9P12-6-3.pdf

TO 9P12-6-3

TECHNICAL MANUAL

OVERHAUL INSTRUCTIONS

WITH

ILLUSTRATED PARTS BREAKDOWN

RAM AIR TURBOPUMP

CEI NO. MA0001A

DETAIL SPEC NO. 41581

PN 953004-5-1

NSN 1650-00-450-4819

AiResearch

AF33(657)-15053

F09603-01-D-0207

This manual supersedes Special Handling AFTO Form 252, (51M00WRCOM6B28SH), dated 12/09/2016.

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 (Administrative or Operational Use) (1 February 2004). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098.

Questions concerning technical content shall be referred to 409 SCMS/GUMAB.

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, as amended, Title 50, U.S.C., App. 2401, et seq. 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

21 JANUARY 2012 CHANGE 2 - 20 NOVEMBER 2016

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . . .21 January 2012 Change . . . . . . . . 1 . . . . . . . 13 July 2014

Change . . . . . . . . 2 . . . 20 November 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 52, CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i - iii iv Blank v - vii viii Blank ix x Blank 1-1 - 1-2 2-1 - 2-17 2-18 Blank 3-1 3-2 3-3 3-4 Blank 4-1 - 4-9 4-10 Blank 4-11 - 4-12 4-13 - 4-14 5-1 5-2 Blank

TO 9P12-6-3

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 Change 2 USAF

TABLE OF CONTENTS

Chapter Page

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

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ix

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

1.1 LEADING PARTICULARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 CLEANING SOLVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 OVERHAUL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.1 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 SPECIAL TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.3 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

2.4 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.5 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

2.6 REPAIR OR REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.7 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2.8 REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

3 TEST PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 HYDRAULIC FLUID CLEANLINESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 PROOF PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.1 High-Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.2 Low-Pressure Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2.3 Sea Level Performance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.3 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

4 ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SECTION I FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 MODELS COVERED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 FINDING PART NUMBERS, ILLUSTRATION, DESCRIPTION . . . . . . . . . . . . . . . . . . . . 4-1

4.4 SIMILAR ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.5 SHEET NUMBER EXPLANATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.6 USABLE ON CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.7 SOURCE, MAINTENANCE, AND RECOVERABILITY (SMR) CODES . . . . . . . . . . . . . . 4-1

4.8 PARTS STANDARDIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.9 MANUFACTURER’S LIST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10 MAINTENANCE PARTS LIST (MPL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.1 Figure and Index Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.2 Part Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.2.1 Commercial Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.2.2 Parts Not Illustrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.2.3 Markings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 i

Chapter Page

4.10.2.4 Government Furnished Equipment (GFE) and Contractor Furnished Equipment (CFE) Covered by Separate Manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.2.5 Alternate Part . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.3 CAGE Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.4 Description Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.10.4.1 Indentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.10.5 Units Per Assembly Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.10.6 Usable on Code Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.10.7 Source, Maintenance, and Recoverability (SMR) Code Column. . . . . . . . . . . . . . . . . . . . . . 4-3

4.11 NUMERICAL INDEX (NI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.11.1 Part Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.11.2 Figure and Index Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.12 REFERENCE DESIGNATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.12.1 Reference Designator Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.12.2 Figure and Index Number Column . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

SECTION II MAINTENANCE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

5 DIFFERENCE DATA SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.1 DIFFERENCE DATA SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

TO 9P12-6-3

TABLE OF CONTENTS - CONTINUED

ii

LIST OF ILLUSTRATIONS

Number PageTitle

2-1 Fits and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-2 Pin Dimensional Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-3 Blade Assembly Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 2-4 Balancing Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 2-5 Sealing Compound Dimensional Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 2-6 Turbopump Governor Performance Graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 4-1 Ram Air Turbopump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4-2 Governor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

LIST OF TABLES

Number PageTitle

1-1 Leading Particulars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-2 Approved Cleaning Solvents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2-1 Special Tools List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2-2 Test Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2-3 Nondestructive Inspection Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 3-1 Hydraulic Fluid Cleanliness Level Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 Troubleshooting Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 iii/(iv blank)

FOREWORD

1 PURPOSE.

This publication contains overhaul instructions with illustrated parts breakdown for the Ram Air Turbopump, PN 953004- 5-1, manufactured by AiResearch Manufacturing Company, Division of The Garrett Corporation, Los Angeles, CA. (See Figure 1.)

2 SCOPE.

Chapter 2 and Chapter 3 of this publication contain overhaul and test instructions for Ram Air Turbopump, PN 953004-5-1.

Overhaul and test instructions for additional turbopumps will be provided in Chapter 5 by the use of Difference Data Sheets.

The additional turbopumps included in Chapter 5 are listed therein. Chapter 4 contains the Illustrated Parts Breakdown for all turbopumps included in this publication. Overhaul and test procedures for turbopumps included in Chapter 5 are the same as procedures given in Chapter 2 and Chapter 3, except for specific differences listed in the applicable Difference Data Sheet.

3 SYMBOLS.

- A dash (-) before an index number denotes a part which is not illustrated.

* An asterisk (*) flush right of the part number denotes a marking that is to be requisitioned in accordance with DODI 5330.03_AFI 33- 395.

# A number sign (#) flush right of a part number indicates that detail parts are listed in a sepa-rate manual.

= Alternate Part F The letter “F” before the figure number means

“follows” and is used when an assembly or part has not been assigned an index number, and the figure and index number of the pre-ceding part has been used.

4 ABBREVIATIONS.

All abbreviations used in this manual are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents.

Figure 1. Ram Air Turbopump, PN 953004-5-1 v

AF Air Force AFTO Air Force Technical Order AP Attaching Parts AR As Required ASSY Assembly CAGE Commercial and Government Entity CFE Contractor Furnished Equipment DoD Department of Defense GFE Government Furnished Equipment I&S Interchangeability and Substitution IPB Illustrated Parts Breakdown MPL Maintenance Parts List NHA Next Higher Assembly NI Numerical Index PN Part Number RDI Reference Designator Index REF Reference SMR Source, Maintenance, and Recoverability UOC Usable on Code

5 RELATED PUBLICATIONS.

The following publications contain information in support of this technical manual.

List of Related Publications

Number Title ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents DODI 5330.03_AFI 33-395 Document Automation and Production Service (DAPS) TO 00-5-1-WA-1 Air Force Technical Order System TO 00-25-195-WA-1 Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and

Equipment TO 00-25-234-WA-1 General Shop Practice Requirements for the Repair, Maintenance, and Test of Electri-cal Equipment

6 RECORD OF APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS (TCTOS).

List of Time Compliance Technical Orders

TCTO

Number

TCTO

Title

TCTO

Date

None

7 HARDNESS CRITICAL ITEMS (HCI).

If included, items with nuclear survivability requirements are marked with the HCI symbol ( ) and a CAUTION immediately preceding the item’s description. The HCI symbol ( ) and CAUTION establish special requirements limit-ing changes and substitutions and that the specific parts listed must be used to ensure hardness is not degraded. All changes to, or proposed substitutions of, HCIs must be approved by the acquiring activity.

8 ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) ITEMS.

If included, items containing ESDS parts are marked with the ESDS symbol ( ) and a CAUTION. Items so marked shall be handled in accordance with the ESDS device handling procedures in TO 00-25-234-WA-1.

vi

9 CHANGE RECOMMENDATIONS.

Recommendations proposing changes to this technical order shall be submitted on an AFTO Form 22 in accordance with TO 00-5-1-WA-1. Forward completed AFTO Form 22 to the Technical Order Management Agency (TOMA) at:

robins.ce.afto22@robins.af.mil.

vii/(viii blank)

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and/or 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 specific task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and under-stood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, condi-tions, or statements which are considered essential to protection of personnel (WARNING) or equipment (CAUTION).

WARNINGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, CAUTION, or icon), a statement of the hazard, minimum precautions, and possible results if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are not essential 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 injury 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.

ix/(x blank)

CHAPTER 1

GENERAL INFORMATION

1.1 LEADING PARTICULARS.

The turbopump is a component of the emergency hydraulic actuation system. The turbopump, when pivoted into the airstream, supplies auxiliary emergency hydraulic power to the flight control subsystem and to the hydraulic motor-driven emergency generator. Refer to Table 1-1 for leading particulars.

Table 1-1. Leading Particulars

Item Characteristics Actuating Power Ram air Direction of Rotation Clockwise Control System Automatic Controlling Device Variable pitch turbine blades Rated Airspeed 165 to 172 knots tas Turbine Speed (Rated) 5,640 to 6,360 rpm Angle of Attack 0° (±15) Pump Inlet Temperature 70° to 120 °F (21.1° to 48.9 °C) Pump Inlet Pressure (Rated) +30 to +32 psig Pump Outlet Pressure (Rated) 2,935 to 3,135 psig Flow Rate (Rated) 34.5 gpm (min) Hydraulic Pump Fluid Military Specification MIL-H-5606 Weight 42.7 lb. (approx.)

1.2 CLEANING SOLVENTS.

Keep solvent cleaners/chemicals in approved safety containers and in minimum quantities. Some solvent cleaners/ chemicals may have an adverse effect on skin, eyes and respiratory tract. Observe manufacturer’s WARNING labels and current safety directives. Use solvent cleaners/chemicals only in authorized areas. Good general venti-lation is required. Discard soiled clothes into safety cans. Unless otherwise indicated in the text, application as described in this TO should not result in any immediate health concerns. When solvent cleaners are being applied, approved explosion-proof lights, blowers and other equipment shall be used. Ensure firefighting equipment and emergency eye wash are readily available and in working order.

Table 1-2 contains approved solvents recommended for cleaning within the categories specified.

Table 1-2. Approved Cleaning Solvents

Cleaning Process Approved Solvents Prior to Painting Isopropyl Alcohol (TT-I-735)

Methyl Isobutyl Ketone (TT-M-268) Turco 6646 (Commercial)

Prior to Sealing Aliphatic Naphtha (TT-N-95) Dry Cleaning Fluid (MIL-PRF-680) DS-108 (Commercial)

1-1

Table 1-2. Approved Cleaning Solvents - Continued

Cleaning Process Approved Solvents Isopropyl Alcohol (TT-I-735) Shop Master RC (Commercial)

Prior to Adhesive Bonding Acetone (ASTM D 329) Aliphatic Naphtha (TT-N-95) Isopropyl Alcohol (TT-I-735) Toluene (A-A-59107)

General Cleaning Dry Cleaning Fluid (MIL-PRF-680) Penetone Formula 724 (Commercial) Isopropyl Alcohol (TT-I-735)

1-2

CHAPTER 2

OVERHAUL INSTRUCTIONS

2.1 SPECIAL TOOLS.

Special tools required to overhaul the turbopump are listed in Table 2-1.

Table 2-1. Special Tools List

Part Number (CAGE*) Nomenclature Use 273854-1 Fixture, Torsion Bar Preload Refer to Paragraph 2.3 and Paragraph 2.8.

(70210) 273886-1 Wrench, Spanner Refer to Paragraph 2.3.

(70210) 904760-1 Driver Plug, Bearing and Bushing Refer to Paragraph 2.8.

(70210) 904761-1 Holding Tool, Ram Air Turbine Blade Refer to Paragraph 2.3 and Paragraph 2.8.

(70210) 904762-1 Fixture, Ram Air Turbine Refer to Paragraph 2.3 and Paragraph 2.8.

(70210) 904763-1 Clamp, Ram Air Turbine Dummy Hous-ing Refer to Paragraph 2.8.

(70210) 904764-1 Holding Device, Cap-Governor Housing-

Bearing Press Refer to Paragraph 2.8.

(70210) 904765-1 Driver, Bearing and Bushing Refer to Paragraph 2.8.

(70210) 904766-1 Adapter, Ram Air Turbine Balancing Ma-chine Refer to Paragraph 2.8.

(70210) 904770-1 Fixture, Ram Air Turbine Refer to Paragraph 2.3.

(70210) 904776-1 Dummy Housing, Ram Air Turbine Refer to Paragraph 2.8.

(70210) 904780-1 Block Set, Balancing Machine Riser Refer to Paragraph 2.8.

(70210) 904782-1 Adapter, Torque Wrench Refer to Paragraph 2.3 and Paragraph 2.8.

(70210) 31S Balancing Machine Refer to Paragraph 2.8.

(24845)

(NSN: 6635-00-390-

8522) 081360 Cleaner, Ultrasonic Refer to Paragraph 2.4.

(99251) MA2 Inspection Unit, Fluorescent Penetrant Refer to Paragraph 2.5.

(81349)

(NSN: 6635-01-103-

3380) RCQ1086 Inspection Unit, Magnetic Particle Refer to Paragraph 2.5.

(37676)

2-1

Table 2-1. Special Tools List - Continued

Part Number (CAGE*) Nomenclature Use NEF242436918 Oven, Electric Thermal Drying Refer to Paragraph 2.6.

(13305)

(NSN: 4430-00-541-

4634) *Commercial and Government Entity

2.2 SPECIAL TEST EQUIPMENT.

Special test equipment is listed in Table 2-2.

Table 2-2. Test Equipment List

Type Designation

(CAGE*)

Nomenclature Use

904758-1-1 Test Stand, Ram Air Turbine Refer to Paragraph 2.8.

(70210) 904774-1 Adapter, Ram Air Turbine Wind Tunnel Refer to Paragraph 3.2.3.

(70210) 904777-1 Template, Blade Angle Refer to Paragraph 2.8.

(70210) 904778-1 Adapter Set, Ram Air Turbine Test Stand Refer to Paragraph 2.8.

(70210) 904880-1-1 Test Stand, Ram Air Turbine Hydraulic System Refer to Paragraph 3.2.3.

(70210) *CAGE - Commercial and Government Entity

2.3 DISASSEMBLY.

Disassemble according to sequence of index numbers assigned to Figure 4-1 and Figure 4-2, observing the following:

a. Do not remove plate (Figure 4-1, index 1), label (3), or decalcomania (4) unless required after inspection.

b. Remove screws (Figure 4-2, index 1) and nose cap (2).

c. Remove bolts and shipping plate from bottom of housing assembly (Figure 4-1 indexes 27 through 30).

d. Remove fitting (9), using a 9/16 hexagon wrench.

NOTE

Nut (14) is torqued 140 to 150 pound-feet.

e. Install turbopump in PN 904761-1, Ram Air Turbine Fixture, in a nose-down position. Cut safetywire and remove nut (14), using a PN 273886-1 Spanner Wrench and a socket wrench.

f. Remove short screws (15) and install PN 953293-11 long Screws furnished with pump (20). Use pump removal handle furnished with pump to remove pump from housing assembly (27 through 30). Install handle, using two screws provided on end of pump.

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Protective caps must be installed on pump (20) to protect pump from damage and contamination.

g. Install protective closures supplied with pump (20) on hydraulic ports of pump.

h. Reach inside of housing assembly (Figure 4-1, indexes 27 through 30) and bend tab of washer (23) out of nut (22).

NOTE

Nut (22) is torqued to 370 to 430 pound-inches.

i. Using a torque wrench and PN 904782-1, Torque Wrench Adapter, remove nut (22) and washer (23).

j. Using a soft mallet, lightly tap housing assembly (27 through 30) upward. Remove bearing (24), washers (25, 26), and housing assembly from shaft (Figure 4-2, index 7); then slide spacer (Figure 4-1, index 31), bearing (32), and washer

(33) from shaft.

k. Do not remove bushings (27, 28) or inserts (29) from housing (30) unless required after inspection.

Torsion bar (Figure 4-2, index 8) is torqued 495 to 505 pound-feet. Inadvertent release of tension may cause severe injury to personnel and damage to turbopump.

l. Using PN 273854-1, Torsion Bar Preload Fixture, hold shaft (Figure 4-2, index 7) from turning and remove screws (3) and washers (4). Pick out sealant from around screws (6) and remove screws. Gradually release preload tension until torsion bar (8) and shaft (7) are unloaded to zero torque. Remove shroud (5), shaft (7), and torsion bar (8).

m. Remove turbopump from nose-down holding fixture and install in PN 904770-1, Ram Air Turbine Fixture, in a nose-up position. Remove screws (11), washers (12), and slide end cap (15) from face gear (35). Do not remove inserts

(14) unless required after inspection. Pull bearings (13) from end cap (15) and housing (34).

n. Do not remove screws (22) or slugs (23) from plates (27, 28).

o. Do not remove pins (31, 32) from housing (34) unless required after inspection. Do not remove inserts (33) from housing unless required after inspection.

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p. Cut safetywire from pins (37, 46) and remove pins from nuts (38, 47).

NOTE

Nuts (38, 47) are torqued to 30 to 50 pound-inches.

q. Insert a wedge between two adjacent nuts (38) to hold nuts from turning. Using PN 904761-1, Ram Air Turbine Blade Holding Tool, on blade (45), turn blade counterclockwise to loosen nut. Insert a wedge between the two remaining nuts

(38) to loosen blade from inner nut. After two nuts are removed, loosen and remove remaining nut (38) by holding nut with a wrench. Repeat same procedures to remove nut (47) from blade (55).

NOTE

Component parts of blade assemblies (37 through 45) and blade assembly (46 through 55) are matched. Make certain that respective parts for each assembly are kept together.

r. Remove blades (45, 55), with assembled components, from housing assembly (69 through 73). Do not disassemble blade assemblies or remove strain gauges (54) from blade (55). Install appropriate nuts (38, 47) on appropriate blade assemblies and retain as matched blade assemblies.

NOTE

Screw (56) is torqued to 30 to 50 pound-inches.

s. Remove screw (56), washer (57), support cone (58), and cover assembly (59, 60) from housing (73). Do not remove insert (59) from cover (60) unless required after inspection.

t. Do not remove bearings (69, 70), cup (71), or inserts (67, 68, 72) from housing (73) unless required after inspection.

2.4 CLEANING.

Use cleaning solvents in a well ventilated area. Avoid prolonged inhalation of fumes. Fumes are toxic and may cause personnel to become seriously ill. Solvent is flammable and must be kept away from flame.

a. Soften and clean sealant from screws (Figure 4-2, index 6), shaft (7), and torsion bar (8) using an approved general cleaning solvent from Table 1-2.

b. Wash all metal parts, except pump (Figure 4-1, index 20), using an approved general cleaning solvent from Table 1-2 and dry thoroughly with low pressure compressed air (20 psig maximum) or a clean, lint-free cloth.

c. Cover all external ports on pump (20). Clean exterior of pump using an approved general cleaning solvent from Table 1-2 and dry thoroughly.

d. Whether replaced or reused, the following parts must be ultrasonically cleaned at each overhaul, using PN 081360, Ultrasonic Cleaner: fitting (9), nut (22), washers (21, 23), and housing assembly (27 through 30).

e. If inspection is not to be performed immediately, spray steel parts with a light coat of lubricating oil (Military Specification MIL-L-6086 (ASG), Grade L) after cleaning. Wrap parts in grease-proof barrier material (Military Specification MIL-B-121).

2.5 INSPECTION.

a. If parts have been coated with lubricating oil (Military Specification MIL-L-6086 (ASG), Grade L), clean in accor-dance with instructions in Paragraph 2.4.

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b. Parts that do not meet inspection requirements as outlined in Table 2-3, Nondestructive Inspection Requirements, and Paragraph 2.5, must be repaired or replaced. Parts must be inspected in accordance with good shop practice by experienced personnel. Full tolerance dimensional inspections are given for individual serviceable parts. Figure 2-1 for fits and clearances. Individual parts may be used or reworked to tolerances given in Figure 2-1. Use PN MA2, Fluorescent Penetrant Inspection Unit, and PN RCQ1086, Magnetic Particle Inspection Unit, to perform nondestruc-tive inspection outlined in Table 2-3.

Table 2-3. Nondestructive Inspection Requirements

Part Name and Index No. Inspection Type Specification or Procedure Excluded Areas Housing (Figure 4-1, in-dex 30) Penetrant MIL-I-6866 (ASG) None

Cap (Figure 4-2, index 2) Penetrant MIL-I-6866 (ASG) None Cam (21) Magnetic MIL-I-6868 None Pins (24, 26) Magnetic MIL-I-6868 None Plates (27, 28) Magnetic MIL-I-6868 None Face Gear (35) Magnetic MIL-I-6868 None Nuts (38, 47) Magnetic MIL-I-6868 None Housing (73) Penetrant MIL-I-6866 (ASG) None

NOTE

Do not discard any part that does not meet inspection requirements until consulting Figure 2-1 to determine if part can be reworked to meet overhaul requirements.

c. Parts that require repair must be so tagged until repair has been accomplished and inspection requirements have been met.

d. Parts that require replacement must be tagged or spotted with red paint to be readily identified as non-serviceable.

e. Visually inspect all parts for scratches, cracks, corrosion, or other damage. Check all threads for cross-threading or stripping. (See Figure 4-1 and Figure 4-2.)

f. Visually inspect painted areas for blisters, flaking, chipping, and worn spots.

g. Visually inspect all gears and splines for pitting, nicks, or chips.

h. Visually inspect all gear teeth for fretting or burrs.

i. Visually inspect plate (Figure 4-1, index 1), label (3), and decalcomania (4) for security of mounting and for legibility.

j. Visually inspect bushings (27, 28) and inserts (29) in housing (30) for damage and security of installation. Inside diameter of bushings (27, 28) must not exceed 2.4415 inches.

k. Dimensionally inspect pins (Figure 4-2, index 31, 32) in housing (34) in accordance with Figure 2-2.

l. Inspect surfaces of cam (Figure 4-2, index 21) coated with black oxide for scratches or scores exposing base metal.

m. Inspect cadmium-plated surfaces of plates (27, 28) for scratches or scores exposing bare metal.

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n. Inspect solid film lubricant on gear teeth surfaces of face gear (35) for scratches, wear, or scores exposing base metal.

NOTE

Component parts of blade assemblies (37 through 45) and blade assembly (46 through 55) are matched. If any part does not meet inspection requirements and cannot be repaired, replace the entire blade assembly.

o. Inspect cadmium-plated surfaces of nuts (38, 47) and pinions (43, 52) for scratches or scores exposing base metal.

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Figure 2-1. Fits and Clearances

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p. Measure resistance of strain gauges (54) on blade (55); resistance must not be greater than 4.0 ohms of resistance value marked on blade.

q. Inspect inside diameter of bearings (69, 70) and cup (71) for wear. Inside diameter of bearing (69) must not exceed

1.0860 inches; inside diameter of bearing (70) must not exceed 0.376 inch; inside diameter of cup (71) must not exceed 0.390 inch.

2.6 REPAIR OR REPLACEMENT.

a. Replace all parts that do not pass inspection requirements and are damaged beyond repair. Repair pump PN 953293-2 in accordance with TO 9H4-5-5-3.

Do not use crocus abrasive cloth (Federal Specification P-C-458) on aluminum parts. This cloth contains an oxide of iron which causes rapid corrosion of aluminum.

b. Remove minor scratches, burrs, and corrosion from steel parts by lightly polishing with crocus abrasive cloth (Federal Specification P-C-458). On aluminum parts, use fine aluminum oxide or silicon carbide abrasive cloth (Federal Speci-fication P-C-451).

Chemical film is moderately toxic to skin, eyes and respiratory tract. Skin and eye protection is required.

c. Touch up reworked aluminum parts with chemical film meeting requirements of Military Specification MIL-C-5541.

Figure 2-2. Pin Dimensional Requirements

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Handle heated parts with heat-resistant gloves to prevent serious burns to personnel.

d. If bushings (Figure 4-1, index 27, 28) require replacement, machine bushings to a thin shell; collapse bushing and remove from housing (30). Using PN NEF242436918, Electrical Thermal Drying Oven, heat housing to a temperature of 325° to 375 °F (162.8° to 190.6 °C) for a minimum of one hour. Apply Primer Coating, Epoxy, Waterborne (Military Specification MIL-PRF-85582) to outside diameters of new bushings. Chill bushings in solid carbon dioxide (Federal Specification BB-C-104) and immediately install bushings in housing. After housing assembly has cooled to room temperature, machine inside diameter of bushings 2.4410 to 2.4415 inches concentric with housing centerline within 0.0005 inch. Machine 40° to 50° x 0.030 to 0.060 inch chamfer on outboard edge of each bushing.

e. If an insert (Figure 4-1, index 29) (Figure 4-2, index 33, 59, 67, 68,) requires replacement, apply Primer Coating, Epoxy, Waterborne (Military Specification MIL-PRF-85582) to new insert and install insert 3/4 to 1-1/2 turns below surface while primer is wet. Remove tangs.

f. If an insert (14) requires replacement, apply Primer Coating, Epoxy, Waterborne (Military Specification MIL-PRF- 85582) to new insert and install insert 0.030 to 0.060 inch below surface while primer is wet.

g. If an insert (72) requires replacement, install new insert one to three turns below counterbore surface.

h. End cap (15), housing (34), and housing (73) are matched parts. If one part is defective and must be replaced, complete housing set (11 through 15, 29 through 34, 67 through 73) must be replaced.

i. If pin (31, 32) is defective, press defective pin from housing (34). Press in new pin in accordance with dimensional requirements as shown in Figure 2-2.

j. If black oxide finish on cam (Figure 4-2, index 21) is defective, refinish surface with black oxide coating (Military Specification MIL-C-13924, Class I).

k. Plates (27, 28) are a matched pair. If either plate fails to pass inspection, both plates must be replaced.

l. If solid film lubricated surfaces of face gear (35) are scratched, scored, or chipped, or if more than 20 percent of base metal is exposed, replace with a uniform coat of solid film lubricant in accordance with Military Specification MIL-

L-8937 (ASG).

NOTE

Component parts of blade assemblies (37 through 45) and blade assembly (46 through 55) are matched. If one part is defective and must be replaced, the entire blade assembly must be replaced.

m. If cadmium-plated surfaces of nuts (38, 47) or pinions (43, 52) are scored or scratched, repair in accordance with Military Specification MIL-C-8837, Type II, Class 3.

n. If resistance of strain gauge (54) on blade (55) exceeds 4.0 ohms of value indicated on blade, all blade assemblies (37 through 55) must be replaced.

NOTE

If cup (71) requires replacement, bearing (70) must also be replaced.

o. If bearings (69, 70) or cups (71) require replacement, machine defective part to a thin shell and remove from housing (73). Apply Primer Coating, Epoxy, Waterborne (Military Specification MILPRF- 85582) to outside diameter of new bearing or cup and press part in housing until bottomed while primer is wet.

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Use solvent in a well ventilated area. Avoid breathing fumes. Fumes are toxic and may cause personnel to become seriously ill. Solvents are flammable and must be kept away from flame.

p. If painted surfaces are chipped, flaked, or peeling, polish rough spots and flaking paint with abrasive cloth (Federal Specification P-C-451, No. 320 Grit). Wipe surface clean, using clean, lint-free cloth moistened in an approved general cleaning solvent from Table 1-2. Touch-up affected areas with three coats of primer (one part Cati-Coat Primer No.

E42GP22 to one part Catalyst V66KP46, Sherwin Williams Co., Cleveland, OH, or equivalent). After each coat, allow to air dry for 15 to 30 minutes followed by baking for one hour at a temperature of 150° to 175 °F (65.6° to 79.4 °C) or bake for 30 minutes at a temperature of 275° to 300 °F (135.0° to 148.9 °C) using PN NEF242436918, Electrical Thermal Drying Oven.

2.7 LUBRICATION.

The following lubricants are used during the overhaul of this turbopump:

a. Grease (Military Specification MIL-G23827) for pump (Figure 4-1, index 20), nut (22), bearings (24, 32), spacer (31), shaft (Figure 4-2, index 7), torsion bar (8), end cap (15), cam (21), bearings (16, 36, 62), face gear (35), pinions (43, 52), and housing (73).

b. Anti-seize Compound (Military Specification MIL-T-5544) for pinions (43, 52) and blades (45, 55).

c. Lubricant (Moly Kote Type Z, Alpha Moly Kote Corp., Stamford, CT, or equivalent) for plates (Figure 4-2, index 27, 28).

d. Grease (Krytox 240AC, Du Pont Company, Wilmington, DE, or equivalent) for seal assembly (63) and housing (73).

e. Solid Film Lubricant (Military Specification MIL-L-8937) (ASG) for face gear (35).

2.8 REASSEMBLY.

Assemble in reverse of numerical sequence of index numbers assigned in Figure 4-1 and Figure 4-2, observing the follow-ing:

a. Install housing (73) in PN 904770-1, Ram Air Turbine Fixture, in a nose-up position. Apply a light coating of grease (Krytox 240AC, Du Pont Company, Wilmington, DE, or equivalent) to mating surfaces of seal assembly (63) and housing (73). Using PN 904760-1, Bearing and Bushing Driver Plug, install bearing (70).

Use solvents in a well ventilated area. Avoid breathing fumes. Fumes are toxic and may cause personnel to become seriously ill. Solvents are flammable and must be kept away from flame.

NOTE

Component parts of blade assemblies (Figure 4-2, index 37 through 45) and blade assembly (46 through 55) are matched parts. Make certain that respective parts for each assembly are kept together. If a new blade assembly is to be installed, select a complete blade assembly that matches the weight of the diametrically opposite complete blade assembly within one gram.

b. Install seal assembly (63) and spacers (65) with washers (64) as required to obtain 0.10 to 0.20 inch compression of seal assembly (63). Remove nuts (38, 47) from blade assemblies and position blade assemblies in housing (73). Coat mating surfaces of bearings (62) and pinions (43) with grease (Military Specification MIL-G-23827) and install bearings. Coat threads of blade assemblies with anti-seize compound (Military Specification MIL-T-5544). Install nuts (38, 47) on blade assemblies, with washers (61) as required to obtain an end play of 0.001 to 0.003 inch of each blade assembly with a 10 to 15 pound axial load applied to end of each blade assembly in both directions, as follows:

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(1) Install one nut on respective blade assembly at end of group of three blade assemblies.

(2) Hold nut with a wrench and using PN 904761-1, Ram Air Turbine Blade Holding Tool, on blade, tighten blade assembly in nut until holes in nut and blade assembly for pin (37) are aligned.

(3) Install nut on center blade assembly, then place a wedge between the two nuts and using PN 904761-1, Ram Air Turbine Blade Holding Tool, on blade, tighten blade assembly in nut until holes in nut and blade assembly for pin are aligned.

(4) Install remaining nut on end blade assembly; then place wedge between the two nuts and using PN 904761-1, Ram Air Turbine Blade Holding Tool, on blade, tighten blade assembly in nut until holes in nut and blade assembly for pin are aligned.

(5) Repeat same procedures to install nuts on remaining group of three blade assemblies.

(6) Apply a light coating of epoxy waterborne primer (Military Specification MIL-PRF-85582) to pins (37, 46) and install pins in nuts (38, 47). Safety-wire pins to nuts in accordance with Military Standard MS33540, using wire (Military Standard MS20995C20) (ASG). Bend ends of wire flat against bottom of nuts. Clean area using an approved general cleaning solvent from table 1-2 and apply sealing compound (RTV732, Dow Corning, Midland, MI, or equivalent) around bent ends of wire.

(7) Rotate blades by hand to ensure freedom of rotation and correct assembly.

c. Position cover assemblies (59, 60) in housing (73) and secure with support cones (58), washers (57), and screws (56).

Torque screws 30 to 50 pound-inches.

d. Coat mating surfaces of bearing (36) and face gear (35) with grease (Military Specification MIL-G-23827) and press bearing to shoulder of gear.

Do not allow primer on inside diameter of bearing to prevent turbopump malfunction.

e. Coat mating surfaces of bearings (13), end cap (15), and housing (34) with epoxy waterborne primer (Military Specification MIL-PRF-85582); then using PN 904764-1, Cap-Governor Housing - Bearing Press Holding Device, and PN 904765-1, Bearing and Bushing Driver, install bearings in end cap and housing flush to 0.020 inch below surface of end cap and housing while primer is wet.

f. Install bearing (25) on pin (24). Apply lubricant (Moly Kote Type Z, Alpha Moly Kote Corp., Stamford, CT, or equivalent) to pin holes of plates (27, 28). Apply sealant and activator (Loctite Composition, Grade A and Locquic Composition, Grade N, American Sealants Co., Hartford, CT, or equivalent) to pin (26). Press plates (27, 28) to shoulder of pin (26) and remove excess sealant from surface of plates.

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g. Align each blade assembly (37 through 45; 46 through 55) to ‘A’ angle, Figure 2-3. Coat mating surfaces of bearing (Figure 4-2, index 36) and housing (73) and teeth of face gear (35) and pinions (43) with grease (Military Specification MIL-G-23827) and install bearing and face gear in housing (73).

h. Coat mating surfaces and outside diameter contour of housing (34) and housing (73) with sealing compound (RTV732, Dow Corning Corp., Midland, MI, or equivalent). Align pins (31, 32) in housing (34) with housing (73) and secure housing (34) to housing (73) with screws (29) and washers (30).

i. Coat splines of face gear (35) and cam (21) with grease (Military Specification MIL-G-23827). Install cam (21) and components of flyweight assembly (22 through 28) with washers (19, 20) as required to obtain 0.015 inch side clearance between cam (21) and plates (27, 28). Install spacer (18) with washers (17) as required to obtain an end play of 0.001 to 0.003 inch between gear and pinions when bearing (16) and end cap (15) are installed. Coat mating surfaces of housing (34) and end cap (15) with sealing compound (RTV732, Dow Corning Corp., Midland, MI, or equivalent; no known Government specification). Coat mating surfaces of bearing (16), end cap (15), and face gear

(35) with grease (Military Specification MIL-G-23827). Install bearing and secure end cap to housing with screws (11) and washers (12).

j. Remove turbopump from nose-up holding fixture and install in PN 904762-1, Ram Air Turbine Fixture, in a nose-down position.

k. Install end of torsion bar (8) flush with end of face gear (35) within 0.020 inch. Apply sealing compound (3997, W.P.

Fuller Co., San Francisco, CA, or equivalent) to mating splines of shaft (7) and torsion bar (8). Coat mating surfaces of housing (73) and shaft with sealing compound (RTV732, Dow Corning Corp., Midland, MI, or equivalent). As-semble shroud (5), shaft (7), and torsion bar (8). Do not install screws (3) and washers (4).

Torquing of torsion bar (8) is critical on overhaul of turbopump. Adjustment to improper torque values will cause turbopump to malfunction.

l. Using PN 273854-1, Torsion Bar Preload Fixture, apply torque of 300 to 310 pound-inches to torsion bar (8) in counterclockwise direction. Lock shaft (7) in place with screws (6); then install screws (3) and washers (4). Remove turbopump from preload fixture and holding fixture.

Figure 2-3. Blade Assembly Installation Requirements

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m. Using PN 904776-1, Ram Air Turbine Dummy Housing; PN 904780-1, Balancing Machine Riser Block Set; PN 904766-1, Ram Air Turbine Balancing Machine Adapter; PN 904763-1, Ram Air Turbine Dummy Housing Clamp;

and PN 31S, Balancing Machine, dynamically balance turbopump governor assembly in two planes as shown in Figure 2-4. Unbalance in Plane I must be no greater than 0.9 gram-inch. Unbalance in Plane II must be no greater than 1.8 gram-inches. Use pins (Figure 4-2, index 9, 66) as required in each plane for unbalance correction. Coat pins with epoxy waterborne primer (Military Specification MIL-PRF-85582) prior to installation.

n. Using PN 904758-1-1, Ram Air Turbine Test Stand; PN 904777-1, Blade Angle Template; high intensity strobe light, and PN 904778-1, Ram Air Turbine Test Stand Adapter Set, test governor assembly to verify full blade travel as follows:

(1) Install hydraulic drive motor (part of adapter set) and connect instrumentation.

(2) Using template, mark base of blade at a point corresponding to zero degree position on template.

(3) Reduce test chamber pressure to 1.0 inch of mercury absolute (maximum).

Figure 2-4. Balancing Requirements

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Do not exceed 7400 rpm and do not exceed 55 degrees arc blade travel or damage to governor assembly may result.

(4) Operate turbopump by slowly increasing rotational speed, without reversing, until blade angle is 53 +2/−0 degrees as indicated on high-intensity strobe light. Rotational speed must not exceed 7400 rpm and there must be no audible indication of governor assembly balance, or visual indication of erratic performance. Blade angle must change smoothly from zero to 53 +2/−0 degrees.

(5) Slowly decrease turbopump rotational speed to zero while visually monitoring turbopump for erratic perfor-mance. Blade angle must return to zero degrees smoothly.

(6) If blade angle travel is out of tolerance during test, retorque torsion bar (8) in accordance with Paragraph 2.8, step q, and rerun angle travel test.

(7) Remove turbopump from test setup.

o. Install turbopump in PN 904762-1, Ram Air Turbine Fixture.

p. Using PN 273854-1, Torsion Bar Preload Fixture, apply torque of approximately 300 pound-inches to torsion bar (8).

Remove screws (3) and washers (4) and loosen screws (6) to release shaft (7).

Torsion bar (8) is torqued 495 to 505 pound-feet. Inadvertent release of tension may cause severe injury to personnel and damage to turbopump.

Torquing of torsion bar (8) is critical on overhaul of turbopump. Adjustment to improper torque values will cause turbopump to malfunction.

q. Retorque torsion bar (8) as follows:

(1) Apply torque of 495 to 505 pound-feet to torsion bar (8) in counterclockwise direction. Record a reference angle at this setting.

(2) From noted reference angle in step (1), increase torque on torsion bar to 655 pound-feet.

(3) Reduce torque to reference angle obtained in step (1) and note torque reading. If torque reading is less than that set at step (1), repeat steps (2) and (3) until specified torque at reference angle is obtained.

(4) Lock shaft (7) in place with screws (6). Fill screw cavities with sealing compound (RTV732, Dow Corning Corp., Midland, MI, or equivalent). Apply sealing compound in fillet form around shaft as shown in Figure 2-5. Apply sealing compound to threads of screws (Figure 4-2, index 3) and to mating surfaces of shroud (5) and shaft (7).

Install screws (3) and washers (4). Remove turbopump from holding fixture.

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r. Recheck turbopump governor assembly balance in accordance with Paragraph 2.8, step n.

s. Using PN 904758-1-1, Ram Air Turbine Test Stand; PN 904777-1, Blade Angle Template; high intensity strobe light;

and PN 904778-1, Ram Air Turbine Test Stand Adapter Set, test governor assembly to determine that governor assembly is within the requirements shown in Figure 2-6 as follows:

(1) Install hydraulic drive motor (part of adapter set) and connect instrumentation.

(2) Using template, mark base of blade at a point corresponding to zero degree position on template.

(3) Reduce test chamber pressure to 1.0 inch of mercury absolute (maximum).

(4) Operate turbopump by slowly increasing rotational speed, without reversing speed, and check with high-intensity strobe light for initial movement of blade. Check speed; speed must not be more than 5700 rpm.

Do not exceed 7400 rpm and do not exceed 55 degrees arc blade travel or damage to governor assembly may result.

(5) Continue slowly increasing turbopump speed, without reversing speed, in increments corresponding to B angular increments of 5 degrees shown in Figure 2-6. Plot corresponding blade angles versus rotational speed until blade is 55 degrees maximum or rotational speed is 7400 rpm maximum, whichever occurs first. There must be no visible indication of erratic or sluggish performance of governor assembly, and blade angle versus rotational speed plotted points must be within the envelope shown in Figure 2-6.

(6) Slowly decrease turbopump speed, without reversing speed, in 5-degree increments and plot corresponding blade angles versus rotational speed until a minimum speed of 5250 rpm is reached. Blade angles versus rotational speed must be within the envelope shown in Figure 2-6.

(7) Reduce turbopump speed to zero and remove turbopump from test setup.

t. Install packing (Figure 4-2, index 10), cap (2), and screws (1). Apply varnish compound (V98VP Varnish, Sherwin Williams Co., Cleveland, OH, or equivalent) around heads of screws (1, 3).

u. Install turbopump in PN 904762-1, Ram Air Turbine Fixture, in a nose-down position.

v. Apply a film of grease (Military Specification MIL-G-23827) to inside and outside diameters of bearings (Figure 4-1, index 24, 32), inside diameter of spacer (31), threads of shaft (Figure 4-2, index 7), and threads of nut (Figure 4-1, index 22).

Figure 2-5. Sealing Compound Dimensional Requirements

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w. Install washer (33) on shaft (Figure 4-2,…