Appendix I - 9H2-7-37-3 (F101 IGVA).pdf

TO 9H2-7-37-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

INLET GUIDE VANE ACTUATOR

(USED ON F101-GE-102/A ENGINE)

PART NO. CONTROL DWG NO.

3810051-101 9736M98P05 3810051-103 9736M98P06

Parker-Hannifin GE Aircraft Engines

PREPARED BY AFSC COMMODITY TEAM

THIS MANUAL SUEPRSEDES TO 9H2-7-37-3, DATED 15 JAUNARY 2016.

THIS MANUAL WAS TRANSFERRED TO A NEW PUBLISHING SYSTEM. THE STYLE AND FORMAT WAS EXTENSIVELY CHANGED/

REVISED, THEREFORE, CHANGE BARS ARE OMITTED IN THIS RELEASE.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D - Distribution authorized to the Department of Defense and U.S. DoD contractors only, Critical Technology, 15 January 2016. Refer other requests for this document to AFLCMC/LPSZB, Tinker AFB, OK 73145-3031.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979 (Title 50, U.S.C., App. 2401 et seq.), as amended. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER AUTHORITY OF THE SECRETARY OF THE AIR FORCE

15 JULY 2018

Dates of issue for original and changed pages are:

Original. . . . . . . .0 . . . . . . . 15 July 2018

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 72, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv Blank v vi Blank 1-1 - 1-4 2-1 - 2-9 2-10 Blank 3-1 - 3-7 3-8 Blank 4-1 4-2 Blank 5-1 - 5-4 6-1 - 6-7 6-8 Blank 7-1 - 7-23 7-24 Blank 8-1 8-2 Blank A-1 - A-2

TO 9H2-7-37-3

LIST OF EFFECTIVE PAGES

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

A USAF

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . ii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . ii

INTRODUCTION . . . . . . . . . . . . . . . . . . . . iii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . v

1 GENERAL INFORMATION . . . . . . . . . . . . 1-1

1.1 GENERAL INFORMATION . . . . . 1-1

1.2 DESCRIPTION . . . . . . . . . . . . . . 1-1

1.3 LEADING PARTICULARS . . . . . . 1-1

2 SPECIAL TOOLS, TEST EQUIPMENT, AND

CONSUMABLE MATERIALS. . . . . . . . . 2-1

2.1 GENERAL . . . . . . . . . . . . . . . . . 2-1

2.2 SPECIAL TOOLS AND TEST

EQUIPMENT . . . . . . . . . . . . . 2-1

2.3 CONSUMABLE MATERIALS . . . 2-1

3 DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . 3-1

3.1 GENERAL . . . . . . . . . . . . . . . . . 3-1

3.2 PREPARATION FOR

DISASSEMBLY . . . . . . . . . . . 3-1

3.3 DISASSEMBLY . . . . . . . . . . . . . 3-1

4 CLEANING . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 GENERAL . . . . . . . . . . . . . . . . . 4-1

4.2 CLEANING . . . . . . . . . . . . . . . . 4-1

5 INSPECTION, REPAIR AND

REPLACEMENT . . . . . . . . . . . . . . . . . . 5-1

Chapter Page

5.1 GENERAL . . . . . . . . . . . . . . . . . 5-1

5.2 INSPECTION . . . . . . . . . . . . . . . 5-1

5.3 REPAIR . . . . . . . . . . . . . . . . . . . 5-3

5.4 REPLACEMENT. . . . . . . . . . . . . 5-3

5.5 PRESERVATION . . . . . . . . . . . . . 5-4

6 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 GENERAL . . . . . . . . . . . . . . . . . 6-1

6.2 ASSEMBLY . . . . . . . . . . . . . . . . 6-1

7 TESTING . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1 GENERAL . . . . . . . . . . . . . . . . . 7-1

7.2 TESTING . . . . . . . . . . . . . . . . . . 7-1

7.3 TROUBLESHOOTING. . . . . . . . . 7-20

7.4 PRESERVATION AFTER

TESTS . . . . . . . . . . . . . . . . . . 7-20

7.5 FINAL ASSEMBLY AND

ADJUSTMENT . . . . . . . . . . . . 7-21

8 TABLE OF LIMITS . . . . . . . . . . . . . . . . . . 8-1

8.1 INTRODUCTION . . . . . . . . . . . . 8-1

8.2 TORQUE VALUES . . . . . . . . . . . 8-1

8.3 IUID . . . . . . . . . . . . . . . . . . . . . 8-1

APPENDIX A ITEM UNIQUE IDENTIFICA-

TION (IUID) SUPPORTING

INFORMATION. . . . . . . . . . . . . . . . . . . . A-1

A.1 IUID SUPPLEMENTAL

INFORMATION . . . . . . . . . . . A-1

i

LIST OF ILLUSTRATIONS

Number PageTitle

1-1 Inlet Guide Vane (IGV) Actuator. . . . . . . 1-2 1-2 Inlet Guide Vane System - ScheMAtic

Diagram . . . . . . . . . . . . . . . . . . . . . 1-3 2-1 Channel Seal Assembly Tool . . . . . . . . . 2-3 2-2 Piston Rod Applicator . . . . . . . . . . . . . . 2-4 2-3 Test Manifold . . . . . . . . . . . . . . . . . . . 2-5 2-4 Test Block . . . . . . . . . . . . . . . . . . . . . . 2-6 2-5 LVDT Assembly Tool . . . . . . . . . . . . . . 2-7 2-6 LVDT Assembly Wrench . . . . . . . . . . . . 2-8 2-7 Wire-forming Tool . . . . . . . . . . . . . . . . 2-9 3-1 Inlet Guide Vane Actuator - Exploded

View . . . . . . . . . . . . . . . . . . . . . . . 3-2 6-1 LVDT Preadjustment - Test

Connections . . . . . . . . . . . . . . . . . . . 6-4 6-2 Locally Manufactured Cable - Test . . . . . 6-6 6-3 Electrical Connector - Orientation . . . . . . 6-7 7-1 Typical Break-in and Feedback Test

Setup . . . . . . . . . . . . . . . . . . . . . . . 7-2 7-2 Typical Proof-pressure with Servovalve and Slew Rate Test Setups . . . . . . . . . 7-4

Number PageTitle

7-3 Break-in Test Connections . . . . . . . . . . . 7-5 7-4 Proof-pressure Without Servovalve Test

Connections . . . . . . . . . . . . . . . . . . . 7-7 7-5 Cross-piston Leakage Test

Connections . . . . . . . . . . . . . . . . . . . 7-8 7-6 Rod-seal Leakage Test Connections . . . . . 7-10 7-7 Friction Drag and Stroke Test

Connections . . . . . . . . . . . . . . . . . . . 7-11 7-8 Proof-pressure with Servovalve Test

Connections . . . . . . . . . . . . . . . . . . . 7-13 7-9 Position Feedback and Slew Rate Test

Connections . . . . . . . . . . . . . . . . . . . 7-14 7-10 LVDT Output versus Stroke . . . . . . . . . . 7-17 7-11 Slew Rate versus Milliamperes . . . . . . . . 7-18 7-12 IGV Actuator in High Voltage

Chamber . . . . . . . . . . . . . . . . . . . . . 7-19 7-13 Dielectric Strength Test . . . . . . . . . . . . . 7-20 8-1 Limits Location . . . . . . . . . . . . . . . . . . 8-1 A-1 IUID Identification Plate Location. . . . . . A-2

LIST OF TABLES

Number PageTitle

1-1 Leading Particulars . . . . . . . . . . . . . . . . 1-4 2-1 Special Tools and Test Equipment . . . . . . 2-1 2-2 Consumable Materials . . . . . . . . . . . . . . 2-2 5-1 Inspection . . . . . . . . . . . . . . . . . . . . . . 5-1 7-1 Optional Chart for Slew Rate Test. . . . . . 7-16

Number PageTitle

7-2 Troubleshooting . . . . . . . . . . . . . . . . . . 7-22 8-1 Table of Limits . . . . . . . . . . . . . . . . . . 8-1 A-1 IUID Required Information . . . . . . . . . . A-1 ii

INTRODUCTION

1 PURPOSE.

This technical manual provides information required for overhaul and testing of the inlet guide vane (IGV) actuator.

The actuator is manufactured by Parker-Hannifin Corpora-tion, Parker-Bertea Aerospace Group Headquarters, 18321 Jamboree Boulevard, PO Box C-19510, Irvine, CA 92713- 1011 for use on GE aircraft engines.

2 SCOPE.

Chapter 1 through Chapter 8 of this manual provides over-haul and test procedures. A table of contents provides chap-ter, paragraph title, and page numbers to help find informa-tion. A list of illustrations and a list of tables provide number, title, and page number of illustrations and tables.

3 ABBREVIATIONS AND SYMBOLS.

Abbreviations and symbols used in this manual are in accor-dance with MIL-STD-12, Abbreviations for Use on Draw-ings, and in Specifications, Standards, and Technical Docu-ments, except as follows:

Abbreviation Definition AF Air Force Hz Hertz

IUID Item Unique Identification LVDT Linear variable displacement transducer MA Milliamperes PSID Pounds per square inch differential Symbol Definition UID Unique Identification UII Unique Item Identifier °F Degrees Fahrenheit

4 LIST OF REFERENCED PUBLICATIONS.

Referenced publications are as follows:

List of Related Publications

Number Title TO 00-25-260 Unique Identification Asset

Marking and Tracking TO 33D4-6-670-1 Fuel Accessory Test Stand TO 33D4-6-672-1 Electrical Accessory Test

Stand TO 44H1-1-117 General Installation of Heli-

Coil Inserts TO 9H2-7-36-3 Inlet Guide Vane Actuator

CONFIGURATION CHART

9736M98P05 - - - - - - - - - - > ECP B071 - - - - - - - - - - > 9736M98P06

5 IMPROVEMENT REPORTS.

Recommendations for improvements to prescribed require-ments and procedures will be submitted by AFTO Form 22, Technical Order System Publication Improvement Report, in accordance with TO 00-5-1.

iii/(iv blank)

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs and NOTEs included in that task shall be reviewed and under-stood.

2 DEFINITIONS.

The following definitions apply to WARNINGS, CAU- TIONS, and NOTES found throughout this publication.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements which are considered essential to protection of personnel (WARNING) or equipment (CAU- TION). WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consists of four parts: heading (WARNING, CAUTIONS or Icon [see HAZARDOUS MATERIALS WARNINGS]), a statement of the hazard, minimum precau-tions, and possible result if disregarded. NOTEs are used in this manual to highlight operating or maintenance proce-dures, practices, conditions or statements which are not es-sential to protection of personnel or equipment. NOTEs may precede or follow the step or procedure, depending upon the information to be highlighted. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in in-jury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which, if not strictly observed, could result in damage to, or destruction of equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition or statement.

3 GENERAL PRECAUTIONS.

4 ASBESTOS/CADMIUM.

This engine and the support equipment called out to main-tain and repair it, may contain small amounts of asbestos or cadmium. When working with this engine, the following precautions shall be rigidly adhered to:

• Parts: A limited number of parts, such as bolts, nuts, and fasteners are cadmium plated. Since you can not visually determine if a part contains asbestos or cadmium or if it is cadmium plated, refer to your Illustrated Parts Breakdown (IPB) (TO 2J-F101-4/

14) to find these parts. Before handling, replacing or disposing of parts containing asbestos or cad-mium, ensure all environmental controls are strictly followed.

• Repairs: It is highly recommended that parts con-taining asbestos or cadmium not be repaired. If however, mechanical removal of material such as grinding, buffing, drilling and sanding is necessary, appropriate personal protective equipment and na-tional environmental controls must be strictly com-plied with. Ensure Material Safety Data Sheets are available and followed for all of the materials used during any process or operation.

v/(vi blank)

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL INFORMATION.

The following paragraphs provide a description and a table of leading particulars for inlet guide vane (IGV) actuator.

1.2 DESCRIPTION.

The actuator (Figure 1-1) is used in an aircraft engine inlet guide vane control system (Figure 1-2). Two actuators are in the system, a MAster and a slave. The master actuator in-cludes a servovalve to which system pressure and control signals are applied. The servovalve on master actuator sends hydraulic power to slave and master actuators so that the two actuators operate in tandem. The information in this manual pertains primarily to the master actuator. Refer to TO 9H2- 7-36-3 for information concerning slave actuator.

1.3 LEADING PARTICULARS.

Refer to Table 1-1 for leading particulars.

1-1

Figure 1-1. Inlet Guide Vane (IGV) Actuator

1-2

Figure 1-2. Inlet Guide Vane System - ScheMAtic Diagram

1-3

Table 1-1. Leading Particulars

Characteristics Specifications Fluid JP-4 filtered to 10 microns absolute Actuator area:

Extend 3.113 square inches Retract 2.675 square inches

Retracted length (bearing bores) 7.905-8.655 inches Stroke 2.000-2.020 inches Rod-end connections 0.2500 +0.0000/-0.0005 inch diameter, both ends Output force:

Compression (extend) 650 lb max Tension (retract) 360 lb max Slew rate 1.26 inches per second at 340 psid JP-4 and 150°F ambient and fluid

Cooling flow 20 pounds per hour at 60°F and 100 psid Temperature:

Ambient (steady-state) -65° to 388°F Transient 476°F Fuel (steady-state) -65° to 325°F

Operating pressures:

Supply 1265 psia maximum Return 185 psia maximum Supply-Return 250 psid minimum

Proof pressure (supply and return) 1875 psia at 325°F Overall servo actuator Gain 0.0643 inch/sec/MA at 1000 psid (extend) Servovalve gain 0.40 cubic inch/sec/MA at 1000 psi, 150°F, JP-4 fuel Null bias (no electrical current) 4 MA-12 MA No-load flow 26.4 cubic inches/sec at 1000 psid and 80 MA input (total) Electrical connector M50TF3018 CL-8 Type 12-12-P9 Torque motor ±40 MA per coil nominal. Each coil rated at 110 MA continuous Transducer:

Excitation 7.07 volts rms at 3000 Hz Gain 0.204 volt per volt per inch ± 0.5 percent of nominal required output at full electrical stroke at 150°F Voltage output 2.884 volts in retracted position (Ref output is 0.408 volt/volt/inch (Pre-set before assembly) Torque 15 to 18 inch-pounds Mounting provisions Four 10-32 UNF-3B threaded inserts provide for attachment to manifold Port connections Four 0.191 ±0.004/-0.002 inch dia port holes (P1 supply, P2 return, C1 extend, and C2 retract) One 0.094 +0.004/-0.002 inch diameter port hole (drain)

Weight 3.7 pounds maximum

1-4

CHAPTER 2

SPECIAL TOOLS, TEST EQUIPMENT, AND CONSUMABLE MATERIALS

2.1 GENERAL.

This chapter provides special tools and test equipment re-quired for maintenance of actuator. Equivalent items may be used if recommended tool or test equipment is not available.

2.2 SPECIAL TOOLS AND TEST EQUIPMENT.

Special tools and test equipment required for maintenance of the actuator are listed in Table 2-1.

2.3 CONSUMABLE MATERIALS.

Refer to Table 2-2 for consumable materials required for overhaul of the actuator.

Table 2-1. Special Tools and Test Equipment

Tool/Equipment Number Figure Number

Nomenclature Use and Application

3C3259G01** Overhaul tool set, consisting of the following items:

3810050-100 - - Slave actuator Slew rate test 3831097-101 (3C3259P02) Figure 2-1 Channel seal assembly tool Channel seal installation and removal 3831098-101 (3C3259P03) Figure 2-2 Piston rod applicator Installation of piston assembly into body of actuator 3831100-101 (3C3259P09) Figure 2-3 Test manifold Connecting test pressure source to master actuator manifold

* M83248/1-010 Packing

* M83248/1-008 Packing

* MS16996-16 Screw

* MS9321-09 Washer 3831101-101 (3C3259P07) Figure 2-4 Test block Replace servovalve during cross-pis-ton leakage test

* M83248/1-010 Packing

* 1405M32P01 Screw

* MS9321-09 Washer 3831102-101 (3C3259P05) Figure 2-5 LVDT assembly tool LVDT installation and removal 3831103-101 (3C3259P04) Figure 2-6 LVDT assembly wrench Removal and installation of LVDT nut 3831104-101 (3C3259P12) Figure 2-7 Wire-forming tool Forming cleaning wire on piston 8627356 LVDT preset test fixture Used on electrical accessory test stand for LVDT preset 3831099-101 Test fixture (part of fuel ac-cessory test stand) Perform testing

3C3960 Electrical accessory test stand (refer to TO 33D4-6- 672-1)

Test actuator

3C3970 Fuel accessory test stand (re-fer to TO 33D4-6-670-1)

Test actuator

2-D Handheld Barcode Reader

IUID

** This tool set contains tools required for support of 3810051-101 actuator. It also contains tools required for support of 3810050-103 actuator (refer to T.O. 9H2-7-36-3).

* These are common engine parts used with the tool, but are not part of the tool.

2-1

Table 2-2. Consumable Materials

Nomenclature Specification or Part Number Cage General Use Adhesive, epoxy EA934NA, parts A and B 12405 Securing nameplate Brush, nonmetallic MIL-B-15319 81349 Cleaning Butt splices 321198 00779 Wire splicing Cloth, abrasive, aluminum oxide P-C-451 81348 Remove high metal on aluminum parts Cloth, abrasive, No. 600 P-C-458 81348 Remove high metal on steel parts Cloth, lint-free CCC-C-46 Class 4 81348 Cleaning Chemical conversion coating MIL-C-5541 81348 Bare metal protection Fluid, calibration MIL-C-7024 Type II 81349 Test fluid Flux Soldering A-A-51145 58536 Soldering Flux Oil, lubricating MIL-L-6081, grade 1010 81439 Lubrication and preser-vation Paper MIL-B-121, grade A 81349 Packaging Petrolatum VV-P-236 81349 Lubrication Polyurethane Humiseal 1A120, 1A33 Coating Potting Compound 94-002, RTV 8111 (alternate), 01139 Potting

MIL-S-23586 (alternate) Solder QQ-5-571, Sn 63 81348 Soldering Solvent, drycleaning MIL-PRF-680, Type II or III Cleaning Isopropyl Alcohol TT-I-735 MIL-C-81302, Type I 81348 Cleaning Tubing, insulation (shrink fit) MIL-I-23053/5 81349 Cover splice Wire, safety MS20995NC32 96906 Safety-wiring

2-2

Figure 2-1. Channel Seal Assembly Tool

2-3

Figure 2-2. Piston Rod Applicator

2-4

Figure 2-3. Test Manifold

2-5

Figure 2-4. Test Block

2-6

Figure 2-5. LVDT Assembly Tool

2-7

Figure 2-6. LVDT Assembly Wrench

2-8

Figure 2-7. Wire-forming Tool

2-9/(2-10 blank)

CHAPTER 3

DISASSEMBLY

3.1 GENERAL.

This chapter provides unpacking and disassembly procedures for the IGV actuator. Determine the extent of disassembly required by preliminary visual inspection, and by performing tests (Chapter 7). No part shall be disassembled unless re-placement or servicing is required, or removal is required to gain access to other parts requiring replacement or servicing.

Preformed packings, rings, and channel seals shall be dis-carded following disassembly. All steps apply unless speci-fied by part number.

3.2 PREPARATION FOR DISASSEMBLY.

The following paragraphs provide instructions for removing shipping cover assembly (Figure 3-1, Sheet 1, 48) and drain-ing preservative fluids or oils from actuator.

NOTE

Shipping cover assembly (48) shall be installed on cylinder body assembly (41) to prevent actuator contamination.

a. Shipping Cover Assembly. If shipping cover assembly

(48) is installed, remove four screws (49), and remove shipping cover assembly from cylinder body assembly (41), Remove cap plug (50).

• Calibration fluid, MIL-C-7024, is flammable and toxic to skin, eyes, and respiratory tract.

Skin and eye protection is required. Use in a well ventilated area.

• Lubricating oil, MIL-L-6081, is toxic to skin, eyes, and respiratory tract. Skin and eye protec-tion is required. Avoid repeated or prolonged contact. Use in a well ventilated area.

b. Preservative Fluids or Oils. After shipping cover as-sembly (48) or cap plug (50) has been removed, drain any trapped fluids in actuator before beginning disas-sembly.

3.3 DISASSEMBLY.

The disassembly procedures are described in detail unless self-evident upon inspection. Figure 3-1 shall be used as a reference for removal of actuator components. Attaching parts immediately follow the parts they attach. Disassemble actuator as follows:

a. Remove two screws (sheet 1, 2) and inspection cover

(1) from cylinder body assembly (41). Remove pre-formed packing (3) from inspection cover (1).

NOTE

Electrical connector (4) shall not be removed un-less replacement is necessary.

To prevent damaging electrical wires, use care when pulling electrical connector (4) from cylin-der body assembly (41). Connector shall be pulled from body, as necessary, to gain access to solder joints of connector terminal pin.

b. Remove four screws (5) and carefully pull electrical connector (4) from cylinder body assembly (41).

c. Remove potting compound from around electrical con-nector (4), using a scribe or equivalent, to gain access to solder joints on connector. Cut heat shrink insula-tion tubing away from solder joints on connector.

d. Desolder eight electrical wires ( Figure 1-2) from con-nector (Figure 3-1, Sheet 1, 4).

3-1

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 1 of 4)

3-2

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 2)

3-3

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 3)

3-4

Legend for Figure 3-1.

1. Inspection Cover 28. Preformed Packing

2. Screw 29. Rod-End Locking Washer

3. Preformed Packing 30. Nut

4. Electrical Connector 31. Rod-End Assembly

5. Screw 32. Bearing Assembly

6. Preformed Packing 33. Roe-End

7. Servovalve 34. Piston

8. Inspection Plate 35. Cleaning Wire

9. Screw 36. Glyd Ring

10. Screw 37. Preformed Packing

11. Washer * 38. Scraper

12. Preformed Packing 39. Channel Seal

13. Preformed Packing 40. Preformed Packing

14. Bolt 41. Cylinder Body Assembly

15. End-Cap and Bearing Assembly 42. Insert

16. Bearing Assembly 43. Insert

17. End-Cap Assembly 44. Insert

18. Nut Assembly 45. Insert

19. Pellet 46. Body

20. Nut 47. Identification Plate

21. Backup Ring 48. Shipping Cover Assembly

22. Preformed Packing 49. Screw

23. Linear Variable Displacement Transducer 50. Cap Plug

24. LVDT Probe 51. Screw

25. LVDT Housing 52. Housing

26. Antirotation Pin 53. Preformed Packing

27. Backup Ring 54. Body

* Used on 9736M98P05 actuators only.

Figure 3-1. Inlet Guide Vane Actuator - Exploded View (Sheet 4)

3-5

e. Remove preformed packing (6) from electrical connector (4) or cylinder body assembly (41).

NOTE

• Servovalve (7) shall not be removed unless re-placement is necessary.

• Servovalve (7) shall be carefully separated from cylinder body assembly (41) for access to wires.

• Electrical wires shall be grasped rather than servovalve (7).

• Screws (9) or inspection plate (8) shall not be removed from servovalve (7).

• Washers (11) are not a part of 9736M98P06 actuators.

f. For 9736M98P05 actuators, remove four screws (10) and washers (11), and carefully pull servovalve (7) and electrical wires from cylinder body assembly (41).

g. For 9736M98P06 actuators, remove four screws (10) and carefully pull servovalve (7) and electrical wires from cylinder body assembly (41).

h. Remove preformed packing (12) and four preformed packings (13) from servovalve (7) and cylinder body assembly (41).

NOTE

The LVDT housing is secured to endcap assembly and will be removed with end-cap and bearing as-sembly.

Pull cover assembly straight to prevent damage to LVDT housing (25).

i. Remove three bolts (14), and carefully pull end-cap and bearing assembly (15) from body assembly (41).

Feed LVDT wires through body while slowly pulling end-cap and bearing assembly (15) from body assem-bly (41).

j. Remove pellet (19) and nut assembly (18) from end-cap and bearing assembly (15) using 3831103- 101 LVDT assembly wrench (ref Figure 2-6).

k. Remove LVDT housing (25) from end-cap and bearing assembly (15) while feeding LVDT wires through end-cap and bearing assembly (15).

l. Remove backup ring (27) and packing (28) from LVDT housing (25).

m. Remove backup ring (21) and packing (22) from end-cap and bearing assembly (15).

n. Press bearing assembly (16) from end-cap assembly (17).

o. Remove antirotation pin (26) from end-cap assembly (17).

p. Install 3831102-101 LVDT assembly tool (ref Figure 2-5) over LVDT probe (24) in piston (34), and loosen nut on end of probe.

q. Remove probe from piston. Do not twist or bend probe.

r. Remove safety wire on rod-end locking washer (29).

Loosen nut (30) on rod end of piston (34).

s. Remove rod-end assembly (31) from piston (34). Re-move washer (29) and nut (30) from piston.

t. Remove bearing assembly (32) from rod end (33).

u. Install 3831098-101 piston rod applicator (ref Figure 2-2) over threaded end of piston. Push piston (34) from body assembly (41).

v. Remove cleaning wire (35) from piston (34). Measure and record wire diameter for installation during assem-bly.

w. Remove Glyd ring (36) and packing (37) from piston (34).

x. Remove scraper (38), two channel seals (39), and two packings (40) from body assembly (41), using a brass rod.

y. Remove inserts (42, 43, 44, or 45, sheet 2 of 2) from body (46).

z. Record all stamped information for transfer to a re-placement identification plate.

aa. Apply a small amount of acetone, O-A-51 under plate to loosen epoxy.

ab. Remove identification plate (47, sheet 1 of 2) from body assembly (41).

3-6

Agents used as cleaning solvents (acetone O-A- 51, or isopropyl alcohol, TT-I-735) are flammable and toxic to skin, eyes, and respiratory tract. Skin, eye, and respiratory protection is required. Avoid repeated or prolonged contact. Use in a well-ven-tilated area.

ac. Clean residual epoxy from body assembly (41), using acetone, O-A-51 or isopropyl alcohol, TT-I-735.

3-7/(3-8 blank)

CHAPTER 4

CLEANING

4.1 GENERAL.

Cleaning instructions for actuator are provided in this chap-ter. All dust, dirt, corrosion, and moisture must be removed before inspecting or assembling parts.

4.2 CLEANING.

Clean components of actuator as follows:

NOTE

Parts shall be free of rust, corrosion, dirt, grease, and other contaminants after cleaning.

Drycleaning solvent, MIL-PRF-680, Type II, is toxic to skin, eyes, and respiratory tract. Skin, eye and respiratory protection is required. Avoid re-peated or prolonged contact.

a. Wash all parts thoroughly with cleaning solvent.

b. Use a MIL-8-15319 brush to loosen caked dirt from exterior surfaces and a piece of soft copper wire or suitable substitute to remove any obstructions from ports and passages.

Do not soak electrical components in solvent.

c. Clean electrical components by wiping with a CCC- C-46 lint-free cloth moistened in solvent.

Compressed air used for cleaning, cooling, or dry-ing can dislodge and propel particles into the air.

Wear eye protection and do not exceed 30 psig.

d. Dry parts thoroughly with a CCC-C-46 lint-free cloth, or use compressed air.

4-1/(4-2 blank)

CHAPTER 5

INSPECTION, REPAIR AND REPLACEMENT

5.1 GENERAL.

This chapter provides instructions for inspection, repair, and replacement of worn, damaged, or defective parts. Excessive wear is defined as any obvious deformation or deterioration of parts that may render actuator inoperative. Replace the part if any doubt exists concerning condition of a part.

5.2 INSPECTION.

Inspect all parts listed in Table 5-1 with a bright light. The Ttable of Limits in Chapter 8, provides a dimensional check of functional surfaces critical to operation of actuator.

NOTE

No special measurement tools are required. Stan-dard inspection measurement instruments such as micrometers, pin gages, and thread gages can be used to measure the parts.

a. Item Unique Identification (IUID) visually inspects the identification plate/item for Unique Item Identifier

(UII) marking. If present, visually inspect for damage to the symbol. Ensure readability by using a handheld electronic reader. If symbol is not present or damaged mark/restore, REF: Drawing 9736M98, Appendix A, Table A.1 of the TO for identification of parts to be marked, TO 00-25-260 and MIL-STD-130.

b. Visually check all parts for contamination, corrosion, or deterioration. Refer to Chapter 4 for cleaning.

c. Check all metallic parts for burrs, dents, damaged threads, and other damage. Refer to Table 8-1 for lim-its. Replace or repair damaged parts.

d. Check components of actuator for excessive wear and damage in accordance with Table 5-1 and Table 8-1.

Table 5-1. Inspection

Part and Index Type of Number (Figure 3-1) Inspection Inspect for Corrective Action

Inspection cover (1) Visual Packing groove dirty or corroded Clean or remove corrosion Visual Protective coating worn to bare metal Apply MIL-C-81706 Class A chemi-cal film coating Electrical connector (4) Visual Damaged pins Replace connector

Heat damage to nonmetallic insula-tor

Replace connector

Servovalve (7) Visual External damage, damaged insula-tion, broken wires, dirty or ob-structed parts

Replace servovalve. Clean parts

End-cap and bearing assembly (15)

Visual Packing groove dirty or corroded Clean or remove corrosion Mechanical Looseness of bearing assembly in axial or radial movement of bear-ing cage within the end cap as-sembly

Replace end cap assembly (Para-graph 5.4)

Mechanical Looseness of spherical bearing within cage is greater than 0.005

Replace end cap assembly (Para-graph 5.4)

5-1

Table 5-1. Inspection - Continued

Part and Index Type of Number (Figure 3-1) Inspection Inspect for Corrective Action

Nut (20) Visual Thread damage. Damage is less than 50 percent of one entrance thread or less than 10 percent of two entrance threads

Cleanup thread damage by chasing and by removing high metal.

Visual Thread damage exceeds limits Replace nut Visual Pellet (19) not secure or worn be-low surface of threads Replace nut assembly

LVDT probe (24) and LVDT housing (25)

Visual External damage Replace part Visual External wires less than minimum length of 2-1/4 inches Replace wires

Visual External teflon sleeving less than minimum length of 1/4 inch

Adjust minimum length or replace teflon sleeving

Visual Damaged insulation Replace wiring Visual Thread damage Cleanup threads with chaser Visual Damage to hex surface Replace parts

Rod-end locking washer (29)

Visual Plating worn through to bare metal Replace washer

Nut (30) Visual Thread damage Replace nut Rod-end assembly (31) Visual Thread damage. Damage is less than 50 percent of one entrance thread or less than 10 percent of two entrance threads Thread dam-age. Damage exceeds limits

Clean up threads with chaser Replace rod-end assembly

Mechanical Looseness of bearing assembly in axial or radial movement of bear-ing cage within rod end assembly

Replace rod end bearing assembly (Paragraph 5.4)

Mechanical Looseness of spherical bearing within cage is greater than 0.005

Replace rod end bearing assembly (Paragraph 5.4)

Piston (34) Visual Thread damage. Damage is less than 30 percent of one thread or less than 20 percent of all threads

Cleanup thread damage by chasing.

Visual Thread damage. Damage exceeds limits

Replace piston

Visual Cleaning wire in orifice does not move freely

Replace cleaning wire

Visual Plating damage. Plating is worn through to parent metal or plating is cracked or chipped. Surface finish of piston rod is not be 8 micro-inches

Replace piston

Dimensional Limits specified in Table 8-1 ex-ceeded

Replace piston

5-2

Table 5-1. Inspection - Continued

Part and Index Type of Number (Figure 3-1) Inspection Inspect for Corrective Action

Cleaning wire (35) Cyl-inder body assembly (41)

Visual Movement restricted Replace cleaning wire Visual Damaged or loose inserts Replace cylinder body assembly

(Paragraph 5.4) Visual Protective coating on external sur-face damaged Apply MIL-C-81706, Class A chemi-cal film coating Visual Damaged grooves for seals and packing Remove high metal

Visual Thread damage. Thread is damaged less than 50 percent of one en-trance thread or less than 10 per-cent of two entrance threads

Repair thread damage by chasing

Visual Thread damage. Damage exceeds limits

Replace body

Visual Blocked passages Clean Dimensional Limits specified in Table 8-1 ex-ceeded Replace body assembly

Identification plate (47) Visual Damaged or illegible stamped data Replace identification plate (Para-graph 6.2)

5.3 REPAIR.

General and detail repair procedures are provided in the fol-lowing paragraphs:

a. Polish out all minor nicks, dents, scratches, and corro-sion on metallic parts with P-C-458 abrasive cloth (use on steel parts only) or P-C-451 aluminum oxide abra-sive cloth (use on aluminum and aluminum alloy parts).

b. After polishing parts, reclean repaired parts (Chapter 4).

Aluminum chemical film coating, MIL-C-81706, Class 1A is flammable and highly toxic to skin, eyes, and respiratory tract. Skin and eye protec-tion and vapor controls are required. Avoid all contact.

c. Repair damage to anodized surfaces of aluminum parts with MIL-C-81706, Class 1A chemical film coating.

5.4 REPLACEMENT.

Replace all parts not meeting inspection requirements of Table 5-1, noting the following details:

a. If preliminary test reveals that actuator should be dis-assembled, replace all packings (Figure 3-1, Sheet 1, 3, 13, 22, 28, 37, and 40, backup rings (21 and 27), Glyd ring (36), scraper (38), and channel seals (39).

b. If preliminary test indicates leakage between the cap and body of the Servo-Valve replace o-ring as follows.

Remove the safety wire and screws (Figure 3-1, Sheet 3, index 51) from cap 52. Replace o-ring with new lubricated o-ring. Reinstall cap 52 on Servo-Valve re-install screws 51 Torque to 30 inch pounds and safety wire.

c. If removed, replace bearing assemblies (16 and 32) with new bearing assemblies. Newly installed bearing assemblies are to be swaged securely into end cap as-sembly (17) or rod end (33). Verify torque required to rotate spherical bearings within tolerances listed in Table 5-1.

d. If removed, replace antirotation pin (26) with a new pin.

e. If cleaning wire (35) is removed, replace with a new wire (ref Paragraph 6.2, Step d.

f. If any threaded inserts (42, 43, 44, or 45, sheet 2 of 2) are to be replaced, refer to general operating proce-dures when replacing inserts (see TO 44H1-1-117, General Installation of Heli-coil Inserts). Also observe the following procedures:

NOTE

Use locally procured collets to hold parts when replacing damaged inserts.

(1) Collets shall be suitably sized and finished to pre-vent damaging operating surfaces.

5-3

(2) Install replacement inserts 1 to 1-1/2 turns below adjacent surface of part.

NOTE

Do not lubricate inserts during installation proce-dures.

(3) Remove drive tang from installed insert.

(4) Visually check insert threads for crossed threads.

g. Replace key-locked inserts as follows:

(1) Obtain 7/32-inch drill.

(2) Drill through centerline of insert to a depth of 5/32 inch.

(3) Using a small punch, deflect insert locking keys inward and break off keys.

(4) Remove insert using a screw extractor.

(5) Clean metal particles from threaded hole.

(6) Chase out locking key broaches, using a suitable broaching tool. If existing broaches are damaged or will not provide insert locking, broach new slots 90 degrees from existing slots. Using a ball peen hammer, drive broaching tool until seated, forcing broaching cutters through threads.

(7) Obtain new insert.

(8) Place insert into threaded hole by hand.

(9) Turn insert until it is below surface of body and locking keys are aligned with slots. Use installa-tion tool.

(10) Carefully drive locking keys into slots as far as the installation tool allows using installation tool and a ball peen hammer. An arbor press can be used instead of a hammer.

5.5 PRESERVATION.

Lubricating oil Grade 1010, MIL-L-6081, is toxic to skin, eyes, and respiratory tract. Skin and eye protection is required. Avoid repeated or prolonged contact. Use in a well ventilated area.

Protect steel parts with MIL-L-6081 lubricating oil and wrap in MIL-B-121 paper to prevent corrosion of parts.

5-4

CHAPTER 6

ASSEMBLY

6.1 GENERAL.

This chapter provides procedures for assembly of the IGV actuator after cleaning, inspection, repair, and replacement have been performed. All steps apply unless specified by part number. Observe the following:

a. Special tools and fixtures required for assembly are listed in Table 2-1.

b. Limit requirement dimensions for the actuator are given in Table 8-1.

c. Replace all nonmetallic parts at each exposure.

6.2 ASSEMBLY.

Assemble actuator as follows:

a. Check that inserts (Figure 3-1, Sheet 2, 42, 43, 44, 45) are installed in body (46). If replacement is required, refer to Paragraph 5.4.

b. Install preformed packings (sheet 1, 40) and channel seals (39) in cylinder body assembly (41) as follows:

(1) Lubricate two channel seals (39) with petrolatum, VV-P-236.

(2) Insert preformed packings (40) into gland grooves in body (46).

(3) Collapse one channel seal (39) as shown in Fig-ure 2-1. Grasp V-shaped part of seal with long-nose pliers or with a hemostat. Use care so seal is not cracked or edges damaged.

(4) Insert channel seal into cylinder body and place rounded portion in groove over preformed pack-ing.

(5) Push 3831097-101 assembly tool through chan-nel seal forcing seal in groove.

(6) Repeat substeps (3) through (5) with second chan-nel seal (Figure 3-1, Sheet 1, 39).

c. Install scraper (38) in piston rod bore of cylinder body assembly (41).

d. If removed, install cleaning wire (35) in orifice of pis-ton (34) as follows:

(1) Insert straight end of cleaning wire (35) into head of piston (34) from piston rod side (Figure 2-7).

(2) Shape straight end of cleaning wire into a bend so that wire will be retained in head of piston, using 3831104-101 wire-forming tool. Form wire so that ends are bent, but shaft remains straight and vertical with holes in piston.

(3) Press cleaning wire against head of piston, using a parallel flat bar (Figure 2-7). Ensure formed loop does not protrude beyond piston shoulder.

To avoid damage to equipment, cleaning wire (Figure 3-1, Sheet 1, 35) shall not be reformed once wire has been bent.

(4) If loop of cleaning wire (Figure 3-1, Sheet 1, 35) protrudes beyond piston (34) shoulder, remove and discard cleaning wire and repeat substeps (1) through (3).

e. Install preformed packing (37) and then glyd ring (36) in groove of piston (34).

f. Install piston (34) in cylinder body assembly (41) as follows:

(1) Lubricate outside diameter of piston (34) and bore of cylinder body assembly (41) with petrolatum, VV-P-236.

(2) Slip 3831098-101 piston rod applicator (Figure 2-2) onto threaded rod end of piston (34).

(3) Insert piston (34) into body assembly (41), with 3831098-101 piston rod applicator leading as shown in Figure 2-2.

(4) When piston (34) is fully inserted in body assem-bly (41), remove 3831098-101 piston rod appli-cator from threaded end of piston.

6-1

(5) Install nut (30) fully onto threaded end of piston

(34) to prevent damaging scraper (38) and chan-nel seals (39) during assembly.

g. Install locking washer (29) on threaded end of piston (34).

h. Install rod-end assembly (31) on threaded end of pis-ton (34). Final position will be set later.

i. Install LVDT probe (24) in piston (34) as follows:

(1) Lubricate threads of LVDT probe (24) with VV- P-236 petrolatum.

(2) By hand, start threaded end of LVDT probe (24) into threaded cavity at rod end of piston (34).

(3) Use 3831102-101 LVDT assembly tool to thread LVDT probe (24) into rod end of piston (34) until LVDT probe is bottomed. Back probe out four turns.

j. Install LVDT housing (25), and end-cap and bearing assembly (15) as follows:

(1) Install antirotation pin (26) in end-cap and bear-ing assembly (15). Turn pin so high portion of step is positioned outward.

(2) Install backup ring (27) and packing (28) on LVDT housing (25).

(3) Carefully thread electrical wires from LVDT housing (25) through wire passage in end-cap and bearing assembly (15).

(a) Carefully pull wires through passage and in-stall LVDT housing (25) in end-cap and bear-ing assembly (15).

(b) Locate index cutout in LVDT housing with anti-rotation pin (26).

(4) Install nut assembly on end-cap and bearing as-sembly.

(a) Slide nut assembly (18) over LVDT housing (25).

(b) Thread nut assembly on end-cap and bearing assembly (15).

(c) Use 3831103-101 LVDT assembly wrench to tighten nut assembly snugly into end-cap and bearing assembly (15).

(5) Place end-cap and bearing assembly (15) in place on body assembly (41). Align end cap so that mounting holes are offset and wires do not pre-vent end cap from mating squarely with body.

(6) Use test fixture to perform preset feedback test. If test as follows requirements are not met, adjust LVDT probe (24) in or out, using 3831102- 101 assembly tool as necessary until test requirements are met.

NOTE

An alternate LVDT preadjustment procedure is in step k.

(a) Using locally manufactured test cable (Fig-ure 6-2), connect actuator LVDT to an elec-trical power source (test stand 3C3960G01) meeting the following requirements:

• Voltage 7.035-7.105 volts at 2900- 3100 Hz sine wave

• Harmonic distortion less than 2 per-cent

• Transducer termination 10,000 ohm load

NOTE

• Pressing VDC and VAC button simultaneously on 655AA and 655BA allows meter to measure Vrms.

• Pressing REAR INPUT IN button to OUT po-sition allows front panel input jacks to be ac-tive.

(b) Preset the following controls:

Control Condition 738DD Operate 738CD Position 2 738CA Ignition 738QA Position 3

733MA OFF/OFF

738MA ENABLE

820NA Full CCW (zero volts) 655AA VDC and VAC simultaneously 655BA VDC and VAC simultaneously 655AA Rear INPUT IN press OUT 655BA Rear INPUT IN press OUT

6-2

Control Condition 706LB 3000 Hz

(c) Power up test stand.

(d) Set the following controls:

738NB Press ON and hold 820NA Slowly adjust to 7.035-7.105 Vrms as read on 655BA DMM 738NB Release

(e) Ensure IGV actuator piston is in full retract position. Press 738NB switch ON and hold.

(f) Ensure 655BA DMM reads 7.035-7.105 Vrms. Check output voltage on 655AA DMM. Retract output voltage shall read be-tween 2.885-2.913 Vrms. Record voltage.

(g) Release 738NB.

(h) Pull IGV actuator piston to full extend posi-tion.

(i) Press 738NB ON and hold.

(j) Ensure 655BA DMM reads 7.035-7.105 Vrms. Check output voltage on 655AA DMM. Extend output voltage shall be 60 mV rms maximum.

(k) Release 738NB and set 738DD switch to

OFF.

k. Perform alternate LVDT probe (24) preadjustment as follows:

(1) Connect actuator to P/N 574041-501 (PRIMARY) test stand (Figure 6-1).

(2) Preset the following controls:

Control Nomenclature Condition 738EH Selector switch Position 2

738EC Selector switch

Position 4

655AB Digital multi-meter

(DMM)

POWER-ON FUNCTION -

VRMS (Press VDC and VAC simultaneously) REAR INP IN - Press in EX GD IN

- Press in RANGE - AUTO

706A Power supply POWER-ON VOLTAGE- 7.07

VAC, AS READ ON 655AB

FREQUENCY- 3.000 Hz.

(3) Turn 738EC selector switch to position 3 to read LVDT output voltage.

(4) Push piston (Figure 3-1, 34) to fully retracted po-sition.

NOTE

Ensure 655AB DMM reads 7.07.

(5) Check LVDT transducer (23) output voltage on 655AB DMM. Shall read 2.835 - 2.913 VRMS.

Record voltage.

(6) Pull piston (34) to fully extended position.

(7) Check output voltage of 655AB DMM. Shall read 60 mvrms maximum.

6-3

(8) If LVDT transducer (23) voltage is out of limits adjust as necessary.

(9) Turn off 706GA power supply.

NOTE

The LVDT preadjustment may have to be per-formed several times.

(10) Adjust LVDT transducer (23) voltage as follows:

(a) Remove actuator from test setup.

(b) Remove three bolts (14) from end-cap assem-bly (17).

(c) Remove end-cap assembly (17) from piston (34).

(d) Remove piston (34) from cylinder body as-sembly (41).

NOTE

Adjusting LVDT probe CCW decreases voltage.

One full turn of probe provides approximately

0.045 VRMS change in voltage reading.

(e) Adjust LVDT probe (24), using 3831102-101 LVDT assembly tool.

NOTE

Reset piston (34) is not a part of 1274M83PI5 ac-tuators.

(f) Install piston (34) cylinder body assembly

(41) ( Paragraph 6.2, Step n through Step o).

(g) Push piston (34) to fully retracted position.

(h) Install end-cap assembly (17) on rod end of piston (34) and onto cylinder body assembly (41). Secure with three bolts (14). Run-on torque shall be 9.5 inch-pounds minimum.

Finally torque the bolts to 140 - 160 inch-pounds over and above run-on torque.

NOTE

• These settings are preliminary measurements intended to permit final testing and to meet limits.

• Settings shall be as close as possible to nomi-nal.

(i) Perform above listed supsteps (2) through

(10) until voltage limits of above listed sub-steps (5) and (7) are met.

Figure 6-1. LVDT Preadjustment - Test Connections

6-4

l. Install end-cap and bearing assembly (15) and parts assembled in step j on body assembly (41).

(1) Install backup ring (21) and packing (22) on end-cap and bearing assembly (15).

(2) Carefully thread wires from end-cap and bearing assembly (15) through passages in body assembly (41).

(3) Install end cap and bearing assembly (15) in body while carefully sliding LVDT housing (25) over LVDT probe (24) and continuing to feed wiring into body assembly (41).

(4) Position end-cap and bearing assembly (15) so bolthole near end of uniball flange is at right side of flat portion of actuator body assembly (41) as shown in Figure 3-1.

(5) Secure end-cap and bearing assembly (Figure 3-1, Sheet 1, 15) to body assembly (41) with three bolts (14).

(6) Torque bolts to 40-50 inch-pounds.

Rod length adjustment should be set as close as possible to 8.280 or complications may occur dur-ing testing.

m. With piston fully retracted, adjust position of rod- end assembly (31) to obtain a dimension of 7.905- 8.655 inches between centers of bearings (16 and 32). Lock position by tightening nut (30). Torque nut (30) to 100-125 in-lbs. Safety-wire to washer (29) using MS20995NC32 safety wire.

NOTE

If inspection required removal of servovalve (7), preflow test (Chapter 7) shall be performed on ac-tuator.

n. Perform testing of actuator (without servovalve) in ac-cordance with Paragraph 7.2, steps a through g.

NOTE

If inspection required removal of servovalve (7) and electrical connector (4), these components shall be installed at this time.

o. Install servovalve (7) on cylinder body assembly (41) as follows:

(1) Install preformed packings (12, 13) in packing re-cesses of servovalve. (7).

(2) Thread wires carefully from servovalve (7) through wire passage in cylinder body assembly

(41) to opening for electrical connector (4).

(3) Remove slack in wires and carefully position ser-vovalve (7) on cylinder body assembly (41).

(4) Align four mounting holes of servovalve (7) with threaded holes in cylinder body assembly (41).

NOTE

Washers (11) are not a part of 9736M98P06 actua-tors.

(5) For 9736M98P05 actuators, secure servovalve (7) to cylinder body assembly (41) with four screws

(10) and four washers (11). Torque screws incre-mentally in an even crisscross pattern to 8-10, 12-14, and 15-18 inch-pounds.

(6) For 9736M98P06 actuators, secure servovalve (7) to cylinder body assembly (41) with four screws (10). Torque screws incrementally in an even crisscross pattern to 8-10,12-14, and 15- 18 inch-pounds.

p. Install electrical connector (4) as follows:

(1) Install preformed packing (6) on electrical con-nector (4).

(2) Ensure wires are available to electrical connector

(4) as follows:

(a) Four wires from servovalve (7) are white, green, yellow, and red.

6-5

(b) Four wires from linear variable displacement transducer (23) are blue, yellow, black, and red.

(3) Prepare wires as follows:

(a) Cut off used ends of wires.

(b) Strip ends of wires approximately 3/8-inch for solder joints.

(c) Tin wires, using solder, QQ-S-571, Sn 63.

Connect white-to-green and red-to-yellow servovalve wires, using butt splices, 321198, if necessary (Figure 1-2).

(4) Install heat shrink tubing, MIL-I-23053/5, over each wire (approximately one-half inch long).

Slide insulation tubing back away from stripped ends of electrical wires for connections to termi-nals on electrical connector (4).

(5) Mechanically connect and then solder each wire in sequence, making connections in accordance with color code (Figure 1-2), using solder, QQ- S-571, Sn 63.

(6) Slide heat shrink tubing over exposed solder joints and connector terminals, and apply heat to shrink the shrink tubing, MIL-I-23053/5, in place.

(7) Install electrical connector (Figure 3-1, Sheet 1, 4)88 to cylinder body assembly (41) with master keyway aligned (Figure 6-3). Secure with four screws (Figure 3-1, Sheet 1, 5). Torque screws to

8-10 IN LB.

(8) Install cap plug (50) on electrical connector (4).

q. Install inspection cover (1) as follows:

(1) Install preformed packing (3) in groove of inspec-tion cover (1).

(2) Place inspection cover (1) on body (46), and align holes in cover with threaded holes in cylinder body assembly (41).

(3) Secure inspection cover (1) to cylinder body as-sembly (41) with two screws (2). Torque screws to 8-10 IN LB.

r. If identification plate (47) is to be replaced, proceed as follows;

(1) Transfer all stamped information from old identi-fication plate (47) to replacement plate ( Para-graph 3.3 step y).

Figure 6-2. Locally Manufactured Cable - Test

6-6

Hysol epoxy, EA934NA, contains asbestos and is highly toxic to skin, eyes, and respiratory tract.

Skin and eye protection, and vapor control are re-quired. Avoid all contact.

(2) Identification plate (47) 3871016-101 has an ad-hesive backing. Epoxy adhesive, EA934NA, is not required.

• Hysol epoxy, EA934NA, contains asbestos and is highly toxic to skin, eyes, and respiratory tract. Skin and eye protection, and vapor con-trol are required. Avoid all contact.

• Do not mix more than one-half pound batch of epoxy. Mixed resin and catalyst generate heat;

large batches may overheat, damaging epoxy or causing a fire hazard.

(3) If identification plate (47) does not have adhesive backing, apply epoxy adhesive, EA934NA, as follows:

Trichlorotrifluoroethane, MIL-C-81302, is toxic to skin, eyes, and respiratory tract. Skin and eye pro-tection is required. Avoid repeated or prolonged contact. Use in a well-ventilated area.

(a) Clean…