COMPONENT MAINTENANCE MANUAL 9028A0002 TRANSMITTAL LETTER TO : THE HOLDERS OF COMPONENT MAINTENANCE MANUAL 27-09-15 DATED Jan 30/84. THIS TRANSMITTAL LETTER RE-ISSUES COMPONENT MAINTENANCE MANUAL 27-09-15, DATED Sep 29/89 INCORPORATING REVISION Nor 1 COMPONENT MAINTENANCE MANUAL 27-09-15 DATED Jan 30/84 IS TO BE WITHDRAWN AND DISPOSED OF. File this Transmittal Letter after the Record of Temporary Revisions. All enquiries affecting this manual should be made to: Liebherr-Aero-Technik, Pfanderstrasse 50-52, D-8998 Lindenberg, Federal Republic of Germany. Tel. (08381) 46-1 Telex: 83818123 REASON FOR ISSUE Due to procedural changes and technical data changes affecting several page blocks, with a layout change for the complete manual, CMM 27-09-15 dated Sep 29/89 has been re-issued incorporating Revision No. 1 27-09-15 TRANSMITTAL Page ‘1 of 1 Sep 29/89LIEBHERR (FSCM) 09893 COMPONENT MAINTENANCE MANUAL WITH ILLUSTRATED PARTS LIST POSITION PICK-OFF UNIT Part Number 9028A0002-01 Issued by Product Support Department LIEBHERR-AERO-TECHNIK GMBH Postfach 1363 D-8998 Lindenberg Federal Republic of Germany * @& (08381/46-209) Tx/Ttx 83818123 Initial Issue: Jan 30/84 Revision No. 1 27-09-15 Sep 29/89Copyright Liebherr-Aero-Technik GnbH 1989 This document is given in confidence and may not be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise in whole or part, without the prior written permission of Liebherr-Aero-Technik GnbH. Unless Liebherr-Aero-Technik GmbH (The company) has accepted a contractural obligation in respect of the information and data contained herein such information and data is provided wi responsibility and the company desclaim all liability ari: from its use.LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 RECORD OF REVISIONS REVISION INSERTE! RI 1 | RE-ISSUE ‘Sep 29/89 | — | — —- ooh — - —+ ay 27-09-15 1 aR as /08COMPONENT MAINTENANCE MANUAL 9028A0002 RECORD OF TEMPORARY REVISIONS Temporary Cancelied || Temporary Cc led Number Revision Number by Revision fm ieee eae L eae oa | SRERSRAR (GHSRERGR! SERSSRORS SERSSREREOE! | eae 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 LIST OF EFFECTIVE PAGES SUBJECT PAGE DATE SUBJECT PAGE = DATE TITLE PAGE Sep 29/89 106 Sep 29/89 107 Sep 29/89 RECORD OF 1 Sep 29/89 108 Sep 29/89 REVISIONS 2 BLANK 109 Sep 29/89 110 Sep 29/89 RECORD OF 1 Sep 29/89 M1 Sep 29/89 TEMPORARY 2 BLANK 112 Sep 29/89 REVISIONS 113. Sep 29/89 114 Sep 29/89 LIST OF 1 Sep 29/89 115 Sep 29/89 EFFECTIVE 2 Sep 29/89 116 Sep 29/89 PAGES 117 Sep 29/89 118 Sep 29/89 SERVICE 1 Sep 29/89 119 Sep 29/89 BULLETIN 2 BLANK 120 Sep 29/89 LIST 121 Sep 29/89 122 Sep 29/89 123 Sep 29/89 LIST OF 1 Sep 29/89 124 Sep 29/89 MATERIALS 2 Sep 29/89 125 Sep. 29/89 126 Sep’ 29/89 TABLE OF 1 Sep 29/89 CONTENTS, 2 Sep 29/89 3 Sep 29/89 AUTOMATIC TEST 201 Sep 29/89 4 BLANK REQUIREMENTS 202 BLANK (ATLAS) INTRODUCTION 1 Sep 29/89 2 Sep 29/89 DISASSEMBLY 301 Sep 29/89 302 Sep 29/89 DESCRIPTION 1 Sep 29/89 303 Sep 29/89 AND OPERATION 2 Sep 29/89 304 Sep 29/89 3 Sep 29/89 4 Sep 29/89 CLEANING 401 Sep 29/89 5 Sep 29/89 402 BLANK «6 Sep 29/89 7 Sep 29/89 CHECK 501 Sep 29/89 8 Sep 29/89 502 BLANK TESTING AND 101 Sep 29/89 REPAIR 601 Sep 29/89 FAULT 102 Sep 29/89 602 BLANK ISOLATION 103 Sep 29/89 REPAIR No. 1 601 — Sep 29/89 104 Sep 29/89 602 BLANK 105 Sep 29/89 TEP Page 1 1 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 LIST OF EFFECTIVE PAGES Cont'd SUBJECT PAGE DATE SUBJECT PAGE DATE ASSEMBLY , 701 Sep 29/89 ~—DETATLED._~—=—1001._—SSep 29/89 INCLUDING _702~ Sep 29/89 PARTS LIST 1001-0 Sep 29/89 STORAGE 703 Sep 29/89 1001-1 Sep 29/89 704 Sep 29/89 1001-2 Sep 29/89 705 Sep 29/89 1001-3 Sep 29/89 706 Sep 29/89 1002-0 Sep 29/89 707 Sep 29/89 1002-1 Sep 29/89 708 Sep 29/89 1002-2 Sep 29/89 709 Sep 29/89 710 Sep 29/89 TAL Sep 29/89 712 Sap 29/89 713 Sep 29/89 714 Sep 29/89 715 Sep 29/89 718 Sep 29/89 717 Sep 29/89 118 BLANK FITS AND 801 Sep 29/89 CLEARANCES 802 Sep 29/89 803 Sep 29/89 804 BLANK SPECIAL TOOLS, 901 Sep 29/89 FIXTURES AND 902 Sep 29/89 EQUIPMENT 903 Sep 29/89 904 BLANK ILLUSTRATED TP1001 Sep 29/89 PARTS LIST 1002. BLANK IPL 1 Sep 29/89 INTRODUCTION 2 Sep 29/89 3 Sep 29/89 4 BLANK NUMERICAL 1 Sep 29/89 INDEX 2 Sep 29/89 3 Sep 29/89 4 Sep 29/89 5 Sep 29/89 6 BLANK eee Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 SERVICE BULLETIN LIST SERVICE BULLETIN NUMBER MODIFICATION INCORPORATED IN MANUAL NUMBER | DATE INITIALS, 27-09-15 StageCOMPONENT MAINTENANCE MANUAL 9028A0002 LIST OF MATERIALS NOTE: Approved alternatives can be used for given items. use —- DESIGNATION FScCM 7 > AND SUPPLIERS NAME z alo SPECIFICATION AND ADDRESS Z\ AND SUPPLIERS NAME of/a}z 2/3 SPECIFICATION AND ADDRESS Eg zZ/s/ElzZl2 Biss /2) ela ls Flalolsle(2]s Polythene Bag Usual Supplier x Waxed Paper Usual Supplier x Desiccant Usual Supplier x Clear Varnish Usual Supplier x Ethanol Usual Supplier x 0-E-00760 Typ III Shock absorbent packing Usual Supplier x material Grease 08375 x x Isoflex Alltime SLI Oel 08375 x Isoflex Alltime 24 Sealant N-F0229 x x PR 340 Aerodur Finish (21/100 HO9S1 x Hardener S66/8 ‘HO951 x Thinner €25/90 HO951 x Araldite, Adhesive 08274 x AW 106 Araldite, Hardener 08274 x HV 953U tl 27-09-15 OM Page 2 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 TABLE OF CONTENTS Page INTRODUCTION INTRO 1 1, General INTRO 1 2. Measurements INTRO 1 3. Abbreviations INTRO 1 DESCRIPTION AND OPERATION 1 + General 1 2 Description 1 A. Housing Assembly 1 B. Synchro Transmitter 1 C. Harmonic Drive 3 3. Operation 6 4, Technical Data 6 A. General 7 + Synchro Transmitter 8 TESTING AND FAULT ISOLATION 101 1. General 101 2. Special Tools, Fixtures and Equipment 101 3. Test Procedure 1oL A. General 101 ; Visual Inspection 103 C! Breakout Torque 103 D. Mechanical Zero Setting if the turns are known 104 (1) PPU-Variant B 104 (2) ppu-Variant A 104 (3) Manual mechanical-zero set-procedure 104 (4) Motor-drive mechanical-zero set-procedure 105 E. Bonding Test 107 F. Electrical and Mechanical-zero Position setting 109 (1) General 109 (2) Preparation at the PPU Variant A 109 (3) Manual zero-setting 109 (4) Motor-drive zero-: asetting 112 (5) Fault isolation 114 &. Electrical/Mechanical-zero position re-setting with unknown 115 rotations H. High Voltage Test 118 1. Error Curve Examination 120 (1) General 120 (2) Procedure rat (3) Fault Isolation 124 TOC Page 1 1 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 Page 4. Receptance Test Procedure 125 ‘A. General 125 B. Break-out Torque 125 C. Running-in 125 D. Electrical/Mechanical Zero Position Test 125 E, Bonding Test 125 F. High Voltage Test 125 G. Error Curve Examination 125 H. Resetting to mechanical/electrical zero position 125 I. Final Assembly 126 J. Final visual check 126 AUTOMATIC TEST REQUIREMENT not used 201 DISASSEMBLY 301 1. General 301 2. Procedure 301 A, Disassembly of Harmonic Drive Assembly 301 8. Removal of the Bearing 302 C. Disassembly of the kheel 302 D. Disassembly of the Spindle 302 E. Disassembly of the Cover Plate (Variante A) 302 F. Disassembly of the Frame (Version 8) 302 G. Disassembly of the Connector 304 H. Disassembly of the Synchros 304 CLEANING 401 1. General 401 2. Cleaning of Assembly Parts 401 3. Cleaning of New Parts 401 CHECK 501 1. Design Changes 501 2. Visual Inspection 501 3. Dimensional Check 501 4. Parts Inspection 501 REPAIR 601 1. General 601 2. Removal of Corrosion 601 3. Special Repairs 601 Replacement of the Coil inserts REPAIR No. 1 601 27-09-15 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 ASSEMBLY, INCLUDING STORAGE 701 1. General 701 . Special Materials 701 3. Assembly Procedure 701 A. Assembly of Spindle 701 8. Assembly of a new Housing 702 C. Assembly of Harmonic Drive onto the wheel 102 0. Assembly of Bearing and Seal 704 E. Assembly of Harmonic Drive Assembly 704 F. Run-out Check 106 G. Assembly of Synchro A and Synchro B 708 4. Adjustment of the Synchros and Running-in 710 A. Adjustment of Synchro A Electrical Zero 710 B. Adjustment of Synchro B Electrical Zero 710 C. Running-in of the PPU 72 5. Final Assembly 712 Safety of the Synchros 712 B. Assembly of the Frame (Variant B) 713 C. Assembly of the Cover Plate (Variant A) 713 D. Assembly of the Wiring 713 6. Acceptance Test Procedure : m4 7. Preparation for Dispatch n4 A. Removal of the PPU from Test-set 4 B. Securing 715 C. Cleaning 715 8. Storage 718 A. General 718 B. Preparation and Packing * 716 CL Removal from Storage ny FITS AND CLEARANCES 801 1. General 801 2. Fits and Clearances 801 SPECIAL TOOLS,” FIXTURES AND EQUIPMENT © : 901 27-09-15 TOC Page 3 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 ILLUSTRATED PARTS LIST 1, Introduction General How to use the IPL Symbols and Abbreviations Effectivity Code Vendor Codes eee ee NUMERICAL INDEX DETAILED PARTS LIST IPL: TP_1001 IFL INTRO 1 TFL INTRO 1 IFL INTRO 2 IFL INTRO 2 IFL INTRO 3 IFL INTRO 3 NI (ALPHA) 1 NI (NUM) 4 1001 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 INTRODUCTION 1. General y A. This Component Maintenance Manual has been prepared with the ATA 100 (AIR TRANSPORT ASSOCIATION OF AMERICA) revision 25. This manual gives the necessary data to understand the function, repair and overhaul of the Position Pick-off unit. B. The maintenance instructions are given in these sections: = Description and Operation Test and Fault Isolation Disassembly Cleaning Check Repair Assembly (This includes Storage) Fits and Clearances Special Tools, Fixtures and Equipment. CAUTION: SOME PARTS OF THE POSITION PICK-OFF UNIT ARE PHYSICALLY INTER- CHANGEABLE WITH PARTS FROM DIFFERENT COMPONENTS. TO PREVENT THIS, YOU MUST OBEY THE DATA GIVEN IN THIS MANUAL. C. Two different identified interchangeable PPU's exist. These are indicated in this manual as "VARIANT A" (Serial No. 2000) and "VARIANT B" (Serial No. 2000). 2, Measurements A. The measurements given in this manual are taken from the original manufacturing drawings. B. All values in this manual are given in SI (Systéme International) units or sub-mltiples of these units. US units, where applicable, are given ‘in parentheses. 3. Abbreviations A, The following abbreviations are used in this manual: A Ampere ASSY Assembly aC Alternating Current ATP Acceptance Test Procedure cM Component Maintenance Manual cw Clockwise a 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 ABBREVIATIONS Cont'd Counter-clockwise Diameter Dial Test Indicator Detail Part List Degree Fahrenheit Degree Celsius Figure Ground Hertz Inside diameter Inch Illustrated Parts List Kilogram Line Replaceable Unit Maximum Minimum Minute Millimeter Millivolt Number Outside diameter Position Pick-off Unit Part Number Percent Reference Revolutions per minute Synchro Analog/Digital Converter Systeme International Unit Under Test Volts Alternating Current Volts Direct Current Volts root mean square Micrometer eae Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 DESCRIPTION AND OPERATION 1. General CAUTION A, The the 1. THE PPU IS SUPPLIED LOCKED IN THE MECHANICAL AND ELECTRICAL ZERO POSITION WITH A RED CABLE BINDER. YOU MUST REMOVE THE CABLE BINDER BEFORE THE PPU IS INSTALLED ON THE NEXT HIGHER ASSEMBLY OR TO A HOLDING FIXTURE. 2. THE PPU IS A SENSITIVE INSTRUMENT. WHEN INSTALLING THE PPU THE ATTACHMENT SCREWS MUST NOT BE USED TO COMPLETE SPLINE ENGAGEMENT. position pick-off units (PPU) are self-contained LRUs installed in aircraft flap/slat system. The PPU monitors the flap/slat system for symmetrical operation and feedback of flight surface position. B. The primary components of the PPU are: - Housing assembly ~ Two synchro contro} transmitters = Harmonic drive assembly. C. The power supply for the PPU is from the 26 Vac 400 Hz aircraft system. 2. Description A. Housing assembly (Fig. 1, Fig. 2) (1) (2) 8. Sync (e) The housing assembly is a sealed metal case which contains the two synchro transmitters and the harmonic drive assembly. Four lugs, which are part of the cover assembly, attach the PPU to the aircraft. On one side of the housing is the identification plate and an inspection window on "VARIANT 8", or a cover plate on “VARIANT A". The window is used during assembly and installation to make sure the mechanical zero marks are aligned (refer to Test and Fault Isolation). The two electrical connectors are fitted to the rear of the housing and are identified as A and B. They connect the PPU synchro units to the aircraft electrical system. The front part of the housing contains the harmonic-drive assembly and input shaft. hro Transmitters (Fig. 2, Fig. 4) The two synchro-transmitters (parallel configuration) change the mechanical input to a three-phase output-signal which is transmitted to the aircraft system. 27-09-15 sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 IDENTIFICATION ELECTRICAL FUaTe: CONNECTOFS INSPECTION WINDOW VARIANT 8 ATTACHING LUG % SYNCHRO COVER, LOCKING PLATE Q “8 HOUSING ASSEMBLY HARMONIC-DRIVE cover INPUT-SHAFT FLANGE CABLE BINDER, (TEMPORARY LOCKING DEVICE) PPU General View Figure 1 27-09-15 Sep 29/89(2) COMPONENT MAINTENANCE MANUAL 9028A0002 ‘The synchro-transmitter is a brushless type that contains a transformer and a synchro. The rotating transformer has two parts, the primary winding (stator) connected to the aircraft supply, and the secondary winding internally connected to the synchro rotor. The synchro-stator is a ¥ wound type. The anti-backlash gears has a pin which supplies the output signal. Each synchro is independently attached to an external connector. The input shaft of each synchro has an anti-backlash gear to remove any piay between the synchro- transmitter and the harmonic drive. . Harmonic Drive (Fig. 2, Fig. 3) (1) (2) (3) The harmonic drive is a reduction gear assembly which lets a high gear-reduction occur in the minimum space. The reduction between the input to the PPU and the synchro-transmitters is 358.695:1. Thus when ‘the input shaft turns 368.695 times the synchro-transmitters ‘turns 360° (one turn). ‘The harmonic drive has six primary components: = Input shaft - Wave generator - Circular spline = Dynamic spline = Flexspline = Output wheel and shaft The splined input-shaft is attached to an elliptical wave-generator. A bearing in the housing cover holds the input shaft. The wave- generator’ is installed in a set of ball bearings, and the two are installed in the flexspline. The flexspline is a flexible ring-gear with external gear teeth. The flexspline keeps the same shape as the wave-generator when the wave-generator turns. The flexspline is installed in a fixed circular-spline and a dynamic-spline that turns. These are also ring gears but have internal gear-teeth. The circular-spline has two gear teeth more than the dynamic and flexspline. The dynamic-spline has a splined shaft that connects to the anti-backlash gears of the synchro- transmitters. The circular and dynamic spline gear-teeth mesh with that part of the flexspline which is adjacent to the larger diameter of the wave-generator. The difference in gear-teeth gives a reduction ratio between the input shaft and the dynamic-spline output-shaft of 110:1. A reduction ratio of 75/23 (approximately 3.26:1) between the dynamic- spline output-whee1 and shaft and the synchro anti-backlash drive gears gives a total reduction ratio of 358.695:1. 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL. 9028A0002 COVER, VARIANT A. SYNCHRO, INSPECTION WINDOW TRANSMITTERS VARIANT & ‘SYNCHRO ANTHBACKLASH GEAR HARMONIC DRIVE ASSEMBLY INPUT SHAFT BEARING Sectional View Figure 2 27-09-15LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 OYNAMIC SPLINE ZERO INDICATOR PIN / _svucuro oRVE GEAR BEARING ———__ SYNCHRO A INPUT SHAFT (HARMONIC DAWE) SYNCHRO 8 WAVE, GENERATOR FLEXSPLINE FIXED CIRCULAR SPLINE — (FIXED TO HOUSING) OUTPUT SHAFT OF THE DRIVE WHEEL (HARMONIC DRIVE) OUTPUT SHAFT FIXED CIRCULAR SPLINE (HARMONIC CRIVE) (FIXED TO HOUSING) —_, FLEXSPLINE WAVE GENERATOR —— INPUT SHAFT (HARMONIC DRIVE) BEARING DYNAMIC SPLINE Harmonic Drive Figure 3 27-09-15 Sep 3709COMPONENT MAINTENANCE MANUAL 9028A0002 (4) The spring-tensioned locking plate meshes with the input-shaft splines when the PPU is removed from the aircraft. This locking~ plate locks the harmonic drive and the synchro-transmitters mechanically. 3. Operation (Fig. 1 to 4) A. When the PPU is installed in the aircraft and the electrical system energizes 26 Vac, 400 Hz to the synchro-transmitters at pins A and B, the primary coil of the rotating transformer (stator) is supplied. The energized primary-coil induces a voltage in the secondary coil of the transformer (rotor). As a result of this, a voltage is induced in each of the three phase-coils (S1, S2 and S3)’of the synchro-generator (stator). The voltage amplitude and phase values from the synchro- generator are made available at pins C, D and £. These output values do not change unless the secondary winding of the transformer (rotor) is moved. Pin F of the connector is connected to ground. Movement of the flap/slat system is transmitted to the input, shaft of the PPU. This movenent is decreased (358.695:1) through the harmonic drive that turns the synchro input-shaft and the secondary coil of the transformer. The secondary coil voltage changes continuously in phase and results in the change of the voltage amplitude and phase values of the synchro-generator, in proportion to the movenent of the secondary coil. 4. Technical Data A. General Operating temperature = 55° to + 90°C (~ 67°F to 194°F) Reduction ratio 358.695:1 Maximum input speed 2000 rpm Dimensions: ~ Length 122,8 m (4,83 in) = Width 80,2 mm (3.16 in) - Height 80,5 mm (3.09 in) > Weight 955 g (2.105 1b) Lubricant Isoflex Alltime SL 27-09-15 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 CONNECTORS IDENTIFICATION MASTER GUIDE ROTATING TRANSFORMER PRIMARY SECONDARY MECHANICAL <7 WINDING. WINDING. INPUT ¥ (STATOR) (ROTOR) POSITION PICK-OFF UNIT L REDUCTION 358,605 : 1 SYNCHRO STATOR (CONNECTOR 8 ‘CONNECTOR A SYNCHRO ROTOR Wiring Diagram Figure 4 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 8. Synchro Transmitter (1) Excitation Voltage (t 102) Frequency (#52) Maximum current (no Toad) 200 mA Power Consumption 1.84 Nominal (2) Signal Output Maximum Voltage (no Toad) 11.8 VRMS Maximum Nul1-vol tage 40 mv NOTE: The synchro transmitters operate with the frequency 400 Hz. In shop test operation, the 400 Hz is also used. 27-09-15 sep 25788LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 TESTING AND FAULT ISOLATION 1. General A c. The PPU test, check and fault isolation instructions are given in this section. These procedures identify a failure or a defective assembly, sub-assembly or part. After any repairs, the tests and checks in the Acceptance Test Procedure (ATP) must be done before the PPU can be put into service. All the tests and check procedures must be satisfactory. The unit is tested using Manual Test Equipment (MTE) or Automatic Test Equipment (ATE). Only those tests that require the NTE are given. . These ambient conditions must be obeyed: = Anbient temperature 17 to 27°C (63 to 81°F) ~ Relative humidity 20 to 80% ~ Atmospheric pressure 867 to 1033 mbar (12,57 to 14,88 psi). Refer to the IPL to find the correct parts if replacement is necessary. 2, Special Tools, Fixtures and Equipment AL 8. Refer to Page Block 901 for the necessary tools and test equipment. General equipment Multimeter/Voltmeter (AC) Function Generator (26 ¥, 400 Hz) Synchro Analog/Digital Converter (SADC) (26 V, 400 Hz) with display 3. Test Procedure AL General (1) The test and fault isolation instructions are divided into these sections: Visual inspection + Break-out torque Nechanical zero setting/Manual or with motor-drive Bonding test Etectrical/nechanical zero setting/Manual or with notor-drive High voltage test Error curve examination. NOTE: These individual tests are also used together in the ATP. 27-09-15 Page 101 Sep 29/89LIEBHERR (COMPONENT MAINTENANCE MANUAL 9028A0002 (2) Zero setting There are several zero setting procedures which may be careied out depending on the status of the PPU position or the type of zero setting required. The following list of procedures can be ised: (a) Mechanical zero position setting (refer to section D) Manual: To be used when the PPU's are known to be near the zero position with the zero marks visible and the proper direction is known (electrical zero position is necessary). Motor-drive: To be used when the PPU's are known to be near. the zero position and the zero marks are not visible and the proper direction is known (electrical zero-position is necessary). (>) Electrical and mechanical zero-position setting when the rotation direction is known (refer to section F). Manual: To be used when the mechanical zero-position setting has been done, the zero marks are visible and the mechanical zero-position is to be confirmed electri- cally. Motor-drive: To be used when the number of turns are too many to turn manually but the zero marks are visible and the mechanical zero-position is to be con- firmed electrically. {c) Electrical and mechanical zero-position setting when the rotations are unknown (refer to section G) Notor-drive: To be used when mechanical and electrical zero position is unknown. 27-07-15 Sep 29/89‘COMPONENT MAINTENANCE MANUAL 9028A0002 B. Visual Inspection (1). Examine the unit and make sure al] of the parts are there and that it has no signs of visible external damage. (2) The visual check must include: = General appearence ~ Overall cleanliness of unit and connectors - Legibility of identification plate = Part number, serial number and amendment status = Damage to connector pins. C. Break-out Torque (1) Attach the PPU to the Mounting Plate (55947S0001) (Refer to Figure 101) and install the plate into a vice or equivalent alternative. (2) Install the Torque Adapter (56081$0000) to the input-drive shaft. (3) Attach a spring-balance to the cable of the torque adapter. (4) Measure the break-out torque necessary at initial turn of the input drive shaft. Do this test in a CW and CCW direction. The torque must not be higher than 0,05 Nm (0.44 Ibf in.). (5) If the torque value is higher than required, continue with fault isolation (Refer to table 101). (6) Fault Isolation DEFECT POSSIBLE CAUSE CORRECTION Break-out Harmonic drive Replace harmonic torque too high assembly (1-130) drive assembly and ci defective (1-220, 1-200, 1-170)} | Friction of seal Replace seal (1-200 (1-190) too high and 1-220, 1-190) Bearing (1-210) Replace bearing defective (1-210 and 1-220) (1-200) (1-170). Break-out. torque Fault Isolation Tabte 101 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0c02 D. Mechanical Zero Setting if the turns are known (Ref, Fig. 102) (1) (2 (3) PPU-VARIANT B (a) Look through the inspection window and make sure that the alignment marks can be seen. (b) If the aligment marks can be seen, do the mechanical zero set procedure manually with the Adjustment Mandrel (5594780002) and the Mounting Plate (55947S0001). (c) If the aligment marks cannot be seen, do the mechanical zero set procedure with the Mechanical Test-Set assembly (5218240000) together with the PPU Contro? Box (52183A0000) or equivalent equipment and motor-drive. PPU-VARIANT A only (a) Remove the locking wire, screws (1-360) and washers (1-370), cover (1-350) and gasket (1-380). (b) Continue the procedure as in (1) (b) and (c). Manual mechanical-zero set-procedure (Ref. Figs. 101 and 1C2). (a) Use two screws to attach the PPU to the Mounting Plate. (b) Push the Adjustment Mandrel on to the harmonic input drive shaft. (c) Make sure that the input-drive shaft is free to turn. (d) Install the Mounting Plate into a vice or equivalent alternative. (e) Rotate the input-drive shaft to zero until the drive-gear zero- park ayions with the fixed pointers in the inspection window of ti (f) Remove the Adjustment Mandrel and make sure that the zero mark on the input-drive shaft aligns with the fixed zero mark. If the marks do not align, rotate the input-drive shaft to get alignment. (g) Make sure this is the correct mechanical zero-position. Confirm the zero-position electrically (refer to section F), after bonding test. 27-09-15LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 (4) Motor-drive mechanical-zero set-procedure (Ref. Figs. 101) (a) Fit the PPU to the PPU Mechanical Test-Set (52182A0000) over the ‘two dowle of the support-block. Make sure that the PPU input- drive shaft engages in the splined bush. NOTE: During attachment of the PPU to the Mechanical Test Set make Sure that the input drive shaft zero-mark, the reference mark of the PPU and the mark on the Test-Set handwheel are all set in the vertical position. (b) Rotate the handwheel and make sure the PPU turns freely. (c) Set the motor to ON and rotate the input-drive shaft until the drive gear zero mark is aligned with the fixed pointer, the pin on the synchro transmitter gear is visable and the mark on the test set handwheel is aligned. . (d) Make sure this is the correct mechanical zero-position. Confirm the zero-position electrically (refer to section G) afer bonding test. PPU VARIANT & LOCATION DOWEL MOUNTING PLATE PPU Manual Zero Setting Figure 101 7 27-09-15 sep 9/893COMPONENT MAINTENANCE MANUAL 9028A0002 FIN OF SYNCHRO TRANSMITTER FOR ZERO INDICATION DRIVE GEAR ZERO MARK FIXED POINTER, VIEW ON INSPECTION WINDOW, PPU-VARIANT A. VIEW ON INSPECTION WINDOW, PPU-VARIANT B. HARMONIC DRIVE INPUT SHAFT ZERO MARK — FIXED ZERO ManK ——___ 6 VIEW ON THE DRIVE SHAFT, PPU-VARIANT 8. Aligment data Figure 102 ae i Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 E. Bonding Test (Ref. Fig. 103) Before any electrical connection or test is carried cut this bonding test must be done. (1) Put a constant-current source (load independent current of 1A) from the flange to pin F of the connector A/B, (2) Connect a Mi11i-Volt-meter from the GND connection of the PPU- housing to pin F of the connector A/B, (3) Neasure the voltage drop. The voltage drop must not be higher than 20 mV. (4) If the voltage drop is a a tolerance, continue with fault isolation (Refer to table (5) Fault isolation DEFECT POSSIBLE CAUSE CORRECTION Resistance too (a) Internal GND connec- | Disassemble the high (voltage tion at the PPU PPU and make the * | drop too high) housing is not contact better sufficient (b) Connector Pin F Disassemble connection is not connector and make sufficient Pin F connection better 4 Bonding test Fault Isolation Table 102 (6) Repeat the bonding test after any maintenance or connection. 27-09-15 sen99/89COMPONENT MAINTENANCE MANUAL 9028A0002 CONTACT ARRANGEMENT CF CONNECTOR A AND B MASTER GUEE PPU HOUSING CONNECTOR A CONNECTOR 6 LOAD LOAD INDEPENDENT INDEPENDENT! mv CURRENT 18, CURRENT 1A 20mv WIRING CONNECTION TO SECTION A ——— WIRING CONNECTION TO SECTION 8 Hiring Arrangement for Bonding Test Figure 103 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 F, Electrical and Mechanical-zero Position setting (Ref. Fig. 104) (1) General (2 (3 ) This test gives data to align the electrical zero position of the synchros.and the mechanical zero. The test can be made with one of these: - Coarse/Fine Selector (52173A0000) and the associated Connection Cables = PPU Control Box (52183A0000-01) with the connection cables and the PPU sensor cable (Refer to Fig. 105) - Wiring circuit (Refer to Fig. 104) with Connector Assembly (5594780200). NOTE: 1. If the zero position can be seen or is known to be close, perform the manual procedure using the Coarse/Fine Selector (52173A0000) together with the Mounting Plate (5594780001) and the Adjustment Mandre? (55947S0002). 2. If the zero position is not visible, is unknown or is fully out off adjustment, the motor-drive zero reset procedure should be used. 3. The zero set procedure using the Coarse/Fine Selector (52173A0000) is described in the dedicated Test Equipment Nanual. The zero set procedure using the wiring circuit diagram Fig, 104 is described in this CMM. Preparation at the PPU-Variant A (a) Remove the locking wire, screws (1-360) and washers (1-370), plate (1-350) and gasket (1-380). Manual zero setting (Ref. Fig. 101, 102 and 104) (a) Use two screws to attach the PPU to the Mounting Plate. ({b) Push the Adjustment Mandrel on to the harmonic input drive » shaft. (c) Make sure that the input-drive shaft is free to turn. (d) Insta] the Mounting Plate into a vice or equivalent. alternative. rele Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 A 100k21% Ct 8. ©. R2 (St g3 0. 1 EASURING. ! 1002 1% RANGE OF ' VOLTMETER t 200 MILLIVOLT Ri s2 ' E. i MEASUREMENT REQUIREMENTS: COURSE A} MAX ADJUSTMENT, COURSE B: J MAX 26v FINE A: MN ACUSTENT, FINE 8: S$ MAX 4omv TOLERANCE BETWEEN FINE A AND FINE B MAX 100mVv COARSE A. COARSE B FINE A?) setector — SWITCH 2 FINE B® 400H2 CONNECTION FOR S¥NCHRO A = CONNECTION FOR SYNCHRO 8 Wiring Arrangement for Setting Electrical Zero Figure 104 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 (e) Turn the input-drive shaft until the drive gear zero mark aligns with the fixed pointer, the pin on the synchro transmitter gear ‘is visable and the mark on the test set handwheel alignes with the reference mark. CAUTION: THE POWER SUPPLY MUST BE SET TO ‘OFF’ BEFORE YOU CONNECT THE COARSE/FINE SELECTOR CIRCUIT. (f) Insta] the Connection Cables to the Coarse/Fine Selector wiring circuit terminals and to the PPU connectors A and B. (g) Set the selector switch to the COARSE A position. (h) Supply the PPU with 26 ¥, 400 Hz. NOTE: The Test Set-up must be switched on for half an hour before adjustment. is started. (i) Turn the input-drive shaft in the eiter direction until the voltmeter shows a maximum voltage of approximately 36 V. (5) Set the selector switch to the FINE A position. ({k) Turn the input-drive shaft until the voltmeter shows a minimum voltage indication of max. 40 mY. The drive gear zero mark indicator must align with the fixed pointer and zero indicator pin must be visible in the window of the PPU. NOTE: One complete turn on the input-drive shaft about the zero position is equivalent to a voltage change of approximately 200 mV. (1) With the PPU in FINE A zero position, set the selector switch to FINE B position. The voltmeter voltage indication should remain constant and must not exceed 100 mV. The zero mark on the input- drive shaft can deviate from the fixed zero mark by only ¢ 45°. If the deviation is more than 100 mV (+ 45°), the PPU is out of the specified zero position tolerance. Continue with fault isolation (Refer to table 104). (m) If the deviation is less than 45° or less than 100 mV rotate by hand to align the input-drive shaft with the fixed zero mark. (n) Set the power supply to OFF and remove the Connection Cables. 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 (4) Motor-drive zero setting (Ref. Figs. 102, 104 and 105) NOTE: 1. Use the PPU Control Box (52183A0000-01) and the PPU Mechanical Test Set (52182A0000), this will reduce the mechanical and electrical zero position set procedure time. 2. The procedure can also be completed with an equivalent test set assembly together with the Coarse/Fine Selector wiring circuit (Refer to Fig. 104) (a) Fit the PPU to the PPU Mechanical Test-Set over the two dowels of the support-block. Make sure that the PPU input drive shaft engages in the splined bush. NOTE: During attachment of the PPU to the Mechanical Test-Set make sure that the input-drive shaft zero mark, the reference mark of the PPU and the mark on the Test-Set handwheel are all set in the vertical position. (b) Turn the handwheel and make sure the PPU turns freely. CAUTION: THE POWER SUPPLY MUST BE SET TO 'OFF' BEFORE YOU CONNECT THE COARSE/FINE SELECTOR CIRCUIT. (c) Install the Connection Cables to the Coarse/Fine Selector wiring circuit terminals and to the PPU connectors A and B. (d) Set the selector switch to the COARSE A position. (e) Supply the PPU with 26 V, 400 Kz. NOTE: The Test Set-up must be switched on for half an 1our before adjustment is started. (f) Switch the motor ON and turn the input-drive shaft in one direction to get the mechanical zero position and the voltmeter shows the maximum voltage indication (max. 36 V). The drive gear zero mark indicator must align with the fixed pointer and the zero indicator pin must be visible in the window of the PPU. NOTE: One complete turn of the input-drive shaft about the zero position is equivalent to a voltage change of approximately 200 mV. (g) Set the selector switch to the FINE A position. eae Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 VOLTMETER RANDWHEEL WITH SETTING. MARKS voToR pee eteeee SELECTOR REVOLUTION COUNTER WITH 26V 400Hz See RESS osteo aie SCHEMATIC TEST SET-UP PPU CONTROL BOX HANOWHEEL TEST EQUIPMENT TEST SET-UP Test Set-up for PPU testing Figure 105 , 27-09-15 oeCOMPONENT MAINTENANCE MANUAL 9028A0002 (h) With handwheel, rotate the input-drive shaft to get a minimum voltage indication of max. 40 mV. Gi With the PPU in the FINE A zero position, set the selector switch to FINE B position. The voltmeter voltage indication should remain constant and must not exceed 100 mV. The zero mark on the ee shaft can deviate from the fixed zero mark by only t 45°. If the deviation is more than 100 nV (4 45°) the PPU is out of the specified zero position tolerance. Continue with fault isolation (Refer to table 103). (§) If the deviation is less than * 45° rotate by hand to align the input-drive shaft zero mark with the fixed zero mark. (k) Switch off the 26/400 Hz power supply and remove the connection cables. (5) Fault Isolation DEFECT PROBABLE CAUSE CORRECTIVE ACTION (1) Voltage more (a) Synchro Transmitter | Replace the Synchro than 36 V A defective Transmitter A (COARSE A) and 40 mV (FINE A) (b) Synchro Transmitter | Mechanical/electri- ‘in mechanical A position to the cal zero adjustment zero-posi tion mech. zero position | necessary (refer to incorrect page block 700) (2) Voltage more (a) Synchro Transmitter | Replace tae synchro than 100 m¥ B defective Transmitter 8 (FINE B) in mech. zero position refer FINE A, OR Zero position Synchro transmitter | Mechanical/electri- deviation of the |B position to the | cal zero adjustment input-drive shaft] mech. zero or to the | necessary (refer to more than * 45° synchro transmitter | Page Block 700 - A out of adjustment | ASSEMBLY Para. 4.) Mechanical/Electrical zero Position Test Fault Isolation Table 103 27-09-15 Page 114 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 G. Electrical/Mechanical zero-position re-setting with unknown rotations (Ref. Figures 101, 104, 105, 106 and Table 104) (1) (2) (3) (4) (5) General This test gives data to align the electrical zero position of the synchros and the mechanical zero. The test can be made with one of these Special Tools: - Coarse/Fine Selector (52173A0000) and the associated Connection Cables - Wiring circuit (Refer to Fig. 104) with Connector Assembly (5594780200) = PPU Control Box (52183A0000-01) with connection cables and the PPU sensor cable (Refer to Fig. 105). This procedure should be carried out in motor-drive mode. The relation between the rotations of the input-drive shaft, the harmonic drive and synchros to the electrical/mechanical zero position is shown in Figure 106, Install the PPU in the test set-up, connect the cables (Refer to F.(4), set the selector switch to COARSE A and switch the power supply 26V/400 Hz to on. Allow for the warm up time of the test circuit. Switch the motor ON, rotate the input-drive shaft in either direction until the next electrical zero-position is reached. The voltmeter must indicate a maximum voltage (approximately 36V if wiring circuit is used). Set the selector switch to the FINE-A position and carry out the fine tuning until the voltmeter indicates a minimum voltage (but not more than 40 mV, if wiring circuit is used). Rotate the input-drive shaft in either direction to the nearest ete Zero-position and record the number of rotations and the rection, 27-09-15 Sep 29/89LIEBHERR 9028A0002 COMPONENT MAINTENANCE MANUAL © uaz TWOWLOSTS/WOINVHOIN, 139 OL SNUNL BY39 BAIS OINOMVH & SMOHS Z NIIIOD ® 9 3NIT 1 NINTT00 So! STavL 338 © SNOILWLOB LIVHS SAIN LNgNt ee cet 40 NoWo3UIG ONY BaaNNN 3H CHOOSE CNY O43Z TWOINYHOAN :oW (OM) OH3Z TVOINVHO3W LSSYV3N 3HL 4338 @) OY3Z WOKLOITS :03 (03) OY3Z TWOILO313 SHL ONS @ t31GWYX3 tye : ozs evs tie $982 © |_| Leez go98 aN LavHS BAO LNdNI— anwa SINOWEYH — O¥HONAS ~ Nowisod ou3z ) 40 SNOLLVILOM AWOLOSTA/WOINVHOAN \ / Page 116 Sep 29/89 27-09-15 Electrical /Mechanical Zero-Position Schematic Figure 106LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 COLUMN 1 COLUMN 2 COLUMN 3 NUMBER OF ROTATIONS FURTHER ROTATIONS FURTHER ROTATIONS IN OF THE INPUT DRIVE IN THE SAME DIRECTION THE OPPOSITE DIRECTION SHAFT REQUIRED FROM OF THE INPUT DRIVE SHAFT OF THE INPUT DRIVE SHAFT ELECTRICAL ZERO TO TO ACHIEVE ELECTRICAL TO ACHIEVE ELECTRICAL THE NEXT ALIGNMENT OF MECHANICAL ZERO (ROTATIONS | MECHANICAL ZERO (ROTATIONS| THE DRIVE GEAR ZERO MARK | OF THE DRIVE GEAR) OF THE DRIVE GEAR) 4,78 1430 (13) 6820 (62) 9.57 2860 (26) 5390 (49) 14,35 4290 (39) 3960 (36) 19,13 $720 ($2) 2530 (23) 23,91 7180 (65) 1100 (10) 28,69 330 (3) 7920 (72) 33,48 1760 (16) 6490 (59) 38,26 3190 (29) 5060 (46) 43,04 4620 (42) 3630 (33) 47,83 6050 (55) 2200 (20) 52,61 7480 (68) 770 (7) 57,39 660 (6) 7590 (69) 62,17 2090 (19) 6160 (56) 66,96 3520 (32) 4730 (43) 71,74 ¢ 4950 (45) 3300 (30) 76,52 6360 (58) 1870 (17) 81,30 7810 (71) 440 (4) 86,08 990 (9) 7260 (66) 90,87 2420 (22) 5830 (53) 95,65 3850 (35) 4400 (40) 100,43 5280 (48) 2970 (27) 105,22 6710 (61) 1540 (14) Table of Rotation Record Table 104 27-09-15 1 aatearas(6) (7) (8) LIEBHERR COMPONENT MAINTENANCE MANUAL. 9028A0002 With the recorded number of rotations, select the respective line of column 1, Table 104. Refer to column 2 and column 3, determine the appropriate number and direction of rotations required to achieve the correct electrical/mechanical zero. NOTE: 1) If the rotations of the input-drive shaft can be measured, use the number of rotations of the input-drive shaft. 2) If the input-drive shaft is rotated by equivalent equipment visually count the number of turns of the harmonic drive gear. Adjust the electrical/mechanical zero-position with the selector settings COARSE A, then FINE A and finally FINE B. A voltage deviation between FINE A and FINE B more than 100 mV (if wiring circuit is used) on a deviation of the input-drive shaft of t 45° from the fixed zero-mark, shows that the PPU is out of tolerance. Continue with fault isolation (Refer to table 104). If the deviation is less than 7 45°, turn the input-drive shaft in the direction of the fixed zero mark until the two marks align. Switch OFF the 26V/400 Hz power supply and remove the connection cables. |. High Voltage Test NOTE: This test is only applicable if the PPU has been disassenbled or a (1) fault has been found. General This test can be made with one of these: - PPU High Voltage Test Box (52186S0000) with the applicable connection cables to a 400 VOC voltage generator. = Voltage generator (400 VDC) and applicable connection cables. ae sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 (2) Procedure Do the high-voltage test with 400 VDC at the pin connection given in table 105. FROM PPU To PPU CONNECTOR | PIN CONNECTOR PIN A A GND * A c GND * LL B Guo * B c GND * A A B A A A B c A c 8 A A c B c * GND = HOUSING (Refer Fig. 103) High Voltage Connections Table 105 (3) Specified value The current of each measurement must be 40 yA. If the test is not satisfactory continue with fault isolation (Refer to table 106). 27-09-15COMPONENT MAINTENANCE MANUAL 9028A0002 (4) Fault Isolation (Refer to table 106) DEFECT POSSIBLE CAUSE CORRECTION Current measured Defective insulation in High Voltage Test too high lation. Synchro defective Replace Synchro. Connector defective Replace Connector High Voltage Test Fault Isolation Table 106 I. Error Curve Examination NOTE: A record of the error curve is only necessary for units chat have been disassembled during maintenance. (1) General This procedure gives the electrical deviation curve of the synchro- transmitters and the gear transmission related to 360 degrees (approximately 360 turns of the input-drive shaft), A record of the error curve can be made with one of these: - PPU Control Box (52183A0000-01), the associated PPU Mechanical Test Set Assembly (52182A0000) and the applicable cables related to the Test Set-Up (refer to Fig. 105). Additionally, a Synchro Analog/Digital Converter and a power supply 26V/400 Hz is also used - Alternative equipment as necessary to the test set-up in Fig. 107. ove Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 DISPLAY | a PPu REVOLUTION COUNTER WITH EXACT ZERO POSITION 26v 200H2 12VA\ Schematic Test Set-up for Shop Testing Figure 107 (2) Procedure NOTE: The PPU must be in the mechanical zero position. (a) Record the error curve in increments of ten rotations at the input-drive shaft. (b) Refer to Table 107 for the rotations of the input-drive shaft in relation to the synchro transmitter turns. (c) The deviation from the nominal value must not be more than . -£0,42°, The accuracy of the SADC is not included. An example of ‘an error curve is given in figure 108. Examine the recorded diagram and find the maximum deviation. 27-09-15 1 sen 99y85COMPONENT MAINTENANCE MANUAL 9028A0002 Examp) Synchro-Transmitter A Number of input shaft rotations: Recorded error-curve value: * Nominal value from table 107 Actual value (30.109° + (-0.200°) Nominal value including tolerance + oe 30 -_0.200° 30.109° 30.309° 30.529° 29.689" Result: Error-curve value 30.309° within specified value. max min * NOTE: The nominal value does not include the accuracy of the SDAC. DEVIATION FROM NOMINAL VALUE “+0,42°-ACCURACY OF SADC +t CURVE OF ERROR GF SYNCHRO A +0200 +0.180-4 260" ROTATIONS OF : ‘SYNCHRG OUTPUT 0,100 4 [oecrees} 0200-4 "|| saupce FoR ERROR . CURVE DETERMINATION: —O.42"FACCURACY OF SADC" /APPROXBIATELY 30 ROTATIONS & 30,109" DEVIATION FROM NOMINAL VALUE +0,42°-ACCURACY OF SADC. ‘CURVE OF ERROR ae GF SYNCHRO 8 ' +0.200-4 +0,100-] ° =0,100- ~0.200-| 0.42" + ACCURACY OF SADC Example of Error Curve, Synchros A and B Figure io8 960" ROTATIONS OF SYNCHRO OUTPUT [pecrees) 27-09-15 Page 122 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 Rotations of, Rotations of Input-Drive Shaft Synchro-Output (Degrees) 0 +000 10.0 10.036 20.0 20.073 30.0 30.109 40.0 40.145 50.0 50.182 60.0 60.218 70.0 70.255 80.0 80.291 90.0 90.327 100.0 100.364 110.0 110.400 120:0 120.436 130.0 130.473 140.0 140.509 150.0 150.546 160.0 160.582 170.0 170.618 180.0 180.655 190.0 190.691 200.0 200.727 210.0 210.764 220.0 220.800 230.0 230. 240.0 240.873 250.0 250.909, 260.0 260.945 270.0 270.982 280.0 281.018 290.0 291.054 300.0 301.091 310.0 311.127 320.0 321.164 330.0 331.200 340.0 341.236 350.0 351.273 360.0 1,309 Nominal Values of Synchro-Gutput (Degrees) in relation to the Rotations of Input-Drive Shaft Table 107 27-09-15 sep 29/88COMPONENT MAINTENANCE MANUAL 9028A0002 (d) If the deviation is not within the ee values, continue with fault isolation (refer to table 108). (e) If the deviation is within the values, set the electrical/mechanical zero position. (3) Fault Isolation DEFECT PROBABLE CAUSE CORRECTIVE ACTION Error Curve (a) Wheel 1-270 and/or | Make an inspection of out of spindle (1-300) wheel and compare with ‘tolerance worn table of fits and clearances. Replace if necessary (b) Synchro A Replace defective or synchro B (2-120)| synchro defective Error Curve Excess Fault Isolation Table 108 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 4, Acceptance Test Procedure A. General The ATP must to be done when the assembly procedures are completed. The ATP includes the individual procedures from the input test procedures, which are given as references only. The test procedure must be done in sequence and all previous sub- procedures must be completed and satisfactory. B. Break-out Torque (refer to section 3.C.). ¢. Running-in NOTE: This procedure must be done when components that are worn or damaged and/or their position dependent parts are replaced. (1) General This test can be made with the PPU Control Box (52183A0000-01), the PPU Mechanical Test~Set (52182A0000) or a suitable test set-up. (2) Procedure (a) Operate the PPU CCW for 360 input shaft rotations, then CW for a further 360 input shaft rotations. Continue this procedure for approximately 30 min. (b) Repeat the break-out torque procedure and the electrical- mechanical zero position test. Electrical/Mechanical Zero Position Test (Refer to section 3.D.). Bonding Test (Refer to section 3. E.). High voltage Test (Refer to section 3.H.). Error Curve Examination (Refer to section 3.1.). zepmmoso ls Resetting to mechanical/electrical zero-position (Refer to section 3.D or 3.F).. 27-09-18 1 : sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 I, Final Assembly (1) Remove the PPU from the Mounting Plate (55947S0001) and make sure it is in the zero position. Install a cable binder (1-430) behind the locking plate (Refer to Fig. 1). (2) Attach a label to the PPU that shows that the component is locked in the electrical/mechanical zero position. J, Final visual check When the PPU is serviceable this final visual check must also be done: (1) Make sure that the data on the identification plate are correct. (2) Make sure that the screws are correctly wire locked. (3) Make sure that a layer of sealant PR 340 is applied to the screws (1-70, 1-140) and the cover (1-85). cca Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 AUTOMATIC TEST REQUIREMENTS (ATLAS) NOT USED 27-09715 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 DISASSEMBLY . General (Ref. IPL Figs. 1 and 2) A This section gives the procedure for the disassembly, of the unit. Complete disassembly is not usually necessary. Refer to Page Block 101 - TESTING AND FAULT ISOLATION to find the disassembly necessary to replace or repair a component. 8. Only replace those items which are damaged or defective. C. Refer to Page Block 901 - SPECIAL TOOLS, FIXTURES AND EQUIPMENT. - Procedure (Ref. Fig. 301) A. Disassembly of the Harmonic Drive Assembly (1-130) (1) Remove and discard the safety-wire from the screws (1-20). (2) Remove the screws (1-20) and the washers (1-30). CAUTION: MAKE SURE THAT THE LOCKING PLATE (1-40) IS NOT AT AN ANGLE TO THE SHAFT OF THE HARMONIC DRIVE ASSEMBLY DURING REMOVAL. (3) Remove the flange (1-10), the plate (1-40) and the springs (1-50). (4) Remove the Sealant, PR 340, from the cover (1-85). (5) Remove the screws (1-70) and the washers (1-80). NOTE: A layer of sealant PR 340 is applied to screws (1-70). During disassembly, the screw head can break off. If the screw head breaks off, remove the remaining part of the screw and replace the coil insert (1-320) (Ref. Page Block 601 - REPAIR). (6) fee cover (1-85) with attached parts of the harmonic-drive NOTE: The dynamic spline of the harmonic-drive, attached to the wheel (1-270), remains in the housing (12340), (7) Remove the screws (1-140) and washers (1-150). (8) Remove circlip (1-160), shim (1-170) and push out the drive shaft of harmonic-drive (1-130) with the wave generator, bearing, flexspline and fixed circular spline from cover tinss}. cae Sep 29/89LIEBHERR (COMPONENT MAINTENANCE MANUAL. 9028A0002 (9) Remove the pins (1-120) and/or the setscrew (1-90) only if they are damaged. Removal of the Bearing (1-210) and the Seal (1-190) from Cover (1-85) (1) Remove the circlip (1-230), spacer (1-220), bearing (1-210), spacer (1-200) ‘and the bush (1-180). (2) Press out the seal (1-190) and discard. . Disassembly of the Wheel (1-270) (1) Get access to the alignment holes in the synchro-transmitter anti backlash-gears (2-120) ‘through the access holes. in the dynamic spline and wheel (1-270). To keep the gears in the spring-loaded mode put two 2 mm diameter pins into the alignment holes. ‘Refer to Fig. 702). (2) Remove the circlip (1-240), the shim (1-250) and the shims (1-260) (3) Remove the whee] (1-270) together with the dynamic spline of harmonic-drive assembly (1-130). (4) Remove the screws (1-280) and remove the wheel from the dynamic spline of the harmonic-drive assembly. . Disassembly of the Spindle (1-300) (1) Remove the screws (1-310). (2) Remove the spindle (1-300). . Disassembly of the Cover Plate (1-350A) (Variant A) (1) Remove and discard the safety wire from the screws (1-360A), (2) Remove the screws (1-360A), the washers (1-370A), the cover plate (1-350A) and the gasket (1-380A). . Disassembly of the Frame (1-385) (Variant B) (1) Remove and discard the safety wire from the screws (1-360B). (2) Remove the screws (1-360B), the washers (1-370B), the frame (1-385), the transparent plate (1-3508) and the gasket (1-380B). 27-09-15 sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 CIRCULAR SPLINE DYNAMIC SPLINE rexsune—__ WAVE GENERATOR | \ DRIVE SHAFT Harmonic Drive Assembly Figure 301 27-09-15 ses SeesLIEBHERR COMPONENT MAINTENANCE MANUAL. 9028A0002 G. Disassembly of the Connectors (2-10) (1) Remove and discard the safety wire from screws (2-20). (2) Remove the screws (2-20) and the washers (2-30). (3) Carefully remove one connector (2-10), the gasket (2-40) and the back nut (2-50), and cut off wires close to the connector. (4) Do steps (1) to (3) for the second connector. H. Disassembly of the Synchros (2-120) (1) Remove and discard the safety wire from the screws (1-400). (2) Remove the screws (1-400) and the washers (1-410). (3) Remove the block assembly (2-60A/60B). (4) Remove and discard the safety wire from the screws (2-100). (5) Remove the screws (2-100), the seals (2-110) and the cover (2-90). (6) Remove and discard the gasket (1-420A/420B). (7) Remove the screws (2-130), (8: (9) Carefully remove the wires from the housing (1-340A/340B). Remove the lock plates (2-140). (10) Remove the synchro A and the synchro B. ae sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 CLEANING 1. General (WARNING: 1, OBEY ALL SAFETY AND HEALTH PRECAUTIONS DURING CLEANING PROCEDURES. 2. TRICHLOROETHANE IS DANGEROUS. DO NOT BREATHE ITS GAS. DO NOT USE IT IN CONFINED AREAS, 3. TRICHLOROETHANE IS A SKIN IRRITANT, USE GLOVES THAT GIVE PROTECTION OR A BARRIER CREAM. CLEAN IMMEDIATELY WITH CLEAN WATER IF IT GETS ON YOUR SKIN, 4, AVOID CONTACT OF THE CLEANER HAKU VK 1025/22 WITH EYES AND SKIN, USE PROTECTIVE CLOVES. 5. DO NOT USE THE CLEANER HAKU VK 1025/22 NEAR FIRE SOURCE OR SMOKE WHILE USAGE. THE CLEANER IS HIGHLY FLAMMABLE. CAUTION: USE ONLY SPECIFIED MATERIALS AND SOLUTIONS OR APPROVED ALTER- NATIVES. THE SURFACE PROTECTION CAN BE DAMAGED IF UNAPPROVED MATERIALS ARE USED. IT IS IMPORTANT THAT THE MANUFACTURERS INSTRUCTIONS ARE OBEYED. A. Cleaning materials and suppliers are given at the front of this manual in the List of Materials. Approved alternatives can be used. B. If the cleaned parts are not examined immediately, protect the parts from damage and corrosion. 2. Cleaning of Assembly Parts A. Clean the surface of parts to which grease, loctite or Mastinox has been applied.with the Cleaner HAKU VK 1025/22. B. Use the ultrasonic procedure to clean al} metal parts, or hand clean with Trichloroethane and a soft-bristle brush. Use a lint-free cloth or clean, dry compressed air to dry the parts. C. Clean al] bearings with a cloth made moist with Ethanol. 3. Cleaning of New Parts A, Fully clean the new parts and remove all of the preservation material. 8. Make sure that bores, electrical connections and screw threads are clear and clear. 27-09-15 1 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL. 9028A0002 CHECK 1, Design Changes ‘A. Refer to the IPL to find if any parts have been modified or have been superseded by other parts. : 2. Visual_ Inspection A, Examine all parts for corrosion, it is important to measure the quantity of corrosion (surface, depth) and location. Some corrosion removal is permitted. Refer to Page Block 601 - REPAIR for corrosion removal data. B. Examine all parts for cracks, scratches, abrasion and distortion. C. Examine al] the sealing surfaces and seal seats for scratches, nicks, and indentations. D. Examine a1] the threads for indentations, breaks, and scoring. E. Examine all the coil inserts for tightness and correct insertion depth. F. Examine a1] ball bearings for corrosion, pitting, fracture, chips, discoloration and rough operation. (1) Light corrosion on the outer surfaces of the bearing rings is permitted if it does not prevent the correct fit of bearings. (2) Discoloration of raceways or rolling elements is not permitted. (3) Cracks, chips or damage to rings, balis or cage is not permitted. (4) Rough operation of the ball bearings is not permitted. G. Examine ai] splines and ensure that they are free from fretting and damage. Wear of a polished nature is only acceptable provided that NO steps or distortion.is evident at extremities of the worn-area. 3. Dimensional Check A, Make a check of the parts for correct dimension given in Page Block 801 - FITS AND CLEARANCES. 4. Parts Inspection A. Inspect the parts and put them into one of the groups given below. Serviceable. (1) (2) Can be repaired. (3) To be discarded. 27-09-15 Page 501/502 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 REPAIR, 1. General A, This section gives the procedures for the repair or replacement of the unserviceable components found in the CHECK or TESTING AND FAULT ISOLATION procedures. B. Components which cannot be repaired with these procedures must be replaced. B. Refer to List of Materials at the front of this Manual for repair materials. WARNING: OBEY ALL HEALTH AND SAFETY PRECAUTIONS APPLICABLE TO THE TOOL AND MATERIAL SUPPLIERS INSTRUCTIONS. 2. Removal of Corrosion A, Remove light corrosion with an abrasive stone or a glass-fibre brush. Measure the areas that have had corrosion removal and make sure the dimensions are not less than the specified tolerances (Refer to Page Block 801 - FITS AND CLEARANCES). B. Use the correct chemicals to remove heavy corrosion. After removal of the corrosion, examine the part and make sure that the mechanical strength of the part has not been decreased. C. The recommended materials are: = JENOLITE RRN1 (Stee1 parts) + DEOXIDINE 624 (Aluminium alloy parts). NOTE: Approved alternatives can be used for given items. 3. Special Repairs ‘A, Replace the Coil Inserts, refer to REPAIR No. 1 B. The only other repairs are the replacement of parts shown in the IPL when maintenance and test facilities are available. 27-09715 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 REPAIR No. 1 1, Replacement of the Coil Inserts (Ref. IPL Fig. 1 and 2) A. Coil inserts at these position: = Cover (1-100) and (1-110), = Housing (1-340A) Variant A; (1-320A) and (1-330), = Housing (1-3408) Variant B; (1-320B) and (1-335), = Block assy (2-60A) Variant A only; (2-70A) that are damaged or loose, are to be replaced as shown below. (1) Use the removal tool to remove the damaged insert. Clean the threaded hole. (2) Examine threads for signs of damage. (3) Apply a coat of Mastinox 6856K to the threaded hole. (4) Use an insertion tool to install the inserts to 1/4 of a turn below the surface of the hole. (5) Break off and remove the tang. 27-09-15 REPAIR No. 1 Page 601/602 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 ASSEMBLY, INCLUDING STORAGE 1. General CAUTION: 1. THE PPU IS SUPPLIED LOCKED IN THE MECHANICAL AND ELECTRICAL ZERO POSITION WITH A RED CABLE BINDER. YOU MUST REMOVE THE. CABLE BINDER BEFORE THE PPU IS INSTALLED ON THE AIRCRAFT. 2. THE PPU IS A SENSITIVE INSTRUMENT. WHEN INSTALLING THE PPU, THE ATTACHMENT SCREWS MUST NOT BE USED TO COMPLETE SPLINE ENGAGEMENT. A, Inspect the parts for the correct part number and make sure that they are in limits shown in Page Block 801 - FITS AND CLEARANCES. B. Parts must be clean and all preservative material used during storage must be removed from all components before assembly. C. Do a cure date check of the seals. NOTE: The life left at installation must not be less than the operational or storage life of the unit. D. After any assemblies the ATP must be done (Refer to Page block 101, section 4). 2. Special Materials A, Refer to List of Materials in front of the Table of Contents. 3. Assembly Procedure (Ref. IPL Figs. 1 and 2) A. Assembly of the Spindle (1-300) (Ref. Fig. 701) (1) Assemble the spindle (1-300) to the housing (1-340A/340B). Apply Loctite 675 to the screws (1-310) and install the screws. Finger tighten screws, at this stage. (2) Install the assembled spindle and housing between two centres and put.a dial test indicator gauge on diameter of the housing. (3) Turn the housing about the centres. Make sure that radial run-out measured by dial indicator gauge is not more than-0,04 nm (0.002 in.). Tighten the two screws (1-310) to attach the spindle (1-300) to the housing. 27-0915 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 B. Assembly of a new Housing (1-340) (Ref. Fig. 701) qa) qa) (2) (3) (4) (5) (6) (7) If a new housing (1-340) is used, assemble the plate (1-345) to the housing as given below: (a) Apply a coat of adhesive Araldite AM 106 to the edges of the plate. Install the plate in the slot of the housing. Make sure that the end of the plate is between 7,9 and 8,5 mm (0.311 and 0.335 in.) from the end of the slot. . Assembly of Harmonic Drive onto the Wheel Assemble the dynamic spline (Ref. Fig. 301) of the harmonic-drive assembly (1-130) to the wheel (12909, Apply Loctite 675 to the screws (1-280), install-and tighten the screws. Lubricate the wheel the dynamic spline and the spindle (1-300) with Isoflex Alltime SLI. Fit the wheel (1-270), the shim (1-260), the spacer (1-250) and the circlip (1-240) onto the spindle (1-300). The axial play batween the wheel and the spindle must not be more than 0,080 mm (0.0031 in). If axial play is more than 0,080 mm (0.003 in.), use the next thickness of the shim (1-260) to give the correct axial play. Turn the wheel manually in each direction and make sure that it turns freely. Install the pin(s) (1-120), if they were removed during disassembly, as given below. (a) Apply a smail amount of Loctite 675 to the small diameter of the pin and install it in the location hole of cover (1-85). (b) Peen the end of pin into the countersunk hole of cover. Make ee that ane distance between the centres of both pins is 25,4 mm (1.00 in.). Assemble the circular spline (Ref. Fig. 301) of the harmonic-drive assembly (1-130) to the cover (1-85). Apply Loctite 675 to the screws (1-140), fit the washers (1-150), install and tighten the screws. 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 SPINDLE (1-300) POINT OF MEASUREMENT (USING (3404/3408) 0 8 HOUSING (1-340A/3408) 7,9 to 8,5mm (35 t0'0.33in) PLATE (1-345) PPU Assembly Measurements Figure 701 27-09-15 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 D. Assembly of Bearing (1-210) and Seal (1-190) (Ref. Fig. 702) (1) Apply Isoflex Ailtime SL1 grease to the seal (1-190) and use a suitable mandrel to push it into the cover (1-85). (2) Install the spacer (1-200), the bearing (1-210), the spacer (1-220) and the circlip (1-230) into the cover (1-85). Make sure that the axial play of the bearing is not more than 0,120 mm (0.0047 in). If axial play of bearing (1-210) is more than 0,120 mm (0.0047 in.), use one or more spacers, (1-220) or remove spacer completely, for correct adjustment. Apply Isoflex Alltime SL1 grease to the bearing and the circular spline. (3 (4 Apply Isoflex Alltime SL1 grease to the shaft, the wave generator and the flexspline of the harmonic-drive assembly. Install the flexspline onto the wave generator. E. Assembly of Harmonic Drive Assembly (Ref. Figs. 301 and 702) ql) Apply Isoflex Alltime SL1 grease to the shaft of the harmonic-drive {1-130) and push the drive shaft into the cover (1-85), NOTE: Make sure that the flexspline is in correct alignmen= in the circular spline. (2) Manually turn the drive shaft of the harmonic-drive assembly and make sure that it is free to turn. (3) Push the bush (1-180) onto the drive shaft (Ref. Fig. 702) of the harmonic-drive assembly. (4) Push the shim (1-170) and the circlip (1-160) onto the drive shaft (Ref. Fig. 702) of the harmonic-drive assembly. NOTE: Replace the shim (1-170) if the circlip (1-160) is not “— correctly installed the groove. (5) Turn the whee] (1-270) in the housing (1-340) until the dr-ve gear zero mark is aligned with the fixed pointer in the inspect‘on window (Ref. Fig. 102). Hold the wheel in position. NOTE: If the Harmonic-Drive Assembly is new, the zero mark at the “~~ input shaft must be engraved after the final electrical/ mechanical zero setting procedure. afer Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 SPINDLE {3003 | 1 INPUT SHAFT. | 1-230) (4-240) 1-260) OF HARMONG | | 1-280) 240) | (1-260) DRIVE ASSEMBLY (REF) SPACER SHIM SPACER SPACER ‘SPACER G-170) 200) 6-220) (1-250) Assembled Harmonic Drive Figure 702 27-09-15 f Sep 29789LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 F. Runout check (Ref. Fig. 703) NOTE: The runout check is necessary only if one or both synchro units are replaced. The runout check must be done on synchro-units (2-120) A and E. (1) Put the synchro-units in a Vee-block or alternative support. (2) Make sure the gear reference mark points towards the Dial Test Indicator. (3) Attach a flat shaped tip to the DTI and use a suitable support to position the DTI on the gear (Refer to Fig. 703). (4) Set the DTI to zero. (5) Turn the synchro-transmitter shaft CCW and note the runout deviation at 90°, 180°, 270° and 360° of shaft rotation. (6) Do the runout check to the second synchro and make a note of the runout deviation at the same positions. (7) Plot the runout deviation of both synchro units (Refer to Fig. 703). Apply the figures obtained to the calculation given below (¥ deviation synchro A) ~ (+ deviation synchro B) = mechanical deviation The deviation must be within (+ 30 ym (0.00012 in.) (8) Select two synchro units for installation that have the least amount of mechanical deviation. (9) Assemble the matched synchro units into the housing, refer to section G. 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 DIAL TEST INDICATOR (GRADUATED IN 0.001mm) GEAR REFERENCE MARK REFERENCE MARK 0° OF SYNCHRO HOUSING BACKLASH GEAR (FIXED SPROCKET) REFERENCE MARK 0° ON SHAFT ROTATION EXAMPLE on, wo 1 1 FR uno * % 1 SYNCHRO A ° “s x $e eo" Tor bor a€ foo (£F4)-(¢F a) =#20um (000120) ia MAXIMUM ————— | +f } SS ———— SYNCHRO 8 oS ‘90° 760° 270% 360° “Fe Synchro Runout Check Figure 703 27-09-15 1 sen 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 G. Assembly of Synchro A and Synchro B (2-120) (Ref. Fig. 704) qa) (2) (3) (4) (5 (6) (7) (8) (9) (10) (1) (12) Install two 2 mm (0.0787 in.) diameter pins into the alignment holes of the synchro units (2-120) anti-backlash gears. This will keep the gears spring-loaded (Ref. Fig. 704). Install synchro units (2-120) A and B in their related positions in the housing (1-340A/340B), so that the 2 mm (0.0787 in.) pins align with the spindle (1-300) (Ref. Fig. 704). Hold during this procedure, the wheel (1-270) of the harmonic drive in position. tock the synchro units with the lock plates (2-140) and the screws 2-130). Remove the pins from the alignment holes and rotate the wheel one rotation clockwise. Apply Isoflex Alltime SL1 grease to the parts in the cover (1-85) and the housing (1-340). Clean the attachment faces of the cover and the housing. Apply a coat of Sealant PR 340 to the attachment faces of the cover and the housing and let sealant dry for 5 to 10 minutes. Attach the cover to the housing with the screws (1-70) and the washers (1-80) and tighten the screws. NOTE: Make sure that the flexspline aligns correctly with the circular and dynamic splines (use the alignment holes in the cover (1-85)). Install the setscrew (1-90) into the cover (1-85) if removed during disassembly. Make sure the setscrew head shows approximately one thread above the surface of the cover. Make sure that all the mechanical zero marks (Ref. Fig. 102) are correctly aligned. Turn the input shaft manually and make sure that it turns freely. Assemble the two springs (1-50), the plate (1-40) and the flange (1-10), Attach the flange (1-10) to the cover (1-85) with the screws (1-20) and the washers (1-30), Tighten the screws. 27-09-15 sep 29/89‘COMPONENT MAINTENANCE MANUAL 9028A0002 POSITION OF PINS POSITION B POSITION A Arrangement of Synchro in the Zero Position 27-09-15 Page 709 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 4, Adjustment of the Synchros (2-120) and Running-in NOTE: Make sure all mechanical zero marks are aligned, refer to Figure 102 AL saystment of Synchro A, Electrical Zero (Figures 102, 104, 105 and 704). CAUTION: MAKE SURE THE SYNCHRO WIRES ARE CONNECTED CORRECTLY BEFORE ZERO SETTING ADJUSTMENT. REFER TO FIGURE (4), DESCRIPTION AND OPERATION, FOR THE SYNCHRO WIRING DIAGRAM. (1) Connect the wires of synchro A to the test set-up configuration as shown in figure 104. (2) Set the selector switch to COARSE A. (3) Supply the PPU with 26V, 400 Hz. (4) Set the power supply to ON, (5) Loosen the screws (2-130) holding the synchro A (Ref. Fig. 705). (6) If the voltmeter does not show a maximum voltage of approximately 36V, carefully turn the housing of synchro A, until the voltmeter shows the maximum voltage. (7) Set the selector switch to FINE A. (8) Carefully turn the housing of synchro A until the voltmeter shows a voltage of approxinately 0 m¥. The maximum voltage must not be more than (9) Tighten the screws (2-130) and lock the synchro A. (10) Disconnect the wires of synchro A from the wiring configuration. B. Adjustment of Synchro B, Electrical Zero (Fig. 102, 104, 105 and 704). CAUTION: MAKE SURE THE SYNCHRO WIRES ARE CONNECTED CORRECTLY BEFORE ZERO SETTING ADJUSTMENT. REFER TO FIGURE (4), DESCRIPTION AND OPERATION, FOR THE SYNCHRO WIRING DIAGRAM. (1) Connect the wires a synchro B to the test set-up configuration shown in figure 105. (2) Set the selector switch to COARSE B. (3) Supply the PPU with 26V, 400 Hz. Page 710 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 POLYESTER BAND a papel eM O ©) Zo WIRE GROUND CABLE BUNDLE KNOT aor POLYESTER BAND SYNCHRO A CONNECTOR A APPLY SEALANT PR40 VIEW ON THE OPPOSITE SIDE OF THE LUG PPU Assembly DetatTs Figure 705 27-095 1 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 (4) Set the power supply to ON. (5) Loosen the screws (2-130) adjacent to synchro B (Ref. Fig. 705). (7) Set the selector switch to FINE B. (8) Carefully turn the housing of synchro B until the voltmeter shows a voltage Of approximately @ nV. The maxinum voltage mist not be more than 40 mV. (9) Tighten the screws (2-130) to Tock synchro B. (10) Disconnect the wires of synchro B from the wiring configuration. C. Running-in of the PPU (1) Do the running-in procedure refer to Page Block chapter 10, section (2) Make a check for axial play of the harmonic drive (1-130). The axial play of the shaft must not be more than 0,08 mm (0.003 in.). (3) Make sure there is lubricant in the unit, if necessary re-lubricate through the inspection window with grease (Isoflex Alltime SL1). (4) Apply some drops of 0i1 (Isoflex Alltime 24) to the harmonic drive and its output shaft through the inspection window. 5. Final Assembly A, Safety of the Synchros Units (1) Remove the screw (2-130) that attaches the terminal of the ground Jead (2-150), (2) Apply Loctite 675 to the screw and refit the terminal of the ground ead (2-150) refer to Figure 705. (3) Remove each of the other screws (2-130) in turn and apply Loctite 675 to the screw before re-fitment. Do this procedure for all the screws. NOTE: The screws (2-130) must be removed and installed one at a time to keep the zero position constant. eteCOMPONENT MAINTENANCE MANUAL 9028A0002 . Assembly of the Frame (1-385) (Variant 8) (1) Fit the frame (1-385), the plate (1-350B) and the gasket (1-380B) ‘ath te screws (1-360B) and the washers (1-370B) to housing 1-340B). (2) Apply one Ardrox 3302 (MIL~( heads of the screws (1-3608). + Assembly of the Cover Plate (1-350A) (Variant A) 16173) to the washers (1-370B) and the (1) Fit the cover (1-350A) and the gasket (1-380A) with the screws (1-360A) and the washers (1-370A) to housing (1-340A). (2) Apply on Ardrox 3302 (MIL-C-16173) to the washers (1-370A) and the heads of the screws (1-360A). . Assembly of the Kiring (1) Push the tube (2-160) into the channel of housing (1-340A/340B) as shown in Figure 705. (2) Push the wires of the synchro (1-120) and ground lead (2-150) through the tube (2-160). (3) Use polyester tape to attach the wires of synchro A and the ground Jead together. Safety the tape with a knot and attach to synchro A with adhesive (Sicomet 8500) refer to Figure 705. NOTE: The position of the knot must be as far as possible from the cover (2-90), (4) Attach the wires of synchros A, B and the ground lead together with polyester tape. Safety the tape with a knot and, attach it with adhesive (Sicomet 8500) to synchro B, refer to Figure 705. NOTE: The position of the knot must be as far as possible from the cover (2-90). (5) Assemble the gasket (1-420) to the housing (1-340). (6) Push the wires of synchro (2-120) A and B and the ground lead through the block assembly (2-60}, refer to Figure 704. (7) Attach the block assembly (2-60) to the housing (1-340) with the screws (1-400) and the washers (1-410). (8) Decrease the length of the wires to 70 mm (2.76 in.). 27-07-13 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 (9) Pass the wires of synchro A through the back nut (2-50) refer to Figure 705. (10) Use a hot-blade wire-stripper to remove 4 mn (0.16 in.) of the insulation from the end of the wires. (11) Push the wires into the sleeves (2-35). Push the sleeves through, the gasket (2-40) into the sockets of the connector (2-10). Then use a crimp tool to crimp the sockets. NOTE: The special tool included with each connector is colour coded Red, for pin insertion and White, for pin extrection. (12) Use the insertion tool to install the pins into the connector (2-10), refer to Figure 4. (13) Install the back nut (2-50) to the connector (2-10). (14) Attach the connector (2-10) and the gasket (2-40) to the block (2-60) with screws (2-20) and the washers (2-30). (15) Do steps (9) to (14) for the wires of synchro B. 6. Acceptance Test Procedure NOTE: The PPU must be fully assembled before the ATP is started. A, Do the ATP given in page block 101, section 4 in sequence. B. If any result from the PPU is not satisfactory, the applicable corrective action must be done. This sub-procedure together with the applicable function must be repeated to make sure the PPU is serviceable. NOTE: If the harmonic drive (1-130) as been replaced, the new input- shaft zero mark is to be engraved on the shaft (refer Fig. 102). 7. Preparation for Dispatch A. Removal of the PPU from Test-set (1) Remove the PPU, locked in electrical/mechanical zero position, from the Test Set Assembly. (2) eee PR 340 to the screws (1-70) and (1-140) in the cover 27-09-15 1 sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 B. Securing (1) Install the red cable binder (1-430) behind the plate (1-40) to prevent movement of the locking plate. (2) Lock the PPU with safety wire (LN 9424-1-4546-9-0-8) to MS 33540 or equivalent. specification. C. Cleaning (1) Clean the area around the setscrew (1-90), and apply Sealant PR 340. Make sure that Sealant PR 340 is not applied to the head of the setscrew. (2) Apply Aerodur Finish Clear to all exposed screws, nuts and the identification plate, except screws (1-360), the washers (1-370) and setscrews (1-90). (a) Mix the two-part polyurethane finish in a ratio of 100 parts volume Aerodur Finish C21/100 to 100 parts volume Hardener $66/8. The mixture must be thinned with the addition of 35 parts volume of Thinner ¢25/90. (b) Apply the first coat to a thickness of 15 um (0.0006 in.) and the final coat to a thickness of 25 to 30 um (0.001 to 0.0012 in.). NOTE: Let each coat dry for 30 minutes at room temperature. (3) Clean_the electrical bonding area of the PPU attachment lug (Ref. Fig. 704) and apply a coat of Sealant PR 340. 8. Storage Procedure A. General (1) The unit must be kept in a clean, dry room or building at a temperature of between 18 and 22°C (64 and 82°F) and a relative humidity of between 25 and 65%. (2) The unit must be kept in its original package. If stacked storage is used, be careful to avoid damage caused by too much weight. (3) The unit must not be kept near a source of corrosive fluids, heat or ozone. (4) The package must be in a position so that the identification and humidity indication labels can be easily read. 27-0 r-13 1 Sep 29/89= COMPONENT MAINTENANCE MANUAL. 9028A0002 (5) Keep the packaged units in a sequence of date. . Preparation and Packing (1) Clean the unit and remove all fingermarks with Ethanol. (2) instal the protective plugs (2-170) to the electrical connectors (3) Apply a thin layer of grease (MIL-G-23827) to all unprotected stee] parts. (4) Give protection to all projections, sharp edges and corners. (5) Wind shock absorbent material around the unit and then wind waxed- paper around the shock absorbent material. CAUTION: THE DESICCANT BAGS ARE HYGROSCOPIC. DO STEPS (6) THRU (10) AS QUICKLY AS POSSIBLE. (6) Put, sealed bags of desiccant along the length of the unit. Use tape to hold the desiccant bag in position. (7) Put the unit into a polythene bag which has a minimum thiccness of 0,2 mm (0.008 in.). Make sure there is sufficient material to use and seal the bag at least three times. (8) Put an identification label into the bag and make sure it can be read externally. (9) Put a humidity indicator into the bag and make sure it can be seen externally, (10) Remove as much air as possible from the bag then use heat to seal it. (11) Attach these labels to the outside of the bag: “A ee that indicates the packing date and that a desiccant is use’ - A label identified, 'DO NOT OPEN UNLESS IT IS NECESSARY’. (12) Put the unit into an ATA 300 container and make sure it cai not move in the container. 27- 09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 (13) Close the container and attach these labels: - Item identification - Desiccant label. (14) Apply a layer of clear varnish to the labels, refer to ATA 300 for label data. C. Removal from Storage (1) Remove the oldest dated unit from storage first. (2) Remove the unit from the container and polythene bag. (3) Remove the packing materials and clean off protective grease. 27-09-15 Page 717/718 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 FITS AND CLEARANCES 1. General A, This section gives fits and clearances. 2. Fits and Clearances (Ref. Fig. 801 and Table 801) A. Identifiers in Colum (1) show location of clearance or dimension to be measured. B. Identifiers in Column (2) identify the parts in the IPL (Figure + item number ). C. Columns (3) give the original manufacturing dimensions and clearances. NOTE: In the case of matched parts, clearances are made with selective fit. D. In-service Wear Limits (Columns 4). The maximum limits are maximum wear limits. If a part is in these limits then it is serviceable. Parts that are worn more than the limits specified must be repaired (Refer to Page Block 601 - REPAIR) or replaced. 27-09-15 1 sep'29/89COMPONENT MAINTENANCE MANUAL 9028A0c02 PA f INPUT SHAFT. OF HARMONIC ORIVE ASSEMBLY (REF.) Fits and Clearances - Location Figure 801 ae Sep 29/89COMPONENT MAINTENANCE MANUAL ; 9028A0002 : = _ 1 2 3 origi! Neg Halve 4 tasService Wear biaiva Mazing | dimens: Assenbdly Allowable | wor | ie auiinesers clearance earance Ref.| Figure {anches) aillimeters miilimeters aillimeters no. | and co) (snonos) (inches) Free a vax (=150) | | Splined | 6,507 5,557 i | 6,997 grace | (0.2562) | (0.2581) (6.2560) | (0.2581) neaeurina| | pine | 0,430 a3 | (6.0169 sa.) Sia w 1-160 | 637! | 6,580 Tear | 6,380 ; overaad | (6.2788) | 5 og | -oroos | (O-2744) | (0.2780) | 9 296 | =0.001) | (=0.0008 -010008 OD 1-150 | 6,966 6,995, ‘ f > 6,986 6,995, 7 > (0.2750) | (0.2754) (0.2750) 0.2754) Ww i210 | 6995 | 7,000 395 | 7,000 | (. (0. Ee (0. ) : Co2t54) | (8.2756) | 5 a9 | gore | KO-2758) | c0-2756) | og | 7 > 7 | 7 op 1-130 | 6,986 | e995 | 1970909) | (050008) | 6 cas | s.agy | (0.0006) [ 27m | teva | co.2750) | 0.2754) wes | v7001 | vTbee ‘year | ror ; | coteess) | (026598) |. ooy corssas) | (06699) |. oye Beeeeaot eben ooo | (2:00004)] (0.90075)! 46 og | 44,599 | (0-80087 (0.8691) | (0.6695) | (0.6690) | (0.6695) | | W i870 | 5,008 | 5,018 Theo Sore (0.1970) | (0.1875) | covrgte) | to. A (0.1970) | (0.1973: 9,004 0,018 | (0.1970) | (0.1974) 0,022 bor dsooE aap oo {o.0001 | (0.0007) | 4, oop rlaaot (0.0009) { (0.1966) | (0.1968) \ (0.1965) | (0.1968) Table of Fits and Clearances Table 801 27-09-15 Page 803/804LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 SPECIAL TOOLS, FIXTURES AND EQUIPMENT 1. General A. This Section gives data about special tools, fixtures and equipment necessary for the maintenance of the PPU. Refer to Table 901 for special tools, fixtures and equipment. NOTE: Approved alternatives can be used for given items. ITEM | PART NUMBER NOMENCLATURE. USE 1 52173A0000 Coarse/Fine Selector Etec trical/Mechanical zero Position 2 5594750000 | Test Set Assembly consist of: 5594750100 | ‘Adjustment Mandre1 Manual Rotating of the drive input shaft 5594750001 | Mounting Plate Mounting of the PPU 5594750200 | Connector Assembly PPU-Connection to a test circuit 3 5608150000 | Torque Adaptor Break-out torque measurenent 4 5218650000 | PPU High Voltage High Voltage Test of Test Box the PPU 5 52183A0000-01 | PPU Control Box = Zero Resetting - Error Curve = Running-in = High Voltage Test 6 | 5218240000 | PPU Mechanical Test Test Set for the PPU Set mechanical operation Special Tools, Fixtures and Equipment Table 901 (Sheet 1 of 1) 27-09-15 1 sep 29/89‘COMPONENT MAINTENANCE MANUAL 9028A0002 COURSE FINE SELECTOR CONNECTION CABLES : FOR PPU Special Tools, Fixtures and Equipment Figure 901 (Sheet 1 of 2) 27-09-15LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 8 POWER SUPPLY CABLE @ MEASUREMENT LINE CONNECTION CABLES: zu conTHoL "| | r Special Tools, Fixtures and Equipment Figure 901 (Sheet 2 of 2) 27-09-15 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 ILLUSTRATED PARTS LIST 27-09-15 IPL TP 1001/1002 Sep 29/89LIEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 1, Introduction A, General The Illustrated Parts List (IPL) gives data for the identification of the Position Pick-off Unit replacement parts. The part numbers are given in the sequence of disassembly. The IPL is divided into this introduction which gives data and instructions for the use of the IPL, and these sections: ~ Introduction - Numerical Index - Detailed Parts List. (1) (2) (3) Introduction This section gives data and instructions for the use of the IPL. Numerical Index The Numerical Index is divided into two sections, alpha and numeric. Each section shows all of the part numbers given in the detailed parts list in alpha-numeric sequence. The ‘Total Required’ column shows the total quantity for each figure and item number of the PN. A stock number column is given for airline use. Detailed Parts List {a) The detailed Parts List (DPL) gives part numbers and their related illustrations. The indenture system, which shows the relation of the data, is given below. A stock number column is given for airline use. 1234567 Assembly Attaching parts for assembly «Detail parts for assembly :Sub-assembly :Attaching parts for sub-assembly +-Detail parts for sub-assembly ++ Sub=sub-assemb ly +-Attaching parts for sub-sub-assembly +++Detail parts for sub~sub-assenbly 27-09-15 IPL INTRO Page 1 Sep 29/89COMPONENT MAINTENANCE MANUAL 9028A0002 (b) The attachment parts are shown directly after the part assembly. They are given below the same indenture number as the item they attach and identified "Attaching Parts" followed with asterisks. NOTE: A dash (-) in front of the item number in the “Figure and Item" column identifies items that are not illustrated. 8. How to use the IPL (1) Part number known When a part number (PN) is known, refer to the Numerical Index (NI). The NI will give you the Figure and Index number for the part. Then use the Figure and Index number to refer to data about the part in the applicable illustration or the DPL. (2) Part Number unknown When a PN is unknown, find the illustration that shows the applicable part. Then use the item number given in the illustration to refer to data about the part in the ODPL. C. Symbols and Abbreviations ALT from PN ~ This identifies an alternative PN specified as a part that is functionally and physically interchangeable after re-work. R - "As Required". This shows that the part is used in a quantity as necessary. Buy Part Number - This shows the PN that must be ordered to replace the ‘item of which the PN shows in the part number column. LH or RH ~ A left-hand or right-hand part. LM ~ A finished part made from raw materials, such as seals, hinge strips, extrusions, etc. NHA - Next Higher Assembly. NP - 'Not procurable'. This shows that the part can not be ordered. OPT to - This shows an ‘optional’ PN that is fully interchangeable with ‘the part in the part-number column. Order Overlgth PN - ‘Order overlength part number‘. This shows a complete PN more than fifteen digits long which is to large for the part number column. Oversize/Undersize - This shows an oversize or undersize part. 27-09-15 TPL INTRO Page 2 Sep 29/89Dd. UEBHERR COMPONENT MAINTENANCE MANUAL 9028A0002 REF or RF - This shows an item given for reference data. Post SB - This shows the Service Bulletin which has an effect on the item shown in the part number colum. See CMM - Refer to the Component Maintenance Manual. See Fig XXX for det or NHA - This shows the IPL location where detail- breakdown locations of a sub-assembly are shown and/or the Next Highest Assembly is shown. SEL from - This shows the part which must be selected as necessary from a group of parts with a basic PN. SUPSD by Item Identifies a part superseded or replaced fn the unit or assembly and is cross-referenced to the new part. SUPSDS Item Identifies the new part used in the unit or assembly and is cross- referenced to the part it supersedes or replaces. Used on MPN - This shows the NHA for the part in the part number column. Effectivity Code A letter (A, B, C, etc.) shows a variant to the related NHA where applicable. . Vendor Codes Vendor codes are given in the nomenclature column of the DPL to show the source of procurement of vendor items. These codes and the address of the vendors are given below. When no code is given, for other than standard parts, the item is an LAT part. Alternatively the Vendor address is given in the nomenclature column. CODE VENDOR NAME AND ADDRESS 09893 LIEBHERR-AERO-TECHNIK gmbH. PO Box 1340 10-8998 Lindenberg (Allgiu) Federal Republic of Germany Fo225 SOURIAU ET CIE SA DIV_“CONNEXION ET SPATIAL" B. P. 410 9 2103 Boulogne Billancourt Cedex FRANCE, 27-09-15 IPL INTRO Page 3/4 Sep 29/89