16A1-5-10-3(2016).pdf

TO 16A1-5-10-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS WITH ILLUSTRATED PARTS BREAKDOWN

DEPOT MAINTENANCE

LINEAR ELECTRO MECHANICAL ACTUATOR

R15033-3

PREPARED BY AFSC COMMODITY TEAM

PLESSEY DYNAMICS CORPORATION

F33657-81-C-0210

THIS PUBLICATION SUPERSEDES TO 16A1-5-10-3, DATED 15 JANUARY 2005 THROUGH CHANGE 4, DATED 1 JUNE 2014.

THIS MANUAL WAS TRANSFERRED TO A NEW EDITING 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 au-thority 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 writ-ten approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to U.S. Government Agencies and their contractors, Administrative or Operational, 1 December 2016. Refer other requests for this document to 406 SCMS/GUEE, Tinker AFB, Oklahoma 73145-3029

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to se-vere criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

PUBLISHED UNDER THE AUTHORITY OF THE SECRETARY OF THE AIR FORCE

1 DECEMBER 2016

Dates of issue for original and changed pages are:

Original . . . . . . 0. . . . . . . .1 December 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 66, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - v vi Blank vii viii Blank 1-1 - 1-3 1-4 Blank 2-1 - 2-5 2-6 Blank

3-1 - 3-7 3-8 Blank 4-1 4-2 Blank 5-1 - 5-3 5-4 Blank 6-1 - 6-6 7-1 7-2 Blank 8-1 - 8-4

9-1 - 9-2 10-1 - 10-10 11-1 11-2 Blank A-1 A-2 Blank Index 1 - Index 3 Index 4 Blank

TO 16A1-5-10-3

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

LIST OF ILLUSTRATIONS . . . . . . . . . . . . iii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . iv

INTRODUCTION . . . . . . . . . . . . . . . . . . . v

SAFETY SUMMARY. . . . . . . . . . . . . . . . . vii

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

1.1 GENERAL. . . . . . . . . . . . . . . . 1-1

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

1.3 THEORY OF OPERATION . . . . 1-1

1.4 LEADING PARTICULARS . . . . 1-1

2 SUPPORT EQUIPMENT AND LIST OF

CONSUMABLES. . . . . . . . . . . . . . . . . 2-1

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

2.2 SUPPORT EQUIPMENT . . . . . . 2-1

2.3 CONSUMABLES . . . . . . . . . . . 2-1

2.4 LOCAL MANUFACTURED

ITEMS. . . . . . . . . . . . . . . . . 2-1

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

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

3.2 REMOVAL FROM SHIPPING

CONTAINER . . . . . . . . . . . . 3-1

3.3 PRELIMINARY INSPECTON. . . 3-1

3.4 EXTERNAL INSPECTION . . . . 3-1

3.5 INTERNAL INSPECTION . . . . . 3-1

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

3.7 ACTUATOR DISASSEMBLY. . . 3-1

3.8 DISASSEMBLY OF MOTOR

AND BRAKE ASSEMBLY. . . 3-2

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

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

4.2 PAINT REMOVAL . . . . . . . . . . 4-1

5 INSPECTION, REPAIR, AND

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

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

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

5.2.1 Item Unique Identification (IUID) 5-1

5.3 REPAIR PROCEDURES . . . . . . 5-1

5.4 MANUFACTURING

PROCEDURES. . . . . . . . . . . 5-1

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

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

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

6.2 ASSEMBLY OF MOTOR AND

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

6.3 ASSEMBLY OF ACTUATOR . . . 6-2

7 ACCESSORIES . . . . . . . . . . . . . . . . . . . . 7-1

8 TESTING . . . . . . . . . . . . . . . . . . . . . . . . 8-1

8.1 GENERAL. . . . . . . . . . . . . . . . 8-1

8.2 BENCH TEST SETUP . . . . . . . . 8-1

8.2.1 Actuator . . . . . . . . . . . . . . . . . . 8-1

8.2.2 Motor and Brake Assembly . . . . . 8-1

8.3 ANALYSIS . . . . . . . . . . . . . . . 8-1

8.4 TEST PROCEDURES . . . . . . . . 8-1

8.4.1 Actuator Tests . . . . . . . . . . . . . . 8-1

8.4.1.1 Dielectric Withstanding Voltage . . 8-1

8.4.1.2 Ground Insulation . . . . . . . . . . . 8-1

8.4.1.3 Insulation Resistance . . . . . . . . . 8-1

8.4.1.4 Bonding . . . . . . . . . . . . . . . . . . 8-1

8.4.1.5 Mechanical Stops . . . . . . . . . . . 8-2

8.4.1.6 Zero Load . . . . . . . . . . . . . . . . 8-2

8.4.1.7 Normal Operating Load . . . . . . . 8-2

8.4.1.8 Maximum Operating Load . . . . . 8-2

8.4.1.9 Clutch Slip . . . . . . . . . . . . . . . . 8-2

8.4.1.10 End Play . . . . . . . . . . . . . . . . . 8-2

8.4.1.11 Overtravel Control (Coast) . . . . . 8-2

8.4.2 Motor and Brake Assembly . . . . . 8-2

8.4.2.1 Dielectric Withstanding Voltage . . 8-2

8.4.2.2 End Play . . . . . . . . . . . . . . . . . 8-2

8.4.2.3 No Load . . . . . . . . . . . . . . . . . 8-2

8.4.2.4 Locked Rotor Torque . . . . . . . . . 8-2

8.4.2.5 Brake Pickup . . . . . . . . . . . . . . 8-3

8.4.2.6 Coast . . . . . . . . . . . . . . . . . . . . 8-3

8.4.2.7 Brake Torque . . . . . . . . . . . . . . 8-3

8.4.2.8 Full Load . . . . . . . . . . . . . . . . . 8-3

9 TABLE OF LIMITS . . . . . . . . . . . . . . . . . 9-1

9.1 INTRODUCTION . . . . . . . . . . . 9-1

9.2 TABLE OF LIMITS . . . . . . . . . 9-1

9.3 LUBRICATION POINTS . . . . . . 9-1

9.4 TORQUE LIMITS. . . . . . . . . . . 9-1

10 ILLUSTRATED PARTS BREAKDOWN . . . 10-1

SECTION I FOREWORD . . . . . . . . . . . 10-1

10.1 GENERAL. . . . . . . . . . . . . . . . 10-1

10.2 MODELS COVERED . . . . . . . . 10-1

TO 16A1-5-10-3

TABLE OF CONTENTS

Chapter Page Chapter Page i

10.3 FINDING PART NUMBERS, IL-

LUSTRATION,

DESCRIPTION. . . . . . . . . . . 10-1

10.3.1 Maintenance Parts List . . . . . . . . 10-1

10.3.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . 10-1

10.3.3 Part Number Column . . . . . . . . . 10-1

10.3.3.1 Commercial Hardware . . . . . . . . 10-1

10.3.3.2 Parts Not Illustrated . . . . . . . . . . 10-1

10.3.3.3 Marking . . . . . . . . . . . . . . . . . . 10-1

10.3.3.4 Government Furnished Equipment

(GFE) and Contractor Fur-nished Equipment (CFE) Cov-ered by Separate Manuals . . . . 10-1

10.3.4 CAGE Column . . . . . . . . . . . . . 10-2

10.3.5 Description Column . . . . . . . . . . 10-2

10.3.5.1 Indentation . . . . . . . . . . . . . . . . 10-2

10.3.5.2 Cross-Reference . . . . . . . . . . . . 10-2

10.3.6 Units per Assembly Column . . . . 10-2

10.3.7 Usable on Code Column. . . . . . . 10-2

10.3.8 Source, Maintenance, and

Recoverability (SMR) Code Column . . . . . . . . . . . . . . . . 10-2

10.3.9 Numerical Index . . . . . . . . . . . . 10-3

10.3.9.1 Part Number Column . . . . . . . . . 10-3

10.3.9.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . 10-3

10.3.10 Reference Designator Index. . . . . 10-3

10.3.10.1 Reference Designator Column . . . 10-3

10.3.10.2 Figure and Index Number

Column . . . . . . . . . . . . . . . . 10-3

10.4 SIMILAR ASSEMBLIES . . . . . . 10-3

10.5 QUICK CHANGE UNITS/RE-

PAIR PARTS KITS . . . . . . . . 10-3

10.6 SHEET NUMBER

EXPLANATION . . . . . . . . . . 10-3

10.7 USABLE ON CODES . . . . . . . . 10-3

10.8 SOURCE, MAINTENANCE,

AND RECOVERABILITY

(SMR) CODES . . . . . . . . . . . 10-4

10.9 NUCLEAR HARDNESS . . . . . . 10-4

10.10 ELECTROSTATIC DISCHARGE

SENSITIVE (ESDS) PARTS . . 10-4

10.11 PARTS STANDARDIZATION. . . 10-4

10.12 COMMERCIAL AND GOVERN-

MENT ENTITY (CAGE) . . . . 10-4

SECTION II MAINTENANCE PARTS

LIST . . . . . . . . . . . . . . . 10-5

11 DIFFERENCE DATA SHEETS . . . . . . . . . 11-1

A UNIQUE IDENTIFICATO (UID) SUPPORT-

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

A.1 IUID SUPPLEMENTAL

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

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

TO 16A1-5-10-3

TABLE OF CONTENTS - CONTINUED

Chapter Page Chapter Page ii

1-1 Linear Electro Mechanical Actuator . . . . 1-2 1-2 Actuator, Linear Electro Mechanical . . . 1-3 1-3 Actuator Block Diagram . . . . . . . . . . . 1-3 2-1 Support Equipment . . . . . . . . . . . . . . . 2-3 3-1 Actuator Assembly . . . . . . . . . . . . . . . 3-4 3-2 Motor and Brake Assembly . . . . . . . . . 3-6 5-1 Actuator Identification Plate . . . . . . . . . 5-3 5-2 Motor and Brake Assembly Identification

Plate . . . . . . . . . . . . . . . . . . . . . . . 5-3 6-1 Wiring Diagram . . . . . . . . . . . . . . . . . 6-4 6-2 Bearing Swaging Details . . . . . . . . . . . 6-5

6-3 Paint Masking Diagram . . . . . . . . . . . . 6-6 8-1 Typical Motor and Brake Assembly Test

Setup . . . . . . . . . . . . . . . . . . . . . . 8-3 8-2 Typical Motor and Brake Assembly Test

Setup . . . . . . . . . . . . . . . . . . . . . . 8-3 9-1 Actuator Limits . . . . . . . . . . . . . . . . . 9-2 9-2 Motor and Brake Assembly Limits . . . . 9-2 10-1 Actuator, Linear Electro Mechanical . . . 10-6 10-2 Motor and Brake Assembly . . . . . . . . . 10-9 A-1 IUID Identification Plate Location. . . . . A-1

TO 16A1-5-10-3

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page iii

1-1 Leading Particulars . . . . . . . . . . . . . . . 1-1 2-1 Support Equipment List . . . . . . . . . . . . 2-1 2-2 List of Consumables . . . . . . . . . . . . . . 2-2 3-1 External Inspection List . . . . . . . . . . . . 3-2 3-2 Internal Inspection List . . . . . . . . . . . . 3-3

5-1 Actuator Inspection. . . . . . . . . . . . . . . 5-1 8-1 Malfunction Isolation Guide . . . . . . . . . 8-4 9-1 Table of Limits . . . . . . . . . . . . . . . . . 9-1 A-1 Item Unique Identification (IUID) Re-quired Information . . . . . . . . . . . . . A-1

TO 16A1-5-10-3

LIST OF TABLES

Number Title Page Number Title Page iv

INTRODUCTION

1 PURPOSE AND SCOPE.

This manual contains overhaul instructions and an illustrated parts breakdown for the Linear Electro Mechanical Actuator, R15033-3, hereinafter referred to as the actuator, manufac-tured by Plessey Dynamics Corporation, Whippany, NJ. This manual provides the minimum data required for experienced maintenance specialists to overhaul the actuator. Methods and procedures described in this publication are not all-inclusive.

Overhaul personnel must apply standard shop practices and maintenance procedures while using these instructions. No detraction from overall efficiency, reliability and operation of the end item is allowed. Performance requirements and other specified values and limits shall be strictly adhered to.

2 ILLUSTRATED PARTS BREAKDOWN.

Introductory material for the illustrated parts breakdown for this manual can be found in Chapter 10.

3 LIST OF TECHNICAL MANUALS.

The following technical manuals are referenced in this manual.

List of Related Publications

Publication Number Publication Title

00-25-195 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and Equipments

00-25-234 General Shop Practice Requirements for the Repair, Maintenance, and Test of Electronic Equipment

1-1-689 Prevention and Control of Corrosion and Fungus in Communications, Electronic, Meteorological, and Avionic Equipment

1-1-691 Aircraft Weapons Systems Cleaning and Corrosion Control

List of Related Publications - Continued

Publication Number Publication Title

44H1-117 General Installation of Helicoil Inserts

4 LIST OF SPECIFICATIONS.

The following specifications are referenced in this manual:

ASTM-E1444 Magnetic Particle Examination

MIL-STD-6866 Inspection, Liquid Penetrant

MS33540 Safety Wiring and Cotter Pinning, General Practices for

5 ABBREVIATIONS/ACRONYMS.

For definitions of standard abbreviations and acronyms used throughout this manual refer to MIL-STD-12(). Non-standard abbreviations and acronyms used in this manual are defined below.

NI Numerical Index RDI Reference Designation Index

6 SYMBOLS.

The following is an explanation of symbols used if appli-cable. All symbols used in this manual are in accordance with symbols per ASME Y14.38M.

# Detail parts are listed in a separate manual

* Requisition this marking in accordance with the requirements of DoDI 5330.03_AFI33-

− Not illustrated = Alternate Part (AP) Attaching parts F Follows

7 IMPROVEMENT REPORTS.

Recommendations for improvements to this TO will be sub-mitted on AFTO Form 22, Technical Order Improvement Re-port and Reply, in accordance with TO 00-5-1. Completed forms will be forwarded to 406 SCMS/GUEE, Tinker AFB, Oklahoma 73145-3029.

v/(vi blank)

SAFETY SUMMARY

1 DEFINITIONS.

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

An operation or maintenance procedure, practice, condition, statement, etc, which, if not strictly ob-served, could result in injury, death, or long-term health hazards to personnel.

An operating or maintenance procedure, practice, statement, etc, which, if not strictly observed, could result in damage/destruction of equipment or loss of mission effectiveness.

2 GENERAL PRECAUTIONS.

The following are general safety precautions that are not re-lated to any specific procedure and therefore do not appear elsewhere in this publication. These are recommended pre-cautions that personnel shall understand and apply during many phases of operation and maintenance.

• GIVE CLEANERS/CHEMICALS SPECIAL CARE.

Keep in approved safety containers and in minimum quantities. Some cleaners/chemicals may have an af-fect on skin, eyes, and respiratory tract. Observe manufacturer’s WARNING labels and current safety directives. Use only in authorized areas. Discard soiled cleaning cloths into safety cans. Unless otherwise indi-cated in the text, use as described in this TO should not result in any immediate health concerns. Consult the local Bio-environmental Engineer for specific pro-tective equipment and ventilation requirements.

• USE SAFETY APPROVED EQUIPMENT. When cleaners and primers are being applied, approved ex-plosion-proof lights, blowers, and other equipment shall be used. Ensure that firefighting equipment is readily available and in working order.

• COMPRESSED AIR. Use of compressed air can cre-ate an environment of propelled foreign particles. Air pressure shall be reduced to less than 30 psi and used with effective chip guarding and personal protective equipment.

• PERSONAL PROTECTIVE EQUIPMENT (PPE).

Wear protective clothing/equipment (gloves, apron, eye protection, etc) approved for the materials and tools being used. Contact supervisor for guidance. If neces-sary, the Bio-environmental Engineer or the Base Safety office should be contacted for guidance.

• KEEP AWAY FROM LIVE CIRCUITS. Operating personnel must at all times observe safety regulations.

Do not replace components or make adjustments in-side the equipment with the voltage supply turned on.

Under certain conditions, dangerous potentials may exist when the power control is in the off position, due to charges retained by capacitors. To avoid injuries, always remove power from, discharge, and ground a circuit before touching it. Adhere to all lock out/tag out requirements.

vii/(viii blank)

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL.

This chapter provides general information that will enable maintenance personnel to understand the actuator and its re-lated systems.

1.2 DESCRIPTION.

The actuator consists of the following major elements: a mo-tor and brake assembly, gear train, ball clutch assembly, and an acme screw and nut assembly. The motor and brake as-sembly receives input electrical power and drives the acme screw and nut assembly through the gear train and ball clutch assembly. Refer to Figure 1-2. A stator assembly and a rotor assembly are the major components of the motor and brake assembly. The bearing-supported rotor assembly has a spring-operated brake mechanism mounted on its shaft. The gear train consists of two spur gears. The spur gears and the ball clutch assembly are supported on ball bearings inside the end housing assembly. The acme screw and nut assembly consists of a rotating acme nut and an acme screw that travels inside the acme nut as the acme nut rotates. A bearing attached to the acme screw transmits the actuator output to the load. A bearing in the end housing assembly anchors the other end of the actuator in the aircraft. Means for electrical grounding are provided by a lug terminal on the actuator. The actuator con-verts electrical energy into controlled linear motion. Refer to Figure 1-3 for a block diagram of the actuator.

1.3 THEORY OF OPERATION.

The actuator is used to position the flight crew ejection seat in the aircraft. When electrical power is applied to the actua-tor, the stator of the motor and brake assembly is energized.

The resulting flux field releases the brake to permit rotation of the motor and brake assembly. The output pinion of the motor and brake assembly drives the gear train to provide torque and motion to the acme screw and nut assembly. The direction of rotation of the motor and brake assembly depends on the phase sequence of the applied 3-phase electrical power. By switching two of the three phases, the direction of rotation can be reversed. This allows for operation of the ac-tuator in either the extend or retract direction. The acme nut of the acme screw and nut assembly is supported on ball and thrust bearings. It is free to rotate, but cannot move laterally.

An acme screw inside the acme nut is restrained from turn-ing by its attachment to the aircraft seat. As the acme nut ro-tates, the acme screw travels inside the acme nut to provide the output motion. Travel limits are determined by mechani-cal stops in the actuator. The ball clutch assembly, which is located between the gear train and the acme screw and nut assembly, slips to protect the motor and brake assembly against overload if a mechanical stop is impacted, or if the seat jams.

1.4 LEADING PARTICULARS.

Leading particulars for the actuator are provided in Table 1-1.

Table 1-1. Leading Particulars

Description Data

Operating voltage 208-248 VAC, 400 (±20) Hz, 3-phase

Operating temperature -65/+203°F

Altitude range Sea level to 70,000 feet

Normal operating load 515 pounds

Maximum operating load 2318 pounds

Ultimate static load 20,600 pounds compression at extend position;

10,300 pounds tension at any position

Speed at normal operating load 0.50-1.0 inch per second

Duty cycle 1 minute on, 5 minutes off

Full retracted length 7.768 (±0.015) inches between mounting centers

Mechanical stroke 4.88 (±0.120) inches

Weight 8.5 pounds

1-1

Figure 1-1. Linear Electro Mechanical Actuator

1-2

Figure 1-2. Actuator, Linear Electro Mechanical

Figure 1-3. Actuator Block Diagram

1-3/(1-4 blank)

CHAPTER 2

SUPPORT EQUIPMENT AND LIST OF CONSUMABLES

2.1 GENERAL.

This chapter lists the support equipment and consumables re-quired for testing and maintaining the actuator.

2.2 SUPPORT EQUIPMENT.

Table 2-1 lists support equipment with their part numbers and type designation required for assembling, testing, and main-taining the actuator. Common tools such as screwdrivers, pli-ers, and sidecutters are not listed. These items are authorized support equipment required to perform the prescribed main-tenance procedures. Use of authorized alternate parts is ap-proved unless the restriction “NO SUBSTITUTIONS AUTHORIZED” appears in the “PART NUMBER” column.

When “NO SUBSTITUTIONS AUTHORIZED” is specified, only the specified item shall be used. Refer to Table 2-1.

2.3 CONSUMABLES.

Table 2-2 provides a list of consumables for assembling, cleaning, and repairing the actuator. Consumable materials are expendable items and supplies consumed during compo-nent maintenance. All consumables not identified in the illus-trated parts breakdown (IPB) chapter are listed in the list of consumables, Table 2-2. Examples are sealants, lubricants, cleaning solvents, paints, etc. Use of authorized alternate parts is approved unless the restriction “NO SUBSTITU- TIONS AUTHORIZED” appears in the “PART NUMBER” column. When “NO SUBSTITUTIONS AUTHORIZED” is specified, only the specified item shall be used. Refer to Table 2-2. In the text of this manual, consumables will be ref-erenced by their index number.

2.4 LOCAL MANUFACTURED ITEMS.

There are no local manufactured items required.

Table 2-1. Support Equipment List

Part Number Nomenclature Type

Designation CAGE Application

AT1061-10 Coast Adapter - 81039 To measure coast of AC motor and brake assembly

AT2352 Fixture, End Play Check, and Split Bushing

81309 To check motor and brake assembly end play

AT2600 Hydraulic Load Test Fixture - 81309 To apply loads and measure limits, stroke, and end play of actuator

AT4817 Electrical Control Panel - 81309 To control application of power to actuator during test

AT5544M1 Electrical Test Panel - 81309 To control application of power to AC mo-tor and brake assembly during test

AT916 Motor Holding Fixture - 81309 To support AC motor and brake during test

DMC-621 Connector, Maintenance Re-pair Kit

- 11851 To repair connectors

T477W Bonding Meter - 01014 To check bonding resistance

1531A Stroboscope - 24655 To measure speed of AC motor and brake assembly

2465 Oscilloscope - 80009 Measure load speeds of motor and brake assembly

2-1

Table 2-1. Support Equipment List - Continued

Part Number Nomenclature Type

Designation CAGE Application

21359 Test Set, Insulation Resis-tance

- 07239 To measure insulation resistance

5328A Counter, Universal Electric - 28480 Measure AC motor and brake assembly coast

106-2.5W Tester, Dielectric Withstand-ing Voltage

- 05611 Dielectric test of actuator and AC motor and brake assembly

Table 2-2. List of Consumables

Index No. Nomenclature Part Number Specification CAGE

1 Adhesive Compound 40 - 05972

2 Compound, Anti-seize - MIL-T-5544 -

3 Compound, Cleaning - MIL-PRF-87937, Type II -

4 Compound, Cleaning - MIL-PRF-680, Type II or Type III -

5 Coating, Corrosive Resistance - MIL-C-5541 -

6 Grease - MIL-G-23827 -

7 Lacquer, Acrylic - MIL-PRF-81352 -

8 Lubricant Aero-lubriplate - 73219

9 Lubricant Molykote Powder, Type Z

- 90895

10 Oil, Lubricating - MIL-L-6035 -

11 Primer - MIL-P-85582, Type I, Class 2

12 Sealant - AMS-S-8802, CL B-1/2 81349

13 Sleeving, Insulation, No. 8 Vinylflex 4000 - 81851

14 Wire, Electrical M81381/12-24-N - 81349

15 Wire, Safety MS20995C20 - 96906

16 Wire, Safety MS20995C32 - 96906

17 Aluminum Foil - MIL-A-148 -

2-2

Figure 2-1. Support Equipment (Sheet 1 of 3)

2-3

Figure 2-1. Support Equipment (Sheet 2)

2-4

Figure 2-1. Support Equipment (Sheet 3)

2-5/(2-6 blank)

CHAPTER 3

DISASSEMBLY

3.1 GENERAL.

This chapter provides information on any special procedures that must be performed prior to inspection, repair or replace-ment of parts. The chapter covers removal from shipping con-tainer, preliminary inspection, and disassembly.

3.2 REMOVAL FROM SHIPPING CONTAINER.

No special unpacking procedures are required for this assem-bly other than retention of the shipping container and pack-ing material for reuse. The equipment is shipped and stored fully assembled. No loose components should be apparent.

Visually inspect the equipment for obvious damage. Docu-ment the obvious damage for future reference.

3.3 PRELIMINARY INSPECTON.

The preliminary inspection of this assembly is in two parts:

(1) prior to disassembly to determine exterior damage and (2) internal inspection to be performed after disassembly. The in-ternal inspection is designed to detect obvious damage to the interior of the equipment.

3.4 EXTERNAL INSPECTION.

The external inspection will be performed in accordance with Table 3-1 and Figure 3-1. The particular area of the assembly under inspection is identified in the “COMPONENT” col-umn. The “INSPECTO CRITERIA” are identified in the sec-ond column. “CORRECTIVE ACTION” directions are pro-vided in the third column. Refer to Paragraph 5.2.1 for Item Unique Identification (IUID) marking instructions.

3.5 INTERNAL INSPECTION.

The internal inspection will be performed in accordance with Table 3-2 and Figure 3-1 and Figure 3-2.

3.6 DISASSEMBLY.

The following paragraphs contain detailed procedures for dis-assembling the actuator assembly and its subassemblies. In-dex numbers are used throughout this chapter to identify in-dividual parts during disassembly procedures. The parts are illustrated with index numbers in Figure 3-1 and Figure 3-2.

3.7 ACTUATOR DISASSEMBLY.

Disassembly of the actuator (Figure 3-1) is provided as fol-lows:

NOTE

Measure and tag shim thickness at disassembly to aid in assembly.

a. Remove all safety wire.

b. If identification plate (1) is mutilated or illegible, re-move the identification plate.

c. Remove screws (2) and separate connector (4) from end housing assembly (12).

d. Using connector maintenance repair kit (Table 2-1), re-move contacts (3) from connector (4).

e. Remove connector (4).

f. Remove screws (5) and motor and brake assembly (6).

g. Remove screws (7) and access cover plate (8).

h. Remove screws (9) and lug terminal (10).

i. Remove screws (11) and end housing assembly (12).

j. If bearing (13) is damaged or worn, press the bearing out of end housing assembly (12).

k. If damaged, remove roller (14) and inserts (15, 16) from housing (17). Remove inserts in accordance with

TO 44H1-1-117.

l. Remove retaining ring (18).

m. Remove one ball bearing (22) from clutch assembly (20). Remove gear (19) from acme screw and nut as-sembly (41).

n. Remove second retaining ring (18).

o. Remove clutch assembly (20) and gear (23) from mounting plate (30).

p. Remove ball bearing (22) and shim (21) from clutch assembly (20).

q. Remove shim (25) and ball bearings (24) from gear (23).

r. Remove screw (26) and detach terminal (27) from mounting plate (30).

3-1

s. If terminal (27) is damaged, remove the terminal from the wire lead.

t. Remove retaining ring (28) from mounting plate (30).

u. Remove mounting plate (30) from bearing housing (48).

v. Remove ball bearing (29).

w. If damaged, remove inserts (31, 32) from mounting plate (30) in accordance with TO 44H1-1-117.

x. Turn the acme screw section of acme screw and nut as-sembly (41) by hand to extend end fitting assembly (34).

y. When pin (33) is accessible, remove and discard the pin.

z. Unscrew end fitting assembly (34) from acme screw and nut assembly (41).

aa. If bearing (35) is damaged or worn, remove the bear-ing from end fitting assembly (34).

ab. Remove shims (36) and guide collar (38).

ac. Remove screws (37) from guide collar (38) and un-screw guide collar.

ad. Remove seal (39) from guide collar (38).

ae. Remove shims (40).

af. Slide acme screw and nut assembly (41) out of bearing housing (48).

ag. Remove ball bearing (42) from bearing housing (48).

ah. Remove thrust washers (43), needle thrust bearings (44), thrust washers (45), and shims (46) from acme screw and nut assembly (41).

ai. If damaged, remove inserts (47) from bearing housing

(48) in accordance with TO 44H1-1-117.

3.8 DISASSEMBLY OF MOTOR AND BRAKE AS-

SEMBLY.

Disassembly of the motor and brake assembly is provided as follows:

NOTE

Measure and tag shim thickness at disassembly to aid in assembly.

a. If it is mutilated or illegible, remove identification plate (Figure 3-2, 1).

b. Remove screws (2), end housing (3), and shims (4).

c. If damaged, remove screws (5) from end housing (3).

d. Remove drive end housing assembly (6) from stator as-sembly (20).

e. Remove rotor assembly (7) from stator assembly (20).

f. Remove bearings (8, 9) from rotor assembly (7).

g. Remove guide assembly (10) from the shaft of rotor as-sembly (7).

h. Remove brake ring (11), brake flange assembly (12), brake disks (13), and disk assembly (14) from guide as-sembly (10).

i. Remove spring (15) from the shaft of rotor assembly (7). See Table 3-2.

j. If mutilated or illegible, remove wire identification sleeves (16, 17, 18, 19) from the wire leads of stator assembly (20).

Table 3-1. External Inspection List

Component Inspection Criteria Corrective Action

Contacts ( Figure 3-1, 3) Bent or broken Replace contacts

Connector (4) Obvious damage to threads, insulator, or case

Replace connector

End housing assembly (12) Cracks or fractures Replace end housing assembly

Bearings (13, 35) Corrosion or obvious wear or damage Replace bearings

Bearing housing (48) Cracks or fractures Replace bearing housing

End housing (Figure 3-2, 3) Cracks or fractures Replace end housing

Drive end housing (6) Cracks or fractures Replace drive end housing

3-2

Table 3-2. Internal Inspection List

Component Inspection Criteria Corrective Action

Ball bearings (Figure 3-1, 22, 24, 29, 42) Corrosion, binding, or rough operation Replace

Gears (19, 23) Cracked, chipped, or scored teeth Replace

Acme screw and nut assembly (41) Cracks or thread damage Replace

Brake components (Figure 3-2, 12, 13, 14) Glazing or scoring of brake surface Replace

Spring (15) Compression load (No. 9, Table 9-1) Replace

3-3

Figure 3-1. Actuator Assembly (Sheet 1 of 2)

3-4

Figure 3-1. Actuator Assembly (Sheet 2)

LEGEND

1. Identification Plate 25. Shim Set

2. Screw (4) 26. Screw

3. Contact (5) 27. Terminal

4. Connector 28. Retaining Ring

5. Screw (4) 29. Ball Bearing

6. Motor And Brake Assembly 30. Mounting Plate

7. Screw (2) 31. Insert (3)

8. Access Cover Plate 32. Insert (4)

9. Screw (4) 33. Pin

10. Lug Terminal 34. End Fitting Assembly

11. Screw (2) 35. Bearing

12. End Housing Assembly 36. Shim Set

13. Bearing 37. Screw (2)

14. Roller 38. Guide Collar

15. Insert (4) 39. Seal

16. Insert (4) 40. Shim Set

17. Housing 41. Acme Screw And Nut Assembly

18. Retaining Ring (2) 42. Ball Bearing

19. Gear 43. Thrust Washer (2)

20. Clutch Assembly 44. Needle Thrust Bearing (2)

21. Shim Set 45. Thrust Washer (2)

22. Ball Bearing (2) 46. Shim Set

23. Gear 47. Insert (2)

24. Ball Bearing (2) 48. Bearing Housing

3-5

Figure 3-2. Motor and Brake Assembly (Sheet 1 of 2)

3-6

Figure 3-2. Motor and Brake Assembly (Sheet 2)

LEGEND

1. Identification Plate 11. Brake Ring

2. Screw (4) 12. Brake Flange Assembly

3. End Housing 13. Brake Disk (2)

4. Shim Set 14. Disk Assembly

5. Screw (2) 15. Spring

6. Drive End Housing Assembly 16. Wire Identification Sleeve

7. Rotor Assembly 17. Wire Identification Sleeve

8. Ball Bearing 18. Wire Identification Sleeve

9. Ball Bearing 19. Wire Identification Sleeve

10. Guide Assembly 20. Stator Assembly

3-7/(3-8 blank)

CHAPTER 4

CLEANING

4.1 GENERAL.

Instructions for cleaning detail parts of the actuator and its subassemblies are discussed in the following paragraphs. The following cleaning methods are approved for use on metal parts:

Cleaning solvent MIL-PRF-680 is flammable and toxic to eyes, skin, and respiratory tract. Skin/eye protection required. Avoid repeated/prolonged con-tact. Use only in a well ventilated area. Wear an air purifying respirator with organic vapor cartridges.

Keep away from open flames or other sources of ignition.

Do not use cleaning compounds of any kind to clean electrical or plastic parts. Do not allow clean-ing compound to come in contact with sealed ball bearings. Do not dip or immerse bearings in clean-ing compound.

a. Ultrasonic cleaning tank using aqueous cleaner (No. 3, Table 2-2). Refer to manufacturer’s instructions for proper cleaning methods.

b. Use cleaning solvent (No. 4, Table 2-2). (Alternate cleaning compound MIL-PRF-29602A, Type I). Use a stiff bristle brush to loosen dirt or other foreign matter as necessary. Blow loosened particles from the parts with dry, filtered, compressed air at 15 psi maximum.

Wipe the parts with a clean, dry lint-free cloth. Use of acetone or alcohol to perform minor cleaning is also authorized.

c. Clean electrical (TO 00-25-234) and nonmetallic parts with a stiff fiber-bristled cleaning brush. Blow loose foreign particles from the parts using dry, filtered, shop air.

d. Dry all parts after cleaning with dry, filtered, shop air.

Apply a thin coat of oil (No. 10, Table 2-2) to steel parts. Wipe off excess oil.

4.2 PAINT REMOVAL.

Remove paint from painted parts that require inspection in accordance with TO 1-1-689.

4-1/(4-2 blank)

CHAPTER 5

INSPECTION, REPAIR, AND REPLACEMENT

5.1 GENERAL.

The following paragraphs contain procedures for the inspec-tion, repair, and replacement operations necessary to restore the actuator to satisfactory condition.Preliminary inspection and disassembly instructions are provided in Chapter 3.

Chapter 8 provides testing and troubleshooting instructions for the equipment and may refer to Chapter 9, Table of Lim-its. The assembly of the equipment and its component parts is presented in Chapter 6.

5.2 INSPECTION.

Table 5-1 contains information necessary to inspect the ac-tuator. The “COMPONENT” column contains a list of actua-tor components to be inspected. The “INSPECT FOR” col-umn contains a list of defects to inspect for on the associated component. The “REMEDY” column contains information on whether the component must be replaced or may be re-paired.After taking the corrective action given in Table 5-1, the equipment must be tested using the procedures in Chap-ter 8. Results of that testing, will determine whether addi-tional repairs are required. In addition to the specific inspec-tion criteria noted in Table 5-1, all component parts should be visually inspected for cracks, wear, corrosion, damage, or any other condition that would render the part unsuitable for use.

5.2.1 Item Unique Identification (IUID). Visually inspect

the identification plate/label/ item for the Unique Item Iden-tifier(UII) marking. If present, visually inspect for damage to the symbol. Ensure readability by using hand-held electronic reader, if symbol is not present or damaged mark/restore.

REF. Drawing 200945069, Appendix A, Table A-1 of this TO for identification of parts to be marked, TO 00-25-260, and

MIL-STD-130.

5.3 REPAIR PROCEDURES.

Repair procedures are provided as follows:

a. Minor scratches or abrasions through the anodized fin-ish on aluminum parts shall be repaired by brush ap-plication of corrosion resistant compound (No. 5, Table 2-2).

b. Damaged inserts shall be replaced in accordance with

TO 44H1-1-117.

c. Remove and discard roller (Figure 3-1, 14) if it is dam-aged. Press in a replacement roller. The roller shall ex-tend 0.09 (±0.01) inch above the adjacent surface of housing (17).

5.4 MANUFACTURING PROCEDURES.

To manufacture identification plates, proceed as follows:

a. Fabricate the identification plates per Figure 5-1 and Figure 5-2 using 0.003 inch thick, reverse etched alu-minum (No. 17, Table 2-2).

b. All lettering to be aluminum.

5.5 REPLACEMENT.

Replace all parts that do not meet inspection criteria and can-not be repaired in accordance with the repair procedures. Af-ter all known defects have been repaired, the equipment must be tested in accordance with Chapter 8.

Table 5-1. Actuator Inspection

Component Inspect For Remedy

Identification Plate (Figure 3-1, 1)

Illegibility or damage Replace identification plate

Contacts (3) Bending or breaks Replace contacts

Connector (4) Cracked insulation or case; damaged threads

Replace connector

Access Cover Plate (8) Cracks or fractures Replace access cover plate

Bearings (13, 35) Oxidation, binding, rough operation, obvious wear

Replace bearing

Inserts (15, 16, 31, 32, 47) Thread damage Replace insert

5-1

Table 5-1. Actuator Inspection - Continued

Component Inspect For Remedy

Housing (17) Cracks using magnetic particle inspection, ASTM-E1444

Replace housing

Gear (19) Chipped or scored teeth; cracks using magnetic particle inspection, ASTM- E1444

Replace gear

Ball Bearings (22, 24, 29, 42) Oxidation, binding, or rough operation Replace ball bearing

Gear (23) Cracked, chipped, or scored teeth Replace gear

Mounting Plate (30) Cracks or fractures Replace mounting plate

Shims (36, 40, 46) Burrs, creases, or deformation Replace shim

Guide Collar (38) Cracks, fractures, or thread damage Replace guide collar

Acme Screw and Nut Assembly (41)

Cracks, fractures, or scoring or gouging of threads or splines

Replace acme screw and nut assembly

Needle Thrust Bearings (44) Oxidation, binding, or rough operation Replace needle thrust bearing

Bearing Housing (48) Cracks, fractures, or thread damage Replace bearing housing

Identification Plate (Figure 3-2, 1)

Illegibility or damage Replace identification plate

End Housing (3) Cracks using penetrate inspection, MIL- STD 6866, Type I, Class 2B

Replace end housing

Shims (4) Burrs, creases, or deformation Relace shim

Drive End Housing Assembly (6) Cracks, fractures, or thread damage Replace drive end housing assembly

Rotor Assembly (7) Cracked or chipped spline Replace rotor assembly

Ball Bearings (8) Oxidation, binding, or rough operation Replace ball bearing

Guide Assembly (10) Cracks, fractures, or damaged spline Replace guide assembly

Brake Ring (11) Cracks, fractures, or damaged threads Replace brake ring

Brake Flange Assembly (12) Cracks, fractures, or damaged threads;

scored, glazed, or visibly worn brake sur-face

Replace brake flange assembly

Brake Disk (13) Scored, glazed, or visibly worn brake sur-faces

Replace brake disk

Disk Assembly (14) Cracks or fractures; scored, glazed, or visibly worn brake surface

Replace disk assembly

Spring (15) Cracks and compression load (No. 9, Table 9-1)

Replace spring

Stator Assembly (20) Cracked or fractured case; winding resis-tance other than 11.2 (±0.56) ohms

Replace stator assembly

Unique Identification Plate/ Label

Missing, damaged or illegible Unique Item Identifier (UII)

Replace Identification Plate, Refer to Paragraph 5.2.1 for Item Unique Identi-fication (IUID) marking.

5-2

Figure 5-1. Actuator Identification Plate

Figure 5-2. Motor and Brake Assembly Identification Plate

5-3/(5-4 blank)

CHAPTER 6

ASSEMBLY

6.1 GENERAL.

The following paragraphs contain complete assembly proce-dures following disassembly and repair.

6.2 ASSEMBLY OF MOTOR AND BRAKE ASSEM-

BLY.

Assemble and test the motor and brake assembly before be-ginning assembly of the acutator. Assembly of the motor and brake assembly is provided as follows:

a. Lightly lubricate outer race of ball bearings (Figure 3-2, 8, 9) with grease (No. 6, Table 2-2).

b. Install ball bearing (8) onto rotor assembly (7).

c. Install rotor assembly (7) in drive end housing assem-bly (6). Ensure that ball bearing (8) seats properly.

d. Pass the wire leads of stator assembly (20) through the leadwire hole in drive end housing assembly (6), and press the drive end housing assembly onto the stator assembly.

e. Install ball bearing (9) on rotor assembly (7).

f. Install end housing (3) on stator assembly (20) over ro-tor assembly (7).

g. Align the screw holes in end housing (3) and drive end housing (6), and install screws (2).

h. Using end play check and split bushing fixture (Table 2-1), measure the end play of rotor assembly (7) with a 5-pound reversing load applied. Note the mea-sured end play (No. 7, Table 9-1).

i. Subtract 0.003 inch from the measured end play re-corded in Step h. This is the required thickness of shims (4).

j. Remove screws (2) and end housing (3).

k. Install shims (4) having the thickness calculated in Step i in the bearing bore of end housing (3).

l. Remove ball bearing (9) from rotor assembly (7), and install the ball bearing over shims (4) in the bearing bore in end housing (3).

m. Install spring (15) on rotor assembly (7).

n. Place guide assembly (10) on a clean flat surface, with the open end up.

o. Insert one brake disk (13), disk assembly (14), a sec-ond brake disk (13), into guide assembly (10).

p. Apply anti-seize compound (No. 2, Table 2-2) to the threads of brake ring (11) and install on brake flange assembly (12). Install in guide assembly (10).

NOTE

Brake ring (11) and brake flange assembly (12) must be removed from guide assembly (10) to make adjustment.

q. Adjust brake ring (11) so that it is underflush with the grooved surface (below outer ring) of guide assembly

(10) by a value equal to the brake air gap listed in the Table of Limits (No. 8, Table 9-1).

r. Align the teeth of all parts installed in guide assembly (10), and install the guide assembly on rotor assembly (7).

s. Install end housing (3) on rotor assembly (7), pressing the end housing down firmly to seat ball bearing (9).

t. Align the screw holes in end housing (3) and drive end housing assembly (6).

u. Coat the threads of screws (2) with antiseize compound (No. 2, Table 2-2) and install the screws.

v. Coat the threads of screws (5) with anti-seize com-pound (No. 2, Table 2-2) and install the screws in end housing (3). Torque the screws 2.0 in-lb to remove all end play of guide assembly (10).

w. Install wire identification sleeves (16, 17, 18, 19) on the wire leads of stator assembly (20) as shown in Fig-ure 6-1. Shrink the wire identification sleeves.

x. Test the motor and brake assembly. (Refer to Chap-ter 8.)

y. After satisfactory testing, safety wire all drilled head screws using safety wire (No. 15, Table 2-2).

6-1

6.3 ASSEMBLY OF ACTUATOR.

Assembly of the actuator is provided as follows:

a. Coat the outer surface area of bearing (Figure 3-1, 35) with primer (No. 11, Table 2-2), and press the bearing into end fitting assembly (34) flush to 0.010 inch un-derflush while the primer is wet.

b. Swage the lip of the race on bearing (35) over the chamfer of end fitting assembly (34) as shown in Fig-ure 6-2. After swaging, the bearing inner race shall ro-tate relative to the outer race with a 20 in-lb applied load.

c. Coat the outer surface area of bearing (Figure 3-1, 13) with primer (No. 11, Table 2-2), and press the bearing into end housing (17) flush to 0.010 inch underflush while the primer is wet.

d. Swage the lip of the race on bearing (13) over the chamfer of end housing (17) as shown in Figure 6-2.

After swaging, the inner race of the bearing shall rotate relative to the outer race with a 20 in-lb applied load.

e. Install the ball bearing (Figure 3-1, 29) in the bearing bore of mounting plate (30).

f. Install retaining ring (28).

g. Coat the cavity between the two sections of acme screw and nut assembly (41) with lubricants (No. 8, 9, Table 2-2) mixed half and half by volume, and screw two sections together.

h. Lubricate needle thrust bearings (44) with grease (No.

6, Table 2-2).

i. Install one thrust washer (45) on each side of the flange on acme screw and nut assembly (41). The chamfer of the thrust washers shall face toward the flange.

j. Install one needle thrust bearing (44) and one thrust washer (43) next to each thrust washer (45).

k. Install shims (46) in bearing housing (48).

l. Insert acme screw and nut assembly (41) into bearing housing (48).

m. Lightly lubricate ball outer race of ball bearing (42) with grease (No. 6, Table 2-2), and install the ball bear-ing in bearing housing (48) over the end of acme screw and nut assembly (41).

n. Insert the other end of acme screw and nut assembly

(41) into ball bearing (29) in mounting plate (30).

o. Press mounting plate (30) and bearing housing (48) to-gether firmly, and check acme screw and nut assembly

(41) for end play. Adjust shims (46) to take up acme screw and nut assembly end play until within limits (No. 1, Table 9-1) without pre-loading needle thrust bearings (44).

p. Cut a 3-1/2 inch length of wire (No. 14, Table 2-2), and strip the insulation from the ends of the wire.

q. Using connector maintenance repair kit (Table 2-1), crimp terminal (27) onto one end of the wire.

r. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screw (26), and attach terminal (27) to mounting plate (30) with screw (26). Torque screw 5.5-

7.5 in-lb.

s. Lightly lubricate outer race of ball bearings (24, 22) with grease (No. 6, Table 2-2).

t. Install ball bearing (24) on short shaft of gear (23).

u. Install ball bearing (22) and shims (21) on short shaft of clutch assembly (20) (No. 6, Table 9-1).

v. Install gear (23) and clutch assembly (20) on mounting plate (30).

w. Install retaining rings (18) and gear (19) on acme screw and nut assembly (41).

x. Lubricate the entire gear train with grease (No. 6, Table 2-2).

y. Install ball bearing (22) onto clutch assembly (20) and ball bearing (24) and shim (25) onto gear (23).

z. Fill the motor and brake assembly pinion cavity in end housing assembly (12) with grease (No. 6, Table 2-2).

aa. Install end housing assembly (12) over the gear train, and seat the end housing assembly against mounting plate (30).

ab. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screws (9). Attach lug terminal (10) under one of the screws and torque all screws 52 - 64 in-lb.

ac. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screws (11) and install the screws. Torque screws 5.5-7.5 in-lb.

ad. Cut a 1-1/2 inch length of sleeving (No. 13, Table 2-2) and install the sleeving over the wire leads of motor and brake assembly (6).

ae. Pass the wire leads of motor and brake assembly (6) through the opening in mounting plate (30).

af. Pass the wire leads of motor and brake assembly (6) and the ground lead attached to terminal (27) through the connector opening in end housing assembly (12).

6-2

ag. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screws (5), and install motor and brake as-sembly (6) on mounting plate (30). Torque screws 16-20 in-lb.

ah. Install seal (39) in guide collar (38).

ai. Install shims (40) and guide collar (38) over the end of acme screw and nut assembly (41). Adjust shims (40) to align the mounting holes in the guide collar (38) and bearing housing (48).

aj. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screws (37) and install the screws. Torque screws 25 in-lb.

ak. Install shims (36) and end fitting assembly (34) at the end of acme screw and nut assembly (41). Torque fit-ting assembly 279-330 in-lb.

al. Using electrical control panel (Table 2-1), apply 230 volts (line to neutral), 400 Hz, to the wire leads. Use phase sequence ACB at the T1, T2, and T3 wire leads, and connect AC neutral to the TO wire lead. Remove the power when the actuator reaches its fully retracted position.

am. Measure the actuator mechanical retract dimension. It shall be within limits (No. 3, Table 9-1). Adjust shims

(36) to adjust the mechanical retract dimension.

an. Using connector maintenance repair kit (Table 2-1), crimp contacts (3) onto the wire leads.

ao. Using connector maintenance repair kit (Table 2-1), in-sert contacts (3) into connector (4) per Figure 6-1.

ap. Apply anti-seize compound (No. 2, 2, Table 2-2) to the threads of screws (Figure 3-13, 5) and install connector

(4) on end housing assembly (12) using the screws. The polarizing key of the connector shall face toward mo-tor and brake assembly (6). Torque the screws 5.5-7.5 in-lb.

aq. Apply anti-seize compound (No. 2, Table 2-2) to the threads of screws (7) and install access cover plate (8) on end housing assembly (12) using the screws. The schematic diagram shall be on the underside of the ac-cess cover plate. Torque the screws 2.0-2.5 in-lb.

ar. Test the actuator. (Refer to Chapter 8.)

as. After testing has been completed, mark the position of end fitting assembly (34), and then remove the fitting assembly.

at. Coat the threads of end fitting assembly (34) with ad-hesive (No. 1, Table 2-2) and reinstall the end fitting assembly (34) to the position marked in Step as. If nec-essary, carefully file or grind ends of swaged pin to pre-vent interference with ID of seal (39) or guide collar (38).

au. Insert pin (33) into the slot in acme screw and nut as-sembly (41) and through the hole in end fitting assem-bly (34). Swage over the smaller diameter end of the pin.

av. If required, transfer all information from identification plate (1) to a replacement identification plate and install the identification plate on bearing housing (48).

aw. Safety wire screws (7), using safety wire (No. 16, Table 2-2) per MS33540.

ax. Clean all exterior surfaces of the actuator thoroughly of all grease, dirt, and other foreign matter as per Chap-ter 4.

ay. Seal all seams and the base of all screw heads as fol-lows:

(1) Apply a smooth, uniform bead of sealant (No. 12, Table 2-2) to all seams and the base of all screw heads. The sealant shall extend onto surrounding surfaces.

(2) Allow sealant to cure fully before applying paint.

az. Mask the crosshatched areas in Figure 6-3 with mask-ing tape.

Lacquer is flammable and toxic. Avoid eye and skin contact. Avoid breathing of vapors. Wear pro-tective goggles, rubber gloves, and a respirator.

Could result in personnel injury.

ba. Apply one coat of primer (No. 11, Table 2-2), followed by two coats of laquer (No. 7, Table 2-2) medium grey color 36231 per FED-STD-595. Reference TO 1-1-8.

6-3

Figure 6-1. Wiring Diagram

6-4

Figure 6-2. Bearing Swaging Details

6-5

Figure 6-3. Paint Masking Diagram

6-6

CHAPTER 7

ACCESSORIES

Not Applicable

7-1/(7-2 blank)

CHAPTER 8

TESTING

8.1 GENERAL.

This chapter includes instructions for testing the actuator and the motor and brake assembly after assembly. The motor and brake assembly shall be tested before it is installed in the ac-tuator.

8.2 BENCH TEST SETUP.

8.2.1 Actuator. The actuator shall be tested for proper per-

formance. The following paragraph provides instructions for the actuator test setup. A typical test setup is illustrated in Figure 8-1. Use the following test setup instructions for test-ing of the actuator:

a. Use dielectric withstanding voltage tester (Table 2-1) to perform a dielectric test of the actuator.

b. Use test set, insulation resistance (Table 2-1) to mea-sure insulation resistance.

c. Use electrical control panel (Table 2-1) to operate the actuator and to measure input current.

NOTE

Unless otherwise specified, use 208 VAC, 420 Hz, 3-phase for all functional tests.

d. Use hydraulic load test fixture (Table 2-1) to apply loads and measure limits, stroke, and end play.

e. Use bonding meter (Table 2-1) to check bonding resis-tance.

8.2.2…