
subassembly (145).
q. Install new packing (139) on check valve (138).
Insert assembled parts in check valve bore of manifold
subassembly (145).
r. Using packing assembly tool (53785-T200)
install new packings (137) and new packing retainers
DMWR 1-4320-271
(136) on packing retainer (135). Insert into check valve
bore of manifold subassembly (145).
s. Refer to Figure 3-8 for correct positioning of ball
bearing (20, Figure 3-2) on internal drive shaft (21) in
holding fixture (61386-T200). Using pressing fixture
(61393-T200) press new bearing onto shoulder of
internal drive shaft. The word THRUST on outer race of
ball bearing should be opposite internal drive shaft bear-
ing shoulder.
t. Install helical compression spring (22) in internal
drive shaft (21).
NOTE
Steps u., v., and w. apply to plain encased
seal (13). For installation of magnetic seal,
see paragraph 3-13.3.
u. Install new packing (18) in nose seal (15) and
then install wavy washer (17), flat washer (16) and nose
seal on shaft and bearing subassembly (19).
v. Install new packing (12) and new packing
backup retainer (11) on mating face seal (14) and install
mating face seal on shaft and bearing subassembly (19).
w. Install step pin (10) in mating face seal.
x. Install oil seal (7) in seal retainer (8). Install new
packing (9) on seal and retainer subassembly (4). Install
seal and retainer subassembly on shaft and bearing
subassembly ensuring step pin (10) is engaged in
notched groove of seal retainer.
y. Install shaft and bearing subassembly (19) with
assembled components (7 through 17) into manifold
subassembly (145) at the same time engaging the
internal splines of spline bushing with external splines of
internal drive shaft.
z. Secure seal and retainer subassembly (4) to
manifold subassembly (145) with washers (6) and screws
(5). Tighten screws to 65 - 70 inch-pounds torque.
aa. Install port plate (160) onto manifold subas-
sembly (145).
ab. Install housing subassembly (175) and as-
sembled parts in manifold subassembly (145); secure
with washers (134) and screws (133). Tighten screws to
60 - 70 inch-pounds torque.
3-75
DMWR 1-4320-271

’THRUST’

21

20

NOTE
ITEM NUMBERS REFER TO FIGURE 3−2. AA3843A
SA

Figure 3-8. Shaft and Bearing Subassembly

ac. Place trunnion cover (161) over opening and

secure with flat washers (163) and buttonhead cap
screws (162). Tighten buttonhead cap screws to 20 - 25
inch-pounds torque.
NOTE
Perform step ad. on utility pump module
assemblies, 70652-02300-048 and -049.
ad. Install new packing (129), breather (128) and
retaining ring (127) in reservoir (132).
• Uncured silicone adhesive-sealant can ir-
ritate eyes, skin, nose, and throat. If contact
with eyes occurs, flush immediately with
water for 15 minutes and seek medical at-
tention. If skin contact occurs, wipe with
dry cloth then wash with soap and water.
Protection: safety glasses or goggles, ap-
proved gloves, NIOSH/MSHA approved
respirator if mists or vapors exceed
established limits.

WARNING CAUTION

• Degreasing solvent is combustible and

toxic to eyes, skin, and respiratory tract.
Do not allow silicone adhesive-sealant to
Wear protective gloves and goggles/face
contact fluid identification and fluid level
shield. Avoid repeated or prolonged
indicator plates (119 and 120), mating
contact. Use only in well-ventilated areas
surface of reservoir to manifold subas-
(or use approved respirator as determined
sembly, shoulder of reservoir mating with
by local safety/industrial hygiene person-
reservoir piston (107), and inner or outer
nel). Keep away from open flames or other
surfaces of sight glass (121).
sources of ignition.

3-76

ae. On utility pump module assembly, 70652-
02300-048, if sight glasses (121) were removed during
disassembly, replace sight glasses in reservoir after first
removing all dirt and grease with degreasing solvent
(item 6, App C). Secure sight glass to reservoir with
silicone adhesive-sealant (item 2, App C). Wipe away
excess adhesive-sealant using low-lint cleaning cloth
(item 22, App C) moistened with degreasing solvent (item
6, App C).
af. On utility pump module assemblies, 70652-
02300-049 and -050, if sight glasses (121) were
removed, replace sight glass as follows:
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals refer, to Material
Safety Data Sheet (MSDS) for specific
component information.
(1) Apply Loctite (item 20, App C) evenly to outer
side of new gasket (126). Place gasket in groove of
retainer (125) lining up hole in gasket and hole in
retainer.
(2) Attach sight glass (121) and sight glass
retainer subassembly (124) to reservoir subassembly
(115) with screws (122) and washers (123).
WARNING
• Degreasing solvent is combustible and
toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged
contact. Use only in well-ventilated areas
(or use approved respirator as determined
by local safety/industrial hygiene person-
nel). Keep away from open flames or other
sources of ignition.
DMWR 1-4320-271
• Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
NOTE
Chemical paint stripper (item 7, App C) is
very effective for removing cured RTV
adhesives.
ag. If fluid identification and fluid level indicator
plates (120 and 119) were removed during disassembly,
replace with new plates as required. Use degreasing
solvent (item 6, App C) to moisten adhesive backing of
plates.
NOTE
Make certain all pertinent information is
transferred to the new plates prior to at-
taching plates to reservoir.
ah. If instruction plate (118) was removed during
disassembly, replace with new instruction plate.
WARNING
Uncured silicone adhesive-sealant can ir-
ritate eyes, skin, nose, and throat. If contact
with eyes occurs, flush immediately with
water for 15 minutes and seek medical at-
tention. If skin contact occurs, wipe with
dry cloth then wash with soap and water.
Protection: safety glasses or goggles, ap-
proved gloves, NIOSH/MSHA approved
respirator if mists or vapors exceed
established limits.
NOTE
If it is necessary to change the identification
plate, make certain all pertinent informa-
tion is transferred to the new or reusable
3-77
DMWR 1-4320-271
plate prior to attaching identification plate
(114) to end plate (113).
ai. If identification plate (114) was removed from
end plate (113), install new or reusable identification
plate on end plate with silicone adhesive-sealant (item 2,
App C).
WARNING
Wear suitable protective gloves when
handling chilled parts.
aj. Install lower piston ring (110), top piston ring
(109), and new radial piston seal (108) on reservoir
piston (107), using assembly tools (62596-T200, 62596-
T201, and 62596-T202). Install assembled parts (107
through 110) in freeze tool (62596-T204) using arbor
press and assembly tool (62596-T206). Place all items in
suitable cold chamber for approximately one hour.
WARNING
Uncured silicone adhesive-sealant can ir-
ritate eyes, skin, nose, and throat. If contact
with eyes occurs, flush immediately with
water for 15 minutes and seek medical at-
tention. If skin contact occurs, wipe with
dry cloth then wash with soap and water.
Protection: safety glasses or goggles, ap-
proved gloves, NIOSH/MSHA approved
respirator if mists or vapors exceed
established limits.
NOTE
Use of freeze tool (62596-T204) is
optional. When the freeze tool (which is
actually a seal and guide ring compression
tool) is not used, place reservoir piston
subassembly (items 107 through 110) into
suitable cold chamber for at least 15
minutes, or until reservoir piston subas-
sembly contracts sufficiently to be inserted
into reservoir subassembly.
ak. Install end plate (113), spring guide (112), and
compression spring (111) in reservoir subassembly (115).
Apply silicone adhesive-sealant (item 2, App C) to
outside edges of end plate (113).
3-78
al. Insert assembly rod (61356-T201) through
opening of end plate until it passes through length of
compression spring and reservoir subassembly.
am. Install assembly plate (62596-T203) and a one
inch number 8 nut over assembly rod (61356-T201).
WARNING
Wear suitable protective gloves when
handling chilled parts.
an. Remove reservoir piston with assembled lower
piston ring, top piston ring, radial piston seal and freeze
tool (62596-T204) from cold chamber. Place reservoir
piston subassembly into reservoir subassembly as quickly
as possible to reduce heat gain and subsequent expan-
sion of reservoir piston subassembly.
WARNING
Use extreme caution in performing the fol-
lowing assembly procedures. Compression
spring (111) has spring load force of 260
pounds.
ao. Thread reservoir piston onto assembly rod
(61356-T201) and turn the one inch number 8 nut suf-
ficient turns to draw the reservoir piston into the reservoir
subassembly and, at the same time, reducing the
compression spring length sufficiently to allow joining the
reservoir subassembly to the manifold assembly.
ap. Install reservoir subassembly (115) with installed
reservoir piston and compression spring still in a secured
position to manifold subassembly (145).
aq. Secure reservoir subassembly (115) to manifold
subassembly (145) with washers (117) and screws (116).
Tighten screws to 65 - 70 inch-pounds torque.
WARNING
Make sure assembly rod does not turn
when unscrewing nut.
ar. Unscrew the number 8 nut from assembly rod
(61356-T201) and remove assembly plate (62596-
T203).

NO
1
NC
2
COM
3 (item 21, App C) completely covering pins. Seal end of
SWITCH
SHOWN IN REFILL POSITION
LOW−LEVEL INDICATOR
AA3844
SA
Figure 3-9. Electrical Schematic
as. Install switch bracket (103) and secure to
reservoir subassembly (115) with washers (105) and
screws (104). Do not torque screws now.
at. Position compression spring (102), switch lever
(101), and pin (100) on switch bracket (103).
au. Install electric switch (96) on switch lever (101)
and secure to switch bracket (103). Secure electric switch
with screws (99), washers (98) and self-locking nuts (97).
Tighten nuts to 7 - 9 inch-pounds torque.
av. If removed during disassembly, install standard
wall tubing (90) and heat shrinkable sleeving (91) over
electric switch (96) lead wires.
aw. If removed during disassembly, install heat
shrinkable sleeving (89) on each lead wire.
ax. Thread lead wires of electric switch (96) through
center hole of header gasket (88).
ay. Refer to Figure 3-9 and solder each lead wire of
electric switch to contact pins of electrical connector (86,
Figure 3-2), using soldering flux and resin core solder.
DMWR 1-4320-271
WARNING
Sealing compound can irritate skin and
cause burns. Avoid contact with skin, eyes,
and clothing. In case of contact, im-
mediately flush skin or eyes with water for
at least 15 minutes. Get medical attention
for eyes.
az. Slip heat shrinkable sleeving over soldered
contact pins of electrical connector and, using standard
heat gun, shrink each sleeving over soldered joints. Fill
back end of electrical connector with sealing compound
heat shrink tubing with sealing compound.
ba. Assemble electrical connector (96) to switch
cover (92), aligning header gasket with holes for attach-
ing screws (87).
bb. Secure electrical connector (96) to switch cover
(92) with four screws (87). Tighten screws and safety with
lockwire (item 8, App C).
bc. Install new packing (83) on plug and bleeder
(82). Install assembled parts in manifold subassembly
(145).
bd. Insert compensator spool (81) in compensator
sleeve (80) and insert both in compensator bore of
manifold subassembly (145).
be. Install new preformed packing (79) on hex head
plug (78) and install hex head plug in compensator bore
of manifold subassembly (145). Tighten hex head plug to
40 - 50 inch-pound torque. Do not lockwire hex head
plug until after testing.
bf. Using packing assembly tool (53785-T200)
install new packing (75) on adjusting screw (74).
bg. Install compression spring (76) in adjusting
screw (74) and assemble spring retainer (77) to compres-
sion spring.
bh. Install adjusting screw (74) into adjusting screw
bore of manifold subassembly (145).
NOTE
Do not attempt any adjustments to adjust-
ing screw (74) at this step. Adjustment is
made during testing.
3-79
DMWR 1-4320-271
69
68
70
NOTE
ITEM NUMBERS REFER TO FIGURE 3−2.
Figure 3-10. Solenoid Spool and Sleeve Adjustment
bi. Thread check nut (73) on adjusting screw (74).
Finger tighten check nut at this step.
CAUTION
Spool and sleeve subassembly (66) are a
matched set. Retain or replace as a
matched set and do not commingle with
other parts.
bj. Install sleeve (68) in tapered fixture (55661-
T200); then refer to Figure 3-10 and steps (1) through
(12) for assembly of solenoid subassembly (61, Figure
3-2).
(1) Install spring tension washer (70) over
threaded area of sleeve (68).
(2) Thread lock nut (69) on sleeve (68) until lock
nut bottoms against spring tension washer (70).
(3) Install compression spring (65) over spool
(67) and insert both in bore of electrical solenoid (63).
3-80
68 72
67
71
72
0.030
65 0.020
MEASURED IN DEENERGIZED POSITION
AA3845C
SA
(4) Remove sleeve (68) with assembled compres-
sion spring (65), tension washer (70), and lock nut (69)
from tapered fixture (55661-T200) and install sleeve over
spring and spool.
(5) Insert 0.028 inch diameter drill blank into
hole of sleeve (68) opposite threaded end of sleeve.
(6) U s i n g h o l d i n g f i x t u r e ( 6 2 6 9 6 - T 2 0 0 )
compress sleeve (68) with sufficient force to overcome
spring until lock nut (69) bottoms against electrical
solenoid (63). With the electrical solenoid in the deener-
gized position, adjust spool and sleeve gap to 0.020 -
0.030 inch by adjusting lock nut (69).
(7) Refer to Figure 3-10 and install two new
packing backup retainers (72, Figure 3-2) and two new
packings (71) on sleeve (68).
NOTE
Upon completion of procedural step bj.,
the solenoid and spool and sleeve subas-
sembly (66) become a matched set. Retain
and replace as a matched set.
(8) When proper clearance has been obtained,
install spool and sleeve subassembly (66) with assembled

compression spring (65), lock nut (69), and spring ten-
sion washer (70) into manifold subassembly (145).
(9) Install new packing (64) on electrical solenoid
(63) and install electrical solenoid on manifold subas-
sembly (145) at same time engaging spring and spool.
(10) S e c u r e s o l e n o i d s u b a s s e m b l y ( 6 1 ) t o
manifold subassembly (145) with two bolts (62). Tighten
bolts to 40 - 45 inch-pounds torque.
bk. Install locking screws (60) into manifold subas-
sembly (145).
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals refer, to Material
Safety Data Sheet (MSDS) for specific
component information.
NOTE
Shutoff assemblies (57) have left hand
threads.
bl. Install new packings (59) and new packing
backup retainers (58) on shutoff assemblies (57). Apply a
minimum amount of Loctite (item 15, App C) to first
threads of shutoff assemblies. Using filter removal tool
(62617-T201), install assembled parts in shutoff as-
sembly bores of manifold subassembly (145). Torque
until snug (avoid overtightening).
NOTE
Install check valves (34) back to back in
pressure port with packing grooves at op-
posite ends. See steps bm. through bo.
bm. Install new packings (35) on check valves (34).
Install one check valve in pressure port of manifold subas-
DMWR 1-4320-271
sembly (145) with packing groove end being inserted
first.
bn. Install new packing (33) on port fitting (32).
bo. Insert second check valve (34) with packing
groove end being inserted first into port fitting and install
port fitting (32) and check valve into manifold subas-
sembly (145). Tighten port fitting to 80 - 120 inch-pounds
torque. Do not lockwire port fitting until after testing.
bp. Install new packings (54 and 53) and new pack-
ing backup retainers (52) on differential pressure indica-
tors (51).
bq. Install differential pressure indicator (51) in dif-
ferential pressure indicator test block (91TB0660TSE0).
(1) Slowly apply 60 psi hydraulic pressure at
85°F (29°C) maximum to differential pressure indicator
test block inlet port. Wait 45 seconds. Slowly increase
inlet pressure to 80 psi. Button shall not actuate. Decrease
inlet pressure to zero.
(2) Increase hydraulic fluid temperature and dif-
ferential pressure indicator test block temperature to
115°F (46°C) (oil bath recommended). Slowly increase
inlet pressure to 60 psi. Wait 45 seconds. Button must not
actuate. Slowly increase inlet pressure. Button must not
actuate by 80 psi maximum. Decrease inlet pressure to
zero.
(3) Attempt to reset button. Button must not reset.
(4) Remove differential pressure indicator from
differential pressure indicator test block. Using a spring
scale to push on lower magnet (bottom of indicator). The
force required to reset button must not exceed 7 pounds.
reset force below 1-1/2 pounds is not acceptable.
br. Install both differential pressure indicators (51) in
manifold subassembly (145). Tighten differential pressure
indicators to 80 - 100 inch-pounds torque.
bs. If required, set both differential pressure indica-
tors (51) by pushing up on plungers of shutoff assemblies
located in manifold head, and at the same time depress-
ing red indicator buttons on differential pressure indica-
tor.
bt. Install dust caps (43) with retaining bands (42)
on differential pressure indicators (51) on utility pump
module assemblies, 70652-02300-049 and -050.
bu. Insert filter elements (56) in filter housing as-
semblies (55) and screw filter housing assemblies in
3-81
DMWR 1-4320-271
manifold subassembly (145). Hand tighten filter housing
assemblies only. Do not exceed 96 inch-pounds torque.
bv. Install new packing (41) on filter bypass valve
(40) and install filter bypass valve in manifold subas-
sembly (145). Tighten filter bypass valve to 80 - 100
inch-pounds torque. Do not lockwire valve until after test-
ing.
bw. Install new packings (37 and 39) and new pack-
ing backup retainers (38) on hydraulic relief valve (36).
bx. Install hydraulic relief valve (36) in manifold
subassembly (145). Tighten hydraulic relief valve to 80 -
120 inch-pounds torque. Do not lockwire hydraulic relief
valve until after testing.
NOTE
Make certain pressure disconnect assembly
(26) is in correct port of manifold subas-
sembly.
by. Install new packings (28 and 27) on pressure
disconnect assembly (26) and screw pressure disconnect
assembly with assembled packings into manifold subas-
sembly (145). Tighten pressure disconnect assembly to 80
- 120 inch-pounds torque.
bz. Install new packings (25 and 24) on return
disconnect assembly (23) and screw return disconnect as-
sembly with assembled packings into manifold subas-
sembly (145). Tighten return disconnect assembly to 80 -
120 inch-pounds torque.
NOTE
Steps ca. through cg. may be performed
during final assembly and testing of
volume and low level indicator test
(paragraph 4-4.3.1) in lieu of present as-
sembly location.
ca. Use dial indicator to measure depth of reservoir
piston (107) from open end of reservoir subassembly to
thread end of reservoir piston.
cb. Install testing adapter plate (53023-T200) on
hydraulic relief valve (84) port of reservoir subassembly
(115) and actuate reservoir piston, using clean filtered
shop oil, to extreme full position and hold.
cc. Measure depth of reservoir piston and record.
Reservoir piston shall be 3.51 - 3.55 inches.
3-82
cd. Connect test light (53023-T201) to electrical
leads of switch with positive installed to normal open lead
and negative installed to common lead. Snug two of four
screws (104). Adjust switch to activate light (ON) then
snug screws (99).
NOTE
The 1.17 inch dimension is measured with
reservoir piston traveling from empty
towards full.
ce. Drop reservoir piston to 1.17 6 0.030 inch
above extreme empty position and hold. Adjust position
of switch and/or bracket to activate test light (53023-
T201). Tighten screws (99) to 7 - 9 inch-pounds and
screws (104) to 15 - 20 inch-pounds torque.
cf. Drop reservoir piston to extreme empty position;
then to extreme full position; then to extreme empty posi-
tion until test light is activated. Check 1.17 6 0.030 inch
dimension.
cg. Slowly move the piston from full towards empty
position. The test light must go out at a point not more
than 0.260 6 0.020 inch past the 1.17 inch distance
established in step cd.
WARNING
Uncured silicone adhesive-sealant can ir-
ritate eyes, skin, nose, and throat. If contact
with eyes occurs, flush immediately with
water for 15 minutes and seek medical at-
tention. If skin contact occurs, wipe with
dry cloth then wash with soap and water.
Protection: safety glasses or goggles, ap-
proved gloves, NIOSH/MSHA approved
respirator if mists or vapors exceed
established limits.
NOTE
If the 0.260 inch dimension, measured in
step cf. is more than 0.280 inch, adjust or
replace the switch and repeat steps ca.
through cg.
ch. Install protective enclosure (106) in end plate
(113). Apply silicone adhesive-sealant (item 2, App C) on
outside edges of end plate.
ci. Install new preformed packing (95) and switch
cover (92) with screws (93) and washers (94) to reservoir

subassembly (115). Torque screws to 15 - 20 inch-
pounds.
cj. Install new packing (85) on hydraulic relief valve
(84) and install hydraulic relief valve into manifold subas-
sembly (145). Torque relief valve to 80 - 100 inch-
pounds. Do not lockwire hydraulic relief valve until after
testing.
ck. Install new packing (31) on coupling (30) and
thread coupling with assembled packing into port fitting
(32). Tighten coupling to 80 - 120 inch-pounds torque.
cl. If removed during disassembly, secure dust cover
(29) to manifold subassembly (145) by placing chain
through drilled chain accommodation hole and crimping
chain link to prevent slipping.
cm. Thread dust cover (29) on coupling (30) finger-
tight only.
cn. Install retaining ring (2) on neck of external drive
shaft (1).
co. Install helical compression spring (3) in external
drive shaft (1) and insert external drive shaft into shaft
and bearing subassembly (19).
cp. Using needle nose pliers, compress retaining
ring (2) around neck of external drive shaft (1) while
depressing external drive shaft to expose locking groove
in internal drive shaft (21).
DMWR 1-4320-271
CAUTION
Make sure that tines of retaining ring (2)
protrude from spacer where teeth have
been removed from internal drive shaft.
cq. Insert retaining ring (2) in locking groove of
internal drive shaft (21) and release pressure on retaining
ring allowing it to snap in place with locking groove of
internal drive shaft.
NOTE
Perform steps cr., cs., and ct. on pump as-
sembly, 70652-02300-050, only.
cr. Install hose connector elbow (49), new packing
(50), and nut (48) into manifold subassembly (145).
cs. Install new packing (129), elbow subassembly
(47), and retaining ring (127) in reservoir (132).
ct. Install tubing (46) to elbow subassembly (47)
and hose tee subassembly (45). Install tubing (44) to hose
connector elbow (49) and hose tee subassembly (45).
cu. Install identification plates (180, 179, and 178)
if removed during disassembly. Install Tempilabels (181)
if removed during disassembly.
3-83
DMWR 1-4320-271
3-13.3. Magnetic Seal Assembly Installation Instructions.
3-13.3.1. Pre-Installation Instructions.
3-13.3.1.1. Magnetic seals (182) should remain in the
packaging until ready for installation, thus avoiding
excessive handling, which could damage seal face.
3-13.3.1.2. Installation should be accomplished in
9clean room9 condition that is free from metal chips which
could be attracted to the magnet (186).
3-13.3.1.3. The seal cavity must be clean and free from
any dirt or foreign matter. The o-ring(s) sealing
diameter(s) must be free from burrs, sharp edges and any
other surface defect(s) which may cause damage to the
o-rings during installation.
3-13.3.1.4. DO NOT slide the seal case (185) across
the magnet face (186) when separating the seal case
from the magnet as the carbon seal ring mat be dam-
aged. The seal case must be pulled away from the
magnet in order to discard the paper separator.
WARNING
• Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
• Ultrachem assembly fluid may irritate the
skin and eyes on contact. If assembly fluid
contacts the eyes, flush immediately for 15
minutes. Prolonged or repeated use without
hand protection may cause dermatitis. At
normal temperatures, assembly fluid poses
minimal health hazard by inhalation. If the
product is heated or applied as a mist, use
of a NIOSH/MSHA approved respirator
may be necessary. Wash hands with soap
and water after use. Protection: chemical
3-84
splash proof goggles or safety glasses, oil
resistant gloves and skin protective cloth-
ing.
3-13.3.1.5. The magnetic seal (182) is supplied with
0.5 gram tube of o-ring lubricant, P/N L-001. A four
ounce tube of the Ultrachem assembly fluid (item 16, App
C) may be used instead of the 0.5 gram tube. No o-ring
lubricant substitution is permitted.
3-13.3.1.6. Tooling required: assembly tool (93058-
T1) (Table 2-1).
3-13.3.2. Installation Instructions.
CAUTION
The split sleeve is designed to grip the
internal drive shaft. DO NOT expand the
split sleeve as it may result in leakage due
to interference with the seal case (185)
bore diameter.
3-13.3.2.1. Assemble the split sleeve (183) by hand
over the internal drive shaft until seated against the
shoulder.
WARNING
Observe all cautions and warnings on
containers when using consumables. When
applicable, wear necessary protective gear
during handling and use. If a consumable
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.
3-13.3.2.2. Completely lubricate the seal case o-ring
(184) with a thin film of the supplied lubricant and using
CARE not to damage, cut, or twist the o-ring, assemble it
over the internal drive shaft until it contacts the split sleeve
(183) (Figure 3-11).
 DMWR 1-4320-271

SPLIT SLEEVE
(183)

INTERNAL DRIVE
SHAFT (21)

O−RING (184)

BALL BEARING
(20)

NOTE

INDEX NUMBERS ARE KEYED TO

FIGURE 3−2.
AB3144
SA

Figure 3-11. Install O-Ring on Internal Drive Shaft

3-13.3.2.3. Assemble the utility pump module assembly 3-13.3.2.4. Remove the magnet o-ring (187) from the
in accordance with the standard procedures to where the magnet (186) and completely lubricate with a thin film of
seal (13) is installed. the supplied lubricant. Install the o-ring into the magnet
o-ring groove by stretching the o-ring over the groove
and then allowing it to freely contract into the groove. DO
NOT roll the o-ring into the groove because the o-ring
WARNING will become twisted. Slide the o-ring evenly towards the
highly polished mating face until the o-ring contacts the
Observe all cautions and warnings on groove shoulder (Figure 3-12).
containers when using consumables. When
applicable, wear necessary protective gear 3-13.3.2.5 Apply a thin film of the supplied lubricant to
during handling and use. If a consumable the seal retainer bore diameter and lead chamfer.
is flammable or explosive, MAKE CERTAIN
consumable and its vapors are kept away
from heat, spark, and flame. MAKE
CERTAIN firefighting equipment is readily
available prior to use. For additional
information on toxicity, flash point, and
flammability of chemicals, refer to Material
Safety Data Sheet (MSDS) for specific
component information.

3-85
DMWR 1-4320-271
HIGHLY POLISHED
MATING FACE
NOTE
INDEX NUMBERS ARE KEYED TO
FIGURE 3−2.
Figure 3-12. Install O-Ring in Magnet
3-13.3.2.6. Magnet Installation into the Seal Retainer.
3-13.3.2.6.1. Place the magnet (186) into the seal
retainer with the highly polished mating face up, install
the assembly tool (93058-T1) (Table 2-1) onto the
magnet and using CARE not to damage or cut the o-ring,
hand press the seal retainer evenly until the magnet is
squarely seated against the bore shoulder (Figure 3-13).
3-13.3.2.6.2. Alternate method is to place the magnet
(186) onto the assembly tool with the highly polished mat-
ing face down, assemble the seal retainer onto the
magnet and using CARE not to damage or cut the o-ring,
hand press the seal retainer evenly until the magnet is
squarely seated against the bore shoulder (Figure 3-13).
WARNING
• Degreasing solvent is combustible and
toxic to eyes, skin, and respiratory tract.
Wear protective gloves and goggles/face
shield. Avoid repeated or prolonged
contact. Use only in well-ventilated areas
(or use approved respirator as determined
3-86
O−RING (187)
MAGNET
(186)
AB3145
SA
by local safety/industrial hygiene person-
nel). Keep away from open flames or other
sources of ignition.
• If hydraulic fluid is decomposed by heat,
toxic gases are released. Prolonged
contact with liquid or mist can cause der-
matitis and irritation. If there is any
prolonged contact with skin, wash
contacted area with soap and water. If
liquid contacts eyes, flush eyes with water
immediately for 15 minutes. Remove
saturated clothing. If fluid is swallowed, do
not induce vomiting. Get immediate medi-
cal attention. When handling liquid, wear
rubber gloves. Inhalation of vapors should
be avoided.
 DMWR 1-4320-271

HIGHLY POLISHED
ASSEMBLY TOOL MATING FACE

MAGNET
(186)

SEAL RETAINER
(8)

TOOL ON TOP

SEAL RETAINER
(8)

MAGNET
(186)

HIGHLY POLISHED
MATING FACE
ASSEMBLY TOOL

TOOL ON BOTTOM

NOTE
INDEX NUMBERS ARE KEYED TO
FIGURE 3−2. AB3146
SA

Figure 3-13. Install Magnet into Seal Retainer

3-87
DMWR 1-4320-271

MAGNET
(186)

SEAL CASE
(185)

NOTE
SEAL RETAINER
INDEX NUMBERS ARE KEYED TO
(8) AB3147
FIGURE 3−2. SA

Figure 3-14. Install Seal Case onto Magnet

3-13.3.2.7. Using CARE not to damage the mating

faces, hold the seal case (185) firmly and GENTLY mate
CAUTION with the magnet (186) (Figure 3-14).

3-13.3.2.8. Using CARE not to damage or cut the

o-rings, install the magnetic seal assembly into the
Mating faces must be clean and free from module subassembly and secure in accordance with
any contamination and/or o-ring standard procedures (Figure 3-15).
lubricant. Clean mating faces with de-
greasing solvent (item 6, App C) or CLEAN
hydraulic fluid (item 9, App C) and wipe
dry with clean lint-free cleaning cloth (item
22, App C) prior to mating faces.

3-88
 DMWR 1-4320-271

MODULE
SUBASSEMBLY

SEAL
RETAINER
(8)

MAGNET
(186)

SEAL CASE
(185)

NOTE
INDEX NUMBERS ARE KEYED TO
AB3148
FIGURE 3−2. SA

Figure 3-15. Install Magnetic Seal into Module Subassembly

3-89/(3-90 blank)
 DMWR 1-4320-271

CHAPTER 4

FINAL ASSEMBLY AND TESTING

Section I. Assembly

4-1. GENERAL. c. Torque must be within specified limits. If part is to

be lockwired, tighten to lowest recommended torque. Un-
4-1.1. The following general instructions shall be fol- less specified, do not drill a second lockwire hole in any
lowed throughout entire assembly procedures. part previously drilled. Replace part if holes cannot be
lined up.
a. Make sure all parts are clean and that corrosion-
preventive materials have been removed.
d. Install lockwire per NASM33540.
b. Replace all parts listed in mandatory replace-
ment parts Table 2-3.

Section II. Final Performance Check

4-2. GENERAL. 4-3.3. Pretest Check. Prior to installing utility pump

module assembly on test stand, turn unit through by hand
4-2.1. The utility pump module assembly shall be to check for binding or jamming.
checked per the following procedures after any repair
has been done. If it is determined that a part must be 4-3.4. Test Hookup. Make test hookup per Figure 4-1,
replaced, remove and replace it, and again do step of using testing adapter plate (53023-T200).
applicable test. Unless otherwise specified, testing shall
be conducted under these conditions. 4-4. TEST PROCEDURES.
a. Rated speed: 7335 rpm
4-4.1. Observe utility pump module assembly closely
b. Rated pressure: 3050 6 50 psig for evidence of malfunction, overheating, excessive leak-
age, noise or vibration. Should any malfunction occur
c. Minimum full flow pressure: 2900 psig during testing procedures, stop test immediately and
determine cause of trouble. Repair pump as required and
d. Minimum rated output flow: 6.2 gpm repeat all tests.
e. Return fluid temperature: 100° to 120°F (38° to
4-4.2. Filter Bypass Valve Check. Remove return filter
49°C)
housing assembly (55, Figure 3-2), shutoff assembly (57),
f. Ambient temperature: 40° to 100°F (4° to 38°C) and filter element (56), if installed. Install plug (P/N
99SPL-12757-A0056), then install fitting with pressure
g. Ambient pressure: Atmospheric page and line to pump inlet. Pressurize manifold to 100
psig. Gage pressure shall drop, indicating proper func-
4-3. TEST REQUIREMENTS. tion of filter bypass valve. Upon completion of test,
remove test hookup and dummy plug. Install shutoff as-
4-3.1. Facilities. Refer to paragraph 2-1 and Figure 4-1 sembly (57), filter element (56), and filter housing as-
for facility requirements. sembly (55).

4-3.2. Test Equipment. Refer to Tables 2-1, 2-2, and NOTE

Figure 4-1 for required test equipment.

NOTE Overhaul and rotation group replace-

ments, only.
The utility pump module assembly shall
rotate counterclockwise, viewing external 4-4.3. Break-In Run. The HPS that has been overhauled
drive end of unit. or with a rotating group replacement shall be subjected to

4-1
DMWR 1-4320-271

P
3

VARIABLE DC AIR SUPPLY OR

POWER SUPPLY HYDRAULIC POWER SUPPLY
OIL
SUPPLY
PRESSURE CONTROL
GROUND
TEST
LOW−LEVEL
INDICATOR

3−MICRON FILTER
TEST ADAPTER PLATE
P / N 53023−T200 P
1
FLOW METER
PRESSURE
VARIABLE UTILITY PUMP
SPEED DRIVE MODULE ASSY LOAD
RETURN
VALVE

P
2

PRESSURE RELIEF VALVE

TEMPERATURE
READOUT

HEAT
EXCHANGER

TEMPERATURE
CONTROL WATER SUPPLY

LEGEND
P1 DISCHARGE PRESSURE 0−5000 PSIG
P2 RETURN PRESSURE 0−100 PSIG
P RESERVOIR PRESSURE 0−100 PSIG
3
AA3846A
SA

Figure 4-1. Test Schematic

4-2
 DMWR 1-4320-271

the following break-in schedule. The time at each condi- inlet and discharge filter assemblies. Run break-in per
tion and the total break-in time shown is a minimum. Table 4-1.
Prior to start of the break-in run, install clean filters in the

Table 4-1. Break-In

Speedset Pressure Flow Return Fluid Temp Time

(rpm) (psig) (gpm) (°F) (minutes)

2200 500 full 80 - 160 5

2200 1000 full 80 - 160 5

2200 2000 1.7 80 - 160 2

3000 2500 full 80 - 160 5

3000 3000 2.0 80 - 160 2

NOTE

Set pump compensator at 3050 6 50 psig at zero flow. Unit shall deliver full flow at 2900 psig minimum.

4000 Note 2.5 100 - 200 5

4000 3050 0 100 - 200 2

5000 3050 1.5 100 - 200 2

5000 2900 full 100 - 200 3

6000 Note 4.0 150 - 240 5

6000 Note 2.0 150 - 240 5

7000 2900 full 150 - 240 10

7335 Note 2.0 150 - 240 5

7335 2900 min 6.2 min 150 - 240 5

NOTE

Pressure is adjusted to establish stipulated flow.

4-3
DMWR 1-4320-271
4-4.4. Reservoir Volume.
NOTE
See paragraph 3-13.2. step bz. through
cf. for additional optional procedures.
4-4.4.1. Volume and Low Level Indicator. With pump
not operating, move the reservoir piston until the low level
indicator light is energized and record the position at
which it occurs. Bottom the reservoir piston and record
the piston position. Actuation of the low level indicator
shall occur at 1.17 6 0.030 inches from the empty posi-
tion and remain actuated between 1.17 6 0.030 inches
and empty. Adjust the switch as necessary to obtain the
desired setting. Move the reservoir piston to the full posi-
tion. The switch must de-energize within 1/4 inch of the
actuation point (1.17 6 0.030). Adjust the switch if
necessary. Total piston travel from empty to full shall be
3.51 - 3.55 inches. Record the reservoir pressure with the
piston at both ends of travel but not bottomed out. The
reservoir pressure shall not exceed 20 psig in the extreme
full position.
4-4.4.2. Relief Valve. Slowly increase the return pres-
sure until the reservoir relief valve actuates. Observe and
record the pressure. The valve cracking pressure must be
50 - 80 psig. The relief valve must be fully open before
the reservoir pressure reaches 100 psig. Reduce the pres-
sure until the relief valve is fully reseated (zero external
leakage). Observe and record the pressure. It should not
be less than 40 psig.
4-4.5. Reservoir Pressurization. Drain reservoir until
piston is 0.1 - 0.2 inches from empty position. Operate
pump at a zero flow condition. Observe return pressure.
Return pressure shall not be less than 5.0 psig.
4-4.6. Depressurization Valve. Operate the HPS at
rated pressure and rpm. Verify that the depressurization
valve solenoid energizes at voltages of 18, 28, and 30
vdc. At 28 vdc, the current shall not exceed 1.0 amps.
Valve shall operate with no delay. Stop the drive. With
the solenoid energized, start the drive and increase the
speed to 7335 6 50 rpm. The pump discharge pressure
shall not exceed 900 psig at the rated fluid temperature
range. Record the discharge pressure and amps. De-
energize the solenoid and verify the HPS goes into the
pressurized mode of operation.
4-4.7. High Pressure Relief Valve. Operate unit at rated
condition. Increase pump compensator setting to provide
full flow at 3300 psig. Observe and record flow. Close
4-4
discharge load valve and increase compensator setting
until discharge pressure ceases to increase; then turn
adjusting screw one complete turn. Observe and record
the pressure. It shall not exceed 3750 psig. Open
discharge load valve and observe and record pressure at
which flow increases to full flow value observed previ-
ously. Pressure shall not be less than 3300 psig. Reset
compensator to 3050 6 50 psig at zero flow.
4-4.8. Full Flow Pressure. Reduce pressure to below
2900 psig and then increase to 2900 psig. The flow shall
be a minimum of 6.2 gpm. Record flow.
4-4.9. Rated Discharge Pressure/Stability.
4-4.9.1. 115°F Operation. Operate the HPS at 2900
psig, rated rpm and full flow. Compensate pump. The
discharge pressure shall be 3050 6 50 psig. There shall
be no indication of discharge pressure instability. Instabil-
ity is defined as freedom from persistent or quasipersis-
tent oscillation or 9hunting9 of compensator system as
measured by the system pressure gage. Instability is a
fluctuation in the discharge pressure gage of more than 6
30 psig. Any apparent unstable condition will be
rechecked by obtaining an oscillographic trace of the
discharge pressure versus time. The trace shall show that
the discharge pressure shall not vary by more than 6 50
psig.
4-4.9.2. 240°F Operation. Repeat paragraph 4-4.9.1.,
with an inlet temperature of 235° to 245°F (113° to
118°C).
4-4.10. Check Valve. With the unit not operating and
the drive shaft free, the return port vented to atmosphere
and the discharge port blocked; pressurize the pump
ground fill port to 2900 - 3000 psig. Maintain pressure
for 2 minutes minimum. The pump drive shaft shall not
rotate. Initial movement is acceptable.
4-4.11. Reservoir Leakage. Make sure that the reservoir
is free of residual oil and cycle the reservoir piston from
empty to full 50 times. The reservoir leakage rate shall not
exceed 5 drops for 25 cycles. Observe the complete HPS
for external leakage. There shall be no external leakage.
There shall be no external leakage except shaft seal leak-
age which shall not exceed 5 milliliter/hour. After
completion of all acceptance testing, rinse the reservoir
housing with compatible solvent. Set the HPS at a 30
degree angle (approx.) with the reservoir vent down.
Observe the HPS for a 24 hour period. Reservoir leakage
shall not exceed 12 drops. The test may be terminated
after 6 hours if no leakage is observed.
 DMWR 1-4320-271

4-4.12. Preservation and Preparation for Storage. prolonged contact with skin, wash
contacted area with soap and water. If
a. Upon completion of testing, a sample of fluid liquid contacts eyes, flush eyes with water
shall be drawn from the HPS and subjected to a particle immediately for 15 minutes. Remove
count. The particle size and count shall not exceed the fol- saturated clothing. If fluid is swallowed, do
lowing limits: not induce vomiting. Get immediate medi-
cal attention. When handling liquid, wear
Size Range Microns Acceptance Test Limit rubber gloves. Inhalation of vapors should
5 - 15 64,000 be avoided.
15 - 25 11,400
NOTE
25 - 50 2,025
50 - 100 360 Reservoir will empty itself of fluid on
Over 100 64 completion of testing because of its spring
action.

b. Following test completion using hydraulic fluid

WARNING (item 9, App C), leave reservoir approximately 1/2 full.
Cap all ports and openings.

If hydraulic fluid is decomposed by heat, c. Lockwire all parts not previously lockwired in the
toxic gases are released. Prolonged manner noted during disassembly procedures, using
contact with liquid or mist can cause der- lockwire (item 14, App C), employing double twist
matitis and irritation. If there is any method per standard NASM33540.

4-5/(4-6 blank)

CHAPTER 5
QUALITY ASSURANCE/QUALITY CONTROL REQUIREMENTS
Section I. General
5-1. RESPONSIBILITY.
5-1.1. The contractor/depot quality assurance activity
is responsible for the performance of the inspections
specified in the DMWR. The contractor/depot may utilize
their own facilities or any commercial laboratory accept-
able to the procuring activity/commodity manager (PA/
CM). The PA/CM reserves the right to perform any of the
inspections specified in the DMWR, when such inspec-
tions are necessary to assure that supplies or services
conform to the prescribed requirements.
5-2. QUALITY ASSURANCE TERMS AND DEFINITIONS.
5-2.1. For quality assurance terms and definitions refer
to ISO9000 and the glossary in the DMWR.
5-3. TEST MEASUREMENT AND DIAGNOSTIC EQUIP-
MENT (TMDE).
5-3.1. The overhaul facility is responsible for acquisi-
tions, maintenance, calibration, and disposition of all TM-
DE. Items of TMDE to be used by AMC (Army) elements
Section II. Inspection Requirements
5-5. GENERAL.
5-5.1. The Quality Department is responsible for ensur-
ing inspections marked 9QA9 or 9QI9 are performed by
qualified personnel.
5-5.2. The Maintenance Technicians shall inspect,
check, and determine the conditions of all other areas to
ensure compliance with the DMWR.
5-5.3. The contractor/depot facility QA activity is
responsible for ensuring that quality assurance is in
compliance with ISO9001.
5-5.4. The contractor/depot facility is responsible for
ensuring that Flight Safety Parts are handled and
processed in compliance with QE-STD-2 of AMCOMR
702-7.
DMWR 1-4320-271
will be acquired in accordance with AR 750-43 and
AMC Supplement 1 to AR 750-43. All TMDE used in
compliance with this DMWR shall be maintained and
controlled in accordance with MIL-I-45607, ISO10012-1
or ANSI Z540.1. Calibration documents for all TMDE
shall be traceable to the National Institute of Standards
and Technology (NIST).
5-4. CERTIFICATION OF PERSONNEL, MATERIALS,
AND PROCESSES.
5-4.1. The contractor/depot QA activity shall be
responsible for ascertaining and certifying that personnel
skills, equipment, and materials meet the requirements of
the work to be accomplished. Unless otherwise specified
in the contract or by PA/CM representative, the
contractor/depot QA activity shall provide the PA/CM
with statements or other evidence that specifications for
such special processes as welding, nondestructive testing,
plating, and the like, have been complied with. Personnel
performing magnetic particle and penetrant tests shall be
certified in accordance with NAS410.
5-6. PRODUCT VERIFICATION AUDIT.
5-6.1. A product verification audit may be performed
in accordance with AMCOMR 702-2 on one of the first
five items produced to verify compliance with the DMWR
and contractual terms.
5-7. IN-PROCESS AND ACCEPTANCE INSPECTIONS.
5-7.1. Diagnostic and nondestructive tests such as
magnetic particle, penetrant, radiographic, and
ultrasonic inspections as required by this DMWR shall be
in accordance with referenced military specifications, and
ASTM-E1444 and ASTM-E1417where not otherwise
specified.
5-7.2. A list of inspection definitions, Table 5-1, is
included at the end of this chapter. Accept and reject
5-1
DMWR 1-4320-271

criteria of these inspections and unique repair methods
are found in applicable areas of this DMWR.
5-7.3. A Quality Deficiency Report (QDR) will be
submitted for all nonconforming government furnished
material received as serviceable for use in the repair/
overhaul process. This QDR will be prepared using SF
368. Instructions for preparing a QDR are provided in
DA PAM 738-751, Functional User’s Manual for The
Army Maintenance Management System - Aviation
(TAMMS-A). QDRs should be mailed directly to Com-
mander, US Army Aviation and Missile Command,
ATTN: AMSAM-MMC-MA-NM, Redstone Arsenal, AL
35898-5230.

Table 5-1. Inspection Definitions

TERM DEFINITION PROBABLE CAUSE

Abrasion Roughened surface, varying from Foreign materials present between

light to severe moving parts

Bend Any change in the intended Application of severe or excessive

configuration force

Break Separation of part Severe force, pressure or overload

Brinnelling Surface marks or blemishes on Vibration or low-radial angle oscil-

(False) balls, rollers, and raceways that lation, or to both, while not rotating
normally have a polished or satin
finish appearance. These marks will
appear as lines at each position for
roller bearings, and as points (or el-
lipses) at each ball position on ball
bearings

Brinnelling Shallow, smooth indentations on Impact during mounting, or station-

(True) balls, rollers, or raceways that have ary overload
the original surface finish lines at
the bottom of the depressions. The
contour of the indentation in the
raceway is the same as the ball or
roller radius

Burn Loss of metal Excessive heat

5-2
 DMWR 1-4320-271

Table 5-1. Inspection Definitions (Cont)

TERM DEFINITION PROBABLE CAUSE

NOTE

Normal burnishing from operational service is not detrimental if coverage approximates the carrying load and if there
is no evidence of burns.

Burnishing The smoothing of a metal surface by Excessive heat

mechanical action, but without loss
of material. Generally found on
plain bearing surfaces. Surface
discoloration is sometimes present
around outer edges of burnished
area

Burr A rough edge or sharp projection Impact from foreign object, or poor
machining

Chipping Breaking away of small metallic Heavy impact of foreign object

particles

Corrosion Surface chemical action that results Improper corrosion preventative

in surface discoloration, a layer of procedures and excessive moisture
oxide, rust, and removal of surface
metal

Crack A break in material Severe stress from overloading or

shock; possible extension of a
scratch

Dent A small smoothly rounded depres- A sharp blow or excessive pressure

sion

Distortion A change from original shape Application of severe heat or ir-

regular forces

Erosion Wearing away of metal Hot gases, corrosive liquids, or grit

5-3
DMWR 1-4320-271
Table 5-1. Inspection Definitions (Cont)
TERM DEFINITION
Fatigue failure Sharp indentations, cracks, tool
marks, and inclusions that result in
progressive yielding of one or more
local areas
Flaking Loose particles of metal or evidence
of surface covering removal
Fracture See break
Galling Fretting or chafing of a mating
surface by sliding contact with
another surface or body. The heat
friction causes the material from
one surface to be welded or
deposited onto the other surface
ultimately destroying the surface
area
Gouging Removal of surface metal. Typified
by rough and deep depressions
Heat oxidizing Characterized by a discoloring film.
Color varies from yellow to brown
and blue to purple
Indenting Cavities with smooth bottoms and
sides. Occurs on rolling contact
surfaces of bearing components
Nick A sharp-bottomed depression that
may have rough outer edges
5-4
PROBABLE CAUSE
Cyclic stress. As stress is repeated,
cracks develop, then spread, usu-
ally from surfaces (or near surfaces)
of the particular section. Finally, so
little sound material remains that
normal stress on part exceeds
strength of the remaining material.
This type of failure is not caused by
metal crystallization. This condition
can be easily determined by visual
inspection of part. Striations will be
evidenced by several lines, more or
less concentric. The center (or focus)
of lines indicates origin of the
failure
Imperfect bond or severe load
Imperfect fit or severe load
Protruding objects, misalignment
High temperature operation
Loose or foreign particles rolling
between rotating elements of a
bearing
Dropping, banging

Table 5-1. Inspection Definitions (Cont)
TERM DEFINITION
Off-square or misalignment of Anti- Indicated by retainer deterioration,
Friction Bearing retainer bore erosion, and gouged
retainer rolling element pockets of
the inner and outer race. Two
distinct rolling element paths may
be seen on the race where off-
square conditions exist
Pitting Small indentations in a surface
Scoring Deep scratch following path of part
travel
Scraping A furrow
Scratch A very shallow furrow or irregular-
ity, usually longer than wide
Seizure Fusion or binding of two adjacent
surfaces preventing continued
movement
Stripped thread Thread of a nut, stud, bolt, or screw
damaged by tearing away part of
thread
Tear Parting of parent material
Wear Slow removal of parent material.
Frequently, wear is not visible to the
naked eye
DMWR 1-4320-271
PROBABLE CAUSE
Caused by rolling element varia-
tion, which jams rolling elements
onto separator pockets
Chemical pitting: Oxidation of
surface or electrolytic action.
Mechanical pitting: Chipping of
loaded surfaces caused by
improper clearances and overload-
ing, and by pressure of foreign
material
Result of localized lubrication
breakdown between sliding
surfaces
Rubbing with any hard, or rough
pointed object
Movement of a sharp object across
the surface
Improper lubrication or wear
Improper installation or thread pitch
or size
Excess tension, caused by an
external force
Result of abrasive substances
contacting rolling surfaces, and act-
ing as a lapping compound
5-5/(5-6 blank)

CHAPTER 6
PACKAGING
6-1. PRESERVATION, PACKAGING, AND MARKING.
6-1.1. Output components will be preserved, packed,
and marked in accordance with the Delivery Order/
Contract, Depot Maintenance Interservice Support Agree-
ment (DMISA), Statement of Work (SOW) Memorandum
of Agreement or other authorization document. Overhaul
will not be considered complete until the output
component is properly packaged.
6-1.2. Output components from organic depot
maintenance and overhaul (M & O) programs will be
packaged in accordance with the FEDLOG Packaging
File and marked in accordance with MIL-STD-129.
Components for which a special or multi-application
container is specified will be packed in the assigned
container. All other components will be packaged
Military Preservation and Level B Pack, unless weight and
dimension requirements of MIL-STD-2073-1, specify a
wood container. The level of pack shall be level A when a
DMWR 1-4320-271
wood container is specified. When components are
received at the overhaul maintenance facility, the
container will be inspected for serviceability in ac-
cordance with Chapter 2, TB 55-8100-200-24. Contain-
ers will be requisitioned as required to replace missing,
improper, or unserviceable containers to ensure avail-
ability of container when component is returned from
overhaul maintenance facility. Waivers, deviations,
container substitution must be approved by the AMCOM
Packaging Branch (AMSAM-MMC-MM-DP).
6-1.3. Questions concerning contractual matters shall
be submitted through the assigned Contracting Officer.
Technical communication, requests for waivers, etc.
should be submitted to Commander, U.S. Army Aviation
and Missile Command, ATTN: AMSAM-MMC-MM-DP,
Redstone Arsenal, AL 35898-5000. Telephone inquiries
may be made to commercial (256) 876-2526, DSN 746-
2526.
6-1/(6-2 blank)
 DMWR 1-4320-271

APPENDIX A

REFERENCES
DA PAM 25-30 (Consolidated Index of Army Publications and Blank Forms) should be consulted for information
concerning changes, revisions, supersession, or replacement of the references listed below.

Military Specifications

MIL-C-5541 Chemical Conversion Coatings on Aluminum and Aluminum Alloys

MIL-I-45607 Inspection Equipment, Acquisition, Maintenance and Disposition of

MIL-S-8512 Support Equipment, Aeronautical, Special, General Specification

for the Design of

NASM33540 Safety Wiring and Cotter Pinning

SAE AS8879 Screw Threads UNJ Profile, Inch, Controlled Radius Root with
Increased Minor Diameter FSC THDS, Industry Standard for

SAE-AMS-STD-2219 Fusion Welding for Aerospace Applications

Military Standards

MIL-STD-129 Military Marking for Shipment and Storage

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-2073-1 DOD Standard Practice for Military Packaging

NAS410 NAS Certification and Qualification of Nondestructive Test Person-

nel

Quality Control/Quality Assurance

Documents

ANSI-Z540.1 Laboratories, Calibration and Measuring and Test Equipment

AR750-43 Including AMC Supple- Test, Measurement and Diagnostic Equipment, Including Prognostic
ment 1 Equipment and Calibration Test/Measurement Equipment

ASTM-E1417 Liquid Penetrant Examination, Standard Practice for

ASTM-E1444 Magnetic Particle Examination, Standard Practice for

AMCOMR 702-2 Aviation Product Verification Audit Requirements

AMCOMR 702-7 Flight Safety Parts/New Source Testing Program Management

ISO9000 Quality Management Systems-Fundamentals and Vocabulary

A-1
DMWR 1-4320-271

ISO9001 Quality Management Systems-Requirements

ISO10012-1 Quality Assurance Requirements for Measuring Equipment, Part 1:

Metrological Confirmation System for Measuring Equipment, Part
1: Metrological Confirmation System for Measuring Equipment

Technical Bulletins

CTA 50-970 Expendable Durable Items (Except Medical Class V, Repair Parts,
and Heraldic Items)

DA PAM 25–30 Consolidated Index of Army Publications and Blank Forms

DA PAM 738-751 Functional Users Manual for The Army Maintenance Management
System-Aviation (TAMMS–A)

TB 55-8100-200-24 Maintenance of Specialized Reusable Containers for Aircraft Equip-

ment

Technical Manuals

TM 1-1520-237-23P Series Aviation Unit and Intermediate Maintenance Repair Parts and
Special Tools List for Helicopter, Utility Transport, UH-60A, UH-60L
and EH-60A

TM 55-1500-322-24 Organizational, Intermediate Depot Maintenance

A-2
 DMWR 1-4320-271

APPENDIX B

REPAIR PARTS AND SPECIAL TOOLS LIST

For repair parts and special tools list refer to TM 1-1520-237-23P Series.

B-1/(B-2 blank)
 DMWR 1-4320-271

APPENDIX C

EXPENDABLE AND DURABLE ITEMS

Section I. Introduction

C-1. SCOPE.

C-1.1. This appendix lists expendable supplies and materials you will need to operate and maintain the utility pump
module assembly. These items are authorized to you by CTA 50-970, Expendable Items (except Medical, Class V, Repair
Parts, and Heraldic Items).

C-2. EXPLANATION OF COLUMNS.

C-2.1. Column 1 - Item Number. This number is assigned to the entry in the listing and is referenced in the narrative
instructions to identify the material (e.g., Use hydraulic fluid (item 9, App C)).

C-2.2. Column 2 - National Stock Number. This is the National Stock Number assigned to the item; use it to request or
requisition the item.

C-2.3. Column 3 - Description. Indicates the Federal item name and, if required, a description to identify the item. The
last line for each item indicates the part number followed by the Commercial and Government Entity (CAGE) Code in
parentheses, if applicable.

C-2.4. Column 4 - Unit of Measure (U/M). Indicates the measure used in performing the actual maintenance function.
This measure is expressed by a two-character alphabetical abbreviation (e.g., ea., in., pr.). If the unit of measure differs
from the unit of issue, requisition the lowest unit of issue that will satisfy your requirements.

Section II. Expendable Supplies and Materials List

(1) (2) (3) (4)

ITEM NATIONAL DESCRIPTION U/M
NUMBER STOCK NUMBER

1 3460-01-079-4533 Abrasive Handpieces,

67894
(08659)

2 5970-01-157-9469 Electrical Insulating Compound 3 OZ

3 6810-00-855-6160 Alcohol, Technical Isopropyl, GL

TT-I-735
(81348)

4 8030-00-938-1947 Corrosion Preventive Compounds, 16 OZ

Water Displacing, Ultra-Thin Film
(Corrosion Preventive Compound),
MIL-C-81309
(81349)

C-1
DMWR 1-4320-271

(1) (2) (3) (4)

ITEM NATIONAL DESCRIPTION U/M
NUMBER STOCK NUMBER

5 5350-00-224-7215 Aluminum Oxide Abrasive Paper PK

(Crocus Cloth),
(80204)

6 6850-01-474-2317 Degreasing Solvent, 5 GL

MIL-PRF-680, Type II
(81349)

7 8010-01-029-8066 Remover, Paint QT

T-251-C (90973)

8 9505-00-221-2650 Wire, Non-Electrical (0.020) LB

(Lockwire)
MS20995C20
(96906)

9 9150-00-149-7432 Hydraulic Fluid, Fire Resistant, GL

Synthetic Hydrocarbon Base, Metric
(Hydraulic Fluid),
MIL-PRF-83282

10 6810-00-823-8003 Ethyl Alcohol, 5 GL

A-A-53880
(58536)

11 6850-011-392-8430 Solvent Cleaning Compound, 55 GL

Brulin 815GD

12 5350-00-151-5600 Lapping Compound,

No. 1800
(90931)

13 7930-00-995-7572 Metal Polish,

A-A-105
(58536)

14 9505-00-293-4208 Wire Non-Electrical, (Safety or Lock)

(Lockwire),
NASM20995C32
(80205)

15 8030-00-981-7005 Loctite, Grade C BT

AA15-1
(05972)

6850-01-474-2329 Brulin Safety Strip,

5896
(94058)

C-2
 DMWR 1-4320-271

(1) (2) (3) (4)

ITEM NATIONAL DESCRIPTION U/M
NUMBER STOCK NUMBER

16 9150-00-159-5012 Assembly Fluid, 4 OZ TU

No. 1

17 5345-01-422-9016 Sharpening Stone,

A-A-3008

18 9905-00-810-9986 Plate, Identification, Metal Foil,

Adhesive Backed
(Adhesive-Backed Aluminum Foil),
MIL-P-19834, Type II

19 6850-01-474-2316 Cleaning Compound Solvent (55 DR

Gal),
(Breakthrough)
MIL-PRF-680
(81349)

20 8040-01-180-4988 Loctite, BT
416
(05972)

21 8030-00-723-2746 Sealing Compound KT

MIL-AMS-S-8802, Class B-2
(81349)

22 7920-00-044-9281 Low-Lint Cleaning Cloth, 10 LB

A-A-59323, Type II
(58536)

23 6850-01-467-1319 Daraclean, 5 GL
257
(37676)

24 8030-00-065-0957 Chemical Film, QT

(Chemical Conversion Coating)
MIL-C-5541
(81349)

25 6810-00-184-4796 Acetone, Technical

ASTM-D329
(81346)

26 3439-00-178-8590 Welding Rod, (0.062 Dia)

AWSA5.10-80, Class ER4033
(31505)

27 6850-01-450-6162 n-Propyl Bromide, GL

0338-06
(0WU71)

C-3
DMWR 1-4320-271

(1) (2) (3) (4)

ITEM NATIONAL DESCRIPTION U/M
NUMBER STOCK NUMBER

28 7930-01-367-0996 Cleaning Solvent, 5 GL

DS-108
(30256)

29 6850-01-375-5553 Cleaning Compound Solvent GL

(Electron)
(0WU71)

30 6850-01-412-0026 Cleaning Compound Solvent CN

(Positron),
(0WU71)

C-4
 DMWR 1-4320-271

APPENDIX D

DEPOT MOBILIZATION REQUIREMENTS

DELETED

D-1/(D-2 blank)
 DMWR 1-4320-271

APPENDIX E

MODIFICATIONS

E-1. SCOPE.

E-1.1. This appendix covers instructions for modification of utility pump module assemblies, part numbers 70652-
02300-048 and -049.

E-2. MODIFICATION.

E-2.1. Modify utility pump module assembly, part number 70652-02300-048 to -049, 70652-02300-049 to -050, as
follows.

a. Disassemble utility pump module assembly per Chapter 3 of this DMWR.

b. Modify utility pump module by removal and replacement of parts listed in Table E-1 or E-2.

c. Procedures for adding, removing and replacing of additional parts are included in Chapter 3 of this DMWR.

d. Reidentify utility pump module assembly by installing a new identification plate with the required information.

Table E-1. Modification of Part No. 70652-02300-048 to 70652-02300-049

Figure 3-2 Replacement/

Nomenclature Index No. Remove Addition

NOTE

Magnetic seal (P/N 93058) is an alternate for plain encased seal ( P/N 67717 and 20807) which are preferred
parts.

Plain Encased Seal 13 67717 20807

Internal Drive Shaft 21 61393 21350

Dust Cap 29 - AE81892H

Retaining Band 42 - 20292

Dust Cap 43 - 20291

Heat Shrinkable Sleeving 90 3004503 M23053/5-103C

Standard Wall Tubing 90 7078208 -

E-1
DMWR 1-4320-271

Table E-1. Modification of Part No. 70652-02300-048 to 70652-02300-049 (Cont)

Figure 3-2 Replacement/

Nomenclature Index No. Remove Addition

Nut 97 MS21044C06 62848

Compression Spring 102 55675 52691

Fluid Identification and 119 62187 21088

Fluid Level Indicator Plate

Fluid Identification and 120 62183 21089

Fluid Level Indicator Plate

Screw 122 - NAS1352-06-6P

Washer 123 - NAS602C6L

Retainer 125 - 20544

Gasket 126 - 21042

Reservoir 132 62574 21085

Screw 144 AN535-00-2 MS21318-1

Identification Plate 178 54987 SS9019-2048

Identification Plate 179 54988 SS9019-2049

Identification Plate 180 54986 SS9109-2050

Tempilabel 181 - 4B-225 or HM200-300

E-2
 DMWR 1-4320-271

Table E-2. Modification of Part No. 70652-02300-049 to 70652-02300-050

Figure 3-2 Replacement/

Nomenclature Index No. Remove Addition

Tubing 44 - 2074402

Hose Tee Subassembly 45 - 20742

Tubing 46 - 2074401

Elbow Subassembly 47 - 20737

Nut 48 - AN6289D4

Hose Connector Elbow 49 - 20743

Packing 50 - MS28778-4

Heat Shrinkable Sleeving 90 - M23053/5-106C

Heat Shrinkable Sleeving 91 - M23053/5-102C

Retaining Ring 127 MS16625-1075 -

Breather 128 53855 -

Packing 129 M83461/1-016 -

E-3/(E-4 blank)
 DMWR 1-4320-271

APPENDIX F

RECAPITALIZATION REQUIREMENTS

F.1. RECAPITALIZATION REQUIREMENTS.

F-1.1. General. This appendix contains all necessary information required to recapitalize the Utility Pump Module As-
sembly. The goal of recapitalization is the recovery of economic life of an aging item. This effort is over and above a
standard overhaul and is designed to replace aging components with new in order achieve recapitalization goals.

F-1.2. Warning. This RECAP Appendix is not applicable to standard overhaul programs. Procedures, limits, and
requirements of this appendix are only applicable to overhaul programs when RECAP is specifically required by program
notice, statement of work, or contract modification. All requirements of this appendix shall apply in total. Partial applica-
tion of the RECAP Appendix shall not be approved.

F-1.3. Approved Modification Work Orders/Engineering Change Proposals. N/A

Table F-1. Mandatory Replacement Parts List

Part Number Location

Item Description (CAGE) NSN Fig. No./ Item No. Qty

Solenoid Subas- 62912 Fig. 3-2, Item 61 1

sembly

Spline Bushing 61388 Fig. 3-2, Item 167 1

Hydraulic relief 61369 Fig. 3-2, Item 36 1

valve

Piston and Shoe 68754 Fig. 3-3, Item 2 9

Subassembly

Hydraulic Relief 62168 Fig. 3-2, Item 84 1

Valve

Check Valve 6980004 Fig. 3-2, Item 138 1

Shutoff Assembly 62617 Fig. 3-2, Item 57 1

Thrust Washer 68756 Fig. 3-3, Item 5 1

Hanger Wear 68617 Fig. 3-3, Item 3 1

Plate

Shoe Retainer 66587 Fig. 3-3, Item 1 1

Plate

F-1
DMWR 1-4320-271

F-1.4. Special Inspection Requirements. N/A

F-1.5. Special Processes. N/A

F-1.6. Special Test Criteria. N/A

F-1.7. Rejected Material Disposition. Forward solenoid subassembly (61, Figure 3-2) to reparable supply for diode
replacement and other repair as required to support overhaul programs.

F-2
FOR THE COMMANDER:
JOHN B. SMITH
Colonel, QM
Chief of Staff

OFFICIAL:

RICHARD E. TURNER
Deputy Director
Integrated Materiel Management Center
 These are the instructions for sending an electronic 2028
The following format must be used if submitting an electronic 2028. The subject line must be
exactly the same and all fields must be included; however only the following fields are
mandatory: 1, 3, 4, 5, 6, 7, 8, 9, 10, 13, 15, 16, 17, and 27.
From: “Whomever” <whomever@wherever.army.mil>
To: 2028@redstone.army.mil
Subject: DA Form 2028
1. From: Joe Smith
2. Unit: home
3. Address: 4300 Park
4. City: Hometown
5. St: MO
6. Zip: 77777
7. Date Sent: 19--OCT--93
8. Pub no: 55--2840--229--23
9. Pub Title: TM
10. Publication Date: 04--JUL--85
11. Change Number: 7
12. Submitter Rank: MSG
13. Submitter FName: Joe
14. Submitter MName: T
15. Submitter LName: Smith
16. Submitter Phone: 123--123--1234
17. Problem: 1
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19. Paragraph: 3
20. Line: 4
21. NSN: 5
22. Reference: 6
23. Figure: 7
24. Table: 8
25. Item: 9
26. Total: 123
27. Text:
This is the text for the problem below line 27.
 Use Part II (reverse) for Repair Parts and Spe- DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND cial Tool Lists (RPSTL) and Supply Catalogs/
Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4. 8/30/02
TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE Organizational, Direct Support, And General
Support Maintenance Manual for Machine Gun, .50
DMWR 1-4320-271 16 Sep 2002 Caliber M3P and M3P Machine Gun Electrical Test Set
Used On Avenger Air Defense Weapon System
ITEM PAGE PARA-- LINE FIGURE TABLE
RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO.

1 WP0005 2 Test or Corrective Action column should identify a different WP number.

PG 3

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTEN-
SION
MSG, Jane Q. Doe, SFC 788--1234
DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command MSG, Jane Q. Doe
ATTN: AMSAM--MMC--MA--NP 1234 Any Street
8/30/02
Redstone Arsenal, AL 35898 Nowhere Town, AL 34565
PART II -- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

MSG, Jane Q. Doe, SFC 788--1234

USAPA V3.01
 Use Part II (reverse) for Repair Parts and Spe- DATE
RECOMMENDED CHANGES TO PUBLICATIONS AND cial Tool Lists (RPSTL) and Supply Catalogs/
Supply Manuals (SC/SM)
BLANK FORMS
For use of this form, see AR 25--30; the proponent agency is ODISC4.

TO: (Forward to proponent of publication or form)(Include ZIP Code) FROM: (Activity and location)(Include ZIP Code)
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP
Redstone Arsenal, AL 35898

PART 1 -- ALL PUBLICATIONS (EXCEPT RPSTL AND SC/SM) AND BLANK FORMS
PUBLICATION/FORM NUMBER DATE TITLE

ITEM PAGE PARA-- LINE FIGURE TABLE

RECOMMENDED CHANGES AND REASON
NO. NO. GRAPH NO. * NO. NO.

* Reference to line numbers within the paragraph or subparagraph.

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/ SIGNATURE
AUTOVON, PLUS EXTEN-
SION

DA FORM 2028, FEB 74 REPLACES DA FORM 2028, 1 DEC 68, WHICH WILL BE USED. USAPA V3.01
TO: (Forward direct to addressee listed in publication) FROM: (Activity and location) (Include ZIP Code) DATE
Commander, U.S. Army Aviation and Missile Command
ATTN: AMSAM-MMC-MA-NP
Redstone Arsenal, AL 35898

PART II -- REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOGS/SUPPLY MANUALS
PUBLICATION NUMBER DATE TITLE

TOTAL NO.
PAGE COLM LINE NATIONAL STOCK REFERENCE FIGURE ITEM OF MAJOR
RECOMMENDED ACTION
NO. NO. NO. NUMBER NO. NO. NO. ITEMS
SUPPORTED

PART III -- REMARKS (Any general remarks or recommendations, or suggestions for improvement of publications and
blank forms. Additional blank sheets may be used if more space is needed.)

TYPED NAME, GRADE OR TITLE TELEPHONE EXCHANGE/AUTOVON, SIGNATURE

PLUS EXTENSION

USAPA V3.01
 The Metric System and Equivalents

Linear Measure Liquid Measure

1 centiliter = 10 milliters = .34 fl. ounce

1 centimeter = 10 millimeters = .39 inch
1 decimeter = 10 centimeters = 3.94 inches
1 meter = 10 decimeters = 39.37 inches
1 dekameter = 10 meters = 32.8 feet
1 hectometer = 10 dekameters = 328.08 feet
1 kilometer = 10 hectometers = 3,280.8 feet
Weights
1 centigram = 10 milligrams = .15 grain
1 decigram = 10 centigrams = 1.54 grains
1 gram = 10 decigram = .035 ounce
1 decagram = 10 grams = .35 ounce
1 hectogram = 10 decagrams = 3.52 ounces
1 kilogram = 10 hectograms = 2.2 pounds
1 quintal = 100 kilograms = 220.46 pounds
1 metric ton = 10 quintals = 1.1 short tons
1 deciliter = 10 centiliters = 3.38 fl. ounces
1 liter = 10 deciliters = 33.81 fl. ounces
1 dekaliter = 10 liters = 2.64 gallons
1 hectoliter = 10 dekaliters = 26.42 gallons
1 kiloliter = 10 hectoliters = 264.18 gallons
Square Measure
1 sq. centimeter = 100 sq. millimeters = .155 sq. inch
1 sq. decimeter = 100 sq. centimeters = 15.5 sq. inches
1 sq. meter (centare) = 100 sq. decimeters = 10.76 sq. feet
1 sq. dekameter (are) = 100 sq. meters = 1,076.4 sq. feet
1 sq. hectometer (hectare) = 100 sq. dekameters = 2.47 acres
1 sq. kilometer = 100 sq. hectometers = .386 sq. mile
Cubic Measure
1 cu. centimeter = 1000 cu. millimeters = .06 cu. inch
1 cu. decimeter = 1000 cu. centimeters = 61.02 cu. inches
1 cu. meter = 1000 cu. decimeters = 35.31 cu. feet

Approximate Conversion Factors

To change To Multiply by To change To Multiply by

inches centimeters 2.540 ounce-inches Newton-meters .007062

feet meters .305 centimeters inches .394
yards meters .914 meters feet 3.280
miles kilometers 1.609 meters yards 1.094
square inches square centimeters 6.451 kilometers miles .621
square feet square meters .093 square centimeters square inches .155
square yards square meters .836 square meters square feet 10.764
square miles square kilometers 2.590 square meters square yards 1.196
acres square hectometers .405 square kilometers square miles .386
cubic feet cubic meters .028 square hectometers acres 2.471
cubic yards cubic meters .765 cubic meters cubic feet 35.315
fluid ounces milliliters 29,573 cubic meters cubic yards 1.308
pints liters .473 milliliters fluid ounces .034
quarts liters .946 liters pints 2.113
gallons liters 3.785 liters quarts 1.057
ounces grams 28.349 liters gallons .264
pounds kilograms .454 grams ounces .035
short tons metric tons .907 kilograms pounds 2.205
pound-feet Newton-meters 1.356 metric tons short tons 1.102
pound-inches Newton-meters .11296

Temperature (Exact)

°F Fahrenheit 5/9 (after Celsius °C

temperature subtracting 32) temperature