Hydraulic Pump and Electric Motor Assembly Component Maintenance Manual With Illustrated Parts List

HYDRAULIC PUMP AND
ELECTRIC MOTOR ASSEMBLY

COMPONENT MAINTENANCE MANUAL
WITH
ILLUSTRATED PARTS LIST
AERO
c..ONTROLEX
GROUP
26380 Curtiss Wright Parkway
Richmond Heights, OH 44143
Hydraulic Pump and Electric Motor Assembly

AeroControlex Group Part Number
4122-006009
Hamilton Standard Part Number

782655-3
This document is the property of TransDigm, Inc., AeroControlex Group,

and is delivered on the express condition that it is not to be disclosed,
reproduced in whole or part, or used for manufacture for anyone other than
TransDigm Inc., AeroControlex Group without its written consent, and that
no right is granted to disclose or to use any information contained in said
document.
61-21-28 COVER
September 21, 2002
AeroControlex Group
Component Maintenance Manual
Pump and Motor Assembly
Part No. 4122·006009
Record of Revisions
Basic: September 21, 2002
REVISION ISSUE DATE INSERTED

NUMBER DATE INSERTED BY
1 Sept. 21, 2002 Sept. 25, 2002 'D"" -;:?/"o/'
2 Sept. 6, 2005 Nov. 14,2005 7)",,-;:?/pr,b
3 April 20, 2007 ,0#Pftl' -
/
61-21-28 Page 1
Record of Revisions
September 21,2002
AeroControlex
Part No. 4122-006009
Record of Temporary Revisions
Temporary Revision
Page Number Issue Date By Date Removed By
No.
r--------------~------+_--------+_----_+--------+_--------I
---------r----------i------------r------ -
-----------r---------- -+------- ------+-------1--------
---------------1-------1------- - - - - - - - - - - - - - f - - - - - - - - - I
--------f-------.-------+-----\------\-------
---------------+------- -f----------\ ------+----------f-------
I------------I-------ic--------t-----+---- - f - - - - - - - -
r--------------f------f--------------- ----------
1----------+-------1-----------------\-------- - - - - - - -
--------- --------+--------
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---- --+----------c--- ----
f-------------f----------------f---------------\--------
'------------- - - - - - - - - - - - - - - 1 - - - - - - - - - - - - - - - - -
-------------------r-------f------+-- ------------
--------------------------
'---------------- - - - - - - - - - - - - - 1 - - - - - - - - - - - - - - - - - - - - -
-------------1----------- -f----------------------
61-21-28 Page 1
Record of Temporary Revisions
September 21,2002
AeroControlex
Pump Assembly and Motor
Part No. 4122-006009
Service Bulletin List
SERVICE BULLETIN
NUMBER: REVISION NUMBER: INCORPORATED BY:
bl-¥: 8 - ~\ ~ 01 \ A. PLjO-vTZ-
61-21-28 Page 1
Service Bulletin List
September 21, 2002
AeroControlex
Part No. 4122-006009
List of Effective Pages

Subject Page Date
Title 1 September 21, 2002
Record of Revisions 1 September 21, 2002
Record of Temp. Revisions 1 September 21, 2002
Service Bulletin List 1 September 21, 2002
List of Effective Pages 1 April 20, 2007

2 April 20, 2007
3 April 20, 2007
4 September 6, 2005
Table of Contents 1 September 21, 2002
Introduction 1 September 21, 2002

2 September 21, 2002
Description and Operation 1 September 21, 2002

Testing and Troubleshooting 101 September 21, 2002

61-21-28 Page 1
April 20, 2007
AeroControlex
Part No. 4122·006009

(continued)
Subject Page Date
Testing and Troubleshooting

(continued) 107 September 21, 2002
Disassembly 301 September 21, 2002

302 September 21,2002
Cleaning 401 September 21, 2002
Check 501 April 20, 2007

502 April 20, 2007
61-21-28 Page 2
April 20, 2007
AeroControlex
Part No. 4122-006009

(continued)
Subject Page Date
Check (cont) 503 September 21, 2002

504 April 20, 2007
Repair 601 September 21, 2002

Assembly 701 September 21, 2002

61-21-28 Page 3
April 20, 2007
AeroControlex
Part No. 4122·006009

(continued)
Subject Page Date
Fits and Clearances 801 September 21. 2002

802 September 21. 2002
Special Tools, Fixtures, and 901 September 21, 2002

Equipment
Illustrated Part List

Introduction 1001 September 21, 2002
1002 September 21, 2002
1003 September 21, 2002
1004 September 21, 2002
Numerical Index 1006 September 6, 2005

Detailed Parts List 1009 September 21, 2002

1010 September 21, 2002
1011 September 21, 2002
1012 September 21, 2002
1015 September 21, 2002
61-21-28 Page 4
September 6, 2005
AeroControlex
Part No. 4122·006009
Table of Contents
Subject
Introduction ..................................................................................................................... 1
Description and Operation .............................................................................................. 1
Testing and Troubleshooting ....................................................................................... 101
Disassembly ............................................................................................................... 301
Cleaning ...................................................................................................................... 401
Check ........................................................................................................................ 501
Repair ........................................................................................................................ 601
Assembly .................................................................................................................... 701
Fits and Clearances ......................................................................................................801
Special Tools,l Fixtures and Equipment. .......................................................................901
Illustrated Parts List. ...................................................................................................1001
61-21-28 Page 1
Table of Contents
September 21, 2002
AeroControlex Group
Part No. 4122-006009
Introduction
1. General
A. This Component Maintenance Manual (CMM) contains shop verified (see paragraph
4, below), self-supporting maintenance procedures for Pump and Motor Assembly
(4122-006009) manufactured by AeroControlex Group of Transdigm, Inc. (FSCM
81833). Hamilton Standard's part number for this Pump and Motor Assembly is
782655-3. This pump and motor assembly is an intermediate duty, electric motor
driven hydraulic pump assembly used for feathering the propeller.
B. Technical information supplied in this CMM will allow a technician familiar with similar
types of equipment to maintain the Pump and Motor Assembly (4122-006009) and
its component parts: the Pump Assembly (4120-08000) and Motor Assembly (4902-
000600).
C. This publication is compiled and issued by the Publications Department of

Transdigm, Inc., AeroControlex Group, Cleveland, OH 44143. This CMM, as
it may be supplemented by Transdigm, Inc., AeroControlex Group through
the use of Temporary Revisions and Service Bulletins, constitutes the authori-
tative statement of Transdigm, Inc., AeroControlex Group approved and rec-
ommended component maintenance procedures for Pump and Motor As-
sembly Part No. 4122-006009.
D. Unusual problems concerning the CMM or its subject components should be

presented to the Service Department either through its field representatives
or by direct contact. All possible assistance will be provided toward the solu-
tion of any problems.
E. Requests for pertinent information not covered in this CMM and suggestions
for modification or amplification of these instructions to increase their useful-
ness will be welcomed by Transdigm, Inc., and should be forwarded to the
Service Department or the Publications Department.
F. Some procedures in this CMM are restricted to Authorized Service

Sites/Organizations." These are identified by the acronym "ASS/O" at the
end of the paragraph heading. These procedures may only be completed by
those service sites/organizations authorized by Transdigm, AeroControlex
and noted in Table 2.
61-21-28 Page 1
Introduction
September 21, 2002
AeroControlex Group
Part No. 4122·006009
2. Content of CMM
A. This INTRODUCTION section briefly explains: a) contents of CMM; b) use of CMM

along with imposed constraints; c) Shop Verification Statement (with exceptions,
when applicable), see Table 1; d) Warranty Information; e) Authorized Service
Sites/Organizations, see Table 2; f) definitions of abbreviations and acronyms, see
Table 3; g) definitions of terms, see Table 4; h) definition of WARNINGS, CAU·
TIONS, and NOTES.
B. DESCRIPTION AND OPERATION section provides general information on the

equipment: what it is, what it does, and its special or outstanding features. This
overview is provided for training and reference purposes. It also provides an over-
view of the covered equipment for management.
C. SECTIONS 101 and 301 through 901 provide procedural information required to re-
turn the equipment to service, along with lists of tools and materials needed. Section
201 is omitted from the CMM in accordance with the governing specification (ATA
100).
D. SECTION 1001 provides an illustrated parts list providing part: position, location,
identification, and ordering information.
3. Use of CMM
A. Inspect and Repair as Necessary (IRAN) is the basic method used in CMM. This
CMM has been prepared to allow user(s) of this document to inspect returned
equipment, repair returned equipment as necessary, verify satisfactory repair ac-
complishment, and return equipment to service or ready for issue stock.
B. IRAN is implemented in this CMM as follows:
(1) Using needed portions of SECTION 101, determine returned equipment is

safe to accomplish fault isolation testing.
(2) Using needed portions of SECTION 101, accomplish fault isolation testing to
verify failure.
(3) If failure cannot be verified and all tests are accomplished successfully, then
return the equipment to service or ready for issue stock, as applicable.
(4) If failure can be verified, then use needed portions of SECTIONS 301
through 901 to repair pump and motor assembly.
61-21-28 Page2
Introduction
September 21,2002
AeroControlex Group
Part No. 4122"()06009
(5) Accomplish applicable testing procedures contained SECTION 101. If tests

are acceptable, return to service or to ready for issue stock for reuse.
C. Some procedures in this CMM are restricted to Authorized Service

Sites/Organizations." These are identified by the acronym "ASS/O" at the
end of the paragraph heading. These procedures may only be completed by
those service sites/organizations authorized by Transdigm, AeroControlex
and noted in Table 2.
4. Shop Verification Statement:
A. Shop Verified Procedures are those procedures that have actually been accom-
plished by AeroControlex personnel during the preparation of this CMM.
B. These procedures enable a shop mechanic who: a) is unfamiliar with this specific
pump and motor assembly, b) but is familiar with similar types of equipment, c) and,
when applicable, is working in an authorized service facility to restore and verify the
restoration of the Pump and Motor Assembly (AeroControlex Group Part Number
4122-006009) and its component parts to a serviceable or ready for issue condition.
See below for further information on Authorized Service Facilities.
C. Unless specifically excepted in Table 1, all TESTING AND FAULT ISOLATION (Sec-
tion 101 ), DISASSEMBLY (Section 301), and ASSEMBLY (Section 701) procedures
contained in this CMM have been shop verified by actual accomplishment using the
identical configuration of the Pump and Motor Assembly (4122-006009) and its com-
ponents that are the subject of this CMM. [2-5-0,1.B]
Table 1. VERIFICATION EXCEPTIONS
Procedural'
SECTION PARAGRAPH EXPLANATION
None None None
Con f Igura f Ion:

SECTION PARAGRAPH EXPLANATION
None None None
61-21-28 Page 3
Introduction
September 21, 2002
AeroControlex Group
Part No. 4122-006009
5. WARRANTY INFORMATION
A. ONLY PRODUCTS AND MATERIALS LISTED IN THIS MANUAL ARE APPROVED

FOR USE WITH THE PUMP AND MOTOR ASSEMBLY.
B. PRODUCTS AND MATERIALS OF MANUFACTURERS OTHER THAN THOSE

LISTED IN THIS MANUAL THAT THE USER MAY DESIRE TO USE AS RE-
PLACEMENT OF APPROVED PRODUCTS AND MATERIALS FIRST SHOULD BE
REFERRED TO TRANSDIGM, INC., AEROCONTROLEX GROUP SERVICE DE-
PARTMENT FOR EVALUATION AND APPROVAL PRIOR TO THEIR USE.
C. USE OF PRODUCTS AND MATERIALS NOT APPROVED BYTRANSDIGM,INC.,

AEROCONTROLEX GROUP COULD VOID THE WARRANTY, RESULT IN IM-
PROPER MAINTENANCE, AND DAMAGE TO EQUIPMENT.
D. SOME PROCEDURES IN THIS CMM ARE RESTRICTED TO AUTHORIZED SER-

VICE SITES/ORGANIZATIONS." THESE ARE IDENTIFIED BY THE ACRONYM
"ASS/O" AT THE END OF THE PARAGRAPH HEADING. ACCOMPLISHMENT OF
THESE RESTRICTED PROCEDURES AT UNAUTHORIZED SERVICE
SITES/ORGANIZATIONS WILL VOID THE WARRANTY
61-21-28 Page 4
Introduction
September 21, 2002
AeroControlex Group
Part No. 4122-006009
6. Authorized Service Sites/Organizations (ASS/O)
A. Certain portions of this text are marked with the acronym (ASS/O). This indicates
that this procedure or task may only be accomplished by technicians who have pre-
viously been qualified by AeroControlex Engineering and are working at
sites/organizations also previously qualified by AeroControlex Engineering.
B. This qualification indicates that authorized technicians and sites/organizations have

the necessary skills, facilities, spares availability, materials, equipment, tooling, and
special tools to safely and satisfactorily accomplish the required work and tests.
C. Accomplishment of tasks or procedures so marked by unqualified technicians or

personnel at unqualified Sites/organizations will VOID THE WARRANTY. A listing of
qualified sites/organizations is provided in Table 2.
Table 2. AUTHORIZED SERVICE SITES/ORGANIZATIONS (ASS/O)
NAME ADDRESS PHONE

AeroControlex Group TransDigm Inc. (216) 289-8900
AeroControlex Group
Destination Bldg., 2nd Floor.
26380 Curtiss Wright Pkwy.
Richmond Hts., OH 44143-0210
Perform Air International Perform Air International, Inc. (602) 829-8086

1854 South MacDonald
Mesa, AZ 85210
61-21-28 Page 5
Introduction
September 21,2002
AeroControlex Group
Part No. 4122·006009
7. Definitions of Abbreviations and Acronyms

Table 3 provides definitions of abbreviations (abbrev) and acronyms used in this CMM.
Table 3. DEFINITION OF ABBREVIATIONS AND ACRONYMS
ABBREV DEFINITION ABBREV DEFINITION

of Degrees Fahrenheit IRAN Inspect and Repair As Necessary
ASSIO Authorized Service kp Killed Part
SitelOrganization
ASSY Assembly Ibs pounds
ATA Air Tran~ort Association MAX Maximum
CMM Component Maintenance MIN Minimum
Manual
DC Direct Current min minutes
DIA Diameter 00 Outside Diameter
DPL Detailed Parts List PN Part Number
Fig Figure PSI Pounds per Square Inch
FSCM Federal Supply Code for PSIA Pounds per Square Inch Absolute
Manufacturers
Ft. Ib Foot pound PSID Pounds per Square Inch Differential
GPM Gallons Per Minute Rev. Revision
hr hour RFI Radio Frequenc~lnterference
ID Inside Diameter RPM Revolutions Per Minute
IPC Illustrated Parts Catalog Temp. Temperature
IPL Illustrated Parts List V Vendor Code
8. Definitions of Terms
Table 4 provides definitions of terms used in this CMM.
Table 4. DEFINITION OF TERMS
TERM DEFINITION
Match mark To mark the relative position of two or more mating parts
One-Time Tasks so marked may only be accomplished once without return to an
ASSIO
61-21-28 Page6
Introduction
September 21,2002
AeroControlex Group
Part No. 4122·006009
9. Definitions of WARNINGS, CAUTIONS, and NOTES
These adjuncts to the text shall be used to highlight or emphasize important pOints when
necessary.
WARNINGS: CALL ATTENTION TO USE OF MATERIALS, PROCESSES, METHODS,

PROCEDURES, OR LIMITS WHICH MUST BE FOLLOWED PRE·
CISELY TO AVOID INJURY TO PERSONS. WARNINGS SHALL BE
LOCATED DIRECTLY ABOVE THE TEXT TO WHICH THEY RELATE
AND VERTICALLY IN LINE WITH THE NUMERICAL OR ALPHABETI·
CAL BREAKDOWN OF THE STEPS TO WHICH THEY APPLY. WARN·
INGS SHALL ALWAYS BE ON THE SAME PAGE AS THE TEXT TO
WHICH THEY APPLY. WARNING SHALL BE PRINTED IN CAPITAL
LETTERS. WARNINGS WILL BE PRINTED IN A BOLD FONT.
CAUTIONS: CALL ATTENTION TO USE OF MATERIALS, PROCESSES, METHODS,

PROCEDURES, OR LIMITS WHICH MUST BE FOLLOWED PRE·
CISELY TO AVOID DAMAGE TO EQUIPMENT. CAUTIONS SHALL BE
LOCATED DIRECTLY ABOVE THE TEXT TO WHICH THEY RELATE
AND VERTICALLY IN LINE WITH THE NUMERICAL OR ALPHABETI·
CAL BREAKDOWN OF THE STEPS TO WHICH THEY APPLY. CAU·
TIONS SHALL ALWAYS BE ON THE SAME PAGE AS THE TEXT TO
WHICH THEY APPLY. CAUTIONS SHALL BE PRINTED IN CAPITAL
LETTERS. CAUTIONS WILL BE PRINTED IN A BOLD FONT.
NOTES Call altention to methods which make the job easier. NOTES shall follow
the text to which they relate. NOTES are located directly under and verti-
cally in line with the text to which they apply. NOTES shall always be on
the same page as the text to which they apply. NOTES shall be in upper
and lower case lelters. NOTES will be printed in a regular font.
61-21-28 Page 7
Introduction
September 21,2002
AeroControlex Group
Part No. 4122·006009
Description and Operation

1. General
This Component Maintenance Manual (CMM) contains maintenance instructions for the
Pump and Motor Assembly (4122-006009) manufactured by AeroControlex Group for
Hamilton Standard.
Significant components of the subject pump and motor assembly are identified below
along with related part numbers.
Aero Hamilton Aero Aero Aero Controlex

Controlex Standard Controlex Controlex Nameplate
Pump and Pump and Pump Motor
Motor Motor Assy Assembly Assembly
Ass
Part 4122-006009 782655-3 4120-008000 4902-000600 4900-000775
No.
Each pump and motor assembly consists of a hydraulic pump assembly mechanically
coupled to an electric motor assembly using an intemal spline type coupler.
Hydraulic fluid within the pump assembly is prevented from entering the motor assembly
by a shaft seal pressed into the pump assembly and over the drive gear.
The motor assembly and the pump assembly are bolted together, and the completely
assembled pump and motor assembly bolts to the propeller control assembly by mounting
holes located on the pump assembly.
See Figures 1 and 2 for identification of major components of the Pump and Motor
Assembly.
See Table 1 for leading particulars on pump assembly.
See Table 2 for general leading particulars on motor assembly.
See Table 3 for specific leading particulars on motor assembly.
See Figure 3 for pump flow diagram and pump assembly intemal components.
61-21-28 Page 1
September 21, 2002
AeroControlex Group
Part No. 4122-006009
OUTLET
INLET
SPLINE COUPliNG
CONNECTOR
seAL DRAIN -GASK[T SEE FIG. (' FOR

POSITION
L_~
puMp
__ JL__ ______ MOTOR'
___,___
ASSEMBLY ASSEMBLY
Pump and Motor Assembly PN 4122-006009

Figure 1
61-21-28 Page 2
September 21, 2002
AeroControlex Group
Part No. 4122·006009
g~
5.5
0
I
,
~
Pump and Motor Assembly· PN 4122·006009
Electric Connector Angle
Figure 2
61-21-28 Page 3
September 21, 2002
AeroControlex Group
Part No. 4122·006009
Table 1 - Leading Particulars for Pump Assembly (4120-008000)
Type Positive displacement gear

Fluid Hydraulic fluid, MIL-L-23699
Inlet pressure -- at sea level 15.0 psia
Inlet pressure -- at altitude 5.5 psia
Outlet pressure, rated flow 690 psi min,750psi max.
Relief pressure, outlet flow blocked 850 psi max
Shaft seal leakctge 1 drop in 20 min., max.
Leakage, check valve 20 drops in 1 min., max.
Rotation CCW facing drive end
Operating Temperature -65°F to +250°F
Welght Approx. 1.2 pounds.
Capacity, at sea level 1.70 gpm min. at 8000 rpm
1.10 gpm min. at 5300 rpm
Manufacturer TransDigm, Inc. AeroControlex
Group
Table 2 - General Leading Particulars for Electric Motor Assembly (4902-000600)
Type Series wound 24 volt DC

Duty Cycle 30 sec ON, 10 min OFF, 4 cycles, 1 hr. OFF
Brushes Four (4) carbon graph~e replaceable cartridQes
Bearings Permanent lubrication
Rotation Clockwise facinQ drive end
Operating -65°F to +250°F
temperature
Time between 50,000 duty operations at above duty cycle
overhaul
Explosion resistance MIL-E-5272
Table 3 - Specific Leading Particulars for Electric Motor Assembly (4902-000600)
stall
Motor Model Amps Torque Weight Altitude Volts Speed Torque
(Max) (Ft.·lb) (Ibs.) (Feet) DC (RPM) (Ft-Ib Min)
4902-000600 45 0.67 Afl2. 4.5 25,000 24 8000 1.67
61-21-28 Page 4
September 21, 2002
AeroControlex Group
Part No. 4122-006009
DISCHARGE
! TRANSFER
TUBES
WITH SEALS
INLET SCREEN
50 X 50 MESH
CHECK VALVE
6 PSID AT RELIEF VALVE
FULL FLOW 690 TO 750 PSI
Pump Assembly Flow Diagram and

Internal Components - PN 4120-008000
Figure 3
61-21-28 Page 5
September 21, 2002
AeroControlex Group
Part No. 4122·006009
2. Description (see Figures 1 and 2)
A. The hydraulic pump supplies hydraulic pressure to feather the propeller on

the propeller control. The assembly mounts directly to the propeller control.
The pump receives hydraulic fluid and delivers pressurized fluid through two
transfer tubes. An electrical connector supplies power to the motor.
B. The assembly consists of a hydraulic pump and an electrical motor coupled

together with an internal spline coupling. The two units are bolted together
by four bolts through holes in the pump base. A gasket mounts between
the two units.
C. The hydraulic pump is a positive displacement gear pump with an internal

pressure relief valve and an internal check valve.
D. The electric motor is a nominal 24 volt direct current motor, series wound
that is designed only for intermittent duty. See Table 2 for duty cycle. The
motor has no thermal or overload protection, nor does it have any RFI
filters. Every possible opening in the motor is sealed for explosion
resistance duty per MIL-E-5272.
3. Operation (see Figures 3)
A. The pump draws hydraulic fluid from the propeller control sump through the
inlet transfer tube. The hydraulic fluid is filtered by a wire mesh screen
before entry into the pump gears. The hydraulic fluid acts as the pump's
lubricant. The internal relief valve limits the pump output pressure from 690
psi to 750 psi. The pressurized fluid goes to the propeller control through
the outlet transfer tube. The discharge check valve ensures the pump does
not rotate due to system pressure under motor-off conditions.
B. The electric motor is actuated by the propeller feathering switch.
61-21-28 Page 6
September 21,2002
AeroControlex Group
Part No. 4122-006009
Testing and Troubleshooting
CAUTION:
Do not operate pump without hydraulic fluid. Pump depends on

fluid for lubrication. Operating pump dry wilf damage pump.
Do not operate motor without a mechanical load. A series

wound motor wilf overs peed and damage itself.
Observe motor duty cycle shown in Table 2, DESCRIPTION AND

OPERATION section. Operating motor continuously at rated
voltage wilf burn out motor.
CAUTION
Some procedures in this CMM are restricted to Authorized

Service Sites/Organizations." These are identified by the
acronym "ASS/O" at the end of the applicable paragraph
heading or, in some cases, at the end of the text.
Procedures marked with "ASS/O," shall only be completed by

those Service Sites/Organizations authorized by Transdigm,
AeroControlex and noted in Table 2, INTRODUCTION section.
Sites that are not Authorized Service Sites/Organizations shall

not accomplish tasks that are marked "ASS/O".
Sites that!.!:!! "ASS/O" may accomplish all required tasks in the

CMM.
61-21-28 Page 101

September 21, 2002,
AeroControlex Group
Part No. 4122-006009
1. General (Testing)
A. Testing is divided into three phases: Pump and Motor Assembly, Pump
Assembly, and Motor Assembly. Pump Assembly testing and Motor Assembly
testing may only be performed by Authorized Service Sites/Organizations.
(1) Pump and Motor Assembly (-1, IPL Fig. 1) may be tested as a unit at
either Non-ASS/O or ASS/O sites. This includes RUN-IN after brush
(170, IPL Fig. 3) (10, IPL Fig. 4) replacement.
(2) Pump Assembly (10, IPL Fig. 1) may be tested as a unit at ASS/O sites.
(3) Motor Assembly (70, IPL Fig. 1) may be tested as a unit at ASS/O sites.
(4) Because the motor assembly can only be operated for short periods of
time (DESCRIPTION AND OPERATION, Table 2), some procedures
must be performed on the pump or the motor separately.
(5) Some test procedures in this section require the same test set-up as
required in REPAIR. Proper planning of work will save time by
performing the necessary calibration test right after performing repair
work. See Table 101.
Table 101. Checks Required After Specific Types of Repair Actions
ASSEMBLY PERFORM THESE CHECKS: AFTER DOING THESE REPAIRS:

PUMP Check valve leakage Gear or Gear or Bearing run-in
ASSEMBLY bearing run-in Relief valve calibration
(ASS/O ONLY) Shaft seal leakage Relief valve retrofit
Pump torque input
MOTOR Motor torque output (pump and Brush replacement (only ONE-TIME
ASSEMBLY motor assembly configuration replacement authorized at NON-ASS/O
only) sites)
MOTOR All motor assembly checks Bearing replacement and any other
ASSEMBLY motor repairs other than brush
(ASS/O ONLY) replacement
61-21-28 Page 102

September 21,2002
AeroControlex Group
Part No. 4122·006009
B. Conduct all tests at ambient room temperature (50°F to 125°F) and local ambient
atmospheric pressure. Maintain test rig lubricating oil at a temperature of 170°F to
190°F for all tests.
C. Test Equipment and Materials
(1) The following material is needed for testing: MIL-L-23699, lubricating oil,
aircraft turbine engine, synthetic base.
(2) Refer to SECTION 901 for a list of special tools, fixtures, and quipment
required in this section.
(3) Refer to Table 102 for a list of test equipment used in this section
D. Instrumentation. Refer to Table 102 for a list of instrumentation used in this

section.
Table 102 - Test Equipment and Instrumentation Requirements
NOTE: Equivalent substitutes may be used for items
Instrument Parameter Range Accuracy

Ammeter. DC Motor Current o to 100 AMPS ±2%
Voltmeter. DC Motor Voltage o to 30 Volts ±2%
Electrical Supply 100 AMP. Motor Power o to 100 AMPS ± 0.5VDC

DC
Oil Flowmeter Pump Output Oto 2.50 GPM ± 1% of Reading

Oil Pressure Gage Pump Output oto 1000 PSIG ± 2%
Oil Pressure Gage Pump Input o to 20 PSIA ±2%
Oil Temperature Operating Oil o to 180°F ± 5° F
Stopwatch Duty Cycle o to 1 hour
Beaker Seal Leakage 1 drop in 20 min Maximum
Beaker Check Valve Leak 20 drops in 1 min Maximum
61-21-28 Page 103

September 21, 2002
AeroControlex Group
Part No. 4122-006009
E. Abbreviations and Symbols. Refer to Table 103 for a list of abbreviations and
symbols used in testing.
Table 103. Abbreviations and Symbols
Abbreviation or Definition
Symbol
AMPS Amperes
CW Clockwise (direction)
CCW Counterclockwise (direction)
DC Direct Current
of Degrees Fahrenheit
PSIA Pounds per square inch absolute
PSIG Pounds per square inch gage
GPM Gallons per minute
VDC Volts direct current
2. Preparation for Testing Motor and Pump Assembly
A. Preliminary data.
(1) Have a clean legible copy ofTEST DATA SHEET (Table 104) ready for
recording TEST AND TROUBLESHOOTING results and disposition. DO
NOT record data in this CMM.
(2) Fill in the required information on top ofTable 104.
61-21-28 Page 104

September 21,2002
AeroControlex Group
Part No. 4122·006009
r
TO SHOP AIR OR VACUUM AS REOUIRED
PRESSURE FOR PUMP INLET CONDITION
REGULATOR
PRESSURE
c-,-J---> GAUGE et: A - - - 24 VOLT DC
o TO 20 PSIA 2 V VARIABLE SUPPLY
o
L
PRESSURE
GAUGE
o TO FLOW METER
RESERVOIR
5 GAL MIN 1000 PSIG o TO 2 5 GPM
CAPACITY
~.---SHUT OFF
VAL YES
HEAT
VALVES AND LINES TO ElXCHANGER
PROVIDE ABSOLUTE
MINIMUM RESTRICTIONS
Q
~) 3 RIGHT ANGLE BENDS
IN 0.437 ID TUBING AS
CLOSE AS POSSI6L.E
Pump and Motor Assembly Test

Figure 101
B. Installation on Test Rig (See Figure 101)
NOTE: Before starting tests, remove inlet transfer tube

and clean out inlet filter screen.
(1) Install pump and motor assembly to test rig with bracket T120-008002 (Table
901, SPECIAL TOOLS, FIXTURES, AND EQUIPMENT section).
(2) Attach hydraulic adaptor T120-008001 (Table 901) to pump and connect pump
input and output lines to test rig.
(3) Use 3 short right-angle sections of tubing in line as close to inlet port as possible.
61-21-28 Page 105

September 21, 2002
AeroControlex Group
Part No. 4122·006009
NOTE: Voltmeter leads should be connected to motor

wires as close to motor as possible for more accurate
readings.
(4) Attach wiring harness T120·008006 (Table 901) to motor connector and
power supply.
(5) Connect voltmeter leads to motor leads as close to the motor assembly
as possible.
(6) Set oil temperature control on test rig to 180°F ± 10°F.
(7) Open output flow valve on test rig.
(8) Track the motor duty cycles during testing. Duty cycle limitations are 30
seconds ON, 10 minutes OFF for 4 cycles. After four cycles, motor
must be OFF for one hour.
3. Pump and Motor Functional Test
A. Test Conditions:
(1) Test fluid shall be MIL-L-23699 hydraulic fluid
(2) Fluid temperature at pump inlet shall be 180° +/- 10°F
(3) Ambient temperature shall be room temperature
(4) Accuracy of instrumentation shall be according to Table 102 of this

document
(5) Test set-up shall be in accordance with Figure 101.
(6) Voltage input to motor shall be 24 VDC nominal or as specified.

Voltmeter and ammeter must be connected as close to motor as
possible.
61-21-28 Page 106

September 21, 2002
AeroControlex Group
Part No. 4122-006009
8. Leakage
Generally no external leakage of hydraulic oil is permitted during pump assembly

operation. However, a small amount of hydraulic oil leakage from the seal drain
hole in the pump assembly is permitted. During testing or troubleshooting, collect
seal drain leakage as described below:
(1) Prior to operation of the pump, verify that the seal drain hole in the pump
housing is not blocked and is pointing down so that leakage can be collected.
(2) Place a beaker beneath the seal drain hole.
(3) More than one drop falling in the beaker during the test shall require the
pump assembly to be tested in accordance with paragraph 58.
(4) External leakage other than from the seal drain hole shall require repair prior
to continuing.
C. Functional Performance Tests
(1) Make a clean legible copy of Table 104, Test Data Sheet. Use Test Data
Sheet to record the results of Testing and Troubleshooting and provide
objective evidence of PASS/FAIL decision.
(2) Adjust inlet pressure to 15 ± 2 psia by adjusting shop air pressure to oil
reservoir. Set inlet oil temperature to 180°F ± 10°F.
(3) Turn on and adjust power supply to 24 volts ± 0.5 volts.
(4) Adjust outlet flow valve for 690 PSI minimum.
(5) Record voltage, inlet pressure, discharge pressure, pump outlet flow and inlet
oil temperature.
(6) Close outlet flow needle valve and record full flow relief pressure and motor
current.
(7) Flow shall be 1.7 GPM minimum for 24 volts, 1.1 GPM minimum for 18 volts.
Full flow relief pressure shall not exceed 850 PSIG. The maximum current
shall be 45 amps.
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September 21, 2002
AeroControlex Group
Part No. 4122·006009
r ~
CAUTION: At NON·ASS/O sites a ONE·TIME brush

replacement is allowed. Otherwise, brush and
commutator wear deposits will build up within the motor
assembly and must be removed at an ASS/O.
(8) If the pump fails to meet minimum requirements and the failure could
be a result of worn brushes, a ONE·TlME brush replacement is
authorized at non-ASS/O sites. Subsequent brush replacements or
lower level repairs are not authorized at non-ASS/O sites.
(9) Repeat the test with the power supply adjusted to 18 volts.
4. Preparation for Testing Pump Assembly (ASS/O)

A. Pump must be separated from the motor for these tests. See
DISASSEMBLY SECTION.
B. This pump performance test must be done after new gear andlor bearing run-
in. Test must also be done after replacement of relief valve, upgrade of relief
valve, or making relief valve adjustments.
C. Preliminary data.
(1) If not already prepared, have copy of test data sheet, Table 104, ready
for recording test data
(2) Fill in Model Number, Serial Number and Rev Number (if any) for
Pump Assembly.
D. Installation on Motoring Dynamometer (See Figure 102).
Note: Before test, clean inlet screen (·170, IPL Fig. 2) in inlet tube
assembly (145, IPL Fig 2).
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September 21, 2002
AeroControlex Group
Part No. 4122·006009
TO SHOP AIR OR VACUUM AS REQUIRED

PRESSURE
REGULATOR
L o
PRESSURE
GAGE
FOR PUMP INLET CONDITION
TO 20 PSIA
DYNAMOMETER
PRESSURE FLOW METER

RESERVOIR GAUGE o TO 2.5 GPM
o TO
5 GAL MIN 101' 1000 PSIG
CAPACITY FILTER
PUMP NEEDLE
VALVE
. r - - - SHUT OFF HERMOMETER
VALVES 0 0 TO 180 0 F
VALVES AND LINES TO

PROVIDE ABSOLUTE
3 RIGHT ANGLE BENDS
IN 0.437 10 TUBING AS
CLOSE AS POSSIBLE
(1) Remove cover from pump, remove relief valve assembly and replace with
relief valve plug, T120-008007. Install cover back on pump.
(2) Install pump assembly to test rig with bracket T120-008002.
(3) Attach hydraulic adaptor T120-008001 to pump and connect pump input and
output lines to test rig.
(4) Use shaft spline coupling T120-008003 to connect pump shaft to

dynamometer shaft.
(5) Set oil temperature control on test rig to (180°F ± 1Q°F ).
(6) Open output flow valve on test rig.
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September 21, 2002
AeroControlex Group
Part No. 4122-006009
5. Pump Assembly Functional Test
A. Test Conditions:
(1) Testfluid shall be MIL-L-23699 hydraulic fluid
(2) Fluid temperature at pump inlet shall be 180°F +/- 10°F
(3) Ambient temperature shall be room temperature
(4) Accuracy of instrumentation shall be according to Table 102 of this

document
(5) Test set-up shall be in accordance with Figure 102.
B. Leakage
Note: No external leakage is allowed at any time during the test except
for shaft leakage of one drop maximum in 20 minutes. Test conditions
are the same as those described in paragraph C, following. See
paragraph E for additional procedures.
Generally no extemal leakage of hydraulic oil is permitted during pump

assembly operation. However, a small amount of hydraulic oil leakage from
seal drain hole in pump assembly is permitted. During testing or
troubleshooting, always monitor the length of time the pump assembly is
operating and collect seal drain leakage as described below: Prior to pump
assembly operation:
(1) Verify that the seal drain hole in the pump housing is not blocked and
is pointing down so that leakage can be collected.
(2) Place a beaker beneath the seal drain hole.
(3) Leakage shall not exceed 1 drop every 20 minutes.
(4) Extemalleakage other than from the seal drain hole shall require
repair prior to continuing.
C. Performance Test, Pump Assembly, with Relief Valve Blocked (ASS/D)
Run the tests and record pump data as follows:
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September 21, 2002
AeroControlex Group
Part No. 4122-006009
(1) Install relief valve plug (T120-008007) into pump assembly.
(2) Adjust inlet pressure to 15 ± 2 PSIA by adjusting shop air to hydraulic fluid
reservoir. Set inlet oil temperature at 180aF ± 1QaF.
(3) Turn on and adjust dynamometer to 8000 RPM ± 160 RPM.
(4) Adjust outlet flow needle valve to 690 PSI minimum.
(5) Record inlet pressure, discharge pressure, pump outlet flow, inlet oil
temperature and torque.
(6) Flow shall be 1.7 GPM minimum. Torque shall be .67 ft Ibs maximum.
(7) Remove relief valve plug T120-008007 from pump assembly.
CAUTION: MAKE SURE RELIEF VALVE PLUG (T120-008007) IS REMOVED FROM

PUMP ASSEMBLY. FAILURE TO REMOVE PLUG COULD DAMAGE
THE PUMP ASSEMBLY.
D. Performance Test, Pump Assembly, with Relief Valve (ASS/O)
(1) Remove pump from dynamometer.
(2) Remove cover and relief valve plug, T120-008007.
(3) Reassemble relief valve parts into pump.
(4) Fasten cover back on pump.
(5) Monitor seal leakage during test.
(6) Adjust inlet pressure to 15 ± 2 PSIA by adjusting shop air to hydraulic fluid
reservoir.
(7) Turn on and adjust dynamometer to 8000 RPM ± 160 RPM.
(8) Adjust outlet flow valve for 690 PSIG minimum.
(9) Record inlet pressure, discharge pressure, pump outlet flow, inlet oil
temperature, speed and torque.
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September 21,2002
AeroControlex Group
Part No. 4122-006009
(10) Flow shall be 1.7 GPM minimum.
(11) Close then open outlet flow needle valve no less than three times.
Close outlet flow needle valve and record relief pressure. Full flow
pressure shall not be greater than 850 PSIG.
(12) Record hydraulic fluid temperature at inlet (180°F ± 10°F).
E. Performance Test, Pump, Shaft Seal Leakage (ASS/O)
(1) Place beaker below shaft seal leakage drain hole in pump housing.
(2) Run pump for 20 minutes. Record outlet pressure.
(3) Measure amount of leakage in beaker (1 drop in 20 minutes

maximum). Record leakage.
(4) Record oil temperature at inlet (180°F ± 10°F ).
(5) Turn off drive to pump.
F. Performance Test, Pump, Check Valve Leakage (ASS/O)
(1) Remove pump from dynamometer.
(2) Remove inlet connection to pump.
(3) Position pump so leakage to inlet port will fall into beaker.
(4) Place beaker beneath inlet port.
(5) Apply pressure connection to outlet.
(6) Adjust outlet pressure to 780 psig ± 30 psig. Record outlet pressure.
Fluid temperature shall be 80 ± 20 deg. F.
(7) After one minute, measure check valve leakage (20 drops in 1 minute
maximum). Record leakage.
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September 21, 2002
AeroControlex Group
Part No. 4122-006009
6. Preparation for Testing Motor (ASS/O)

A. Preparation.
(1) If not already accomplished, have test data sheet ready, Table 104.
Record serial number of item being tested.
(2) While observing duty cycle requirements identified in Table 2 of

DESCRIPTION AND OPERATION section, perform testing with motor
assembly separated from pump assembly. No repair actions are
authorized on the motor assembly.
CAUTION: Do not operate motor assembly without a mechanical

load. A series wound motor will overspeed and damage itself.
(3) Mount motor on absorption dynamometer with mounting block T120-

008004. Use a coupling with a tachometer wheel to couple motor shaft
to dynamometer.
(4) Connect power supply to motor connector with wire cable T120-008006.
NOTE: Connect voltmeter leads as close to motor as possible.
TACHOMETER
PICK~UP""
6 CONNECTOR
OR TERMINAL " "
BLOCK
1r
- VOLTMETER
24
DYNAMO
- VOLTS
c MOTOR
~METER +POWER
IMTG I
I- ep SUPPLY
Motor Test Set-Up

Figure 103
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September 21, 2002
AeroControlex Group
Part No. 4122-006009
7. Performance Test. Motor. Nominal Load (ASS/O)

A. Run the test and record motor data as follows:
(1) Set dynamometer load at 0.67 ft. lb. minimum.

(2) Set power supply to 24 volts. Turn on motor.
(3) Record dynamometer load, voltage, current and motor speed.
(4) Current shall not exceed 45 amps. Motor speed shall be 8000 RPM
minimum.
(5) Repeat test at 18 VDC and record motor amps
(6) Current shall not exceed 45 amps.
B. This test may be completed by the motor manufacturer for new motors.
8. Test Data Sheet/Record

Table 104 is contained on the following pages. Make a Clean Copy of Table 104 and
Record Test Data and Subsequent Disposition Based on Recorded Data for Pump and
Motor Assembly (4122-006009), Pump Assembly (4120-008000), and Motor Assembly
(4902-000600). Do Not Mark on the table contained in this CMM.
61 -21 -28 Page 114

September 21,2002
AeroControlex Group
Part No. 4122-006009
Table 104. Test Data Sheet for Pump and Motor Assembly (4122-006009),
Pump Assembly (4120-008000), and Motor Assembly (4902-000600)
Assy Model: 4122-006009 Assy Serial # _ _ _ _ _ Rev _ _
Pump Model: 4120-008000 Pump Serial # _____ Rev _ _
Motor Model: 4902-000600 Motor Serial # _ _ _ _ _ Rev _ _
Technician: _ _ _ _ _ _ __ Date: _ _ _ _ _ _ _ _ _ __
Disposition of Pump Assembly after Testing: _ _ _ _ _ _ _ _ _ _ __
Disposition of Motor Assembly after Testing: _ _ _ _ _ _ _ _ _ _ __
Disposition of Pump and Motor Assembly after Testing: _ _ _ _ _ _ _ __
Pump and Motor Assembly Test

(Reference Paragraph 2 and 3, above)
Inlet Motor Outlet Outlet Motor Block Inlet Test Performed

Pressure Volts Pressure Flow Amps Press. Temp on Date: By:
15±2 24 690 1.70 45 850 180 ± Date Initial
psia ±0.5 psi. gpm amps psi 10°F DD/MMI
volts min. min. max max. yy
15±2 18 690 1.10 45 850 180 ± Date Initial

psia ±0.5 psi. gpm amps psi 10°F DD/MMI
volts min. min. max max. yy
61-21-28 Page 115

September 21, 2002
AeroControlex Group
Part No. 4122-006009
Pump Assembly Test - Performance (ASS/O)

Inlet Pump Outlet Pump Block Test Performed

Pressure Torque Pressure Flow Speed Pressure Temp on Date: By:
15±2 0.67 ft 690 psi. 1.70 8000 ± 850 psi 180 ± Date Initial
psia Ibs max gpm 2% rpm max. 10°F DD/MM
min.
Pump Assembly Test - Shaft Seal Leakage (ASS/O)

(Reference Paragraph 5, above)
Inlet Pump Outlet Outlet Pump Leakage Rate Test Test Per-
Pressure Torque Press- Flow Speed Maximum Date formed BY:
ure
15±2 0.67± 690 psi. 1.70 8000 ± 1 drop in 20 Date Initial
psi a 2% ft Ibs gpm 2% min. DD/M
rpm MIYY
Pump Assembly Test - Check Valve Leakage (ASS/O)

(Reference Paragraph 5, above)
Outlet Pressure Check Valve Leakage to Date Initial

780 ± 30 psi Inlet Port DD/MM/YY
20 drops in 1 min., max.
61-21-28 Page 116

September 21, 2002
AeroControlex Group
Part No. 4122·006009
Motor Assembly Test· Nominal Load {AS SID)

Motor Load Motor Motor Amps Motor Tested on & By:

Volts Speed
0.67 ± 2% Ft 24 ± 0.5 45 amps 8000 rpm Date Initial
Lbs. volts max. min.@24V DD/MMIYY
0.67 ± 2% Ft 18 ± 0.5 45 amps 8000 rpm Date Initial

Lbs. volts max. min.@24V DD/MMIYY
END OF TEST DATA SHEET
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September 21, 2002
AeroControlex Group
Part No. 4122-006009
9. Troubleshooting.
A. A problem in pump and motor assembly can be localized to pump or motor

by torque requirements at 8000 rpm, as shown in Table 105.
Table 105 - Torque Requirements
PUMP MOTOR
Hydraulic Power Out for Torque In Torque Out for Electric Power In
Min Capacity Max Torque in Min Torque out Max AMPS
at 690 PSI at 8000 RPM at 8000 RPM at 24 VOLTS
1.7 gpm 0.67 ft-Ib 0.67 ft-Ib 45 amps
B. Troubleshooting procedures are listed in Table 106.
61-21-28 Page 118

September 21,2002
AeroControlex Group
Part No. 4122-006009
Table 106 - Troubleshooting
Trouble Possible Cause Isolating Correction

Procedure
Assy noisy Coupling pump Visual inspection Replace coupling (1-50) pump
shaft and/or motor shaft (2-74), or motor armature
shaft bad (3-60) (ASS/O)
Assy loose Gasket, screws or Visual inspection Replace gasket (1-40), screws
washers bad (1-20), washers (1-30) (ASS/O)
Not enough flow or Inlet screen Inspect screen Clean or replace screen (2-170)
_pressure clogged
Relief valve spring Inspect spring, Replace spring (2-110), valve
broken, valve worn, valve seat, valve set (2-130), or seals (2-100 and
or seals leaking poppet, and seals 2-140) (ASS/O)
Gear set damaged Inspect gear set Replace with matched gear set
(2-70). (ASS/O)
Bearing worn or Inspect bearings Replace bearings (2-60, 2-66,
damaged 2-68) (ASS/O)
Bearing springs Inspect springs Replace bearing springs (2-90)
weak or broken (ASS/O)
Bearing seals Inspect seals Replace seals (2-80) (ASS/O)
Housing worn or Gage housing-to- Replace pump housing (2-260).
scored gear clearance (ASS/O)
Pressure hi/lo Relief valve not Testing Adjust shim stack (2-120, 2-123,
properly set 2-126) (ASS/O)
Pump leaking Shaft or shaft seal Inspect shaft and Replace gear set (2-70) or seal
worn shaft seal (2-250) (ASS/O)
Cover seal bad or I nspect seal and Replace seal (2-50) or cover
cover warped cover (2-40) (ASS/O)
Inlet transfer tube Inspect tube and Replace inlet tube (2-145) or
seals seals (2-160)
Outlet transfer tube Inspect tube and Replace outlet tube (2-180) or
seals seals (2-190)
Housing Cracked or Visual inspection Replace housing assembly
warped (2-260) (ASS/O)
61 -21 -28 Page 119

September 21, 2002
AeroControlex Group
Part No. 4122·006009
Table 106 (continued)
Trouble Possible Cause Isolating Correction

Procedure
Check valve leaks Valve spring Check valve does Replace spring (2-220) poppet
broken, poppet or not hold pressure (2-230) or pump housing
seat worn when purnp is off (2-260) (ASS/O)
Motor draws no Open field winding Continuity checks Replace field housing
amps or low arnps (3-50)(ASS/O)
Open wire or joint Continuity checks Replace or solder (ASS/O)
Open armature Continuity checks Replace armature (3-60)
(ASS/O)
Worn brushes or Continuity checks Replace brushes (3-10)
new brushes not ONE-TIME brush replacement
run-in only.
Motor draws excess Shorted field Ohmmeter Replace field housing (3-50)
current winding (ASS/O)
Shorted armature Growler test Replace armature (3-60)
windings (ASS/O)
Comrn end bell not Motor "clock" test Position end bell (3-30)
positioned correctly for proper arnps and rpm.
(ASS/O)
Shorted Motor "clock" test Turn down cornmutator and
comrnutators undercut segments (ASS/Ot
Insulation failure Hi-Pot test Replace darnaged or worn
components: wiring, connector
(3-220), armature (3-60) or
field housing (3-50) (ASS/O)
Motor noisy Bearings worn Inspect armature Replace bearings (3-70 or
for scraping on 3-80), as required. (ASS/O)
poles
Excess end play Inspect Adjust shirn (3-100) stack
(ASS/O)
Shaft too short Gage Adjust shim (3-100) stack
(ASS/O)
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Septernber 21, 2002
AeroControlex Group
Part No. 4122-006009
OISASSEMBLY
Note: Refer to TESTING AND TROUBLESHOOTING to establish

condition of component or probable cause of any
malfunction in order to determine extent of disassembly and
repair required.
1. General
CAUTION: Some procedures in this CMM are restricted to Authorized



Sites that are "ASS/O" may accomplish all required tasks in the
CMM.
Caution:
Handle close-tolerance parts and matched parts with care to
avoid damage.
A. Place close-tolerance parts in separate plastic containers. Retain

identification of matched parts and shim stacks to assure proper reassembly.
B. Replace all O-rings, seal rings, screws or washers, and any standard parts
which are found to be damaged beyond repair.
61-21-28
Page 301
September 21, 2002
AeroControlex Group
Part No. 4122-006009
c. When a component may be installed in more than a single orientation, match

mark component and mating component to ease assembly.
Note: Actual replacement of parts may be based on in-service

experience.
2. Disassembly of Pump and Motor Assembly (See IPL. Figure 1.) (ASS/O)
A. Removal of Pump from Motor
(1) Remove safety wire from the pump/motor retaining screws (20).
(2) Remove four screws (20) and washers (30) from assembly.
(3) Remove pump (10) from motor (70).
(4) Remove gasket (40) from pump or motor
(5) Remove spline coupling (50) from pump shaft.
Note: Do not remove nameplate (60) from motor (70) unless

damaged or loose.
3. Disassembly of Pump (See IPL. Figure 2)
A. Removal of inlet tube assembly (-145) and outlet transfer tube (180)
(1) Remove outlet transfer tube (180) and inlet tube assembly (-145) from
pump housing (260).
(2) Remove two O-rings (190) from outlet transfer tube (180).
(3) Remove two O-rings (160) from inlet tube assembly (-145).
Note: Inlet screen (-170) is staked into inlet transfer tube (-150). These
items are not normally disassembled.
61-21-28
Page 302
September 21, 2002
AeroControlex Group
Part No. 4122-006009
B. Removal of Pump Cover (ASS/O)
(1) Remove safety wire from four screws (20).
(2) Remove four cover screws (20) and washers (30).
(3) Remove cover (40) and O-ring (50) from the pump housing (260).
C. Removal of Relief Valve (ASS/O)
(1) Remove O-ring (100), spring (110), sleeve (128) and shim stack (120)
from pump housing (260).
(2) Slide out relief valve poppet (134) and valve seat (137) from pump
housing (260). Poppet and seat are matched pair (130), and must be
replaced as a set.
(3) Remove O-ring (140) from relief valve seat (137).
D. Removal of Gear Set (ASS/O)
(1) Remove fixed bearings (62, 64) from the pump housing (260).
Fixed bearings are a matched pair (60) and must be replaced as a set
Caution:
Put spline cover tool T120-008008 over drive gear shaft to
protect shaft seal from damage when the gear is removed.
(2) Remove driven and drive gears (74, 77) from pump housing (260).
Gears are a matched pair (70) and must be replaced as a set.
(3) Remove floating bearings (66, 68) from the pump housing (260).
(4) Remove O-rings (80) from floating bearings (66, 68).
(5) Remove two floating bearing springs (90) from the pump housing
(260).
61-21-28
Page 303
September 21, 2002
AeroControlex Group
Part No. 4122-006009
E. Removal of Check Valve (ASS/~)
(1) Remove retaining ring (200) from pump housing (260).
(2) Remove spring retainer (210). spring (220) and check valve poppet
(230) from pump housing (260).
(3) Check valve seat is a non-replaceable part.
F. Removal of Shaft Seal (ASS/~)
Replace shaft seal (250) only if it is absolutely necessary. See REPAIR.
61-21-28
Page 304
September 21. 2002
AeroControlex Group
Part No. 4122·006009
4. Disassembly of Motor Assembly (-1, IPL Figure 3)
A. Removal of Brushes
(1) Remove lockwire and two Screws (150) and Washers (170) from
Brush Cover Band (20).
(2) Carefully remove Brush Cover Band (20) for Motor Assembly.
(3) Brushes (10) are now exposed.
(4) Mark the End Bell (40) with numbers to keep track of individual
Brush locations.
(5) Remove Screws (130) and Washers (200).
(6) Pull the torsion spring (280) away from the Brush (10) and secure off
to the side.
(7) Remove the Brush (10) and tag with the respective number marked
on the End Bell (40).
B. Removal of Electrical Connector Housing -(Remove only if replacement is

required) (ASS/O)
(1) Remove three screws (160) and three Washers (180) from
Connector Housing (90).
(2) Remove four Screws (140) and one Ground Strap Connector (240)
from Electrical Connector (220).
(3) Pull Electrical connector (220) away from housing (90) and
Desolder wires.
61-21-28
page 305
September 21,2002
AeroControlex Group
Part No. 4122·006009
C. Removal of Major Components (remove brushes prior to this operation)

(ASS/~)
(1) Remove motor thru bolts (120).
(2) Pull drive end bell (30) away from field housing (50).
(3) Pull armature (60) out of drive end of the field housing (50).
(4) If bearings (70 and/or 80) require replacement, see REPAIR section.
(5) Pull field housing (50) away from commutator end bell (40).
(6) Remove four screws (290) and pull brush guide assembly (300)
away from commutator End Bell (40).
(7) Remove Shims (100) and Wavy Washer (230) out of Commutator End Bell
(40).
61-21-28
Page 306
September 21,2002
AeroControlex Group
Part No. 4122-006009
Cleaning
1. Cleaning Materials
A Cleaning materials are listed in Table 401.
Note: Equivalent substitutes may be used for listed items.
Table 401 - Cleaning Materials
Nomenclature S~ecificationor Manufacturer

Trichlorotrifluoroethane Commercially available
Agitene Graymills Corp.

3705 N. Lincoln Ave.
Chicago, IL 60613-32517
(26023)
2. Cleaning Procedures
Warning:
Use Solvent in a well-ventilated area. Avoid breathing of fumes and
excessive contact with skin. Keep solvent away from open flame
Caution:
Do not use a nylon-bristled brush for cleaning. Brush may
disintegrate in cleaning solvent.
A. Clean all parts except electrical components in trichlorotrifluoroethane in

sonic or ultrasonic cleaning equipment.
B. Use a soft brush to lightly scrub parts. A soft wire may be used to poke dirt
out of recesses.
C. Wipe exterior surfaces of electrical components and wires with a soft

cloth moistened with Agitene. Dry clean surfaces with a clean lintless
cloth. Blowout parts with dry, clean compressed air. Agitene may be
used to clean electrical components and plastic parts.
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September 21 , 2002
AeroControlex Group
Part No. 4122·006009
Check
CAUTION: Some procedures in this CMM are restricted to Authorized Service

Sites/Organizations." These are identified by the acronym "ASS/O"
at the end of the applicable paragraph heading or, in some cases,
at the end of the text.
Procedures marked with "ASS/O," shall only be completed by those

Service Sites/Organizations authorized by Transdigm,
Sites that are not Authorized Service Sites/Organizations shall not

accomplish tasks that are marked "ASS/O".
Sites that ~ "ASS/O" may accomplish all required tasks in the

CMM.
1. Special Tools -- No special tools required for check.
2. General Check Requirements
A. Check all parts for obvious damage in accordance with standard industry
practices. Refer to Table 501 for specific checks.
8. Perform penetrant examination if necessary on all aluminum parts in

accordance with ASTM-E1417 to detect cracks which may have developed
in service. Perform magnetic particle examination if necessary on all
ferrous parts in accordance with ASTM-E1444 to detect cracks which may
have developed in service. (ASS/O)
Note: A "wear" surface is defined as a surface of a part that is

designed for dynamic contact with a surface of another part.
C. Electrical checks are performed with an ohmmeter and an insulation tester.
3. Specific Checks -- Refer to Table 501 for specific checks.
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April 20, 2007
AeroControlex Group
Part No. 4122·006009
Table 501 • Specific Checks

Nomenclature IPL Type of
Item & Fig No. Check Procedure Limits or Remarks
Spline Coupling Visual. See Check for "step" on No step felt in tooth face.
50, IPL Fig. 1. Figures 501 spline tooth faces with Outside dia. 0.2586/0.2563
Drive Gear and 502 0.020 diameter scribe. over 0.040 pins. Inside dia.
74, IPL Fig. 2 Check pitch diameters 0.1790/0.1750 between 0.030
inside and outside. pins. (ASS/O)
Spline Coupling Visual Check for cracks. No cracks. See REPAIR.
50. Fig. 1 Cadium plate. (ASS/O)
Gasket 40. Fig 1 Visual Check for tears, wear No defects allowed. (ASS/O)
and holes
Transfer tubes - Visual Check anodic coating If base metal is visible, see
145. 180 FiQ 2 AMS2470 for damaQe. REPAIR.
Penetrant Check for cracks per No cracks allowed. (ASS/O)
jOptional) ASTM-E1417 Type 1.
Pump Cover Visual Check anodic coating If base metal is visible, see
40 Fig 2. AMS2470 for damage. REPAIR.
Penetrant Check for cracks per No cracks allowed. (ASS/O)
(Optional) ASTM-E1417 Type 1.
Inlet Screen Visual Check for clogging Scrub with solvent.
-170, FiQ. 2.
Relief Valve Spring Visual Check for defects and 0.727" height at 10.6 ±1lb.
110, Fig 2. deflection. (ASS/O)
Relief Valve Visual Check valve faces for Replace as matched pair.
130. Fig 2. wear and nicks. (ASS/O)
Fixed Bearing set Visual Check gap between See Fig. 503. (ASS/O)
60, Fig. 2. bearing flats with
bearings in housing.
Visual Check bearing See Figure 504 (ASS/O)
thickness and bore.
Visual Check on face and 0.0002" max. Replace if
bore for scoring. defective. (ASS/O)
Gear Set 70, Fig 2. Visual Check Gear tooth-to- See Fig. 505. (ASS/O)
cavity Qap in housinQ.
Visual Check gear teeth for See Fig. 506 (ASS/O)
defects.
Visual check gear faces and See Fig. 507. (ASS/O)
journals for scoring
Visual Check pitch dia. on See Fig. 508. (ASS/O)
both Qears.
Table 501 (continued on page 504)
61-21-28 Page 502

April 20, 2007
AeroControlex Group
Part No. 4122·006009
0.020 DIA SCRIBE

/
Spline Tooth Wear: Coupling, Pump and Motor Shafts (ASS/O)

Figure 501
Note: Step in tooth face must not be felt with a 0.020"

diameter scribe.
{,~I',,\\~\\--r--f-
!/( \ \\ 0.1790
-
m,\\'-+,-/'/0//; B~'~~:~N
0.2586
0 .2563
OVER
\\~"N"i~1
'::Y ttl '0/
TWO 0.030
DIA. PINS I
TWO 0.040
DIA PINS
COUPLING MOTOR AND PUMP SHAFTS
Spline Diameter Check (ASS/O)

Figure 502
61-21-28 page 503

September 21,2002
AeroControlex Group
Part No. 4122·006009
Table 501 • Specific Checks (continued)
Nomenclature IPL Type of Check

Item & Fig No. Procedure Limits or Remarks
Floating Bearings Visual Check gap between flats See Fig 503 (ASS/O)
66 and 68, Fiq 2. with bearinQs in housinQ
Visual Check on face and bore 0.0002" max. Replace if
for scoring. defective. (ASS/O)
Visual Check bore size. See Fig. 504. (ASS/O)
Bearing Springs Visual Check for defects and 0.160" height at 5 ± 0.5
90, Fig 2. compression length. Ibs. (ASS/O)
Pump Housing Visual Check cavity for tangential Replace if more than 3
260, Fig 2. scoring scores: 0.0005 wide,
0.0010 deep. (ASS/O)
Check Valve Spring Visual Check for defects and 0.549" height at 0.1 ±
220, Fig 2. compression length. 0.01 Ibs. (ASS/O)
Check Valve Poppet Visual Check valve faces for Replace if defective.
230, Fig 2 wear and nicks. (ASS/O)
and Valve Seat.
Shaft Seal Visual Check for wear and Examine before removal.
250, Fig. 2. tearing on two (2) seal lips. Replace if defective.
(ASS/O)
Pump Housing Visual Check anodic coating If base metal is visible,
260, Fig 2. AMS2470 for damage. see REPAIR.
Penetrant Check for cracks per No cracks allowed.
(Optional) ASTM-E1417 Type 1. (ASS/OJ
Male Spline on See Procedure Without disassembling Same as drive gear 74,
Installed Output Block motor assembly, inspect Fig. 2. (ASS/O)
Shaft of Motor exposed male spline on
Assembly 70, Fig. 2. motor output shaft in the
same manner as the
spline on the end of drive
gear 74, Fig.2.
Table 501 (continued on page 508)
61-21-28 Page 504

April 20, 2007
AeroControlex Group
Part No. 4122-006009
FLOATING
BEARINGS
1-0_ _ _ 0.0002 MIN.

0.0006 MAX.
FIXED
BEARINGS
Floating and Fixed Bearing Gap (ASS/O)

Figure 503
r
0.4170
-------j- 0 . 4 168
I PAIR MATCHED
I TO 0.0002
---- {03125
0.3120
Pump 4120-008000
Fixed Bearing Dimensions and Floating Bearing Bore (ASS/O)

Figure 504
61-21-28 Page 505

September 21, 2002
AeroControlex Group
Part No. 4122-006009
0.0008 MAX.
0.0003 MIN.
o o
Gear-to-Housing Clearance (ASS/O)
Figure 505
CAVITIES ON
GEAR TEETH
Notes: 1. No defects in tooth top edges.

2. No defects in fillet area
3. One defect. 0.020 long by 0.005 wide by 0.003 deep allowed per tooth
Gear Teeth Defects (ASS/O)

Figure 506
61-21-28 Page 506

September 21, 2002
AeroControlex Group
Part No. 4122·006009
SCORING AND WEAR

ON JOURNALS
0.3110
0.3105
0.248
0.249
0.2620
SPLINE 0.2615
BREAKDOWN MATEDHED
TO 0.0002
SCORING IN
SEAL AREA -SCORING ON
GEAR FACES
Pump Assembly 4120-008000

Gear Defects and Dimensions (ASS/O)
Figure 507
n;0.7145
)0'0.7115
OVER TWO
YC"'--~~~~~ J 00.0864
PINS
Pump Assembly 4120-008000

Gear Pitch Diameter (ASS/O)
Figure 508
61-21-28 Page 507

September 21,2002
AeroControlex Group
Part No. 4122·006009
Table 501 • Specific Checks (continued)
Nomenclature IPL Type of Check

Item & Fig No. Procedure Limits or Remarks
Brushes (four) Visual Check brush wear. Figure 0040" min. length.
10 Fig.3 509. Replace worn brushes.
A ONE·TIME brush
replacement is
authorized at NON-
._--------'"---------------.1-0-_.-_. --------- f---=,---..---------_.----- (A~.s/Ol..3ite!,>_. ______
Bearings Visual Check for binding, wear or Replace if defective.
70,80 Fig. 3 ~k of lubricant. (ASS/O)
Bearings bores in Measure Check bore for tolerance. Replace if defective.
end bells See Figure 510 (ASS/O)
_~~Q!..fJg:l. ______.___ -.-----"--.-- !-:::-,-------------_.---- ----------.-----.-------------
End bells Visual Check anodic coating If base metal is visible,
30,40, Fig.3. AMS2470 for damage. see REPAIR. (ASS/O)
Armature 60, Fig. 3 Visual Check commutator Turn down commutators
segments for scoring and and undercut segments.
shorting.
-_._----_._.__.-----._-- ------------------ ---------_._._._-----------_.- __~~~£ifl.LJ.r.~.~lL_ (ASS/()J_
Check for shorted Growler test. (ASS/O)
windinQs.
Check for dynamic Adjust with EPO
-
balance. Dynaweight. (ASS/O)
Field coils in field Ohmmeter Continuity 0.079 to 0.065 ohm
housing 50, Fig 3. (ASS/O)
Connector Visual Check for bent or Replace if defective.
220, Fig 3. corroded pins, cracked (ASS/O)
insert.
Penetrant Check for cracks per No cracks allowed.
(Optional) ASTM-E-1417 (ASS/O)
61-21-28 Page 508

September 21,2002
AeroControlex Group
Part No. 4122-006009
MINIMUM
" L"
0.40
0.8687
MAXIMUM
Drive End Commutator End
Brush Length (ASS/O) Motor Bearing Bores (ASS/O)
Figure 509 Figure 510
1
1.150
MINIMUM
Commutator Turn Down and Undercut (ASS/O)

Figure 511
61-21-28 Page 509

September 21, 2002
AeroControlex Group
Part No. 4122-006009
Repair
CAUTION: Some procedures in this CMM are restricted to Authorized Service
Sites/Organizations." These are identified by the acronym "ASS/O" at
the end of the applicable paragraph heading or, in some cases, at the
end of the text.
Procedures marked with "ASS/O," shall only be completed by those

Service Sites/Organizations authorized by Transdigm, AeroControlex
and noted in Table 2, INTRODUCTION section.
Sites that are not Authorized Service Sites/Organizations shall not

accomplish tasks that are marked "ASS/O".
Sites that.!ill! "ASS/O" may accomplish all required tasks in the CMM.
1. Repair Materials -- Reference Table 601
Table 601 - Repair Materials
Nomenclature Specific or Mfr Use

Anodic coating AMS-A-8625 Type 2, Class II Coating bare aluminum.
dyed Grey-blue. (ASS/O)
Alodine AMS-C-5541 Type 1, Grade B, Chemical film for aluminum.
Class I.
Impregnate compound MIL-I-17563 Impregnate pump body.
(ASS/O)
Balancing weight EPO Dynaweight Commercial Dynamic balancing for motor
Chemical, Cincinnati, OH armature (ASS/O)
Cadmium plating AMS-QQ-P-416 Class C, Type II Replate coupling. (ASS/O)
Brush, stiff bristle (not Commercially available General repair.
nylon)
Crocus cloth, 400 grade Commercially available General surfaces.
Crocus cloth, 800 grade Commercially available Microfinished surfaces.
61-21-28 Page 601

September 21, 2002
AeroControlex Group
Part No. 4122-006009

Lapping compound, 1200 Commercially available Gear surfaces. (ASS/O)
grit
Pruss ian blue (bluing) Commercially available Bearing surfaces.(ASS/O)
2. Special Tools Fixtures and Equipment - Reference Table 602
Table 602 - Special Tools and Fixtures and Equipment

Hydraulic adaptor T120-008001 Connect hydraulic lines.
Mounting bracket T120-008002 Mount pump.
Spline coupling T120-008003 Pump to dynamometer.
.(ASS/O)
Motor mount T120-008004 Motor Testing (ASS/O)
Wire cable T120-008005 Connect to motor assembly
(70, IPL FIG. 1)
Relief valve bypass plug T120-008007 Block pump bypass valve flow
during run-in (ASS/O)
Spline cover T120-008008 Protect shaft seals during
assembly or disassembly.
(ASS/O)
3. Repair of Pump Assembly Surfaces and Components
A. Repair of Coupling (50, FIG. 1) by applying cadmium plating. (AS SID)
Strip and replate per AMS-QQ-P-416, Class C, Type II.
s. General repair of aluminum parts of pump assembly (10, IPL FIG. 1) Anodic
Coating, AMS-A-8625, Type 2, Class II, Dyed Greyblue on Aluminum Parts of
Pump.
Alodine per AMS-C-5541, Type I, Grade S, Class 1.
C. Repair of Housing Assembly (260, IPL FIG. 2) Leaks (ASS/~).
61-21-28 Page 602

September 21 ,2002
AeroControlex Group
Part No. 4122-006009
(1) Impregnate per MIL-I-17563. Perform leak test after impregnation.
(2). Replace Shaft Seal (2-250).
CAUTION Do not replace shaft seal unless it is absolutely

necessary.
(a) Cut out sealing elements of old seal with a sharp knife.
(b) Pull out old seal with a bearing puller.
(c) Press in new seal (with sealing elements towards pressure side)
as shown in Figure 601.
(d) Press seal into pump housing (260) until it bottoms .
--
. 275
SEALS .265
~. -- '- -.~.. .~.
. ~-SHAf=T
(74, II::JL FIG 2)
SEAL ASSY.
(250, IPL. Fie 2)
Seal Replacement
Figure 601
61-21-28 Page 603

September 21,2002
AeroControlex Group
Part No. 4122·006009
4. Run-In Procedure After Repair of Pump Assembly (ASS/~)
A. Perform pump run-in procedure after replacing gear set or bearings or

replating bearings:
(1) Remove pump cover. Replace relief valve assembly with plug T120-
008007. Reassemble pump.
(2) Set up pump on motor dynamometer as shown in Figure 602. Use

hydraulic adaptor T120-008001 , mounting bracket T120-008002 and
shaft coupling T120-008003.
(3) For the run-in procedure, the following conditions will be maintained:
• Inlet Pressu re ......................... 15 ± 2 psia

• Fluid Temperature .............. 145°F ± 45°F
(4) If input torque suddenly rises and/or output pressure fluctuates

radically, reduce speed and output pressure until condition stabilizes.
(5) Run pump at each condition shown in Table 603.
(6) Operate pump at each condition until torque and output pressure are
stabilized or not less than one minute before going to the next
condition.
(7) Remove pump from test set-up, remove relief valve plug (T120-
008007) and install relief valve parts.
(8) Clean inlet screen (2-170) inlet tube assembly (2-145).
(9) After run-in is finished, perform pump torque calibration test to

specifications shown in Table 604 and record results on, Table 105,
TESTING AND TROUBLESHOOTING section.
61-21-28 Page 604

September 21, 2002
AeroControlex Group
Part No. 4122-006009
b:-- SHOP AIR
PRESSURE
REGULATOR
~ Je o
PRESSURE
GAUGE
TO 20 PSIA
DYNAMOMETER
PRESSURE FLOW METER

GAUGE o TO 2.5 GPM
RESERVOIR o
TO
5 GAL MIN 1000 PSIG
CAPACITY
,-)+-D------j X
OFF~ ~ j NEEDLE
VALVE
X SHUT
VAL VES THERMOMETER
0' TO 180'F
HEAT
- - I ElXCHANGER 1---\-·-----
r
VALVES AND LINES 10
PROVIDE ABSOLUTE
- 3 RIGHT ANGLE BENDS
IN 0.437 10 TUBING AS
CLOSE AS POSSIBLE
Pump Run-in
Figure 602
Table 603 - Gear/Bearing Run-in Schedule
Speed RPM Pressure Increments

1500 50,250,500
4500 50,250,500,750
8000 50,250,500,750,850
61-21-28 Page 605

September 21, 2002
AeroControlex Group
Part No. 4122·006009
Table 604 • Pump Torque Calibration
Model Torque Flow RPM±2% Pressure Fluid

Ft-Lb GPM Min Inlet Outlet Temp.
Maximum PSIA PSIG ±5°F
MinIMax
4120-008000 0.67 1.70 8000 15 ± 2 690/750 120°F
5. Repair of Motor Assembly (-1, IPL Fig. 3)
A. Brush (3-10) Replacement:
CAUTION: Non-ASS/O sites using these procedures may replace

brushes only on a "ONE-TIME" basis. If additional brush
replacement is attempted, brush and commutator wear
deposits may build up within the motor assembly. Damage
to the motor assembly may result. Such damage may not
be remedied at Non-ASS/O sites
(1) Remove brushes (3-10) in accordance with DISASSEMBLY section

procedures.
(2) Install new brushes (3-10) in accordance with ASSEMBLY section

procedures.
(3) Brush Wear-In at Non-ASS/O site:
CAUTION: Non-ASS/O sites may accomplish brush wear-in only in

the pump and motor assembly (-1, IPL Fig. 1)
configuration. Damage to the pump and motor
assembly may result if the following procedures are
not followed.
(a) New brushes installed in motor must be worn-in until they fit
commutator shape as shown in Figure 603 ..
(b) Install pump and motor assembly into test stand as described
in TESTING AND TROUBLESHOOTING section.
61-21-28 Page 606

September 21, 2002
AeroControlex Group
Part No. 4122-006009
(c) While pump and motor assembly is being run for brush wear-in at a
Non- ASS/O site, make sure the following conditions are met to
prevent damage to the pump and motor assembly:
• Pump inlet oil pressure 15 ± 2 PSIA.
• Adjust power supply voltage to 10 ± 0,5 volts.
• Adjust outlet flow needle valve to make sure outlet pressure

is 100 PSI minimum to 105 PSI maximum.
• Make sure a cooling fan is used to cool motor assembly as

described below.
CAUTION: Cooling air must blow on motor assembly during

brush wear-in. Otherwise, overheating may occur
and damage the motor assembly.
(d) Once above conditions have been, read, understood, and met, brush
wear-in shall generally be accomplished as described below for
ASS/O site---except, motor and pump shall be assembled and
installed on test stand
(e) Motor assembly shall not be disassembled to blow carbon dust out of
comm end bell at Non-ASSO site.
61-21-28 Page 607

September 21, 2002
AeroControlex Group
Part No. 4122'()06009
DIRECTION 1 +00 % MINIMUM

OF ROrTION ~II~
1----1--76% MINIMUM
Brush Wear-in
Figure 603
(4) Brush Wear-In at ASS/O site: (ASS/O)
(a) Fasten motor with mount T120-008004 and connect electrical wire
cable specified in Table 602 as shown in figure 604.
Caution:
Supply a source of cooling air on motor during procedure to prevent
motor from overheating.
(b) Turn on power supply and adjust voltage to 10 volts ± 0.5 volts.
(c) Turn on fan to supply cooling air.
CONNECTOR
OR TERMINAL
BLOCK .....--.
"..
VOLTMETER
10
NO LOAD ON VOLTS
MOTOR SHAFT
MOTOR + POWER
SUPPLY
Brush Wear-in Set-up

Figure 604
61-21-28 Page 608

September 21, 2002
AeroControlex Group
Part No. 4122-006009
(d) For first few minutes of operation, observe motor operation for
excessive noise, vibration and heat. If motor is operating without
problems, continue run-in. If not, find cause and correct.
(e) Continue run-in for minimum of eight (8) hours.
CAUTION: Be sure to replace brushes exactly as they were

taken out in order to preserve a valid run-in
(f) Stop run-in. Remove each of four brushes and check for
conformance to the dimensions in Figure 603.
(g) If brushes are not worn-in, continue run. If anyone brush shows
significantly less wear than the others, check brush assembly for
weak spring and brush holder for obstructions.
(h) When brushes are worn-in, disassemble motor and blow carbon
dust out of comm end bell with clean, dry air.
B. Bearing(s) (70,80, IPL Fig. 3) Replacement: (ASS/O)
(1) Remove brushes (3-10) in accordance with DISASSEMBLY section.
(2) Disassemble major components of motor assembly in accordance with

DISASSEMBLY section.
(3) Replace bearings as follows:
(a) Remove bearings from each end of armature shaft with bearing
puller, making sure not to damage shaft ends or armature windings.
Discard bearings.
CAUTION: MAKE SURE TO PRESS ONLY AGAINST THE INNER

RACE OF THE BEARINGS. THIS WILL PREVENT
DAMAGE TO INTERNAL COMPONENTS OF BEARING.
(b) Press new bearings down to shaft shoulder on each armature

end. Make sure pressure is applied only to inner race of bearings.
61-21-28 Page 609

September 21,2002
AeroControlex Group
Part No. 4122-006009
(4) Assemble major components of motor assembly in accordance

with ASSEMBLY section.
(5) Install brushes (3-10) in accordance with ASSEMBLY section.
C. Replacing Brush Face Insulators. If damaged or burned,

replace(ASS/O)
D. Replacing Field Coils. Non-replaceable part. Replace entire field

housing. (ASS/O)
E. Adjusting motor brush position, as follows: (ASS/O)
CAUTION If the comm end bell has been removed from the field housing,
the brushes must be repositioned dynamically even if the motor
was assembled to the original alignment marks.
(1) Fasten motor with mount T120-008004 and connect electrical

wire cable specified in Table 602 as shown in Figure 605. Use
coupling with tachometer wheel between motor shaft and
dynamometer load.
(2) With the motor assembly screws (3-70) slightly loose, operate
the motor at 24 volts and minimum rated torque as shown in
Table 605.
CONNECTOR
OR TERMINAL
TACHOMETER
PICK-IUP.
VOLTMETER
24
DYNAMO VOLTS
MOTOR
-METER +
POWER
SUPPLY
Brush Adjustment Set-up

Figure 605
61-21-28 Page 610

September 21, 2002
AeroControlex Group
Part No. 4122·006009
CAUTION:: Observe maximum motor running time schedule when

conducting this test.
Table 605 • Brush Adjustment Data
Motor Part Minimum Motor Speed Maximum

Number Torque Ft· RPM Motor Amps
Lb
4902·000600 0.67 8000 minimum 45
(3) Adjust the motor speed and amps by rotating comm end bell (3-30).
Rotate comm end bell in direction of motor rotation to DECREASE
speed and amps.
(4) Rotate comm end bell AGAINST direction of motor rotation to

INCREASE speed and amps.
(5) Tighten screws after adjustment.
6. Ordering Repair Parts
A. Order pump repair parts, repair kits and upgrade kits from Transdigm, Inc.,
AeroControlex Group
B. Order pump and motor assembly, pump assembly, and motor assembly parts
from Transdigm, Inc., AeroControlex Group .. Return damaged assemblies
that cannot be repaired using these procedures to AeroControlex Group.
FSCM Name and Address

81833 TransDigm Inc.
AeroControlex Group
Destination Bldg., 2nd FI.
26380 Curtiss Wright Pkwy
Richmond Hts., OH 44143
Returns and Repairs to: AeroControlex Group

4223 Monticello BLVD
Cleveland, Ohio 44121
61-21-28 Page 611

September 21, 2002
AeroControlex Group
Part No. 4122·006009
Assembly
1. General
A. Refer to Table 701 for a list of consumable materials used during

ASSEMBLY.
CAUTION:
Some procedures in this CMM are restricted to Authorized



Sites that are "ASS/O" may accomplish all required tasks in the
CMM.
B. Special tools, fixtures or equipment required during ASSEMBLY are shown

in table 702.
61-21-28
Page 701
September 21, 2002
AeroControlex Group
Part No. 4122·006009
TABLE 701 - Assembly Materials
Nomenclature Specification or Manufacturer Use

Compound, Dow Corning 4 Dow Corning Corp. Midland, MI, Lubricate O-rings and seal rings
48640 prior to assembly.
GL YPTAL 1201, Paint, Red Commercially Available Mark screw heads
Enamel
Loctite 242 Loctite Corporation, Newington, Adhesive for threaded fasteners
CT 06111
Loctite 271 Loctite Corporation, Newington, Adhesive for threaded fasteners
CT 06111
Sleeving, 8 gauge, 1151-XL-200 Commercially Available Protect motor leads
Solder (60/40, 0.032 dia.) Commercially Available Attach motor leads to connector
Thermalcote, Type 120-5 Wakefield Manufacturing, Thinly coats bearing pockets in
Wakefield, MA 01880 motor assembly
Table 702 • Special Tools, Fixtures or Equipment
Nomenclature Specification or Manufacturer Use

Cover, spline T120-008008 Lubricate O-rings and seal rings
prior to assembly. Protect pump
shaft seal from damage by shaft
splines during assembly or
disassembly
61-21-28
Page 702
September 21, 2002
AeroControlex Group
Part No. 4122-006009
2. Assembly of Pump Assembly (See IPL Figure 2) (ASS/O)
A. Assembly of Shaft Seal.
NOTE: Replace shaft seal (2S0) only if absolutely necessary.
(1) If shaft seal (250) must be replaced, see REPAIR.
B. Assembly of Check Valve (ASS/O)

(1) Install check valve poppet (230), spring (220) and spring retainer (21 O)
into pump housing (260).
(2) Hold down spring retainer (210) and install retainer ring (200) into
groove in pump housing (260).
C. Assembly of Gear Set and Bearings (ASS/O)

(1) Install two floating bearing springs (90) into pump housing (260)
(2) Lubricate and install two O-rings (80) on floating bearings (66 and 68).
(3) Install floating bearings (66 and 68) into pump housing (260). Make
sure relief passages on face of bearings match direction shown in
Figure 701.
(4) Place spline cover, T120-008008, over shaft splines of drive gear (74)
and install matched gears (74) and (77) in pump housing (260).
(5) Install fixed bearings (62) and (64) into pump housing (260). Make
sure that relief passages on face of bearing pair are toward gear set.
Direction of passages is shown in Figure 701. Dotted lines show
location of relief passages on back side of fixed bearing pair.
D. Assembly of Relief Valve (ASS/O)

(1) Lubricate and install O-ring (140) on relief valve seat (137) and install
in pump housing (260).
61-21-28
Page 703
September 21, 2002
AeroControlex Group
Part No. 4122-006009
(2) Install relief valve poppet (134), shim washer (120) stack, which is a
combination of (120,123 and 126) and relief valve spring (110) in
pump housing (260).
(3) Lubricate and install a-ring (100) in groove on face of pump housing
(260).
(4) Install spring sleeve (128) between spring (110) and poppet (134).
(5) Install new nameplate (270) when required on pump cover (40) Also,
add new assembly nameplate (60 IPL Figure 1). on motor assembly
(70).
E. Assembly of Pump Cover (See IPL Figure 2) (ASS/O)

(1) Lubricate and install a-ring (50) in groove on face of pump housing
(260).
(2) Install cover (40) on pump housing.
(3) Install four cover screws (20) through washers (30) cover (40) and into
screw holes in housing (260).
(4) Tighten four cover screws (20) to 20-25 pound inches.
(5) Safety wire four cover screws (20) together, per MS33540.
F. Assembly of Inlet Tube Assembly (145) and Outlet Transfer Tube

(180)
(1) Lubricate and install two a-rings (190 IPL Figure 2) on outlet transfer
tube (180). Insert transfer tube into pump housing (260).
(2) Lubricate and install two a-rings (160) on inlet tube assembly (145).
NOTE: Inlet screen (-170) is staked in place in inlet transfer tube

(-150).
(3) Install inlet tube assembly (145) into pump housing (260).
61-21-28
Page 704
September 21, 2002
AeroControlex Group
Part No. 4122-006009
New pump break-in is required if new gears and/or bearings

were installed in pump. Perform the break-in procedure
described in REPAIR.
Pump Assembly (10, IPL Fig. 1) break-in or testing shall only be

accomplished at ASS/D.
Motor Assembly (70, IPL Fig. 1) break·in or testing shall only be

accomplished at ASS/D.
Pump and Motor Assembly (-1, IPL Fig. 1) break-in (e.g. brush
wear-in) or testing may be accomplished at any site.
61-21-28
Page 705
September 21, 2002
AeroControlex Group
Part No. 4122-006009
FLOATING
BEARINGS
FIXED BEARINGS
NOTE: DETAILS
ON BACK SIDE
Direction for Floating and Fixed Bearings

Figure 701
61-21-28
Page 706
September 21, 2002
AeroControlex Group
Part No. 4122·006009
G. Pump Acceptance and Performance Tests (ASS/O)
NOTE: Shaft seal leakage test can only be done with pump
separated from motor. Performance test on pump can be done
as a separate unit or as a motor and pump assembly, except as
noted in TESTING.
(1) Record all pertinent test data on copy of Table 105, TESTING AND
TROUBLESHOOTING.
3. Assembly of Motor Assembly (-1, IPL FIG 3)
A. Assembly of Major Components (ASS/O)
(1) Measure existing shim pack, consisting of shims (100) and fully
compressed wavy washer (230). If shim pack thickness is 0.30 ±
0.005 inch, use the existing shim pack. If shim pack thickness is not
within this limit, or if a new shim pack must be assembled:
(a) Fully compress wavy washer (230) and measure thickness.
(b) Add or subtract shims (100) as needed to make a shim pack

thickness of 0.30 ±0.005 inch.
(c) Make sure wavy washer (230) is fully compressed. Verify shim
pack thickness of 0.30 ±0.005 inch.
(d) Mark or tag wavy washer (230) and shims with total thickness.
(e) Keep shim pack together ready for assembly.
(2) Install measured shim pack consisting of shims (100) and wavy
washer (230) into end bell (40) bearing pocket. Install shims (100)
first.
(3) Install brush guide assembly (290) and attach to end bell (40), as
follows:
(a) Align screw holes and any previously applied match marks on
brush guide assembly (290) with end bell (40).
61-21-28
Page 707
September 21, 2002
AeroControlex Group
Part No. 4122-006009
(b) Hold brush guide assembly (290) against end bell (40).
(c) Apply Loctite 271 to threads of four screws (280).
(d) Install screws (280) through brush guide assembly (290) and
thread into end bell (40).
(e) Altemately and evenly tighten screws (280) securely.
(f) Apply 1201 GL YPTAL to heads of installed screws (280).
(4) Mate Field Housing (50) to commutator end bell (40), as follows:
(a) Align through holes and any match marks made on field
housing (50) and end bell (40) during disassembly.
(b) Thread red leads through 1 inch of 8 gauge sleeving, 1151-XL-

200.
(c) Thread black leads through 1 inch of 8 gauge sleeving, 1151-

XL-200.
(d) Thread red and black leads through grommet (260) in end bell
(40).
(e) As field housing (50) is installed, pull slack in leads through

grommet (260).
(f) Mate field housing (50) to end bell (40) and align all match
marks.
(5) If bearings (70 and/or 80) have been removed, install as follows:
CAUTION:
During installation, make sure forces are only applied to the

inner race of the bearing. Failure to do this may damage the
rotating components of the bearing
61-21-28
Page 708
September 21, 2002
AeroControlex Group
Part No. 4122"()06009
(a) Only press on the inner race of bearing (70). Press bearing
onto commutator end of armature shaft until it bottoms against
shoulder machined on end of armature.
(b) Only press on the inner race of bearing (80). Press bearing
onto drive end of armature shaft until it bottoms against
shoulder machined on end of armature.
CAUTION:
Make sure brushes (10) are not installed. Nothing should

obstruct installation of armature (60) commutator.
(6) Install armature (60) with bearings as follows:
CAUTION:
To prevent damage to the components of the motor assembly,

apply thermalcote 120-5 sparingly to inside diameters (10) of the
bearing bores in each end bell.
(a) Apply a thin coat of Thermalcote 120-5 to ID of bearing pockets

in end bells (30 and 40).
(b) Verify previous installation of shim pack into bearing pocket in

end bell (40). Shim pack consists of shim(s) (100) and wavy
washer (230).
(c) Commutator end first, install armature (60) with installed

bearings (70 and 80) through drive end of the field housing (50).
(d) Seat installed bearing (70) into bearing pocket in end bell (40).
(7) Install drive end bell (30), as follows:
(a) Align grooved pin (250) in end bell (30) with mating hole in field
housing (50). This will ensure that any match marks made
during disassembly are aligned.
61-21-28
Page 709
September 21 , 2002
AeroControlex Group
Part No. 4122-006009
(b) Install end bell (over installed bearing (80) and mate with field
housing (50). Align through holes and any match marks made
during disassembly.
(c) Install motor thru bolts (120) through end bell (40) and and field
housing (50).
(d) Thread thru bolts (120) into threads in end bell (30).
(e) Tighten bolts alternately and evenly to a torque of 45 ±5 inch

pounds.
B. Installation of Electrical Connector Housing (90) and Connector

(220). (See Figure 702 and IPL Fig. 3) (ASS/O)
(1) Make sure red and black leads coming through grommet (260) in end
bell (40) are not pinched or kinked.
(2) Run leads through housing (90).
14 GA. BLACK LEADWIRE TO

PIN .. B" ON CONNECTOR
ct COIL No.4
N
16 GA. MAGNET WIRE 16 GA. MAGNET WIRE
FROM SHUNT COIL No.1 FROM SHUNT COIL NO.4
<t COIL No.1

§ ct COIL No.2
N
14 GA BLACK LEADWIRE TO
PIN "B" ON CONNECTOI,
Motor Assembly Electrical Arraggement

Figure 702
61-21-28
Page 710
September 21,2002
AeroControlex Group
Part No. 4122-006009
(3) Align holes in housing (90) with threaded holes in end bell (40) and
any match marks made previously during disassembly.
(4) Place washers (180) over screws (160). Apply Loctite 242 to threads
of screws (160).
(5) Install screws (160) and washers (180) through housing (90) and
thread into end bell (40). Securely tighten screws (160) altemately
and evenly.
(6) Using solder, 60/40 .032 dia., solder black (negative) leads to pin "8"
of connector (220).
(7) Using solder, 60/40 .032 dia., solder red (positive) leads to pin "A" of
connector (220).
(8) Carefully install black and red leads into housing (90) and place
connector (220) onto housing. Align connector mounting holes.
(9) Apply Loctite 242 to threads of four screws (140).
(10) Thread screws through connector (220) and into housing (90).
(11) Securely tighten screws (40) altenately and evenly.
C. Installation of Brushes (10)
CAUTION:
/ ~
Non-ASS/O sites using these procedures may replace brushes
only on a "ONE-TIME" basis. If additional brush replacement is
attempted, brush and commutator wear deposits may build up
within the motor assembly. Damage to the motor assembly may
result. Such damage may not be remedied at Non-ASS/O sites.
, ~
(1) Properly align brushes (10) to mate with commutator and install
brushes (10) into appropriately marked holder in the end bell (40).
61-21-28
Page 711
September 21, 2002
AeroControlex Group
Part No. 4122-006009
(2) Install screws (130) and washers (200) through torsion spring on each
brush and attach to appropriate terminal using screws (130) and
washers (200). tighten screws securely.
(3) Carefully install brush cover band (20) around end bell (40).
(4) Align holes in brush cover band (20) with mating holes in end bell (40).
(5) Install screws (150) and washers (170) through holes in band (20).
Torque screws (150) to 10 inch pounds.
D. Performance test motor assembly using test preparation and

testing procedures in TESTING AND TROUBLESHOOTING
section.
(1) After successful performance testing of motor assembly (70, IPL Fig.
1) apply safetywire (C801-000002) in accordance with MS33540 to
screws (140,150, and 160, IPL Fig. 3) and thru bolts (120, IPL Fig. 3).
5. Motor Assembly Acceptance Test (ASS/O)
A. Perform motor assembly acceptance tests as described in

TESTING AND TROUBLESHOOTING.
B. Record all pertinent test data on copy of Table 105, TESTING

AND TROUBLESHOOTING.
6. Assembly of Pump Assembly to Motor Assembly (See IPL, Fig. 1)
A. Assemble Pump to Motor (ASS/O)
(1) Place spline coupling (50) on shaft of motor assembly (70).
(2) Place gasket (40) on top of motor assembly (70).
(3) Put pump assembly (10) on top of gasket (40).
(4) Put four screws (20) through four washers (30) and pump assembly
(10) into screw holes in motor (70).
61-21-28
Page 712
September 21,2002
AeroControlex Group
Part No. 4122·006009
(5) Tighten four screws (20) to 20-25 pound-inches.
(6) Safety wire four pump screws (20) together per MS33540.
B. Motor and Pump Assembly Acceptance and Performance Tests
(1) Perform pump and motor assembly acceptance tests as described in

TESTING AND TROUBLESHOOTING.
(2) Record all pertinent test data on a copy of Table 106.
7. Prepare for Storage
A. After successful Acceptance and Performance of the Pump

and Motor Assembly:
(1) Drain excess test fluid from pump and motor assembly.
(2) Plug transfer tubes with plastic caps.
(3) Cap or cover electrical connector
B. Place assembly in clean plastic bag and seal bag.
C. Place unit in sturdy container with sufficient packing to

prevent damage to the units.
61-21-28
Page 713
September 21, 2002
AeroControlex Group
Part No. 4122-006009
Fits and Clearances

1. Fits and Clearances
A Assembly fits and clearances are listed in Tables 801 and 802.
Table 801 "Fits and Clearances -- PN 4914-000904 Coupling
Permissable
IPL Fig & New Dimension Worn
Item Name Part Max Min Dimension Other
1-50 Coupling Inside Dia 0.1790 0.1750 0.1800 Between Two
(ASS/~) 0.030 Dia Pins
1-70 Motor Shaft Outside Dia 0.2586 0.2563 0.2553 Over Two
(ASS/O) 0.040 Dia Pins
Table 802 - Fits and Clearances -- PN 4120-008000 Pump Assembly
Permissable
2-70 Drive gear Spline Dia 0.2586 0.2563 0.2553 Over Two
and 0.040 Diameter
Driven Shaft Dia 0.3110 0.3105 0.3095 Pins
Gear
(ASS/O)
Tooth 0.2620 0.2615 0.2605
Width Pair Thickness
Matched to
0.0002"
Pitch Dia 0.7145 0.7115 0.7105 Measured over

two .0864 dia
pins
Gap 0.0008 0.0003 0.0013

Gear-to-
Housing
61-21-28 Page 801

September 21, 2002
AeroControlex Group
Part No. 4122-006009
Permissable
2-60 Fixed Dia 0.7115 0.7110 0.7100
Bearing
Pair Bore 0.3125 0.3120 0.3135
(ASS/O)
Width 0.4170 0.4168 0.4158 Pair Thickness
Matched to
0.0002"
Gap 0.0006 0.0002 0.0008 Between Flats

2-66 & 2- Floating Gap 0.0006 0.0002 0.0008 Between Flats
68 Bearing
Pair Bore 0.3125 0.3120 0.3135
(ASS/O)
Dia 0.7115 0.7110 0.7100
2-250 Seal Depth 0.27 0.23 Into Pump Body
(ASS/~)
2. Torque Values
A. Assembly torque requirements are listed in Table 803.
Table 803 - Torque Values
IPL Fig and Item Nomenclature Torque (Pound-Inches)

1-20 Screws, Pump to Motor Assy 20 - 25
2-20 Screws, Pump Cover 20 - 25
3-70 Thru Bolts, Motor Assembly 40 - 50
3-150 Screws, Brush Cover Band 10-12
3-140 Screws, Connector 3-4
3-120 Screws, Motor Assembly 32-36
3-130 Screws, Brush Holder Seat pi us 1/4...:t:::cur",n,-------,
61-21-28 Page 802

September 21, 2002
AeroControlex Group
Part No. 4122-006009
Special Tools. Fixtures, and Equipment
1. General
Refer to Table 901 for a complete list of special tools, fixtures and equipment listed
throughout this manual.
Table 901
Special Tools, Fixtures and Equipment
Tool No. Nomenclature Use

T120-008001 Adaptor block for pump inlet and Performance test. run in procedure for
outlet transfer tubes new bearings or gears.
T120-008002 Mounting bracket for pump Performance test. Run in procedure for
new bearings or gears.
T120-008003 Spline coupling for pump or motor Performance tests. Run in procedure
shafts. for new bearings or gears. Run in
procedure for new brushes.
Performance test. Run in procedure for

T120-008004 Mounting bracket for mounting new brushes.
motor without pump.
T120-008005 Electrical cable for motor assembly Motor tests.
T120-008007 Relief valve plug. Pump run-in, check valve leakage,

pump torque.
T120-008008 Spline cover. Insert pump shaft thru seal without

damage.
61-21-28 Page 901

September 21, 2002
AeroControlex Group
Part No. 4122·006009
ILLUSTRATED PARTS LIST

1. Introduction
A. Purpose
Note: This introduction provides definition of the terms, procedures and

format used.
(1) This parts list provides detail parts information necessary to support
end item configurations.
(2) Parts information is arranged in the following sequence:

• Introduction
• Numericallndex
• Detailed Parts List
• Configuration Change Summary
(3) This parts list includes information which provides customers with
continuing equipment configuration change identification for parts
designed and manufactured by AeroControlex.
B. Configuration Control (When Applicable)
(1) Item numbers and Variants in the Detailed Parts List.
(a) Item numbers are assigned in broken sequence to facilitate

insertions of added part numbers. Added parts may also be
placed at the end of a listing using previously unassigned item
numbers.
(b) Variant letters assigned to item numbers indicate part number

changes.
(2) Effectivity Codes.
(a) Used to identify changes required by the addition of models.
(b) See paragraph C. (2), below.
61-21-28 Page 1001

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
C. Parts Listing Procedures
(1) Part Numbers.
(a) The digits of a TransDigm, Inc., AeroControlex Group part

number have no significance other than to form a number with
which to identify a part.
(b) The letters RFN prefixing a number in the part number column
indicate a nonprocurable group of assemblies, subassemblies
and/or detailed parts, created expressly for the convenience of
illustration or in the case of weldments, because a part
number has not been assigned. The letters RFL prefixing a
number are used when the digits of the true part number
exceed the limitation of the part number column. (In this case,
the true part number is placed in the description column
following the nomenclature and prefixed by the words "Ident
as".)
(c) Vendor part numbers are shown if the part is used as

furnished by the vendor without modification or selection. The
vendor code (preceded by the letter "V") appears in the
nomenclature column followed by the TransDigm, Inc.,
AeroControlex Group "ID" part number. The letters ID are not
a part of the Transdigm, Inc., AeroControlex Group part
number.
(d) When Industrial Standard numbers for electronic parts are

shown in the part number column, the equivalent TransDigm,
Inc., AeroControlex Group part number is given in the
nomenclature column. Such parts will be supplied by
Transdigm, Inc., AeroControlex Group using the TransDigm,
Inc., AeroControlex group part number.
(e) The words "PARTIAL BREAKDOWN FOLLOWS" appearing in

the nomenclature column indicate that two or more detailed
parts of the subassembly are not listed.
(f) Part changes are identified by the terms "SUPSDS ITEM" or

"SUPSD BY ITEM" in the nomenclature column. Supersedure
61-21-28 Page 1002

Detailed Parts List
September 21,2002
AeroControlex Group
Part No. 4122·006009
as used in these terms shall be defined as the action whreby

an item is removed and another item is installed in its place for
any reason.
(2) Effectivity Codes (When Applicable)
(a) When needed, effectivity code letters are assigned each different
end item on the detailed parts list to establish applicability of detail
parts to end items. Detail parts which are not common to all end
items show the same code assigned to the end item of which it is a
detail. Parts common to all end items shown no code.
(b) Effectivity codes assigned apply only to the figure/listing in which
they appear.
(3) Abbreviations and Symbols.
(a) Abbreviations are generally in accordance with MIL·STD-12. The

following abbreviations are common on parts lists prepared by
TransDigm, Inc., AeroControlex Group.
AR As required. Quantity determined to suit specific requirements.
NHA Next higher assembly

NP Non-procurable
RF Reference
Note: The following paragraphs are applicable

dependent upon the contents and purpose of the
detailed parts list:
Paragraph D is applicable to parts lists printed on green paper. In

Illustrated Parts Catalogs, the transmitlalletler defines the purpose as
advance provisioning information.
61-21-28 Page 1003

Detailed Parts List
September 21,2002
AeroControlex Group
Part No. 4122·006009
D. Provisioning Parts List Procedures.
(1) Special procedures have been implemented to expedite changed

parts information dissemination to the field. Provisioning parts lists
are issued in IPLlIPC format in advance of, or concurrent with normal
component maintenance manual or illustrated parts catalog
revisions, as schedule requirements dictate. When issued in
advance of manual revisions, the changed information will appear in
a subsequent manual revision.
(2) Provisioning parts lists correlated with component maintenance

manuals are printed on green paper, but provisioning parts lists
correlated with Illustrated Parts Catalogs are printed on white.
(3) Each provisioning parts list includes a List of Effective Pages which
identifies the date of each page of the current issue. Pages changed
in the latest issue will bear the date of the issue. Back-up pages
used in the latest issue may bear the appropriate previous
provisioning parts list, or a later date ref/ecting use of that page in the
Component Maintenance Manual.
(4) Parts list items which have changed since the last manual revision
have been illustrated only when deemed essential to the utility of this
provisioning document.
(6) Material Information Table.
(a) A Material Information Table, which is not cumulative, giving

all the data necessary for procurement of those new parts to
which a change code has been assigned, is provided as a
supplement to the parts list. The material information
provided is pertinent only to those parts changed in the
revision within which it is furnished.
(b) In lieu of revised material information, new tables will be

provided with each subsequent revision. Pages of material
information will be dated, but page numbers have been
intentionally omitted.
61-21-28 Page 1004

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
E. Vendor Codes.
(1) Vendor code numbers for parts not manufctured by TransDigm, Inc.,
AeroControlex Group, appear in the nomenclature column of the Detailed
Parts List followed by the equivalent TransDigm, Inc., AeroControlex Group
part number.
(2) These codes are prefixed by the letter "V" and are contained in Federal
Supply Codes for Manufacturers Handbook H4-1 or Handbook H4-2. A
listing of all vendor codes contained in this parts list follows:
V81833
TransDigm, Inc., AeroControlex Group
Destination Bldg., 2nd FI.
26380 Curtiss Wright Pkwy.
Richmond Hts., OH 44143
61-21-28 Page 1005

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122·006009
2. Numerical Index (Note: "." prior to item no. means "non· .......
illustrated")
PART NUMBER AIRLINE FIGUREI TOTAL

PART NUMBER ITEM NO. REQ.
C1 00-01111 0 2/140 1
C1 00-01311 0 2/80 2
C1OO-013110 2/190 2
C1OO-014110 2/100 1
C1 00-01611 0 2/160 2
C1 00-02411 0 2/50 1
C450-000073 3/190 2
C450-000079 3/180 3
C450-000088 3/10 4
C450-000089 3/20 1
C450-000090 3/30 1
C450-000091 3/290 1
C450-000097 3/200 4
C450-000098 3/210 2
C450-000099 3/80 1
C450-000100 3170 1
C450-000101 3/100 AR
C450-000107 3/160 3
C450-000 108 3/140 4
C450-000 109 3/230 1
C450-000 114 3/170 2
C450-000148 3/260 1
C450-000163 3/110 4
C450-000168 3/130 4
C450-000171 3/150 2
C450-000181 3/270 4
C450-000187 3/310 16"
C450-000191 3/90 1
C450-000 193 3/220 1
C450-000 197 3/40 1
C450-000214 3/240 .25
C450-000216 3/50 1
C450-000217 3/60 1
C450-000218 3/120 2
C450-000221 3/280 4
C450-000222 3/300 1
61-21-28 Page 1006

Numerical Index
September 6, 2005
AeroControlex Group
Part No. 4122-006009

C450-000224 3/320 12"
C450-000231 3/250 1
C450-000236 3/330 1
C950-000620 1 /30 4
C950-001600 2/30 4
C950-00 1856 2/20 4
C950-001860 1 /20 4
C950-00 1889 2/240 1
C950-002077 2/200 1
4120-008000 1 / 10 1
4120-008000 2/-1 RF
4122-006009 1 /-1 RF
4900-000675 3/-340 1
4900-000775 1 /60 1
4900-000795 2/270 1
4902-000600 1170 1
4902-000600 3/-1 RF
4904-000035 1/40 1
4907-000630 2/145 1
4914-000035 2/90 2
4914-000045 2/220 1
4914-000055 2/110 1
4914-000250 2/250 1
4914-000440 2/-170 1
4914-000450 2/260 1
4914-000674 2/40 1
4914-000684 2/230 1
4914-000694 2/210 1
4914-000704 2/137 NP
4914-000714 2/134 NP
4914-000724 2/120 AR
4914-000725 2/-123 AR
4914-000726 2/-126 AR
4914-000740 2/ -105 1
4914-000804 2/-150 1
4914-000814 2/180 1
4914-000904 1 /50 1
4914-000989 2/-310 KIT
4914-001399 3/-320 KIT
61-21-28 Page 1007

Numerical Index
September 6, 2005
AeroControlex Group
Part No. 4122-006009

4914-001429 2 J -280 KIT
4914-001439 2 J -290 KIT
4914-001459 2 J -300 KIT
4914-001704 2 J 130 1
4914-001744 2 J 128 1
4915-000504 2174 NP
4915-000514 2177 NP
4915-000524 2170 1
4920-000424 2 J 60 1
4920-000434 2 J 62 NP
4920-000444 2 J 64 NP
4920-000454 2 J 66 1
4920-000464 2/68 1
61-21-28 Page 1008

Numerical Index
September 6, 2005
AeroControlex Group
Part No. 4122-006009
3. Detailed Parts List
40 50
~
70

Figure 1
61-21-28 Page 1009

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
FIG. AIRLINE EFF UNITS

ITEM PART NUMBER PART NO. NOMENCLATURE CODE PER
1234567 ASSY
1 -1 4122-006009 Pump and Motor Assembly RF

(HS 782655-3)
10 4120-008000 Pump Assembly 1
(SEE IPL FIG 2)
ATTACHING PARTS
20 C950-001860 Screw, Soc. Hd. (kp) 4

30 C950-000620 Washer, Flat (kp) 4
***
40 4904-000035 Gasket (kp) 1
50 4914-000904 Coupling 1
60 4900-000775 Nameplate (kp) 1
70 4902-000600 Motor Assembly, Elec), 1
(MTR ASSY SHALL
NOT BE DISASSEMBLED)
- ITEM NOT ILLUSTRATED

(kp) = Kitted Part. See Pump Repair Kits list, below.
61-21-28 Page 1010

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
<::Y"190
@-lBO
0 - 190
0-200
~-210
,-220
&_230 240
250 ~
,;-®\J
Pump Assembly
Figure 2
61-21-28 Page 1011

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
Fig & Part Number Airline Chng Eff Code

Item PIN 1234567 Nomenclature Code UPA
2 -1 4120-008000 Pump Assembly RF
20 C950-00 1856 Screw, Soc Hd. (kp) 4
30 C950-00 1600 Washer, Flat (kp) 4
40 4914-000674 Cover 1
50 C1 00-02411 0 O-Ring (kp) 1
60 4920-000424 Bearing Set, Fixed Set, (kp) 1
Contains Matched Parts,
Breakdown Follows:
62 4920-000434 Bearing, Fixed, Drive NP
Matched Part
Order Item 60
64 4920-000444 Bearing, Fixed, Driven NP
Matched Part
Order Item 60
66 4920-000454 Bearing, Floating, Drive 1
68 4920-000464 Bearing, Floating, Driven 1
70 4915-000524 Gear Set, Matched Set (kp) 1
Contains Matched Parts,
Breakdown Follows:
74 4915-000504 Gear, Drive, Matched Part NP
Order Item 70
-ITEM NOT ILLUSTRATED
(kp) = Killed Part. See Pump Repair Kits list, below.
61-21-28 Page 1012

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122·006009

2 77 4915-000514 Gear, Driven, Matched Part NP
Order Item 70
80 C100-013110 O'Ring (kp) 2
90 4914-000035 Spring, Bearing (kp) 2
100 C100-014110 O-ring (kp) 1
-105 4914-000740 Valve Subassembly, Relief 1
(Contains items 110-137)
110 4914-000055 Spring, Relief Valve (kp) 1
120 4914-000724 Shim, 0.010 Thick (kp) AR
-123 4914-000725 Shim, 0.005 Thick, (kp) Part AR
Added by SB 40-0205 &
40-0206
-126 4914-000726 Shim, 0.0025 Thick, (kp) Part AR
Added by SB 40-0205 &
40-0206
128 4914-001744 Sleeve, Spring, (kp) Part Added 1
by SB 40-0205 & 40-0206
130 4914-001704 Relief Valve Set, (kp) Contains 1
Matched Parts
Breakdown Follows:
134 4914-000714 Poppet, Relief Valve NP
Matched Part Order Item 130
137 4914-000704 Seat, Relief Valve NP
Matched Part Order Item 130
140 C100-011110 O'Ring (kp) 1
145 4907-000630 Tube Assembly, Inlet (kp) 1
(See Items 150 and 170)
-150 4914-000804 Transfer Tube, Inlet 1
(Order Item 145, above)
160 C100-016110 O'ring (kp) 2
-170 4914-000440 Screen, Inlet 1
(Order Item 145, above)

61-21-28 Page 1013

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122·006009

2 180 4914-000814 Tube, Transfer, Outlet (kp) 1
190 C100-013110 O'Ring (kp) 2

200 C950-002077 Retainer Ring (kp) 1
210 4914-000694 Retainer, Spring 1
220 4914-000045 Spring, Check Valve 1
230 4914-000684 Poppet, Check Valve 1
240 C950-00 1889 Retaining Ring, Seal (kp) 1
250 4914-000250 Seal, Shaft (kp) 1
260 4914-000450 Housing Assembly 1
270 4900-000795 Nameplate, Pump (kp) 1

61-21-28 Page 1014

Detailed Parts List
September 21,2002
AeroControlex Group
Part No. 4122·006009
***Pump Repair Kits Follow***
*'*Model 4120-008000 Pump Repair Kits ***
Figure & Airline Part Chg Eff

Item Part Number No. 1234567 Nomenclature Code Code UPA
2 -280 4914-001429 Kit, Fixed Bearings & Gears Breakdown Kit
Follows:
2 60 4920-000424 · Fixed Bearing Set, Matched 1
2 70 4915-000524 · Gear Set, Matched 1
2 -290 4914-001439 Kit, Seals (kp) Breakdown Follows: Kit
1 -40 4904-000035 · Gasket 1

2 50 Cl00-024110 · O-Ring 1
2 80 Cl00-013110 · O-Ring 2
2 100 C100-014110 · O-Ring 1
2 140 C100-011110 · O-Ring 1
2 160 Cl00-016110 · O-Ring 2
2 190 Cl00-013110 · O-Ring 2
2 250 4914-000250 · Seal, Shaft 1
2 -300 4914-001459 Kit, Hardware Breakdown Follows: Kit
1 -20 C950-001860 · Screw 4

1 30 C950-000620 · Washer 4
2 20 C950-001856 · Screw 4
2 30 C950-001600 · Washer 4
2 90 4914-000035 · Spring, Floating Bearing 2
2 120 4914-000724 · Shim, 0.010 Inch Thick 1
2 200 C950-002077 · Retainer Ring, Check Valve 1
2 240 C950-001889 · Retainer RinQ, Shaft Seal 1
2 -310 4914-000989 Kit, Check Valve Kit
2 230 4914-000684 .Poppet, Check Valve 1
2 210 4914-000694 .Retainer, Spring 1
2 220 4914-000045 .Spring, Check Valve 1
2 200 C950-002077 .Retainer, Ring 1
2 -320 4914-001399 KIT, Tube, Transfer (Breakdown follows) KIT

2 145 4907-000630 · Tube Assembly, Inlet 1
2 180 4914-000814 · Tube, Transfer, Outlet 1
2 -290 4914-001439 · KIT, Seals (see above for breakdown) KIT
61-21-28 Page 1015

Detailed Parts List
September 21, 2002
AeroControlex Group
Part No. 4122-006009
Motor Assembly
Figure 3
61-21-28 Page 1016

Detailed Parts List
September 6, 2005
AeroControlex Group
Part No. 4122-006009
Figure Eft.
& Item Part Number Airline Part No. Nomenclature Code UPA
3 -1 4902-000600 MOTOR ASSEMBLY RF
10 C450-000088 BRUSH & SHUNT ASSEMBLY 4
20 C450-000089 BRUSH COVER BAND 1
30 C450-000090 END BELL (DRIVE END) 1
40 C450-000197 END BELL ASSEMBLY (AD.E.) 1
50 C450-000216 FIELD HOUSING ASSEMBLY 1
60 C450-000217 ARMATURE ASSEMBLY 1
70 C450-000 100 BEARING 1
80 C450-000099 BEARING 1
90 C450-000191 CONNECTOR BOX 1
100 C450-000101 SHIM AR
110 C450-000 163 TERMINAL 4
120 C450-000218 BOLT 2
130 C450-000168 SCREW 4
140 C450-000108 SCREW 4
150 C450-000 171 SCREW 2
160 C450-000107 SCREW 3
170 C450-000114 FLAT WASHER 2
180 C450-000079 FLAT WASHER 3
190 C450-000073 FLAT WASHER 2
200 C450-000097 LOCK WASHER 4
210 C450-000098 LOCK WASHER 2
220 C450-000 193 CONNECTOR 1
230 C450-000 109 WAVE WASHER 1
240 C450-000214 O-RING .25"
250 C450-000231 PIN 1
260 C450-000148 GROMMET 1
270 C450-000 181 SPRING 4
280 C450-000221 SCREW 4
290 C450-000091 BRUSH HOLDER ASSEMBLY 1
300 C450-000222 JUMPER ASSEMBLY 1
310 C450-000 187 LEADWIRE #14 GA BLACK E 16"
320 C450-000224 LEADWIRE #14 GA RED E 12"
330 C450-000236 RETAINING RING 1
-340 4900-000675 NAMEPLATE 1
( - ) INDICATES ITEM NOT ILLUSTRATED
61-21-28 Page 1017

Detailed Parts List
September 6, 2005

Hydraulic Pump and Electric Motor Assembly Component Maintenance Manual With Illustrated Parts List

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HYDRAULIC PUMP AND

ELECTRIC MOTOR ASSEMBLY

Hydraulic Pump and Electric Motor Assembly

Hamilton Standard Part Number

This document is the property of TransDigm, Inc., AeroControlex Group,

REVISION ISSUE DATE INSERTED

Record of Temporary Revisions

Service Bulletin List

List of Effective Pages

Title 1 September 21, 2002

Record of Revisions 1 September 21, 2002

Record of Temp. Revisions 1 September 21, 2002

Service Bulletin List 1 September 21, 2002

List of Effective Pages 1 April 20, 2007

Table of Contents 1 September 21, 2002

Introduction 1 September 21, 2002

Description and Operation 1 September 21, 2002

Testing and Troubleshooting 101 September 21, 2002

List of Effective Pages

Subject Page Date

Testing and Troubleshooting

Disassembly 301 September 21, 2002

Cleaning 401 September 21, 2002

Check 501 April 20, 2007

List of Effective Pages

Subject Page Date

Check (cont) 503 September 21, 2002

Repair 601 September 21, 2002

Assembly 701 September 21, 2002

List of Effective Pages

Subject Page Date

Fits and Clearances 801 September 21. 2002

Special Tools, Fixtures, and 901 September 21, 2002

Illustrated Part List

Numerical Index 1006 September 6, 2005

Detailed Parts List 1009 September 21, 2002

Description and Operation .............................................................................................. 1

Testing and Troubleshooting ....................................................................................... 101

Disassembly ............................................................................................................... 301

Cleaning ...................................................................................................................... 401

Check ........................................................................................................................ 501

Repair ........................................................................................................................ 601

Assembly .................................................................................................................... 701

Fits and Clearances ......................................................................................................801

Special Tools,l Fixtures and Equipment. .......................................................................901

Illustrated Parts List. ...................................................................................................1001

C. This publication is compiled and issued by the Publications Department of

D. Unusual problems concerning the CMM or its subject components should be

F. Some procedures in this CMM are restricted to Authorized Service

A. This INTRODUCTION section briefly explains: a) contents of CMM; b) use of CMM

B. DESCRIPTION AND OPERATION section provides general information on the

B. IRAN is implemented in this CMM as follows:

(1) Using needed portions of SECTION 101, determine returned equipment is

(5) Accomplish applicable testing procedures contained SECTION 101. If tests

C. Some procedures in this CMM are restricted to Authorized Service

4. Shop Verification Statement:

Table 1. VERIFICATION EXCEPTIONS

Con f Igura f Ion:

A. ONLY PRODUCTS AND MATERIALS LISTED IN THIS MANUAL ARE APPROVED

B. PRODUCTS AND MATERIALS OF MANUFACTURERS OTHER THAN THOSE

C. USE OF PRODUCTS AND MATERIALS NOT APPROVED BYTRANSDIGM,INC.,

D. SOME PROCEDURES IN THIS CMM ARE RESTRICTED TO AUTHORIZED SER-

6. Authorized Service Sites/Organizations (ASS/O)