28 22 04R5 PDF

COMPONENT MAINTENANCE MANUAL
60-989
TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL (CMM) 28-22-04, REVISION 4 DATED

JUN 30/00 FOR FUEL BOOST PUMP ASSEMBLY, PART NO. 60-989 SERIES.
REVISION NO. 5, DATED JAN 09/2004
HIGHLIGHTS
Replace all copies of CMM 28-22-04, Revision 4 dated JUN 30/00 with CMM 28-22-04, Revision 5 dated JAN
09/2004. Revision 5 is a complete reissue in compliance with the latest engineering changes and ATA
Specification 2200 Maintenance Task Oriented Support System (MTOSS) and ATA Digital Data Standards
requirements.
Due to the extent of the changes, change bars are not used in this revision.
The highlights of the changes are given below. The changes apply to all configurations covered by this
publication unless otherwise noted in the Effectivity column.
PAGE NO. DESCRIPTION OF CHANGE EFFECTIVITY
All Pages Reformatted the manual to the current Hydro-Aire All

CMM SGML template; incorporated Service
Information Letter (SIL) 60-72101-04-01 and
Service Bulletins 60-98902-28-1, 60-98904-28-1,
60-98906-28-1, and 60-98976-28-1 and Crane
Hydro-Aire Motor-Impeller-28-01; Incorporated
Temporary Revision Numbers 6, 7, 8, 9, 11, and
12.
Title Page Updated the revision number and date. All
Record of Revisions Added Revision 5. All
Record of Temporary Added Temporary Revisions and date. All

Revision
List of Effective Pages Updated the issue date for all Revision 5 pages. All
28-22-04 Highlights Page 1

Jan 09/2004
60-989
THIS PAGE INTENTIONALLY LEFT BLANK
28-22-04 Highlights Page 2

Jan 09/2004
Component Maintenance Manual
with
Illustrated Parts List
FUEL BOOST PUMP ASSEMBLY

PART NO.
60-989 (BOEING PART NO. 60B89004)
60-989-1 (BOEING PART NO. 60B89004)
60-989-2 (BOEING PART NO. 60B89004)
60-989-3 (BOEING PART NO. 60B89004)
60-989-5 (BOEING PART NO. 60B89004)
60-989-6 (BOEING PART NO. 60B89004)
60-989-8 (BOEING PART NO. 60B89004)
MOTOR-IMPELLER SUBASSEMBLY
PART NO.
60-98902 (BOEING PART NO. 60B89004-2)
60-98902A (BOEING PART NO. 60B89004-21)
60-98904 (BOEING PART NO. 60B89004-4)
60-98904A (BOEING PART NO. 60B89004-41)
60-98906 (BOEING PART NO. 60B89004-6)
60-98906A (BOEING PART NO. 60B89004-61)
60-98976 (BOEING PART NO. 60B89004-9)
60-98976-1 (BOEING PART NO. 60B89004-11
HOUSING SUBASSEMBLY
PART NO.
60-98901 (BOEING PART NO. 60B92404-1)
60-98901A (BOEING PART NO. 60B92404-1A)
60-98905 (BOEING PART NO. 60B92404-5)
CRANE AEROSPACE, HYDRO-AIRE, INC.
CRANE AEROSPACE
HYDRO-AIRE, INC.
3000 WINONA AVENUE
P.O. BOX 7722
BURBANK, CALIFORNIA 91510-7722
Initial Issue Date: Dec 8/81

28-22-04 Page TP-1
Rev. No. 5
Jan 09/2004
60-989
COPYRIGHT: 2004 CRANE AEROSPACE, HYDRO-AIRE, INC.

All rights reserved.
COMMERCIAL EXPORT ADMINISTRATION REGULATIONS (EAR)
These commodities, technology, or software were exported from the United States in accordance with the
Export Administration Regulations. Diversion contrary to U.S. law is prohibited.
PROPRIETARY NOTICE
FREEDOM OF INFORMATION ACT (5 USC 552) AND DISCLOSURE OF CONFIDENTIAL

INFORMATION GENERALLY (18 USC 1905)
This document contains proprietary information which is the property of Crane Aerospace, Hydro-Aire,
Inc. It may not be copied or reproduced, in whole or in part, or the contents divulged or used for
manufacture, without the specific written permission of Crane Aerospace, Hydro-Aire, Inc. Recipient, by
the acceptance, use, or retention of this document, acknowledges and agrees to the foregoing, and to
maintain the contents in confidence. The information disclosed herein falls within exemption (b)(4) of 5
USC 552 and the prohibitions of 18 USC 1905.
We welcome your comments concerning this manual. Although every effort has been made to keep it free
from errors, some may occur. When reporting a specific problem, please describe it briefly and include
the manual number, the paragraph or figure number, and the page number.
Please submit comments regarding this manual to the Technical Publications Coordinator at the following
address:
Crane Aerospace
Hydro-Aire, Inc.
3000 Winona Avenue
P.O. Box 7722
Burbank, California 91510
TELEPHONE: 818-526-2600
FAX: 818-842-6117 (24 hr)
WEBSITE: www.hydroaire.com
28-22-04 Page TP-2

Jan 09/2004
60-989
RECORD OF REVISIONS
Keep this record in the front of this document.
When a revision is received:
(1) Remove and discard the superseded pages.
(2) Put the revised pages into this document.
(3) Enter the insertion date and your initials below.
INSERTED INSERTED
REV. ISSUE REV. ISSUE
NO. DATE DATE BY NO. DATE DATE BY
1 Jan 06/86 Jan 06/86 HA
2 May 15/90 May 15/90 HA
3 Dec 15/93 Dec 15/93 HA
4 Jun 30/00 Jun 30/00 HA
5 Jan 09/04 Jan 09/04 HA
28-22-04 Page ROR-1

Jan 09/2004
60-989
28-22-04 Page ROR-2

Jan 09/2004
60-989
RECORD OF TEMPORARY REVISIONS
When a temporary revision is received:
(1) Put the temporary revision page(s) into this document.
(2) Record the Temporary Revision (TR) number, issue date, insertion date, your initials, and the
page number.
When a permanent revision is received:
(1) Remove the temporary revision page(s) and put the permanent revision into this document.
(2) Record of the removal date and removers initials.
TEMP ISSUE INSERTED REMOVED

PAGE NO.
REV NO. DATE DATE BY DATE BY
6 Nov 20/2000 Jan 09/2004 HAI 10030
7 Feb 14/2001 Jan 09/2004 HAI 10023
8 Feb 14/2001 Jan 09/2004 HAI 10028
9 Feb 14/2001 Jan 09/2004 HAI 10033
10 Feb 14/2001 Jan 09/2004 HAI RTR-1
11 Jul 12/2001 Jan 09/2004 HAI 10025
12 Jul 12/2001 Jan 09/2004 HAI 10025
28-22-04 Page RTR-1

Jan 09/2004
60-989
28-22-04 Page RTR-2

Jan 09/2004
60-989
SERVICE BULLETIN LIST

This list provides the service bulletin number, revision number, incorporation date, and subject title. When a
service bulletin does not affect the CMM, the words "NO EFFECT" are shown in the service bulletin
incorporation date column.
SERVICE
REVISION INCORPORATION
BULLETIN SUBJECT TITLE
NUMBER DATE
NUMBER
60-98902-28-1 1 Jan 09/2004 Modification of Motor-Impeller Subassembly P/N
60-98902 and 60-98902A (Boeing P/N 60B89004-2
and 60B89004-21) to P/N 60-98976-4 (Boeing
P/N 60B89004-15)
60-98904 and 60-98904A (Boeing P/N 60B89004-4
and 60B89004-4A) to P/N 60-98976-4 (Boeing
P/N 60B89004-15)
60-98906 and 60-98906A (Boeing P/N 60B89004-6
and 60B89004-61) to P/N 60-98976-4 (Boeing
P/N 60B89004-15)
60-98976 and 60-98976-1 (Boeing P/N 60B89004-
9 and 60B89004-11) to P/N 60-98976-4 (Boeing
P/N 60B89004-15)
Crane Hydro-Aire 2 Jan 09/2004 Motor-Impeller Subassembly Inspection to Detect
Motor-Impeller-28-01 Improper Fuel Pump Internal Wire Bundle Routing
SIL 60-72101-04-01 0 Jan 09/2004 Improper Fuel Pump Internal Wire Bundle Routing
SIL 60-703/989-11-1 0 Jan 09/2004 Modification to Fuel Pump Motor-Impeller
Subassemblies
28-22-04 Page SBL-1

Jan 09/2004
60-989
28-22-04 Page SBL-2

Jan 09/2004
60-989
LIST OF EFFECTIVE PAGES
SUBJECT PAGE DATE SUBJECT PAGE DATE

Title Page TP-1 Jan 09/2004 Testing and Fault 1012 Jan 09/2004
TP-2 Jan 09/2004 Isolation (Cont) 1013 Jan 09/2004
1014 Jan 09/2004
Record of ROR-1 Jan 09/2004 1015 Jan 09/2004
Revisions ROR-2 Jan 09/2004 1016 Jan 09/2004
1017 Jan 09/2004
Record of RTR-1 Jan 09/2004 1018 Jan 09/2004
Temporary RTR-2 Jan 09/2004 1019 Jan 09/2004
Revisions 1020 Jan 09/2004
1021 Jan 09/2004
Service Bulletin SBL-1 Jan 09/2004 1022 Jan 09/2004
List SBL-2 Jan 09/2004 1023 Jan 09/2004
1024 Jan 09/2004
List of Effective LEP-1 Jan 09/2004
Pages LEP-2 Jan 09/2004 Schematic and 2001 Jan 09/2004
LEP-3 Jan 09/2004 Wiring Diagrams 2002 Jan 09/2004
LEP-4 Jan 09/2004
Disassembly 3001 Jan 09/2004
Table of Contents TOC-1 Jan 09/2004 3002 Jan 09/2004
TOC-2 Jan 09/2004 3003 Jan 09/2004
TOC-3 Jan 09/2004 3004 Jan 09/2004
TOC-4 Jan 09/2004 3005 Jan 09/2004
3006 Jan 09/2004
Introduction Intro-1 Jan 09/2004 3007 Jan 09/2004
Intro-2 Jan 09/2004 3008 Jan 09/2004
Intro-3 Jan 09/2004 3009 Jan 09/2004
Intro-4 Jan 09/2004 3010 Jan 09/2004
Intro-5 Jan 09/2004 3011 Jan 09/2004
Intro-6 Jan 09/2004 3012 Jan 09/2004
Description and 1 Jan 09/2004 Cleaning 4001 Jan 09/2004

Operation 2 Jan 09/2004 4002 Jan 09/2004
3 Jan 09/2004 4003 Jan 09/2004
4 Jan 09/2004 4004 Jan 09/2004
5 Jan 09/2004
6 Jan 09/2004 Check 5001 Jan 09/2004
7 Jan 09/2004 5002 Jan 09/2004
8 Jan 09/2004 5003 Jan 09/2004
9 Jan 09/2004 5004 Jan 09/2004
10 Jan 09/2004 5005 Jan 09/2004
5006 Jan 09/2004
Testing and Fault 1001 Jan 09/2004 5007 Jan 09/2004
Isolation 1002 Jan 09/2004 5008 Jan 09/2004
1003 Jan 09/2004 5009 Jan 09/2004
1004 Jan 09/2004 5010 Jan 09/2004
1005 Jan 09/2004 5011 Jan 09/2004
1006 Jan 09/2004 5012 Jan 09/2004
1007 Jan 09/2004 5013 Jan 09/2004
1008 Jan 09/2004 5014 Jan 09/2004
1009 Jan 09/2004 5015 Jan 09/2004
1010 Jan 09/2004 5016 Jan 09/2004
1011 Jan 09/2004 5017 Jan 09/2004
28-22-04 Page LEP-1

Jan 09/2004
60-989

Check (Cont) 5018 Jan 09/2004 Assembly (Cont) 7016 Jan 09/2004
5019 Jan 09/2004 7017 Jan 09/2004
5020 Jan 09/2004 7018 Jan 09/2004
5021 Jan 09/2004 7019 Jan 09/2004
5022 Jan 09/2004 7020 Jan 09/2004
5023 Jan 09/2004 7021 Jan 09/2004
5024 Jan 09/2004 7022 Jan 09/2004
7023 Jan 09/2004
Repair 6001 Jan 09/2004 7024 Jan 09/2004
6002 Jan 09/2004 7025 Jan 09/2004
6003 Jan 09/2004 7026 Jan 09/2004
6004 Jan 09/2004 7027 Jan 09/2004
6005 Jan 09/2004 7028 Jan 09/2004
6006 Jan 09/2004 7029 Jan 09/2004
6007 Jan 09/2004 7030 Jan 09/2004
6008 Jan 09/2004 7031 Jan 09/2004
6009 Jan 09/2004 7032 Jan 09/2004
6010 Jan 09/2004 7033 Jan 09/2004
6011 Jan 09/2004 7034 Jan 09/2004
6012 Jan 09/2004
6013 Jan 09/2004 Fits and 8001 Jan 09/2004
6014 Jan 09/2004 Clearances 8002 Jan 09/2004
6015 Jan 09/2004
6016 Jan 09/2004 Special Tools, 9001 Jan 09/2004
6017 Jan 09/2004 Fixtures, and 9002 Jan 09/2004
6018 Jan 09/2004 Equipment 9003 Jan 09/2004
6019 Jan 09/2004 9004 Jan 09/2004
6020 Jan 09/2004 9005 Jan 09/2004
6021 Jan 09/2004 9006 Jan 09/2004
6022 Jan 09/2004 9007 Jan 09/2004
6023 Jan 09/2004 9008 Jan 09/2004
6024 Jan 09/2004
6025 Jan 09/2004 Storage 15001 Jan 09/2004
6026 Jan 09/2004 15002 Jan 09/2004
6027 Jan 09/2004 15003 Jan 09/2004
6028 Jan 09/2004 15004 Jan 09/2004
6029 Jan 09/2004
6030 Jan 09/2004 Illustrated Parts 10001 Jan 09/2004
List 10002 Jan 09/2004
Assembly 7001 Jan 09/2004 10003 Jan 09/2004
7002 Jan 09/2004 10004 Jan 09/2004
7003 Jan 09/2004 10005 Jan 09/2004
7004 Jan 09/2004 10006 Jan 09/2004
7005 Jan 09/2004 10007 Jan 09/2004
7006 Jan 09/2004 10008 Jan 09/2004
7007 Jan 09/2004 10009 Jan 09/2004
7008 Jan 09/2004 10010 Jan 09/2004
7009 Jan 09/2004 10011 Jan 09/2004
7010 Jan 09/2004 10012 Jan 09/2004
7011 Jan 09/2004 10013 Jan 09/2004
7012 Jan 09/2004 10014 Jan 09/2004
7013 Jan 09/2004 10015 Jan 09/2004
7014 Jan 09/2004 10016 Jan 09/2004
7015 Jan 09/2004 10017 Jan 09/2004
28-22-04 Page LEP-2

Jan 09/2004
60-989

Illustrated Parts 10018 Jan 09/2004
List (Cont) 10019 Jan 09/2004
10020 Jan 09/2004
10021 Jan 09/2004
10022 Jan 09/2004
10023 Jan 09/2004
10024 Jan 09/2004
10025 Jan 09/2004
10026 Jan 09/2004
10027 Jan 09/2004
10028 Jan 09/2004
10029 Jan 09/2004
10030 Jan 09/2004
10031 Jan 09/2004
10032 Jan 09/2004
10033 Jan 09/2004
10034 Jan 09/2004
10035 Jan 09/2004
10036 Jan 09/2004
10037 Jan 09/2004
10038 Jan 09/2004
10039 Jan 09/2004
10040 Jan 09/2004
10041 Jan 09/2004
10042 Jan 09/2004
10043 Jan 09/2004
10044 Jan 09/2004
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Jan 09/2004
60-989
28-22-04 Page LEP-4

Jan 09/2004
60-989
TABLE OF CONTENTS
SUBJECT PAGE
Introduction ......................................................................................................................................... Intro-1

1. Scope..................................................................................................................................... Intro-1
2. Product Support Services ...................................................................................................... Intro-1
3. Facility and Equipment Requirements ................................................................................... Intro-1
4. Format and Content ............................................................................................................... Intro-1
5. How to Use This Manual........................................................................................................ Intro-2
6. Associated Publications ......................................................................................................... Intro-2
7. Abbreviations and Acronyms ................................................................................................. Intro-3
8. Maintenance Task Oriented Support System (MTOSS) ........................................................ Intro-5
Description and Operation .......................................................................................................................... 1
1. Description ......................................................................................................................................1
2. Leading Particulars .........................................................................................................................8
Testing and Fault Isolation .................................................................................................................... 1001
1. General .....................................................................................................................................1001
2. Test Tools, Fixtures, and Test Equipment ................................................................................1001
3. Test Materials ...........................................................................................................................1003
4. General Test Requirements......................................................................................................1004
5. Pre-Test Examination ...............................................................................................................1004
6. Impeller Clearance Inspection ..................................................................................................1004
7. Motor-Impeller Subassembly Tests ..........................................................................................1006
8. Housing Subassembly Tests ....................................................................................................1016
9. Fault Isolation ...........................................................................................................................1019
Schematic and Wiring Diagrams........................................................................................................... 2001
1. General .....................................................................................................................................2001
Disassembly.......................................................................................................................................... 3001
1. General .....................................................................................................................................3001
2. Disassembly Tools and Equipment...........................................................................................3001
3. Disassembly Materials ..............................................................................................................3002
4. Pump Assembly ........................................................................................................................3003
5. Motor-Impeller Subassembly ....................................................................................................3003
6. Housing Subassembly ..............................................................................................................3006
Cleaning ................................................................................................................................................ 4001
1. General .....................................................................................................................................4001
2. Cleaning Tools and Equipment.................................................................................................4001
3. Cleaning Materials ....................................................................................................................4001
4. Cleaning Procedures ................................................................................................................4002
Check .................................................................................................................................................... 5001
1. General .....................................................................................................................................5001
2. Check Tools and Equipment.....................................................................................................5001
3. Check Materials ........................................................................................................................5002
4. General Inspection....................................................................................................................5002
5. X-Ray Inspection ......................................................................................................................5003
6. Spring Inspection ......................................................................................................................5010
7. Visual/Dimensional Inspection ..................................................................................................5010
8. NDI Procedures........................................................................................................................5024
28-22-04 Page TOC-1

Jan 09/2004
60-989
Repair.....................................................................................................................................................6001
1. General .....................................................................................................................................6001
2. Repair Tools and Equipment ....................................................................................................6002
3. Repair Materials........................................................................................................................6003
4. Repair Minor Thread Damage ..................................................................................................6005
5. Repair Nicks, Scratches, and Burrs ..........................................................................................6007
6. Repair Anodized and Chem-Film Finishes ...............................................................................6007
7. Replace Identification Plate ......................................................................................................6008
8. Repair or Rebuild Ground Wire Assembly ................................................................................6009
9. Replace Insulation Strips ..........................................................................................................6009
10. Repair Stator Assembly ............................................................................................................6010
11, Repair Inlet Plate Assembly and Primer Discharge Plate.........................................................6011
12, Replace Lee Plug Sets .............................................................................................................6012
13. Replace Thread Inserts ............................................................................................................6013
14. Wire Etching, Soldering, and Potting for Potted Connectors ....................................................6013
15. Shrink Sleeving Installation.......................................................................................................6023
Assembly................................................................................................................................................7001
1. General .....................................................................................................................................7001
2. Assembly Tools and Equipment ...............................................................................................7002
3. Assembly Materials...................................................................................................................7002
4. Motor-Impeller Subassembly ....................................................................................................7012
5. Housing Subassembly ..............................................................................................................7030
Fits and Clearances .............................................................................................................................. 8001
1. General .....................................................................................................................................8001
2. Torque Limits ............................................................................................................................8001
3. Wear Limits...............................................................................................................................8001
4. Assembly Clearances ...............................................................................................................8001
Special Tools, Fixtures, and Equipment.................................................................................................9001
1. General .....................................................................................................................................9001
2. Special Tools, Fixtures, and Equipment ...................................................................................9001
3. Materials ...................................................................................................................................9004
Special Procedures .................................................................................................. 11001 (Not applicable)
Removal ................................................................................................................... 12001 (Not applicable)
Installation ................................................................................................................ 13001 (Not applicable)
Servicing .................................................................................................................. 14001 (Not applicable)
Storage................................................................................................................................................ 15001
1. General ...................................................................................................................................15001
2. Storage Materials....................................................................................................................15001
3. Storage Instructions................................................................................................................15001
Rework ..................................................................................................................... 16001 (Not applicable)
Illustrated Parts List............................................................................................................................. 10001
1. General ...................................................................................................................................10001
2. Explanation and Usage...........................................................................................................10001
3. Parts Replacement Data.........................................................................................................10003
4. Equipment Designator Index ..................................................................................................10004
5. Numerical Index......................................................................................................................10004
6. Vendor Information .................................................................................................................10014
28-22-04 Page TOC-2

Jan 09/2004
60-989
LIST OF ILLUSTRATIONS
FIGURE TITLE PAGE
Intro-1 Example of Maintenance Task Oriented Support System .............................................. Intro-6

1 Motor-Impeller Subassembly ...................................................................................................3
2 Main Components (Sheet 1 of 4) .............................................................................................4
1001 Impeller Clearance and Axial Movement Inspection..........................................................1006
1002 Electrical Bonding Test Points, Motor-Impeller Subassembly ...........................................1008
1003 Functional Test Setup, Motor-Impeller Subassembly ........................................................1012
1004 Pump Inlet Tube Fabrication..............................................................................................1013
1005 Functional Test Setup, Housing Subassembly ..................................................................1018
2001 Wiring and Pin-Out Diagrams ............................................................................................2001
3001 Connector Removal Details (Sheet 1 of 3) ........................................................................3008
3002 Rotor Disassembly Details.................................................................................................3011
5001 Orientation for X-Ray Inspection........................................................................................5006
5002 Sample Radiographs (Sheet 1 of 3)...................................................................................5007
5003 Spring Check Data.............................................................................................................5010
5004 Component Check Data (Sheet 1 of 6)..............................................................................5018
6001 Ground Wire Repair ...........................................................................................................6009
6002 Repair of Inlet Plate Assembly and Primer Discharge Plate..............................................6012
6003 Looped Wire in Etchant Solution........................................................................................6019
6004 Sleeving on Hermetic Connectors with Ceramic Mounts...................................................6026
7001 Cross-Section Views – Motor-Impeller Subassembly (Sheet 1 of 8) .................................7004
7002 Primer Liner, Inlet Plate, and Tube Installation ..................................................................7016
7003 Rotor Assembly Clearance Dimensions ............................................................................7017
7004 Inlet Impeller Clearance .....................................................................................................7025
7005 Cable Assembly on End Cap Assembly (60-98902, 60-9892A, 60-98904, 60-98904A,
60-98906, 60-98906A, and 60-98976 ONLY) (Sheet 1 of 2) .............................................7026
7006 Cable Assembly on End Cap Assembly (60-98976-1 ONLY) ...........................................7028
7007 End Cap installation and Sealant Application ....................................................................7029
7008 Cross-Section Views – Housing Subassembly (Sheet 1 of 2) ...........................................7032
15001 Typical Component Packaging ........................................................................................15002
IPL Figure 1 Fuel Boost Pump Assembly.............................................................................................10018
IPL Figure 2 Motor-Impeller Subassembly (60-98902, 60-98904, 60-98906, and 60-98976 ONLY)
(Sheet 1 of 2) ...................................................................................................................10021
IPL Figure 2A Motor-Impeller Subassembly (60-9892A, 60-98904A, and 60-98906A ONLY)
(Sheet 1 of 2) ...................................................................................................................10027
IPL Figure 2B Motor-Impeller Subassembly (60-98976-1 ONLY) (Sheet 1 of 2)....................................10033
IPL Figure 3 Rotor Assembly ...............................................................................................................10039
IPL Figure 4 Housing Subassembly ....................................................................................................10041
28-22-04 Page TOC-3

Jan 09/2004
60-989
LIST OF TABLES
TABLE TITLE PAGE
Intro-1 Abbreviations and Acronyms .......................................................................................... Intro-3

1 Leading Particulars ..................................................................................................................8
1001 Tools, Fixtures, and Test Equipment .................................................................................1001
1002 Test Materials ....................................................................................................................1003
1003 Electrical Test Procedures, Motor-Impeller Subassembly .................................................1007
1004 Functional Test and Calibration Procedures......................................................................1009
1005 Pressure Rise Limits ..........................................................................................................1014
1006 Functional Test Procedures, Housing Subassembly .........................................................1016
1007 Fault Isolation Procedures .................................................................................................1019
3001 Disassembly Tools and Equipment....................................................................................3002
3002 Disassembly Materials .......................................................................................................3002
4001 Cleaning Tools and Equipment..........................................................................................4001
4002 Cleaning Materials .............................................................................................................4002
5001 Check Tools and Equipment..............................................................................................5001
5002 Check Materials .................................................................................................................5002
5003 Component Check Procedures..........................................................................................5011
6001 Repair Tools and Equipment .............................................................................................6002
6002 Repair Materials.................................................................................................................6003
6003 Thread Data .......................................................................................................................6006
7001 Assembly Tools and Equipment ........................................................................................7002
7002 Assembly Materials............................................................................................................7002
8001 Torque Limits .....................................................................................................................8001
8002 Assembly Fits and Clearances ..........................................................................................8002
9001 Special Tools, Fixtures, and Equipment ............................................................................9001
9002 Materials ............................................................................................................................9005
15001 Storage Materials.............................................................................................................15001
10001 Equipment Designator Index............................................................................................10004
10002 Numerical Index ...............................................................................................................10005
28-22-04 Page TOC-4

Jan 09/2004
60-989
INTRODUCTION
TASK 28-22-04-99F-805-A01
1. Scope
This component Maintenance Manual (CMM) contains operation and maintenance instructions and lists
replacement parts for the Fuel Boost Pump Assemblies, Motor-Impeller Subassemblies, and Housing
Subassembly listed on the title page. The pump assemblies, motor-impeller subassemblies, and housing
subassembly are made by Crane Aerospace Hydro-Aire, Inc. of Burbank, California.
TASK 28-22-04-99F-810-A01
2. Product Support Services
Repair and overhaul services, replacement parts, technical documentation, and other product support
services are available from Hydro-Aire, Inc. Please contact:
CRANE AEROSPACE
HYDRO-AIRE,INC.
3000 Winona Avenue
P.O. Box 7722
Burbank, California 91510-7722 USA
Telephone: 818-842-6121
FAX: 818-842-6117 (24 hr)
SITA: BURHYXD
WEBSITE: WWW.HYDROAIRE.COM
TASK 28-22-04-99F-815-A01
3. Facility and Equipment Requirements
This component is critical to the certified performance of the aircraft. It is therefore equally critical that all
maintenance activities performed on this component be carried out strictly in accordance with the
provisions of this publication. Only those parts identified in the Illustrated Parts List (IPL) of the CMM are
approved replacement parts.
All special tools and equipment must be calibrated within the intervals specified by the manufacturer, or a
maximum interval of six months. All calibration procedures and standards must be traceable to the U.S.
National Bureau of Standards, British Standards Institute, or equivalent national standards.
TASK 28-22-04-99F-820-A01
4. Format and Content
A. This manual is written to ATA Specification 2200 and in AECMA Simplified English. British/American
units are used in this manual, with the Standard System of Units of Measurement (admissible SI unit
and/or Specific Units of Measurement) in parentheses.
B. This manual describes maintenance on the component in a workshop. It does not describe
maintenance on the component when it is installed in the aircraft. Refer to the system Aircraft
Maintenance Manual (AMM) for on-aircraft maintenance information.
C. Only approved personnel with the necessary skills must be used for the maintenance procedures
described in this manual.
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Jan 09/2004
60-989
D. Maintenance Task Oriented Support System (MTOSS) task and subtask identification is used in this
manual. The maintenance tasks and other data have special MTOSS numbers for the use of Electronic
Data Processing (EDP). The MTOSS numbers may be ignored by the user of the manual. Refer to the
Description given below.
E. This manual contains:
(1) Technical data for the component. This CMM is current with drawing revisions as of the
publication date.
(2) Maintenance and repair procedures verified by actual performance. The verification dates are
given below.
(a) TESTING AND FAULT ISOLATION: Verified Jun 11/2003.
(b) DISASSEMBLY: Verified Jun 11/2003.
(c) ASSEMBLY: Verified Jun 11/2003.
(3) An IPL for the component parts. The parts are identified in all sections of the manual by the IPL
figure and item number.
TASK 28-22-04-99F-825-A01
5. How to Use This Manual
A. Make sure the manual contains the information applicable to your component. Look on the title page
for the part number.
B. If you need to identify a part or find a part number, refer to the IPL. The IPL has an introduction to show
the procedure.
C. The instructions in this manual must be used for all component maintenance. Read all the applicable
WARNINGS, CAUTIONS, and NOTES before you do the work on the component. WARNINGS and
CAUTIONS immediately precede the text to which they apply. NOTES immediately follow the related
text.
(1) WARNINGS are provided before potentially dangerous procedures, materials, methods, and
processes which must be followed precisely to avoid injury or death.
(2) CAUTIONS are provided before procedures, materials, methods, and processes which must be
followed precisely to avoid equipment damage.
(3) NOTES are provided after applicable procedural steps, when necessary, to highlight or clarify
information.
TASK 28-22-04-99F-830-A01
6. Associated Publications
A. The Federal Aviation Regulations (FAR) given below are incorporated in this CMM by reference.
(1) Part 43: Maintenance, Preventive Maintenance, Rebuilding and Alterations.
(2) Part 45: Identification and Registration Markings.
(3) Part 65: Certification of Airmen Other Than Flight Crew Members.
(4) Part 145: Repair Stations.

Jan 09/2004
60-989
B. The documents given below are incorporated in this CMM by reference.
(1) Acceptance Test Procedure (ATP) 60-98907, Revision C or later.
(2) ATP 60-98908, Revision N or later.
(3) ASTM Y14.38.
(4) Henkel Corporation (CAGE 84063), Technical Process Bulletin No. 1161.
(5) National Aerospace Specification NASM33540.
(6) National Aerospace Specification NAS1638.
(7) Military Specification MIL-C-5541, Class 3.
(8) Military Standard MIL-STD-45662.
(9) Requirements for Electronic Grade Solder Alloys, J-STD-006.
TASK 28-22-04-99F-832-A01
7. Abbreviations and Acronyms
A. The abbreviations and acronyms used in this CMM are defined in Table Intro-1. (Refer to Table Intro-1
"TABLE-28-22-04-99A-820-A01" on page Intro- 3.)
B. Units of measure, standard electronic terms, and circuit signal names are not listed. Refer to ASTM
Y14.38, Abbreviations and Acronyms for definitions of standard terms.
Intro-1
TABLE 28-22-04-99A-820-A01
Abbreviations and Acronyms—Table Intro-1
ITEM DEFINITION
AC Alternating Current
AD Airworthiness Directive
AEB Airline Engineering Bulletin
AECMA Association Europeene des Constructeurs de Materiel Aerospatial
ALT Alternate
AMM Aircraft Maintenance Manual
AR As Required
ASTM American Society for Testing and Materials
ATA Air Transport Association
ATP Acceptance Test Procedure
BMS Boeing Material Specification
CAGE Commercial And Government Entity
CMM Component Maintenance Manual
CSD Control Specification Drawing
EDP Electronic Data Processing
EFF Effectivity
Abbreviations and Acronyms (Sheet 1 of 2)—Table Intro-1

Jan 09/2004
60-989
ITEM DEFINITION
ESDS Electrostatic Discharge Sensitive
FAR Federal Aviation Regulation
FIG. Figure
GEO LOC Geographic Location
GN2 Gaseous Nitrogen
IPL Illustrated Parts List
LEP List of Effective Pages
LRU Line Replaceable Unit
MEK Methyl-Ethyl-Ketone
MTOSS Maintenance Task Oriented Support System
NHA Next Higher Assembly
NDI Non-Destructive Inspection
NO. Number
OJT On-The-Job
OPT Optional
P/N Part Number
PRFD Preferred
RA Roughness Average
REV. Revision
RF Reference
RPLCD Replaced
RPLCS Replaces
RWK Rework
SAE Society of Automotive Engineers
SB Service Bulletin
SCD Source Control Drawing
SGML Standard Generalized Markup Language
SIL Service Information Letter
SUPSD Superseded
SUPSDS Supersedes
TIR Total Indicator Reading
THD Thread
TR Temporary Revision
TTL REQ. Total Required
UUT Unit Under Test
V Vendor
Abbreviations and Acronyms (Sheet 2 of 2)—Table Intro-1

Jan 09/2004
60-989
TASK 28-22-04-99F-835-A01
8. Maintenance Task Oriented Support System (MTOSS)
A. The MTOSS is used for Electronic Data Processing of Maintenance data.
NOTE: For more information refer to Component Maintenance Manual, Section 2-5-3, in the Air
Transport Association (ATA) iSpec 2200.
(1) The MTOSS system uses standard and unique number combinations to identify maintenance
tasks and sub-tasks.
(2) The MTOSS structure is a logical approach to organize maintenance tasks and sub-tasks. The
MTOSS numbering system includes the ATA chapter-section-subject number as well as a
function code and unique identifiers.
(3) The purpose of incorporating the MTOSS numbering system is to provide a means for the
automated sorting, retrieval, and management of digitized data.
B. The MTOSS numbering system is an expansion of the ATA three element numbering system. An
MTOSS number has seven elements of which the first five elements are mandatory for each task and
sub-task. The sixth and seventh elements are applied when necessary. This CMM incorporates the
use of six of the seven elements. The elements are specified as follows: (Refer to Figure Intro 1
"GRAPHIC-28-22-04-99B-806-A01" on page Intro- 6.)
(1) Elements 1, 2, and 3 - These elements are the Chapter, Section, and Subject (ATA) numbers.
(a) Element 1: CHAPTER
(b) Element 2: SECTION
(c) Element 3: SUBJECT
(2) Element 4 - The fourth element numerically gives the maintenance function of the Task.
NOTE: For more information on maintenance functions, refer to Component Maintenance

Manual, Section 2-5-3, in the ATA Specification 100.
(a) Maintenance function code 990 is expanded as follows in this CMM.
1 99A - Is used to identify TABLES
2 99B - Is used to identify ILLUSTRATIONS
3 99C - Is used to identify FRONT MATTER for PAGE BLOCK or TASK
4 99D - Is used to identify ACCESS
5 99E - Is used to identify REFERENCES
6 99F - Is used to identify GENERAL/INTRODUCTION
(b) Maintenance function code 940 is expanded as follows in this CMM.
1 94A - Is used to identify CONSUMABLES and MATERIALS
2 94B - Is used to identify TOOLS, FIXTURES, and EQUIPMENT
(3) Element 5 - The fifth element makes the Task or Subtask unique for all tasks or sub-tasks which
have the same first four elements. Tasks are numbered from 801 through 999. Sub-tasks are
numbered 001 through 800.

Jan 09/2004
60-989
(4) Element 6 - The sixth element is a three position alpha-numeric number which identifies
differences in configurations or methods and techniques, variations of standard practice
applications, etc. Most tasks in this CMM use "A01" as the sixth element. This shows the task is
used for all configurations with no variation. If the sixth element is an "S01", it shows that a
service bulletin is related to the task.
(5) Element 7 - The seventh element is a three position alpha-numeric number for customer use.
Intro 1
28-22-04-99B-806-A01-001.cgm
NOTE: ELEMENT NO.7 IS NOT USED.
GRAPHIC 28-22-04-99B-806-A01
Example of Maintenance Task Oriented Support System
Figure Intro 1

Jan 09/2004
60-989
DESCRIPTION AND OPERATION
TASK 28-22-04-870-810-A01
1. Description
A. Purpose
(1) The fuel boost assembly is an AC motor driven pump with reprime capability. It provides aircraft
fuel to an engine-driven fuel pump.
(2) The motor-impeller subassembly and housing subassembly are components of the fuel boost
pump. The motor-impeller mounts inside the pump housing subassembly, as shown in Figure 1,
which is semi-permanently mounted in the aircraft fuel tank. When coupled with an inlet and
discharge check valve (not supplied by Hydro-Aire), the motor-impeller subassembly can be
removed from and replaced in the aircraft-mounted housing without draining the fuel tank.
(3) The motor-impeler and housing subassemblies are purchased separately. The motor-impeller
subassembly is interchangeable with all like housing subassemblies.
B. Differences Between Configurations
(1) This CMM covers seven configurations of the 60-989 series pump assemblies. The differences
between the configuratios are in the motor-impeller subassemblies and housing subassemblies.
(2) Each pump assembly configuration can be upgraded to the improved P/N 60-98976-4 motor-
impeler subassembly. The upgrade installs a pottingless connector to prevent the accumulation
of corrosive or conductive fuel contaminants that can lead to electrical arcing and possible fuel
leaks. Refer to Service Bulletins 60-98902-28-1, 60-98904-28-1, 60-98906-28-1, and 60-98976-
28-1 and modification kit 60-98976-4902. Refer to CMM 28-22-07 for maintenance instructions
and an IPL for motor-impeller subassembly P/N 60-98976-4.
C. Primary Components
(1) Pump Assemblies
(a) The primary components of the pump assemblies are described below and shown in
Figures 1 and 2. (See Figure 1 "GRAPHIC-28-22-04-99B-801-A01" on page 3.)(See Figure
2 "GRAPHIC-28-22-04-99B-802-A01" on page 4.)
(b) Wiring and pin-out diagrams are shown in SCHEMATIC AND WIRING DIAGRAMS.
(c) The pump assemblies are made up of a motor-impeller subassembly mounted inside a
housing subassembly with standard hardware.
(2) Motor-Impeller Subassemblies
(a) The primary components of the motor-impeller subassemblies are described below and
shown in Figure 2.
(b) Each motor-impeller subassembly is powered by the three-phase stator assembly (AC
motor). The stator assembly consists of six AC coils installed on a stator stack assembly.
Three thermal fuses prevent overheating of the coils.
(c) The rotor assembly is made up of the primer impeller, tolerance ring, thrust bearing holder,
gimbal plate, thrust bearing plate, thrust washer, and rotor/shaft assembly. It fits inside the
stator assembly and extends through the center of the inner housing. The inlet impeller is
attached to the inlet end of the shaft.
28-22-04 Page 1
Jan 09/2004
60-989
(d) When the stator assembly is energized, an induced field causes the rotor assembly and
inlet impeller to rotate. The rotor assembly shaft turns in bearing assemblies mounted in the
inner housing and end cap. The bearing assemblies are held in place by bearing holder
assemblies and retaining rings.
(e) The end cap provides a mounting boss for the connector, a port for the AN814-4DL drain
plug, and a mounting socket for one of the two bearing assemblies. It also provides an
integral handle to aid removal of the motor-impeller subassembly from the pump housing
subassembly. The ground wire assembly is attached to the back side. The end cap can be
removed for maintenance access to the stator assembly and other internal components.
(f) The connectors used on the early configurations mate with BACC45FM14C456 connectors
with a 14-4 insert arrangement. The connectors used on the 60-98976-4 motor-impeller
subassembly mate with BACC45FM14C456 connector with a 14-4 insert arrangement. The
three wire leads from the stator assembly (one for each phase) and the ground wire lead
are soldered directly to pin contacts in the connector and insulated with potting compound
(early configurations) or insulation sleeving (upgraded configuration).
(g) The inner housing is machined from a single aluminum casting. It includes a mounting boss
and threads for the end cap and a housing for the stator assembly and other internal
components.
(h) The inner housing fits directly inside the housing subassembly and is secured by standard
hardware. Packings provided with the motor-impeller subassembly seal between the inner
housing and pump housing.
(3) Housing Subassembly
(a) The primary components of the housing subassemblies are described below and shown in
Figure 2. THIS PAGE INTENTIONALLY LEFT BLANK
(b) The primer check valve assembly is made up of a torsion spring, flapper assembly, and
valve seat. It mounts on the outer housing assembly primer discharge boss under the
primer discharge port. Packings seal between the check valve, housing, and primer
discharge port. The torsion spring is pre-loaded to close the flapper assembly. The flapper
assembly includes a rubber seal that seals against the valve cap.
(c) The outer housing assembly provides a sealed enclosure to hold the motor-impeller
subassembly. Threaded inserts are provided in the motor-impeller mounting flange and
aircraft mounting flange.
D. Operation
(1) The motor-impeller stator assembly is energized with 115/200 Vac, 400 Hz, 3-phase aircraft
power. With the motor energized and fuel available at the housing inlet port, the stator assembly
turns the rotor assembly shaft and inlet impeller. This pumps (impels) fuel from the housing inlet
port to the outlet port at the rated flow given in Table 1.
(2) With the motor energized and no fuel available at the inlet port, the primer impeller supplies the
self-priming function so that the pump can start operation when fuel again becomes available at
the inlet port. The unit will reprime after up to 11 minutes with the pump running dry.
(3) The stator assembly includes a non-resettable thermal fuse in each of the three phases. The
thermal fuses open at 375 °F (191 °C) to protect the stator assembly coils from overheating.
28-22-04 Page 2
Jan 09/2004
60-989
PART NUMBERS
60-98902, 60-98904, 60-98906,
AND 60-98976
PART NUMBERS
60-98902A, 60-98904A,
AND 60-98906A
PART NUMBER
60-98976-1
28-22-04-99B-801-A01-001.cgm
GRAPHIC 28-22-04-99B-801-A01
Motor-Impeller Subassembly
Figure 1
28-22-04 Page 3
Jan 09/2004
60-989
PART NUMBERS
60-98902, 60-98904, 60-98906,
AND 60-98976
ROTOR
BEARING ASSEMBLY CONNECTOR
ASSEMBLY
INDUCER
INLET
ADAPTOR INLET PUMP
IMPELLER INNER BEARING REMOVAL
STATOR
HOUSING ASSEMBLY BRACKET
ASSEMBLY
ASSEMBLY ASSEMBLY
ROTOR
ASSEMBLY THRUST
BEARING
PRIMER
HOLDER
LINER GIMBAL
PLATE
ROTOR/SHAFT
ASSEMBLY
PRIMER
IMPELLER
28-22-04-99B-802-A01-001.cgm
THRUST
INLET THRUST WASHER
PLATE BEARING
ASSEMBLY PLATE
PRIMER
DISCHARGE
PLATE
GRAPHIC 28-22-04-99B-802-A01 Main Components (Sheet 1 of 4)

Figure 2
28-22-04 Page 4
Jan 09/2004
60-989
PART NUMBERS
60-98902A, 60-98904A,
AND 60-98906A
ROTOR
BEARING ASSEMBLY CONNECTOR
ASSEMBLY
INDUCER
INLET
ADAPTOR INLET PUMP
STATOR
ASSEMBLY
ASSEMBLY ASSEMBLY
ROTOR
ASSEMBLY THRUST
BEARING
PRIMER
HOLDER
LINER GIMBAL
PLATE
ROTOR/SHAFT
ASSEMBLY
PRIMER
IMPELLER
28-22-04-99B-802-A01-002.cgm
THRUST
INLET THRUST WASHER
PLATE BEARING
ASSEMBLY PLATE
PRIMER
DISCHARGE
PLATE
Main Components (Sheet 2 of 4)

Figure 2
28-22-04 Page 5
Jan 09/2004
60-989
PART NUMBER
60-98976-1
ROTOR
BEARING ASSEMBLY
ASSEMBLY
CONNECTOR
INDUCER
INLET
ADAPTOR INLET PUMP
STATOR
ASSEMBLY
ASSEMBLY ASSEMBLY
ROTOR
ASSEMBLY THRUST
BEARING
PRIMER
HOLDER
LINER GIMBAL
PLATE
ROTOR/SHAFT
ASSEMBLY
PRIMER
IMPELLER
28-22-04-99B-802-A01-003.cgm
THRUST
INLET THRUST WASHER
PLATE BEARING
ASSEMBLY PLATE
PRIMER
DISCHARGE
PLATE

Figure 2
28-22-04 Page 6
Jan 09/2004
60-989
HOUSING
SUBASSEMBLY
PRIMER CHECK
VALVE ASSEMBLY
FLAPPER
VALVE ASSEMBLY
SEAT
DISCHARGE
PRIMER
PIN
DISCHARGE
PORT
TORSION
SPRING
28-22-04-99B-802-A01-004.cgm
INLET
HYDRO-AIRE, INC.
A SUBSIDIARY OF CRANE CO.
HOUSING SUB-ASSY
TBC SCD NO. 60B89004-1
HYDRO-AIRE PN 60-98901
SERIAL NO. 07740034

Figure 2
28-22-04 Page 7
Jan 09/2004
60-989
TASK 28-22-04-870-812-A01
2. Leading Particulars
The leading particulars of the pump assembly are given in Table 1. (Refer to Table 1 "TABLE-28-22-04-
99A-822-A01" on page 8.)
TABLE 28-22-04-99A-822-A01 Leading Particulars—Table 1
ITEM SPECIFICATION
Manufacturer Hydro-Aire, Inc. (V81982)
Part Numbers:
Hydro-Aire, Inc. 60-689, -1, -2, -3, -5, -6, -8
Boeing Aircraft Company 60B92404
Nomenclature Fuel Boost Pump Assembly
Functional Performance:
Type AC motor-driven self-priming boost pump
Fluid MIL-T-5624G, Grades JP-4 and JP-5 and ASTM D 1655

Aviation Turbine Fuels
Pressure Limits:
Operating 50 psig (345 kPag) maximum
Proof 75 psig (517 kPag) minimum
Burst 125 psig (862 kPag) minimum
Negative -6 psig (-41 kPag) minimum
Input Power:
Voltage
Nominal 115/200 Vac, 3-phase
Range 180 to 220 Vac
Frequency
Nominal 400 Hz
Range 380 to 420 Hz
Power Requirement 1,350 Watts maximum with 0.75 minimum power factor
Circuit Protection Non-resettable thermal fuses (one for each phase)
Rated Flow at Sea Level Estimated at 28,000 lb/hr (pph) (3.54 kg/s) at 12 psi
(83 kPa) minimum pressure rise with JP-4 fluid at specific
gravity of 0.75, temperature 110 °F (43 °C) and sea level
Pressure and Leakage Limits:

Housing Subassembly
Negative Pressure No external leakage at -6 psig (-42 kPag)
Positive Pressure
2 to 50 psig (14 to 345 kPag) No external leakage
75 psig (517 kPag) 1 drop per minute maximum through housing walls only
Discharge Check Valve 5 cc/minute maximum at 0.5 to 5.0 psig (3.4 to 34.5 kPag)
Leading Particulars (Sheet 1 of 2)—Table 1
28-22-04 Page 8
Jan 09/2004
60-989
ITEM SPECIFICATION
Temperature Limits:
Fluid -65 to 135 °F (-54 to 57 °C)
Ambient -65 to 160 °F (-54 to 71 °C)
Connector Specifications:
Receptacle Type 60-703108
Mating Connector BACC45FM14C456
Physical Characteristics:
Pump Assembly
Envelope Dimensions:
Length 12.26 inches (311.4 mm) maximum from inlet flange to
outer end of connector
Diameters
Inlet Flange 7.15 inches (181.6 mm) maximum
Motor-Impeller Flange 4.20 inch (106.7 mm) diameter hole pattern
Weight 7.6 lb (3.5 kg) maximum
Mounting Provisions
Inlet Flange Six 0.279 to 0.291 inch (7.09 to 7.39 mm) diameter thru
holes on 4.20 inch (106.7 mm) diameter
Motor-Impeller Flange Twelve MS21209F4-15P inserts with 0.250-28UNF thread
on 6.00 inch (152.4 mm) diameter
Motor-Impeller Subassembly
Envelope Dimensions
Length 9.3 inches (236 mm) maximum
Diameter 4.5 inches (114 mm) maximum
Weight
60-98902, 60-9802A, 60-98904,
60-98904A, 60-98906, 60-98906A,
and 60-98976 6.83 lb (3.10kg) maximum
60-98976-1 7.00 lb (3.18 kg) maximum
Mounting Provisions Five 0.186 to 0.192 inch (4.72 to 4.88 mm) diameter thru
Housing Subassembly
Envelope Dimensions
Length 8.46 inches (214.9 mm) between outside surfaces of inlet
and motor-impeller flanges
Diameters
Inlet Flange 7.15 inches (181.6 mm) maximum
Motor-Impeller Flange 4.20 inch (106.7 mm) diameter hole pattern
Weight 3.37 lb (1.53 kg) maximum
Mounting Provisions
Inlet Flange Six 0.279 to 0.291 inch (7.09 to 7.39 mm) diameter thru
Motor-Impeller Flange Twelve MS21209F4-15P inserts with 0.250-28UNF thread
on 6.00 inch (152.4 mm) diameter
Six MS122119 inserts with 0.164-32UNC thread on 4.00
inch (101.6 mm) diameter
Leading Particulars (Sheet 2 of 2)—Table 1
28-22-04 Page 9
Jan 09/2004
60-989
28-22-04 Page 10
Jan 09/2004
60-989
TESTING AND FAULT ISOLATION
TASK 28-22-04-99C-820-A01
1. General
A. This section contains test, calibration, and fault isolation procedures for the Fuel Boost Pump
Assembly.
(1) Perform the test and calibration procedures before disassembly as an aid to fault isolation.
Perform the procedures after assembly to verify unit operation. Separate test procedures are
provided for the motor-impeller subassembly and housing subassembly.
(2) Before tests of the motor-impeller subassembly, check the clearance between the inlet adapter
(20, IPL Figures 2, 2A, and 2B) and inlet impeller (35) before and after test. The check
procedures are included in this section before the motor-impeller test procedures.
(3) If a malfunction or incorrect result is found, refer to the fault isolation procedures for the probable
cause and corrective action. Do the test again after the unit is repaired.
B. The tests must be done in the sequence presented to prevent omissions and errors.
C. Referenced Information
(1) Acceptance Test Procedure (ATP) 60-98902, Revision E or later and ATP 60-98904, Revision N
or later.
(2) Military Standard MIL-STD-45662.
(3) National Aerospace Specification NAS1638.
TASK 28-22-04-94B-822-A01
2. Test Tools, Fixtures, and Test Equipment
A. The recommended tools, fixtures, and test equipment are given in Table 1001. (Refer to Table 1001
"TABLE-28-22-04-99A-823-A01" on page 1001.)
NOTE: Equivalent items can be used.
B. All test equipment must be in current calibration to MIL-STD-45662. The required accuracy is given in
the table of tools, fixtures, and equipment.
1001
TABLE 28-22-04-99A-823-A01
Tools, Fixtures, and Test Equipment—Table 1001
PART OR SPECIFICATION
NOMENCLATURE SOURCE (CAGE) *
NUMBER
Ammeter, AC (3 Required) Model 904; 0 to 10 Amp; ± 0.5% accuracy Weston Instruments Inc.
(V3N285)
Check Valve, Discharge Model 217200-1 (Boeing P/N 10-60526-2) HR Textron, Inc.
APCO Division
(V96124)
* Refer to the IPL for the address.
** "x-count” is the number of least significant digits.
Tools, Fixtures, and Test Equipment (Sheet 1 of 3)—Table 1001
28-22-04 Page 1001

Jan 09/2004
60-989
NUMBER
Circulating Pump Corcoran Model 2000; 30 gpm (113 lpm) Frederick Pump Co. (V04TR4)
at 30 psi (207 kPa)
Clock, Time Model S-1; 0 to 5 seconds; 0.01 second Standard Instrumentation Inc.
accuracy (V66466)
Dielectric Tester 100 megohm at 500 Vdc, 6 mA at 1500 Commercially Available
Vac rms; 5% of full scale accuracy
Flow Counter Model 5214-L; 1% accuracy Hewlett-Packard Co. (V28480)
Flowmeter, 1.5 Inch AN 24; 10 to 75 gpm (38 to 284 lpm); 1% Cox Air Gauge System
(38 mm) accuracy (V86292)
Frequency Meter Model 22-173; 45 to 999.9 Hz at 0 to 122 Arga Controls Inc. (V50290)
°F (50 °C); ± 0.1 Hz accuracy
Gate Valve, 1.0 and 1.5 Inch Models 430 and 438 Crane Co. (V14959)
(25 and 38 mm)
Heat Exchanger Model F606EY2P; 30 gpm (113 lpm) at Young Radiator Co. (V8M984)
100 to 160 °F (38 to 71 °C)
Inlet Tube, Pump To Boeing Spec. 60B89004; Refer to Local Fabrication
Figure 1004
Micro-Ohmmeter Model 580; Keithley Instruments Inc.
200 kilohms ±0.075% + 2 count ** (V80164)
20 kilohms ±0.05% + 2 count
200 milliohms ±0.04% + 3 count
Microswitch Model EX-AR; explosion-proof, normally- Sypris Data Systems Inc.
open (V28009)
Potentiometer Model BB201J; -10 to 1200 °F (-23 to 649 Omega Engineering, Inc.
°C) ± 2.8 °F (1.6 °C); ± 0.1% accuracy (V29007)
Power Supply, AC Model A3334-1; 200 Vac, 400 Hz, Magnetek Inc. (V0B4V8)
3-Phase, 25 kW
Pressure Gage, JP-4 or Model 1801-T; 0 to 60 psig (414 kPag); U. S. Gage
P-D-680 Fluid 0.5% accuracy
Pressure Switch Model 608G-1; normally-closed, Custom Components Inc.
adjustable 0 to 30 psig (207 kPag) (V62117)
actuation pressure
Reservoir No Specific; 600 gallon (2271 liter) Commercially Available
minimum tank
Scale, Weight Model D5; 0 to 10 lbs (4.5 kg) ± 0.15% Ohaus Corp. (V85973)
Test Housing T-32411 (or pump housing subassembly Hydro-Aire, Inc. (V81982)
60-98901, 60-98903, or 60-98905)
28-22-04 Page 1002

Jan 09/2004
60-989
NUMBER
Thermocouple Junction Type J, Stainless Steel Sheath; 32 to 1382 Omega Engineering, Inc.
°F; (0 to 750 °C); ± 2 °F (1 °C) or 0.5% (V29007)
accuracy, whichever is greater
Voltmeter Model 433; 0 to 150 Vdc, 0 to 300 Vac; Weston Instruments Inc.
± 0.75% accuracy (V3N285)
Wattmeter Model 3-447; 0 to 333 W X20 (current Arga Controls Inc. (V50290)
ratio); 1% of full scale accuracy
TASK 28-22-04-94B-824-A01
3. Test Materials
WARNING: JP-4 FUEL IS VERY FLAMMABLE. THE LIQUID CAN KILL IF SWALLOWED AND CAN
CAUSE EYE AND SKIN IRRITATION. VAPORS CAN CAUSE IRRITATION OF THE EYES,
RESPIRATORY TRACT, AND NERVOUS SYSTEM. KEEP FUEL AWAY FROM SPARKS,
OPEN FLAMES, AND HEAT. DO NOT BREATHE VAPORS. KEEP CONTAINERS
CLOSED. MAKE SURE THE WORK AREA HAS SUFFICIENT AIR FLOW TO KEEP
VAPOR CONCENTRATIONS BELOW DANGEROUS LIMITS. WEAR CHEMICAL
SAFETY GOGGLES AND PROTECTIVE CLOTHING SUCH AS GLOVES, APRON, AND
BOOTS. COVER YOUR FACE WHEN THE CONDITIONS OR FREQUENCY OF USE
MAKE FACIAL EXPOSURE POSSIBLE.
WARNING: STODDARD SOLVENT P-D-680 IS TOXIC AND FLAMMABLE AND CAN CAUSE
INJURY. DO NOT ALLOW THE SOLVENT TO TOUCH THE SKIN FOR LONG PERIODS
OF TIME. KEEP AWAY FROM OPEN FLAMES. MAKE SURE THERE IS SUFFICIENT AIR
FLOW IN THE WORK AREA TO KEEP VAPOR CONCENTRATIONS BELOW
DANGEROUS LIMITS.
A. The recommended materials are given in Table 1002. Equivalent items can be used.
(Refer to Table 1002 "TABLE-28-22-04-99A-826-A01" on page 1003.)
1002
TABLE 28-22-04-99A-826-A01 Test Materials—Table 1002
NUMBER
Calibration Fluid (Optional Test Military Specification MIL-C-7024 Commercially Available

Fluid)
Cap, Protective, Tapered EP-16 Protective Closures Co., Inc.

(Connector) (V99017)
Test Materials (Sheet 1 of 2)—Table 1002
28-22-04 Page 1003

Jan 09/2004
60-989
NUMBER
Jet Fuel, JP-4 Military Specification MIL-T-5624 Commercially Available
Stoddard Solvent (Optional Test Federal Specification P-D-680, Type II Commercially Available
Fluid)
Test Materials (Sheet 2 of 2)—Table 1002
TASK 28-22-04-700-801-A01
4. General Test Requirements
A. The tests must be done in the sequence presented to prevent omissions and errors.
B. The tests can be done at prevailing laboratory conditions.
C. Use JP-4 jet fuel, Stoddard solvent, or calibration fluid (Table 1002) as the test fluid. Unless otherwise
specified, the fluid temperature must be held between 60 and 90 °F (16 and 32 °C).
D. Unless otherwise specified, the motor-impeller subassembly (also referred to as the Unit Under Test or
UUT) requires 115/200 ± 2 Vac, 400 ± 1 Hz, 3-phase power.
TASK 28-22-04-700-803-A01
5. Pre-Test Examination
A. Visually examine the UUT for workmanship and visible damage. Pay special attention to the item
identification, cleanliness, and the condition of the electrical connector, ports, and finishes. Refer to
CHECK for more details.
B. Use the weight scale to weigh the unit. Units 60-98902, 60-9802A, 60-98904, 60-98904A, 60-98906,
60-98906A, and 60-98976 must not exceed 6.83 lb (3.10 kg). Unit 60-98976-1 must not exceed 7.00 lb
(3.18 kg).
TASK 28-22-04-700-805-A01
6. Impeller Clearance Inspection
A. Verify that the inducer (30, IPL Figures 2, 2A, and 2B) and inlet impeller (35) rotate freely and do not
rub the inlet adapter (20). (See Figure 1001 "GRAPHIC-28-22-04-99B-826-A01" on page 1006.)
B. Mark the inlet adapter (20) with indelible ink next to the V GROOVE at point A (Figure 1001) to aid later
alignment.
C. Check the axial movement of the inducer (30) and inlet impeller (35), as follows:
(1) Before the test, move the inducer (30) and inlet impeller (35) in and out as shown in Figure 1001.
The total axial movement must not exceed 0.001 to 0.004 inch (0.025 to 0.102 mm).
(2) After the test, line up the marks on the inlet impeller (35) and inlet adapter (20), and do the
measurement again. The axial movement must be 0.001 inch (0.025 mm) minimum and not more
than 0.002 inch (0.051 mm) greater than the pre-test measurement.
(3) If the axial movement is greater than specified, remove, check, and reassemble the thrust washer
(45, IPL Figure 3) and primer impeller (20).
28-22-04 Page 1004

Jan 09/2004
60-989
D. Measure the clearance between the inlet adapter (20, IPL Figures 2, 2A, and 2B) and inlet impeller
(35), as follows:
(1) Position the inlet impeller (35) toward the inlet adapter (20).
(2) Use a feeler gage to measure the clearance between the inlet adapter (20) and inlet impeller (35)
as shown in Figure 1001.
NOTE: The feeler gage must have a width of 0.200 inch (5.01 mm) or less and a thickness of
0.007 to 0.010 inch (0.178 to 0.254 mm).
(3) The clearance must be 0.007 to 0.010 inch (0.178 to 0.254 mm).
E. If the clearance is not 0.007 to 0.010 inch (0.178 to 0.254 mm), remove the inlet adapter (20), inducer
(30), inlet impeller (35), and drive pin (50) to access the shim(s) (55 and/or 60). Add or remove shim(s)
as needed to adjust the clearance.
NOTE: The ratio of clearance to shim is 1:2. That is, a 0.001 inch (0.025 mm) difference in clearance
makes a 0.002 inch (0.051 mm) change in shims necessary. For example, if the clearance is
0.005 inch (0.127 mm), remove 0.008 inch (0.203 mm) thickness of shims to get a 0.009 inch
(0.229 mm) inlet impeller-to-inlet adapter clearance. If the clearance is 0.012 inch (0.305 mm),
add 0.008 inch (0.203 mm) thickness of shims to get a 0.008 inch (0.203 mm) inlet impeller-to-
inlet adapter clearance.
28-22-04 Page 1005

Jan 09/2004
60-989
1001
V-GROOVE IN
"A" MARK(APPROXIMATELY) INLET ADAPTER
ON INLET IMPELLER (35) (20)
SHIM(S)
(55 AND/OR 60)
(AS REQUIRED)
SELF-LOCKING
SCREW (40)
INLET
ADAPTER
(20)
3.060 (77.72)
MAXIMUM 0.001 TO 0.004
DIAMETER (0.025 TO 0.102)
OVER LOCKWIRE AXIAL MOVEMENT
INDUCER
(30)
SCREW (25)
(3 PLACES)
28-22-04-99B-826-A01-001.cgm
INLET
IMPELLER (35)
NOTES: 1. THE ITEM NUMBERS IN 0.007 TO 0.010

PARENTHESES REFER (0.178 TO 0.254)
TO IPL FIGURES 2, 2A, CLEARANCE BETWEEN
AND 2B. INLET ADAPTER (20)
2. THE DIMENSIONS ARE AND INLET IMPELLER (35)
GIVEN IN INCHES (MM).
GRAPHIC 28-22-04-99B-826-A01
Impeller Clearance and Axial Movement Inspection
Figure 1001
TASK 28-22-04-700-807-A01
7. Motor-Impeller Subassembly Tests
A. Electrical Tests
(1) Refer to Table 1003 for motor-impeller electrical test procedures. (Refer to Table 1003 "TABLE-
28-22-04-99A-830-A01" on page 1007.)
28-22-04 Page 1006

Jan 09/2004
60-989
1003
TABLE 28-22-04-99A-830-A01
Electrical Test Procedures, Motor-Impeller Subassembly—Table 1003
STEP ACTION RESULT

INSULATION RESISTANCE AND DIELECTRIC TEST
WARNING: HIGH VOLTAGE IS USED FOR THIS TEST. USE EXTREME CAUTION AND
FOLLOW STANDARD ELECTRICAL SAFETY GUIDELINES.
1 Electrically connect and short together pins 1, 2, and 3 of
the connector (70, IPL Figures 2, 2A, and 2B).
2 Connect the dielectric tester (Table 1001) between the
shorted pins and the connector (70), pin 4.
3 Apply and maintain 500 Vdc at a uniform rate not to The insulation resistance must be 100
exceed 100 Volts/second. Hold the voltage for 1 minute megohms or greater.
minimum, then decrease the voltage at the same rate.
CAUTION: THE DIELECTRIC TEST IS A DESTRUCTIVE TEST. DO THIS TEST ONLY IF
FAILURE OF THE STATOR ASSEMBLY IS SUSPECTED. THE UNIT IS TESTED AT 1500 VAC
RMS AT THE FACTORY. FOR FIELD TESTS, DECREASE THE APPLIED VOLTAGE TO 1125
VAC RMS. REPEATED TESTS CAN DAMAGE THE STATOR CIRCUIT.
4 Apply 1125 Vac rms, 60 Hz at a uniform rate between 250 There must be no arc-over, flash-over,
and 500 Volts/second. Hold the voltage for one minute, or other evidence of insulation
then decrease the voltage at the same rate. breakdown. The AC leakage current
must not exceed 6 mA.
NOTE: Fluctuations in the leakage current or a steady increase in leakage current indicate
failure.
5 Apply and maintain 500 Vdc at a uniform rate not to The insulation resistance must be 100
exceed 100 Volts/second. Hold the voltage for 1 minute megohms or greater.
minimum, then decrease the voltage at the same rate.
6 Disconnect the dielectric tester.
ELECTRICAL BONDING TEST
1 Use the micro-ohmmeter (Table 1001) to measure the The resistance must not exceed
resistance between the bare metal on the back side of the 0.010 Ohm.
end cap assembly (150) flange and the connector (70), pin
4. Set the micro-ohmmeter scale to the 200 milliohm
range or less. (See Figure 1002 "GRAPHIC-28-22-04-
99B-828-A01" on page 1008.)
2 Measure the resistance between the connector (70) shell The resistance must not exceed
and the bare metal on the back side of the end cap 0.005 Ohm.
assembly (150) flange.
3 Measure the resistance between the bracket assembly The resistance must not exceed
(120) and the bare metal on the back side of the end cap 0.005 Ohm.
assembly (150) flange.
Electrical Test Procedures, Motor-Impeller Subassembly —Table 1003
28-22-04 Page 1007

Jan 09/2004
60-989
1002
0.005 MAXIMUM
MICRO-
OHMMETER
END CAP
ASSEMBLY
(150)
BRACKET ASSEMBLY
MOUNTING LUG
CONNECTOR
(70)
PIN 4
INNER
HOUSING
ASSEMBLY
(210)
MICRO-
OHMMETER
0.005 MAXIMUM
MICRO-
28-22-04-99B-828-A01-001.cgm
OHMMETER
0.010 MAXIMUM BRACKET
ASSEMBLY (120)
NOTES: 1. THE ITEM NUMBERS IN
PARENTHESES REFER
TO IPL FIGURES 2, 2A, AND 2B.
2. USE CONDUCTIVE SURFACE ON END CAP
NEXT TO THE BRACKET MOUNTING LUG
TO MEASURING BONDING RESISTANCE.
GRAPHIC 28-22-04-99B-828-A01
Electrical Bonding Test Points, Motor-Impeller Subassembly
Figure 1002
B. Functional Test Procedures
(1) Refer to Table 1004 for functional test and calibration procedures. Refer to the fault isolation
procedures given later in this section if a test fails. (Refer to Table 1004 "TABLE-28-22-04-99A-
840-A01" on page 1009.)
(2) When specified in the test procedures, refer to Figure 1003 for a test setup diagram. Local
fabrication dimensions for the pump inlet tube are shown in Figure 1004. (See Figure 1003
"GRAPHIC-28-22-04-99B-830-A01" on page 1012.) (See Figure 1004 "GRAPHIC-28-22-04-
99B-831-A01" on page 1013.)
28-22-04 Page 1008

Jan 09/2004
60-989
1004
TABLE 28-22-04-99A-840-A01
Functional Test and Calibration Procedures—Table 1004
STEP ACTION RESULT
EXTERNAL LEAKAGE TEST
1 Install the UUT into the test housing (Table 1001) or

pump housing subassembly.
2 Install the test housing or pump housing subassembly

in the test setup shown in Figure 1003. (See Figure
1003 "GRAPHIC-28-22-04-99B-830-A01" on
page 1012.)
NOTE: Dimensions for local fabrication of the inlet tube are given in Figure 1004. (See Figure
3 Cap the outlet and vent ports.
NOTE: Refer to DESCRIPTION AND OPERATION to identify and locate components. The
vent port is located at the top of the test housing.
4 Apply fluid pressure to the test housing inlet port.

Bleed all air from the UUT.
5 Apply 2 psig (14 kPag) pressure to the inlet port for 5 There must be no external leakage.
minutes.
6 Apply 50 psig (345 kPag) pressure to the inlet port for There must be no external leakage.
5 minutes.
7 Decrease the pressure to zero.
BREAK-IN RUN TEST
CAUTION:THE UUT REQUIRES 200 ± 2 VAC, 400 ± 1 HZ, 3-PHASE POWER.
1 Install the test housing or pump housing subassembly

with installed UUT in the test setup shown in Figure
1003.
2 Operate the UUT for 15 minutes at a flow rate of The UUT must operate properly for the
28,000 pph (3.5 kg/s) with the tank fluid level 4 to 15 full 15 minute test.
inches (10 to 38 cm) above the bellmouth of the inlet
tube. Measure and record the current of each phase The current must not exceed 7.8 Amps.
at the start and end of the 15 minute test. The phase unbalance must not exceed
10 percent.
CALIBRATION
1 Install the test housing with installed UUT in the test

setup shown in Figure 1003.
Functional Test and Calibration Procedures (Sheet 1 of 3)—Table 1004
28-22-04 Page 1009

Jan 09/2004
60-989
STEP ACTION RESULT
2 Operate the UUT at each of the flow rates given The pressure rise limits must be within
below. Keep the tank fluid level 10 to 15 inches (25 to the limits given in Table 1005 for the
38 cm) above the bellmouth of the inlet tube. Measure flow rate and fuel specific gravity. (Refer
and record the pressure rise and current for each to Table 1005 "TABLE-28-22-04-99A-
phase at each of the flow rates. 845-A01" on page 1014.)
0 The current must not exceed 7.8 Amps.

4,000 pph (0.50 kg/s) The phase unbalance must not exceed
10 percent.
7,000 pph (0.88 kg/s)
10,000 pph (1.26 kg/s)
13,000 pph (1.64 kg/s)
16,000 pph (2.02 kg/s)
20,000 pph (2.52 kg/s)
24,000 pph (3.03 kg/s)
28,000 pph (3.54 kg/s)
3 Decrease the pressure and flow to zero. De-energize

the UUT.
REPRIME AT SEA LEVEL TEST
1 Install the test housing (or pump housing

subassembly) with installed UUT in the test setup
shown in Figure 1003.
NOTE: Use Stoddard solvent for this test.
2 Fill the test tank to 1 ± 0.125 inch (2.5 ± 0.3 cm) above
the bellmouth of the inlet tube.
3 Verify that the bellmouth of the inlet tube is 20 to 21

inches (51 to 53 cm) below the centerline of the UUT
inlet.
4 Operate the UUT for 8 to 12 minutes at a flow rate of

28,000 pph (3.53 kg/s) with the discharge pressure
(pressure rise) within the limits given in Table 1005.
5 Raise the bellmouth of the inlet tube 1.5 to 2.5 inches

(3.8 to 6.4 cm).
6 Operate the UUT for 28 to 32 seconds with no fluid

supplied at the bellmouth of the inlet tube.
28-22-04 Page 1010

Jan 09/2004
60-989
STEP ACTION RESULT
7 Lower the bellmouth of the inlet tube 1 ± 0.125 inch Within 4 seconds, the UUT must
(2.5 ± 0.3 cm) below the fluid level. reprime and operate at a flow rate of
28,000 pph (3.53 kg/s) with the
discharge pressure (pressure rise)
within the limits given in Table 1005.
8 Decrease the pressure and flow to zero. De-energize

the UUT.
POST TEST PROCEDURE
1 Remove the UUT from the test setup. Disconnect and

stow all test equipment.
2 Drain the UUT to drip-dry.
3 Install the protective cap over the connector (70).
4 Recheck the impeller clearance. Refer to paragraph 6

earlier in this section.
5 Refer to the final assembly instructions in ASSEMBLY

to complete assembly of the UUT.
28-22-04 Page 1011

Jan 09/2004
60-989
1003
PRESSURE GAGE G1
PRESSURE RISE
TIME CLOCK 60 PSIG (414 KPAG)
PRESSURE
SWITCH
FLOW COUNTER
(GPM)
10 DIAMETERS
MAXIMUM
1.5 INCH
GATE VALVE
DISCHARGE
CHECK VALVE
FLOWMETER
TEST CABLE
WITH CONNECTOR
VENT
MICRO
SWITCH
CENTERLINE INLET
OF UUT INLET PORT
FLUID LEVEL
UUT
3 TEST
INLET CHECK 2
VALVE HOUSING
AMMETER
1 (3 PLACES)
RETURN VOLT-
METER
TEST
TANK
INLET TUBE WATTMETER
(SEE FIGURE 1004)
TEMPERATURE
REGULATED AC
POWER SUPPLY GND
FUEL SUPPLY
FREQUENCY
METER
28-22-04-99B-830-A01-001.cgm
1 TEST HOUSING T-32411 OR PUMP HOUSING ASSEMBLY, P/N 60-98901, 60-98903, OR 60-98905.
2 4 TO 15 INCHES (10 TO 38 CM) AS APPLICABLE ABOVE BELLMOUTH OF PUMP INLET TUBE

FOR BREAK-IN RUN TEST.
3 BELLMOUTH OF PUMP INLET TUBE 15 TO 16 INCHES (38 TO 41 CM) BELOW CENTERLINE

OF PUMP INLET FOR REPRIME AT SEA LEVEL TEST.
4 THE RECOMMENDED TEST EQUIPMENT IS LISTED IN TABLE 1001.
GRAPHIC 28-22-04-99B-830-A01
Functional Test Setup, Motor-Impeller Subassembly
Figure 1003
28-22-04 Page 1012

Jan 09/2004
60-989
1004
31.90
52° (81.0)
30'
25.40
(64.5)
2.00 (5.08) CHECK
39.40 VALVE
(100.0) DIAMETER
BY 0.028 (0.071)
17.75 WALL THICKNESS
(45.1)
16°
1.00
(2.5)
1.00 RADIUS C PUMP
L IMPELLER
(2.5)
4.00 (10.2)
DIAMETER 16° 30'
VIEW A 12.60
(32.0)
TRUE
90°
VOL. = 280 CU. IN 10.80
(4589 CU CM) (27.4) 7° 5.70
(14.5)
A
2.10 4.00 RADIUS 7.90
1.30 (5.3) (10.2) (20.1)
(3.3)
28-22-04-99B-831-A01-001.cgm
* BEND RADII 4 TIMES DIAMETER (EXCEPT AS SHOWN).
CALCULATED PRESSURE 0.79 PSI (5.44 KPA) AT 28,000
PHR (3.53 KG/S) AND 60° F (16° C).
NOTES: 1. THE DIMENSIONS ARE

GIVEN IN INCHES (CM).
2. THE DIMENSION TOLERANCES ARE:
X.XX = ±0.03
X.XXX = ±0.010
GRAPHIC 28-22-04-99B-831-A01
Pump Inlet Tube Fabrication
Figure 1004
28-22-04 Page 1013

Jan 09/2004
60-989
1005
TABLE 28-22-04-99A-845-A01
Pressure Rise Limits—Table 1005
FUEL FLOW RATE PRESSURE RISE GAGE READING IN PSIG (KPAG)

SPECIFIC
GRAVITY PPH GPM LPM MINIMUM MAXIMUM
0.800 0 0 0 19.2 (132) 25.6 (177)

0.790 19.0 (131) 25.3 (174
0.780 18.7 (129) 25.0 (172)
0.770 18.5 (128) 24.6 (170)
0.760 18.2 (126) 24.3 (168)
0.750 18.0 (124) 24.0 (166)
0.800 4,000 10.0 37.8 18.6 (128) 25.6 (177)
0.790 10.2 38.6 18.3 (126) 25.3 (174
0.780 10.3 38.9 18.1 (125) 25.0 (172)
0.770 10.4 39.3 17.9 (123) 24.6 (170)
0.760 10.5 39.7 17.6 (121) 24.3 (168)
0.750 10.7 40.4 17.4 (120) 24.0 (166)
0.800 7,000 17.5 66.2 17.9 (123) 25.6 (177)
0.790 17.7 66.9 17.6 (121) 25.3 (174
0.780 18.0 68.0 17.4 (120) 25.0 (172)
0.770 18.2 68.8 17.2 (119 24.6 (170)
0.760 18.4 69.6 17.0 (117) 24.3 (168)
0.750 18.7 70.7 16.8 (116) 24.0 (166)
0.800 10,000 25.0 94.5 17.1 (118) 25.6 (177)
0.790 25.3 95.6 16.9 (117) 25.3 (174
0.780 25.6 96.8 16.7(115) 25.0 (172)
0.770 25.9 97.9 16.6 (114) 24.6 (170)
0.760 26.3 99.4 16.3 (112) 24.3 (168)
0.750 26.7 100.9 16.1 (111) 24.0 (166)
0.800 13,000 32.5 122.9 16.4 (113) 25.6 (177)
0.790 32.9 124.4 16.2 (112) 25.3 (174
0.780 33.3 125.9 16.0 (110) 25.0 (172)
0.770 33.8 127.8 15.8 (109) 24.6 (170)
0.760 34.2 129.3 15.6 (108) 24.3 (168)
0.750 34.7 131.2 15.4 (106) 24.0 (166)
Pressure Rise Limits (Sheet 1 of 2)—Table 1005
28-22-04 Page 1014

Jan 09/2004
60-989
FUEL FLOW RATE PRESSURE RISE GAGE READING IN PSIG (KPAG)

SPECIFIC
GRAVITY PPH GPM LPM MINIMUM MAXIMUM
0.800 16,000 40.0 151.2 15.7 (108) 25.6 (177)

0.790 40.5 153.1 15.5 (107) 25.3 (174
0.780 41.0 155.0 15.3 (106) 25.0 (172)
0.770 41.6 157.2 15.1 (104) 24.6 (170)
0.760 42.1 159.5 14.9 (103) 24.3 (168)
0.750 42.7 161.4 14.7 (101) 24.0 (166)
0.800 20,000 50.0 189.0 14.7 (101) 25.6 (177)
0.790 50.6 191.3 14.5 (100) 25.3 (174
0.780 51.3 193.9 14.4 (99.3) 25.0 (172)
0.770 52.0 196.6 14.2 (97.9) 24.6 (170)
0.760 52.6 198.8 14.0 (96.5) 24.3 (168)
0.750 53.3 201.4 13.8 (95.2) 24.0 (166)
0.800 24,000 60.0 226.8 13.8 (95.2) 25.6 (177)
0.790 60.8 229.8 13.6 (93.8) 25.3 (174
0.780 61.5 232.5 13.4 (92.4) 25.0 (172)
0.770 62.3 235.5 13.2 (91.0) 24.6 (170)
0.760 63.2 238.9 13.1 (90.3) 24.3 (168)
0.750 64.0 241.9 12.9 (88.9) 24.0 (166)
0.800 28,000 70.0 264.6 12.8 (88.3) 25.6 (177)
0.790 70.9 268.0 12.6 (86.9) 25.3 (174
0.780 71.8 271.4 12.5 (86.2) 25.0 (172)
0.770 72.7 274.8 12.3 (84.8) 24.6 (170)
0.760 73.7 278.6 12.2 (84.1) 24.3 (168)
0.750 74.7 282.4 12.0 (82.7) 24.0 (166)
Pressure Rise Limits (Sheet 2 of 2)—Table 1005
28-22-04 Page 1015

Jan 09/2004
60-989
TASK 28-22-04-700-824-A01
8. Housing Subassembly Tests
A. Refer to Table 1006 for functional test procedures. Refer to the fault isolation procedures given later in
this section if a test fails. (Refer to Table 1006 "TABLE-28-22-04-99A-850-A01" on page 1016.)
B. When specified in the test procedures, refer to Figure 1005 for a test setup diagram. (See Figure 1005
"GRAPHIC-28-22-04-99B-832-A01" on page 1018.)
1006
TABLE 28-22-04-99A-850-A01
Functional Test Procedures, Housing Subassembly—Table 1006
STEP ACTION RESULT

NEGATIVE PRESSURE TEST
1 Clean all fuel from inside the housing subassembly
(UUT).
2 Install caps on the UUT ports as shown in Figure
1005.
3 Connect ports A and B (Figure 1005) to a vacuum
system with flexible hoses.
4 Immerse the test setup in a tank of fuel.
5 Apply a negative pressure (vacuum) of -6.0 psig (-41
kPag). Hold the vacuum for 5 minutes, then remove
the vacuum.
6 Remove the test setup from the fuel tank. Clean all
fuel residue from the outside of the UUT.
7 Remove all port caps. Visually examine the inside of There must be no leakage.
the UUT and the flange area (Figure 1005) for
leakage.
POSITIVE PRESSURE TEST
1005. Make sure the primer discharge port is capped
with test fixture, P/N T-32411 (cap seal assembly).
2 Completely fill the UUT with test fluid at ports A and B
(Figure 1005).
3 Place the UUT on a clean workbench.
4 Apply 2.0 psig (14 kPag) air or GN2 pressure to port There must be no leakage.
A. Apply 6.0 psig (41 kPag) air or GN2 pressure to
port B. Hold the pressures for 5 minutes, then visually
check the outer surface of the UUT for leakage.
5 Decrease the pressure at port B to zero.
6 Increase the pressure at port A to 50 psig (345 kPag). There must be no leakage.
Hold the pressure for 5 minutes, then visually check
the outer surface of the UUT for leakage.
Functional Test Procedures, Housing Subassembly (Sheet 1 of 2)—Table 1006
28-22-04 Page 1016

Jan 09/2004
60-989
STEP ACTION RESULT

7 Increase the pressure at port A to 75 psig (517 kPag). There must be no leakage at the flange
Hold the pressure for 5 minutes, then visually check surfaces. A slight seepage, not to
the outer surface of the UUT for leakage. exceed one drop each minute, is
acceptable through the UUT walls.
PRIMER DISCHARGE PORT VALVE LEAKAGE TEST
1005, except do not cap the primer discharge port
with test fixture, P/N T-32411 (cap seal assembly).
Leave the primer discharge port open.
2 Connect port A (Figure 1005) to a vacuum system
with a flexible hose.
3 Apply a negative pressure (vacuum) of -5.0 psig
(-34 kPag) at port A.
4 Fill the primer discharge port to the brim with test fluid The leakage at the primer discharge
and start to time the test. After 5 minutes, measure port must not exceed 5 cc in 5 minutes.
the leakage of test fluid at the primer discharge port.
5 Decrease the negative pressure (vacuum) at port A to
-3.0 psig (-21 kPag).
7 Decrease the pressure to -1.5 psig (-10 kPag).
9 Decrease the pressure to -0.5 psig (-3.5 kPag).
11 Increase the pressure to zero.
POST TEST PROCEDURE
1 Remove the UUT from the test setup. Disconnect and
stow all test equipment.
2 Drain the UUT to drip-dry. Install the protective caps
over the ports.
3 If applicable, refer to the final assembly instructions in
ASSEMBLY to complete assembly of the UUT.
Functional Test Procedures, Housing Subassembly (Sheet 2 of 2)—Table 1006
28-22-04 Page 1017

Jan 09/2004
60-989
1005
PORT A 5
7
9
8
3
PORT B
10
6
1
4
FLANGE
AREA
2 10CC
HOUSING LEAKAGE
SUBASSEMBLY BEAKER
(UUT)
TEST FIXTURE T-32411

1 CAP END
2 CAP INLET
3 CAP DISCHARGE
4 NUT
5 CAP SEAL ASSEMBLY
- CHUCK JAWS
28-22-04-99B-832-A01-001.cgm
- BASE PLATE
- PLUG
6 MS29513-212
7 MS29513-224
8 MS29513-260
9 MS29513-236
10 MS29513-229
GRAPHIC 28-22-04-99B-832-A01
Functional Test Setup, Housing Subassembly
Figure 1005
28-22-04 Page 1018

Jan 09/2004
60-989
TASK 28-22-04-810-840-A01
9. Fault Isolation
A. Refer to Table 1007 for fault isolation procedures. (Refer to Table 1007 "TABLE-28-22-04-99A-860-
A01" on page 1019.)
B. The problem (fault) is listed in the PROBLEM column. Except for the in-operation/in-service faults
listed at the back of the table, the faults are failures of the test requirements given in Tables 1003,
1004, and 1007.
C. The PROBABLE CAUSE column lists the likely cause(s) of the fault, with the most probable cause
listed first. This column does not cover all possible causes.
D. The recommended corrective action is given in the CORRECTIVE ACTION column. Unless otherwise
specified, refer to DISASSEMBLY and ASSEMBLY to replace the faulty components.
1007
TABLE 28-22-04-99A-860-A01 Fault Isolation Procedures—Table 1007
PROBLEM PROBABLE CAUSE CORRECTIVE ACTION
MOTOR IMPELLER CLEARANCE AND END PLAY
The inlet impeller (35, IPL Incorrect installation of inlet Refer to DISASSEMBLY and ASSEMBLY
Figures 2, 2A, and 2B) components. to reassemble the components.
does not rotate freely or
rubs the inlet adapter (20). Worn or damaged rotor assembly Refer to CHECK to examine the
(205) or other components. components for damage; replace the
damaged component.
The axial movement (end Worn thrust washer (45, IPL Refer to CHECK to examine the
play) of the inlet impeller Figure 3) or loose primer impeller components for damage; replace the
(35) is greater than (20). damaged component.
specified.
The clearance between the Incorrect number of shim(s) (55 Add or remove shim(s) as required.
inlet adapter (20, IPL and 60).
Figures 2, 2A, and 2B) and
inlet impeller (35) is not as
specified.
MOTOR-IMPELLER SUBASSEMBLY ELECTRICAL TESTS
INSULATION RESISTANCE AND DIELECTRIC TESTS
The insulation resistance is Dirty connector (70). Refer to CLEANING and clean the
less than 100 megohms. connector.
Faulty stator assembly (200) or Test each component separately to

connector (70). determine which is faulty; replace the
damaged component.
Fault Isolation Procedures (Sheet 1 of 6)—Table 1007
28-22-04 Page 1019

Jan 09/2004
60-989
MOTOR-IMPELLER ELECTRICAL TESTS (CONT)
Arc-over, flash-over, or Dirty connector (70). Refer to CLEANING and clean the
other evidence of connector.
insulation breakdown. AC
leakage current greater Faulty stator assembly (200) or Test each component separately to
than 6.0 mA during high connector (70). determine which is faulty; replace the
potential (hi-pot) test. damaged component.
ELECTRICAL BONDING TEST
The bonding resistance Poor probe contact with the inner The micro-ohmmeter probe must make full
from the connector, pin 4 to housing (210); damaged or contact with a chem-film (non-anodized)
inner housing (210) anodized chem-film finish; dirty surface; refer to CLEANING to clean the
mounting flange is not as connector. connector (70) and end cap (150)
specified. electrical bonding surfaces.
The ground wire assembly (105) is Refer to DISASSEMBLY and ASSEMBLY

loose, has damaged insulation, or to reassemble the components; refer to
is poorly soldered to the connector CHECK and REPAIR to repair the ground
(70). wire assembly.
The bonding resistance Poor probe contact with the The micro-ohmmeter probe must make full
from the connector shell to connector (70) shell; dirty contact with non-anodized metal; refer to
the conductive end cap connector/interface; damaged CLEANING to clean the connector (70)
surface is not as specified. chem-film. and end cap (150) electrical bonding
surfaces.
Contamination on the end cap Refer to DISASSEMBLY and ASSEMBLY

(150) or connector (70) electrical to reassemble the components; pay
bonding surface. special attention to the instructions for
component cleaning and handling and the
application of adhesives and sealers.
MOTOR-IMPELLER FUNCTIONAL TESTS
STOP AND RESTART TEST
The UUT does not operate. Short in the stator assembly With an ohmmeter, measure the
(200) circuit; open windings on the resistance of each phase (between pins
stator coil. 1-2, 1-3, and 2-3) at the connector (70);
the resistance must be 2.8 ±0.14 Ohms at
78 °F (26 °C). If the resistance is within
tolerance, refer to the next probable cause
given below.
If the resistance is not as specified, do an

insulation resistance test (part of the
dielectric test in Table 1003); if the
insulation resistance test fails, remove and
test the connector (70), ground wire
assembly (105), and stator assembly (200)
separately to find the faulty component.
28-22-04 Page 1020

Jan 09/2004
60-989
MOTOR-IMPELLER FUNCTIONAL TESTS (CONT)
The UUT does not operate. Refer to CHECK to examine the stator
(Cont) assembly (200) and rotor assembly (205)
lamination for shorted, broken, or burned
wires; replace the damaged component.
The UUT does not operate Light contact between Check the inlet impeller (35) and inlet
as specified. components that should not be in adapter (20) for contamination; clean the
contact (inlet adapter/impeller, components as required.
primer impeller/rotor, or stator/
rotor). Refer to the impeller clearance inspection
in this section to check the inlet impeller
(35) clearance; adjust the clearance as
required.
Refer to CHECK, Figure 5004 to check the

clearance between the stator assembly
(200) and rotor assembly (205) lamination;
repair or reassemble the components as
required.
Too much friction between a Refer to CHECK to examine the

bearing assembly (190) and the components for damage; replace the
rotor assembly (205). damaged component.
The current does not Short in the stator assembly (200) Refer to DISASSEMBLY and CHECK to
stabilize within ± 0.10 Amp circuit; open windings on the stator remove and check the connector (70),
of the recorded reading coil. ground wire assembly (105), and stator
after the test is stopped assembly (200) for damage.
and restarted.
Replace the damaged component; if
applicable, refer to REPAIR to cover
damaged insulation on the stator assembly
(200) wire leads with shrink sleeving, or
refer to ASSEMBLY to resolder the wire
leads to the connector (70).
CALIBRATION
The UUT operates but Bent or damaged rotor assembly Refer to DISASSEMBLY and CHECK to
vibrates too much. (205). remove and check the rotor assembly
(205) and related components for damage.
Bent or damaged inlet impeller Refer to DISASSEMBLY and CHECK to

(35). remove and check the inlet impeller (35)
and related components for damage.
Damaged or worn bearing assem- Refer to CHECK to examine the bearing

bly (190). assemblies for damage; replace the
damaged component.
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Jan 09/2004
60-989
MOTOR-IMPELLER FUNCTIONAL TESTS (CONT)
The UUT operates but The drive pin (45) is sheared off. Replace the drive pin (45).
does not pump fuel.
Damaged inlet impeller (35) or Refer to CHECK to examine the inlet
inlet adapter (20). impeller (35) and inlet adapter (20) for
damage; replace the damaged
component.
REPRIME AT SEA LEVEL TEST
The UUT does not The primer impeller (20, IPL Check the primer impeller (20) and primer
reprime. Figure 3) is binding. discharge plate (30) for contamination;
remove and clean the primer impeller.
The inlet plate (5) and primer Check the clearance between the primer
discharge plate (30) are installed impeller and primer discharge plate as
backwards and/or in reverse. shown in ASSEMBLY, Figure 7003;
reassemble or replace the components as
required.
The Stabond seal between the Refer to ASSEMBLY and rebuild the seal.
inlet plate (5), primer discharge
plate (30), and primer liner (10) is
faulty.
EXTERNAL LEAKAGE TEST
External leakage. Damaged or incorrectly installed Replace the faulty packing.

packing.
Scratches in the component Refer to CHECK to examine the

packing groove or mating surface. components for damage; replace the
damaged component.
MOTOR-IMPELLER IN-OPERATION / IN-SERVICE FAULTS
The motor-impeller Short in the stator assembly With an ohmmeter, measure the
subassembly does not (200, IPL Figures 2, 2A, and 2B) resistance of each phase (1-3, 1-3, and
operate. circuit; open windings on the stator 2-3) at the connector (105); the resistance
coil. must be 2.8 ±0.14 Ohms at 78 °F (26 °C).
If the resistance is within tolerance, refer to
the next probable cause given below.
If the resistance is not as specified, do an

insulation resistance test (part of the
dielectric test in Table 1003); if the
insulation resistance test fails, remove and
test the connector (70), ground wire
assembly (105), and stator assembly (200)
separately to determine which component
is faulty.
28-22-04 Page 1022

Jan 09/2004
60-989
MOTOR-IMPELLER IN-OPERATION / IN-SERVICE FAULTS (CONT)
The motor-impeller Short in the stator assembly (200) Refer to CHECK to examine the stator
subassembly does not circuit; open windings on the stator assembly (200) and rotor assembly (205)
operate. (Cont) coil. lamination for shorted, broken, or burned
wires; replace the damaged component.
Worn or damaged rotor assembly Refer to CHECK to examine the

(205) shaft; too much friction components for damage; replace the
between a bearing assembly (190) damaged component.
and the shaft, or between the
stator assembly (200) and rotor Measure the gap between the stator
assembly lamination. assembly (200) and rotor assembly (205)
lamination as shown in CHECK, Figure
5004; if the gap is not as specified, replace
the damaged component.
Jammed inlet impeller (35). Check between the inlet impeller (35) and
inlet adapter (20) for contamination;
remove and clean the components as
required.
Refer to the impeller clearance inspection

in this section to check the inlet impeller
(35) clearance; adjust the clearance as
required.
The motor-impeller Bent or damaged rotor assembly Refer to CHECK to examine the rotor
subassembly operates but (205) shaft. assembly (205) for damage; replace the
vibrates too much. damaged component.
Bent or damaged inlet impeller Refer to CHECK to examine the inlet

(35). impeller (35) for damage; replace the
damaged component.
Damaged or worn bearing assem- Refer to CHECK to examine the bearing

bly (190). assemblies for damage; replace the
damaged component.
The motor-impeller The primer impeller (20, IPL Check the primer impeller (20) and primer
subassembly operates but Figure 3) is binding. discharge plate (30) for contamination;
does not reprime. remove and clean the primer impeller.
The inlet plate (5) and primer Check the clearance between the primer
discharge plate (30) are installed impeller and primer discharge plate as
backwards and/or in reverse. shown in ASSEMBLY, Figure 7003;
reassemble or replace the components as
required.
28-22-04 Page 1023

Jan 09/2004
60-989
MOTOR-IMPELLER IN-OPERATION / IN-SERVICE FAULTS (CONT)
The motor-impeller The Stabond seal between the Refer to ASSEMBLY and rebuild the seal.
subassembly operates but inlet plate (5), primer discharge
does not reprime. (Cont) plate (30), and primer liner (10) is
faulty.
The motor-impeller The drive pin (45, IPL Figures 2, Replace the drive pin (45).
subassembly operates but 2A, and 2B) is sheared off.
does not pump fuel.
Damaged inlet impeller (35) or Refer to CHECK to examine the inlet
inlet adapter (20). impeller (35) and inlet adapter (20) for
damage; replace the damaged
component.
HOUSING FUNCTIONAL TESTS
PRESSURE TESTS
External leakage. Damaged or incorrectly installed Check the test setup and retest; external
packings on the test caps; test leakage around a test cap is not a test
caps not tight enough. failure unless the outer housing (75, IPL
Figure 4) boss is damaged or there are
crossed or stripped threads in the housing
mounting holes.
Cracked or porous outer housing Refer to CHECK to examine the outer

(75). housing (75) for damage; replace the
damaged outer housing.
PRIMER CHECK VALVE LEAKAGE TEST
Excessive leakage at the Damaged or incorrectly installed Replace the packings (20).
primer check valve assem- packing (20).
bly (25, IPL Figure 4).
Crossed or stripped threads on the Refer to REPAIR to check the screw (10)
screws (10); bent screws; screws threads; replace the screws when they are
not torqued properly. damaged; at reassembly, tighten the
screws to the torque specified in FITS
AND CLEARANCES.
Scratches in the primer check Refer to CHECK to examine the

valve assembly (25) packing components for damage; replace the
groove or on the mating surface. damaged component.
Damaged primer check valve Refer to CHECK to examine the

assembly (25); deformed or components for damage; replace the
permanently set spring (35); bent damaged component.
or loose pin (30); damaged sealing
surface on the flapper assembly
(40) or valve seat (45).
28-22-04 Page 1024

Jan 09/2004
60-989
SCHEMATIC AND WIRING DIAGRAMS
TASK 28-22-04-800-803-A01
1. General
This section contains wiring and pin-out diagrams for the Fuel Boost Pump Assembly. (See Figure 2001
2001
UNITS WITH
CONNECTOR AND
GROUND WIRE ASSEMBLY
STATOR
THERMAL FUSE ASSEMBLY
ASSEMBLY
(TYPICAL) BLACK
1 PHASE A
4
RED
3 2 PHASE B
1 GREEN
28-22-04-99B-838-A01-001.cgm
3 PHASE C
2
BLUE
4 GROUND
GROUND WIRE CONNECTOR

ASSEMBLY
CONNECTOR
PIN-OUT WIRING
DIAGRAM
GRAPHIC 28-22-04-99B-838-A01
Wiring and Pin-Out Diagrams
Figure 2001
28-22-04 Page 2001

Jan 09/2004
60-989
28-22-04 Page 2002

Jan 09/2004
60-989
DISASSEMBLY
TASK 28-22-04-99C-855-A01
1. General
CAUTION: THE MOTOR-IMPELLER SUBASSEMBLY AND HOUSING SUBASSEMBLY CONTAIN

PRECISION TOLERANCE COMPONENTS WITH HIGHLY-POLISHED FINISHES. THE
COMPONENTS CAN BE DAMAGED BY CONTAMINATION OR ROUGH HANDLING.
CAUTION: REMOVE THE PROTECTIVE CAP AND PLUGS FROM THE MOTOR-IMPELLER
CONNECTOR AND HOUSING INLET PORT, DISCHARGE PORT, PRIMER DISCHARGE
PORT, AND MOTOR-IMPELLER BOSS ONLY WHEN NECESSARY FOR
MAINTENANCE. THE PLUGS MUST BE INSTALLED AT ALL OTHER TIMES TO
PREVENT COMPONENT DAMAGE.
A. This section contains disassembly instructions for the Motor-Impelller Subassembly and Housing
Subassembly.
B. Do the test procedures given in TESTING AND FAULT ISOLATION before disassembly to find the
cause of the malfunction. Disassemble the motor-impeller subassembly or housing subassembly only
as necessary to correct the problem.
C. The disassembly instructions in this section are identified, by item number, to the exploded-view
illustrations in the ILLUSTRATED PARTS LIST. Refer to IPL Figures 1, 2 , 2A, 2B, 3, and 4 for the
breakdown of the pump assembly into detail parts.
D. Use standard shop tools for disassembly.
E. Do all work in a clean, ventilated room with good lighting.
F. Store the parts in clean containers in the sequence they are removed to aid assembly.
CAUTION: PROTECT SEALING SURFACES FROM DAMAGE WHEN PACKINGS ARE REMOVED.
G. Use a rounded, dull-edged nylon pick to remove packings. Replace all exposed packings at each
overhaul. Discard the packings after removal.
H. Make a note of the way components are lockwired to aid assembly. Use side cutters and long-nosed
pliers to remove the lockwire. Discard the lockwire after removal.
I. Install a protective cap on the connector to prevent damage. Remove the cap only when necessary for
maintenance.
TASK 28-22-04-94B-850-A01
2. Disassembly Tools and Equipment
A. The recommended tools and equipment are given in Table 3001. (Refer to Table 3001 "TABLE-28-22-
04-99A-862-A01" on page 3002.)
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Jan 09/2004
60-989
3001
TABLE 28-22-04-99A-862-A01
Disassembly Tools and Equipment—Table 3001
NUMBER
Aluminum Ring 2.45 inch (62.23 mm) OD Local Fabrication

1.75 inch (44.45 mm) ID
1.00 inch (25.40 mm) width mini-
mum (refer to Figure 3002)
Arbor or Hand Press No Specific Commercially Available
Assembly Tool, Housing Stud T-65977 Hydro-Aire, Inc. (V81982)
Oven Model AF500; 250 to 310 °F The Grieve Corp. (V90423)

(121 to 154 °C)
Disassembly Tools and Equipment —Table 3001
B. Referenced Information
None.
TASK 28-22-04-94A-850-A01
3. Disassembly Materials
Refer to Table 3002 for a list of disassembly materials. Equivalent items can be used. (Refer to Table 3002
"TABLE-28-22-04-99A-863-A01" on page 3002.)
3002
TABLE 28-22-04-99A-863-A01
Disassembly Materials—Table 3002
NUMBER

Gloves, Heat Resistant Protection at 350 °F (177 °C) with Commercially Available
adequate finger movement
Plug, Protective, Housing: Protective Closures Co., Inc.

Inlet Port Caplug C-425 (Cover) (V99017)
Discharge Port Caplug 17
Primer Discharge Port Caplug 13
Impeller Subassembly Boss Caplug 55-A
Disassembly Materials —Table 3002
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Jan 09/2004
60-989
TASK 28-22-04-000-857-A01
4. Pump Assembly
NOTE: The housing subassembly (20, IPL Figure 1) is semi-permanently mounted in the aircraft fuel cell
and should be removed only if it is damaged. The motor-impeller subassembly (5) should be
removed from the housing subassembly while the housing is mounted in the aircraft fuel cell.
A. Cut and remove the lockwire from the screws (10). Remove the screws and washers (15).
B. Use the handle to pull the motor-impeller subassembly (5) from the housing subassembly (20).
C. If necessary, remove the mounting hardware and housing subassembly (20) from the aircraft fuel cell.
Refer to the applicable Aircraft Maintenance Manual (AMM) for removal instructions.
TASK 28-22-04-000-858-A01
5. Motor-Impeller Subassembly
NOTE: The P/N 60-98902, 60-98902A, 60-98904, 60-98904A, 60-98906, 60-98906A, 60-98976, and 60-
98976-1 motor-impeller subassemblies should be upgraded to the improved P/N 60-98976-4
configuration at the earliest maintenance opportunity. To do this, refer to Service Bulletins 60-
98902-28-1, 60-98904-28-1, 60-98906-28-1, and 60-98976-28-1 and modification kit P/N 60-
98976-4902. Refer to CMM 28-22-07 for maintenance instructions and an IPL for motor-impeller
subassembly P/N 60-98976-4.
A. Cut and remove any safety wire required to replace the faulty component. Note the location and style
to aid assembly.
B. Remove and discard the packings (5, 10, and 15, IPL Figures 2, 2A, and 2B).
NOTE: The packings (5, 10, and 15) may have been removed when the motor-impeller subassembly
was removed from the aircraft. If not, remove and discard the packings.
C. Remove the screws (25) and inlet adapter (20) from the inner housing assembly (210).
CAUTION: DO NOT DAMAGE THE INLET IMPELLER WHEN REMOVING THE SELF-LOCKING
SCREW.
D. Remove the self-locking screw (40). Remove the inducer (30) and inlet impeller (35) from the rotor
assembly (205) shaft. Separate the components and remove the spring pins (45).
NOTE: The self-locking screw (40) threads were coated with primer and sealant at assembly.
Although a new screw must be used for final assembly, retain the screw for use during
assembly checks.
E. Remove the drive pin (50) from the rotor assembly (205) shaft.
F. Remove the shim washer(s) (55 and 60). Note the number of each washer (or stack thickness) to aid
assembly.
G. Remove the retaining ring (180), bearing holder (185), and bearing assembly (190) from the inner
housing assembly (210).
H. Remove the screws (75), hex nuts (80), and washers (85) to disassemble the cable assembly
connector (70) from the bracket assembly (120).
NOTE: The terminal assembly (90) will be disassembled from the end cap assembly (150) after the
end cap assembly is removed from the inner housing assembly (210).
28-22-04 Page 3003

Jan 09/2004
60-989
I. Remove the screws (155), washers (160), and bracket assembly (120). If the label (125) is damaged,
peel the adhesive-backed label off the bracket assembly.
NOTE: The bracket assembly (120) must be removed to remove the end cap/stator assembly and
other internal components.
J. Remove the drain plug (130). Remove and discard the packing (135).
NOTE: The drain plug (130), identification plate (140), and other components attached to the outside
of the end cap assembly (150) can be removed before or after the end cap assembly is
removed.
K. If necessary, refer to REPAIR to replace the identification plate (140) and drive screws (145).
L. Remove the end cap/stator assembly from the inner housing assembly (210), as follows:
NOTE: The end cap assembly (150) with attached terminal assembly (90) and stator assembly (200)
should be removed as an assembly from the inner housing assembly (210), and then
disassembled. This makes it easier to inspect and test the stator to connector electrical
interface without removal of the terminal assembly or connector from the end cap assembly.
(1) Remove the screws (165) that retain the end cap assembly (150).
(2) Carefully pull the end cap assembly (150) and attached components from the inner housing
assembly (210) only far enough to access the stator assembly (200). Do not pull, twist, or
otherwise damage the ground wire assembly (105), terminal assembly (90), and stator assembly
wire leads.
CAUTION: THE STATOR ASSEMBLY MUST BE CAREFULLY REMOVED SO THE WIRE

INSULATION IS NOT PINCHED OR CUT AND THE ROTOR AND INNER HOUSING
ASSEMBLY ARE NOT DAMAGED. DAMAGE TO THE WIRE INSULATION CAN
CAUSE ELECTRICAL SHORTING/ARCING.
(3) Remove the stator assembly (200) and rotor assembly (205) from the inner housing assembly
(210), as follows:
(a) Apply Vaseline to the inner diameter of the inner housing assembly (210).
CAUTION: PROTECT THE END CAP ASSEMBLY WITH ATTACHED CONNECTOR AND
WIRE BUNDLE FROM HEAT DAMAGE.
(b) Place the inner housing assembly (210), inlet impeller (35) end down, in an oven. Heat the
inner housing assembly to 150 °F (65 °C).
NOTE: The inner housing assembly (210) must be heated to expand it so the stator
assembly (200) and rotor assembly (205) can be removed. The inner housing
assembly will cool enough to prevent movement of the stator assembly within 1
minute of removal from the oven.
WARNING: WEAR GLOVES AND OTHER PROTECTIVE GEAR AS NEEDED TO HANDLE

THE HEATED COMPONENTS. THE HOT METAL CAN CAUSE SERIOUS
BURNS.
(c) Turn over the inner housing assembly (210) to allow the Vaseline to coat more of the inner
diameter.
(d) Carefully remove the stator assembly (200) and rotor assembly (205) from the inner
housing assembly (210). Do not pull, twist, or otherwise damage the ground wire assembly
(105), terminal assembly (90), and stator assembly wire leads.
28-22-04 Page 3004

Jan 09/2004
60-989
(e) Carefully remove the stator assembly (200) off the rotor assembly (205) lamination.
M. Remove the screw (110) and washer (115) to disconnect the ground wire assembly (105) from the
inside surface of the end cap assembly (150). Refer to REPAIR to repair the ground wire assembly.
CAUTION: DO NOT PULL OR TWIST THE CONNECTOR/STATOR ASSEMBLY WIRE LEADS. THIS
CAN DAMAGE THE SOLDER CONNECTIONS TO THE CONNECTOR OR THE STATOR
ASSEMBLY.
CAUTION: DO NOT REMOVE THE CONNECTOR UNLESS THE STATOR ASSEMBLY OR

CONNECTOR MUST BE REPLACED. IF THE WIRE LEADS ARE CUT TOO SHORT, THE
STATOR ASSEMBLY WIRE LEADS WILL NOT REACH TO THE CONNECTOR AT
ASSEMBLY.
N. Remove the terminal assembly (90), as follows:
NOTE: The cable assembly (65) must be replaced with a new pottingless connector to upgrade the
60-98902, 60-98902A, 60-98904, 60-98904A, 60-98906, 60-98906A, 60-98976, and 60-
98976-1 configuration to 60-98976-4. This should also be done if the end cap assembly (150)
or stator assembly (200) must be replaced. Refer to Service Bulletins 60-98902-28-1, 60-
98904-28-1, 60-98906-28-1, and 60-98976-28-1 for more information.
NOTE: Refer to Figure 3001 for connector removal details. Refer to SCHEMATIC AND WIRING
DIAGRAMS, Figure 2001 for wiring and pin-out diagrams. (Refer to Figure 3001 "GRAPHIC-
28-22-04-99B-842-A01" on page 3008.)
(1) Remove the screws (95) and washers (100) that hold the terminal assembly (90) to the end cap
assembly (150).
(2) For 60-98902A, 60-98904A, and 60-98906A only, remove the screws (95) and washers (100) that
hold the terminal assembly (90) and bracket assembly (116) to the end cap assembly (150).
(3) Carefully pull the terminal assembly (90) out from the end cap assembly (150) far enough to
access the potting and wire interface at the back of the connector. Do not pull or twist the wire
leads.
(4) Cut the wire leads as close as possible to the potting. Remove and discard the cable assembly
(65).
(5) Remove the Teflon tubing.
(6) Remove and discard the packing (170).
O. Remove and discard the packing (175) from the end cap assembly (150).
P. Remove the retaining ring (180), bearing holder (185), and bearing assembly (190) from inside the end
cap assembly (150).
Q. For 60-98902, 60-98902A, 60-98904, 60-98904A, 60-98906, 60-98906A, and 60-98976 ONLY. Refer
to REPAIR to replace the insulation strip (195) bonded inside the end cap assembly (150).
NOTE: The insulation strip is bonded in place with C-111 adhesive.
R. Disassemble the rotor assembly (205) and attached components, as follows:
NOTE: Refer to Table 3002 for more information. (Refer to "TABLE-28-22-04-99A-863-A01" on

page 3002.)
28-22-04 Page 3005

Jan 09/2004
60-989
(1) If necessary, place the rotor/shaft assembly (65, IPL Figure 3) with attached components in an
oven and heat the assembly to 290 to 310 °F (145 to 155 °C).
NOTE: The components may have to be heated to loosen the retaining compound that secures
the primer impeller (20) and tolerance ring (25).
WARNING: WEAR GLOVES AND OTHER PROTECTIVE GEAR AS NEEDED TO HANDLE THE
HEATED COMPONENTS. THE HOT METAL CAN CAUSE SERIOUS BURNS.
(2) Install the rotor/shaft assembly (65) and aluminum ring (Table 3001) on an arbor or hand press as
(3) Install a 0.190-32UNF-3A threaded screw (item 40, IPL Figures 2, 2A, and 2B can be used) in the
upper end of the rotor/shaft assembly (65, IPL Figure 3).
CAUTION: DO NOT APPLY HIGH FORCE THAT CAN DAMAGE THE ROTOR/SHAFT
ASSEMBLY. IF TOO MUCH FORCE IS REQUIRED THAT MIGHT DAMAGE THE
COMPONENTS, HEAT THE ASSEMBLY TO LOOSEN THE RETAINING COMPOUND.
(4) Use the arbor or hand press to apply steady downward force on the rotor/shaft assembly (65).
This will cause the aluminum ring to force the primer impeller (20), primer discharge plate (30),
thrust bearing holder (35), and attached components from the rotor/shaft assembly.
NOTE: The primer impeller (20) and tolerance ring (25) are secured to the rotor/shaft assembly
(65) with retaining compound.
(5) Separate and remove the primer liner (10), primer discharge plate (30), and inlet plate assembly
(5). Remove the tubes (15).
NOTE: The bonded items should separate when they are pressed off the rotor/shaft assembly
(65). If not, insert a knife blade or an equivalent tool to break the adhesive bond and
separate the items.
(6) Remove and discard the tolerance ring (25) from the rotor/shaft assembly (65).
(7) Remove the gimbal plate (50), thrust bearing plate (40), and thrust washer (45) from the rotor/
shaft assembly (65).
(8) Press or drive the spring pins (60) from the rotor/shaft assembly (65) only if they are damaged.
(9) Remove the temporary screw from the rotor/shaft assembly (65).
(10) Refer to REPAIR to replace the insulation strip (55) bonded inside the thrust bearing holder (35).
TASK 28-22-04-000-859-A01
6. Housing Subassembly
A. Remove and disassemble the primer check valve assembly (25, IPL Figure 4), as follows:
(1) Remove the screws (10), washers (15), and primer discharge port (5).
(2) Remove the primer check valve assembly (25) from the outer housing (55). Remove and discard
the packings (20).
(3) Disassemble the primer check valve assembly (25), as follows:
(a) Press out the pin (30).
(b) Separate the spring (35) and flapper assembly (40) from the valve seat (45).
28-22-04 Page 3006

Jan 09/2004
60-989
B. Use assembly tool T-65977 (Table 3001) to remove the stud (50) from the outer housing assembly
(55).
NOTE: The stud (50) is coated with MIL-S-22473, Grade C retaining compound before installation.
C. Refer to REPAIR to replace the plug sets (60) in the outer housing (75).
D. Refer to REPAIR to replace the screw thread inserts (65 and 70) in the outer housing (75).
28-22-04 Page 3007

Jan 09/2004
60-989
3001
PART NUMBERS
60-98902, 60-98904, 60-98906
AND 60-98976 TERMINAL
ASSEMBLY
(90)
END
VIEW
CONNECTOR
(70)
SCREW (95) SCREW (75)

WASHER (100) HEX NUT (80)
(2 PLACES) WASHER (85)
REMOVE
LOCKWIRE
DETAIL 0.18 (4.6)

VIEW MAXIMUM
8° TO 12° POTTING COMPOUND

1.18 (30.0) AND HARDWARE
DIAMETER
TERMINAL
28-22-04-99B-842-A01-001.cgm
RTV 1200 AND RTV 1205 ASSEMBLY

PRIME COAT WITH RTV (REF)
730 SEALANT
END CAP
ASSEMBLY
NOTES: 1. THE ITEM NUMBERS IN (REF)
PARENTHESES REFER
TO IPL FIGURE 2.
2. THE DIMENSIONS ARE
GRAPHIC 28-22-04-99B-842-A01
Connector Removal Details (Sheet 1 of 3)
Figure 3001
28-22-04 Page 3008

Jan 09/2004
60-989
3001
PART NUMBERS
60-98902A, 60-98904A,
AND 60-98906A TERMINAL
ASSEMBLY
(90)
END
VIEW
CONNECTOR
(70)
SCREW (95) SCREW (75)

WASHER (100) HEX NUT (80)
(2 PLACES) WASHER (85)
REMOVE
LOCKWIRE
DETAIL
VIEW 0.18 (4.6)
MAXIMUM
8° TO 12° POTTING COMPOUND

1.18 (30.0) AND HARDWARE
DIAMETER
TERMINAL
28-22-04-99B-842-A01-002.cgm
RTV 1200 AND RTV 1205 ASSEMBLY

PRIME COAT WITH RTV (REF)
730 SEALANT
END CAP
ASSEMBLY
NOTES: 1. THE ITEM NUMBERS IN (REF)
PARENTHESES REFER
TO IPL FIGURE 2A.

Figure 3001
28-22-04 Page 3009

Jan 09/2004
60-989
3001
PART NUMBER
60-98976-1
TERMINAL
ASSEMBLY
END (90)
VIEW
CONNECTOR
(70)
SCREW (75)
SCREW (95)
HEX NUT (80)
WASHER (100)
WASHER (85)
(2 PLACES)
(4 PLACES)
END CAP
(XXX)
REMOVE
LOCKWIRE
DETAIL
VIEW
0.51 (13.0)
0.10 (2.5) MAXIMUM
MINIMUM
CONNECTOR
WIRE LEADS TO
(REF)
STATOR ASSEMBLY
AND GROUND
WIRE ASSEMBLY
AMS3653
TEFLON TUBING
28-22-04-99B-842-A01-003.cgm
SOLDER
CONNECTIONS
POTTING
COMPOUND
PARENTHESES REFER
TO IPL FIGURE 2B.

Figure 3001
28-22-04 Page 3010

Jan 09/2004
60-989
3002
ARBOR
PRESS
RAM
TEMPORARY
SCREW
INLET PLATE
ASSEMBLY (5)
PRIMER TUBE (15)

LINER (10) (3 PLACES)
PRIMER IMPELLER TOLERANCE

(20) RING (25)
PRIMER THRUST BEARING
DISCHARGE HOLDER (35)
PLATE (30)
THRUST
THRUST BEARING
WASHER (45)
PLATE (40)
GIMBAL
FABRICATED PLATE (50)
ALUMINUM RING 1
BASE OF
ARBOR PRESS
ROTOR/SHAFT
ASSEMBLY
(65)
28-22-04-99B-843-A01-001.cgm
1 2.45 (62.23) OUTER DIAMETER

1.75 (44.45) INNER DIAMETER
1.00 (25.40) WIDTH
MINIMUM
NOTE: THE ITEM NUMBERS IN
PARENTHESES REFER
TO IPL FIGURE 3.
GRAPHIC 28-22-04-99B-843-A01
Rotor Disassembly Details
Figure 3002
28-22-04 Page 3011

Jan 09/2004
60-989
28-22-04 Page 3012

Jan 09/2004
60-989
CLEANING
TASK 28-22-04-99C-870-A01
1. General
A. This section contains cleaning procedures for the Motor-Impeller Subassembly, Housing Subassembly,
and detail components.
B. Do all work in a clean, ventilated room with good lighting.
C. Wear necessary protective equipment at all times.
D. Remove and discard all packings before the components are cleaned.
E. Make sure the ports, sealing surfaces, threaded areas, and internal passages are clean.
TASK 28-22-04-94B-873-A01
2. Cleaning Tools and Equipment
04-99A-865-A01" on page 4001.)

4001
TABLE 28-22-04-99A-865-A01
Cleaning Tools and Equipment—Table 4001
NUMBER
Bioblaster System No Specific USF Surface Preparation Group

(V1RCQ9)
Media Blast Abrasive (MBA) No Specific USF Surface Preparation Group

Cabinet (V1RCQ9)
Cleaning Tools and Equipment—Table 4001
B. Operating Instructions for the Bioblaster System and MBA cabinet are available from USF Surface
Preparation Group (CAGE 1RCQ9).
TASK 28-22-04-94A-871-A01
3. Cleaning Materials
The recommended cleaning materials are given in Table 4002. Equivalent items can be used. (Refer to
Table 4002 "TABLE-28-22-04-99A-867-A01" on page 4002.)
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Jan 09/2004
60-989
4002
TABLE 28-22-04-99A-867-A01 Cleaning Materials—Table 4002
NUMBER
Alcohol, Isopropyl Federal Specification TT-I-735, Commercially Available
Grade A or B
Applicator, Cotton Tip No Specific Commercially Available
Bag, Polyethylene Military Specification MIL-B-117 Commercially Available
Brush, Soft-Bristle Fiber, No Specific Commercially Available
Non-contaminating
Cloth, Lint-Free Military Specification MIL-C-85043 Commercially Available
Eraser, Rubber No Specific Commercially Available
Gas, Dry Nitrogen No Specific Commercially Available
Gloves, Protective Nitrile or latex, powder and silicone Commercially Available
free
Goggles, Safety No Specific Commercially Available
Solvent, Aqueous No Specific Commercially Available
Cleaning Materials —Table 4002
TASK 28-22-04-160-873-A01
4. Cleaning Procedures
WARNING: CLEANING SOLVENTS ARE TOXIC TO THE SKIN, EYES, AND RESPIRATORY TRACT.
USE THE SOLVENTS ONLY IN AREAS THAT HAVE GOOD VENTILATION. WEAR
GOGGLES AND GLOVES TO PROTECT YOUR EYES AND SKIN.
CAUTION: SOME CLEANING SOLVENTS ARE DANGEROUS TO THE ENVIRONMENT. KEEP

CLEANING SOLVENTS IN APPROVED SAFETY CONTAINERS AND IN MINIMUM
QUANTITIES. READ AND FOLLOW ALL WARNING LABELS AND INSTRUCTIONS.
DISCARD UNUSED CLEANING SOLVENTS IN ACCORDANCE WITH APPROVED
PROCEDURES FOR THE DISPOSAL OF HAZARDOUS MATERIALS.
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Jan 09/2004
60-989

COMPONENTS CAN BE DAMAGED BY INTERNAL CONTAMINATION AND ROUGH
HANDLING.
A. Electrical Components
CAUTION: DO NOT IMMERSE ELECTRICAL COMPONENTS IN CLEANING SOLVENT. THIS

CAN CAUSE ELECTRICAL DAMAGE WITH POSSIBLE OPEN OR SHORTED
CIRCUITS.
(1) Fill a container with clean, hot water and enough aqueous solvent to fully clean the components.
NOTE: The water temperature must be approximately 185 °F (85 °C).
(2) Wet clean, lint-free cloths with the cleaning solvent.
CAUTION: SOLVENTS (THINNERS, ACETONE, MEK, ETC.) CAN CRACK THE MAGNET WIRE
INSULATION USED ON THE STATOR ASSEMBLY. DO NOT ALLOW SOLVENTS TO
CONTACT THE STATOR ASSEMBLY. USE SOLVENTS ONLY TO CLEAN THE
CONNECTOR SOLDER JOINTS.
(3) Wipe the electrical components with the cloth to remove dirt and other contamination. Use a
soft-bristled brush if necessary to clean hard-to-reach areas. Do not clean the stator assembly
(200, IPL Figures 2, 2A, and 2B) magnet wire insulation.
(4) Use a soft rubber eraser to remove tarnish from electrical contacts.
(5) Refer to paragraph 4.E, below for component storage after cleaning.
B. Non-Electrical Components
(1) Use a soft-bristled brush to loosen the contamination.
(2) Clean the components with clean, lint-free cloths and cotton-tipped swabs moistened with
isopropyl alcohol.
(3) Examine the components for cleanliness. If the components are not clean, refer to paragraph
4.C, below for Bioblaster System cleaning. If the components are clean, refer to paragraph 4.E for
component storage after cleaning.
C. Bioblaster System Cleaning
NOTE: Use this procedure before aqueous solvent cleaning when grease, corrosion, and
contamination is visible after disassembly.
NOTE: This procedure uses the MBA Cabinet and Bioblaster System available from USF Surface
Preparation Group (CAGE 1RCQ9). Refer to USF Surface Preparation Group documentation
for more information.
(1) Place the components in the MBA cabinet.
(2) Adjust the media grade of the baking soda and the pressure of the blast nozzle as required.
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Jan 09/2004
60-989
(3) Use the blast nozzle to remove dirt, grease, and other contamination from the components.
(4) Examine the components for cleanliness. If the components are not clean, refer to paragraph
4.D, below for aqueous solvent cleaning. If the components are clean, refer to paragraph 4.E for
component storage after cleaning.
D. Aqueous Solvent Cleaning
NOTE: Use this procedure after Bioblaster System cleaning if the Bioblaster System cleaning did not
remove all contamination from the component.
(1) Fill a container with clean, hot water and enough aqueous solvent to fully clean the components.
NOTE: The water temperature must be approximately 185 °F (85 °C).
(2) Soak the components in the solvent for 2 to 10 minutes.
(3) Use a brush or lint-free cloth to remove dirt and other contamination.
(4) Rinse the components with clean, hot water.
CAUTION: TO PREVENT CORROSION, FULLY DRY THE COMPONENTS.
(5) Dry the components with dry Nitrogen gas (GN2). Make sure the components are fully dry to
prevent corrosion.
(6) Examine the components to make sure they are clean. Do this procedure again if the
components are not clean. If the components are clean, refer to Paragraph 4.E for component
storage after cleaning.
E. Component Storage After Cleaning
(1) Install a protective cap over the motor-impeller connector. Install protective plugs and cover in the
housing ports and bosses.
(2) Store all other components in clean, polyethylene bags or on clean, lint-free cloths. Keep the
components in a clean, dry area until they are needed for CHECK and ASSEMBLY.
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Jan 09/2004
60-989
CHECK
TASK 28-22-04-99C-885-A01
1. General

A. This section contains x-ray, borescopic, visual, dimensional, and Non-Destructive Inspection (NDI)
examination procedures for detail components of the Motor-Impeller Subassembly and Housing
Subassembly.
B. Examine the components under a strong light. Magnification is recommended.
C. Replace any parts that do not meet CHECK requirements.
TASK 28-22-04-94B-886-A01
2. Check Tools and Equipment
04-99A-870-A01" on page 5001.)

5001
TABLE 28-22-04-99A-870-A01 Check Tools and Equipment—Table 5001
NUMBER
Bright Light (for visual checks) No Specific Commercially Available
Magnifying Glass 4X to 10X magnification Commercially Available
Multimeter or Milliohmmeter 1% accuracy Commercially Available

(Continuity Checks)
X-Ray Inspection Equipment 160 to 200 kV, 5 mA, and 2.0 minutes Commercially Available
(typical); 35 inches (900 mm) minimum
source to film distance; 0.010 inch (0.25
mm) thick front and back lead screen;
0.2 inch (5.6 mm) maximum focal spot
dimension
Check Tools and Equipment —Table 5001
B. All tools and equipment must be in current calibration to MIL-STD-45662. The required accuracy is
given in the table.
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Jan 09/2004
60-989
TASK 28-22-04-94A-886-A01
3. Check Materials
Refer to Table 5002 for a list of materials. Equivalent items can be used. (Refer to Table 5002 "TABLE-28-
22-04-99A-871-A01" on page 5002.)
5002
TABLE 28-22-04-99A-871-A01
Check Materials—Table 5002
NUMBER
Film, X-Ray Inspection ASTM E 1815, Class 1 or Better Commercially Available
Film, X-Ray Inspection EN 584-1 Class C2 or Better Commercially Available
(Alternate)
Check Materials —Table 5002
TASK 28-22-04-210-889-A01
4. General Inspection
A. Refer to CLEANING to clean all disassembled components before inspection.
B. Visually examine all components for cracks, corrosion, deterioration, and signs of damage such as
burrs, nicks, and scratches.
NOTE: Burrs, nicks, and scratches are defined as material raised above the parent metal which, if not
removed, would prevent the complete and proper mating of parts and sealing surfaces. Dents
must not impair the finish or functional operation.
C. Visually examine all threaded parts for crossed or stripped threads. The required thread is given in
Paragraph 7 and in REPAIR.
NOTE: Replace the part if more than two entrance threads are damaged. Otherwise, refer to REPAIR
to rework the threads.
D. Refer to the dimensions given in Paragraph 7 to check components for wear or damage. If any doubt
exists concerning the serviceability of a part, replace the part.
E. Examine plated areas for pits, blisters, scoring, charring, wear, and other damage.
F. Examine anodized and chem-film finishes for corrosion, deterioration, and other damage. Repair
instructions are given in REPAIR.
G. Examine wire insulation and connections for corrosion, open or intermittent circuits, and evidence of
aging, cracks, or burning.
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60-989
TASK 28-22-04-210-890-A01
5. X-Ray Inspection
NOTE: As an alternate, borescopic inspection of the wire bundle can be done with the motor-impeller
subassembly mounted on the aircraft or in the shop. Refer to Service Bulletin Crane Hydro-Aire
Motor-Impeller-28-1 for more information.
A. General
(1) Hydro-Aire Service Information Letter (SIL) 60-72101-04-01 identified a potentially hazardous
condition on the P/N 60-98976-4 motor-impeller subassembly due to the improper routing of the
wire bundle connecting the stator assembly to the connector. If the wire becomes caught under
the bearing support of the end cap assembly, the wire bundle can be forced into the gap between
the stator end windings and the bearing support. If this happens, the wire bundle can become
lodged in such a way as to contact the rotor assembly. This contact can cause the protective
Teflon spiral wrap on the wire bundle and wire insulation to wear to the point of allowing an
electrical short.
NOTE: Refer to CMM 28-22-07 for maintenance and description of motor-impeller subassembly
P/N 60-98976-4.
(2) The changes to the P/N 60-98976-4 wire harness contribute to an increased possibility of
incorrect assembly over the P/N 60-98902, 60-98902A, 60-98904, 60-98904A, 60-98906, 60-
98906A, 60-98976, and 60-98976-1 configurations. The P/N 60-98902, 60-98902A, 60-98904,
60-98904A, 60-98906, 60-98906A, 60-98976, and 60-98976-1 configurations do not have the
stiffer section of shrink sleeving next to the terminal assembly (90, IPL Figures 2, 2A, and 2B)
and use a solid Teflon tube instead of the spiral wrap found on the P/N 60-98976-4 wire harness.
Because of these differences, it is easier to route the P/N 60-98902, 60-98902A, 60-98904, 60-
98904A, 60-98906, 60-98906A, 60-98976, and 60-98976-1 wire bundle correctly.
(3) Even with the differences, the wire harness configuration of the P/N 60-98902, 60-98902A, 60-
98904, 60-98904A, 60-98906, 60-98906A, 60-98976, and 60-98976-1 configurations is similar in
assembly to the P/N 60-98976-4 configuration. An investigation has shown that the same failure
can happen in the P/N 60-98902, 60-98902A, 60-98904, 60-98904A, 60-98906, 60-98906A, 60-
98976, and 60-98976-1 configurations.
B. Inspection Requirements
(1) All motor-impeller subassemblies that are assembled and not installed on aircraft are to be x-ray
or borescopic inspected. The inspection will ensure that the wire bundle is properly routed and
must be done before the motor-impeller subassembly can be installed on any airplane.
(2) All motor-impeller subassemblies that are disassembled must be reassembled and then
inspected as specified in ASSEMBLY to ensure that the wire bundle is properly routed. Removal
of the end cap from the inner housing constitutes disassembly.
(3) A motor-impeller subassembly is considered suspect if it does not meet the acceptance criteria
specified in this procedure. In the event a suspect unit is found, it must be disassembled and the
wire bundle examined for any evidence of damage or wear. If any damage is present, the
assembly must be reworked as specified in this CMM.
(4) A motor-impeller subassembly is considered suspect if it does not meet the acceptance criteria
specified in this procedure. In the event a suspect unit is found, it must be disassembled and the
wire bundle examined for any evidence of damage or wear. If any damage is present, the
assembly must be reworked as specified in this CMM.
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Jan 09/2004
60-989
C. X-Ray Inspection Procedure
(1) Scope
(a) This procedure is a radiographic technique to check for stator-to-connector wire bundles
that are improperly located within the end cap assembly (150) cavity.
(b) Any motor-impeller subassembly that does not meet the acceptance criteria provided in this
section is considered suspect and must not be put into service until it is reworked to meet
these requirements.
(2) Personnel/Process Qualification
(a) The personnel that perform this procedure and make the accept/reject decisions based on
the results of radiographic examination must be trained and certified as an NDT Level II
(or 2) technician to local industry standards such as ATA 105, ASNT TC-1A, NAS 410, or
EN 4179. If no qualified personnel are available, personnel can be trained and certified by
Hydro-Aire Quality Assurance.
(b) Hydro-Aire has developed, verified, and documented basic parameters and procedures for
the application and control of the radiographic technique, processing methods, materials
control, etc. Inspection facilities other than Hydro-Aire must comply with these parameters
and procedures. They can be modified as applicable to the equipment and facility in use.
(c) Inspection personnel are required to undergo 8 hours of On-The-Job (OJT) training
conducted by Hydro-Aire Quality Assurance in the interpretation of the radiographic images
and the accept/reject criteria. Upon completion of the OJT training, a performance
demonstration is required to ensure the personnel are qualified to conduct the x-ray
inspection.
(3) Inspection Equipment
(a) The recommended x-ray inspection equipment are listed in Table 5001. The film is listed in
Table 5002. Equivalent items can be used.
(b) The parameters given in Table 5001 for the x-ray inspection equipment are intended as
guidelines to control the quality of the radiographic image. The technique and parameters
used can vary due to factors such as the manufacturer and type of equipment, radiation
source energy level, film, film processing equipment, and other factors. The equipment must
be capable of providing a uniform image that is sensitive enough to determine the location
of the wire bundle.
(4) Component Inspection
(a) Orient the motor-impeller subassembly for the radiograph approximately as shown in Figure
5001. Place the motor-impeller subassembly on the film with the rotor assembly (205, IPL
Figures 2, 2A, and 2B) shaft horizontal and the terminal assembly (90) and drain plug (130)
in the same horizontal plane at approximately 3 and 9 O'clock. (See Figure 5001
NOTE: If the radiograph is not taken perpendicular to the rotor assembly (205) shaft the
image produced of the top of the stator end turns will be elliptical. If this is the
case, the wire bundle can appear to be below the top of the stator end turns
because of the angle of the shot. This may require additional exposures to
determine acceptability.
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Jan 09/2004
60-989
(b) Radiographs of multiple units can be done on a single image provided the radiation source
is approximately perpendicular to the rotor assembly (205) shaft and the radial location of
the terminal assembly (90) and drain plug (130) are noted to aid interpretation of the
radiograph.
(c) The motor-impeller subassembly can be rotated one-quarter turn for additional images to
establish the location of the wire bundle. Additional exposures may be required to
determine the acceptability of a unit.
(d) Sample radiographs are given in Figure 5002 to show acceptable and unacceptable
conditions. The examples are intended to aid interpretation of the radiographs and are not
representative of the quality of the actual radiographic images. (See Figure 5002
(5) Disposition of Suspect Units
(a) Any motor-impeller subassembly that fails to meet the acceptance requirements as shown
in Figure 5002 is considered suspect and must not be put into service until the steps given
below are completed.
CAUTION: STATOR ASSEMBLIES WITH DAMAGED WIRE LEADS MUST BE REPLACED.

REFER TO THE VISUAL/DIMENSIONAL INSPECTION PROCEDURES GIVEN
IN TABLE 5003 LATER IN THIS SECTION.
(b) The unit must be disassembled to visually inspect the stator-to-connector wire bundle for
damage to the Teflon sleeve/spiral wrap and the insulation on the conductor wires. The wire
leads must be free of any damage from the point where they exit the stator assembly (205)
end turn windings to the terminal assembly (90) solder joints.
(c) The unit must be reassembled as specified in ASSEMBLY.
(d) The unit must pass x-ray inspection after reassembly.
(6) Re-Identification
Upon successful verification of the proper assembly of the motor-impeller subassembly by x-ray
inspection, stamp the letter "T" on the identification plate (140) as a suffix to the serial number.
Refer to REPAIR for more information.
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Jan 09/2004
60-989
5001
X-RAY
28-22-04-99B-845-A01-001.cgm
X-RAY FILM
GRAPHIC 28-22-04-99B-845-A01 Orientation for X-Ray Inspection

Figure 5001
28-22-04 Page 5006

Jan 09/2004
60-989
5002
GRAPHIC 28-22-04-99B-846-A01 Sample Radiographs (Sheet 1 of 3)

Figure 5002
28-22-04 Page 5007

Jan 09/2004
60-989
5002
Sample Radiographs (Sheet 2 of 3)

Figure 5002
28-22-04 Page 5008

Jan 09/2004
60-989
5002
Sample Radiographs (Sheet 3 of 3)

Figure 5002
28-22-04 Page 5009

Jan 09/2004
60-989
TASK 28-22-04-210-891-A01
6. Spring Inspection
Refer to Figure 5003 to examine the torsion spring (35, IPL Figure 4) for deformation or permanent set.
Discard the damaged spring. (See Figure 5003 "GRAPHIC-28-22-04-99B-847-A01" on page 5010.)
5003
PRIMER CHECK VALVE

SPRING (35, IPL FIG. 4)
78°
40°
TO 50°
0.030
(0.76)
0.072 TO 0.082
(1.83 TO 2.08)
DIAMETER
28-22-04-99B-847-A01-001.cgm
0.250 (6.35)
MAXIMUM
INSTALLED
POSITION
(REF)
NOTE: THE DIMENSIONS ARE

GRAPHIC 28-22-04-99B-847-A01 Spring Check Data

Figure 5003
TASK 28-22-04-210-892-A01
7. Visual/Dimensional Inspection
subassemby P/N 60-98976-4.
A. Refer to Table 5003 for visual and dimensional inspection procedures. (Refer to Figure 5003
B. Refer to Figure 5004 when referenced for component check dimensions. (Refer to Figure 5004
28-22-04 Page 5010

Jan 09/2004
60-989
5003
TABLE 28-22-04-99A-876-A01
Component Check Procedures—Table 5003
METHOD OF
COMPONENT CHECK FOR CORRECTIVE ACTION
INSPECTION
MOTOR-IMPELLER SUBASSEMBLY
Inlet Adapter (20, Visual Deformation; cracks around mounting Refer to REPAIR to repair
IPL Figures 2, 2A, holes; anodized finish scratched or the finish, or replace the
and 2B) worn to base metal; corrosion. inlet adapter (20).
Inducer (30) Visual Deformed or pitted vane; nicks or burrs Replace the inducer (30).
on the leading edge; anodized finish
scratched or worn to base metal;
corrosion.
Inlet Impeller (35) Visual Deformed or pitted vane; anodized Replace the inlet impeller
finish scratched or worn to base metal; (35).
corrosion.
Drive Pin (50) Visual Deformation. Replace the drive pin (50).
Cable Assembly Visual Corroded, broken, or misaligned Replace the cable
(65) connector (70) or terminal assembly assembly (65).
(90) contacts; evidence of arcing; worn
keyway; corroded or cut seal.
Visual Worn, cracked, cut, or burned wire Replace the cable
insulation; broken wire leads; exposed assembly (65).
conductors.
Visual Poorly formed solder cups where the Refer to ASSEMBLY to
stator wire leads are connected to the resolder the wire leads or
terminal assembly (90); cracked or reapply potting compound.
missing potting over solder
connections.
Functional If the terminal assembly (90) is still Refer to ASSEMBLY to
connected to the ground wire assembly reconnect the wire leads, or
(105) and stator assembly (200) wire replace the cable assembly
leads, check for open or intermittent (65).
wire connections at the connector (70);
refer to TESTING AND FAULT ISOLA-
TION to test the continuity, dielectric
strength, and insulation resistance of
all circuits; make sure the terminal
assembly or connector shell is not
shorted to a wire lead.
Component Check Procedures (Sheet 1 of 7)—Table 5003
28-22-04 Page 5011

Jan 09/2004
60-989
METHOD OF
INSPECTION
MOTOR-IMPELLER SUBASSEMBLY (CONT)
Bracket Assembly Visual Deformation; cracks around mounting Replace the bracket
(120) holes. assembly (120).
Labels (115) Visual Unreadable; torn or cut edges. Replace the adhesive-
backed labels (115).
Drain Plug (130) Visual Crossed or stripped 0.4375-20UNF-3A Replace the drain plug
threads; stripped hex wrench flats. (130).
Identification Plate Visual Unreadable; torn or cut edges; loose or Refer to REPAIR to
(140) missing drive screws (145). replace or reinstall the
identification plate (140)
and drive screws (145).
End Cap Assembly Visual Burns or other evidence of arcing; Replace the end cap
(150) erosion damage. assembly (135).
Visual Anodized or chemical film finishes Refer to REPAIR to repair
scratched or worn to base metal; the finish.
corrosion; refer to Figure 5004 for
surfaces that must be free of anodize
and chem-film.
Visual Crossed or stripped 0.138-32UNC-2B Refer to REPAIR to repair
threads for the mounting screws (165). the threads, or replace the
end cap assembly (150).
threads for the terminal assembly (90) the threads, or replace the
mounting screws. end cap assembly (150).
threads for the ground wire assembly the threads, or replace the
(105) mounting screw. end cap assembly (150).
Visual Crossed or stripped 0.4375-20UNF-3B Refer to REPAIR to repair
threads in the MS33649-04 drain port. the threads, or replace the
Visual Deteriorated insulation strip (195) Refer to REPAIR to replace
bonded inside the end cap assembly the insulation strip (195).
(150); loose bond.
Visual Worn, loose, or corroded shrink-fit Replace the end cap
chrome plated liner in the inner flange; assembly (150).
the chrome finish must be smooth to 16
microinch or better.
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Jan 09/2004
60-989
METHOD OF
INSPECTION
End Cap Assembly Dimensional Inner chrome-plated diameter not Replace the end cap
(150) (Cont) 1.0000 to 1.0005 inch (25.400 to assembly (150).
25.413 mm); refer to Figure 5004. (See
Figure 5004 "GRAPHIC-28-22-04-99B-
848-A01" on page 5018.)
Ground Wire Visual Cut or corroded terminal; terminal not Refer to REPAIR to replace
Assembly (105) securely crimped to the wire lead; the damaged components,
insulator cracked or degraded. or replace the ground wire
assembly (105).
Functional If the ground wire assembly (105) is Refer to REPAIR to replace
still connected to the terminal assembly the damaged components,
(90), check for an open or intermittent or replace the ground wire
wire connection; refer to TESTING assembly (105).
AND FAULT ISOLATION to test the
continuity, dielectric strength, and
insulation resistance of the circuit;
make sure the wire lead is not shorted
to the terminal assembly or connector
shell.
Bearing Holders Visual Deformation; cracked or bent locking Replace the damaged
(185) tabs; refer to Figure 5004 for bearing holders (185).
dimensions.
Bearing Visual Wear or surface finish damage; refer to Replace the damaged
Assemblies (190) Figure 5004. bearing assemblies (190).
Sator Assembly Visual Cut, cracked, split, or abraded If a wire lead is spliced or a
(200) insulation on the wire leads; spliced or conductor is damaged,
damaged conductor; wire leads less replace the stator assembly
than 4 inches (102 mm) or more than 6 (200); refer to REPAIR to
inches (152 mm) long. cover the damaged
insulation with Teflon heat
shrink sleeving.
Visual Burns or other evidence of arcing, Replace the stator
charring, or other visible damage to the assembly (200).
end turns and wrapping; cracks visible
on magnet wire at 10X magnification.
Functional Open or intermittent stator circuit; refer If any lead wire pair shows
to TESTING AND FAULT ISOLATION an open circuit, the
to test the dielectric strength and resistance of the coil
insulation resistance of the circuits. windings varies more than
10 percent, or the unit fails
a test, replace the stator
assembly (200).
28-22-04 Page 5013

Jan 09/2004
60-989
METHOD OF
INSPECTION
Stator Assembly Visual Deep scoring, nicks, pits, or other Refer to REPAIR to repair
(200) (Cont) damage to the varnish finish on the the varnish finish, or
coil; exposed wire; a thin coat of replace the stator assembly
varnish must remain on the inner (200).
diameter; the minimum allowable inner
diameter after varnish is 1.547 inch
(39.29 mm); the ends of the coil must
be clean and free of varnish; refer to
Figure 5004.
Dimensional Check for 0.0075 to 0.0085 inch (0.191 Replace the damaged
to 0.216 mm) minimum air gap component, or refer to
clearance between each side of the ASSEMBLY to reinstall the
rotor assembly (205) lamination and stator assembly (200) on
the stator assembly (200); refer to the rotor assembly (205)
Figure 5004. lamination.
Rotor Assembly Visual Lamination loose on the shaft; apply a Replace the rotor/shaft
(205) 500 lb (227 kg) push test to the end of assembly (65, IPL
the shaft as shown in Figure 5004; the Figure 3).
shaft must not move in the lamination.
Visual Scratches or scoring on the inlet plate Refer to REPAIR to repair
assembly (5); the side toward the the finish, or replace the
primer impeller (20) must be smooth to inlet plate assembly (5).
32 microinch or better.
Visual Loose bond between the primer liner Replace or reinstall the
(10), inlet plate assembly (5), and/or primer liner (10); refer to
primer discharge plate (30); check for ASSEMBLY to rebond the
cracks in the primer liner, particularly components.
around the holes for the tubes (15).
Visual Deformed tube (15); if the tubes are Replace the damaged
installed, they must be tight in the tubes (15).
primer liner (10) and not bent; the
tubes must extend 0.156 inch (3.96
mm) maximum from the face of the
inlet plate assembly (5); there must be
sufficient adhesive to close the gaps
between the inlet plate and tubes.
Visual Obstruction in the inner diameter of a Clean the tubes (15) to
tube (15). clear the obstruction, or
replace the obstructed
tubes.
28-22-04 Page 5014

Jan 09/2004
60-989
METHOD OF
INSPECTION
Rotor Assembly Visual Corrosion or pitting on the primer Pitting caused by cavitation
(Cont) impeller (20) blades; nicks, burrs, or is acceptable if the depth of
scratches at 10X magnification on the the pits is not more than
sides; refer to Figure 5004 for one-half the thickness of
dimensions. the part; if the pitting is
unacceptable, replace the
primer impeller (20).
Visual Scratches or scoring on the primer Refer to REPAIR to repair
discharge plate (30) caused by contact the finish, or replace the
with the primer impeller (20); the side primer discharge plate (30).
of the plate toward the primer impeller
must be smooth to 32 microinch or
better.
Visual Wear on the thrust bearing holder (35); Replace the thrust bearing
refer to Figure 5004 for dimensions and holder (35).
for surfaces that must be free of
anodize and chem-film.
Visual Deterioration of the insulation strip (55) Refer to REPAIR to replace
bonded inside the thrust bearing holder the insulation strip (55).
(35); loose bond.
Visual Nicks, gouges, or wear on the running Replace the thrust bearing
surface of the thrust bearing plate (40); plate (40).
refer to Figure 5004 for check
requirements.
Visual Cracks or chips on the running surface Replace the thrust washer
of the thrust washer (45); refer to (45).
Figure 5004 for check requirements.
Dimensional Worn bearing journals on the rotor/ Replace the rotor/shaft
shaft assembly (65); cut lamination; assembly (65).
plating scratched or worn; crossed or
stripped internal 0.190-32UNF-3B
threads; refer to Figure 5004 for
dimensions.
Inner Housing Visual Burns or other evidence of arcing; Replace the inner housing
Assembly (210, IPL erosion damage. assembly (210).
Figures 2, 2A, and
Visual Worn, loose, or corroded shrink-fit Replace the inner housing
2B)
chrome plated liner in the inner flange; assembly (210).
the chrome finish must be smooth to 16
microinch or better; refer to Figure
5004.
28-22-04 Page 5015

Jan 09/2004
60-989
METHOD OF
INSPECTION
Inner Housing Dimensional Inner chrome-plated diameter not Replace the inner housing
Assembly (210, IPL 1.000 to 1.001 inch (25.40 to 25.43 assembly (210).
Figures 2, 2A, and mm); refer to Figure 5004.
2B) (Cont)
threads for the inlet adapter (20) the threads, or replace the
mounting screws. inner housing assembly
(210).
Visual Crossed or stripped 0.1900-32UNF-2B Refer to REPAIR to repair
threads for the bracket assembly (140) the threads and chem-film,
mounting screws; the threads must or replace the inner
have chem-film finish. housing assembly (210).
and chem-film.
Dimensional Nicks, burrs, or scratches under 10X Replace the inner housing
magnification on the inner diameter; assembly (210).
the finish must be smooth to 32
microinch or better for 0.75 inch (19.05
mm) minimum; refer to Figure 5004.
HOUSING SUBASSEMBLY
Primer Discharge Visual Corrosion; anodized finish scratched or Refer to REPAIR to repair
Port (5, IPL Figure worn to base metal. the finish, or replace the
4) primer discharge port (5).
Visual Deformation; cracks around mounting Replace the primer
holes. discharge port (5).
Primer Check Valve Dimensional Deformed or permanent set spring Replace the spring (35).
Assembly (25) (35); refer to Figure 5004.
Visual Bent or worn pin (30). Replace the pin (30).
Visual Cracked, cut, or permanently set seal Replace the flapper
on the flapper assembly (40); cracked assembly (40); field repair
or loose rivet or deformed seal retainer; is not authorized.
cracked or bent flapper.
Visual Nicks, burrs, or scratches on the valve Refer to REPAIR to repair
seat (45) or in the packing grooves; the finish, or replace the
deformation; cracks around mounting valve seat (45).
holes; anodized finish scratched or
worn to base metal; refer to Figure
5004 for dimensions.
28-22-04 Page 5016

Jan 09/2004
60-989
METHOD OF
INSPECTION
HOUSING SUBASSEMBLY
Outer Housing Visual Evidence of external leakage at a plug Refer to REPAIR to replace
Assembly (55) set (60); pin installed diagonally or the damaged plug sets
partially into plug; plug not seated fully (60), or replace the outer
in the outer housing (75). housing assembly (55).
Visual Loose or damaged screw thread insert Refer to REPAIR to repair
(65 or 70); crossed or stripped threads the damaged screw thread
in the tapped holes in the outer housing inserts (65 or 70).
(80).
threads for the primer check valve the threads, or replace the
mounting screws (10). outer housing assembly
(55).
and chem-film.
corrosion; refer to REPAIR for surfaces
that must be free of anodize and chem-
film.
28-22-04 Page 5017

Jan 09/2004
60-989
5004
END CAP
ASSEMBLY
(150, IPL FIG. 2, 2A, AND 2B)
0.138-32 UNC-2B
THREADS (2 PLACES)
-A-
SHRINK-FIT
LINER
16 32
1.0000 TO 1.0005
(25.400 TO 25.413)
2.7485 TO 2.7495
DIAMETER
(69.812 TO 69.837)
DIAMETER
A 0.001 (0.025) MS33649-04

DRAIN PORT
NO ANODIZE
OR CHEM-FILM
BEARING HOLDERS
(185, IPL FIG. 2, 2A, AND 2B)
0.160 (4.06)
SURFACES MUST BE
FLAT WITHIN 0.003
PER INCH (0.076 PER MM)
28-22-04-99B-848-A01-001.cgm
0.032 (0.813)
RADIUS
90°
MAXIMUM
GRAPHIC 28-22-04-99B-848-A01
Component Check Data (Sheet 1 of 6)
Figure 5004
28-22-04 Page 5018

Jan 09/2004
60-989
5004
BEARING ASSEMBLIES
A 0.002 (0.051)
(190, IPL FIG. 2, 2A, AND 2B)
0.500 (12.70)
RADIUS A 0.001 (0.0025)
A 0.002 (0.051)
0.5002 TO 0.5005 0.9994 TO 0.9998

(12.705 TO 12.713) (25.385 TO 25.395)
DIAMETER LAP DIAMETER
-A-
SURFACE TO INCLUDE
0.001 (0.025) MINIMUM
THICKNESS PER SIDE OF
HARD ANODIZE PER
MIL-A-8625, TYPE III
STATOR ASSEMBLY SURFACES MUST
(200, IPL FIG. 2, 2A, AND 2B) BE FREE OF VARNISH
ROTOR/SHAFT ASSEMBLY
(65, IPL FIG. 3) ROTOR/SHAFT
ASSEMBLY
STATOR
ASSEMBLY
1.532 TO 1.533 0.4990 TO 0.4998
(38.913 TO 38.938) 1
(12.675 TO 12.695) 2.7505 TO 2.7525
ROTOR/SHAFT DIAMETER (69.863 TO 69.614)
ASSEMBLY OD
AFTER VARNISH
0.4992 TO 0.4995
1 (12.680 TO 12.687)
JOURNAL DIAMETER
500 lb (227 kg)

LOAD DIRECTION
0.4992 TO 0.4995
1 (12.680 TO 12.687)
JOURNAL DIAMETER
0.3746 TO 0.3749
1 (9.515 TO 9.522) 28-22-04-99B-848-A01-002.cgm
ENTIRE DIAMETER
SUPPORT SURFACE MUST BE COATED
0.0075 TO 0.0085 FOR PUSH TEST WITH VARNISH
(0.191 TO 0.216)
AIR GAP CLEARANCE
THE DIMENSIONS (AFTER PLATING) MUST BE
1 CONCENTRIC TO WITHIN 0.0005 (0.0127) TIR.


Figure 5004
28-22-04 Page 5019

Jan 09/2004
60-989
5004
PRIMER IMPELLER
(20, IPL FIG. 3)
0.500 TO 0.501 0.800

(12.700 TO 12.725) (20.32)
DIAMETER DIAMETER
0.691 TO 0.693
(17.55 TO 17.60)
32 32
THRUST BEARING
HOLDER
NO ANODIZE
(35, IPL FIG. 3) OR CHEM-FILM
B 0.001 (0.025)
B 0.001 (0.025)
1.249 TO 1.251
(31.725 TO 31.7775) A 0.005 (0.127)
-B-
0.528 TO 0.540
(13.411 TO 13.716)
DIAMETER
2.747 TO 2.748
(69.774 TO 69.799)
DIAMETER
28-22-04-99B-848-A01-003.cgm
-A-


Figure 5004
28-22-04 Page 5020

Jan 09/2004
60-989
5004
THRUST BEARING 8
PLATE (40, IPL FIG. 3) SURFACE MUST BE
FLAT AND PARALLEL
0.248 TO 0.252
0.020 (0.508) (6.299 TO 6.401)
DEPTH OF GROOVE
(TYPICAL)
0.560 (14.224)
DIAMETER
-A-
A 0.0003 (0.0076)
0.0003 (0.0076)
THRUST WASHER
(45, IPL FIG. 3)
-B-
A 0.001 (0.025)
A 0.001 (0.025)
B 0.0002 (0.0051)
1 2 3
SURFACE
WITH LETTERING
0.187 TO 0.190
(4.75 TO 4.83)
0.5005 TO 0.5015 E A G
(12.713 TO 12.738) ID A
S
IN
C E T H IS
ST SHO
1.310
(33.27)
A
L U
LD P
-A-
ER
A 0.004 (0.102)
28-22-04-99B-848-A01-004.cgm
1 THIS SURFACE MUST HAVE NO PITS LARGER THAN 0.012 x 0.012 (0.305 x 0.305).
ADJACENT PITS MUST BE NO CLOSER THAN 0.030 (0.762) MEASURED BETWEEN
THE PIT EDGES.
2 95% OF THIS SURFACE MUST HAVE A SURFACE FINISH AND FLATNESS
WITHIN TWO MONOCHROMATIC LIGHT BANDS.
3 THE SURFACE FINISH REQUIRES 8 MICROINCH RA (ROUGNESS AVERAGE).

Figure 5004
28-22-04 Page 5021

Jan 09/2004
60-989
5004
INNER HOUSING
ASSEMBLY
(210, IPL FIG. 2, 2A, AND 2B)
NO ANODIZE
A 0.002 (0.051)
OR CHEM-FILM -A-
1.000 TO 1.001
(25.40 TO 25.43)
16
2.750 TO 2.751
(69.85 TO 69.88)
DIAMETER
TO 0.75 (19.05)
32
MINIMUM
SHRINK-FIT
LINER
PRIMER CHECK
VALVE SEAT
(45, IPL FIG. 4)
32
C AT CREST OF FULL
RADIUS ONLY
63
63
28-22-04-99B-848-A01-005.cgm
63


Figure 5004
28-22-04 Page 5022

Jan 09/2004
60-989
5004
OUTER HOUSING
ASSEMBLY
(75, IPL FIG. 4)
63
NO ANODIZE
OR CHEM-FILM
63
63
63 63 32
63
SCREW THREAD
INSERTS (70, IPL FIG. 4)
(12 PLACES)
63
28-22-04-99B-848-A01-006.cgm
6.685 (169.80)
NO VISIBLE SURFACE
DEFECTS ALLOWED


Figure 5004
TASK 28-22-04-210-893-A01
28-22-04 Page 5023

Jan 09/2004
60-989
8. NDI Procedures
Not applicable.
28-22-04 Page 5024

Jan 09/2004
60-989
REPAIR
TASK 28-22-04-99C-900-A01
1. General
CAUTION: UNLESS SPECIFIED IN THIS SECTION, DO NOT ATTEMPT TO REPAIR, REBUILD, OR

REMANUFACTURE ANY COMPONENTS OF THE MOTOR-IMPELLER SUBASSEMBLY
OR HOUSING SUBASSEMBLY. THIS INCLUDES REWINDING OF THE STATOR OR
REPAIRS TO THE ROTOR, HOUSING, AND IMPELLERS. UNLESS OTHERWISE
SPECIFIED, REPAIRS ARE NOT AUTHORIZED.

A. This section contains the limited repair instructions and information given below for detail components
of the Motor-Impeller Subassembly and Housing Subassembly. Refer to DISASSEMBLY and
ASSEMBLY to replace all non-repairable components.
(1) Repair minor thread damage.
(2) Repair nicks, scratches, and burrs.
(3) Repair anodized and chem-film finishes.
(4) Replace the identification plate (140, IPL Figures 2, 2A, and 2B) and drive screws (145).
(5) Repair or rebuild the ground wire assembly (105).
(6) Replace the insulation strip (195) bonded inside the end cap assembly (150).
(7) Repair the stator assembly (200) varnish finish.
(8) Cover damaged insulation on the stator assembly (200) wire leads.
(9) Repair the inlet plate assembly (5, IPL Figure 3) and primer discharge plate (30).
(10) Replace the insulation strip (55) bonded inside the thrust bearing holder (35).
(11) Replace Lee plug sets (60, IPL Figure 4) in the housing subassembly.
(12) Replace screw thread inserts (65 and 70) in the housing subassembly.
(13) Wire etching, soldering, and potting procedures. Refer to these procedures when specified in
REPAIR and ASSEMBLY.
(14) Shrink sleeving installation. Refer to these procedures when specified in REPAIR and
ASSEMBLY.
B. Replace all packings exposed at disassembly. Refer to DISASSEMBLY and ASSEMBLY.
28-22-04 Page 6001

Jan 09/2004
60-989
C. If removed, replace the self-locking screw (40, IPL Figures 2, 2A, and 2B), cable assembly (65), and
tolerance ring (25, IPL Figure 3).
NOTE: The self-locking screw must be discarded each time it is removed.
D. Replace all components that do not pass check requirements and cannot be repaired with the
procedures in this section. Refer to CHECK.
TASK 28-22-04-94B-901-A01
2. Repair Tools and Equipment
04-99A-901-A01" on page 6002.)
6001
TABLE 28-22-04-99A-901-A01 Repair Tools and Equipment—Table 6001
NUMBER
Adapter, Heat Deflector Model 40060 Master Appliance Corp.

(V83284)
Adapter, Nozzle Models 07461, 07051, 07061 Steinel America Inc. (V65309)
Crimping Tool, Terminal 49900 Amp, Inc. (V00779)
Heat Gun ** Model HG3002 LCD; 60 Hz, 2000 Watt Steinel America Inc. (V65309)
Injection Gun, Adhesive Model 800V EFD Inc. (V0XUL4)
Insert Replacement Tools, Emhart Industries, Inc./Helicoil

MS122119 Inserts: (V1D1Q0)
Hand Extraction Tool 1227-06
Hand Insertion Tool 7551-2
Tang Breakoff Tool 3695-2
Insert Replacement Tools, Emhart Industries, Inc./Helicoil

MS21209F4-15P Inserts: (V1D1Q0)
Hand Extraction Tool 1227-6
Hand Insertion Tool 7552-4
Tang Breakoff Tool 3695-4
Mixer, Pneumatic Mixpac 200 (DP200-70-10) ConProTec
Oven, Curing Model AF500; 350 °F (177 °C) The Grieve Corp. (V90423)
Soldering Iron Model 900L ESD; 50 Watt Minimum, American Hakko Products Inc.
700 to 825 °F (371 to 440 °C) (V0W6S2)

** The Model HG 3002 LCD heat gun is an adjustable heat gun with temperature meter display. Before use,
this heat gun must be tested and adjusted at the workstation to ensure the hot air stream will not melt solder.
Repair Tools and Equipment (Sheet 1 of 2)—Table 6001
28-22-04 Page 6002

Jan 09/2004
60-989
NUMBER
Soldering Pot (For Pre-Tinning Model SP-500T; 500 to 600 °F (260 to Plato Products Inc. (V32399)
Wires) 315 °C)
Solder Puller Silverstat Model AS196 Caltronics (V3W576)
Solder Wick No. 3 Chemtronics Inc. (V21267)
Soldering Station Model 927 ESD; 60 Watt, 392 to 899 °F American Hakko Products Inc.
(200 to 480 °C) (V0W6S2)
Tool Kit, PLGA3430010A Lee The Lee Co. (V92555)

Plugs:
Installation CUTA3430203A
Extraction CUTA3430103B

** The Model HG 3002 LCD heat gun is an adjustable heat gun with temperature meter display. Before use,
Repair Tools and Equipment (Sheet 2 of 2)—Table 6001
(1) Military Specification MS33537.
(2) Military Specification MIL-C-5541, Class 3.
(3) Henkel Corporation (CAGE 84063), Technical Process Bulletin No. 1161.
TASK 28-22-04-94A-901-A01
3. Repair Materials
A. The recommended materials are given in Table 6002. Unless otherwise noted, equivalent items can be
used. (Refer to Table 6002 "TABLE-28-22-04-99A-902-A01" on page 6003.)
6002
TABLE 28-22-04-99A-902-A01 Repair Materials—Table 6002
NUMBER
Abrasive Cloth, Aluminum Oxide 211K-500J; Federal Specification 3M Co. (V28124)
P-C-451
Abrasive Cloth, Crocus 011K; Federal Specification P-C-458 3M Co. (V28124)
Acetone ASTM D329 Commercially Available
Adhesive C-111 (V81982 SCD S30-001) Stabond Corp. (V25670)
** Equivalent items not allowed.
Repair Materials (Sheet 1 of 3)—Table 6002
28-22-04 Page 6003

Jan 09/2004
60-989
NUMBER
Aero-Methyl-Ethyl-Ketone (Aero RHO-SOLV 7228 (ASTM D740, RHO-Chem Corp. (V21414)
MEK) Type 1)
Alcohol, Isopropyl Federal Specification TT-I-735, Grade Commercially Available
A or B
Alodine 1200L; SAE AMS-C-5541 Henkel Corp. (V84063)
Anti-Wicking Tweezers, 16 or 18 AW16 or AW18 Clauss Cutlery Co. (V71827)
AWG
Non-contaminating
Deionized Water ASTM D1193, Type IV Commercially Available
Epoxy Hardener 951 ** CIBA Specialty Chemicals
Corp. (V99384)
Etchant Solution Tetra-Etch ** W. L. Gore and Associates
Inc. (V1BX19)
Flux Formula 185 ** Kester Solder Division Litton
Systems Inc. (V75297)
Flux Paste SP229-25 Kester Solder Division Litton
Flux Remover 5768 Bio-Kleen Saponifier ** Kester Solder Division Litton
free
Gloves, Handling Disposable, clean white cotton Commercially Available
Mixer, Disposable Statomix MCX-08-24 ConProTec
Mixer, Disposable, Cartridge Mixpac 200 ConProTec
Plastic Cups No Specific Commercially Available
28-22-04 Page 6004

Jan 09/2004
60-989
NUMBER
Potting Mold, Disposable 60-35766 Hydro-Aire, Inc. (V81982)
(60-98908 ONLY)
Potting Mold, Disposable 730609 or 60-73609GHA Hydro-Aire, Inc. (V81982)
(60-989100 ONLY)
Potting Resin 220A Epocast CIBA Specialty Chemicals
Corp. (V99384)
Primer, Zinc Chromate Boeing Material Specification Commercially Available
BMS10-11
Solder (With Type 285 Flux) Sn95Sb05WRMA (QQ-S-571) ** Kester Solder Division Litton
Solder, Bar Solid Sn95Sb05 ** Kester Solder Division Litton
Syringe, Disposable Barrel Reservoir EFD Inc. (V0XUL4)
Terminal, Crimp Style R-4122SB Electro Term Inc. (V14726)
Terminal, Crimp Style (Alternate) 324955 Tyco Electronics Corp.
(V00779)
Thinner, Varnish 6001S (V81982 SCD S33-027) The Epoxylite Corp. (V11147)
Tongue Depressor Ultra No. 600SR Applied Technology
Franklin Park, IL
Tubing, Teflon AMS3653, No. 6, Standard Wall Commercially Available
Varnish 6001 (V81982 SCD S33-017) The Epoxylite Corp. (V11147)
Wipes, Lint-Free No Specific Commercially Available
Wire, Electrical, 16 AWG, Blue, M22759/12-16-6 (MIL-W-22759/12) Commercially Available
Nickel Plated
TASK 28-22-04-350-904-A01
4. Repair Minor Thread Damage
NOTE: Threaded components can be repaired if less than two entrance threads are damaged.
A. Chase the damaged threads with an appropriate die or tap. Refer to the thread data given in Table
6003. (Refer to Table 6003 "TABLE-28-22-04-99A-905-A01" on page 6006.)
B. Thread the component into the mating component and check the fit and alignment. If the fit and
alignment are incorrect, replace the damaged component.
28-22-04 Page 6005

Jan 09/2004
60-989
6003
TABLE 28-22-04-99A-905-A01 Thread Data—Table 6003
ITEM THREAD MATING COMPONENT SPECIFICATION
Screws (25, IPL Figures 2, 2A, 0.138-32UNC-2A Inner Housing Assembly (210) MIL-S-7742
and 2B) for Inlet Adapter (20)
Screws (95) for Terminal 0.138-32UNC-2A End Cap Assembly (150) MIL-S-7742
Assembly (90)
Drain Plug (130) 0.4375-20UNF-3A End Cap Assembly (150) MS33649-04
Screws (155) for Bracket 0.190-32UNF-2A Inner Housing Assembly (210) MIL-S-7742
Assembly (120) and End Cap
Assembly (150)
Screw (110) for Ground Wire 0.164-32UNC-2A End Cap Assembly (150) MIL-S-7742
Assembly (105)
End Cap Assembly (150) 0.138-32UNC-2B Screws (95) for Terminal FED-STD-H28
Assembly (90)
0.4375-20UNF-3B Drain Plug (130) MS33649-04
0.164-32UNC-2B Screw (110) for Ground Wire FED-STD-H28

Assembly (105)
Inner Housing Assembly (210) 0.138-32UNC-2B Screws (25) for Inlet Adapter FED-STD-H28/2
(20)
0.190-32UNF-2B Screws (155) for Bracket FED-STD-H28/2

Assembly (120) and End Cap
Assembly (150)
Rotor/Shaft Assembly (65, IPL 0.190-32UNF-3B Self-Locking Screw (40, IPL MIL-S-7742
Figure 3) Figures 2, 2A, and 2B) for
Inducer (30) and Inlet Impel-
ler (35)
Screws (10, IPL Figure 4) for 0.138-32UNC-2A Outer Housing Assembly (55) MIL-S-7742
Primer Discharge Port (5)
Outer Housing Assembly (55) 0.138-32UNC-2B Screws (10) for Primer FED-STD-H28/2
Discharge Port (5)
Thread Data —Table 6003
28-22-04 Page 6006

Jan 09/2004
60-989
TASK 28-22-04-350-907-A01
5. Repair Nicks, Scratches, and Burrs
A. Replace, do not repair, the component if one or more of the conditions given below apply.
(1) The repair will change the function, serviceability, and/or structural integrity of the part.
(2) The damage is on a surface next to a seal or packing groove.
(3) The damage is on a critical sealing or pressure containment surface.
(4) The damage covers more than 25 percent of the surface area of the part or is more than 0.010
inch (0.25 mm) deep.
CAUTION: DO NOT USE CROCUS ABRASIVE CLOTH ON ALUMINUM, ALUMINUM ALLOY, OR

MAGNESIUM PARTS. CROCUS CLOTH CONTAINS AN IRON OXIDE WHICH CAN
QUICKLY OXIDIZE ALUMINUM. DO NOT POLISH MICROFINISH SURFACES.
CAUTION: DO NOT REPAIR THE FINISH ON THE PRIMER IMPELLER. IF ITS SURFACE IS
DAMAGED, REPLACE THE PART.
B. Polish out nicks, scratches, and corrosion on non-mating steel surfaces with crocus abrasive cloth.
C. Polish out nicks and scratches to a depth of 0.002 inch (0.051 mm) aluminum or aluminum alloy parts
with aluminum oxide abrasive cloth. Do not polish critical mating surfaces.
D. Clean the reworked parts before assembly. Refer to CLEANING.
TASK 28-22-04-350-910-A01
6. Repair Anodized and Chem-Film Finishes
NOTE: Use this procedure to touch-up or rework anodized and chem-film finishes on aluminum
components. Refer to CHECK, Table 5003 to identify all anodized and chem-filmed components.
WARNING: AERO-MEK IS FLAMMABLE AND TOXIC TO THE SKIN, EYES, AND RESPIRATORY
TRACT. USE THE SOLVENTS ONLY IN AREAS THAT HAVE GOOD VENTILATION.
WEAR GOGGLES AND GLOVES TO PROTECT YOUR EYES AND SKIN.
A. Clean the component with Aero-MEK to remove dirt and oxide film. Keep the solution on the
component for 1 to 3 minutes. Keep the entire rework surface wet.
B. Rinse the component by swabbing the surface with clean wipes or sponges soaked in water. Rinse the
component at least two times, and wring-out the wipes or sponge after each rinse.
WARNING: ALODINE IS VERY FLAMMABLE AND CAN DAMAGE YOUR EYES AND NOSE. USE
THE ALODINE ONLY IN A WELL-VENTILATED AREA AWAY FROM OPEN FLAMES.
WEAR RUBBER GLOVES, AN APRON, AND GOGGLES TO AVOID CONTACT WITH THE
SOLUTION.
C. Mix four volumes of Alodine 1200L concentrate with six volumes of water.
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60-989
WARNING: DO NOT ALLOW THE APPLICATORS USED TO APPLY THE ALODINE SOLUTION TO
DRY OUT. WHEN DRY, THEY ARE AN EXTREME FIRE HAZARD. RINSE CLOTH
APPLICATORS THOROUGHLY IN WATER AFTER USE.
D. Refer to Technical Process Bulletin No. 1161 to repair the anodized finish on the surfaces given below
on housing subassembly components.
NOTE: Technical Process Bulletin No. 1161 is available from the Henkel Corp. (CAGE 84063). The
bulletin gives the tools, inspection criteria, and procedures needed to apply anodized finishes.
(1) Primer discharge port (5, IPL Figure 4). Refer to MIL-A-8625, Type II, Class 1.
(2) Primer check valve seat (45). Refer to MIL-A-8625, Type I, Class 1.
(3) Outer housing assembly (55) to MIL-A-8625, Type I, Class 1. Do not anodize the motor-impeller
mounting flange, aircraft mounting holes, and tapped threads for the inserts (65 and 70).
E. Refer to MIL-C-5541, Class 3 to repair the chem-filmed outer housing assembly (55) aircraft mounting
holes. These surfaces must be free of anodic coating, contamination, and corrosion to ensure
adequate electrical bonding.
F. Refer to MIL-C-5541, Class 3 to repair the chem-filmed surfaces given below on motor-impeller
subassembly components. These surfaces must be free of anodic coating to ensure adequate
electrical bonding.
(1) End cap assembly (150, IPL Figures 2, 2A, and 2B) mounting threads for the terminal assembly
(90) and ground wire assembly (155), back side of the mounting flange, mounting holes in the
lugs (4 places), and inner surface that mates against the stator assembly (200). Refer to CHECK,
Figure 5004.
(2) The inside end of the main bore inside the inner housing assembly (210). Refer to CHECK,
Figure 5004.
TASK 28-22-04-350-911-A01
7. Replace Identification Plate
A. Use a 3/32 inch (2.38 mm) steel stamp or laser mark to transfer the data from the old identification
plate (125, IPL Figure 2) to a new identification plate. Complete the BCAG and Hydro-Aire
configuration dash numbers and serial number (SERNO) fields.
NOTE: After verification of proper assembly by x-ray or borescopic inspection, the letter "T" is
stamped on the identification plate as a suffix to the serial number. Transfer the "T" when
applicable to new identification plates.
B. Carefully drill out and discard the drive screws (145). Remove the identification plate (140) from the
end cap assembly (150). Use care to not enlarge the screw mounting holes.
C. Clean the end cap assembly (150) to remove contamination in the mounting area.
D. Orient the identification plate (140) as shown in IPL Figures 2, 2A, and 2B. Secure the identification
plate in place with new drive screws (145). Make sure the drive screws are installed fully and securely.
E. Brush Alodine 1200L over the newly steel-stamped or laser-marked identification plate (140). Refer to
instructions in this section to use and apply Alodine.
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TASK 28-22-04-350-912-A01
8. Repair or Rebuild Ground Wire Assembly
A. If necessary, open the crimp and break the solder connection between the wire lead and terminal.
Discard the damaged component.
B. Cut a new wire lead (Table 6002) to the dimensions given in Figure 6001. (See Figure 6001
C. Refer to the general instructions given in this section to etch and solder the wire lead to the terminal
(Table 6002). Refer to Figure 6001 for dimensions.
D. Use the crimping tool (Table 6001) to crimp the terminal to the wire lead. Refer to manufacturer
instructions for more information.
6001
4.00 (101.6) 0.05 (12.7)

MINIMUM MAXIMUM
0.05 (12.7)
MAXIMUM
16 AWG WIRE TERMINAL

(P/N M22759/12-16-6) (P/N R-4122SB
28-22-05-99B-850-A01-001.cgm
(TABLE 6002) OR 324955)
(TABLE 6002)

GRAPHIC 28-22-04-99B-850-A01
Ground Wire Repair
Figure 6001
TASK 28-22-04-350-914-A01
9. Replace Insulation Strips
NOTE: Use this procedure to replace the insulation strips bonded inside the end cap assembly (150, IPL
Figures 2 and 2A) and thrust bearing holder (35, IPL Figure 3).
A. Before removal of the damaged insulation strip (195, IPL Figures 2 and 2A) and (55, IPL Figure 3),
note the location and trimming to aid replacement.
TRACT. USE THE SOLVENTS ONLY IN AREAS THAT HAVE GOOD VENTILATION.
B. Remove and discard the insulation strip from inside the end cap assembly (150, IPL Figures 2 and 2A)
or thrust bearing holder (35, IPL Figure 3). If necessary, use Aero-MEK to loosen the adhesive.
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C. Refer to CLEANING to clean the end cap assembly or thrust bearing holder. Remove all adhesive
residue and other contamination.
D. Refer to CHECK to examine the end cap assembly or thrust bearing holder for wear and damage.
Repair or replace the damaged components.
CAUTION: USE ONLY ENOUGH ADHESIVE FOR COMPLETE ADHESION OF THE INSULATION
STRIP. MAKE SURE THE INSULATION STRIP IS SET EVENLY (NOT SKEWED).
E. Bond the new insulation strip to the end cap assembly or thrust bearing holder with adhesive (Table
6002).
F. On the end cap assembly (150, IPL Figures 2 and 2A), install the insulation strip (195) fully bottomed in
the end cap. Overlap the end, and trim flush with surface X. Cut the insulation strip as needed to open
the slots in the end cap assembly.
G. On the thrust bearing holder (35, IPL Figure 3), install the insulation strip (55), overlap the end, and
trim flush with surface X. Cut the insulation strip as needed to open the slots in the holder.
H. Let the adhesive dry for 10 to 15 minutes. Trim the excess insulation strip material.
I. Refer to CLEANING to remove any excess adhesive and other contamination from the end cap
assembly or thrust bearing holder. Refer to ASSEMBLY for installation instructions.
TASK 28-22-04-350-915-A01
10. Repair Stator Assembly
NOTE: Use this procedure to repair the varnish finish on the stator assembly (200, IPL Figures 2, 2A, and
2B) lamination assembly and install Teflon heat shrink sleeving to cover damaged wire insulation.
A. Repair the varnish on the lamination assembly, as follows:
TRACT. USE THE SOLVENT ONLY IN AREAS THAT HAVE GOOD VENTILATION.
(1) Remove the old varnish from the area that must be repaired. Use a lint-free cloth moistened with
Aero-MEK or acetone.
CAUTION: WEAR GLOVES AND OTHER PROTECTIVE GEAR AS NEEDED TO HANDLE THE
HEATED COMPONENTS. THE HOT METAL CAN CAUSE SERIOUS BURNS.
(2) Place the stator assembly (200) in an oven. Heat the assembly to 350 °F (177 °C) for 2 hours.
(3) Let the assembly cool to 200 °F (93 °C).
(4) Mix the varnish (Table 6002) with thinner to a viscosity suitable for spraying.
CAUTION: REMOVE OVERSPRAY IMMEDIATELY FROM THE SHAFT OF THE ROTOR/SHAFT

ASSEMBLY. THE VARNISH CAN CAUSE BINDING.
(5) Apply a light spray coat of varnish to the lamination assembly. Remove any overspray
immediately from the faces of the lamination end rings.
NOTE: A thin coat of varnish must remain on the inner diameter. The minimum diameter after
varnishing must be 1.547 inch (39.29 mm). The ends of the coil must be clean and free
of varnish.
(6) Place the assembly vertically in the oven. Bake the assembly at 250 °F (121 °C) for 2 hours, then
at 300 °F (149 °C) for 3 hours.
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CAUTION: DO NOT SPLICE THE STATOR ASSEMBLY WIRE LEADS. THIS CAN CAUSE OPEN OR
SHORT CIRCUITS AND POSSIBLE ARCING OR UNIT FAILURE.
B. Cover cracked, nicked, or damaged insulation on the stator assembly (200) wire leads with shrink
sleeving, as follows:
NOTE: Refer to the general procedure later in this section for shrink sleeving installation.
(1) Examine the wire leads under 10X magnification. Verify that the conductor is not spliced or
damaged. If the conductor is spliced or damaged, replace the stator assembly (200).
(2) Select an appropriate diameter Teflon heat-shrink sleeving. Cut a length long enough to overlap
0.5 inch (12.7 mm) on either side of the damaged area.
NOTE: Use the maximum overlap possible where overlap space is limited.
(3) Center the sleeving over the damaged area. Use the heat gun to shrink the sleeving. Apply heat
from 250 to 350 °F (121 to 177 °C).
(4) Examine the repaired area. Make sure the sleeving is tight and fully covers the damaged area.
The sleeving must be tight enough to not come off or move under unusual handling and usage
conditions.
TASK 28-22-04-350-916-A01
11. Repair Inlet Plate Assembly and Primer Discharge Plate
NOTE: Use this procedure to repair the finish on the inlet plate assembly (5, IPL Figure 3) and primer
discharge plate (30).
A. If not already done, insert a knife blade or an equivalent tool to break the adhesive bond and separate
the primer liner (10), primer discharge plate (30), and inlet plate assembly (5). Pull the components
from the rotor/shaft assembly (65).
B. Refer to CLEANING to clean the primer discharge plate (30) and inlet plate assembly (5). Remove all
adhesive residue and other contamination.
C. Visually check the plates at 10X magnification for scoring and scratches. If necessary, grind the plates
to within the dimensions given in Figure 6002 to remove any surface damage. If the damage is deeper
than allowed, replace the damaged plates. (See Figure 6002 "GRAPHIC-28-22-04-99B-853-A01" on
page 6012.)
D. Refer to CLEANING to clean the plates. Refer to ASSEMBLY for installation instructions.
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6002
INLET PLATE ASSEMBLY PRIMER DISCHARGE PLATE

(5, IPL FIG. 3) (30, IPL FIG. 3)
EDGE VIEW EDGE VIEW
PRIMER PRIMER
IMPELLER IMPELLER
FACE FACE
0.141 (3.581) 0.121 (3.073)

MINIMUM MINIMUM
32 32
0.001 (0.025) A 0.001 (0.025) A 0.001 (0.025) 0.001 (0.025)
28-22-04-99B-853-A01-001.cgm
-A- -A-
NOTES: 1. THE DIMENSIONS ARE GIVEN IN INCHES (MM).

2. REPAIR IS LIMITED TO THE DIMENSIONS SHOWN
AND THE ABILITY TO SHIM THE INLET IMPELLER
(35, IPL FIG. 2, 2A, AND 2B) FOR PROPER CLEARANCE.
GRAPHIC 28-22-04-99B-853-A01
Repair of Inlet Plate Assembly and Primer Discharge Plate
Figure 6002
TASK 28-22-04-350-917-A01
12. Replace Lee Plug Sets
NOTE: Use this procedure to replace the Lee plug sets (60, IPL Figure 4) in the housing subassembly.
A. Refer to Process Specification 203 to remove the Lee plug sets (60). The required tools are given in
Table 6001.
NOTE: Process Specification 203 is available from The Lee Company (CAGE 92555). The
specifications give the tools, inspection criteria, and removal/installation procedures needed
to replace the components.
B. Clean and dry the bore hole.
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C. Examine the bore hole for damage. If necessary, ream the bore to 0.010 inch (0.25 mm) over the
original size with the same depth and tolerances.
NOTE: When the bore hole is no longer serviceable, ream to 0.010 inch (0.25 mm) over the original
size (same depth and tolerances), and install the oversize replacement item given in the IPL.
D. Refer to Process Specification 203 to install new Lee plug sets (60) in the outer housing (75). The
required tools are given in Table 6001.
TASK 28-22-04-350-918-A01
13. Replace Thread Inserts
NOTE: Use this procedure to replace damaged thread inserts (65 and 70, IPL Figure 4) in the housing
subassembly. Refer to Military Specification MS33537 for more information.
A. Use the applicable hand extraction tool (Table 6001) to remove the damaged insert.
B. Clean and dry the tapped hole. Refer to CLEANING.
C. Examine the tapped hole for crossed or stripped threads. Retap the threads or replace the outer
housing (75).
D. Apply a light film of zinc chromate primer to the surface of the new insert and the tapped hole.
E. Use the applicable hand insertion tool (Table 6001) to install the insert one thread below the surface.
F. If applicable, use the tang break-off tool (Table 6001) to break off the tang at the notch.
TASK 28-22-04-350-922-A01
14. Wire Etching, Soldering, and Potting for Potted Connectors
NOTE: Use this procedure to etch, solder, and pot the wire leads for the terminal assembly (90, IPL
Figures 2, 2A, and 2B). If applicable, refer to CMM 28-22-07 to install the pottingless connector
required for the P/N 60-98976-4 configuration.
NOTE: All personnel who perform soldering of motor-impeller subassembly components must be trained
in the requirements of this procedure. To assure optimum repair results, a “Connector Soldering
and Potting” training video produced in April, 2000 is available from Hydro-Aire Product Support at
www.hydroaire.com.
A. General Requirements
WARNING: BEFORE USING ANY COMPOUNDS, SOLVENTS, OR OTHER CHEMICALS, REFER

TO THE MATERIAL SAFETY DATA SHEET (MSDS) FOR EACH MATERIAL FOR
HANDLING INSTRUCTIONS.
CAUTION: DO NOT USE MATERIALS FROM DAMAGED CONTAINERS OR CONTAINERS ON

WHICH THE SEAL IS NOT COMPLETE. KEEP ALL MATERIALS IN CLOSED
CONTAINERS UNTIL THEY ARE TO BE MIXED FOR USE.
(1) Store and control all materials as specified by manufacturer instructions. Storage-sensitive
materials, or materials that deteriorate with age, must be received, checked, labeled, released for
use, stored, tracked, updated, isolated, and discarded as specified in approved quality
procedures.
(2) Materials that are older than their original storage-life limit or that show signs of contamination
must not be used for potting of electrical connectors and must be discarded as specified in the
quality procedures.
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(3) The soldering and potting must be done in a room intended for this purpose and prepared for the
specific job. This room must be clean from contamination such as dirt, dust, oil, and grease.
Food, beverages, cosmetics, hand creams, or other personal items must not be allowed at the
same bench where the soldering is being done. Also, the environmental control system for the
room (air conditioning, air circulation, etc.) must not be a source of contamination of any items
involved in potting. No uncured silicone materials are allowed in this room.
(4) All soldering and potting equipment (including the molds, tools, etc.) must be clean and free of
any potential contamination. Greasy and oily tools and equipment must not be permitted on the
same surface or near the bench where the soldering and potting is done.
(5) All molds, details, and assemblies that have been cleaned before potting must be handled with
clean cotton gloves (Table 6002) at all times.
WARNING: COMPRESSED AIR CAN CREATE AIRBORNE PARTICLES THAT CAN ENTER
YOUR EYES OR PENETRATE THE SKIN. THE PRESSURE MUST NOT BE
MORE THAN 15 PSI (103 KPA). WEAR GOGGLES TO PROTECT YOUR EYES,
AND DO NOT DIRECT THE COMPRESSED AIR AGAINST YOUR SKIN OR IN
THE DIRECTION OF OTHER PERSONNEL.
(6) Compressed Air Requirements
(a) If compressed air is used for cleaning and drying of tools, connector assemblies,
component parts, it must as a minimum be from a system that removes free moisture, oil,
and particulate contamination larger than 40 micron in size.
(b) Certified dry compressed air or other inert gases (e.g., dry Nitrogen, dry Helium) in
canisters or bottles that were obtained as brand-name products and are regulated to 15 psi
(103 kPa) maximum can be used as an alternative to plant system compressed air.
(c) Perform a “point-of-use” test for plant system compressed air before use of the compressed
air to remove flux or the other uses specified in this section.
1 Tape a sheet of white copier paper to a flat plate, a piece of sheet metal, or other
clean, flat surface.
2 Exhaust the compressed air line. To do this, cover the nozzle with a clean cloth and
hold the nozzle valve open for 5 seconds.
3 Hold the nozzle 6 to 10 inches (15 to 25 cm) from the paper and pointed squarely at
the center of the paper. Open the nozzle and hold it open for at least 5 seconds.
4 Examine the blast of air at the nozzle for mist, dust, oil, water, or particles.
5 Immediately after the test blast, examine the test paper under normal office lighting. If
the compressed air has left any visible discoloration or oil, water, or solid particles, the
compressed air system must not be used until it has been serviced, retested, and
approved. If the air is contaminated, use a bottled supply.
(7) Mixer Requirements
(a) The potting compound mixer must be able to mix at temperatures from 60 to 90 °F
(15 to 32 °C).
(b) Refer to Table 6001 for equipment approved for use in preparing the 220A/951 potting
compound.
(8) Requirements for Injection Guns and Disposable Syringes
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(a) Pneumatic type injection guns must be used for potting. The injection guns must have: (1) a
disposable inner chamber, (2) an air valve that releases the pressure on the potting
compound, and (3) a disposable plastic nozzle.
(b) The injection guns must be able to inject compound material at temperatures from 60 to 90
°F (15 to 32 °C). Refer to Table 6001 for an injection gun approved for use.
(9) Oven Requirements
The oven used to cure the potting compound must have forced-air circulation and must be able to
control temperature within ±10 °F (±12 °C) of the set temperature. Refer to Table 6001 for an
oven approved for use.
(10) Requirements for Exclusion of Silicone Materials
(a) Uncured silicone-based materials must not be allowed in any room where any other
adhesion-sensitive process steps are, or will be, conducted. These steps include finishing,
cleaning, potting, bonding, etc.
(b) Keep the mixing equipment, containers, and sealing cartridges used for silicone materials in
a separate room from those used for non-silicone materials.
(11) Compound Storage Requirements
(a) Do not use materials from damaged containers or containers on which the seal is not
complete.
(b) Keep all materials in closed containers until they are to be mixed for use.
B. Wire Etching and Soldering
(1) Wire Etching
CAUTION: MAKE SURE THE ETCHANT SOLUTION IS AT THE STRENGTH SPECIFIED

BY THE MANUFACTURER INSTRUCTIONS. A SOLUTION THAT IS WEAK OR
TOO OLD WILL NOT PROPERLY ETCH THE WIRE SURFACE.
(a) Use the etching material (Tetra-Etch) specified in Table 6002.
(b) Do not strip the wire insulation before etching.
CAUTION: DO NOT ALLOW ETCHANT SOLUTION TO CONTACT THE WIRE STRANDS.

THIS CAN CAUSE CORROSION.
(c) Loop the wire group so the etchant will not enter the open cut ends. Refer to Figure 6003.
(See Figure 6003 "GRAPHIC-28-22-04-99B-854-A01" on page 6019.)
NOTE: If the wires are too short for the looping method, coat 0.13 to 0.25 inch (3.3 to 6.3
mm) of the open cut end with paraffin wax.
(d) Use a clean cloth moistened with acetone to fully clean all wire surfaces to be potted plus at
least 2 inches (51 mm) above these surfaces.
(e) Remove the bottle of etchant solution (Table 6002) from refrigerated storage. Allow the
bottle to warm to room temperature.
(f) Shake the bottle of etchant solution vigorously for at least 15 seconds, then remove the cap.
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(g) Refer to Figure 6003. Put the looped or wax-protected wires fully in the solution. In the case
of looped wires, keep the open ends a minimum of 0.75 inch (19.1 mm) above the etchant.
The lead wires should also be etched a minimum of 0.75 inch (19.1 mm) above the area to
be potted in order to provide visual evidence after potting that the wire insulation was
correctly etched. Do not let the insulation of different wires make contact with each other
during etching.
(h) Keep the wire leads in the solution for 15 to 30 seconds. When the insulation is properly
etched, it will have a dull, frosted appearance in its original color.
(i) Put the etched region in clean isopropyl alcohol for a minimum of 30 seconds.
(j) Wipe the etched region clean with a clean cloth moistened with isopropyl alcohol to make
sure all white crust or film is removed.
(k) If additional etching is necessary, make sure the wire leads are fully dry and clean before
the wire leads are put back in the etchant.
(l) When the wires leads are properly etched, replace the cap on the bottle tightly and return
the bottle to refrigerated storage.
NOTE: To maximize the solution shelf life, put dry nitrogen into the bottle or refill the bottle
with etchant.
(m) Cut off the unetched or waxed end of each lead wire.
(2) Stripping
(a) Strip approximately 0.25 inch (6.35 mm) of insulation from the ends of the wires to allow
attachment to the terminal or solder cup with clearance between the terminal and insulation
(see paragraph (c), below). The stripped wire must not have more than two nicked strands.
Broken strands are not acceptable.
(b) Make sure the stripping tools or machines are the correct size for the wire leads and are
correctly adjusted and calibrated.
(c) Check the insulation clearance, as follows:
1 Minimum Clearance. The insulation must not touch the solder joint. The contour of the
conductor must not be hidden at the termination end of the insulation.
2 Maximum Clearance. The clearance must be less than two wire diameters (including
insulation) or 0.06 inch (1.52 mm), whichever is larger. The clearance must not allow
shorting between adjacent conductors.
(d) On the fuel side of potted electrical connectors, make sure the wire insulation is covered by
the potting material a minimum of 0.10 inch (2.5 mm). Check the depth with the potting boot
before soldering.
(3) Soldering
(a) Cleaning Before Soldering
1 Use Aero-MEK, acetone, or isopropyl alcohol (Table 6002) to remove grease and oil
from conductors and terminals.
2 Remove oxides and varnishes. Use methods that do not damage the wire leads or
parts, cause contamination, or prevent solder wetting. Do not use sand blasting.
Remove all dust or other loose material.
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(b) Tinning Wire Conductors
1 Heat sink the wire with anti-wicking tweezers.
2 Put approximately one-quarter of the stripped length in Type 185 liquid flux (Table
6002), then put the wire momentarily into a soldering pot with molten solder. If a
soldering pot is not available, conductor wires can be tinned with a hand soldering iron
and Sb95Sb05WRMA solder.
(c) Temperature of Iron Tip
CAUTION: AN IRON TEMPERATURE LESS THAN 700 °F (371 °C) WITH HIGH-
TEMPERATURE SOLDER WILL RESULT IN UNSATISFACTORY SOLDER
JOINTS.
1 For high-temperature solder Sb95Sb05WRMA, set the soldering station temperature

controller for an iron tip temperature of 700 to 825 °F (371 to 441 °C).
(d) Prefilling Solder Cups
CAUTION: TO PREVENT DAMAGE TO THE GLASS INSULATOR IN THE

ELECTRICAL CONNECTOR, DO NOT MAKE CONTACT WITH THE
INSULATOR AND DO NOT HOLD THE IRON TO THE CUP LONGER
THAN NECESSARY TO FLOW THE SOLDER.
1 Prefill solder cups with Sb95Sb05WRMA solder. To do this, place the iron tip as close
as possible to the bottom of the solder cup and feed solder into the cup. The level of
the solder must be applicable to the size of the wire to be inserted into the individual
solder cup. The solder must be fed slowly to prevent the formation of voids (i.e., empty
spaces).
NOTE: Use liquid flux Type 185 (Table 6002) as necessary. Some cups are
pretinned and do not need prefilling.
2 Cups that are not pretinned (i.e., when gold plating is evident) must be filled, wicked
out, and refilled to prevent the solder junction from becoming brittle (i.e., easy to crack
or break).
(4) Insertion of Wires into Solder Cups
CAUTION: TO PREVENT TOO MUCH WICKING ACTION UNDER THE WIRE INSULATION
AND TO PREVENT DAMAGE TO THE GLASS INSULATOR IN THE
ELECTRICAL CONNECTOR, DO NOT HOLD THE IRON TO THE CUP LONGER
THAN NECESSARY TO FLOW THE SOLDER.
(a) Hold the soldering iron as close as possible to the bottom side of the solder cup. As the
solder in the prefilled cup melts, feed the tinned wire down to the bottom of the cup. Do not
hold soldering iron to the cup longer than necessary to flow the solder.
(b) Avoid wicking action and do not move the wire until the solder has become cool and solid.
Make sure the contour of the wire can be seen, as long as the wire and solder cup are the
same size. The solder must form a fillet between the wire and solder cup.
NOTE: Wicking is acceptable in the insulation gap as long as it does not hide the contour
of the conductor at the solder cup end of the insulation. Wicking should not cause
deformation or damage to the insulation. Wicking under the insulation of the
stranded wire is allowed, as long as that portion of the wire is completely covered
by the potting compound.
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(5) Flux Removal
NOTE: Because the flux can become insoluble to the flux remover solvent after 30 minutes, all
excess flux must be removed immediately after soldering.
(a) Fill the electrical connector with fresh 5240 flux remover (Table 6002). Use a non-
contaminating brush to clean the solder joint and surfaces to be potted, including wire
insulation.
(b) Brush the surfaces at least four separate times with clean flux remover from a squirt bottle
or a tube inserted into a reservoir of flux removal solvent. Rinse surfaces with flux remover
after each brushing. Approximately 20 ml of flux remover should be used for each brush/
rinse.
(c) Hold the electrical connector to allow free drainage, and rinse the connector with deionized
water (after the final rinse with flux remover). Rinse away all flux remover and then do a
complete final rinse.
(d) Wipe off the deionized water with clean, lint-free wipes.
(e) After removing the deionized water, dry the component with compressed air. Refer to the
requirements given earlier in this section.
(6) Quality Check
(a) Visual Appearance
1 The solder junctions must be smooth and show the outlines of the parts in the
connection. Solder joints of high-temperature Sb05A alloy solder typically have a gray
appearance and are acceptable.
2 There must be no excess solder or solder globules, peaks, strings, or bridging

between adjacent conductive paths.
(b) Causes for Rejection
NOTE: Refer to the definitions given earlier in this section for an explanation of some of
the items given below. Visually examine the solder junctions at 2X to 4X
magnification. As a cross-check, 10X magnification can be used.
1 Overheated joint.
2 Excessive solder.
3 Not enough solder.
4 Disturbed solder joint.
5 Cold solder joint.
6 Rosin joint.
7 Excessive wicking.
8 Splattered (i.e., spread out) solder or flux.
9 Solder peaks.
10 Excessive pitting or too many holes.
11 Burned, charred, or cracked connector insert.
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12 Bent or cracked connector pins/terminals.
13 Contour of wire not visible.
14 Insufficient lead wrap on terminal.
15 Two or more nicked strands.
16 Burned wire insulation.

6003
OPEN
END
0.075 (1.9)
ETCHANT
28-22-05-99B-854-A01-001.cgm
LOOPED
WIRE

GRAPHIC 28-22-04-99B-854-A01
Looped Wire in Etchant Solution
Figure 6003
C. Wire Junction Potting
(1) Precleaning Process
NOTE: This connector and solder junctions must be precleaned if the wire leads were soldered
to the connector more than 12 hours before the potting is to be done. If less than 12
hours has passed and the connector is clean, go to the final cleaning procedure given
below.
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(a) Use Aero-MEK, acetone, or isopropyl alcohol (Table 6002) to remove grease and oil from
conductors and terminals. Do not permit contamination to spread to a larger area than
originally contaminated, and do not damage items being cleaned.
(b) Wet the surface with small, fresh portions of solvent, then wipe the surface clean with clean,
lint-free wipes. Use a non-contaminating brush if brushing is required to get the surface
clean.
(c) If necessary, the surface can be washed with larger portions of fresh solvent poured onto
the surface. Soak up the contaminated solvent with fresh, clean wipes.
(d) Rinse and wipe or brush the surface several times with clean solvent and clean wipes.
(e) Wipe up any excess solvent with clean, lint-free wipes. Dry the cleaned surfaces with
compressed air.
(2) Final Cleaning Process
(a) Potting Molds
Use a blast of compressed air to blow dust or other light contamination off the potting
molds. Use hand cleaning to remove other contamination.
(b) Connector Potting Surfaces
1 While cleaning the connector and solder junctions, do not damage or contaminate any
etched wire coverings. The connector can be held by the wires while it is cleaned.
Hold the connector over a catch basin or tub and fill the connector with a stream of
clean isopropyl alcohol.
2 Use a non-contaminating brush to clean the inner surfaces of the connector that will
contact the potting compound. This includes the case, pins, wires, and insulation.
Then pour out the used solvent into the catch basin or tub.
3 Hold the connector to allow the solvent to drain, and flush the cavity with isopropyl
alcohol. Completely rinse the case. Do not allow solvent to contact your gloved hand
and then flow back onto the connector.
4 Do steps 1, 2, and 3 again with Aero-MEK solvent.
5 Do another complete rinse with clean Aero-MEK solvent. This time, allow the solvent
to quickly run out of the connector case.
6 Put the cleaned connector in a position that will let it dry without contamination.
Compressed air can be used to help drying, but only if the compressed air
requirements given earlier in this section are met.
7 After drying, visually examine the potting surfaces to make sure that they are fully
clean. The potting surfaces must not be allowed to contact other components,
surfaces, or your skin. If contact or contamination does occur, clean the connector
again from step 5, above. The connector must also be cleaned again if any part of the
connector case contacts an oily or greasy surface.
8 Freshly cleaned and dried connectors must be potted within two hours after final
cleaning. Between final cleaning and potting, cover and handle the connectors to
prevent contamination.
9 The used cleaning solvent collected from final cleaning can be used for the potting
precleaning.
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(3) Potting Procedure: Mixing Resin and Hardener By Weight (Preferred Method)
(a) General
1 The potting must be done within 2 hours of completing the final cleaning process.
2 Handle the connector and other components with clean cotton gloves (Table 6002).
Change to a fresh pair of gloves after handling any item that may be contaminated.
3 Do not use a release agent.
(b) Mixing By Weight
1 The 220A resin can be preheated in its container with the lid removed. Preheat the
resin for 1 hour minimum in an oven at 100 to 110 °F (38 to 43 °C).
2 While it is still warm and in its original container, stir the resin for 5 minutes minimum.
Use long, smooth strokes to prevent air bubbles.
3 Weigh 100 parts 220A resin to 7 parts 951 curing agent by weight as specified in the
manufacturer recommendations. Use a balance or other device that is sensitive to
within 0.1 percent of the amount being weighed and accurate to within 1 percent of the
desired weight readings.
NOTE: Always use a clean plastic cup or other container and make sure the
workbench, balance, and other equipment are also clean. Mixed Epocast
220A/951 must be used within 30 minutes.
4 In a plastic cup, mix the resin and curing agent in the proper ratio at 100 °F (38 °C)
maximum. Use long, smooth strokes to prevent air bubbles. Usually 7 to 8 minutes of
mixing is required. The finished mix must be completely blended.
5 Do not mix anything else with compound components or their mixes.
6 Put the mixed resin and its container in a vacuum of 26 to 29 in-Hg (660 to 737
mm-Hg) minimum for 5 minutes minimum at 60 to 90 °F (15 to 32 °C). To prevent too
much foam, multiple vacuum cycles can be used to slowly build up to the required
vacuum level. To help burst the bubbles trapped in the potting compound, during each
cycle rapidly release the vacuum to return to atmospheric pressure.
NOTE: Potting of the connector must start within 5 minutes of this step.
7 Load the mixture into a syringe (Table 6002). De-aeration before loading the syringe is
optional.
8 Before starting the potting, make sure that the potting will encapsulate (fully cover) the
ends of the wire insulation by at least 0.10 inch (2.5 mm). Check the depth with the
potting mold (Table 6002) installed.
9 Discard the first 5 to 10 cc of potting compound into a waste container. This will
remove the initial fill, which can contain trapped air bubbles.
10 The connector and other components being potted can be heated to 100 °F (38 °C) to
make potting easier.
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CAUTION: BE CAREFUL WHEN YOU REMOVE AND REINJECT TIPS TO MINIMIZE

AIR ENTRAPMENT.
11 Use an injection gun (Table 6001) to inject the potting compound. Inject slowly, and
start at the lowest or deepest point of the volume to be potted. Keep the tip of the gun
slightly below the surface of the potting compound to not trap air. When syringes are
used for insertion, use only the disposable types given in Table 6002.
12 First, pot the connector body. Hold the connector to make potting easier and to
prevent the formation of air bubbles.
13 Next, place the disposable potting mold (Table 6002) over the connector body.
Continue to inject potting compound to the top of the potting mold.
14 Cure the potting compound for 24 hours minimum at room temperature.
15 Cut and remove the potting mold. The disposable mold can be discarded.
16 Refer to ASSEMBLY to complete the connector and end cap installation.
(4) Potting Procedure: Mixing Resin and Hardener With a Mixer (Alternate Method)
(a) General
1 The potting must be done within 2 hours of completing the final cleaning process.
2 Handle the connector and other components with clean cotton gloves (Table 6002).
Change to a fresh pair of gloves after handling any item that may be contaminated.
3 Do not use a release agent.
(b) Mixing By Weight
1 The 220A resin can be preheated in its container with the lid removed. Preheat the
resin for 1 hour minimum in an oven at 100 to 110 °F (38 to 43 °C).
2 While it is still warm and in its original container, stir the resin for 5 minutes minimum.
Use long, smooth strokes to prevent air bubbles.
3 Put the resin into the larger chamber of a new, clean cartridge. Put the 951 curing
agent into the smaller chamber.
4 Put the cartridge in a vacuum of 26 to 29 in-Hg (660 to 737 mm-Hg) minimum for
5 minutes minimum at 60 to 90 °F (15 to 32 °C). To prevent too much foam, multiple
vacuum cycles can be used to slowly build up to the required vacuum level. To help
burst the bubbles trapped in the potting compound, during each cycle rapidly release
the vacuum to return to atmospheric pressure.
NOTE: Potting of the connector must start within 5 minutes of this step.
5 Install the cartridge in the mixer, and install a new mixing nozzle as specified in the
manufacturer instructions. Do not reuse the cartridge or mixing nozzle. Discard used
cartridges and mixing nozzles.
6 Before starting the potting, make sure that the potting will encapsulate (fully cover) the
ends of the wire insulation by at least 0.10 inch (2.5 mm). Check the depth with the
potting mold (Table 6002) installed.
NOTE: Mixed Epocast 220A/951 must be used within 30 minutes.
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60-989
7 Discard the first 10 to 20 cc of potting compound into a waste container. This will
remove the initial fill, which can contain trapped air bubbles.
8 The connector and other components being potted can be heated to 100 °F (38 °C) to
make potting easier.
CAUTION: BE CAREFUL WHEN YOU REMOVE AND REINJECT TIPS TO MINIMIZE

AIR ENTRAPMENT.
9 Use an injection gun (Table 6001) to inject the potting compound. Inject slowly, and
start at the lowest or deepest point of the volume to be potted. Keep the tip of the gun
slightly below the surface of the potting compound to not trap air. When syringes are
used for insertion, use only the disposable types given in Table 6002.
10 First, pot the connector body. Hold the connector to make potting easier and to
prevent the formation of air bubbles.
11 Next, place the disposable potting mold (Table 6002) over the connector body.
Continue to inject potting compound to the top of the potting mold.
12 Cure the potting compound for 24 hours minimum at room temperature.
13 Cut and remove the potting mold. The disposable mold can be discarded.
14 Refer to ASSEMBLY to complete the connector and end cap installation.
(5) Quality Check
The potting must be securely bonded to the connector case. There must be no air bubbles or
cracks.
TASK 28-22-04-350-924-A01
15. Shrink Sleeving Installation
NOTE: Use this procedure to install shrink sleeving used on the motor-impeller subassembly. All
personnel who install shrink sleeving must be trained in the requirements of this procedure.
NOTE: This procedure documents the proper techniques in the use of hot air heat shrink equipment to
install Polyvinyl Chloride (PVC), Fluoropolymer, and Polyolefin heat shrink tubing. In addition, this
procedure explains the accept and reject criteria for an acceptable heat shrink tubing application.
NOTE: This is a general procedure applicable to all required shrink sleeving installation. Specific
instructions are given in ASSEMBLY for installation of shrink sleeving on the pottingless
connector. When this procedure is used to covered damaged insulation on the stator assembly
wire leads, do the repair with the wire leads disconnected from the connector.
28-22-04 Page 6023

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60-989
A. General Requirements and Standard Installation
(1) Store and control all materials as specified by manufacturer instructions. Storage-sensitive
materials, or materials that deteriorate with age, must be received, checked, labeled, released for
use, stored, tracked, updated, isolated, and discarded as specified in approved quality
procedures.
(2) Materials that are older than their original storage-life limit or that show signs of contamination
must not be used and must be discarded as specified in the quality procedures.
(3) Before installation of heat shrink sleeving over soldered joints or components, all surfaces that
will contact the sleeving must be visually free of loose debris, oil, solder flux, flux residue, grease,
and other contamination. If there is contamination on the soldered joints, refer to the soldering
procedures given above to clean the solder junctions. During cleaning, do not wet the interfacial
seal on the pin side of the connector.
(4) Before installation of heat shrink tubing to a connection or a soldered terminal, cut the shrink
sleeving to the length specified. The ends of the heat shrink sleeving must be cut square.
(5) The lead wires from the stator assembly are part of the assembly and are therefore already
connected to the stator coil. For this reason, the heat shrink tubing must be installed over the wire
leads before the solder connection is made. The soldered joints must be inspected by a certified
soldering technician before the heat shrink sleeving is installed.
(6) The use of a heat deflector adapter on the heat gun is recommended. This will more evenly
distribute the stream of hot air, which will provide a smoother application of heat shrink sleeving.
(7) The operator must select the appropriate nozzle size or nozzle adapter for the heat gun. Hot air is
more effectively directed to the component with the proper nozzle.
WARNING: WEAR GLOVES AND OTHER PROTECTIVE GEAR AS NEEDED TO PROTECT

YOUR SKIN FROM THE HOT AIR.
(8) Use adequate lighting. Magnification can also be used if needed. Install the heat shrink sleeving
over the area to be covered completely before application of hot air. Start the flow of hot air. Turn
the item to be covered by hand into the stream of hot air. Use locking tweezers (or equivalent) to
manipulate the sleeving in position during the initial application of heat. The use of heat resistant
gloves is recommended.
NOTE: The hot air from the heat gun will not be instantly hot, and can require 30 to 60 seconds
to get to the set heat level. The most efficient working distance is 0.25 to 0.75 inch (6.4
to 19 mm) from the tip of the nozzle.
(9) When multiple layers of heat shrink sleeving are required, each layer can be held in place by
locking tweezers. This allows the covered area to be rotated by hand into the hot air stream.
(10) Start the shrink at one end of the sleeving to get the initial “grip” of the sleeving on area to be
covered. This helps to assure even shrinkage.
(11) Continue to apply heat evenly around the sleeving from the initial start to the opposite end of the
sleeve to complete the heat shrink process.
B. Hermetic Electrical Connectors With Ceramic Mounts and Two Layers Of Sleeving
NOTE: General Requirements and Standard Installation, steps (1) through (5) (soldered joints
certification) are mandatory requirements. The other paragraphs must be applied when they
are applicable to the application.
NOTE: Refer to Figure 6004. (See Figure 6004 "GRAPHIC-28-22-04-99B-856-A01" on page 6026.)
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60-989
CAUTION: CONTINUOUSLY MOVE THE HEAT SHRINK SLEEVING WITHIN THE HOT AIR
STREAM FROM THE HEAT GUN. IF THIS IS NOT DONE, THE SHRINK SLEEVING
AND SOLDER JUNCTION CAN BE OVERHEATED.
(1) The use of a heat deflector adapter with a nozzle diameter of 0.38 inch (9.7 mm) or smaller for
the heat gun is recommended to shrink the sleeving on insulated wires. This gives a more even
distribution of the hot air stream, which provides a smoother application of heat shrink sleeving.
(2) In the case of electrical connectors with terminals embedded into ceramic mounts, two layers of
heat shrink tubing are required. The inner layer will be slightly smaller in outside diameter than
that of the inside diameter of the outer layer. Sleeve type, size, and length is specified in
ASSEMBLY.
(3) Before the application of hot air to the inner layer of heat shrink sleeving, the sleeving must be
held down over the soldered joint and then butted up against the top of the ceramic mount.
Detailed instructions and procedures are given in ASSEMBLY.
(4) Make sure the end edge of the inner sleeving does not get shrunk onto outer diameter of the
ceramic mount. This can interfere with the fit of the outer layer of shrink tubing.
(5) Start the flow of hot air at the connector end of the inner layer. Make sure it has started an even
“grip” of the terminal before shrinking the remaining length of sleeving.
(6) Shrink fit the remaining pieces of inner sleeving over the other connector terminals and against
the ceramic mounts as described above. Inspect the workmanship on the inner shrink sleevings
per the instructions given below before the outer layer of shrink sleeving is moved into position.
(7) Fit the outer layer of shrink sleeving over the inner layer sleeving on the terminal and over the
outer diameter of the ceramic mount. Hold the sleeve down onto the surface of the connector
(against the hermetic glass seal surface).
(8) Start the flow of hot air with a heat gun to the connector end of the outer layer heat shrink
sleeving over the ceramic mount. Make sure it has started an even “grip” of the mount before
shrinking the remaining length of sleeving.
(9) Shrink fit the remaining pieces of outer sleeving over the other connector terminals and against
the ceramic glass seal surface as described above. Inspect the workmanship per the instructions
given below.
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60-989
6004
CERAMIC
MOUNT
HERMETIC
CONNECTOR
WITH CERAMIC
MOUNTS
WIRE LEAD
28-22-05-99B-856-A01-001.cgm
PIN
HEAT SHRINK
CONTACT
SLEEVING
SOLDER GLASS
JOINT SEAL
GRAPHIC 28-22-04-99B-856-A01
Sleeving on Hermetic Connectors with Ceramic Mounts
Figure 6004
C. Workmanship and Inspection
(1) Standard Installations
(a) Inspect the shrink sleeving under adequate lighting. Rejection criteria are given below. Any
nonconformance is cause for rejection and rework.
NOTE: Rework instructions are given in paragraph D, below.
(b) There must be no visual evidence of permanent discoloration, burns, charring, and
blistering of the shrink sleeve material. Such damage is usually due to overheating or
contamination.
(c) Both ends of the sleeving must be molded snugly to the covered surface. The remaining
length of shrunk sleeving must also conform snugly but light local gathering or wrinkling with
total combined axial length not to exceed 0.2 inch/inch (0.5 cm/cm) is acceptable. This
problem can generally be corrected with the further application of hot air.
NOTE: For example, if a component is covered by a 1.5 inch (38.1 mm) length of sleeving,
only a maximum total of 0.3 inch (7.6 mm) length axially is allowed to show slight
gathering or wrinkling. The rest of the sleeving must conform snugly to the covered
surface.
(d) Through-breaks in the sleeving are not allowed.
(2) Hermetic Electrical Connectors With Ceramic Mounts and Two Layers of Sleeving
(a) Before the application and installation of the heat shrink sleeving to the solder joints, the
solder joints must be visually inspected by a certified soldering operator or an inspector.
There must be no visual evidence of flux residue or other contamination.
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60-989
(b) Before installation of the second layer of heat shrink sleeving, the first layer of heat shrink
sleeving must be visually inspected. Use adequate lighting. Rejection criteria are given
below. Any nonconformance is cause for rejection and rework.
NOTE: Rework instructions are given in paragraph D, below.
(c) The rejection criteria for the inner layer of sleeving are as follows:
1 The ceramic mount must not be covered at any point by the first layer of sleeving.
2 There must be no contamination, burns, blistering, discoloration, or charring of the

sleeving.
3 The inner layer of sleeving must be shrunk completely before the outer layer is
installed.
(d) The rejection criteria for the outer layer of sleeving are as follows:
1 The ceramic mount must not be exposed for more than 0.06 inch (1.52 mm) between
the connector hermetic glass seal and sleeving.
2 There must be no contamination, burns, blistering, discoloration, or charring of the

sleeving.
3 The outer layer of sleeving must be shrunk snugly over the ceramic mount and a
minimum 1 inch (25 mm) uninterrupted length on the inner layer of sleeving. It is
preferred to have the outer layer shrunk snugly over the entire length of the inner layer
and wire insulation, however the outer layer can be loose over the wire insulation if
specified in ASSEMBLY. An impression of the contour of the end of the inner layer
sleeving shown by the shrunk outer layer indicates a snug fit between the inner and
outer layers of sleeving. See also the maximum length of slight gathering given below.
(e) The rejection criteria for both layers of sleeving are as follows:
1 Through-breaks in the sleeving are not allowed.
2 There must be no axial nicks or cuts that are not through-breaks. Such cuts can cause
the sleeving to split at high temperatures.
3 There must be no visual evidence of permanent discoloration, burns, charring, and

blistering of the shrink sleeve material. Such damage is usually due to overheating or
contamination.
4 Any gathering or wrinkling of the outer layer with total combined axial length not to
exceed 0.2 inch/inch (0.5 cm/cm) is acceptable. This problem can generally be
corrected with the further application of hot air.
NOTE: For example, if a component is covered by a 1.5 inch (38.1 mm) length of
sleeving, only a maximum total of 0.3 inch (7.6 mm) length axially is allowed
to show slight gathering or wrinkling. The rest of the sleeving must conform
snugly to the covered surface.
28-22-04 Page 6027

Jan 09/2004
60-989
D. Rework Instructions
NOTE: Use these procedures as needed to rework heat shrink sleeving that fail inspection and must
be replaced.
(1) Standard Installations
(a) Remove any components or items that are in direct contact with, or are in the way of, the
sleeving to be replaced.
(b) Mount the connector flange in a tabletop vise. Grasp the wire lead to be reworked in one
hand and pull gently to straighten out the wire. Shield the wire leads not being reworked
with cardboard or equivalent material to prevent damage.
CAUTION: DO NOT NICK, SCRATCH, OR CRACK THE SURFACE OF THE CONNECTOR

CERAMIC MOUNTS. DAMAGED CONNECTORS MUST BE REPLACED.
(c) Use a pointed or sharp edge tool (for example, a probe or X-Acto knife) to lightly score the
outer surface of the sleeving. Do not cut through the sleeving. To ensure no damage on the
connector ceramic mount, do not score the sleeving that covers the outside of the connector
ceramic mount. Start scoring the sleeving on the solder joint closest to the top of the
connector ceramic mount and continue over the wire lead. Stop scoring approximately 0.06
inch (1.52 mm) short of the end of the sleeving (stator end) to the wire insulation.
(d) Use a heat gun with 0.38 inch (9.65 mm) nozzle diameter or smaller to apply heat. This
should cause the sleeving material to tear open at the scoring and separate. As the sleeving
separates from the wire lead, use needle-nose pliers to gently pull the sleeving off the
connector ceramic mount.
(e) Use the needle-nose pliers to completely cut and tear the sleeving away from the wire lead.
Repeat the scoring and heat application if necessary. Do not cut or tear the wire insulation.
(f) Use a soldering iron to melt the solder junction. Continue to apply heat and draw off the
molten solder with a solder-puller or solder wick (braided copper wire). Apply heat with the
soldering iron, as needed, and gently work free and remove the wire by hand.
(g) Use adequate lighting to visually inspect the reworked areas of the wire leads and
connector terminals. The acceptance criteria are given below.
1 Wire lead. The rework must not nick, cut, crack, or burn or melt the wire insulation.
The stripped wire must not have more than two nicked strands. Broken strands are not
acceptable.
NOTE: The damaged part of the wire lead can be cut off, or the stator assembly
must be replaced. The wire lead can only be cut if there is adequate wire
length remaining to for proper stator and end cap installation. No wire splices
are allowed.
2 Connector: There must be no visible cracks, nicks, or scratches on the surface of the
ceramic mounts.
3 Discoloration. Discoloration of the rework areas of ceramic mounts and connector

terminals is acceptable. The discoloration can be flux residue or shrink sleeving
material adhered to the ceramic mount, wire lead, or terminal after the sleeving is
removed. If discoloration is present, clean the surface with a non-contaminating brush
and acetone or isopropyl alcohol, then flush to remove any loose particles. Visually
inspect to ensure there is no other damage concealed by the discoloration.
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Jan 09/2004
60-989
(h) Reinstall new heat shrink sleeving over the wire lead. Refer to the soldering instructions
given earlier in this section to solder the wire lead to the connector terminals.
(2) Hermetic Electrical Connectors With Ceramic Mounts and Two Layers of Sleeving
(a) Remove any components or items that are in direct contact with, or are in the way of, the
sleeving to be replaced.
(b) Mount the connector flange in a tabletop vise. Grasp the wire lead to be reworked in one
hand and pull gently to straighten out the wire. Shield the wire leads not being reworked
with cardboard or equivalent material to prevent damage.
CAUTION: DO NOT NICK, SCRATCH, OR CRACK THE SURFACE OF THE CONNECTOR

CERAMIC MOUNTS. DAMAGED CONNECTORS MUST BE REPLACED.
(c) Use a pointed or sharp edge tool (for example, a probe or X-Acto knife) to lightly score the
outer surface of the sleeving. Do not cut through the sleeving. To ensure no damage on the
connector ceramic mount, do not score the sleeving that covers the outside of the connector
ceramic mount. Start scoring the sleeving on the solder joint closest to the top of the
connector ceramic mount and continue over the wire lead. Stop scoring approximately 0.06
inch (1.52 mm) short of the end of the sleeving (stator end) to the wire insulation.
(d) Use a heat gun with 0.38 inch (9.65 mm) nozzle diameter or smaller to apply heat. This
should cause the sleeving material to tear open at the scoring and separate. As the sleeving
separates from the wire lead, use needle-nose pliers to gently pull the sleeving off the
connector ceramic mount.
(e) Use the needle-nose pliers to completely cut and tear the sleeving away from the wire lead.
Repeat the scoring and heat application if necessary. Do not cut or tear the wire insulation.
(f) Use a soldering iron to melt the solder junction. Continue to apply heat and draw off the
molten solder with a solder-puller or solder wick (braided copper wire). Apply heat with the
soldering iron, as needed, and gently work free and remove the wire by hand.
(g) Use adequate lighting to visually inspect the reworked areas of the wire leads and
connector terminals. The acceptance criteria are given below.
1 Wire lead. The rework must not nick, cut, crack, or burn or melt the wire insulation.
The stripped wire must not have more than two nicked strands. Broken strands are not
acceptable.
NOTE: The damaged part of the wire lead can be cut off, or the stator assembly
must be replaced. The wire lead can only be cut if there is adequate wire
length remaining to for proper stator and end cap installation. No wire splices
are allowed.
2 Connector: There must be no visible cracks, nicks, or scratches on the surface of the
ceramic mounts.
3 Discoloration. Discoloration of the rework areas of ceramic mounts and connector

terminals is acceptable. The discoloration can be flux residue or shrink sleeving
material adhered to the ceramic mount, wire lead, or terminal after the sleeving is
removed. If discoloration is present, clean the surface with a non-contaminating brush
and acetone or isopropyl alcohol, then flush to remove any loose particles. Visually
inspect to ensure there is no other damage concealed by the discoloration.
(h) Reinstall new heat shrink sleeving over the wire lead. Refer to the soldering instructions
given earlier in this section to solder the wire lead to the connector terminals.
28-22-04 Page 6029

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60-989
28-22-04 Page 6030

Jan 09/2004
60-989
ASSEMBLY
TASK 28-22-04-99C-915-A01
1. General
CAUTION: UNLESS SPECIFIED IN REPAIR, DO NOT ATTEMPT TO REPAIR, REBUILD, OR

REMANUFACTURE ANY COMPONENTS OF THE MOTOR-IMPELLER SUBASSEMBLY
OR HOUSING SUBASSEMBLY. THIS INCLUDES REWINDING OF THE STATOR OR
REPAIRS TO THE ROTOR, HOUSING, AND IMPELLERS. UNLESS OTHERWISE
SPECIFIED, REPAIRS ARE NOT AUTHORIZED.

MAINTENANCE. THE CAP AND PLUGS MUST BE INSTALLED AT ALL OTHER TIMES
TO PREVENT COMPONENT DAMAGE.
A. This section contains assembly instructions for the Motor-Impeller Subassembly and Housing
Subassembly.
B. Do all work in a clean, ventilated room with good lighting. Use the referenced special tools, equipment
and materials to prevent damage to components.
C. The assembly instructions are keyed, by item number, to the exploded-view illustrations in the
ILLUSTRATED PARTS LIST. Install only the components specified in the IPL. Do not substitute
components without written approval from Crane Aerospace, Hydro-Aire, Inc.
D. Assembly torque limits are included as they apply in the assembly procedure. They are also shown in
FITS AND CLEARANCES. When specified, the torque given is in addition to rundown torque.
E. Refer to CLEANING to clean all components before assembly. Do not handle the cleaned components
with your bare hands.
F. Refer to CHECK to examine all components for damage and wear. Repair or replace damaged
components as specified.
G. Before assembly, examine all parts for clean surfaces, corrosion, distortion, or damage. Threads must
be free of damage or cross threading. Repair or replace damaged components.
H. Replace all packings exposed at disassembly.
I. If removed, replace the self-locking screw (40, IPL Figures 2, 2A, and 2B) and tolerance ring (25, IPL
Figure 3).
NOTE: The self-locking screw (40, IPL Figures 2, 2A, and 2B) must be discarded each time it is
removed.
J. If replacement of the cable assembly (65) is required, the motor-impeller subassembly should be
upgraded to P/N 60-98976-4. Refer to CMM 28-22-07 and Service Bulletins 60-98902-28-1, 60-
98904-28-1, 60-98906-28-1, and 60-98976-28-1.
K. Storage materials and instructions are given in STORAGE.
28-22-04 Page 7001

Jan 09/2004
60-989
TASK 28-22-04-94B-916-A01
2. Assembly Tools and Equipment
04-99A-918-A01" on page 7002.)

7001
TABLE 28-22-04-99A-918-A01
Assembly Tools and Equipment—Table 7001
NUMBER
Arbor (or Hand) Press No Specific Commercially Available
Assembly Fixture, Rotor T-31137 Hydro-Aire, Inc. (V81982)
Assembly Fixture, Rotor T-31834 Hydro-Aire, Inc. (V81982)
Assembly Tool, Housing Stud T-65977 Hydro-Aire, Inc. (V81982)
Installation Sleeve T-62957 Hydro-Aire, Inc. (V81982)
Oven Model AF500; 250 °F (121 °C) The Grieve Corp. (V90423)
Pliers, Snap Ring No Specific Tru-Arc
Press Fixture T-20959 Hydro-Aire, Inc. (V81982)
Torque Wrench 3 to 50 in-lb (0.3 to 5.7 Nm) Commercially Available
Assembly Tools and Equipment —Table 7001
National Aerospace Specification NASM33540.
TASK 28-22-04-94A-916-A01
3. Assembly Materials
A. The recommended materials are given in Table 7002. Unless otherwise specified, equivalent items can
be used. (Refer to Table 7002 "TABLE-28-22-04-99A-920-A01" on page 7002.)
7002
TABLE 28-22-04-99A-920-A01 Assembly Materials—Table 7002
NUMBER
Adhesive, General Purpose C-111 (V81982 SCD S30-001) Stabond Corp. (V25670)
Adhesive, Fluorosilicone Rubber, RTV 730 (V81982 SCD S30-028) Dow Corning Corp. (V71984)
White (60-98908 ONLY)
Assembly Materials (Sheet 1 of 2)—Table 7002
28-22-04 Page 7002

Jan 09/2004
60-989
NUMBER
Aero-MEK RHO-SOLV 7228 (ASTM D740, RHO-Chem Corp. (V21414)
Type 1)
Bonding Grease Pentrox A (V81982 SCD S33-001) FCI USA Inc. (V09922)
Grease Aeroshell 16 Shell Oil Co. (V54527)
Lockwire, 20 Gage Military Specification MS20995C20 Commercially Available
(NASM20995)
(NASM20995)
Petrolatum Jelly Federal Specification VV-P-236 Plough Laboratories Inc.
(V81982 SCD S31-011) (V26045)
Primer, Yellow No. T7471 (V81982 SCD S30-052) Loctite Corp. (V05972)
Prime Coat, Clear (60-98908 RTV 1205 (V81982 SCD S30-026) Dow Corning Corp. (V71984)
ONLY)
Prime Coat, Red or Clear RTV 1200 (V81982 SCD S30-012 Dow Corning Corp. (V71984)
(60-98908 ONLY) and S33-007)
Retaining Compound, Stud Military Specification MIL-S-22473, Commercially Available
Grade C
Retaining Compound, High No. 635 (V81982 SCD S30-069) Loctite Corp. (V05972)
Strength
Seal, Alucast 911H Stoffel Seals Corp. (V01019)
Sealant, High Strength, Coarse No. 08731 (V81982 SCD S30-063) Loctite Corp. (V05972)
Thread, Grade AV
Shim Stock 0.0015 to 0.0025 inch (0.0381 to Commercially Available
0.0635 mm)
Tubing, Teflon: AMS3653: Commercially Available
P/N 60-98908 0.166 ID X 0.020 Wall
P/N 60-989100 0.208 ID X 0.020 Wall
Assembly Materials (Sheet 2 of 2)—Table 7002
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Jan 09/2004
60-989
7001
PART NUMBERS
60-98902, 60-98904, 60-98906
AND 60-98976
DETAIL DETAIL
A B
(SHEET 1) (SHEET 4)
DETAIL PACKING
A (5) INLET
INDUCER IMPELLER
(30) (35)
RETAINING
RING (180)
BEARING
SELF-LOCKING HOLDER (185)
SCREW (40)
INLET
ADAPTER BEARING
(20) ASSEMBLY
(190)
SCREW (25)
(3 PLACES)
28-22-04-99B-858-A01-001.cgm
PACKING
SPRING
(10)
PIN (45)
(2 PLACES) SHIM(S)
(55 AND/OR 60)
(AS REQUIRED)
PARENTHESES REFER
TO IPL FIGURE 1.
GRAPHIC 28-22-04-99B-858-A01
Cross-Section Views – Motor-Impeller Subassembly (Sheet 1 of 8)
Figure 7001
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Jan 09/2004
60-989
7001
PART NUMBERS
60-98902A, 60-98904A,
AND 60-98906A
DETAIL DETAIL
A B
(SHEET 2) (SHEET 5)
DETAIL PACKING
A (5) INLET
INDUCER IMPELLER
(30) (35)
RETAINING
RING (180)
BEARING
SCREW (40)
INLET
ADAPTER BEARING
(20) ASSEMBLY
(190)
SCREW (25)
(3 PLACES)
28-22-04-99B-858-A01-002.cgm
PACKING
SPRING
(10)
PIN (45)
(2 PLACES) SHIM(S)
(55 AND/OR 60)
(AS REQUIRED)
PARENTHESES REFER
TO IPL FIGURE 2A.

Figure 7001
28-22-04 Page 7005

Jan 09/2004
60-989
7001
PART NUMBER
60-98976-1
DETAIL DETAIL
A B
(SHEET 3) (SHEET 6)
DETAIL PACKING
A INLET
INDUCER (5) IMPELLER
(30) (35)
RETAINING
RING (180)
BEARING
SCREW (40)
INLET
ADAPTER BEARING
(20) ASSEMBLY
(190)
SCREW (25)
(3 PLACES)
28-22-04-99B-858-A01-003.cgm
PACKING
SPRING
(10)
PIN (45)
(2 PLACES) SHIM(S)
(55 AND/OR 60)
(AS REQUIRED)
PARENTHESES REFER
TO IPL FIGURE 2B.

Figure 7001
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Jan 09/2004
60-989
7001
DETAIL
B
(P/N 60-98902, 60-98904,
60-98906, AND 60-98976) SCREW (150)
PACKING (2 PLACES)
STATOR PACKING
(15)
ASSEMBLY (175) PACKING TERMINAL
PRIMER
(200) (170) ASSEMBLY
LINER
(REF) (90) (REF)
INLET
PLATE INNER BEARING
RETAINING
ASSEMBLY HOUSING ROTOR ASSEMBLY
RING (180)
(REF) ASSEMBLY ASSEMBLY (205) (190)
BEARING
(210) (SHEET 6) HOLDER (185)
END
VIEW
A
SCREW (75)
TERMINAL HEX NUT (80)
ASSEMBLY (90) WASHER (85)
CABLE
ASSEMBLY (4 PLACES)
(65) CONNECTOR
(70)
IDENTIFICATION
PLATE (125)
SCREW (95)
WASHER (100)
B DRIVE SCREWS (130)
(2 PLACES)
A BRACKET
28-22-04-99B-858-A01-004.cgm
END CAP
ASSEMBLY ASSEMBLY
(135) (95)
SCREW (97)
WASHER (98)
(4 PLACES)
B
DRAIN PLUG (105)
NOTE: THE ITEM NUMBERS IN PACKING (110)
PARENTHESES REFER
TO IPL FIGURE 2.

Figure 7001
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Jan 09/2004
60-989
7001
DETAIL
B
(P/N 60-98902A, 60-98904A,
AND 60-98906A) SCREW (150)
PACKING (2 PLACES) PACKING
STATOR (15) (175) PACKING TERMINAL
ASSEMBLY
PRIMER (170) ASSEMBLY
(200)
LINER (90) (REF)
(REF)
INLET
PLATE INNER BEARING
RETAINING
RING (180)
BEARING
(210) (SHEET 6) HOLDER (185)
END
VIEW
A
SCREW (75)
CABLE
ASSEMBLY (4 PLACES)
(65) CONNECTOR
(70)
IDENTIFICATION
PLATE (125)
SCREW (95)
WASHER (100)
(2 PLACES)
A BRACKET
28-22-04-99B-858-A01-005.cgm
END CAP
ASSEMBLY ASSEMBLY
(135) (95)
SCREW (97)
WASHER (98)
(4 PLACES)
B
NOTE: THE ITEM NUMBERS IN DRAIN PLUG (105)
PARENTHESES REFER PACKING (110)
TO IPL FIGURE 2A.

Figure 7001
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Jan 09/2004
60-989
7001
DETAIL
B
(P/N 60-98976-1) SCREW (150)
PACKING (2 PLACES) PACKING
STATOR (15) (175) PACKING
ASSEMBLY
PRIMER (170)
(200) TERMINAL
LINER
ASSEMBLY
(REF)
(90) (REF)
INLET
PLATE INNER BEARING
RETAINING
RING (180)
BEARING
(210) (SHEET 6) HOLDER (185)
END
VIEW
A
SCREW (75)
CABLE
ASSEMBLY (4 PLACES)
(65) CONNECTOR
(70)
IDENTIFICATION
PLATE (125)
SCREW (95)
WASHER (100)
(2 PLACES)
A BRACKET
28-22-04-99B-858-A01-006.cgm
END CAP
ASSEMBLY ASSEMBLY
(135) (95)
SCREW (97)
WASHER (98)
(4 PLACES)
B
NOTE: THE ITEM NUMBERS IN DRAIN PLUG (105)
PARENTHESES REFER PACKING (110)
TO IPL FIGURE 2B.

Figure 7001
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Jan 09/2004
60-989
7001
INLET PLATE
ASSEMBLY
(REF)
TUBE
(REF)
PRIMER
LINER
(REF)
ROTOR
ASSEMBLY
(205) (REF)
VIEW
A-A
END CAP
ASSEMBLY (150)
(REF)
GROUND WIRE
ASSEMBLY (105)
28-22-04-99B-858-A01-007.cgm
SCREW (110)
WASHER (115)
VIEW
B-B
PARENTHESES REFER
TO IPL FIGURE 2, 2A, AND 2B.

Figure 7001
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Jan 09/2004
60-989
7001
ROTOR
ASSEMBLY
(IPL FIG. 3) THRUST
BEARING
INLET PLATE THRUST
HOLDER (35)
ASSEMBLY WASHER
(5) (45)
INSULATION
STRIP (55)
GIMBAL
TUBE (15) PLATE (50)
(3 PLACES)
TOLERANCE
RING (25)
PRIMER
IMPELLER
(20) ROTOR/SHAFT
ASSEMBLY (65)
SPRING
28-22-04-99B-858-A01-008.cgm
PIN (60)
PRIMER (2 PLACES)
LINER (10)
THRUST BEARING
DISCHARGE PLATE (40)
PRIMER PLATE
(30)
PARENTHESES REFER
TO IPL FIGURE 3.

Figure 7001
28-22-04 Page 7011

Jan 09/2004
60-989
TASK 28-22-04-400-920-A01
4. Motor-Impeller Subassembly
NOTE: Cross-section views of the motor-impeller subassembly are shown in Figure 7001. (See Figure
subassembly P/N 60-98976-4.
A. Packing Installation Guidelines
NOTE: This procedure provides general instructions to install new packings. Refer to Figure 7001 for
installation location and arrangement. Refer to this procedure when it is referenced in the
assembly procedures.
(1) Replace the packings each time they are exposed. Make sure dated materials used for
replacement are within their shelf life.
(2) Rinse the items in Acetone or Aero MEK.
(3) Inspect all items for cuts, nicks, moldline flashing, and other damage. Replace damaged items.
CAUTION: DO NOT APPLY PETROLATUM TO PACKINGS UNLESS SPECIFIED IN THE

ASSEMBLY PROCEDURE. IMPROPERLY USED PETROLATUM CAN AFFECT UNIT
OPERATION.
(4) When specified in the assembly procedure, lightly coat the packings with petrolatum before
installation. Some packings must be installed without petrolatum.
CAUTION: DO NOT INSTALL THE PACKINGS UNTIL SPECIFIED IN THE ASSEMBLY

PROCEDURE. THE PACKINGS CAN BE DAMAGED BY INCORRECT
INSTALLATION.
(5) Do not use steel tools for installation. Steel tools can scratch or mar microfinish surfaces. Use
brass or plastic tools.
(6) Use standard bullets and other assembly aids to install the items over threads, splines, and
surfaces that could cause damage. Use care to avoid pinching or cuts.
(7) After installation, make sure the items are fully seated in the component groove and are not
damaged or twisted. Use standard sizing tools to fully seat the items in the component groove.
B. Rotor Assembly
(1) Refer to REPAIR if necessary to bond a new insulation strip (55, IPL Figure 3) inside the thrust
bearing holder (35).
(2) Use an arbor or hand press and press fixture T-20959 to install the spring pins (60) in the shaft of
the rotor/shaft assembly (65). Make sure the pins extend equally from both sides of the shaft.
(3) Mount the rotor-shaft assembly (65) and assembled components vertically in assembly fixture T-
31137 (Table 7001) with the lamination down.
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Jan 09/2004
60-989
CAUTION: MAKE SURE THE MARKED SIDE OF THE THRUST WASHER IS INSTALLED
AGAINST THE GIMBAL PLATE.
(4) Install the gimbal plate (50) and thrust washer (45) on the shaft of the rotor/shaft assembly (65),
with the side marked on the thrust washer against the shaft shoulder. Set the slots in the thrust
washer over the spring pins (60).
(5) Install the thrust bearing plate (40), with the slotted side toward the thrust washer (45), on the
shaft of the rotor/shaft assembly (65).
CAUTION: CAREFULLY INSTALL THE THRUST BEARING HOLDER. DO NOT DAMAGE THE
CARBON THRUST BEARING AND THE BEARING JOURNAL OF THE ROTOR/
SHAFT ASSEMBLY.
(6) Install the thrust bearing holder (35), with the insulation strip (55) side inward, on the rotor/shaft
assembly (65). Make sure the flat recess is mated with one of the sides of the thrust bearing plate
(40).
(7) Refer to CLEANING and clean the notch in the rotor/shaft assembly (65) and the inner diameter
of the primer impeller (20).
CAUTION: MAKE SURE NO GREASE TOUCHES THE TOLERANCE RING NOTCH IN THE
ROTOR/SHAFT ASSEMBLY.
(8) Apply a thin film of Aeroshell 16 grease (Table 7002) on the mating sides of the inlet plate
assembly (5), primer impeller (20), and primer discharge plate (30). Apply the grease near the
shaft to prevent the retaining compound to be applied later from curing in unwanted places.
(9) Install the primer discharge plate (30), with the indentation toward the thrust bearing holder (35),
on the rotor/shaft assembly (65).
(10) Apply yellow primer (Table 7002) to the inner diameter of the primer impeller (20), the inner and
outer diameters of the tolerance ring (25), and to the tolerance ring notch in the rotor/shaft
assembly (65). Let the primer dry for 3 to 5 minutes at 72 °F (22 °C).
(11) Spread the tolerance ring (25) with needle nose pliers. Install it on the rotor/shaft assembly (65)
next to the edge of the tolerance ring notch.
(12) Apply a thin coat of retaining compound (Table 7002) to the tolerance ring notch. Install the
tolerance ring (25) in the notch.
(13) Install the rotor/shaft assembly (65) and assembled components into screw-type assembly fixture
T-31834 (Table 7001).
(14) Apply a thin coat of retaining compound to the outer diameter of the tolerance ring (25) and the
inner diameter of the primer impeller (20).
CAUTION: WHEN YOU INSTALL THE PRIMER IMPELLER ONTO THE TOLERANCE RING,
MAKE SURE THE LUBRICATED SIDE OF THE PRIMER IMPELLER FACES THE
PRIMER DISCHARGE PLATE.
(15) Lightly lubricate the tip and mating sides of each blade of the primer impeller (20) with Aeroshell
grease as shown in Figure 7002. This will keep the adhesive used during final assembly from
bonding with the impeller. (See Figure 7002 "GRAPHIC-28-22-04-99B-861-A01" on page 7016.)
(16) Install the primer impeller (20) on the shaft next to the tolerance ring (25).
28-22-04 Page 7013

Jan 09/2004
60-989
(17) Use a arbor or bench press and the second part of assembly fixture T-31137 to install the primer
impeller (20) onto the tolerance ring (25) until there is a 0.002 to 0.004 inch (0.051 to 0.102 mm)
gap between the primer impeller and primer discharge plate (30). (See Figure 7003 "GRAPHIC-
28-22-04-99B-862-A01" on page 7017.)
NOTE: Use shim stock (Table 7002) as feeler gages to get the necessary clearance between
the primer impeller (20) and primer discharge plate (30). Check the top and bottom.
(18) Wipe off excess retaining compound, primer, and grease. Use a cotton swab moistened with
isopropyl alcohol if necessary. Do not remove the Aeroshell grease from the primer impeller (20).
(19) Place the rotor assembly vertically in an oven with the rotor/shaft assembly (65) lamination at the
top. Oven cure the assembly for 15 minutes at 200 °F (93 °C).
NOTE: As an alternative to the oven, the assembly can be cured for 4 hours at room
temperature.
(20) Refer to CLEANING to flush the assembly with solvent to remove excess retaining compound
and grease.
(21) Install the rotor/shaft assembly (65) on alignment tool T-62957 (Table 7001).
CAUTION: THE TUBES ARE SAFETY CRITICAL ITEMS. VERIFY PROPER INSTALLATION AS
SPECIFIED BELOW.
(22) Install the three tubes (15), primer liner (10), and inlet plate assembly (5), as follows:
(a) Install the three tubes (15) through the primer discharge plate (30) and into the thrust
bearing holder (35). (Refer to Figure 7003 "GRAPHIC-28-22-04-99B-862-A01" on
page 7017.)
(b) Use a clean cotton swab dipped in Aero-MEK to clean the mating surfaces on the primer
liner (10) and primer discharge plate (30) as shown in Figure 7002.
CAUTION: TAKE CARE TO PREVENT THE ADHESIVE FROM SETTING UP AND THE
PRIMER DISCHARGE PLATE, PRIMER LINER, AND INLET PLATE ASSEMBLY
FROM CENTERING WHEN THE COMPONENTS ARE INSTALLED IN THE
INNER HOUSING ASSEMBLY.
(c) Apply a narrow, even bead of adhesive (Table 7002) to the full diameter of the mating
surface of the primer liner (10) with the primer discharge plate (30). Allow the adhesive to
cure for 1 minute maximum. Install the primer liner (10) before the adhesive fully cures.
(d) Install the primer liner (10) onto the shaft of the rotor/shaft assembly (65) and over the three
tubes (15) and primer impeller (20). The center tube must go through the hole in the primer
liner. The outer two tubes pass just over the outer diameter of the primer liner.
(e) Align the outer diameter of the primer liner (10) with the outer diameter of the primer
discharge plate (30). Press the components together to establish the bond.
(f) Use a clean cotton swab dipped in Aero-MEK to remove any excess adhesive.
(g) Rotate the rotor/shaft assembly (65). If it does not turn smoothly without binding, check the
alignment of the primer liner (10) and other components. Reassemble the components if
necessary.
(h) Use a clean cotton swab dipped in Aero-MEK to clean the mating surface of the primer liner
(10) with the inlet plate assembly (5) as shown in Figure 7002. Do not remove the Aeroshell
grease from the tips of the primer impeller (20).
28-22-04 Page 7014

Jan 09/2004
60-989
CAUTION: USE ONLY ENOUGH ADHESIVE TO COVER THE MATING SURFACES, AND
REMOVE EXCESS ADHESIVE. TOO MUCH ADHESIVE WILL INTERFERE
WITH THE FUNCTION OF THE PRIMER IMPELLER.
(i) Apply a narrow, even bead of adhesive to the full diameter of the mating surface of the
primer liner (10) with the inlet plate assembly (5). Allow the adhesive to cure for 1 minute
maximum. Install the inlet plate assembly (5) before the adhesive fully cures.
(j) Install the inlet plate assembly (5), with the indentation side away from the primer impeller
(20). Engage the three tubes (15) with the holes in the inlet plate assembly.
(k) Align the outer diameter of the inlet plate assembly (5) with the outer diameter of the primer
liner (10). Press the components together to establish the bond.
(l) Apply adhesive to seal around the three tubes (15) at the inlet plate assembly (5). Verify
that the tubes extend 0.156 inch (3.96 mm) maximum from the inlet plate assembly as
(m) Use a clean cotton swab dipped in Aero-MEK to remove any excess adhesive. Make sure
there is no adhesive buildup on the inner diameter of the primer liner (10) or on the outer
diameter of the inlet plate assembly (5) and primer discharge plate (30).
28-22-04 Page 7015

Jan 09/2004
60-989
7002
INLET PLATE
ASSEMBLY
(5)
PRIMER
LINER (10)
ADHESIVE
(BOTH SIDES)
PRIMER
IMPELLER
(20)
PRIMER
DISCHARGE
PLATE (30)
ROTOR/SHAFT
TUBE (15) ASSEMBLY
(3 PLACES) (65)
PROTECTIVE
AEROSHELL
GREASE ON PRIMER
IMPELLER (20)
THRUST
BEARING
HOLDER
(35)
28-22-04-99B-861-A01-001.cgm

PARENTHESES REFER
TO IPL FIGURE 3.
GRAPHIC 28-22-04-99B-861-A01
Primer Liner, Inlet Plate, and Tube Installation
Figure 7002
28-22-04 Page 7016

Jan 09/2004
60-989
7003
0.156 (3.96)
MAXIMUM
(3 PLACES)
TUBE (15) THRUST

(3 PLACES) BEARING
HOLDER (35)
TOLERANCE
RING (25)
INLET PLATE
ASSEMBLY
(5)
PRIMER
PRIMER
IMPELLER (20)
DISCHARGE
PLATE (30)
0.002 TO 0.004
(0.051 TO 0.102)
28-22-04-99B-862-A01-001.cgm
CHECK WITH SHIM STOCK
TOP AND BOTTOM

0.002 ± 0.0005 PARENTHESES REFER
(0.051 ± 0.0127) TO IPL FIGURE 3.
SHIM STOCK 2. THE DIMENSIONS ARE
GRAPHIC 28-22-04-99B-862-A01
Rotor Assembly Clearance Dimensions
Figure 7003
C. Motor-Impeller Subassembly
NOTE: Cross-section views of the motor-impeller subassembly are shown in Figure 7001.
(1) Clean the inner diameter of a bearing assembly (190, IPL Figures 2, 2A, and 2B) with a soft-
bristled brush.
CAUTION: DO NOT DAMAGE THE CARBON BEARING SURFACE DURING INSTALLATION OF

THE BEARING ASSEMBLY.
(2) Install the bearing assembly (190) in the bearing receptacle in the inner housing assembly (210).
Align the slots on the bearing assembly with the slots in the inner housing.
(3) Install the bearing holder (185) over the bearing assembly (190). Engage the tangs with the slots
on the bearing assembly.
CAUTION: MAKE SURE THE RETAINING RING IS FULLY SEATED IN THE GROOVE. AN
IMPROPERLY INSTALLED RING CAN DAMAGE INTERNAL COMPONENTS.
(4) Use snap ring pliers to install the retaining ring (180). Press it into place and engage the slot
inside the bearing receptacle.
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Jan 09/2004
60-989
(5) Install the rotor assembly (205) in the inner housing assembly (210), as follows:
(a) Install the rotor assembly (205) in installation sleeve T-62957 (Table 7001).
(b) Install the inner housing assembly (210) down over the rotor assembly (205). The tubes
(15, IPL Figure 3) must enter the alignment holes in the inner housing assembly.
(c) Rotate the rotor assembly (205, IPL Figures 2, 2A, and 2B). If the shaft does not turn
smoothly without binding, check alignment of the components. Reassemble the
components if necessary.
(6) Oven cure the assembly for 60 minutes at 200 to 265 °F (93 to 129 °C) to cure the adhesive.
NOTE: The inlet adapter (20) can be installed as a temporary precaution to protect the shaft of
the rotor assembly (205) that extends from the inner housing assembly (210).
(7) Refer to REPAIR if necessary to bond a new insulation strip (195) inside the end cap assembly
(150).
(8) Pre-assemble the end cap assembly (150), cable assembly (65), and stator assembly (200), as
follows:
NOTE: The stator assembly (200) will be installed in the inner housing assembly (210) after the
wire leads are connected to thecable assembly (65) and the connector is installed in the
(a) Use Aero-MEK and lint-free wipes the clean the inner diameter of the remaining bearing
assembly (190).
CAUTION: DO NOT DAMAGE THE CARBON BEARING SURFACE DURING

INSTALLATION OF THE BEARING ASSEMBLY.
(b) Install the bearing assembly (190) in the recess in the back of the end cap assembly (150).
Align the slots on the bearing assembly with the slots in the end cap assembly.
(c) Install the bearing holder (185) over the bearing assembly (190). Engage the tangs with the
slots on the bearing assembly.
CAUTION: MAKE SURE THE RETAINING RING IS FULLY SEATED IN THE GROOVE. AN
IMPROPERLY INSTALLED RING CAN DAMAGE INTERNAL COMPONENTS.
(d) Use snap ring pliers to install the retaining ring (180). Press it into place and engage the slot
inside the end cap assembly (150).
(e) Refer to REPAIR if necessary to repair the ground wire assembly (105). Secure the ground
wire assembly terminal to the back of the end cap assembly (150) with the screw (155) and
washer (160). Torque the screw 20 to 22 in-lb (2.3 to 2.5 Nm) in addition to the run-down
torque.
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Jan 09/2004
60-989
(f) Install the cable assembly (65) on the end cap assembly (150), as follows:
NOTE: This procedure provides instructions to solder the wire leads from the stator
assembly (200) and ground wire assembly (105) to the terminal assembly (90),
cover the solder junctions with potting compound, and install the terminal
assembly and other components on the end cap assembly.
NOTE: Hydro-Aire, Inc. recommends that the P/N 60-98902, 60-98902A, 60-98904, 60-
98904A, 60-98906, 60-98906A, 60-98976, and 60-98976-1 motor-impeller
subassembly be upgraded to the improved P/N 60-98976-4 configuration at the
earliest maintenance opportunity. To do this, refer to Service Bulletins 60-98902-
28-1, 60-98904-28-1, 60-98906-28-1, and 60-98976-28-1 and modification kit P/N
60-98976-4902. Refer to CMM 28-22-07 for maintenance instructions and an IPL
for motor-impeller subassembly P/N 60-98976-4.
CAUTION: SPLICES OF ANY TYPE IN THE STATOR WIRE LEADS ARE NOT
ALLOWED. THE STATOR ASSEMBLY MUST BE REPLACED, OR IF
POSSIBLE, THE SPLICED AREA CUT FROM THE WIRES IF THE WIRES
ARE SPLICED.
1 Refer to CHECK to examine the stator assembly (200) wire leads for cut, cracked,
split, or abraded wire insulation, spliced or damaged conductor, or wire leads less than
4 inches (102 mm) or longer than 6 inches (152 mm). If a wire lead is spliced or a
conductor is damaged, replace the stator assembly. If applicable, refer to REPAIR to
cover the damaged insulation with Teflon heat-shrink sleeving.
CAUTION: THE STATOR ASSEMBLY REQUIRES TEFLON TUBING WITH 0.166 ID X

0.020 THICK WALL.
2 Route the stator assembly (200) wire leads through new packings (170 and 175). Do
not apply petrolatum to the packings. Details are shown in Figure 7004. (See Figure
NOTE: The packings (170 and 175) will be installed on the terminal assembly (90)
and end cap assembly (150) after the stator assembly (200) is installed.
However, the wire leads must be routed through the items before they are
soldered to the connector.
3 Install Teflon tubing (Table 7002) on each stator assembly (200) wire lead. The tubing
must cover all of the wire leads except approximately 1.5 inch (3.8 mm).
4 Refer to REPAIR to solder the stator assembly (200) and ground wire assembly (105)
wire leads to the terminal assembly (90) and cover the solder joints with potting
compound.
NOTE: Use REPAIR procedure Wire Etching, Soldering, and Potting for Potted
Connectors.
5 Pre-form the stator assembly (200) wire leads to have an approximate 90 degree bend
next to the terminal assembly (200) as specified below. Reheat the Teflon tubing if
necessary.
a The direction of bend must be opposite the ground lug on the inside of the end
cap assembly (150).
28-22-04 Page 7019

Jan 09/2004
60-989
b The wire leads must have room to lay at the back of the end cap assembly (150),
on top the stator assembly (200) end windings. Use a plastic stick to support the
wire lead when they are pre-formed to minimize the stress on the terminal
assembly (90) pins.
c Hold the pre-form bend for 30 seconds minimum to assure the wire bundle is
trained and set in the direction required.
6 Before further assembly, refer to TESTING AND FAULT ISOLATION and check the
stator assembly (200) and cable assembly (65) insulation resistance and dielectric
strength. Refer to REPAIR to repair the varnish finish on the stator lamination, or
replace the stator assembly if it fails either test.
7 Use lint-free wipes and Aero-MEK or other approved solvent (Table 7002) to clean the
mating surfaces of the terminal assembly (90) and end cap assembly (150) to remove
grease and other contamination. Make sure the electrical bonding surfaces (chem-film
finish surfaces) are not contaminated or damaged.
8 Install the terminal assembly (90) on the end cap assembly (150) with pin 4 at the12
O’clock position (Figure 7005). Do not lubricate the packing (170).
9 With the packing (170) in place, secure the terminal assembly (90) to the end cap
assembly (150) with the screws (95) and washers (100). Torque the screws 7 to 9 in-lb
(0.8 to 1.0 Nm).
10 For 60-98902A, 60-98904A, and 60-98906A only, with the packing (170) in place,
secure the terminal assembly (90) and bracket assembly (116) to the end cap
assembly (150) with the screws (95) and washers (100). Torque the screws 7 to 9 in-lb
(0.8 to 1.0 Nm).
11 Install MS20995C20 or MS20995C32 lockwire (Table 7002) to lockwire the terminal

assembly mounting screws (95) to each other. Refer to NASM33540 and Figure 7005.
(9) Refer to REPAIR to replace or reinstall the identification plate (140) and drive screws (145) on the
(10) Install the pre-assembled stator/end cap assembly in the inner housing assembly (210), as
follows:
(a) Verify that the stator assembly (200) wire leads are pre-formed to have an approximate 90
degree bend next to the terminal assembly (90). If not, reheat the Teflon tubing and again
pre-form the wire leads.
1 The direction of bend must be opposite the ground lug on the inside of the end cap
assembly (150).
2 The wire leads must have room to lay at the back of the end cap assembly (150), on
top the stator assembly (200) end windings. Use a plastic stick to support the wire
lead when they are pre-formed to minimize the stress on the terminal assembly (90)
pins.
3 Hold the pre-form bend for 30 seconds minimum to assure the wire bundle is trained
and set in the direction required.
(b) Place the end cap assembly (150), bearing assembly (190) face up, on a stable surface.
NOTE: A holding fixture is suggested to properly support the assembly.
28-22-04 Page 7020

Jan 09/2004
60-989
(c) Install the packing (175) on the shoulder of the end cap assembly (150). Apply a light coat
of petrolatum (Table 7002) to the packing.
CAUTION: MAKE SURE THE WIRE LEADS ARE COILED IN THE OPPOSITE DIRECTION
OF THE GROUND WIRE ASSEMBLY AS SHOWN ON FIGURE 7007.
OTHERWISE, DAMAGE TO THE WIRE LEADS COULD OCCUR WHEN THE
END CAP IS INSTALLED.
CAUTION: THE STATOR ASSEMBLY MUST BE CAREFULLY INSTALLED SO THE WIRE

INSULATION IS NOT PINCHED OR CUT AND THE ROTOR AND INNER
HOUSING ARE NOT DAMAGED. DAMAGE TO THE WIRE INSULATION CAN
CAUSE ELECTRICAL SHORTING/ARCING.
CAUTION: DO NOT DAMAGE THE BEARING SURFACE OR PINCH THE WIRE LEADS ON
THE ROTOR ASSEMBLY SHAFT.
(d) Coil the wire bundle in the direction opposite that of the ground wire assembly (80) and
install the stator assembly (200) on top the end cap assembly (150). Verify that all stack-up
components are properly seated against each other with no binding or pinching.
(e) Rotate the stator assembly (180) clockwise (when looking through the stator cavity at the
end cap bearing, item 190) to expand the wire bundle radius so the bundle rests against the
inner diameter of the outer wall of the end cap assembly (150).
(f) Visually check that the packing (170) is seated properly in the end cap assembly (150) and
the stator assembly (200) wire bundle does not protrude into the gap between the end cap
bearing support and stator end windings visible from inside the stator.
(g) Heat the inner housing assembly (210) with installed rotor assembly (205) to approximately
265 °F for 15 to 30 minutes to aid stator assembly (180) installation.
WARNING: WEAR GLOVES AND OTHER PROTECTIVE GEAR AS NEEDED TO HANDLE

THE HEATED COMPONENTS. THE HOT METAL CAN CAUSE SERIOUS
BURNS.
(h) Use heat-resistant gloves to remove the inner housing assembly (210) from the oven.
NOTE: The inner housing assembly (190) will cool enough to prevent installation of the
stator assembly (200) within 1 minute of removal from the oven.
(i) Apply a light coat of petrolatum (Table 7002) to the outer diameter of the stator assembly
(200) and inner diameter of the inner housing assembly (210).
(j) Invert the inner housing assembly (210) and align the mounting holes in the end cap
assembly (150) with the inner housing assembly. Make sure the connector (70) is oriented
properly.
(k) Install the inner housing assembly (210) onto the stator assembly (200) and other
components. Continue to push the inner housing assembly down over the stator assembly
until the thrust bearing holder (35, IPL Figure 3) bottoms out against the stator and the end
cap packing (175, IPL Figure 2) is seated in the inner housing assembly.
(l) Hold the end cap assembly (150) against the inner housing assembly (210) and turn the
unit upright.
NOTE: When the unit is turned upright, the end cap assembly (150) must remain in
contact with the stack-up of parts on top the stator assembly (200) inside the inner
housing assembly (190). This assures the wire bundle will not move from its
position on top the stator end windings.
28-22-04 Page 7021

Jan 09/2004
60-989
(m) If necessary, realign the screw holes in the end cap assembly (150) and inner housing
assembly (210).
(n) Install new screws (165) to secure the end cap assembly (150) to the inner housing
assembly (210). Torque the screws 12 to 14 in-lb (1.4 to 1.6 Nm).
(o) Install the screws (155) and washers (160) to secure the bracket assembly (120) to the
inner housing assembly (210). Torque the screws 25 to 27 in-lb (2.8 to 3.0 Nm).
(p) Install new adhesive-backed labels (125) if necessary on the bracket assembly (120).
(11) Refer to TESTING AND FAULT ISOLATION and check the connector (70) electrical bonding. If
the unit fails the test, disassemble and check the chem-film bonding surfaces for contamination or
damage.
(12) Apply sealant around the end cap assembly (150) and connector (70), as follows:
CAUTION: DO NOT APPLY SEALANT TO THE MATING SURFACES BETWEEN THE

CONNECTOR AND END CAP ASSEMBLY. THIS CAN PREVENT PROPER
ELECTRICAL BONDING.
(a) Brush P/S890 Class B sealant (Table 7002) onto adjacent surfaces of the end cap
assembly (150) and the connector (70) mounting flange, and onto adjacent surfaces of the
screws (75) and connector flange. This assures a proper seal. Refer to Figure 7007.
(b) Apply a 0.20 inch (5.1 mm) minimum fillet of sealant around the interfaces of the end cap
assembly (1350) and connector (70) mounting flange. Cover the lockwired screws (75)
except for the tops of the screw heads.
(c) Apply sufficient sealant to fill a 0.36 inch (9.1 mm) diameter over each of two exposed screw
cavities in back of the end cap assembly (150) mounting flange.
(13) If applicable, remove the inlet adapter (20) installed earlier to protect the rotor assembly (205)
shaft.
(14) Reinstall the shim(s) (55 and 60) removed during disassembly. If the stack thickness was not
noted at disassembly, install a 0.060 to 0.070 inch (1.52 to 1.78 mm) stack.
NOTE: Install the same number or stack thickness as noted at disassembly. The stack will be
adjusted if necessary later in this procedure.
(15) Use pin installation tool T-66998 (Table 7001) to install the spring pins (45) into the inducer (30).
Check the height of the spring pins and gently tap then in with a small hammer if required.
(16) Install the drive pin (50) in the shaft of the rotor assembly (205). The drive pin must extend
equally from both sides of the shaft.
(17) Install the inducer (30) and inlet impeller (35) on the shaft of the rotor assembly (205). Secure the
parts with a temporary self-locking screw (40). Torque the screw 15 to 20 in-lb (1.7 to 2.3 Nm) in
addition to the run-down torque.
NOTE: Install the old self-locking screw (40) if it is available. A new self-locking screw must be
used for final assembly.
(18) Install the inlet adapter (20) on the inner housing assembly (210). Do not install the screws (25) at
this time.
(19) Place the unit vertically on the workbench with the inlet adapter (20) down. This will hold the inlet
adapter in place to aid measurement of the clearance between the inlet adapter and inlet impeller
(35).
28-22-04 Page 7022

Jan 09/2004
60-989
(20) Rotate the inlet impeller (35) until the inlet adapter-to-inlet impeller clearance is tightest at the
location shown in Figure 7004. (See Figure 7004 "GRAPHIC-28-22-04-99B-866-A01" on
page 7025.)
(21) Use a feeler gage to measure the clearance between the inlet adapter (20) and inlet impeller (35)
as shown in Figure 7004.
NOTE: The feeler gage must have a width of 0.200 inch (5.01 mm) or less and a thickness of
0.007 to 0.010 inch (0.178 to 0.254 mm). Feeler gage T-28069 available from Hydro-
Aire can be used.
(22) If the clearance is not within 0.007 to 0.010 inch (0.178 to 0.254 mm) as shown, remove the inlet
adapter (20), inducer (30), inlet impeller (35), and drive pin (50) to access the shim(s)
(55 and/or 60). Add or remove shim(s) as needed to adjust the clearance.
NOTE: The ratio of clearance to shim is 1:2. That is, a 0.001 inch (0.025 mm) difference in
clearance makes a 0.002 inch (0.051 mm) change in shims necessary. For example, if
the clearance is 0.005 inch (0.127 mm), remove 0.008 inch (0.203 mm) thickness of
shims to get a 0.009 inch (0.229 mm) inlet impeller-to-inlet adapter clearance. If the
clearance is 0.012 inch (0.305 mm), add 0.008 inch (0.203 mm) thickness of shims to
get a 0.008 inch (0.203 mm) inlet impeller-to-inlet adapter clearance.
(23) Do steps (16) through (18) again to reinstall the inlet adapter (20), inducer (30), inlet impeller
(35), and drive pin (50) with associated attaching parts.
(24) Do steps (19) through (22) again to measure the clearance between the inlet adapter (20) and
inlet impeller (35). If necessary, adjust the shim (55 and/or 60) stack again until the parts have the
required clearance.
(25) Install the screws (25) to secure the inlet adapter (20) to the inner housing assembly (190).
Torque the screws 3 to 5 in-lb (0.3 to 0.6 Nm).
CAUTION: A NEW SELF-LOCKING SCREW MUST BE INSTALLED AFTER FINAL

ADJUSTMENT. PRIMER AND SEALANT MUST BE APPLIED TO THE FIRST THREE
THREADS OF THE SCREW WITHOUT TOUCHING THE NYLON INSERT, OR THE
SCREW CAN LOOSEN DURING NORMAL OPERATION.
(26) Remove and discard the self-locking screw (40) that attaches the inducer (30) and inlet impeller
(35) to the rotor assembly (185) shaft.
(27) Apply primer (Table 7002) to a minimum of 3 threads of a new self-locking screw (40), starting
with the first thread (the thread farthest from the head).
NOTE: Refer to manufacturer instructions to apply the primer and sealant. If the clearance must
be adjusted again after the self-locking screw (40) is installed, the screw must be
replaced again after final adjustment.
(28) Let the primer air dry for 3 to 4 minutes, then apply Loctite 08731 sealant (Table 7002) to the self-
locking screw (40) threads over the primer.
(29) Install the self-locking screw (40). Torque the screw 15 to 20 in-lb (1.7 to 2.3 Nm) in addition to
the run-down torque.
(30) Apply a light coat of petrolatum to the packing (135). Install the packing over the threaded end of
the drain plug (130).
(31) Install the drain plug (105) in the end cap assembly (150). Torque the drain plug 40 to 50 in-lb
(4.5 to 5.7 Nm).
28-22-04 Page 7023

Jan 09/2004
60-989
D. Final Assembly
(1) Refer to CHECK, paragraph 5 to x-ray inspect the assembled motor-impeller subassembly. The
unit must pass the x-ray inspection before functional test.
(2) Refer to TESTING AND FAULT ISOLATION to complete the functional test procedures.
(3) Install MS20995C20 or MS20995C32 lockwire (Table 7002) to secure the screws (155) that
attach the bracket assembly (120) to each other. Crimp an Alucast seal to the end of the lockwire
as shown. Refer to Figures 7001 and 7007 and NASM33540.
(4) Install MS20995C20 lockwire (Table 7002) to secure the screws (25) that attach the inlet adapter
(20). Verify that the lockwire does not extend beyond the maximum outside diameter of 3.060
inch (77.72 mm) as shown in Figure 7004.
(5) Install a protective cap (Table 7002) on the connector (70).
(6) Pack new packings (5, 10, and 15) in polyethylene bags. Keep the bags with the motor-impeller
subassembly for aircraft installation.
(7) Refer to STORAGE for shipping and storage instructions.
28-22-04 Page 7024

Jan 09/2004
60-989
7004
SHIM(S)
(55 AND/OR 60)
SELF-LOCKING (AS REQUIRED)
SCREW (40)
INLET
ADAPTER (20)
3.060 (77.72)
MAXIMUM 0.001 TO 0.004
DIAMETER (0.025 TO 0.102)
OVER LOCKWIRE AXIAL MOVEMENT
INDUCER
(30)
SCREW (25)
(3 PLACES)
INLET
28-22-04-99B-866-A01-001.cgm
IMPELLER (35)
0.007 TO 0.010
(0.178 TO 0.254)
NOTES: 1. THE ITEM NUMBERS IN CLEARANCE BETWEEN
PARENTHESES REFER INLET ADAPTER (20)
TO IPL FIGURES 2, 2A, AND 2B. AND INLET IMPELLER (35)
GRAPHIC 28-22-04-99B-866-A01
Inlet Impeller Clearance
Figure 7004
28-22-04 Page 7025

Jan 09/2004
60-989
7005
PART NUMBERS
60-98902, 60-98902A, 60-98904,
60-98904A, 60-98906, 60-98906A,
AND 60-98976
TERMINAL
(BLUE, PIN 4) (90)
LEAD WIRE A
(BLACK, PIN 1)
PACKING
NO.4 (170)
TEFLON A
TUBING
(TABLE 7002)
LEAD WIRE
(GREEN, PIN 3)
LEAD WIRE
(RED, PIN 2)
POTTING MOLD
(TABLE 7002)
28-22-04-99B-870-A01-001.cgm
END CAP
ASSEMBLY
PARENTHESES REFER
(150)
TO IPL FIGURES 2 AND 2A.
GRAPHIC 28-22-04-99B-870-A01
Cable Assembly on End Cap Assembly (60-98902, 60-98902A, 60-98904, 60-98904A,
60-98906, 60-98906A, and 60-98976 ONLY) (Sheet 1 of 2)
Figure 7005
28-22-04 Page 7026

Jan 09/2004
60-989
7005
ETCH WIRE LEADS FROM STATOR

ASSEMBLY (200) AND GROUND WIRE
ASSEMBLY (105); WIRE INSULATION
MUST EXTEND NOT LESS THAN
0.10 INCH (2.5 MM) INTO POTTING
0.18 (4.6)
ENCAPSULATION; REFER TO REPAIR
MAXIMUM
FOR INSTRUCTIONS
POTTING COMPOUND
7° TO 12°
AND HARDENER
1.18 (30.0)
DIAMETER SOLDER WIRE LEADS TO
TERMINAL ASSEMBLY CONTACTS;
REFER TO REPAIR FOR
INSTRUCTIONS
AMS3653
TEFLON TERMINAL
TUBING ASSEMBLY
(REF)
RTV 1200 AND RTV 1205
PRIME COAT WITH RTV END CAP
730 SEALANT ASSEMBLY
(REF)
CLEAN
TERMINAL
ASSEMBLY
(REF)
SCREW (95)
WASHER (100)
(2 PLACES)
END CAP
ASSEMBLY
(150)
28-22-04-99B-870-A01-002.cgm
BEAD OF SEALANT
RTV 730

PARENTHESES REFER
TO IPL FIGURES 2 AND 2A.
Cable Assembly on End Cap Assembly (60-98902, 60-98902A, 60-98904, 60-98904A,

60-98906, 60-98906A, and 60-98976 ONLY) (Sheet 1 of 2)
Figure 7005
28-22-04 Page 7027

Jan 09/2004
60-989
7006
TERMINAL
(BLUE, PIN 4) (90)
LEAD WIRE A PART NUMBER

(BLACK, PIN 1) 60-98976-1
PACKING
NO.4 (170)
TEFLON A
TUBING
(TABLE 7002)
LEAD WIRE
(GREEN, PIN 3)
LEAD WIRE
(RED, PIN 2)
POTTING MOLD
BLUE
(TABLE 7002)
WIRE
BLACK 4
GREEN
WIRE 1 3
2 WIRE
END CAP RED CONNECTOR
ASSEMBLY WIRE PIN/SOLDER CUP
(150) (TYPICAL)
REAR VIEW
OF CONNECTOR
BEFORE POTTING
ETCH WIRE LEADS FROM STATOR 0.51 (15.0)

ASSEMBLY (200) AND GROUND WIRE MAXIMUM
ASSEMBLY (105); WIRE INSULATION
MUST EXTEND NOT LESS THAN
0.10 INCH (2.5 MM) INTO POTTING TERMINAL
ENCAPSULATION; REFER TO REPAIR ASSEMBLY
FOR INSTRUCTIONS (REF)
AMS3653
28-22-04-99B-872-A01-001.cgm
TEFLON TUBING
SOLDER WIRE LEADS TO

CONNECTOR CONTACTS; REFER
TO REPAIR FOR INSTRUCTIONS
POTTING COMPOUND PARENTHESES REFER
AND HARDENER; TO IPL FIGURE 2B.
REFER TO REPAIR 2. THE DIMENSIONS ARE
FOR INSTRUCTIONS GIVEN IN INCHES (MM).
GRAPHIC 28-22-04-99B-872-A01
Cable Assembly on End Cap Assembly (60-98976-1 ONLY)
Figure 7006
28-22-04 Page 7028

Jan 09/2004
60-989
7007
PACKING (160)
END CAP
ASSEMBLY GROUND WIRE
(150) ASSEMBLY
(105)
COIL WIRE
LEADS IN WIRE
DIRECTION LEADS
SHOWN
STATOR
ASSEMBLY
(200)
END CAP INSTALLATION
0.20 (5.1) BEAD/FILLET

OF P/S890 SEALANT AROUND
SCREW TO SEAL BETWEEN
SCREW AND TERMINAL
ASSEMBLY
(2 PLACES)
ALUCAST
SEAL
LOCKWIRE
(TYPICAL)
0.20 (5.1) MINIMUM

0.10 (2.5) FROM
EACH INTERFACE
28-22-05-99B-873-A01-001.cgm

PARENTHESES REFER
TO IPL FIGURES 2, 2A, AND 2B.
GRAPHIC 28-22-04-99B-873-A01
End Cap installation and Sealant Application
Figure 7007
28-22-04 Page 7029

Jan 09/2004
60-989
TASK 28-22-04-400-922-A01
5. Housing Subassembly
NOTE: Exploded views of the housing subassembly are shown in the IPL. Cross-section views are shown
in Figure 7008. (See Figure 7008 "GRAPHIC-28-22-04-99B-875-A01" on page 7032.)
A. Packing Installation Guidelines
NOTE: This procedure provides general instructions to install new packings. Refer to Figure 7001 for
installation location and arrangement. Refer to this procedure when it is referenced in the
assembly procedures.
(1) Replace the packings each time they are exposed. Make sure dated materials used for
replacement are within their shelf life.
WARNING: AERO-MEK AND ACETONE ARE FLAMMABLE AND TOXIC TO THE SKIN, EYES,
AND RESPIRATORY TRACT. USE THE SOLVENTS ONLY IN AREAS THAT HAVE
GOOD VENTILATION. WEAR GOGGLES AND GLOVES TO PROTECT YOUR EYES
AND SKIN.
(2) Rinse the items in Acetone or Aero-MEK.
(3) Inspect all items for cuts, nicks, moldline flashing, and other damage. Replace damaged items.
CAUTION: DO NOT APPLY PETROLATUM TO PACKINGS UNLESS SPECIFIED IN THE

ASSEMBLY PROCEDURE. IMPROPERLY USED PETROLATUM CAN AFFECT UNIT
OPERATION.
(4) When specified in the assembly procedure, lightly coat the packings with petrolatum before
installation. Some packings must be installed without petrolatum.
CAUTION: DO NOT INSTALL THE PACKINGS UNTIL SPECIFIED IN THE ASSEMBLY

PROCEDURE. THE PACKINGS CAN BE DAMAGED BY INCORRECT
INSTALLATION.
(5) Do not use steel tools for installation. Steel tools can scratch or mar microfinish surfaces. Use
brass or plastic tools.
(6) Use standard bullets and other assembly aids to install the items over threads, splines, and
surfaces that could cause damage. Use care to avoid pinching or cuts.
(7) After installation, make sure the items are fully seated in the component groove and are not
damaged or twisted. Use standard sizing tools to fully seat the items in the component groove.
B. Electrical Bonding Components
(1) Refer to CLEANING to clean all components before assembly. Contamination can cause
corrosion or affect electrical bonding.
(2) Hand wipe all components in the electrical (ground) bonding path with Aero-MEK before
assembly. Wipe the components with isopropyl alcohol for final cleaning.
(3) After the initial and final cleaning, wear gloves and do not handle the electrical bonding
components with your bare hands.
C. Housing Subassembly
(1) Refer to REPAIR to install new screw thread inserts (65 and 70, IPL Figure 4) in the outer
housing (75).
28-22-04 Page 7030

Jan 09/2004
60-989
(2) Install the stud (50) in the outer housing assembly (55), as follows:
(a) Clean the stud (50) with isopropyl alcohol (Table 7002).
(b) Apply a light coat of Grade C retaining compound to the stud (50) and in the mounting hole
in the outer housing assembly (55).
(c) Install the stud (50) in the outer housing assembly (55). Use assembly tool T-65977 (Table
7001) to tighten the stud.
(3) Assemble and install the primer check valve assembly (25), as follows:
(a) Clean the electrical bonding components. Refer to the general instructions given earlier.
(b) Install the spring (35) and flapper assembly (40) on the valve seat (45) with the pin (30).
Pre-load the spring as shown in Figure 7009 to close the flapper assembly.
(c) Apply a light coat of petrolatum (Table 7002) to the packings (20).
(d) Install the packings (20) on the primer check valve assembly (25), one on top the valve seat
(45) and the other below. Refer to the general instructions given earlier.
(e) Position the primer check valve assembly (25) on the outer housing assembly (55) with the
hinge toward the small flange end of the housing.
(f) Install the primer discharge port (5) over the primer check valve assembly (25). Align the
mounting holes.
(g) Install the screws (10) and washers (15). Do not dislodge or damage the packings (20).
Torque the screws 7 to 9 in-lb (0.8 to 1.0 Nm).
D. Final Assembly
(1) Refer to TESTING AND FAULT ISOLATION to test and check the housing subassembly.
(2) After testing, fill the cavities of the screw thread inserts (65 and 70, IPL Figure 4) with corrosion
inhibiting paste (Table 7002).
(3) Install MS20995C20 or MS20995C32 lockwire (Table 7002) to secure the primer discharge port
(5) mounting screws (10) to each other. Refer to Figure 7001 and NASM33540.
(4) Install the protective plugs and cover (Table 7002) in the ports.
(5) If applicable, refer to STORAGE for shipping and storage instructions.
28-22-04 Page 7031

Jan 09/2004
60-989
7008
PRIMER
DISCHARGE
PORT (5)
SCREW (10)
WASHER (15) PRIMER
(3 PLACES) CHECK VALVE
ASSEMBLY (25)
PACKING (20) (SHEET 2)
(2 PLACES)
HYDRO-AIRE, INC.
A SUBSIDIARY OF CRANE CO.
HOUSING SUB-ASSY
TBC SCD NO. 60B89004-1
HYDRO-AIRE PN 60-98901
SERIAL NO. 07140034
OUTER
HOUSING
ASSEMBLY (75) A
(SHEET 2)
STUD
(50)
28-22-04-99B-875-A01-001.cgm
VIEW NOTE: THE ITEM NUMBERS IN

A-A PARENTHESES REFER
TO IPL FIGURE 4.
GRAPHIC 28-22-04-99B-875-A01
Cross-Section Views – Housing Subassembly (Sheet 1 of 2)
Figure 7008
28-22-04 Page 7032

Jan 09/2004
60-989
7008
OUTER HOUSING
ASSEMBLY (55)
B
SCREW THREAD
INSERT (75)
(8 PLACES)
OUTER
28-22-04-99B-875-A01-002.cgm
HOUSING
(80) SCREW THREAD
SCREW THREAD INSERT (75)
INSERT (70) PLUG SET (65)
VIEW (6 PLACES) (4 PLACES)
B-B

PARENTHESES REFER
TO IPL FIGURE 4.
Cross-Section Views – Housing Subassembly (Sheet 2 of 2)

Figure 7008
28-22-04 Page 7033

Jan 09/2004
60-989
28-22-04 Page 7034

Jan 09/2004
60-989
FITS AND CLEARANCES
TASK 28-22-04-99C-955-A01
1. General
A. This section contains assembly torque limits and in-service wear limits for the Motor-Impeller
Subassembly and Housing Subassembly.
B. The components are identified, by item number, to the exploded view illustrations in the ILLUSTRATED
PARTS LIST.
TASK 28-22-04-820-956-A01
2. Torque Limits
Assembly torque limits are given in Table 8001. When specified, the values given are in addition to the run-
down torque. (Refer to Table 8001 "TABLE-28-22-04-99A-940-A01" on page 8001.)
8001
TABLE 28-22-04-99A-940-A01 Torque Limits—Table 8001
IPL FIGURE AND TORQUE

COMPONENT
ITEM NUMBER IN-LB Nm
Screws (Inlet Adapter) 2, 2A, 2B-25 3 to 5 0.3 to 0.6
Screw (Inducer and Inlet Impeller) 2, 2A, 2B-40 15 to 20 Plus 1.7 to 2.3 Plus
Run-Down Torque Run-Down Torque
Screws (Terminal Assembly) 2, 2A, 2B-95 7 to 9 0.8 to 1.0
Screw (Ground Wire Terminal) 2, 2A, 2B-110 20 to 22 2.3 to 2.5
Drain Plug 2, 2A, 2B-130 40 to 50 4.5 to 5.7
Screw (Bracket) 2, 2A, 2B-155 25 to 27 Plus 2.8 to 3.0 Plus

Run-Down Torque Run-Down Torque
Screws (End Cap) 2, 2A, 2B-165 12 to 14 1.4 to 1.6
Screws (Primer Discharge Port) 4-10 7 to 9 0.8 to 1.0
Torque Limits—Table 8001
TASK 28-22-04-820-957-A01
3. Wear Limits
No service wear limits are applicable. Refer to CHECK for microfinish requirements.
TASK 28-22-04-820-958-A01
4. Assembly Clearances
A. The assembly fits and clearances are given in Table 8002. The information is referenced by paragraph
to the assembly procedures in ASSEMBLY. (Refer to Table 8002 "TABLE-28-22-04-99A-941-A01" on
page 8002.)
28-22-04 Page 8001

Jan 09/2004
60-989
8002
TABLE 28-22-04-99A-941-A01
Assembly Fits and Clearances—Table 8002
REQUIREMENT
FIT OR CLEARANCE PARAGRAPH FIGURE
INCHES MM
Inlet Adapter (20, IPL Figures 2, 2A, Assembly, 7004 0.007 to 0.020 0.178 to 0.508
and 2B) to Inlet Impeller (35) 4.C, Steps (22)
and (23)
Axial Movement of Inlet Impeller (35) Testing and 1001

Fault Isolation,
6, Step C
Before Test 0.001 to 0.004 0.025 to 0.102
After Test Within 0.002 of Within 0.051 of

pre-test mea- pre-test mea-
surement surement
Primer Impeller (35) to Primer Assembly, 4.B, 7003 0.002 to 0.004 0.051 to 0.102
Discharge Plate (15, IPL Figure 3) Step (18)
Assembly Fits and Clearances—Table 8002
28-22-04 Page 8002

Jan 09/2004
60-989
SPECIAL TOOLS, FIXTURES, AND EQUIPMENT
TASK 28-22-04-99C-970-A01
1. General
A. This section contains summary lists of the special tools, fixtures, equipment, and materials
recommended for use in other sections of this manual.
B. Unless otherwise specified, the special tools, fixtures and equipment shown in Table 9001 and the
materials shown in Table 9002 can be ordered from:
Crane Aerospace
Hydro-Aire, Inc.
3000 Winona Avenue
P.O. Box 7722
Burbank, CA 91510-7722
TASK 28-22-04-94B-971-A01
2. Special Tools, Fixtures, and Equipment
A. The recommended special tools, fixtures, and equipment are given in Table 9001. (Refer to Table
9001 "TABLE-28-22-04-99A-950-A01" on page 9001.)
B. All test equipment must be in current calibration to MIL-STD-45662. The required accuracy is given in
the table of tools, fixtures, equipment, and materials.
9001
TABLE 28-22-04-99A-950-A01
Special Tools, Fixtures, and Equipment—Table 9001
NUMBER
Adapter, Heat Deflector Model 40060 Master Appliance Corp.

(V83284)
Adapter, Nozzle Models 07461, 07051, 07061 Steinel America Inc. (V65309)
Aluminum Ring 2.45 inch (62.23 mm) OD Local Fabrication

1.75 inch (44.45 mm) ID
1.00 inch (25.40 mm) width minimum
(refer to Figure 3002)
Ammeter, AC (3 Required) Model 904; 0 to 10 Amp; ± 0.5% Weston Instruments Inc.

accuracy (V3N285)
Arbor or Hand Press No Specific Commercially Available

*** The Model HG 3002 LCD heat gun is an adjustable heat gun with temperature meter display. Before use,
Special Tools, Fixtures, and Equipment (Sheet 1 of 4)—Table 9001
28-22-04 Page 9001

Jan 09/2004
60-989
NUMBER
Assembly Fixture, Pin Installa- T-66639 Hydro-Aire, Inc. (V81982)

tion
Bioblaster System No Specific USF Surface Preparation Group

(V1RCQ9)
Bright Light (for visual checks) No Specific Commercially Available
Check Valve, Discharge Model 217200-1 (Boeing P/N 10- APCO

60526-2)
Circulating Pump Corcoran Model 2000; 30 gpm (113 Frederick Pump Co. (V04TR4)
lpm) at 30 psi (207 kPa)
Clock, Time Model S-1; 0 to 5 seconds; 0.01 second Standard Instrumentation Inc.
accuracy (V66466)
Crimping Tool, Terminal 49900 Tyco Electronics Corp. (V00779)
Dielectric Tester 100 megohm at 500 Vdc, 6 mA at 1500 Commercially Available

Vac rms; 5% of full scale accuracy
Flow Counter Model 5214-L; 1% accuracy Hewlett-Packard Co. (V28480)
Flowmeter, 1.5 Inch (38 mm) AN 24; 10 to 75 gpm (38 to 284 lpm); Cox Air Gauge System (V86292)
1% accuracy
Frequency Meter Model 22-173; 45 to 999.9 Hz at 0 to Arga Controls Inc. (V50290)

122 °F (50 °C); ± 0.1 Hz accuracy
Gate Valve, 1.0 and 1.5 Inch Models 430 and 438 Crane Co. (V14959)
(25 and 38 mm)
Heat Exchanger Model F606EY2P; 30 gpm (113 lpm) at Young Radiator Co. (V8M984)
100 to 160 °F (38 to 71 °C)
Heat Gun *** Model HG3002 LCD; 60 Hz, 2000 Watt Steinel America Inc. (V65309)
Injection Gun, Adhesive Model 800V EFD Inc. (V0XUL4)
Inlet Tube, Pump Refer to TESTING AND FAULT Local Fabrication

ISOLATION, Figure 1004
Installation Sleeve T-62957 Hydro-Aire, Inc. (V81982)
Magnifying Glass 10X Magnification Minimum Commercially Available
Media Blast Abrasive (MBA) No Specific USF Surface Preparation Group

Cabinet (V1RCQ9)

28-22-04 Page 9002

Jan 09/2004
60-989
NUMBER
Micro-Ohmmeter Model 580; Keithley Instruments Inc.

200 kilohms ±0.075% + 2 count ** (V80164)
200 milliohms ±0.04% + 3 count
Mixer, Pneumatic Mixpac 200 (DP200-70-10) ConProTec
Microswitch Model EX-AR; explosion-proof, Sypris Data Systems Inc.

normally-open (V28009)
Multimeter or Milliohmmeter 1% accuracy Commercially Available

(Continuity Checks)
Oven, Curing Model AF500; 150 to 200 °F The Grieve Corp. (V90423)
(66 to 93 °C); 350 °F (177 °C)
Pin Installation Tool T-66998 Hydro-Aire, Inc. (V81982)
Pliers, Snap Ring No Specific Tru-Arc
Potentiometer Model BB201J; -10 to 1200 °F (-23 to Omega

649 °C) ± 2.8 °F (1.6 °C); ± 0.1%
accuracy
Power Supply, AC Model A3334-1; 200 Vac, 400 Hz, Magnetek Inc. (V0B4V8)
3-Phase, 25 kW
Pressure Gage, JP-4 or Model 1801-T; 0 to 60 psig (414 kPag); U. S. Gage

P-D-680 Fluid 0.5% accuracy
Pressure Switch Model 608G-1; normally-closed, Custom Components Inc.

adjustable 0 to 30 psig (207 kPag) (V62117)
actuation pressure
Punch, Drive Screw Installation T-66932 Hydro-Aire, Inc. (V81982)
Punch, Pin Installation T-66118 Hydro-Aire, Inc. (V81982)
Reservoir No Specific; 600 gallon (2271 liter) Commercially Available

minimum tank
Scale, Weight Model D5; 0 to 10 lbs (4.5 kg) Ohaus Corp. (V85973)
± 0.15%
Soldering Iron Model 900L ESD; 50 Watt Minimum, American Hakko Products Inc.
700 to 825 °F (371 to 440 °C) (V0W6S2)

28-22-04 Page 9003

Jan 09/2004
60-989
NUMBER
Soldering Pot (For Pre-Tinning Model SP-500T; 500 to 600 °F (260 to Plato Products Inc. (V32399)
Wires) 315 °C)
Solder Puller Silverstat Model AS196 Caltronics (V3W576)
Solder Wick No. 3 Chemtronics Inc. (V21267)
Soldering Station Model 927 ESD; 60 Watt, 392 to 899 °F American Hakko Products Inc.
(200 to 480 °C) (V0W6S2)
Test Housing T-32411 (or pump housing subassem- Hydro-Aire, Inc. (V81982)
bly 60-98901, 60-98903, or 60-98905)
Thermocouple Junction Type J, Stainless Steel Sheath; 32 to Omega

1382 °F; (0 to 750 °C); ± 2 °F (1 °C) or
0.5% accuracy, whichever is greater
Torque Wrench 3 to 50 in-lb (0.3 to 5.7 Nm) Commercially Available
Voltmeter Model 433; 0 to 150 Vdc, 0 to 300 Vac; Weston Instruments Inc.
± 0.75% accuracy (V3N285)
Wattmeter Model 3-447; 0 to 333 W X20 (current Arga Controls Inc. (V50290)
ratio); 1% of full scale accuracy
X-Ray Inspection Equipment 160 to 200 kV, 5 mA, and 2.0 minutes Commercially Available
(typical); 35 inches (900 mm) minimum
source to film distance; 0.010 inch
(0.25 mm) thick front and back lead
screen; 0.2 inch (5.6 mm) maximum
focal spot dimension

TASK 28-22-04-94A-971-A01
3. Materials
The recommended materials are given in Table 9002. Unless otherwise specified, equivalent items can be
used. (Refer to Table 9002 "TABLE-28-22-04-99A-955-A01" on page 9005.)
28-22-04 Page 9004

Jan 09/2004
60-989
9002
TABLE 28-22-04-99A-955-A01 Materials—Table 9002
NUMBER
Abrasive Cloth, Aluminum 211K-500J; Federal Specification 3M Co. (V28124)

Oxide P-C-451
Abrasive Cloth, Crocus 011K; Federal Specification P-C-458 3M Co. (V28124)
Adhesive C-111 (V81982 SCD S30-001) Stabond Corp. (V25670)
Aero-Methyl-Ethyl-Ketone RHO-SOLV 7228 (ASTM D740, RHO-Chem Corp. (V21414)

(Aero MEK) Type 1)
Alcohol, Isopropyl Federal Specification TT-I-735, Grade Commercially Available

A or B
Alodine 1200L; SAE AMS-C-5541 Henkel Corp. (V84063)
Anti-Wicking Tweezers, 16 or AW16 or AW18 Clauss Cutlery Co. (V71827)

18 AWG
Applicator, Cotton Tip No Specific Commercially Available

Non-contaminating
Calibration Fluid (Optional Test Military Specification MIL-C-7024 Commercially Available

Fluid)

Cloth, Lint-Free Military Specification MIL-C-85043 Commercially Available
Corrosion Inhibiting Paste, Cor-Ban 27L (Boeing Material Specifi- Atwater-General Corp. (V95037)
Non-Drying cation BMS3-38)
Deionized Water ASTM D1193, Type IV Commercially Available
Epoxy Hardener (60-755100-2 951 ** CIBA Specialty Chemicals Corp.

ONLY) (V99384)
Eraser, Rubber No Specific Commercially Available
Etchant Solution Tetra-Etch ** W. L. Gore and Associates Inc.

(V1BX19)
Film, X-Ray Inspection ASTM E 1815, Class 1 or Better Commercially Available
Film, X-Ray Inspection EN 584-1 Class C2 or Better Commercially Available

(Alternate)

Materials (Sheet 1 of 4)—Table 9002
28-22-04 Page 9005

Jan 09/2004
60-989
NUMBER
Flux Formula 185 ** Kester Solder Division Litton

Flux Paste SP229-25 Kester Solder Division Litton

Flux Remover 5768 Bio-Kleen Saponifier ** Kester Solder Division Litton

Gas, Dry Nitrogen No Specific Commercially Available

free
Gloves, Handling Disposable, clean white cotton Commercially Available
Goggles, Safety No Specific Commercially Available
Grease Aeroshell 16 Shell Oil Co. (V54527)
Jet Fuel, JP-4 Military Specification MIL-T-5624 Commercially Available
Lacquer, Red (FED-STD-595 Federal Specification A-A-3165 Commercially Available

Color No. 11136)

(NASM20995)

(NASM20995)
Mixer, Disposable Statomix MCX-08-24 ConProTec
Mixer, Disposable, Cartridge Mixpac 200 ConProTec
Nitrogen (GN2) or Air Supply 100 psig (690 kPag) Commercially Available
Packings, Housing Test MS29513-212 Commercially Available

MS29513-224
MS29513-229
MS29513-237
MS29513-260
Pad, Abrasive, Mild Scotchbrite 3M Co. (V28124)
Petrolatum Jelly Federal Specification VV-P-236 Plough Laboratories Inc.

(V81982 SCD S31-011) (V26045)
Plastic Cups No Specific Commercially Available

28-22-04 Page 9006

Jan 09/2004
60-989
NUMBER

Potting Mold, Disposable 730609HA or 60-989502 Hydro-Aire, Inc. (V81982)

(60-755100-2 ONLY)
Potting Resin (60-755100-2 220A Epocast CIBA Specialty Chemicals Corp.

ONLY) (V99384)
Primer, Yellow No. T7471 (V81982 SCD S30-052) Loctite Corp. (V05972)
Retaining Compound, Stud Military Specification MIL-S-22473, Commercially Available

Grade C
Retaining Compound, High No. 635 (V81982 SCD S30-069) Loctite Corp. (V05972)
Strength
Seal, Alucast 911H Stoffel Seals Corp. (V01019)
Sealant, High Strength, Coarse No. 08731 (V81982 SCD S30-063) Loctite Corp. (V05972)
Thread, Grade AV
Sealant, Polysulfide Liquid P/S 890, Class B (V81982 SCD S30- PRC-Desoto International Inc.
Polymer, Two-Part, Gray 067) (MIL-S-8802) (V92108)
Shim Stock 0.0015 to 0.0025 inch (0.0381 to Commercially Available

0.0635 mm)
Sleeving, Electrical, Insulation, RT-555-1/8-0 (V81982 SCD S28 G104- Raychem Corp. (V06090)
Heat-Shrink (60-755100-4 0); 0.125 ID (as supplied), Black **
ONLY)
Sleeving, Electrical, Insulation, RT-555-3/16-0 (V81982 SCD S28 Raychem Corp. (V06090)
Heat-Shrink (60-755100-4 G105-0); 0.187 ID (as supplied),
ONLY) Black **
Solder Wire (With Type 285 Sb05AWROL161.57 (J-STD-006) ** Kester Solder Division Litton
Flux) (60-755100-4 ONLY) Systems Inc. (V75297)
Solder (With Type 285 Flux) Sn95Sb05WRMA ** Kester Solder Division Litton
(60-755100-2 ONLY) Systems Inc. (V75297)
Solder, Bar Solid (60-755100-2 Sn95Sb05 ** Kester Solder Division Litton

ONLY) Systems Inc. (V75297)
Solvent, Aqueous No Specific Commercially Available
Spiral Wrap, Teflon T12T (Specify Length) ** Panduit Corp. (V06383)

28-22-04 Page 9007

Jan 09/2004
60-989
NUMBER
Stoddard Solvent (Optional Test Federal Specification P-D-680, Type II Commercially Available
Fluid)
Syringe, Disposable Barrel Reservoir EFD Inc. (V0XUL4)
Tape, Nomex Flat Braided, TNC 20042 (V81982 SCD Trimtex Co. Inc. (V1LNS0)
0.010 Inch Thick (Maximum) X S53-14-02) **
0.080 Inch Wide, Type V
(60-755100-4 ONLY)
Terminal, Crimp Style R-4122SB Electro Term Inc. (V14726)
Terminal, Crimp Style (Alter- 324955 Tyco Electronics Corp. (V00779)

nate)
Thinner, Varnish 6001S The Epoxylite Corp. (V11147)
Tongue Depressor Ultra No. 600SR Applied Technology

Franklin Park, IL
Tubing, Teflon (60-755100-2 AMS3653, No. 4, Standard Wall: Commercially Available

ONLY) 0.208 ID X 0.020 Wall
Varnish 6001 The Epoxylite Corp. (V11147)
Wire, Electrical, 16 AWG, Blue, M22759/12-16-6 (MIL-W-22759/12) Commercially Available

Nickel Plated

28-22-04 Page 9008

Jan 09/2004
60-989
STORAGE
TASK 28-22-04-99C-990-A01
1. General
This section contains storage instructions for the Motor-Impeller Subassembly and Housing Subassembly.
TASK 28-22-04-94A-937-A01
2. Storage Materials
NOTE: Package the component to protect it from humidity and shock before it is shipped and stored.
Repack the component in the original shipping container when possible.
A. The recommended materials are given in Table 15001. (Refer to Table 15001 "TABLE-28-22-04-99A-
960-A01" on page 15001.)
15001
TABLE 28-22-04-99A-960-A01 Storage Materials—Table 15001
NUMBER
Box, Corrugated Paper Federal Specification PPP-B-636 Commercially Available

Paper, Packing Military Specification MIL-B-121, Commercially Available

Grade A

Tag, Identification No Specific Commercially Available
Storage Materials —Table 15001
None.
TASK 28-22-04-620-935-A01
3. Storage Instructions
A. Install an EP-16 cap (Table 15001) over the connector (70, IPL Figures 2, 2A, and 2B).
B. Install protective plugs (Table 7002) in the housing subassembly ports. (See Figure 15001 "GRAPHIC-
28-22-04-99B-890-A01" on page 15002.)
28-22-04 Page 15001

Jan 09/2004
60-989
15001
NO. 17
CAPLUG
C-425 NO. 13
COVER CAPLUG NO. 55-A
CAPLUG (USED WHEN
SHIPPING HOUSING
SUBASSEMBLY ONLY)
CUSHIONING
MATERIAL
POLYETHYLENE
HOUSING
BAG
SUBASSEMBLY
TYPICAL
MOTOR-IMPELLER
SUBASSEMBLY
EP-16
CAPLUG
28-22-04-99B-890-A01-001.cgm
BOX
GRAPHIC 28-22-04-99B-890-A01
Typical Component Packaging
Figure 15001
28-22-04 Page 15002

Jan 09/2004
60-989
C. Pack new packings (5, 10, and 15) in polyethylene bags. Keep the bags with the motor-impeller
subassembly for aircraft installation.
D. Pack the motor-impeller subassembly and/or housing subassembly in a polyethylene bag. Wrap the
bag with cushioning material.
E. Write the unit nomenclature, part number, serial number, and maintenance date on a tag. Attach the
tag to the component.
F. Pack the unit in a corrugated paper box.
G. Write the unit nomenclature, part number, serial number, and maintenance date on the box.
H. Store the unit in a clean, dry room with good ventilation. The room temperature must be kept between
55 to 91°F (13 to 33 °C) with a relative humidity of 25 to 65%.
28-22-04 Page 15003

Jan 09/2004
60-989
28-22-04 Page 15004

Jan 09/2004
60-989
ILLUSTRATED PARTS LIST
TASK 28-22-04-99C-980-A01
1. General
A. This Illustrated Parts List (IPL) illustrates and lists authorized replacement components for the Pump
Assembly. It includes a detailed parts list referenced to detail component illustrations.
B. When equipment designators are used for electrical/electronic parts they are shown in the detailed
parts list and in the Equipment Designator Index.
C. When the detailed parts list is more than five pages, a Numerical Index is included in this section.
D. Vendor Information includes vendor CAGE codes, names, and addresses.
TASK 28-22-04-99C-981-A01
2. Explanation and Usage
A. The IPL FIG. /ITEM column shows the figure number and the item number for each detail part. The
figure number is shown once in the header row. Each part is identified by an item number. A part which
is not illustrated will have a dash (-) before the item number.
(1) Alpha variants, letters A through Z (except I and O), are used with an item number to show:
(a) Alternate parts.
(b) Optional parts.
(c) Service bulletin changes.
(d) Configuration differences.
(2) An alpha variant item number is not shown on the exploded view when the shape and location of
the alpha variant item is the same as the basic item number.
B. The PART NUMBER column shows the part number for each detail part. Use the part number exactly
as shown when procuring parts, except as noted below.
(1) When the part number contains characters that are different from Air Transport Association (ATA)
requirements, the differences are shown in the nomenclature column.
(2) When the part number is more than 15 characters, it is shown in the IPL as follows:
PART NUMBER 1234567 NOMENCLATURE
M55302-60-20C10 .WASHER (Overlength P/N M55302-60-20C100)
(3) When the part number contains a "-" between a number and a letter, it is shown in the IPL as
follows:
BACR12BM223 .BACKUP RING (Complete P/N BACR12BM-223)
(4) When the part number contains a "/" between two numbers, it is shown in the IPL as follows:
M25988-1-009 .PACKING (Complete P/N M25988/1-009)
28-22-04 Page 10001

Jan 09/2004
60-989
(5) When the part number contains a "/" between a number and a letter, it is shown in the IPL as
follows:
M25988-1-009 .PACKING (Complete P/N M/259881-009)
(6) If there is a design change, modification, or change of material for a part, the manufacturer
assigns a new part number. The original and new part numbers are included in the parts list, with
the new superseding number shown as the alpha variant.
(7) When vendor parts are used, the vendor part number is put in the PART NUMBER column and
the vendor CAGE code is put in the NOMENCLATURE column. If applicable, the manufacturer
assigned Control Specification Drawing (CSD) is also put in the NOMENCLATURE column.
Standard parts such as AN, MS, NAS are not given Vendor codes.
(8) When standard parts are used, the standard part number is put in the PART NUMBER column.
Standard parts such as AN, MS, NAS are not given Vendor codes.
C. The AIRLINE PART NO. column is for the airline stock number.
D. The NOMENCLATURE column gives descriptive information about the detail part.
(1) This column contains the keyword(s) and other defining words from the drawing title consistent
with ATA specification 2200. The column can also contain the designation ESDS if electronic
components are electrostatic discharge sensitive, the CAGE code of the company that made the
part (if it is not made by Crane Hydro-Aire, Inc.), the full part number (if it is longer than 15 digits),
any service bulletins that apply to the part, and any obsolete part numbers.
(2) The part listed in the nomenclature column is indented to show the relationship of the part to the
next higher assembly. For example:
Top Assembly
.Detail Parts for Top Assembly
.Sub-Assembly
ATTACHING PARTS
---***---
DELETED
..Detail Parts for Sub-Assembly
..Sub-Sub-Assembly
ATTACHING PARTS
---***---
...Detail Parts for Sub-Sub Assembly
(3) Components subject to modification, deletion, addition or replacement by an issued service

bulletin or Airline Engineering Bulletin (AEB) are annotated to indicate both the pre- and post-SB
configurations. The term (PRE SB XXXX) in the NOMENCLATURE column designates the
original configuration, and the term (POST SB XXXX) identifies assemblies and parts after the
modification has been completed. If an SB is related to an Airworthiness Directive (AD), the AD
number is also identified (AD XXXX).
28-22-04 Page 10002

Jan 09/2004
60-989
E. The EFF CODE column is used to identify different configurations. It shows how parts relate to the top
assembly. Each configuration is assigned a code letter (letters A through Z, except I and O). All detail
parts for a specified configuration are coded with the same letter. A blank space in the effectivity
column shows that the detail part is used on all configurations of the top assembly.
F. The UNITS PER ASSY column gives the total quantity for each part. The abbreviation AR shows that
the total quantity will be identified during assembly procedures. The abbreviation RF shows the item is
shown for reference only.
TASK 28-22-04-99C-982-A01
3. Parts Replacement Data
If parts are interchangeable, the way the parts relate to each other is identified in the NOMENCLATURE
column. A list of the terms used and their definition is as follows:
PARTS LIST
TERM ABBREVIATION DEFINITION
Alternate ALT The part fully meets functional and structural

specifications, but is different in external
dimensions, connection installation, and/or mounting
provisions. Rework or possible modifications can be
necessary.
Optional OPT The part is fully interchangeable in form, fit and

function with the subject part number. This gives a
choice of parts for procurement and support functions.
Preferred PRFD The part is preferred over other alternate or

optional parts shown.
Replaced by REPLD BY The part is replaced by and interchangeable with the

item number shown.
Replaces REPLS The part replaces and is interchangeable with the item
number shown.
Superseded by SUPSD BY The part is replaced by and is not interchangeable with

the item number shown.
Supersedes SUPSDS The part replaces and is not interchangeable with the
item number shown.
Service Bulletins SB PRE Identifies when a service bulletin has an effect on a part.
The use of PRE shows the condition of the part before
the work in the service bulletin is done.
SB POST Identifies when a service bulletin has an effect on a part.

The use of POST shows the condition of the part after
the work in the service bulletin is done.
SB RWK Identifies when a service bulletin has an effect on a part.

The use of RWK shows the part is reworked by the
service bulletin.
28-22-04 Page 10003

Jan 09/2004
60-989
TASK 28-22-04-960-984-A01
4. Equipment Designator Index
A. The Equipment Designator Index is an aid to find electronic and electrical components in the Detailed
Parts List by equipment designator. The equipment designator, figure number, and item number are
given for each entry. (Refer to Table 10001 "TABLE-28-22-04-99A-980-A01" on page 10004.)
B. The EQUIPMENT DESIGNATOR column lists the component equipment designators in alphanumeric
sequence.
C. The GEO LOC column gives the location of the component. Refer to the Figure given in the FIG-ITEM
column and locate the specific grid location on the parts list figure.
D. The FIG-ITEM column gives the IPL figure and parts list item. Refer to the figure and location the item
in the detailed parts list.
10001
TABLE 28-22-04-99A-980-A01
Equipment Designator Index—Table 10001
EQUIPMENT GEO FIG- EQUIPMENT GEO FIG- EQUIPMENT GEO FIG-

DESIGNATOR LOC ITEM DESIGNATOR LOC ITEM DESIGNATOR LOC ITEM
NONE
Equipment Designator Index —Table 10001
TASK 28-22-04-970-985-A01
5. Numerical Index
A. The Numerical Index is an aid to find the parts in the Detailed Parts List by part number. The figure
number, item number, and total quantity are given for each entry. (Refer to Table 10002 "TABLE-28-
22-04-99A-985-A01" on page 10005.)
B. The PART NUMBER lists the component part numbers in alphanumeric sequence, with the numbers
sorted one character at a time from the left to the right.
C. The AIRLINE PART NUMBER column gives the equivalent airline part numbers, when applicable.
D. The FIG. and ITEM columns give the IPL figure and item numbers for the component. Refer to the
specified figure and locate the item number in the detailed parts list.
E. The TTL REQ. (Total Required) column the total number of components required for each item
number. For example, if four screws are required to attach one component, and four components are
required, the total number of screws required is sixteen (4 X 4 = 16).
28-22-04 Page 10004

Jan 09/2004
60-989
10002
TABLE 28-22-04-99A-985-A01 Numerical Index—Table 10002
PART NUMBER AIRLINE PART NO. FIG. ITEM TTL REQ.

AN116963 2 -25A DEL
2A -25A DEL
AN814-4DL 2 -130A 1
2A -130A 1
2B -130A 1
AN814-4DL4 2 130 1
2A 130 1
2B 130 1
BN050050 3 25 1
LEP500-6-5X1 2 -25E 3
2A -25E 3
2B 25 3
LL57N02P14X0 2 -40B 1
2A -40B 1
2B 40 1
LL57N02S14X0 2 -40C 1
2A -40C 1
2B -40A 1
LP22N62S5MX1 2 -25F 3
2A -25F 3
2B -25A 3
2A 15 1
MS122119 4 65 6
MS16627-4112 2 180 2
2A 180 2
2B 180 2
MS171498 3 60 2
MS21090-0833 2 110 1
2A 110 1
Numerical Index (Sheet 1 of 9)—Table 10002
28-22-04 Page 10005

Jan 09/2004
60-989

MS21090-0833 2B 110 1
MS21209F4-15P 4 70 12
MS21318-1 2 145 1
2A 145 1
2B 145 1
MS29512-04 2 135 1
2A 135 1
2B 135 1
MS29513-019 2 170 1
2A 170 1
MS29513-023 2B 170 1
MS29513-027 4 20 2
MS29513-144 2 175 1
2A 175 1
2B 175 1
MS35275-204 2 -25C DEL
2A -25C DEL
MS35275-213 2B -95A 4
2B 75 4
MS35275-215 2 75 4
2A 75 4
2B -75A 4
2B 95 4
MS35275-226 2 95 2
2A 95 2
MS35275-227 2 25 DEL
2A 25 DEL
MS35275-230 2 -95A 2
2A -95A 2
4 10 3
MS35275-245 1 10 5
28-22-04 Page 10006

Jan 09/2004
60-989

MS35276-265 2 155 4
2A 155 4
2B 155 4
M25988-1-149 2 -5A 1
2A -5A 1
2B -5A 1
M25988-1-150 2 -10A 1
2A -10A 1
2B -10A 1
M25988-1-152 2 15 1
2A 15 1
M25988-1-152 2B 15 1
NAS1352C06H4P 2 -25D DEL
2A -25D DEL
NAS1407N3M5 2 45 2
2A 45 2
2B 45 2
NAS1407N5M10 4 30 1
NAS620C10L 2 160 4
2A 160 4
2B 160 4
NAS620C4 2 85 4
2A 85 4
2B 100 4
2B 85 4
NAS620C6 2 100 2
2A 100 2
4 15 3
NAS620C8 1 15 5
2 115 1
2A 115 1
28-22-04 Page 10007

Jan 09/2004
60-989

NAS620C8 2B 115 1
NAS679C04M 2 80 4
2A 80 4
2B 80 4
NKS35276-266 2 40 DEL
2A 40 DEL
PLGA3430010 4 60 4
S24A0-0500-0390 2A 55 AR
2B 55 AR
S24A0-0750-0390 2 55 AR
2A -55A AR
2B -55A AR
S24A2-0500-0390 2A 60 AR
2B 60 AR
S24A2-0750-0390 2 60 AR
2A -60A AR
2B -60A AR
TA54N0632S09 2 165 2
2A 165 2
2B 165 2
TA54N3632S14 2 -40A DEL
2A -40A DEL
60-01333 2 90 1
2A 90 1
60-02927 2 50 1
2A 50 1
2B 50 1
60-05118 3 45 1
60-703108 2 70 1
2A 70 1
2B 70 1
28-22-04 Page 10008

Jan 09/2004
60-989

60-703109 2 125 1
2A 125 1
2B 125 1
60-703119 2 190 2
2A 190 2
2B 190 2
60-70357 2 185 2
2A 185 2
2B 185 2
60-75521 4 25 1
60-75523 4 45 1
60-75524 4 40 1
60-75529 4 5 1
60-75536 3 10 1
60-75538 3 20 1
60-75544 4 35 1
60-75549 2 105 1
2A 105 1
2B 105 1
60-75551 4 50 1
60-75569 3 -20A 1
60-75598 4 -45A 1
60-989 1 -1 RF
60-989-1 1 -1A RF
60-989-2 1 -1B RF
60-989-3 1 -1C RF
60-989-5 1 -1D RF
60-989-6 1 -1E RF
60-989-8 1 -1F RF
60-98901 1 20 1
4 -1 RF
28-22-04 Page 10009

Jan 09/2004
60-989

60-98901A 1 -20A 1
4 -1A RF
60-98902 1 5 1
2 -1 RF
60-98902A 1 5A 1
2A -1 RF
60-98903 1 -20B 1
4 -1B RF
60-98904 1 5B 1
2 -1A RF
60-98904A 1 5C 1
2A -1A RF
60-98905 1 -20C 1
4 -1C RF
60-98906 1 5D 1
2 -1B RF
60-98906A 1 5E 1
2A -1B RF
60-989101 2B 65 1
60-989102 2B 150 1
60-98911 4 -55 1
60-98911-1 4 75 1
60-98914 2 210 1
2A 210 1
2B 210 1
60-98916 2 30 1
2A 30 1
2B 30 1
60-98917 2 35 1
2A 35 1
2B 35 1
28-22-04 Page 10010

Jan 09/2004
60-989

60-98918 2 20 1
2A 20 1
60-98920 3 5 1
60-98921 3 15 3
60-98922 2 205 1
2A 205 1
2B 205 1
3 -1 RF
60-98924 3 35 1
60-98926 3 30 1
60-98928 2 -150A 1
2A -150A 1
60-98931 2 120 1
2A 120 1
2B 120 1
60-98932 3 40 1
60-98933 3 50 1
60-98934 2 -140D 1
60-98935 2 65 1
2A 65 1
60-98939-11 2 195 1
2A 195 1
60-98939-12 3 55 1
60-98944 4 -55A 1
60-98944-11 4 -75A 1
60-98945 2 -20A 1
2A -20A 1
2B 20 1
60-98946 2 -140A 1
60-98947 4 -50A 1
60-98948 2 -150B 1
28-22-04 Page 10011

Jan 09/2004
60-989

60-98948 2 -150B DEL
60-98949 2 -140B 1
60-989501 2B 90 1
60-989550 2 5 1
2A 5 1
2B 5 1
60-989551 2 10 1
2A 10 1
2B 10 1
60-989552 2 -15A 1
2A -15A 1
2B -15A 1
60-989553 2 -25B DEL
2A -25B DEL
60-98956 2 150 1
2A 150 DEL
60-98958 2 140 1
2A 140 1
2B 140 1
60-98972 2 -65A 1
2A -65A 1
60-98973 2 -140C 1
60-98976 1 5F 1
2 -1C RF
60-98976-1 1 5G 1
2B -1 RF
60-98990 2A 116 1
78-16912 3 65 1
78-17512 3 -65A 1
78-17515 2 200 1
2A 200 1
28-22-04 Page 10012

Jan 09/2004
60-989

78-17515 2B 200 1
78-17515-1 2B -200A 1
28-22-04 Page 10013

Jan 09/2004
60-989
6. Vendor Information
The CAGE code, name, and address for the companies that make the parts, materials, special tools, and
test equipment referenced in this CMM are given below. The codes are taken from Cataloging Handbook
H4/H8. No code is given in the parts list when the part is made by Crane Hydro-Aire, Inc. or is a standard
MIL-SPEC part (AN, MS, NAS, etc.).
CODE VENDORS NAME AND ADDRESS
V0B4V8 Magnetek Inc.

Corporate Headquarters
26 Century Boulevard
Nashville, TN 37229-0159
V0W6S2 American Hakko Products Inc.

25072 Anza Drive
Valencia, CA 91355
V0XUL4 EFD Inc.

Specialty Products Division
977 Waterman Avenue
East Providence, RI 02914-1378
V00779 Tyco Electronics Corp.

M/S 38-77
2800 Fulling Mill Road
Middletown, PA 17057
V01019 Stoffel Seals Corp.

400 High Avenue
Nyack, NY 10960
V03038 Long-Lok Fasteners Corp.

14119 Chadron Avenue
Hawthorne, CA 90250-8208
V04TR4 Frederick Pump Co.

1934d John Towers Avenue
El Cajon, CA 92020
V05972 Loctite Corp

1001 Trout Brook Crossing
Rocky Hill, CT 06067-3582
V06090 Tyco Electronics/Raychem

309 Constitution Drive
Menlo Park, CA 94025-1164
V06383 Panduit Corp.

17301 Ridgeland Avenue
Tinley Park, IL 60477-0981
V1BX19 W. L. Gore and Associates Inc.

1500 North 4th Street
Flagstaff, AZ 86004
28-22-04 Page 10014

Jan 09/2004
60-989
V1LNS0 Trimtex Co. Inc.

400 Park Avenue
Williamsport, PA 17701
V1RCQ9 USF Surface Preparation Group

22703 72nd Avenue S, Suite A105
Kent, WA 98032
V11147 The Epoxylite Corp.

9400 Toledo Way
Irvine, CA 19671
V14726 Electro Term Inc.

1601 North Powerline Road
Pompano Beach, FL 33069-1622
V14959 Crane Co.

860 Remington Boulevard
Bolingbrook, IL 60440
V21267 Chemtronics Inc.

8125 Cobb Center Drive
Kennesaw, GA 30152-4386
V21414 Rho-Chem Corp.

425 Isis Avenue
Inglewood, CA 90301-2009
V25670 Stabond Corp.

14010 South Western Avenue
Gardena, CA 90249-3008
V26045 Plough Laboratories Inc.

3022 Jackson Avenue
Memphis, TN 38151
V28009 Sypris Data Systems Inc.

605 East Huntington Drive
Monrovia, CA 91016
V28124 The 3M Co.

Abrasive Systems Division
3M Center
St. Paul, MN 55144-1000
V28480 Hewlett-Packard Co.

Corporate Headquarters
3000 Minuteman Road
Andover, MA 01810-1032
V29907 Omega Engineering, Inc.

One Omega Drive
Stamford, CT 06907-2390
28-22-04 Page 10015

Jan 09/2004
60-989
V3N285 Weston Instruments Inc.

Subsidiary of Schlumberger Ltd.
614 Frelinghuysen Avenue
Newark, NJ 07114-1384
V3W576 Caltronics
410 Lincoln Drive Center
San Mateo, CA 94404-1124
V32399 Plato Products Inc.

Empire State Fuel Products Service Division
18731 Railroad Street
City Of Industry, CA 91748
V50290 Arga Controls Inc.

35 East Glenarm Street
Pasadena, CA 91105-3418
V51588 Roller Bearing Co. of America

400 Sullivan Way
Trenton, NJ 08628
V54527 Shell Oil Co.

1 Shell Plaza
Houston, TX 77001
V62117 Custom Components Inc.

20 Meridian Road
Eatontown, NJ 07724-2267
V65309 Steinel America Inc.

9051 Lyndale Avenue S
Minneapolis, MN 55420
V66466 Standard Instrumentation Inc.

Charleston, WV 25300
V71827 Clauss Cutlery Co.

223 North Prospect Street
Fremont, OH 43420
V75297 Litton Systems Inc.

Kester Solder Division
515 East Touhy
Des Plaines, IL 60018-2675
V8M984 Young Radiator Co.

Dewey Avenue
Centerville, IA 52544
V80164 Keithley Instruments Inc.

28775 Aurora Road
Solon, OH 44139-1891
28-22-04 Page 10016

Jan 09/2004
60-989
V81982 Hydro-Aire, Inc.

3000 Winona Avenue
P. O. Box 7722
Burbank, CA 91510-7722
V83284 Master Appliance Corp.

2420 18th Street
Racine, WI 53401
V84063 Henkel Corp.

Horsham Business Center
300 Welsh Road, Building 2, Suite I
Horsham, PA 19044
V85973 Ohaus Corp.

29 Hanover Road
Florham Park, NJ 07932
V86292 Cox Air Gauge System

Los Angeles, Ca 90000
V90423 The Grieve Corp.

500 Hart Road
Round Lake, IL 60073
V92003 Parker Hannifin Corp.

Aerospace Group Headquarters
14300 Alton Parkway
Irvine, CA 92618
V92108 PRC-Desoto International Inc.

5454 San Fernando Road
Los Angeles, CA 91203
V96124 HR Textron, Inc.

APCO Division
Pacoima, CA 91331-1609
V99017 Protective Closures Co., Inc.

Caplugs Division
2150 Elmwood Avenue
Buffalo, NY 14207-1910
V99384 CIBA Specialty Chemicals Corp.

5121 San Fernando Road W
Los Angeles, CA 90039-1011
28-22-04 Page 10017

Jan 09/2004
60-989
FIGURE 28-22-04-950-880-A01 IPL FIGURE 1

IPL Figure 1
20A
5
10
15
5A
5B
28-22-04-99B-880-A01-001.cgm
GRAPHIC 28-22-04-99B-880-A01
Fuel Boost Pump Assembly
IPL Figure 1
28-22-04 Page 10018

Jan 09/2004
60-989
IPL UNITS
FIG. 1/ PART AIRLINE NOMENCLATURE EFF PER
ITEM NUMBER PART NO. 1234567 CODE ASSY
-1 60-989 PUMP ASSY, Fuel Boost A RF
-1A 60-989-1 PUMP ASSY, Fuel Boost B RF
-1B 60-989-2 PUMP ASSY, Fuel Boost C RF
-1C 60-989-3 PUMP ASSY, Fuel Boost D RF
-1D 60-989-5 PUMP ASSY, Fuel Boost E RF
-1E 60-989-6 PUMP ASSY, Fuel Boost F RF
-1F 60-989-8 PUMP ASSY, Fuel Boost G RF
5 60-98902 . MOTOR-IMPELLER SUBASSY, Fuel A,B 1

Boost Pump (Boeing P/N 60B89004-2)
(28-20, SB, PRE) (See IPL Fig. 2 for
DET BKDN)
5A 60-98902A . MOTOR-IMPELLER SUBASSY, Fuel A,B 1

Boost Pump (Boeing P/N 60B89004-
21) (28-20, SB, POST) (See IPL Fig.
2A for DET BKDN)
5B 60-98904 . MOTOR-IMPELLER SUBASSY, Fuel C 1

(28-19, SB, PRE) (28-20, SB, PRE)
(28-18, SB, POST) (See IPL Fig. 2 for
DET BKDN)
5C 60-98904A . MOTOR-IMPELLER SUBASSY, Fuel C 1

41) (28-19, SB, POST) (28-20, SB,
POST) (See IPL Fig. 2A for DET
BKDN)
5D 60-98906 . MOTOR-IMPELLER SUBASSY, Fuel D 1

(28-20, SB, PRE) (28-19, SB, POST)
(See IPL Fig. 2 for DET BKDN)
5E 60-98906A . MOTOR-IMPELLER SUBASSY, Fuel E 1

61) (28-20, SB, PRE) (28-19, SB,
POST) (See IPL Fig. 2A for DET
BKDN)
5F 60-98976 . MOTOR-IMPELLER SUBASSY, Fuel F 1

(See IPL Fig. 2 for DET BKDN)
- ITEM NOT ILLUSTRATED
28-22-04 Page 10019

Jan 09/2004
60-989
IPL UNITS
5G 60-98976-1 . MOTOR-IMPELLER SUBASSY, Fuel G 1

11) (See IPL Fig. 2B for DET BKDN)
ATTACHING PARTS
10 MS35275-245 . SCREW, Fillister Head 5
15 NAS620C8 . WASHER, Flat 5

- - - *** - - -
20 60-98901 . HOUSING SUBASSY, Fuel Boost A 1

Pump (Boeing P/N 60B89004-1) (28-
19, SB, PRE) (See IPL Fig. 4 for DET
BKDN)
-20A 60-98901A . HOUSING SUBASSY, Fuel Boost A 1

Pump (Boeing P/N 60B89004-1A) (28-
19, SB, POST) (See IPL Fig. 4 for DET
BKDN)
-20B 60-98903 . HOUSING SUBASSY, Fuel Boost B, C 1

Pump (28-19, SB, PRE) (See IPL Fig.
4 for DET BKDN)
-20C 60-98905 . HOUSING SUBASSY, Fuel Boost B,C,D, 1

Pump (Boeing P/N 60B89004-5) (28- E, F, G
19, SB, POST) (See IPL Fig. 4 for DET
BKDN)
28-22-04 Page 10020

Jan 09/2004
60-989

IPL Figure 2
20
25
30
40
45
35
185
190
55
210 60
180
165
5
10
50
15
205
80
120
85
75
28-22-04-99B-881-A01-001.cgm
125
160
155
GRAPHIC 28-22-04-99B-881-A01
Motor-Impeller Subassembly (60-98902, 60-98904, 60-98906, and 60-98976 ONLY) (Sheet 1 of 2)
IPL Figure 2
28-22-04 Page 10021

Jan 09/2004
60-989
IPL Figure 2
195
A
180 PART NUMBERS
200 185 60-98902, 60-98904, 60-98906,
190 175 AND 60-98976
150
110
115
100
170 95
90
105
135
28-22-04-99B-881-A01-002.cgm
130 70
65
140
145
Motor-Impeller Subassembly (60-98902, 60-98904, 60-98906, and 60-98976 ONLY) (Sheet 2 of 2)

IPL Figure 2
28-22-04 Page 10022

Jan 09/2004
60-989
IPL UNITS
-1 60-98902 MOTOR-IMPELLER SUBASSY, Fuel A RF

(28-20, SB, PRE) (See IPL Fig. 1 for
NHA)
-1A 60-98904 MOTOR-IMPELLER SUBASSY, Fuel B RF

(28-19, SB, PRE) (28-20, SB, PRE)
(28-18, SB, POST) (See IPL Fig. 1 for
NHA)
-1B 60-98906 MOTOR-IMPELLER SUBASSY, Fuel C RF

(28-20, SB, PRE) (28-19, SB, POST)
(See IPL Fig. 1 for NHA)
-1C 60-98976 MOTOR-IMPELLER SUBASSY, Fuel D RF

(See IPL Fig. 1 for NHA)
5 60-989550 . PACKING, Preformed 1
-5A M25988-1-149 . PACKING, Preformed (Complete P/N 1

M25988/1-149) (OPT to Item 5)

M25988/1-150) (OPT to Item 10)
15 M25988-1-152 . PACKING, Preformed (Complete P/N 1

M25988/1-152) (PRFD Spare)
-15A 60-989552 . PACKING, Preformed (OPT to Item 1

15)
20 60-98918 . ADAPTER, Inlet A 1
-20A 60-98945 . ADAPTER, Inlet B,C,D 1
ATTACHING PARTS
25 MS35275-227 DELETED
-25A AN116963 DELETED
-25B 60-989553 DELETED
-25C MS35275-204 DELETED
-25D NAS1352C06H4P DELETED
-25E LEP500-6-5X1 . SCREW (V03038) 3
28-22-04 Page 10023

Jan 09/2004
60-989
IPL UNITS
-25F LP22N62S5MX1 . SCREW (V03038)(OPT to Item -25E) 3

- - - *** - - -
30 60-98916 . INDUCER 1
35 60-98917 . IMPELLER, Inlet 1
ATTACHING PARTS
40 NKS35276-266 DELETED
-40A TA54N3632S14 DELETED
-40B LL57N02P14X0 . SCREW, Pan Head, Self-Locking 1

(10-32UNF-2A THD X 1.875 Long)
(V03038)(Not Reusable - Replace at
Overhaul)
-40C LL57N02S14X0 . SCREW, Pan Head, Self-Locking 1

(V03038)(OPT to Item 40B) (PRFD
Spare) (Not Reusable - Replace at
Overhaul)
45 NAS1407N3M5 . PIN, Spring 2

- - - *** - - -
50 60-02927 . PIN, Drive 1
55 S24A0-0750-0390 . SHIM, Washer Type, CRES 301, MIL- AR

S-5059, Full Harness (0.010 Inch Thick
X 0.750 Inch OD X 0.390 Inch ID)
60 S24A2-0750-0390 . SHIM, Washer Type, CRES 301, MIL- AR

S-5059, Full Harness (0.002 Inch Thick
X 0.750 Inch OD X 0.390 Inch ID)
65 60-98935 . CABLE ASSY (SUPSD by Item -65A; A,B,C 1

See SIL 60-989-4-8-15)
-65A 60-98972 . CABLE ASSY (SUPSDS Item 65; See D 1

SIL 60-989-4-8-15)
70 60-703108 . . CONNECTOR (Non-Procurable; 1

Order NHA)
ATTACHING PARTS
75 MS35275-215 . . SCREW, Pan Head 4
80 NAS679C04M . . NUT, Hex 4
28-22-04 Page 10024

Jan 09/2004
60-989
IPL UNITS
85 NAS620C4 . . WASHER, Flat 4

- - - *** - - -
90 60-01333 . . TERMINAL ASSY (Non-Procurable; 1

Order NHA)
ATTACHING PARTS
95 MS35275-226 . . SCREW, Pan Head (SUPSD by Item 2

-95A)
-95A MS35275-230 . . SCREW, Pan Head (SUPSDS Item 2

95)

- - - *** - - -
105 60-75549 . WIRE ASSY, Ground 1
ATTACHING PARTS
110 MS21090-0833 . SCREW 1
115 NAS620C8 . WASHER 1

- - - *** - - -
120 60-98931 . BRACKET ASSY 1
125 60-703109 . . LABEL, Pump Removal 1
130 AN814-4DL4 . PLUG, Drain (Incorrect P/N; Use Item 1

-130A)
-130A AN814-4DL . PLUG, Drain 1
135 MS29512-04 . PACKING, Preformed 1
140 60-98958 . PLATE, Identification (Incorrect P/N; A 1

Use Item -140D)
-140A 60-98946 . PLATE, Identification B 1
-140B 60-98949 . PLATE, Identification C 1
-140C 60-98973 . PLATE, Identification D 1
-140D 60-98934 . PLATE, Identification A 1
ATTACHING PARTS
145 MS21318-1 . SCREW, Drive 1

- - - *** - - -
150 60-98956 . CAP ASSY, End A 1
28-22-04 Page 10025

Jan 09/2004
60-989
IPL UNITS
-150A 60-98928 . CAP ASSY, End B 1
-150B 60-98948 . CAP ASSY, End C, D 1
ATTACHING PARTS
155 MS35276-265 . SCREW, Pan Head 4
160 NAS620C10L . WASHER, Flat 4
165 TA54N0632S09 . SCREW, 6-32 THD (V03038)(Not 2

Reusable - Replace at Overhaul)
- - - *** - - -
180 MS16627-4112 . RING, Retaining, Internal 2
185 60-70357 . HOLDER, Bearing 2
190 60-703119 . BEARING ASSY 2
195 60-98939-11 . STRIP, Insulation (Bonded Inside End 1

Cap Assembly)
200 78-17515 . STATOR ASSY 1
205 60-98922 . ROTOR ASSY (See IPL Fig. 3 for 1

DET BKDN)
210 60-98914 . HOUSING ASSY 1
28-22-04 Page 10026

Jan 09/2004
60-989
FIGURE 28-22-04-950-882-A01 IPL FIGURE 2A

IPL Figure 2A
20
25
30
40
45
35
185
190
55
210 60
180
165
5
10
50
15
205
80
105
85
75
28-22-04-99B-882-A01-001.cgm
110
145
140
GRAPHIC 28-22-04-99B-882-A01
Motor-Impeller Subassembly (60-98902A, 60-98904A, and 60-98906A ONLY) (Sheet 1 of 2)
IPL Figure 2A
28-22-04 Page 10027

Jan 09/2004
60-989
IPL Figure 2A
195
A
180 PART NUMBERS
200
185 60-98902A, 60-98904A,
190 175 AND 60-98906A
150
110
115
170
90 70
105
116
28-22-04-99B-882-A01-002.cgm
135
130
65
140
100
95
145
Motor-Impeller Subassembly (60-98902A, 60-98904A, and 60-98906A ONLY) (Sheet 2 of 2)

IPL Figure 2A
28-22-04 Page 10028

Jan 09/2004
60-989
IPL
FIG. UNITS
2A/ PART AIRLINE NOMENCLATURE EFF PER
-1 60-98902A MOTOR-IMPELLER SUBASSY, Fuel A RF

21) (28-20, SB, POST) (See IPL Fig. 1
for NHA)
-1A 60-98904A MOTOR-IMPELLER SUBASSY, Fuel B RF

for NHA)
-1B 60-98906A MOTOR-IMPELLER SUBASSY, Fuel C RF

for NHA)

M25988/1-149) (OPT to Item 5)

M25988/1-150) (OPT to Item 10)
15 M25988-1-152 . PACKING, Preformed (Complete P/N 1

M25988/1-152) (PRFD Spare)

15)
20 60-98918 . ADAPTER, Inlet A 1
-20A 60-98945 . ADAPTER, Inlet B, C 1
ATTACHING PARTS
25 MS35275-227 DELETED
-25A AN116963 DELETED
-25B 60-989553 DELETED
-25C MS35275-204 DELETED
-25D NAS1352C06H4P DELETED
-25E LEP500-6-5X1 . SCREW (V03038) 3
-25F LP22N62S5MX1 . SCREW (V03038)(OPT to Item -25E) 3

- - - *** - - -
28-22-04 Page 10029

Jan 09/2004
60-989
IPL
FIG. UNITS
30 60-98916 . INDUCER 1
ATTACHING PARTS
40 NKS35276-266 DELETED
-40A TA54N3632S14 DELETED
-40B LL57N02P14X0 . SCREW, Pan Head, Self-Locking 1

Overhaul)
-40C LL57N02S14X0 . SCREW, Pan Head, Self-Locking 1

(V03038)(OPT to Item 40B) (PRFD
Overhaul)

- - - *** - - -
50 60-02927 . PIN, Drive 1
55 S24A0-0500-0390 . SHIM, Washer Type, CRES 301, AR

MIL-S-5059, Full Harness (0.010 Inch
Thick X 0.500 Inch OD X 0.390 Inch
ID) (SUPSD by Item -55A)
-55A S24A0-0750-0390 . SHIM, Washer Type, CRES 301, AR

ID) (SUPSDS Item 55)

ID) (SUPSD by Item -60A)

ID) (SUPSDS Item 60)
65 60-98935 . CABLE ASSY (28-20, SB, PRE) (Not 1

-65A 60-98972 . CABLE ASSY (28-20, SB, POST) 1
28-22-04 Page 10030

Jan 09/2004
60-989
IPL
FIG. UNITS

Order NHA)
ATTACHING PARTS
75 MS35275-215 . . SCREW, Pan Head 4
80 NAS679C04M . . NUT, Hex 4

- - - *** - - -
90 60-01333 . . TERMINAL ASSY (Non-Procurable; 1

Order NHA)
ATTACHING PARTS
95 MS35275-226 . . SCREW, Pan Head (SUPSD by Item 2

-95A)
-95A MS35275-230 . . SCREW, Pan Head (SUPSDS Item 2

95)

- - - *** - - -
105 60-75549 . WIRE ASSY, Ground 1
110 MS21090-0833 . SCREW 1
115 NAS620C8 . WASHER 1

- - - *** - - -
116 60-98990 . BRACKET ASSY (28-20, SB, POST) 1
120 60-98931 . BRACKET ASSY 1
130 AN814-4DL4 . PLUG, Drain (Incorrect P/N; Use Item 1

-130A)
140 60-98958 . PLATE, Identification A 1
ATTACHING PARTS

- - - *** - - -
28-22-04 Page 10031

Jan 09/2004
60-989
IPL
FIG. UNITS
150 60-98956 DELETED
-150A 60-98928 . CAP ASSY, End A,B 1
-150B 60-98948 . CAP ASSY, End C 1
ATTACHING PARTS

- - - *** - - -
190 60-703119 . BEARING ASSY 2
195 60-98939-11 . STRIP, Insulation (Bonded Inside End 1

Cap Assembly)
200 78-17515 . STATOR ASSY 1

DET BKDN)
210 60-98914 . HOUSING ASSY 1
28-22-04 Page 10032

Jan 09/2004
60-989
FIGURE 28-22-04-950-883-A01 IPL FIGURE 2B

IPL Figure 2B
20
25
30
40
45
35
185
190
210 55
60
180
165
5
10
50
15
205
80
105
85
75
A
28-22-04-99B-883-A01-001.cgm
125
160
155
GRAPHIC 28-22-04-99B-883-A01
Motor-Impeller Subassembly (60-98976-1 ONLY) (Sheet 1 of 2)
IPL Figure 2B
IPL Figure 2B
28-22-04 Page 10033

Jan 09/2004
60-989
180
185
A
190 175 PART NUMBER
200
60-98976-1
135
110
115
170
65
90
105 70
135
130
28-22-04-99B-883-A01-002.cgm
100
95
140
145
Motor-Impeller Subassembly (60-98976-1 ONLY) (Sheet 2 of 2)

IPL Figure 2B
28-22-04 Page 10034

Jan 09/2004
60-989
IPL UNITS
FIG. 2B/ PART AIRLINE NOMENCLATURE EFF PER
-1 60-98976-1 MOTOR-IMPELLER SUBASSY (See RF

IPL Fig. 1 for NHA)
-5A M25988-1-149 . PACKING, Preformed (Complete P/ 1

N M25988/1-149) (OPT to Item 5)
-10A M25988-1-150 . PACKING, Preformed (Complete P/ 1

N M25988/1-150) (OPT to Item 10)
15 M25988-1-152 . PACKING, Preformed (Complete P/ 1

N M25988/1-152) (PRFD Spare)

15)
20 60-98945 . ADAPTER, Inlet 1
ATTACHING PARTS
25 LEP500-6-5X1 . SCREW (V03038) 3
-25A LP22N62S5MX1 . SCREW (V03038)(OPT to item 25) 3

- - - *** - - -
30 60-98916 . INDUCER 1
ATTACHING PARTS
40 LL57N02P14X0 . SCREW, Pan Head, Self-Locking 1

Overhaul)
-40A LL57N02S14X0 . SCREW, Pan Head, Self-Locking 1

(V03038)(OPT to Item 40) (PRFD
Overhaul)

- - - *** - - -
50 60-02927 . PIN, Drive 1
28-22-04 Page 10035

Jan 09/2004
60-989
IPL UNITS

MIL-S-5059, Full Harness (0.010
Inch Thick X 0.500 Inch OD X 0.390
Inch ID) (SUPSD by Item -55A)

Inch ID) (SUPSDS item 55)

Inch ID) (SUPSD by Item -60A)

Inch ID) (SUPSDS item 60)
65 60-989101 . CABLE ASSY 1

Order NHA)
ATTACHING PARTS
75 MS35275-213 . . SCREW, Pan Head (Incorrect P/N; 4

Use item -75A)
-75A MS35275-215 . . SCREW, Pan Head 4
80 NAS679C04M . . NUT, Hex 4

- - - *** - - -
90 60-989501 . . TERMINAL ASSY (Non-Procur- 1

able; Order NHA)
ATTACHING PARTS
95 MS35275-215 . . SCREW, Pan Head (incorrect P/N; 4

Use item -95A)
-95A MS35275-213 . . SCREW, Pan Head 4

- - - *** - - -
28-22-04 Page 10036

Jan 09/2004
60-989
IPL UNITS
105 60-75549 . . WIRE ASSY, Ground (Non-Procur- 1

able; Order NHA)
ATTACHING PARTS
110 MS21090-0833 . . SCREW 1
115 NAS620C8 . . WASHER 1

- - - *** - - -
120 60-98931 . BRACKET ASSY 1
130 AN814-4DL4 . PLUG, Drain (Incorrect P/N; Use 1

Item -130A)
140 60-98958 . PLATE, Identification 1
ATTACHING PARTS

- - - *** - - -
150 60-989102 . CAP ASSY, End 1
ATTACHING PARTS

- - - *** - - -
190 60-703119 . BEARING ASSY 2
195 NOT USED
200 78-17515 . STATOR ASSY 1
28-22-04 Page 10037

Jan 09/2004
60-989
IPL UNITS
-200A 78-17515-1 . STATOR ASSY (OPT to Item 200) 1

DET BKDN)
210 60-98914 . HOUSING ASSY 1
28-22-04 Page 10038

Jan 09/2004
60-989

IPL Figure 3
10
20
25
30
15
35
55
65
40
45
50
60
28-22-04-99B-884-A01-001.cgm
GRAPHIC 28-22-04-99B-884-A01
Rotor Assembly
IPL Figure 3
28-22-04 Page 10039

Jan 09/2004
60-989
IPL UNITS
-1 60-98922 ROTOR ASSY, Pump (See IPL Fig. RF

2, 2A and 2B for NHA)
5 60-98920 . PLATE ASSY, Inlet 1
10 60-75536 . LINER, Primer (Bonded) 1
15 60-98921 . TUBE 3
20 60-75538 . IMPELLER, Primer (Non Procur- 1

able - Order Item -20A)
-20A 60-75569 . IMPELLER, Primer (OPT to Item 1

20)
25 BN050050 . RING, Tolerance (V51588) 1
30 60-98926 . PLATE, Primer Discharge 1
35 60-98924 . HOLDER, Thrust Bearing 1
40 60-98932 . PLATE, Thrust Bearing 1
45 60-05118 . WASHER, Thrust 1
50 60-98933 . PLATE, Gimbal 1
55 60-98939-12 . STRIP, Insulation (Bonded) 1
60 MS171498 . PIN, Spring 2
65 78-16912 . ROTOR/SHAFT ASSY (SUPSD by 1

Item -65A)
-65A 78-17512 . ROTOR/SHAFT ASSY (SUPSDS 1

Item 65)
28-22-04 Page 10040

Jan 09/2004
60-989

IPL Figure 4
10
15
PRIMER
CHECK VALVE
5 ASSEMBLY (25)
40
35
20
25
45
20
30
80
75 OUTER
HOUSING
ASSEMBLY
(55)
28-22-04-99B-885-A01-001.cgm
70
50
65
GRAPHIC 28-22-04-99B-885-A01
Housing Subassembly
IPL Figure 4
28-22-04 Page 10041

Jan 09/2004
60-989
IPL UNITS
-1 60-98901 HOUSING SUBASSY, Pump (See A RF

IPL Fig. 1 for NHA)
-1A 60-98901A HOUSING SUBASSY, Pump (See B RF

IPL Fig. 1 for NHA)
-1B 60-98903 HOUSING SUBASSY, Pump (See C RF

IPL Fig. 1 for NHA)
-1C 60-98905 HOUSING SUBASSY, Pump (See D RF

IPL Fig. 1 for NHA)
5 60-75529 . PORT, Primer Discharge 1
ATTACHING PARTS
10 MS35275-230 . SCREW, Fillister Head 3
15 NAS620C6 . WASHER, Flat 3

- - - *** - - -
20 MS29513-027 . PACKING, Prefomed 2
25 60-75521 . VALVE ASSY, Check, Primer 1
30 NAS1407N5M10 . . PIN, Slotted Spring 1
35 60-75544 . . SPRING, Torsion 1
40 60-75524 . . FLAPPER ASSY 1
45 60-75523 . . SEAT, Valve (SUPSD by Item 1

-45A)
-45A 60-75598 . . SEAT, Valve (SUPSDS Item 45) 1
50 60-75551 . STUD, Mounting Aligment A, C 1

(Bonded) (28-19, SB, PRE)
-50A 60-98947 . STUD, Mounting Alignment B, D 1

(Bonded) (28-19, SB, POST)
-55 60-98911 . HOUSING ASSY, Outer A, B 1
-55A 60-98944 . HOUSING ASSY, Outer C, D 1
60 PLGA3430010 . . PLUG SET, Short (0.343 OD) 4

(V92555)
65 MS122119 . . INSERT, Screw Thread (0.164- 6

32UNC THD X 0.246 LG)
28-22-04 Page 10042

Jan 09/2004
60-989
IPL UNITS
70 MS21209F4-15P . . INSERT, Screw Thread,Self-Lock- 12

ing (0.250-28UNF THD X 0.375 LG X
1.5 DIA)
75 60-98911-11 . . HOUSING, Outer A, B 1
-75A 60-98944-11 . . HOUSING, Outer C, D 1
28-22-04 Page 10043

Jan 09/2004
60-989
28-22-04 Page 10044

Jan 09/2004

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COMPONENT MAINTENANCE MANUAL

TO: HOLDERS OF COMPONENT MAINTENANCE MANUAL (CMM) 28-22-04, REVISION 4 DATED

REVISION NO. 5, DATED JAN 09/2004

PAGE NO. DESCRIPTION OF CHANGE EFFECTIVITY

All Pages Reformatted the manual to the current Hydro-Aire All

Title Page Updated the revision number and date. All

Record of Revisions Added Revision 5. All

Record of Temporary Added Temporary Revisions and date. All

28-22-04 Highlights Page 1

THIS PAGE INTENTIONALLY LEFT BLANK

28-22-04 Highlights Page 2

FUEL BOOST PUMP ASSEMBLY

Initial Issue Date: Dec 8/81

COPYRIGHT: 2004 CRANE AEROSPACE, HYDRO-AIRE, INC.

FREEDOM OF INFORMATION ACT (5 USC 552) AND DISCLOSURE OF CONFIDENTIAL

28-22-04 Page TP-2

1 Jan 06/86 Jan 06/86 HA

2 May 15/90 May 15/90 HA

3 Dec 15/93 Dec 15/93 HA

4 Jun 30/00 Jun 30/00 HA

5 Jan 09/04 Jan 09/04 HA

28-22-04 Page ROR-1

THIS PAGE INTENTIONALLY LEFT BLANK

28-22-04 Page ROR-2

RECORD OF TEMPORARY REVISIONS

Keep this record in the front of this document.

When a temporary revision is received:

(1) Put the temporary revision page(s) into this document.

When a permanent revision is received:

(2) Record of the removal date and removers initials.

TEMP ISSUE INSERTED REMOVED

28-22-04 Page RTR-1

THIS PAGE INTENTIONALLY LEFT BLANK

28-22-04 Page RTR-2

SERVICE BULLETIN LIST

Keep this record in the front of this document.

28-22-04 Page SBL-1

THIS PAGE INTENTIONALLY LEFT BLANK

28-22-04 Page SBL-2

LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE SUBJECT PAGE DATE

Description and 1 Jan 09/2004 Cleaning 4001 Jan 09/2004

28-22-04 Page LEP-1

SUBJECT PAGE DATE SUBJECT PAGE DATE

28-22-04 Page LEP-2

SUBJECT PAGE DATE SUBJECT PAGE DATE

28-22-04 Page LEP-3

THIS PAGE INTENTIONALLY LEFT BLANK

28-22-04 Page LEP-4

Introduction ......................................................................................................................................... Intro-1

28-22-04 Page TOC-1

28-22-04 Page TOC-2

FIGURE TITLE PAGE

Intro-1 Example of Maintenance Task Oriented Support System .............................................. Intro-6

28-22-04 Page TOC-3

TABLE TITLE PAGE

Intro-1 Abbreviations and Acronyms .......................................................................................... Intro-3

28-22-04 Page TOC-4

2. Product Support Services

3. Facility and Equipment Requirements

4. Format and Content

28-22-04 Page Intro-1

E. This manual contains: