Aerospace

Boeing C-17 Transport

Boeing C-17 Component and Systems Overview Eatons Aerospace Group Product Capabilities

The United States Air Force Boeing C-17 Globemaster III is a high-wing, four-engine, T-tailed aircraft with a rearloading ramp. It is 174 feet in length, has a height of 55.08 feet and a wingspan of 169.75 feet. Maximum takeoff gross weight is 585,000 lbs.; maximum payload is 164,900 lbs. It was designed to expand the capability of the Air Mobility Command (AMC) by enabling the long distance transport of troops and heavy combat equipment directly to small austere landing sites. The austere landing site capability of the aircraft is further enhanced by having all systems fully independent of ground support equipment. The Boeing C-17 also embodies Short Takeoff and Landing (STOL) technology. The unique ability to land cargo on very short airstrips and then take off again is achieved through the utilization of propulsive lift aerodynamics and advanced composite structures for lighter weight. The aircraft is powered by four Pratt & Whitney PW2040 series (757 Derivative) turbofan engines, designated by the Air Force as F117 PW-100, each producing 40,440 lbs. of thrust, located on pylons ahead of and below the wing leading edge. Engine thrust is blown through the fully extended flaps to create additional lift. This feature is useful in short takeoff and landings, and in low speed maneuvers. The engines are also equipped with directed-flow thrust reversers capable of deployment in flight. On the ground, a fully loaded aircraft using engine thrust reversers, can back up a 2 percent slope.

Eaton is a recognized leader in the aerospace industry and is a key supplier of fluid power, electro-mechanical, fluid conveyance, power and load management and avionics products on the C-17 With this cutting edge . technology, Eaton provides a broad array of products including a 4000 psi quad redundant hydraulic system. Two of four systems are connected using a reversible motorpump, in case of emergency shut down of any engine. All four systems incorporate a primary and secondary Vickers brand engine-driven pump ensuring a constant supply of hydraulic power during all phases of flight. In the event of a four engine failure, a Vickers brand Ram Air Turbine Pump is deployed to provide hydraulic power until the aircraft is safely on the ground. The C-17's unique capability to land on short runways is assisted with Eaton's Pitch Trim motors. The pitch trim motors position the horizontal stabilizer during the short landings and take offs for optimal performance. The C-17 hydraulic system incorporates main engine and AC motor-driven pumps as well as pitch trim and OBIGGS drive motors. Eaton also provides additional system hydraulic and pneumatic units. These include servo control valves, a brake pressure metering valve, winch modules and a cargo ADS control manifold. Electrical equipment provided by Eaton includes the APU air inlet actuator, landing gear control indicator panel, throttle module, ramp lock, logistic rail locks and RAT release actuator.

The C-17 is also equipped with Eaton fluid health monitoring technology. The magnetic chip collectors, electro-optic and float activated sensors and system check valves are on all secondary power systems. These products are primarily used to monitor harmful materials in the flow of hydraulic and lube fluids during the run time of the aircraft. Other products on the C-17 include Eatons Aeroquip brand quick disconnect couplings and self sealing Bnut fittings and hose products, including high pressure Kevlar hose. In addition, Eaton provides the Aeroquip brand pylon-mounted main fuel line for each engine, incorporating two quick disconnects into a convoluted hose joined with a complex bent tube. Eaton also provides Fuel Boost Pumps and Canisters which were specifically designed for the C-17 They were designed . and manufactured to provide excellent pumping performance at high climb rates and altitudes with many different types of fuel. To enhance fire safety, Eaton also provides the aircraft mounted valves that control the flow of nitrogen gas from the OBIGGS system to the fuel tanks.

EATON Aerospace Group C5-14E October 2011

Eatons Boeing C-17

VARIABLE RESTRAINT ASSEMBLY CABLE TENSION ARM ASSEMBLY

DUAL BRAKE METERING VALVES OBIGGS LP VALVE FUEL BOOST PUMP FUEL CROSSFEED GATE VALVE APU AIR INLET ACTUATOR FLAP/SLAT POSITION TRANSMITTER MAGNETIC CHIP COLLECTORS

ENGINE DRIVEN PUMPS CARGO WINCH CONTROL PANEL AFT/FLAP SLAT MODULE LANDING GEAR CONTROL THROTTLE MODULE STEERING & BYPASS CONTROL VALVES RATIO CHANGER ACTUATOR AILERON RATIO CHANGER ASSY. RUDDER CABLE CONTROL ASSY. AILERON LOAD FEEL ASSY. RUDDER LOAD FEEL ASSY. TRIM ACTUATOR CONTROL ELEVATOR LOAD FEEL ASSY.
4 EATON Aerospace Group C5-14E October 2011

OBIGGS HP VALVE RAT PUMP RAT RELEASE ACTUATOR REMOTE CONTROL CIRCUIT BREAKER CONTROL STICK RUDDER PEDAL ASSY. PARK BRAKE MECHANISM

Systems Components

PITCH TRIM MOTORS RAMP LOCK ACTUATOR GATE RELEASE ASSY. STABILIZATION STRUT SYSTEM CARGO AIR DELIVERY MANIFOLD CARGO RAIL ACTUATOR WINCH CONTROL MODULE AC MOTORPUMP OBIGGS COMPRESSOR MOTOR OBIGGS II SUPER JOINT ASSEMBLY LEVELMASTER FLOAT ACTIVATED LEVEL SENSORS FLUID CONVEYANCE LINE ASSY. MAINSHAFT CARBON SEALS DIFFERENTIAL PRESSURE SWITCH BREATHERS GEARBOX SEALS MAIN FUEL LINE

EATON Aerospace Group C5-14E October 2011

145/155 Series Soft Seal Ground Support Couplings Eaton's 145/155 series couplings have been the industry standard for ground service applications for over 50 years. During this time the design has been continuously improved to increase reliability, safety and ease of operation. The C-17 design is no exception. Improvements have been made to include elastomeric soft seals in both the aircraft half and ground cart half to virtually eliminate fluid spillage and air inclusion during operation, and blunt start threads to prevent cross threading.

C-17 Main Fuel Line Eaton's Aeroquip brand main fuel line provides fuel from the engine pylon to the engine fuel pumps on each C-17 engine. The product features 2 diameter convoluted Teflon hoses,covered with slip-on silicon fire protection sleeves, and integrally mated with two quick disconnect coupling halves and a complex bent tube. Aeroquip brand convoluted hose combines the routing flexibility of lightweight rubber hose with the temperature range and fluid compatibility of Teflon. The assembly can be disconnected from the pylon with no fuel spillage.

Flexible Hose Assemblies Eaton's Aeroquip brand hose assemblies are utilized extensively throughout the C-17 aircraft. The assemblies can be found in the hydraulic system, the oxygen system, the fuel system and lube oil system. Eaton provides lightweight Nomex braided, convoluted hose assemblies to AS1227 Kevlar . reinforced Teflon hoses to AS4623 are used in the 4,000psi hydraulic system offering a significant weight savings over more traditional wire reinforced hose assemblies.

1817 Low Profile Ball Bearing Plane Swivel Joints Rotational movement in the landing gear hydraulic system of the C-17 is supplied by Eaton's Aeroquip brand 1817 series low profile ball bearing plane swivel joints. The 1817 series was designed and qualified to MIL -J5513 for low torque, high side load applications.

Low Profile, Self-Sealing Hydraulic "B" Nut Fittings Eaton's Aeroquip brand low profile, self-sealing hydraulic "B" nut fittings, offer a small envelope size with minimal weight. The "B" nut design is for both 4,000 psi high pressure and low pressure hydraulic systems used on the Boeing C-17 .

OBIGGS II Flex-Coupling Assembly Eaton provides its Flex-Coupling Assembly that supports the second generation on-board inert gas generator system that replaces gas bottles used in older generation aircraft and replaces a first generation OBIGGS system.

Mainshaft Seals Mainshaft Seals are used along the aircraft engine main shaft, sealing in lubrication of the main bearings.

Gearbox Seals Seals that contain bearing lubrication in the gearbox mounted on the engine from which the accessories receive their power - accessories include all the units that power the ancillary functions around the engine including the starter, fuel controls, fuel pumps, hydraulic pumps, etc.

EATON Aerospace Group C5-14E October 2011

Pitch Trim Actuator Motor The C-17 pitch control is maintained by a rotary actuator located in the aircraft empennage. The pitch trim actuator motor provides positional control of the horizontal stabilizer. Two Vickers brand bi-directional inline hydraulic motors, with a displacement of .22 cu. in./rev. (3.60 ml/rev), produce a theoretical torque of 137 in. Ibs. at 3900 psi (26,889 kPa) pressure differential. The motor is designed to withstand two million reverse load cycles, and 2000 psi return pressure. The MF3-022 motor contains anti-cavitation check valves and weighs 6.2 Ibs. (2.81 kg).

OBIGGS Compressor Drive Motor The OBIGGS compressor is driven by a Vickers brand inline, constant speed hydraulic motor which features integral speed control and an electrically operated shut off valve. When 28 VDC is applied to the solenoid, the motor will rotate, creating a constant speed between 2250 and 2550 rpm, over the power range required by the compressor output flow. Motor displacement is .598 cu. in./rev. (9.80 ml/rev). The weight of the OBIGGS drive motor and controls is 14.6 Ibs. (6.62 kg).

Engine-Driven Hydraulic Pump The unique design and construction of these Vickers brand 4000 psi (27 ,579 kPa) pumps allow them to operate at relatively high efficiencies, thus enabling each unit to generate nearly 80 hydraulic horsepower. Additional features of the PV3-190 include an Electrical Depressurization Valve (EDV), a blocking valve, and an inlet boost impeller. The package also weighs less than 28 Ibs dry. (12.25 kg).

AC Motor Driven Pump Eaton provides four Vickers brand .42 cu. in./rev. (6.88 ml/rev) displacement AC motor driven pumps per aircraft. The AC Motorpumps provide flow to each of the four aircraft hydraulic systems. This allows the aircraft to be fully checked out before flight without the need of a ground cart. The AC Motorpump is also used to power the on-board cargo loading system, and to stabilize the aircraft during loading. The variable displacement motorpump produces .87 up to 10 gpm (37 L/min) at 6000 rpm. The 3 phase, 200/115 volt, 400 Hz electric motor is a dry rotor oil jacket cooled design with integral thermal annunciation. Dry weight of this complete assembly is 42.5 1bs. (19.28 kg). Dual Brake Pressure Metering Valve Assembly These units are installed in the landing gear wheel well and are controlled by the pilot through a mechanical closed loop cable system. The assembly controls the hydraulic actuation pressures to the brakes as a function of input position from the rudder pedals. Included in the assembly are two force command metering valves for modulating brake pressure and a despin actuator to stop the wheels from spinning upon landing gear retraction.

Cargo/Air Delivery System (ADS) Control Manifold The Cargo/ADS Control Manifold is designed for air drop operations and on/off loading on the ground. The Cargo/ADS Control Manifold contains all valving necessary to control the cylinders in the Aerial Delivery System including, the cargo ramp, ramp latches, ramp toes, and cargo door actuators. It also controls the cargo door up and down locks, the left and right drouge parachute and the deploy mechanisms, and the tow/release and drogue chute jettison mechanism. The Control Manifold can be operated electrically from the forward loadmaster station, or manually from the rear station.

Winch Control Module Eatons control module provides control of fluid flow to the hydraulic motor operated winch when commanded by the Loadmaster. The module regulates hydraulic flow in response to an electrical input command from Eatons 6055 winch control panel. The Winch Control Module consists of a servo valve, relief valve across the motor ports, anti-cavitation make up check valve and two inlet pressure blocking valves. One is used for the winch brake release and the other is for control of the hydraulic motor dual speed feature.

Steering and Bypass Control Valves The C-17 hydraulic system includes a set of nosewheel steering control (P/N 70909) and nosewheel steering bypass (P/N 70910) valves. The bypass valve is used to unload the steering actuators during towing and allows for centering of the Nose Gear while being stowed. The Steering Valve receives a clockwise or counter-clockwise manual input from the rudder pedals, and provides hydraulic fluid flow to the nosewheel steering control actuators. Position feedback to the valve is achieved through a closed loop cable system. The valves are tandem redundant, dual system with rip stop construction between the two hydraulic systems.

EATON Aerospace Group C5-14E October 2011

Differential Pressure Switch The Eaton type 21SN04 deltaP differential pressure switch is an exceptionally rugged switch, used in the fuel system, designed for engine-mounted applications and other hostileenvironment conditions. It may be used to detect fuel or oil filter clogging or to detect low-fuel booster pump pressure and to close a warning indicator circuit.

Three Phase Remote Control/ Circuit Breaker The Eaton 3-phase remote control circuit breakers are rated at 115v / 200vac 400Hz continuos duty 20 amp with a high rupture capability of 3600 amp. The unit utilizes a magnetically latched coil with double break contact design. The remote controlled circuit breaker combines the function of a mechanical contactor in conjunction with current sensing capability. This RCCB also has a single pole double throw (SPDT) 28vdc / 115vac 400 Hz auxiliary switch rated at 3 amp. This product is available in current ranges from 5 to 60 amps.

Remote Power Controller The Eaton 28vdc single pole single throw (SPST) remote power controller is designed for continuos duty power operation at 150 and 200 amps with a rupture capability of 2500 amp and is used as a buss cross-tie controller on the C-17 The trip current . levels can be closely controlled and can be customized for specific applications. The remote power controller combines the function of a mechanical contactor in conjunction with current sensing capability. This device also employs a single pole single throw (SPST) auxiliary switch rated at 28vdc 15v 400Hz 3 amp.

Levelmaster The C-17 Levelmaster provides four discrete bits of potable water level information. The assembly consists of four electro-optic sensors positioned at customer specified levels of: full, 2/3, 1/3 and empty. As liquid covers each prism point, a light is activated in a panel mounted indicator, providing level status. A press-to-test button on the indicator will energize those lights corresponding to the sensors which are not immersed in liquid.

Magnetic Chip Collectors The C-17 engine oil system incorporates Eatons Tedeco brand magnetic chip collectors for the capture of ferrous engine wear debris. These collectors have a self-closing valve which will prevent oil leaks up to 300 psig (20.69 bar), and rare earth magnets for effective debris capture over long periods of time.

System Check Valve The C-17 integrated drive generator (IDG) contains an Eaton 2C6107 system check valve. This valve has a 10 micron sintered disc for filtering capability, and a flow restrictor that controls air flow through the valve.

Float-Activated Level Sensor The 2E6139 Float-Activated Liquid Level Sensor is located in the C-17 Integrated Drive Generator (IDG). The sensor, weighing approximately 30 grams, provides feedback upon sensing an insufficient fluid level in the IDG.

EATON Aerospace Group C5-14E October 2011

Rudder Ratio Changer & Door Lock Actuator Eatons Rudder Travel Actuator imparts controlled linear motion to change the rudder input to output ratio of the control mechanism. This feature is engaged when part or full manual reversion control of the aircraft surfaces is required. In this mode, the mechanical inputs to the airleron and elevator control valves are changed depending on the authority required. The actuator consists of reduction gears, a screw jack, and attached fittings that are driven by an integral 28 Vdc electric motor. The actuator is capable of having its direction reversed at any intermediate position. Stroke reversal is accomplished by reversing DC voltage polarity to the motor by means of external switching. Internal switching. This function removes power from the motor at each end of the stroke. Ramp Lock Actuator The model 6057 Ramp Lock Actuator provides control of the cargo ramp lock on the aircraft. A helical spring on the actuator helps to overcome flight loads and extends the actuator to release the Ramp Lock. The actuator is operated by a 28 Vdc motor driving through a two-stage spur gear drive train into a multiplate slip clutch and a ball screw assembly. Motor direction is controlled by electro-mechanical relays that are energized and de-energized by the Aerial Delivery System Controller. Actuator control feedback is provided by external position sensors. The multiplate slip clutch allows the actuator to be overriden in the event that power is lost to the actuator.

Aileron & Rudder Trim Actuator This actuator provides a linear output force which operates the slat hydraulic control valve and trims the aileron and rudder control systems on the C-17 . The actuator is powered by two redundant DC motors. Four linear variable differential transformers (LVDT) are mounted integrally with the actuator housing and provides position feedback to the four flight control computers. A direct gear drive permits individual or simultaneous motor operation. Each motor is locked in position by a spring loaded brake. The brake holds the actuator in place and prevents backdriving of the other motor during single motor operation. Mechanical stops limits both extend and retract travel.

Rotary Actuator This actuator operates the APU air inlet and consists of a reversible DC motor with an electrical brake. The brake is disengaged when electric power is applied to the motor, and engaged when power is off, preventing the output shaft from being back driven. Rotation of the output shaft is controlled by applying voltage to the CW or CCW fields. Internal limit switches open at the end of the stroke to limit rotation of the output shaft. Internal mechanical stops limit the travel in the event of an overrun of the electrical limit switches

Gate Release Assembly The model 6047 Gate Release Actuator is used on the C-17 aircraft to trip cargo pallet tie-downs during airborne off-loading. Operation of the actuator is electrically controlled by the aircraft loadmaster. A 28 Vdc brush-type motor, directly coupled to a ballscrew, provides the quick retraction stroke required for a clean release of the load. An internal extension spring returns the actuator to the "locked" position after electrical power is removed.

Cargo Rail Actuator The model 6056 Actuator is used to perform the lock/arm/release function for the cargo pallets constrained by cargo bay logistics and aerial delivery rails on the C-17 aircraft. The actuator is operated by a 115 Vdc, 400 Hz, three-phase motor that drives a reduction gear to a ball screw and output rod. The input gear for the ball screw is located between two pairs of Belleville spring washers, which absorb the peaks of shock loads when the output contacts the mechanical stops. The actuator is available with or without a brake on the motor. The manual brake override allows the actuator to be back driven when power is removed.

Landing Gear Control and Indicator Panel This Eaton unit provides pilot/copilot control of the landing gear and presents landing gear warning and gear position status. The gear control handle is a twoposition, overcenter, snap-action type requiring 6 1 pounds to move from "GEAR UP" to "GEAR DOWN". An NVS compatible red light in the handle illuminates when the gear disagrees with the handle position or a warning signal is received from the Flight Control Computer.

Thrust Control Module The Throttle Assembly is used to control engine thrust on each of the C-17's four engines. The position of each throttle lever is monitored by electrical outputs from resolvers and cam operated switches. The quad output of the resolvers is sent to each of the four control computers. A separate resolver output is sent to each of the four electronic engine control computers. An autothrottle actuator can drive all four throttle levers simultaneously in the segment of travel between forward stop and idle stop. An integral clutch is used to override the autothrottle when necessary. The Throttle Module also controls the thrust reverser system, and includes thrust reverser lock out solenoids to prevent an inadvertant actuation.

EATON Aerospace Group C5-14E October 2011

High and Low Pressure Regulating Valves Eaton's aircraft mounted pressure valves control the flow of nitrogen gas from the Onboard Inert Gas Generation System (OBIGGS) to the fuel tanks to enhance fire safety. Pressure regulation reduces the elevated pressure of the stored gas down to the near-atmospheric levels required for the fuel tanks. Each system comprises one High Pressure Regulating Valve (HPRV) and two Low Pressure Regulating Valves (LPRV), each incorporating shut-off valves.

Fuel Boost Pump Type 9201 and Canister Type 9202 Eatons Fuel Boost Pump is fitted in a tank mounted canister for ease of installation and to avoid draining the tank when removing the pump. It is specifically designed and manufactured to provide excellent pumping performance at high climb rates and altitudes with many different types of fuel. This pump has the ability to provide vapour free fuel, even at near boiling conditions, with hot volatile fuels.

Variable Restraint Assembly Eatons model 6347 Rotary Actuators are used to adjust the release point on the Variable Restraint Lock mechanisms on the aircrafts Aerial Delivery Rail. The actuator is powered by a Bi-directional 115 VAC single phase motor. The motor has an integral brake which holds the output shaft in position when power is removed. The brake is released upon re-application of power. A film type multi-turn potentiometer is connected to the epicyclic gear train and is used to track the number of revolutions of the output shaft and displays the load setting at the sidewall control panel.

RAT Deployment Actuator Eatons model 6060 Ram Air Turbine Actuator is a quick, short stroke device designed to release the latch that holds the ram air turbine in stowed position, on the aircraft. The actuator is operated by a 28 VDC motor splined directly to an Acme screw. An Acme nut, restrained from rotation by a spline interface with the housing, provides the linear action to position an output rod. An Acme screw is held between two pairs of Belleville spring washers in contact with thrust bearings, which absorb peak shock loads when the output rod strikes the mechanical stops.

Breather (supplied to Hamilton Sundstrand) Eatons 2B6464 Breather provides pressure equalization and air filtration for the lubrication circuit for the On Board Inert Gas Generation Systems (OBIGGS) compressor. The filter element is made of corrosion resistant mono filament material.

Stabilization Strut System The Eaton provided Stabilization Strut System is used to stabilize the aircraft for cargo loading and unloading and to jack up the rear of the aircraft for changing the main landing gear tires. The system consists of four different components, the 70795-12 Stabilization Strut, the 7079524 Door Deployment Actuator, the 70795-33 Control Manifold, and the 70795-4 Isolation Valve. The control manifold is used to operate the system manually or electronically, and maintains a set pressure in the stabilization strut as cargo is loaded. The door actuator is used to open the strut compartment door to deploy the strut.

Fuel Crossfeed Gate Valve Eaton's Crossfeed Gate Valve is a 2-1/2 inch gate valve used to control the transfer of fuel from one tanks boost pumps to another tanks engine. The valve assembly consists of a tank mounted body assembly, a motor operated actuator, and an actuator support assembly. The actuator, gate body, and primary seals are interchangeable and removable without draining the tank. The weight of the complete valve assembly is 4.4 lbs (2.0 kg).

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EATON Aerospace Group C5-14E October 2011

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