REVISION NO. 3 DATED 15 NOVEMBER 2008 HIGHLIGHTS
Revised pages are outlined below together with the highlights of the revision. Please delete the affected pages and add new pages. Enter date revised on the Record of Revision Sheet and initial.
Chapter/Section
and Page No. Description of Change
All Pages: Added new page header to reflect Eaton Aerospace Title Page: Changed copyright date
Record of Revisions: Added Revision 3. Record of Temporary
Revisions:
Added Temporary Revision 29-3.
Service Bulletin List Added Service bulletin 971533-29-02 (Eaton Ref: 910386-2) Chronological
Service Eng.Change Record
Add Modification letter “B” Reliability Improvement
List of Effective Pages
Added revision date of Nov. 15/08 for all applicable Revision 3 change pages.
Page 101 Changed paragraph reference to 7 and removed space Page 102 Added “Optional” to Electric Motor SA test
Page 122 Added “Optional” to Electric Motor SA test record Page 127 Corrected reference in paragraph 7.A and 7.B Page 401 Removed Trichloroethane (O-T-620) and added
SkyKleen 1000
Page 402 Removed Trichloroethane (O-T-620) and added SkyKleen 1000
Page 601 Removed outdated materials Page 604 Corrected typing error
Page 610 Added Corrosion Reduction-Filter Box Repair Page 701 Corrected typing error
29-10-60
Page 1012 Corrected items 45 & 55
Page 1017 Added Eaton part numbers Page 1018 Added Eaton part numbers Page 1019 Added Eaton part numbers Page 1020 Added Eaton part numbers
and Page No. Description of Change
Highlights, Page 1 Nov 15/08
ILLUSTRATED PARTS LIST
DC ELECTRIC MOTORPUMP ASSEMBLY
PART NUMBER
971533
MODEL NUMBER
MPEV3-008-6
Original Date July 30, 1996
EATON CORPORATION -CONFIDENTIAL AND PROPRIETARY
NOTICE TO PERSONS RECEIVING THIS DOCUMENT AND/OR TECHNICAL INFORMATION
This document, (which includes the drawings and information contained there on), is confidential and the exclusive property of Eaton Corporation, and is merely on loan for evaluation, inspection, or configuration control purposes and subject to recall by Eaton at any time.Disclosure of this data to the designated recipient is expressly conditioned upon the recipient’s consent that the use is limited to said use only within the recipient’s company. By taking possession of this document, the recipient acknowledges and agrees that the document cannot be used in anymanner adverse to the
29-10-60
RECORD OF REVISION REV NO ISSUE DATE DATE INSERTED BY REV NO ISSUE DATE DATE INSERTED BY REV NO ISSUE DATE DATE INSERTED BY 1 7/15/99 2 11/15/04 3 11/15/08 Page RR-1/RR-2 Nov 15/08
RECORD OF TEMPORARY REVISION TEMPORARY REV NO PAGE NUMBER ISSUE DATE BY DATE REMOVED BY 29-3 1015-1018 Oct 15/05 Eaton Nov 15/08 Eaton
29-10-60
SERVICE BULLETIN LIST
SERVICE BULLETIN NUMBER ATA CONTROL NO. VICKERS CONTROL NO REVISION NUMBER DATE BULLETIN INCORPORATED INTO MANUAL 971533-29-01 910386-1 - Jul 15/99 971533-29-02 910386-2 - Nov 15/08 Page SBL-1/SBL-2 Nov 15/08
CHRONOLOGICAL
SERVICE ENGINEERING CHANGE RECORD
Sequential serial numbers are stamped on the identification plate of each unit at time of manufacture. Modification letters are added to these serial numbers or recorded on a separate record plate to denote engineering changes made to the unit subsequent to its initial release.The following service bulletins and/or change letter assignments apply.
Service Bulletin Description
Modification Letter
Identification Effective
Date 971533-29-01 Motor Bearing Product Improvement A 1 Sept 98 971533-29-02 Reliability Improvement B 12 July 07
29-10-60
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Title Page TP-1 Nov 15/08 Testing and Trouble Shooting 101 Nov 15/08 102 Nov 15/08 Record of Revisions
ROR-1 Nov 15/08 103 Nov 15/04
ROR-2 Blank 104 Nov 15/04
105 Nov 15/04 Record of Temporary RTR-1 Nov 15/08 106 Nov 15/04 RTR-2 Blank 107 Nov 15/04 Revisions 108 Nov 15/04 109 Nov 15/04 Service Bulletin List SBL-1 Nov 15/08 110 Nov 15/04 SBL-2 Blank 111 Nov 15/04 112 Nov 15/04 Chronologi-cal Service Engineering Change Record
SECR-1 Nov 15/08 113 Nov 15/04
SECR-2 Blank 114 Nov 15/04
115 Nov 15/04 116 Nov 15/04 117 Nov 15/04 118 Nov 15/04 List of Effec-tive Pages
LEP-1 Nov 15/08 119 Nov 15/04
LEP-2 Nov 15/08 120 Nov 15/04
LEP-3 Nov 15/08 121 Nov 15/04
LEP-4 Blank 122 Nov 15/08
123 Nov 15/04 Table of
Contents
TOC-1 Nov 15/04 124 Nov 15/04
TOC-2 Blank 125 Nov 15/04
126 Nov 15/04 Introduction INTRO-1 Nov 15/08 127 Nov 15/08
INTRO-2 Blank 128 Nov 15/04
129 Nov 15/04 Description and Operation 1 Nov 15/04 130 Blank 2 Nov 15/04 3 Nov 15/04 4 Nov 15/04 5 Nov 15/04 6 Nov 15/04 7 Nov 15/04 8 Blank LEP-1 Nov 15/08
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Disassembly 301 Nov 15/04 Repair 601 Nov 15/08
302 Nov 15/04 602 Nov 15/04 303 Nov 15/04 603 Nov 15/08 304 Nov 15/04 604 Nov 15/08 305 Nov 15/04 605 Nov 15/04 306 Nov 15/04 606 Nov 15/04 307 Nov 15/04 607 Nov 15/04 308 Nov 15/04 608 Nov 15/04 309 Nov 15/04 609 Nov 15/04 310 Nov 15/04 610 Nov 15/08 311 Nov 15/04 611 Blank 312 Blank Assembly 701 Nov 15/08
Cleaning 401 Nov 15/08 702 Nov 15/04
402 Nov 15/08 703 Nov 15/04
403 Blank 704 Nov 15/04
705 Nov 15/04
Check 501 Nov 15/04 706 Nov 15/04
502 Nov 15/04 707 Nov 15/04 503 Nov 15/04 708 Nov 15/04 504 Nov 15/04 709 Nov 15/04 505 Nov 15/04 710 Nov 15/04 506 Nov 15/04 711 Nov 15/04 507 Nov 15/04 712 Nov 15/04 508 Nov 15/04 713 Nov 15/04 509 Nov 15/04 714 Nov 15/04 510 Nov 15/04 715 Nov 15/04 511 Nov 15/04 716 Nov 15/04 512 Nov 15/04 717 Nov 15/04 513 Nov 15/04 718 Nov 15/04 514 Nov 15/04 719 Nov 15/04 515 Nov 15/04 720 Nov 15/04
29-10-60
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE
Fits and Clearances
801 Nov 15/04 llustrated 1001 Nov 15/04 802 Nov 15/08 Parts List 1002 Nov 15/08
803 Nov 15/04 1003 Nov 15/08 804 Nov 15/04 1004 Nov 15/04 805 Nov 15/04 1005 Nov 15/04 806 Nov 15/04 1006 Nov 15/04 807 Nov 15/04 1007 Nov 15/04 808 Nov 15/04 1008 Nov 15/04 809 Nov 15/04 1009 Nov 15/04 810 Nov 15/04 1010 Nov 15/08 811 Blank 1011 Nov 15/04 Special Tools,Fixtures and Equipment 1012 Nov 15/08 901 Nov 15/04 1013 Nov 15/04 902 Nov 15/04 1014 Nov 15/04 903 Nov 15/04 1015 Nov 15/04 904 Nov 15/04 1016 Nov 15/04 905 Nov 15/04 1017 Nov 15/08 906 Blank 1018 Nov 15/08 1019 Nov 15/08 1020 Nov 15/08 1021 Blank LEP-3
TABLE OF CONTENTS
SUBJECT PAGE
Description and Operation 1
Testing and Fault Isolation 101
(Not applicable) 201 Disassembly 301 Cleaning 401 Check 501 Repair 601 Assembly 701
Fits and Clearances 801
Special Tools, Fixtures and Equipment 901
29-10-60
INTRODUCTION
This publication is issued as a Component Maintenance Manual for Hydraulic Motorpump Assembly, Part Number 971533 (Model Number MPEV3-008-6) manufactured by Eaton Aerospace, Hydraulics Systems Division, Jackson, Mississippi 39206. Throughout the remainder of this manual, this assembly will be referred to as a motorpump assembly.
This publication establishes the requirements for acceptance testing, disassembly, cleaning, checking, repair and assembly of this hydraulic motorpump assembly. An illustrated parts list is also included to provide a part number identification of assembly components.This publication contains data converting U.S. Standard system of measurements to the metric system.Throughout this publication, metric equivalents (in parentheses) follow the U.S.Standard measurements.
The maintenance and test procedures contained in this publication have been verified in actual shop practices at Eaton. These procedures should be used as a guide to develop the necessary skills for proper expedient maintenance of these hydraulic motorpump assemblies. However some degree of flexibility is permissible since user experience will result in equally acceptable procedures to accomplish the same end.
The assembly and test areas assigned for the repair and maintenance of these hydraulic motorpump assemblies should be isolated from particle generating equipment such as grinders, lapping machines, paint spray booths and sandblasting machines. Adequate ventilation and good housekeeping practices should be maintained at all times to assure minimum contamination.
Verification:
Testing/Fault Isolation: Sep 94 Disassembly: Sep 94
Assembly: Sep 94
Page INTRO-1/INTRO-2 Nov 15/08
DESCRIPTION AND OPERATION 1. Description.
The hydraulic motorpump assembly consists of a DC electric motor driven variable displacement, hydraulic pump. The motorpump supplies fluid flow, as required, for operation of aircraft hydraulic system components. Normal functions of the motor-pump, in an aircraft hydraulic system, is to provide auxiliary standby power during flight and for system checkouts on the ground. See Fig. 1.
The pump section of the motorpump assembly consists of the following major component parts; a cylinder block (1, Fig. 2), nine piston and shoe subassemblies(2), valve block(3),yoke (4), yoke control springs (5), pressure compensator valve(6), shaft seal subassembly (7), mating ring (8), mounting flange (9), ball bearing (10), pump housing (11) and drive shaft (12).
The drive shaft (12) is supported in the pump by bearings (10 and 19). The cylinder block is splined to the drive shaft and driven in rotation by the motor driven shaft. The cylinderblock(1) is held against the valve block (3) valving face by the action of spring(13).
29-10-60
Yoke (4) is supported in the mounting flange by two pintle bearings (14). The yoke swivels through an arc from 0° to maximum yoke angle. Yoke angle is controlled bymetered outlet fluid pressure acting on yoke control piston (15) and by yoke control springs (5) which oppose the metered outlet pressure. The piston and shoe subassemblies (2) are retained in the yoke by retainer (16), piston shoes retaining plate (17) and screws, and ride on the shoe bearing late (18) during drive shaft rotation.
Valve block (3), which contains the inlet and outlet ports, provides valving action to direct fluid flow to and from the cylinder block (1). The valve block also contains the pressure compensator valve (6), pressure adjusting screw (20) and needle bearing(19).
The mounting flange contains the yoke (4), seepage and case drain ports, shaft ball bearing (10), shaft seal subassembly (7) and mating ring (8).
The electric motor is a four-pole, compound-field dc motor designed specifically to drive the motorpump hydraulic pump. The motor is cooled internally by means of a cooling fan directly driven by the motor shaft. Intake air is pulled through an opening equipped with a flame arrestor screen, and exhausted through a one inch (25.4 mm) O.D. port connected to outside air. Power is supplied to the motor through a RFI filter on the negative and positive leads. The purpose of the filter is to suppress radio frequency noise that may try to escape from the motor into the system.
2. Operation.
Operation is fully automatic. The pump is designed to build up and maintain pressure without manual control. The pressure is maintained within a pre-adjusted range and is ready for instant use in the amount required within this range.
With electric motor operating, hydraulic fluid flows through the pump inlet port and valve block (3, Fig. 2) valving slots, then into piston bores in cylinder block (1). The cylinder block is driven by the drive shaft (12) in a rotary motion and the nine piston and shoe subassemblies (2) are in turn driven by the cylinder block. At any outlet pressure less than pressure adjustment setting, the yoke is moved to maximum displacement position by yoke control springs (5). In this position, the angle between yoke and centerline of the drive shaft creates a reciprocating movement of the pistons within the cylinder block bores during drive shaft rotation.
Inlet fluid enters the bores of the cylinder block on the outward stroke of the pistons and is discharged through the outlet port on the inward stroke of pistons. This action provides acontinuous, non-pulsating flow of fluid to the hydraulic system.
Page 2 Nov 15/04
29-10-60
Figure 3. Compensator Operation
Operation of the compensator valve is shown on Figure 3. With no load on the pump the yoke will be at maximum angle. As load increases, outlet pressure (Ps) increases. When (Ps) is sufficient to overcome the force of the compensator spring, the compensator valve spool moves downward, metering increasing control pressure (Pc) to the yoke actuator piston. This causes the yoke angle to decrease. Decreased yoke angle shortens the stroke of the pistons within the cylinder block bores and reduces outlet flow.
As outlet pressure (Ps) continues to increase, yoke angle and pump output flow continues to decrease. At or near maximum pressure, outlet fluid flow continues to be metered through the pressure compensator to yoke actuator piston, until extension of actuator piston moves the yoke to the ”zero flow” position. The yoke remains in the “zero flow” position until aircraft system demand for flow is initiated. Upon demand, outlet pressure decreases to a value that allows the yoke control springs to override metered fluid pressure (Pc) to the yoke actuator piston, this allows yoke angle and flow to increase as necessary to satisfy system demand.
3. Leading Particulars:
Motorpump mounting positions Motorpump must be mounted inverted.Pump case drain connection must be connected directly to the reservoir in such a manner that the pump housing remains filled with hydraulic fluid during all
operations. Pump internal parts depend on this fluid for lubrication. Mounting position must also be such that seep drain connection is at or near the 6 o’clock position. Pump case must be completely filled with fluid before operation.
Motorpump connections Provide a drain from seep drain connection Do not return seepage fluid to hydraulic system
Seep drain 0.4375-20 UNJF-3B thread (Per Specification MS33649-4) Inlet 0.5625-18 UNJF-3B thread
(Per Specification MS33649-6) Outlet 0.4375-20 UNJF-3B thread
(Per Specification MS33649-4) Case drain 0.4375-20 UNJF-3B thread
(Per Specification MS33649-4) Electrical connectors
Motor MS3459L24-12P mates with MS3459L24-12S
Thermal switch MS3470L833P mates with MS3476L833S Hydraulic Pump Characteristics:
Rated output flow (min) with 40 psia (276 kPa) (absolute) inlet pressure and 2750 psig (18 960 kPa) outlet
pressure. 1.5 gpm (5.7 l/m)
29-10-60
Pressure at which
displacement begins to reduce
2775 to 2825 psig (19133 to 19478 kPa) Rated inlet pressure (min) 35 psia (241 kPa) (absolute)
Rated
Speed-Full flow 7950 rpm
Zero flow 9300 rpm
Filtration requirements 10 micro (nominal)
Fluid temperature range -65°F to + 275°F (-54°C to +135°C) Number of pistons 9
Direction of rotation (when viewed from motor end)
Counter clockwise Coupling shaft spline data
Motor mating end 12 teeth, external involute, flat root, side fit, 32/64 pitch, 0.3750 pitch diameter, 30° pressure angle. 0.3960/ 0.3930 major diameter, 0.3335/0.3255 minor
diameter.
Pump mating end 12 teeth, external involute, flat root, side fit,32/64 pitch, 0.3750 pitch diameter, 30° pressure angle. 0.3960/ 0.3930 major diameter 0.3335/0.3255 minor diameter. Electric motor characteristics:
Direction of rotation (Viewing drive end)
Clockwise
Cooling Internal fan
Input
voltage-VDC rated 28
VDC operating 20-32
Weight (motor only) 15.0 lbs. (8.2 kg) Mounting pad AND 20000
Drive spline data 12 teeth, internal involute, flat root, side fit, 32/64 pitch, 0.3750 pitch diameter, 30° pressure angle, 0.4143/0.4063 major diameter, 0.3496/0.3466 min or diameter
Page 6 Nov 15/04
Explosion proof With shroud connected to outside air. Terminal
designations-Power connector Pin “A” of MS3459L-12P requires 28 VDC with pin “C” being ground. Pins “B”,“D” and “E” are not used. Thermal switch. Indirect acting normally closed thermal switch
connected to pins “A” and “B” of connector MS3470L833P.
Total dry weight of motorpump
18.7 lbs (8.5 kg) max
Operating altitude SL to 35,000 ft (SL to 10 668 M) Fluid medium Alkyl Phosphate Ester Base
29-10-60
THIS PAGE LEFT BLANK INTENTIONALLY
Page 8 Nov 15/04
TESTING AND FAULT ISOLATION 1. Receiving Check.
WARNING: USE CLEANING SOLVENTS IN WELL VENTILATED AREA TO PREVENT INJURY. AVOID PROLONGED BREATHING OF FUMES. KEEP SOLVENTS AWAY FROM OPEN FLAME.
A. With all ports plugged, clean exterior of hydraulic motorpump assembly using dry cleaning solvent P-D-680 (or equivalent) and a stiff bristle brush to remove any contaminant that may have accumulated. Do not allow solvent to enter electric motor. Air blow unit dry.
B. Visually check exterior for evidence of damage. If damage is noted and if damage is such that it will impair unit operation, refer to applicable paragraphs of overhaul sections for repair. If no external damage is noted, proceed with receiving check. C. Remove case drain plug and drain unit. Collect discharged contents and check for
metal particles. Presence of metal particles will not necessary mean deterioration of unit but should be a warning to thoroughly check it before subjecting it to performance tests.
D. If unit appears to be satisfactory after performing these preliminary procedures, perform as many operational tests as possible beginning with tests called for in paragraph 7. If it will pass all tests, return unit for a continuation of its time between overhaul period. If it will not, refer to Table 101 for repair procedures before tagging unit for complete overhaul.
2. Special Tools.
Refer to SPECIAL TOOL, FIXTURES AND EQUIPMENT for a complete listing of special tools and test equipment recommended for maintenance of these motor- pump assemblies and a description of their function. Tooling and test equipment other than herein specified may be used provided they perform the required operation. Refer to the following table for tools and/or fixtures recommended for testing:
29-10-60
Special Tools
3. Test Electric Motor Subassembly (Optional).
A. Test equipment shall include a 28 vdc power supply capable of 500 amperes starting surge and regulated operation at 130 amperes sustained.
B. A precision dynamometer capable of operation at 25 pound inches (2.8 Nm) torque and at 7,950 rpm is required to load motor for test. A mating spline and coupling is also required to adapt motor to dynamometer.
C. The test stand shall be equipped with suitable instrumentation to measure torque, speed, voltage and current. All equipment shall be certified to industry standards. 4. Test Conditions.
A. Motor brushes shall be seated 100% in the direction of rotation and 90% in the axial direction.
B. The test load shall not be maintained for more than twenty (20) seconds with out allowing the motor to cool to room temperature.
CAUTION: DO NOT HI-POT FINAL MOTOR SUBASSEMBLY. INTERNAL DAMAGE WILL OCCUR TO RFI FILTER CAPACITORS.
C. Direction of motor rotation shall be clockwise when viewed from drive end. 5. Acceptance Test.
The motor shall meet the following minimum performance criteria:
A. Load (Pound Inches/Nm) . . . 25.0 (2.8) B. RPM . . . 7,950 ± 500 C. Current (Max. Amps., Continuous Operation) . . . 130
D. Voltage, VDC . . . 20
T-233247 Flushing Set
T-442698 Test Plate
T-302537 A” Frame Test Stand Local Manufacture (Refer to
Description and Operation (Leading Particulars) for motor spline data)
Coupling Adapter(Adapt Dynamometer to Motor)
Page 102 Nov 15/08
6. Test Hydraulic Pump Subassembly (Optional). A. Test Conditions.
(1) Use test equipment providing the arrangement shown in Fig. 101. (2) Use a hydraulic test stand capable of supplying the following:
(a) Drive rotation, counterclockwise.
(b) Variable speed drive capable of developing a minimum of 20 horsepower (15 kw).
(c) Capable of measuring output speed to a maximum of 12,000 rpm. (d) Capable of recording outlet pressure to a maximum of 4000 psig (27 579 kPa) and flow from zero to 2 gpm (7.6 L/m).
(e) Capable of providing inlet supercharge pressure of 25 psig (172 kPa). (f) Capable of filtering test circuit fluid to a maximum of ten micron absolute. (g) Capable of controlling inlet fluid temperatures of 160° ± 10°F (71° ±6°C). (3) Maintain test conditions as follows, unless otherwise stated in the test
instructions:
(a) Maintain inlet fluid temperature at 160° ±10°F (71° ± 6°C). (b) Maintain inlet pressure of 25 ± 5 psig (172 ± 34 kPa).
(c) Maintain case pressure of 15 ± 5 psig (103 ± 34 kPa) above inlet pressure B. External Leakage.
(1) Shaft Seal.
29-10-60
NOTE: Conduct the following tests prior to installing the pump in the test circuit. (1) Binding. Rotate drive shaft of test unit manually to check for binding. There
shall be no evidence of bind. If binding is noted, disassemble pump and correct the trouble before proceeding.
(2) Proof Test. Plug inlet and outlet ports and apply 150 psig (1034 kPa) to the case drain connection for two minutes. There shall be no evidence of external leakage except at the drive shaft seal. Shaft seal leakage shall not exceed ten drops in five minutes.
(3) Flush Operation. Using flushing set T-233247, thoroughly flush the test unit through the case drain connection for two minutes. Do not allow case pressure
to exceed 150 psig (1034 kPa). D. Test Circuit.
Connect the test unit in a hydraulic test circuit as illustrated in Fig. 101. Make certain test unit and test circuit are completely full of clean alkyl phosphate ester hydraulic fluid.
E. Preliminary Compensator Adjustment.
Prior to starting test unit in operation, be sure that adjusting screw (35, IPL Fig. 2) is turned in sufficiently to allow full flow and 1500 psig (10 342 kPa) from outlet portwhen test unit is started up in the following run-in test. Do not run test unit below 1500 psig (10 342 kPa).
F. Run-In.
NOTE: This test is necessary only after the replacement of rotating group parts. NOTE: During any of the following tests, external leakage shall be as specified in paragraph 4B.
(1) With load valve (2, Fig. 101) open, start hydraulic supercharge source and power drive to drive test unit at 3600 rpm for five minutes.
29-10-60
Pump Schematic Test Setup
Figure 101 (Sheet 2 of 2) INDEX
NO NOMENCLATURE DESCRIPTION 1 Flow meter 0 to 2.0 gpm (0 to 7.6 L/m) 2 Load Valve Manual Control (high pressure)
3 Relief Valve Adjustable, Set at 3100 psig (21 374 kPa) 4 Filter High Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity 5 Pressure Gage 0 to 4000 psig (0 to 27 579 kPa) 6 Pressure Gage 0 to 100 psig (o to 689 kPa) 7 Load Valve Manual Control (low pressure)
8 Relief Valve Adjustable, set at 50 psig (345 kPa 9 Shutoff Valve Manual Control (low pressure) 10 Beaker 2000 cc Capacity Graduated in 25 cc increments
11 Filter Low Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity 12 Pressure Gage 0 to 100 psig (0 to 689 kPa) 13 Temperature Gage 32° to 200°F (0° to 93°C) Range 14 Filter Low Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity 15 Supercharge Source Pump 0 to 50 psig (0 to 345 kPa) at 3 gpm (11.4 L/m) capacity 16 Test Stand 10 gal. (37.9 l) capacity Reservoir 17 Frequency (RPM) 0 to 12,000 rpm range Counter 18 Power Drive 20 horsepower (15 kw), variable to 12,000 rpm
(2) Adjust supercharge pump (15) to provide inlet pressure of 25 ± 5 psig (172 ± 34 kPa) as indicated on inlet pressure gage (12).
(3) Close load valve (7) and adjust relief valve (8) to provide a case pressure of 15 ± 5 psig (103 ± 34 kPa) above inlet pressure as indicated on case pressure
gage (6).
(4) Gradually close load valve (2) to increase outlet pressure, as shown on
pressure gage (5), from 1500 psig (10 342 kPa) to 2950 psig (20 340 kPa) and zero flow on flow meter (1) during the first five minutes.
(5) During the next five minutes, gradually increase speed to 9350 ± 50 rpm. Continue at this speed and zero flow for five minutes. During this run-in, open shutoff valve (9) and measure case drain flow in beaker (10).
NOTE: Case drain flow at 9350 rpm and 2950 psig (20340 kPa) outlet pressure shall not exceed 0.47 gpm (1780 cc/min.).
(6) During run-in observe unit for unusual noise or chatter. Stop test and investigate trouble observed.
G. Compensator Adjustment.
(1) With unit operating at 9350 ± 25 rpm and load valve (2) closed (zero flow), adjust compensator adjusting screw (35, IPL Fig. 2) to obtain 2900 + 50, - 0 psig (19995 + 345, -0 kPa). Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches(4.0 to 4.5Nm).
NOTE: Make all pressure compensator settings on rising pressure.
(2) Alternately open and close load valve (2, Fig. 101) rapidly. This will purge any air that may have become trapped in the compensator. After this operation, repeat step(1).
H. Pressure Shift.
(1) With unit operating at 9350 rpm, adjust load valve (2) to cycle from zero flow (2900 + 50, - 0 psig (19 995 + 345, -0 kPa) to 2700 + 50, -0 psig (19 995 +
345,-0kPa) to 2700 ± 50 psig (18 616 + 345, - 0 kPa) five times.
29-10-60
While operating test unit at zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa), vary pump speed from 9350 rpm to 6000 rpm and back to 9350 rpm. There shall be no indications of any persistent oscillations lasting more than one second. J. Delivery Check.
(1) Reduce test unit speed to 7950 ±25 rpm.
(2) Adjust load valve (2) as necessary to obtain 2700 ± 50 psig (18 616 ± 345 kPa) on outlet pressure gage (5). Delivery of the pump shall not be less than 1.32 gpm(5.0 L/m) or greater than 1.72 gpm (5.5 L/m) as shown on flowmeter (1). K. Case Flow Check.
(1) Continue to operate test unit at conditions established in paragraph 4J. Open shutoff valve (9) and measure case drain flow. Flow shall not exceed 0.22 gpm(835 cc/min).
(2) Operate test unit at 9350 ±25 rpm and 2900 + 50, - 0 psig (19 995 + 345, - 0 kPa) outlet pressure (zero flow). Measure case drain flow. Flow shall not exceed 0.47 gpm (1780 cc/min.).
L. Cylinder Block Lift Test.
NOTE: During the following tests monitor case drain leakage (flow) and outlet flow (delivery) to ascertain that cylinder block lift does not occur during acceleration and steady state conditions. Cylinder block lift will be
indicated by high case drain leakage, low outlet flow (pump delivery) and pressure oscillations.
(1) Operate test unit at 9350 ± 25 rpm and reduce outlet pressure as low as possible (full flow).Record pressure for reference during test. Decelerate unit to zero rpm.
(2) Uniformly accelerate test unit to 10,300 rpm within two seconds. Continue to operate at low pressure and high speed for thirty seconds. There shall be no evidence of cylinder block lift.
M. Friction Test.
(1) After test unit has successfully passed all tests specified in this paragraph, hand torque required to turn pump drive shaft shall be measured. Breakaway torque shall not exceed 7.0 pound inches (0.8 Nm) and turning torque shall not exceed 4.0 pound inches (0.45 Nm).
Page 108 Nov 15/04
7. Test Motorpump Assembly.
CAUTION: A LIGHT SHALL BE INSTALLED (SEE FIG. 102) TO ALERT
OPERATING PERSONNEL OF OVERTEMPERATURE CONDITION IN BRUSH AREA. IF OVERTEMPERATURE CONDITION IS
EXPERIENCED THE TESTS SHALL BE DISCONTINUED UNTIL THE MOTOR HAS HAD ADEQUATE TIME TO COOL. THE THERMAL PROTECTION DEVICE FOR THE MOTOR IS LOCATED IN THE BRUSH AREA. THIS DEVICE IS NORMALLY CLOSED;
THEREFORE,OVERTEMPERATURE CONDITION WILL BE
INDICATED WHEN PILOT LIGHT GOES OFF DURING OPERATION. CAUTION: ELECTRIC MOTOR IS NOT RATED FOR CONTINUOUS-DUTY AT
FULL-FLOW (MAXIMUM CURRENT DRAW) CONDITIONS. MOTOR PUMP SHALL NOT BE OPERATED CONTINUOUSLY IN FULL FLOW FOR MORE THAN ONE (1) MINUTE.
A. Test Conditions.
Refer to paragraphs 3B and 4A. External leakage shall be as specified in paragraph 4B.
B. Test Equipment.
(1) Test equipment shall include a 28 vdc power supply capable of 500 amperes starting surge and 130 amperes sustaining.
(2) Test stand shall be equipped with suitable instrumentation to measure voltage and current, and pump test setup as shown in Fig. 102.
(3) MS3476L833S or equivalent connector to couple thermal switch and light to 28vdc power supply. MS3459L24-12S or equivalent connector is required for
motor power supply.
(4) The motorpump is oriented in an inverted position in the aircraft installation. If required, a fixture shall be locally manufactured to mount motorpump as shown in Fig. 102. The motor base mounting dimensions are shown in Fig. 103.
29-10-60
NOTE: Shock mounts shall not be installed on motor during test. Refer to
DISASSEMBLY, paragraph 3B(3) for shock mount removal and to ASSEMBLY, paragraph 5A for reinstallation after test.
D. Break-In.
(1) Set power supply voltage at 28 vdc.
(2) Open load valve (2, Fig. 102), start hydraulic supercharge source (15) and adjust supercharged inlet pressure as shown on pressure gage (12) to 25 ± 5 psig (172 ± 34 kPa).
(3) Close load valve (7) and adjust relief valve (8) to provide a case drain pressure of 15 ± 5 psig (103 ± 34 kPa) above inlet pressure.
(4) Operate test unit for three minutes with load valve (2) adjusted to provide 0.3 gpm (1.1 L/m) as indicated on flowmeter (1). During this period, observe, motorpump for any unusual noise or indication of possible malfunction.
(5) Uniformly adjust load valve (2) to increase flow on flow meter (1) to obtain full flow pressure, (2700 ± 50 psig (18616 ± 345 kPa)) over a thirty second period. Operate at full flow for one minute.
E. Outlet Pressure Check.
(1) With test unit operating at 28 vdc, adjust load valve (2) for zero delivery (outlet flow) and check outlet pressure on gage (5). If pressure is not within
2900 + 50,-0 psig (19 995 + 345, - 0 kPa), adjust compensator adjusting screw (35, IPL Fig.2) as necessary to obtain zero delivery outlet pressure.
(2) Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches (4.0 to 4.5 Nm) and secure with lockwire MS20995C32.
Page 110 Nov 15/04
29-10-60
Motorpump Schematic Test Setup
Figure 102 (Sheet 2 of 2) INDEX
NO. NOMENCLATURE DESCRIPTION
1 Flow meter 0 to 2.0 gpm (0 to 7.6 L/m) 2 Load Valve Manual Control (high pressure) 3 Relief Valve Adjustable, Set at 3100 psig (21 374 kPa) 4 Filter High Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity 5 Pressure Gage 0 to 4000 psig (0 to 27 579 kPa)
6 Pressure Gage 0 to 100 psig (0 to 689 kPa) 7 Load Valve Manual Control (low pressure) 8 Relief Valve Adjustable, set at 50 psig(345 kPa) 9 Shutoff Valve Manual Control (low pressure) 10 Beaker 2000 cc Graduated in 25 cc increments 11 Filter Low Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity 12 Pressure Gage 0 to 100 psig (0 to 689 kPa) 13 Pressure Gage 32° to 200°F (0° to 93°C) 14 Filter Low Pressure 10 micron (absolute), 3 gpm(11.4 L/m) capacity
15 Supercharge 0 to 50 psig (0 to 345 kPa) at 3 gpm 16 Source Pump (11. 4 L/m) capacity
17 Reservoir 10 gal. (37.9 l) capacity
Motorpump Mounting Dimensions Figure 103
F. Current Draw.
(1) With test unit operating at voltages, pressures and/or flows as specified in the following steps, measure parameters listed as follows:
(a) Amperage (b) Outlet pressure (c) Case drain flow
29-10-60
(3) Full flow check-operate test unit at 28 vdc and full flow (2700 ± 50 psig
(18 616 ± 345 kPa). Full flow delivery shall not be less than 1.32 gpm (5.0 L/m) or greater than 1.72 gpm (6.5 L/m). Maximum current draw shall not exceed 130 amperes. Case drain flow shall not exceed 0.22 gpm (835 cc/min.). G. Test Completion.
After satisfactory testing, proceed as follows: (1) Remove test unit from test setup.
(2) Drain pump of test fluid and flush unit.
NOTE: Pump must be filled with fluid for corrosion prevention. Fluid from test stand can be used if cleanliness exceeds SAE AS4059, Class 7 level. If.teststand fluid cleanliness levels are not maintained, flush and fill with clean fluid.
(3) Be sure sealing screws (20, IPL Fig. 2) and locking nut (30) are secured with lockwire.
(4) Prepare motorpump for shipment or storage as instructed in ASSEMBLY,paragraph 6.
8. Fault Isolation.
The following fault isolation chart, Table101, has been prepared to assist personnel in locating cause for malfunction of the unit. It lists troubles, probable cause of each, and the necessary remedial steps.
Page 114 Nov 15/04
Fault Isolation and Repair Procedure Chart Table 101 (Sheet 1 of 6)
ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
1 Electric motor inoperative
No electric input. Provide required input power to electric motor connector. Refer to TESTING 2 Pump not delivering (with electric motor operating
Inlet to test unit blocked or insufficient fluid in hydraulic circuit.
Remove restriction from hydraulic lines. Maintain correct fluid level in reservoir.
Inlet pressure to test unit too low.
Provide required inlet pressure test unit. Refer to TESTING.
Yoke stuck in minimum flow position.
Remove pump housing (135, IPL Fig. 2) and check movement of control piston (140). Piston shall move freely in pump housing. Correct any malfunction and reassemble unit.
Electric motor not wired for proper rotation.
Check correct wiring of electric motor. Refer to Fig. 702.
3 Electric motor overheating or drawing current in excess of 130 amps.
Insufficient heat dissipation in hydraulic circuit
Assure inlet fluid temperature does not exceed value specified in TESTING.
Insufficient electric power to motor.
Provide required electrical power input to motor connector specified in TESTING.
Insufficient clearance for pis-ton and shoe subassemblies (210, IPL Fig. 2).
Disassemble pump components check piston and shoe clearance Refer to ASSEMBLY. Correct mal-function and re-assemble unit.
29-10-60
Fault Isolation and Repair Procedure Chart
Table 101 (Sheet 2) ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
3
(Cont’d)
Damaged drive shaft (Cont'd) bearing (285, IPL Fig. 2)and/ or (245 and 265, IPL Fig. 3).
Tag unit for complete overhaul.
Compensator adjustment screw (35, IPL Fig. 2)
improperly Fig. 2) improperly
Readjust compensator adjusting screw (35, IPL Fig. 2) as required. Refer to TESTING
Insufficient end play for cylin-der block (180, IPL.Fig. 2).
Disassemble pump components and check cylinder block end play specified in ASSEMBLY Correct malfunction and re--assemble unit. Brushes are not properly
seated.
Check electric motor brushes as specified in TESTING
4 Electric motor drive shaft
binding.
Excessive preload on bear-ing (245 and 265, IPL Fig. 3).
Check bearing preload as outlined in ASSEMBLY.
Interference between fan and end bell.
Check fan (180, IPL Fig. 3) for proper installation.
5 Thermostat switch
Switch remains closed at room temperature
Check switch as specified in Fig.501 6 Shaft seal leakage exceeds limits specified in TESTING.
Sealing faces of shaft Seal element (125, IPL Fig. 2) and/or mating ring (320) are worn or
damaged.
Remove shaft sealing element (125) and mating ring (110). Lap sealing faces of each part as described in REPAIR.
Reassemble and test unit.
Page 116 Nov 15/04
Fault Isolation and Repair Procedure Chart Table 101 (Sheet 3)
ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
6 (Contd)
Shaft seal wave spring (145, IPL Fig. 2) compression relaxed.
Remove wave spring and test part as specified in Fig. 501 and 801. Correct malfunction and reassemble unit
7 Low outlet flow
Insufficient electrical power to trical power to
Provide proper electrical power input. Refer to TESTING
Pressure control not properly set, allowing yoke to move to zero flow position before full volume and pressure
develops.
Readjust pressure compensator as specified in TESTING.
Spool (70,IPL Fig. 2) not operating freely in valve block (60).
Remove pilot valve and check for freedom of movement in valve bore.If necessary, lap as specified in Fig. 501. Reassemble unit after correction of malfunction. Actuator piston (175, IPL
Fig.2)not operating freely in housing bores
Remove pump housing (155, IPL Fig. 2) and check for freedom of movement of actuator piston. Refer to Fig. 801 for clearance require-ment. Correct malfunction and reas-semble unit
29-10-60
Fault Isolation and Repair Procedure Chart
Table 101 (Sheet 4) ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
7 (Contd) Low outlet flow (cont’d)
Bowed or broken Bowed or broken control springs (265 and 260, IPL Fig. 2).
Remove pump housing (155, IPL Fig. 2) and check springs as specified in Fig. 501. Replace damaged springs and reassemble unit.
Excessive clearance between piston and shoe subassemblies (225, IPL Fig. 2) and piston bores in cylin-der block (180).
Remove pump housing (155, IPL Fig. 2). Refer to Figs. 501 and 801 for fit of pis-ton to bore.Replace pispis-ton and shoe subassemblies as necessary, being sure to preserve matched fit of all piston shoes, and reassemble unit.
Scored valving faces of valve block (60, IPL Fig. 2) and/or cylinder block (180).
Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve block and cylinder block for requirements specified in Figs 501 and 801. If neces-sary, lap damaged face of each part as described
in REPAIR Cylinder block (180, IPL
Fig. 2)partially lifting from valve block(60).
Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve block and cylinder block for requirements specified in Figs 501 and 801. If neces-sary, lap dam aged face of part as described in REPAIR
Page 118 Nov 15/04
Fault Isolation and Repair Procedure Chart Table 101 (Sheet 5)
ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
8 Pressure creeps more than ± 25 psig (± 172 kPa) with yoke zero flow (2900 psig (19 995 kPa)).
Trapped air in test circuit and/ or pressure compensator
Bleed all air from test circuit and test unit.
Sticky operation of actuator piston (175,IPL Fig. 2).
Remove pump housing (155, IPL Fig. 2) and check for freedom of movement of actuator piston. Refer to Figs. 501 and 801 for clearance requirements. Correct malfunction and reassemble unit.
Case drain pressure varies during test period
Maintain constant case drain pres-sure during test period.
9 Excessive internal leakage. (Case flow exceeds limits specified in test). Excessive clearance between piston and shoe subassemblies (225, IPL Fig. 2) and piston bores in cylin-der block (180).
Remove pump housing (155, IPL Fig. 2). Refer to Figs. 501 and 801 for fit of piston to bore. Replace pis-ton and shoe subassemblies as necessary, being sure to preserve match fit of all piston shoes, and reassemble unit
Scored valving faces of valve block (60, IPL Fig. 2) and/or cylinder block(180)
Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve plate and cylinder block for requirements specified in Figs 501 and 801. If necessary, lap damaged face of each part as
29-10-60
Fault Isolation and Repair Procedure Chart
Table 101 (Sheet 6) ITEM
NO. TROUBLE PROBABLE CAUSE REMEDY
9 (contd)
Cylinder block (180, IPL Fig. 2)partially lifting from valve block (60)
Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve block and cylinder block for requirements specified in Figs.501 and 801. If necessary, lap dam aged face of part as described in REPAIR
10 Outlet pressure fluctuation.
Trapped air in test circuit and/ or pressure control
Bleed trapped air. Refer to TEST.
Foreign matter in pressure compensator.
Disassemble pressure compensator and clean parts. Refer to
CLEANING. Burr on spool (70, IPL Fig. 2)
and/or valve block(60).
Disassemble pressure compensator and remove burrs.
Sticky actuator piston (175,
IPL Fig.2) Remove control piston and check for clearance and surface finish as specified in Figs. 501 and 801. Cylinder block (180, IPL
Fig. 2) partially lifting rom valve block(60)
Remove pump housing (155, IPL Fig. 2). Inspect sealing surfaces of valve block and cylinder block for requirements specified in Figs.. 501 and 801. If necessary, lap dam aged face of part as described in REPAIR.
Page 120 Nov 15/04
9. Test Record.
Remove test record pages and make a copy of the pages, replace originals into manual. Initial or record information as requested. Attach completed record to pump and place a copy of completed test record in the history file of the pump.
29-10-60
TEST RECORD
Date: Assembly No.:
Model: Test Operator
Model Name: Fluid Used:
Serial No.: Test Stand No.:
Customer No.: Q.A. Acceptance: Work Order:
Para Test Performed Limits Actual Data
3 3.A., B & C 4
5
Test Electric Motor Subassembly (Optional)
Test setup, see Para 3. _______Comply Test Conditions,see Para 4. _______Comply CAUTION: DO NOT HI-POT FINAL MOTOR SUBASSEMBLY. INTERNAL
DAMAGE WILL OCCUR TO RFI FILTER CAPACITORS Acceptance Test:
The motor shall meet the following minimum RPM: Performance criteria:
Load: 25.0 lbs. in. (2.8 N.m)7,950 ±500
Current: 130 amps max. Voltage: 20 vdc
_______Accept _______Accept _______Accept _______Accept 6 Test hydraulic Pump
Subassembly (Optional). 6.A. Test Conditions.
See para 6A (1) thru (3)
______Comply 6.B. External Leakage.
6.B.(1) Shaft Seal. Shaft Seal shall not exceed two (2) drops per minute during all phases of testing. One drop is equal to
approximately 1/20 ml.
______Accept
6.B.(2) External Leakage. External leakage other than a slight wetting insufficient to form a drop, through andy seal or gasket (except shaft seal) shall be cause for rejection.
______Accept
Test Record Table 102 (Sheet 1 of 8)
Test Record
Para Test Performed Limits Actual Data
6.C
6.C(1)
6.C(2)
6.C(3)
Preliminary Tests.
NOTE: Conduct the following tests prior to installing the pump in the test circuit.
Binding. Rotate drive shaft of test unit manually to psig (1034 kPa) to the case drain connection for two minutes.
If binding is noted, disassemble pump and correct the trouble before proceeding
____Accept
Proof Test. Plug inlet and outlet ports and apply 150 psig (1034 kPa) to the case drain connection for two minutes.
There shall be no evidence of external leakage except at the drive shaft seal. Shaft seal leakage shall not exceed ten drops in five minutes.
____Accept
Test Circuit. ____Accept
6.D Connect the test unit in a hydrau-lic test circuit as illustrated in Fig. 101. Make certain test unit and test circuit are completely full of clean phosphate ester hydraulic fluid or equivalent
___ Comply
6.E Preliminary Compensator Adjustment.
____Accept Prior to starting test unit in
opera-tion, be sure that adjusting screw (35, IPL Fig.2) is turned in suffi-ciently to allow:
Full flow and 1500 psig (10 342 kPa) from outlet port when test unit is started up in the following run-in test. Do not run test unit below 1500 psig (10 342 kPa)
29-10-60
Test Record
Table 102 (Sheet 3)
Para Test Performed Limits Actual Data
6.F Run-In.
NOTE: During any of the following tests, external leakage shall be as specified in paragraph 4B 6.F(1) 6.F(2) 6.F(3) 6.F(4) 6.F(5) 6.F(6)
With load valve (2, Fig. 101) open, start hydraulic super-charge source and power drive to drive test unit at:
3600 rpm for five minutes. ___Comply
Adjust supercharge pup (15) to
provide inlet pressure 25 ± 5 psig (172 ± 34 kPa)as indicated on inlet pressure gage (12).
___Comply
Close load valve (7) and adjust relief valve (8) to provide a case pressure of:
15 ± 5 psig (103 ± 34 kPa) above inlet pressure as indicated on case pressure gage (6).
___Comply
Gradually close load valve (2) to increase outlet pressure, as shown on pressure gage (5), from:
1500 psig (10 342 kPa) to 2950 psig (20 340 kPa) and zero flow on flowmeter (1) during the first five minutes
___Comply
During the next five minutes, gradually increase speed to 9350 ± 50 rpm. Continue at this speed and zero flow for five minutes
During this run-in, open shut-off valve (9) and measure case drain flow in beaker (10).
___Comply
NOTE: Case drain flow at 9350 rpm and 2950 psig (20340 kPa) outlet pressure shall not exceed 0.47 gpm (1780 cc/min.). During run-in observe unit for
unusual noise or chatter Stop test and investigate trouble observed.
___Comply 6.G Compensator Adjustment.
6.G(1) With unit operating at 9350 ± 25 rpm and load valve (2) closed (zero flow), adjust compensator adjusting screw (35, IPL Fig. 2) to obtain:
2900 + 50, - 0 psig (19 995 + 345, - 0 kPa). Torque locking nut (30, IPL Fig. 2) 35 to 40 pound inches (4.0 to 4.5 Nm).
___Comply
Para Test Performed Limits Actual Data 6.G(2) Alternately open and close load
valve (2, Fig. 101 rapidly. in the compensator. After this operation, repeat step 4.G(1)
This will purge any air that may have become trapped
___Comply
6.H Pressure Shift.
6.H(1) With unit operating at 9350 rpm, adjust load valve (2) to cycle from: to 2700 + 50,
Zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa to) 18 616 + 345, - 0 kPa)
five times.
___Comply
6.H(2) Operate unit for three minutes at 9350 ± 25 rpm with zero delivery. not shift more than 25 psig
Outlet pressure, as shown on pressure gage (5), shall (172 kPa) above or below
pressure assumed at the time of shutoff
____Accept
6.I Stability Check.
NOTE: During the following check, minimum time for the sweep shall be 60 seconds from maximum to minimum speed and 60 seconds from minimum to maximum speed. While operating test unit at zero
flow (2900 + 50, - 0 psig (19995 + 345, - 0kPa), vary pump speed from 9350 rpm to 6000 rpm and back to 9350 rpm.
There shall be no indications of any persistent oscillations lasting more than one second.
__Accept
6.J Delivery Check.
6.J(1) Reduce test unit speed to: 7950 ± 25 rpm. ___Comply 6.J(2) Adjust load valve (2) as
neces-sary to obtain 2700 ± 50 psig (18 616 ± 345 kPa)
Delivery of the pump shall not be less than 1.32 gpm (5.0 L/ m) or greater than 1.72 gpm
29-10-60
Test Record
Table 102 (Sheet 5)
Para Test Performed Limits Actual Data
6.K Case Flow Check. ____Accept
6.K(1) Continue to operate test unit at conditions established in paragraph 4.J. Open shutoff valve (9) and measure case drain flow.
Flow shall not exceed 0.22 gpm (835 cc/min).
____Accept
6.K(2) Operate test unit at 9350 ± 25 rpm and 2900 + 50, - 0 psig (19 995 + 345, - 0 kPa) gpm.outlet pressure (zero flow).
____Accept
6.L Cylinder Block Lift Test.
NOTE: During the following tests monitor case drain leakage (flow) and outlet flow (delivery) to ascertain that cylinder block lift does not occur during acceleration and steady state conditions. Cylinder block lift will be indicated by high case drain leakage, low outlet flow (pump delivery) and pressure oscillations.
6.L(1) Operate test unit at 9350 ± 25 rpm and reduce outlet pressure as low as possible (full flow).
Record pressure for refer-ence during test Decelerate unit to zero rpm.
___Comply
6.L(2) Uniformly accelerate test unit to 10,300 rpm within two seconds. Continue to operate at low pressure and high speed for thirty seconds.
There shall be no evidence of cylinder block lift.
____Accept
6.M Friction Test.
After test unit has passed all tests specified in this paragraph, hand torque required to turn pump drive shaft shall be mea-sured
Breakaway torque shall not exceed 7.0 pound inches (0.8 Nm) and turning torque shall not exceed 4.0 pound inches (0.45 Nm).
____Accept
Page 126 Nov 15/04
Para Test Performed Limits Actual Data 7. Test Motorpump Assembly.
CAUTION: A LIGHT SHALL BE INSTALLED (SEE FIG. 102) TO ALERT
OPERATING PERSONNEL OF OVERTEM PERATURE CONDITION IN BRUSH AREA. IF OVERTEMPERATURE CONDITION IS
EXPERIENCED THE TESTS SHALL BE DISCONTINUED UNTIL THE MOTOR HAS HAD ADEQUATE TIME TO COOL. THE
THERMAL PROTECTION DEVICE FOR THE MOTOR IS LOCATED IN THE BRUSH AREA. THIS DEVICE IS NORMALLY CLOSED; THEREFORE, OVERTEMPERATURE CONDITION WILL BE INDICATED WHEN PILOT LIGHT GOES OFF DURING OPERATION.
CAUTION: ELECTRIC MOTOR IS NOT RATED FOR CONTINUOUS- DUTY AT FULL-FLOW (MAXIMUM CURRENT DRAW) CONDITIONS.
MOTOR-PUMP SHALL NOT BE OPERATED CONTINUOUSLY IN FULL-FLOW FOR MORE THAN ONE (1) MINUTE.
7.A Test Conditions.
Refer to paragraphs 3B and 4A. External leakage shall be as specified in paragraph 6.B ___Comply 7.B Test Equipment. Refer to paragraph 7.B ___Comply 7.C Test Circuit.
Connect test unit into a test circuit as illustrated in Fig.102. Be sure hydraulic pump and test circuit are completely full of clean phosphate ester hydraulic fluid
___Comply
29-10-60
Test Record
Table 102 (Sheet 7)
Para Test Performed Limits Actual Data
7.D 7.D(1) 7.D(2) 7.D(3) 7.D(4) 7.D(5) Break-In.
Set power supply voltage at: 28 vdc. ___Comply Open valve (2, Fig. 102),start
hydraulic supercharge source (15) and adjust supercharged inlet pressure as shown on pressure gage (12) to:
25 ± 5 psig (172 ± 34 kPa). ___Comply
Close load valve (7) and adjust relief valve (8) to provide a case drain pressure of:
15 ± 5 psig (103 ± 34 kPa)
above inlet pressure. ___Comply
Operate test unit for three minutes with load valve (2) adjusted to provide 0.3 gpm (1.1 L/m) as indicated on flowmeter (1).
During this period, observe motorpump for any unusual noise or indication of possible malfunction
___Accept
Uniformly adjust load valve (2) to increase flow on flowmeter (1) to obtain full flow pressure, (2700 ± 50 psig (18 616 ± 345 kPa)) over a thirty second period
Operate at full flow for one minute.
___Comply
7.E 7.E(1)
7.E(2)
Outlet Pressure Check.
With test unit operating a 28 vdc, adjust load valve (2) for zero delivery (outlet flow) and check outlet pressure on gage (5).
If pressure is not within 2900 + 50, -0 psig (19 995 + 345,-0 kPa), adjust compensator adjusting screw (35, IPL Fig2) as necessary to obtain zero delivery outlet pressure.
____Accept
Torque locking nut (30, IPL Fig. 2). to 4.5 Nm).Secure with lockwire MS20995C32.
35 to 40 pound inches (4.0 ___Comply ___Comply
Para Test Performed Limits Actual Data 7.F 7.F(1) 7.F(2) 7.F(3) Current Draw.
With test unit operating at
voltages, pressures and/or flows as specified in the following steps, measure parameters listed as follows
(a) Amperage (b) Outlet pressure (c) Case drain flow (d) Delivery (outlet flow) (e) Inlet pressure
Zero flow check-operate test unit at 28 vdc and zero flow (2900 + 50, - 0 psig (19 995 + 345, - 0 kPa).
Maximum current draw shall not exceed 65 amperes.
___Accept Case flow shall not exceed
0.47 gpm (1780 cc/min.).
___Accept Full flow check- operate test unit
at 28 vdc and full flow (2700 ± 50 psig (18 616 ± 345 kPa).
Full flow delivery shall not be less than 1.32 gpm (5.0 L/m) or greater than 1.72
gpm(5.5L/m)
___Accept
Maximum current draw shall not exceed 130 amperes.
____Accept Case drain flow shall not
exceed 0.22 gpm (835cc/ min.).
____Accept
7.G Test Completion.
After satisfactory testing, proceed as follows:
(1) Remove test unit from test setup and install shock
mounts as instructed in ASSEMBLY paragraph 5A.
___Comply
(2) Drain pump of test fluid and flush unit
___Comply (3) Be sure sealing screws
(20, IPL Fig. 2) and locking nut (30) are secured with
29-10-60
THIS PAGE LEFT BLANK INTENTIONALLY
DISASSEMBLY
1. General.See TESTING AND FAULT ISOLATION for operational test and fault isolation to establish the condition of the unit or the most probable cause of malfunction. This is to determine the extent of disassembly required without completely tearing down and rebuilding the unit.
2. Special Tools.
See SPECIAL TOOLS, FIXTURES AND EQUIPMENT for a complete list of special tools and test equipment recommended for maintenance of these hydraulic
motorpump assemblies and a description of their function. Tooling and test equipment other than herein specified may be used provided they perform the required operations. Refer to following table for special tools recommended for disassembly.
List of Special Tools Table 301
NOTE: Always use the proper tool for the job. Be sure wrenches fit properly on nutsor bolt heads. Do not use pliers to remove nuts or bolts. Do not use screwdrivers to separate mating parts. Use a soft faced rod or mallet for
T-300664 Mechanical Positioner Adapter
T-304103 Bearing Removal Plate
T-304104 Bearing Driver T-304105 Bearing Puller
T-304106 Holding Clamp
T-304165 Bearing Puller
T-443364 Assembly Fixture
29-10-60
WARNING: CARE SHALL BE TAKEN IN THE REMOVAL OF LOCKWIRE.
FORCEFULLY PULLING WIRE OUT OF RETAINED PARTS MAY CAUSE PERSONAL INJURY.
(1) Remove external lockwire.
(2) Remove outlet plug (325, IPL Fig. 2), seep plug (335) and case drain plug (345) and packings (330, 340 and 350).
(3) Remove inlet plug (355) and packing (360). Drain all hydraulic fluid from pump. B. Disassembly.
(1) Remove nuts (10, IPL Fig. 1) and washers (15) securing hydraulic pump (5) to electric motor (50).
(2) Carefully separate pump from motor and remove gasket (20).
CAUTION: DURING REMOVAL OF SHOCK MOUNT SUBASSEMBLIES (25), HOLD MOUNT (45) BY WRENCHING FLATS TO PREVENT INTERNAL DAMAGETO SHOCK MOUNT.
(3) Remove nuts (30) and washers (35) securing shock mount subassemblies to motor footing.
(4) Do not disassemble shock mount subassemblies (25) unless replacement stud (40) or shock (45) is necessary.
(5) Do not remove identification plate (55) unless replacement is necessary. If replacement is necessary, refer to REPAIR.
4. Disassemble Hydraulic Pump Subassembly.
NOTE:Refer to IPL Fig. 2 for disassembly of hydraulic pump. A. Remove Coupling Shaft.
(1) Grasp coupling shaft (5, IPL Fig. 2) and pull straight out.
(2) Remove packing (10) and retaining ring (15) from coupling shaft. B. Remove Pressure Compensator.
(1) Attach mechanical positioner adapter T-300664 to power arm (Wilton Model 801, or equivalent).
Page 302 Nov 15/04
Figure 301. Pump/Power Arm Assembly
(2) Remove sealing screws (20, IPL Fig. 2) from pump and remove packings (25) from sealing screws.
(3) Remove locking nut (30) from adjusting screw (35).
(4) Remove adjusting screw (35) from pump and remove packing (40) from adjusting screw.
(5) Disassemble spring seat (45), compensator spring (50), and spring guide (55) from valve block (60).
29-10-60
(4) Using bearing puller T-304105 and assembly fixture T-443364 as shown in
Figure 302, remove needle bearing (80, IPL Fig. 2) from valve block (60). (5) Do not remove alignment pin (85) unless loose or damaged.
(6) Remove packings (90 and 95) from valve block and housing, respectively. (7) Place valve block in a protective container to prevent damage to valving face. D. Remove Shaft Seal Subassembly and Associated Parts
(1) Remove four screws (105, IPL Fig. 2) and remove retaining plate (100). CAUTION: USE CARE WHEN HANDLING MATING RING (110). THIS PART
HAS A LAPPED FACE THAT MATES WITH SHAFT SEAL ELEMENT (125).
(2) Remove mating ring (110) and disassemble preformed packing (115).
CAUTION: USE CARE WHEN HANDLING SHAFT SEAL ELEMENT (125). THIS PART HAS A LAPPED FACE THAT MATES WITH MATING RING (110).
Figure 302. Removal of Needle Bearing
Page 304 Nov 15/04
(3) Remove shaft seal element (125), grommet (130), garter spring (135), shaft seal spacer (140) and wave washer (145) from drive shaft (290).
(4) Carefully remove retainer (150) from drive shaft (290) by lifting a tongue of the retainer (two places 180 degrees apart) out of a drilled hole in the drive shaft. Do not scratch the surface of the drive shaft when removing the retainer. E. Remove Housing Subassembly.
CAUTION: IN THE FOLLOWING OPERATION, DO NOT ALLOW CYLINDER BLOCK (180) TO SEPARATE FROM PISTON AND SHOE
SUBASSEMBLIES (225). DAMAGE TO PISTON AND SHOE SUBASSEMBLIES MAY RESULT.
CAUTION: IN THE FOLLOWING OPERATION, DO NOT ALLOW ACTUATOR PISTON(175) TO FALLOUT OF HOUSING BORE DURING
HOUSING REMOVAL. DAMAGE TO PISTON MAY RESULT. (1) Remove screws (160, IPL Fig. 2) and washers (165) securing housing and
inserts subassembly (155) to mounting flange subassembly (295).
(2) Place finger over hydraulic fluid passageway in housing, to retain actuator piston,and carefully remove housing (155).
(3) Remove actuator piston (175).
(4) Do not remove inserts (170) unless loose or damaged. F. Remove and Disassemble Cylinder Block
CAUTION: IN THE FOLLOWING OPERATION, USE CAUTION WHEN
REMOVING CYLINDER BLOCKS (180 IPL FIG. 2) TO PREVENT DAMAGE TO PISTON AND SHOE SUBASSEMBLIES (225) AND TO VALVING FACE OF CYLINDER BLOCK.
29-10-60
(5) Place cylinder block in a protective container.
G. Remove Piston and Shoe Subassemblies.
(1) Remove screws (205, IPL Fig. 2) and washers (210) securing piston and shoe subassemblies to yoke, ball and pin subassembly (240).
CAUTION: IN THE FOLLOWING STEPS, USE CAUTION TOPREVENT DAMAGE TO PISTON AND SHOE SUBASSEMBLIES (225). DO NOT ALLOW THE SUBASSEMBLIES TO STRIKE ONE
ANOTHER OR OTHER METAL SURFACES.
(2) Carefully disassemble retainer (215), piston shoe retaining plate (220), piston and shoe subassemblies (225) and shoe bearing plate (230) from yoke, ball and pin subassembly (240).
(3) Place piston and shoe subassemblies in a protective container. H. Remove Yoke, Ball and Pin Subassembly.
(1) Remove mounting flange (295, IPL Fig. 2) from mechanical positioner adapter. (2) Using holding clamp T-304106 as shown in Fig. 304, compress yoke control
springs (260) and (265) until yoke is free of spring load.
Fig. 303. Removal of Retaining Ring.
Page 306 Nov 15/04
Fig. 304. Compressing Control Springs.
(3) Using bearing puller T-304165, remove pintle bearings (235, IPL Fig. 2). NOTE: It may be necessary to lift up on drive shaft to allow room for yoke
removal.
(4) Carefully remove yoke (240) from mounting flange (295).
(5) Release holding clamp tension on control springs and disassemble spring guide (255), outer spring (260), inner spring (265) and control spring
seat (270).
(6) Do not remove locating pin (245) nor inserts (250) unless replacements are necessary.
I. Remove and Disassemble Drive Shaft and Components.
(1) Carefully remove shaft and bearing subassembly (280, IPL Fig. 2) from mounting flange (295).
29-10-60
J. Disassemble Mounting Flange Subassembly.
Do not remove aligning pin (300, IPL Fig. 2) nor inserts (305 and 310) from mounting flange unless replacements are necessary.
K. Remove Data Plates.
Do not remove rotation plate (315) nor instruction plate (320) unless replacement is necessary. If replacement is necessary, refer to REPAIR.
Fig. 305. Removing Drive Shaft. 5. Disassemble Electric Motor Subassembly.
NOTE: Refer to IPL Fig. 3 for disassembly of electric motor. A. Remove Filter, Conduit and Connector Assembly.
(1) Remove cap plugs (5, IPL Fig. 3), nuts (10A), lock washers (15) and detach electrical terminals (20), lead wires (25) and sleevings (30), from filter assembly (40A). Do not remove terminals sleevings or grommets (35A) unless replacement is required.
(2) Remove filter assembly (40A) from cover (135) by removing screws (45) and lock washers (50).
Page 308 Nov 15/04
necessary unless replacement is required. If disassembly is necessary, proceed as applicable.
(3) Remove conduit (65, IPL Fig. 3) by disconnecting connector adapter (55) from electrical connector (70) and female adapter (60) from bulkhead adapter (85). Pull pins from connector (70). Remove conduit (65).
NOTE: Electrical connector tool set is required to pull pins from connector (70) NOTE: If conduit (65) becomes damaged replacement is necessary,.
(4) If replacement of thermostat (75) becomes necessary, remove sleeving (80), and remove thermostat from electrical leads. Remove lead wires only if necessary.
(5) Do not remove bulkhead adapter (85) or lead wires (90 or 95) unless
replacement is required. If required, remove nuts (100A) and lockwashers (105), and remove lead wires from filter posts. Do not remove terminals (110), sleeving (115), and contact bushing (315) unless required.
(6) Remove bulkhead adapter (85) mounting nut and remove adapter from filter (40A).
B. Remove Front Shroud and Cover Assembly.
(1) Remove screws (125, IPL Fig. 3) and lockwashers (130), and carefully separate shroud (120) from drive end bell (250).
(2) Remove screws (140) and lockwashers (145) and separate cover assembly (135) from commutator end bell (230).
(3) Do not remove insulator (150) from cover unless damaged or necessary. C. Remove Fan.
(1) Loosen screw (155, IPL Fig. 3) sufficiently to allow removal of fan (160). Carefully remove fan from armature (235) drive shaft.
29-10-60
CAUTION: TO PREVENT DAMAGE TO BRUSHES,DO NOT USE SHUNT
LEADS TO PULL BRUSHES OUT OF HOLDERS. USE A HOOK TO PULL BRUSH RETENTION SPRINGS BACK SO THAT BRUSHES SLIDE OUT FREELY.
CAUTION: IF BRUSHES ARE TO BE RE-USED, IDENTIFY BRUSHES WITH HOLDERS. BRUSHES MUST BE RE-INSTALLED INTO SAME HOLDERS.
(1) Remove locknuts (165, IPL Fig. 3) and washers (170) securing brush leads to holder posts. Detach terminals (175 and 180) from brush holders (190) and remove brushes (185) from holders assemblies.
(2) Remove retaining ring (195) and shims (200, 205 and 210) from commutator end bell (230). Retain shims for re-use at assembly.
NOTE: Commutator end bell (230), field housing (240) and drive end bell (250) must be aligned at the same positions during reassembly. (3) Scribe alignment marks on commutator end bell, field housing and drive end
bell to assure correct alignment of these components during re-assembly. (4) Remove bolts (215) and lockwashers (220) securing commutator end bell, field
housing and drive end bell together.
(5) Carefully separate commutator end bell (230) from rear ball bearing (225) and armature assembly (235).
(6) Remove armature (235) from field housing (240).
(7) Remove front ball bearing (245A) and rear ball bearing (225A) from armature (235).
(8) Remove drive end bell (250) from field housing (240). Do not remove set screws (255) unless replacement is necessary.
(9) Do not remove mounting base (260), unless damaged or necessary. If necessary, remove screws (265A), lockwashers (270A) and flat wash (271). (10) Do not disassemble field housing (240).
(11) Disassembly of commutator end bell (230), brush holder assemblies (190), or associated parts, screws (275), lockwashers (280), washers (285), jumper (lead) wires(290), and terminals (295) is not required unless individual parts require replacement.
Page 310 Nov 15/04
(12) Do not remove name plate (300, IPL Fig. 3) or warning placard (305) unless replacement is necessary. Refer to REPAIR.
29-10-60
THIS PAGE LEFT BLANK INTENTIONALLY
Page 312 Nov 15/04
CLEANING
1. Cleaning of Hydraulic Pump.A. The consumable materials listed in Table 401 are required during cleaning operations. Equivalent substitutes may be used.
Cleaning Materials Table 401
B. After lapping operations, thoroughly brush lapped surface of part with a bristle brush in a soap and water solution. Follow this operation cleaning part in a sonic or ultrasonic cleaner.
WARNING: USE CLEANING SOLVENTS IN WELL VENTILATED AREA TOPREVENT INJURY. AVOID PROLONGED BREATHING OF FUMES.KEEP SOLVENTS AWAY FROM OPEN FLAME. CAUTION: DO NOT APPLY SONIC OR ULTRASONIC CLEANING
OPERATIONSTO PARTS THAT CONTAIN OR ARE COMPOSED OF NON-METALLIC MATERIAL.
CAUTION: DO NOT IMMERSE HYDRAULIC MOTORPUMP ASSEMBLY IN
MATERIAL AVAILABILITY
Cleaner, Ultrasonic Commercially available Containers, Parts, Sealable Commercially available Solvent, Dry cleaning (P-D-680) Commercially available Skykleen 1000 Solution, St. Louis, MO Wipers, Cotton Commercially available Fluid, Hydraulic (Alkyl Phosphate Ester) Commercially available
