Appendix_L_-_Operations_and_Maintenace_Manual.pdf

T.O. 33D4-6-668-1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS

LUBE ACCESSORY

TEST STAND

PART NO.

3C3966G05

(ATOS)

(GE Aircraft Engines)

F33657-81-C-2006

F34601-95-D-0180

THIS MANUAL SUPERSEDES APPROVED SPECIAL HANDLING AFMC FORM 252, PROJECT NUMBER 51MOCARGA6Z018R.

DISCLOSURE NOTICE: This information is furnished upon the condition that it will not be released to another nation without the specific authority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the Department of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT D: Distribution authorized to Department of Defense and U.S. DoD contractors only, Critical Technology, 1 February 2002. Refer other requests for this document to 748 CBSG/OM, Tinker AFB, Oklahoma 73145-3031.

WARNING: This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C. 2751 et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violation of these export-control laws is subject to severe criminal penalties. Dissemination of this document is controlled under DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction of the document.

Published under authority of the Secretary of the Air Force

1 FEBRUARY 2002 CHANGE 4 - 1 JUNE 2006

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by miniature pointing hands.

Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are:

Original . . . . . . . . . . . . . . . . . . . . 0 . . . . . . . . . . 1 February 2002 Change . . . . . . . . . . . . . . . . . . . . 3 . . . . . . . . . . . . . . 15 May 2004 Change . . . . . . . . . . . . . . . . . . . . 1 . . . . . . . . . . 15 January 2004 Change . . . . . . . . . . . . . . . . . . . . 4 . . . . . . . . . . . . . . . 1 June 2006 Change . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . 15 February 2004

TOTAL NUMBER OF PAGES IN THIS MANUAL IS 152, CONSISTING OF THE FOLLOWING:

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A Change 4 USAF

TABLE OF CONTENTS

Chapter Page Chapter Page

FOREWORD ..............................................................iii 4.12 Operating Procedures ...............................4-28

4.13 Test Stand - Initial Operation ..................4-30

4.14 Test Stand - Startup and Pressure

SAFETY SUMMARY.................................................v Controller Card - Calibration Check ...................................................4-32

4.15 Test Stand - UUT Testing........................4-34

1 GENERAL INFORMATION...................................1-1 4.16 Test Stand - Shutdown .............................4-35

1.1 General Information ...................................1-1 5 MAINTENANCE INSTRUCTIONS .......................5-1

1.2 Significant Item Numbers (Sin) -

Description .............................................1-1 5.1 Introduction.................................................5-1

1.3 Test Stand Assembly..................................1-2 5.2 Inspection and Preventive Mainte-

1.4 Leading Particulars .....................................1-3 nance ......................................................5-1

1.5 Consumable Materials ................................1-3 5.3 Seventy-Five-Gallon Oil Tank -

Filling .....................................................5-2 2 SPECIAL TOOLS AND TEST EQUIP- 5.4 Three-Gallon Oil Tanks - Filling...............5-3

MENT...................................................................2-1 5.5 Oil System - Bleeding................................5-3

5.6 Cleaning ......................................................5-4

2.1 Introduction.................................................2-1 5.7 Troubleshooting ..........................................5-5

2.2 Special Tools and Test Equipment ............2-1 5.8 Functional Relationship..............................5-5

2.3 Special Tools and Test Equipment 5.9 Basis Of Test Stand Trouble-

- Fabrication...........................................2-1 shooting..................................................5-5

5.10 General Troubleshooting ............................5-53 PREPARATION FOR USE AND SHIP-

5.11 Detailed Troubleshooting Tech-MENT...................................................................3-1 niques .....................................................5-5

5.12 Repair........................................................5-133.1 Introduction.................................................3-1

5.13 Turbine Flowmeter - Repair.....................5-133.2 Preparation For Use....................................3-1

5.14 Calibration.................................................5-163.3 Installation Facilities...................................3-1

5.15 Flowmeters - Calibration 029DA,3.4 Installation Requirements ...........................3-1 and 029DB ...........................................5-203.5 Unpacking and Locating ............................3-1

5.16 Micro-Flo 100 Calibration Tables ..........5-253.6 Service Connections ...................................3-1

5.17 Micro-Flo 100 - Calibration.....................5-273.7 Preparation For Shipment...........................3-4

5.18 Timer Counter - Calibration.....................5-43

5.19 Voltage Ratiometer - Calibration.............5-434 OPERATION INSTRUCTIONS .............................4-1

5.20 8806A Fluke Multimeter - Cali-bration ..................................................5-444.1 Introduction.................................................4-1

5.21 Temperature Indicator - Calibra-4.2 Controls and Indicators ..............................4-1 tion .......................................................5-444.3 Theory of Operation...................................4-1

5.22 Micrometer Caliper Head - Cali-4.4 Hydraulic System - Theory of bration ..................................................5-45Operation Circuit ...................................4-1

5.23 Pressure Gage - Calibration .....................5-454.5 Water System - Theory of Opera-

5.24 8840A/Af Fluke Multimeter - Cal-tion .......................................................4-21 ibration .................................................5-454.6 Pneumatic System - Theory of Operation..............................................4-21

6 DIAGRAMS..............................................................6-14.7 Electrical System - Theory of Op-eration through 348DD........................4-22

6.1 Introduction.................................................6-14.8 Instrumentation System - Theory

6.2 Significant Item Number (SIN)of Operation.........................................4-24

Locator ...................................................6-14.9 Ventilation System - Theory of

6.3 Contents ......................................................6-1Operation..............................................4-26

4.10 Safety Features .........................................4-26

4.11 Emergency Stop Switches - Safety

Features ................................................4-28

Change 1 i

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Lube Accessory Test Stand............................ 1-1 5-2 Typical Micro-Flo 100 and Circuit 2-1 Thermocouple Cable - Fabrication ................ 2-1 Board Layout ........................................... 5-19 3-1 Service Connections ....................................... 3-3 5-3 Flowmeter Curves - Typical ........................ 5-22 4-1 Panel Locator .................................................. 4-9 5-4 Sample Calibration Data Chart .................... 5-23 4-2 Panel E - Front View ................................... 4-10 5-5 Component Location Diagram ..................... 5-24 4-3 Panel F - Front View.................................... 4-11 5-6 Analog-to-Digital (A/D) Converter Card..... 5-30 4-4 Panel G - Front View................................... 4-13 5-7 PRC-408A Flow Rate Converter ................. 5-41 4-5 Panel H - Front View................................... 4-15 5-8 RC51 Pulse Rate Converter ......................... 5-42 4-6 Panel J ........................................................... 4-16 5-9 Temperature Indicator (649DA) - Cali- 4-7 Panel K.......................................................... 4-17 bration....................................................... 5-44 4-8 Panel L .......................................................... 4-18 FO-1 Wiring Diagram ............................................FP-1 4-9 Panel M......................................................... 4-19 FO-2 Hydraulic/Pneumatic Schematic.................FP-19 4-10 Service Panel ................................................ 4-20 FO-3 Electrical Schematic ...................................FP-25 5-1 Turbine Flowmeter Repair ........................... 5-15

LIST OF TABLES

Number Title Page Number Title Page

1 Related Publications............................................ iii 4-8 Controls - Shutdown Positions for Main- 2 Symbols and Nonstandard Abbreviations ......... iv tenance ........................................................ 4-35

List of Time Compliance Technical Or- 5-1 Periodic Inspection............................................ 5-1 ders.................................................................. iv 5-2 Annunciator Troubleshooting ........................... 5-6

1-1 Technical Orders for Units Under Test ........... 1-2 5-3 Test Stand Troubleshooting .............................. 5-8 1-2 Leading Particulars............................................ 1-3 5-4 Calibration Data .............................................. 5-16 1-3 Consumable Materials....................................... 1-5 5-5 Flowmeter Calibration Data............................ 5-21 2-1 Test Equipment ................................................. 2-2 5-6 Temperature Indication Calibration Data ....... 5-29 3-1 Service Connections.......................................... 3-2 5-7 Pressure Transducer - Calibration .................. 5-32 4-1 Controls and Indicators ..................................... 4-4 5-8 Pressure Indication - Calibration Data ........... 5-33 4-2 Micro-Flo 100 Transducers, Connections, 5-9 Pressure Indication - Adjustment Data........... 5-34 and Bleed Controls..................................... 4-25 5-10 Liquid Flow Indication - Calibration 4-3 Micro-Flo 100 Thermocouples ....................... 4-25 Data............................................................. 5-35 4-4 Micro-Flo 100 Flowmeters ............................. 4-26 5-11 Airflow Indication - Calibration Data ............ 5-38 4-5 Temperature Indicator Thermocouples........... 4-26 5-12 Airflow Indication - Adjustment Data ........... 5-38 4-6 Annunciator Channels ..................................... 4-27 5-13 Temperature Indicator Channel Selection ..... 5-45 4-7 Controls - Initial Positions.............................. 4-28 6-1 Significant Item Number (SIN) Locator .......... 6-1 ii Change 1

FOREWORD

1. INTRODUCTION. The manual is divided into front matter, six chapters, and an alphabetical index. In the front matter, a table of

This section contains purpose, scope, and arrangement of contents provides chapter numbers, paragraph titles, and this manual, and general information for the 3C3966 lube page numbers to help locate information. A list of illustra-accessory test stand (Figure 1-1). This section contains tions and a list of tables indicate the number, title, and page Related publications, symbols, and nonstandard number of each illustration and table. Chapter 1 contains abbreviations. general information on the test stand, and lists of consuma-ble materials, referenced publications, and symbols and

2. PURPOSE. nonstandard abbreviations. Chapter 2 lists special tools and test equipment required for operation, maintenance, and This manual contains operation and maintenance instruc- calibration of the test stand. Chapter 3 contains instructions tions for the test stand 3C33966. for unpacking the test stand, preparation for use, and for shipment and storage. Chapter 4 contains theory of opera-

3. SCOPE. tion, safety features, and detailed instructions for test stand operation. Chapter 5 contains instructions for maintenance This manual contains instructions for preparing, installing, of the test stand. Instructions are provided for operational operating, and maintaining the test stand. All test equip- checkout, inspection and preventive maintenance, trouble-ment and consumable materials necessary to check out, shooting, repair, test, and calibration. Chapter 6 contains service, and calibrate the test stand are included. Wiring wiring diagrams and hydraulic, pneumatic, and electrical diagrams and hydraulic, pneumatic, and electrical schemat- schematics. All foldout drawings are located at back of ics are included. manual. An alphabetical index is located ahead of the foldout drawings. This index is a listing of all major items4. ARRANGEMENT.

and types of procedures in alphabetical order, referenced to paragraph numbers.

Table 1. Related Publications

Publication Title MIL-STD-12 Abbreviations for Use on Drawings, and in Specifications, Standards and

Technical Documents

TO 00-25-234 General Shop Practice Requirements for the Repair, Maintenance and Test of Electrical Equipment

TO 1-1-691 Aircraft Weapons Systems - Cleaning and Corrosion Control

TO 33D4-6-668-4 Illustrated Parts Breakdown, Lube Accessory Test Stand

TO 33K6-4-15-1 Calibration Procedures, Caliper and Depth Micrometers

TO 33K6-4-26-1 Calibration Procedure, Gas Flowmeters (Rotometers)

TO 33K6-4-427-1 Calibration Procedure, Pressure Gage (Bourdon Type)

TO 33K6-4-1083 Calibration Procedure, Turbine Flowmeter with Signal Conditioner, ANC8-4, 10 W/104-052

TO 33K8-4-120-1 Calibration Procedures, Digital Multimeter (8860A)

Change 1 iii

Table 2. Symbols and Nonstandard Abbreviations

Symbol / Abbreviation Definition °C Degrees Celsius

°F Degrees Fahrenheit

* Enter key (used on Micro-Flo 100 keyboard)

= Equal

- Minus

% Percent

+ Plus

± Plus or minus x Times (multiplication)

: To (ratio)

ACFM Actual cubic feet per minute

CAGE Commercial and Government Entity

DMM Digital multimeter

EXT Exit

Hg Mercury

HI High

Hz Hertz kVA Kilovolt amperes

PSID Pounds per square inch differential

SCIM Standard cubic inch per minute

SCFM Standard cubic feet per minute

SIN Significant item number

5. The following list of Time Compliance Technical from this list when rescinded, superseded, or fully Orders (TCTOs) affect the technical content of this man- incorporated.

ual. Only current TCTOs are listed. A TCTO is deleted

List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

33D4-6-668-504 Modification of Lube Accessory Test Stand Part Number 3C3966G05 1 Feb 96 iv Change 1

SAFETY SUMMARY

1. DEFINITIONS. • Do Not Service Or Adjust Alone. Do not attempt internal service or adjustment of equipment unless another

The following definitions apply to WARNINGS, CAU- person capable of rendering aid and resuscitation is present.

TIONS, and NOTES throughout this publication:

• Resuscitation. Personnel working with or near dangerous voltage shall be trained in modern methods of

WARNING resuscitation. Information and training sources may be obtained from the Director of Base Medical Services.

An operation or maintenance procedure, prac- • Electrostatic Discharge. Certain circuit card tice, condition, statement, etc., which, if not assemblies and their components will be damaged by strictly observed, could result in injury to or seemingly undetectable electrostatic discharge. Care must death of personnel. be exercised during handling/repair of these items. Use electrostatic discharge precautionary procedures outlined in

TO 00-25-234.

CAUTION

• Compressed Air. Air pressure, used in work areas for cleaning or drying operations, shall be regulated to 30An operation or maintenance procedure, prac- PSI or less. Use approved safety equipment (goggles/facetice, condition, statement, etc., which, if not shield) to prevent injury to the eyes. Do not direct the jet ofstrictly observed, could result in damage to or compressed air at self or other personnel; or so that refusedestruction of equipment or loss of mission is blown onto adjacent work stations. If additional aireffectiveness.

pressure is required to dislodge foreign materials from parts, ensure that approved safety equipment is worn.

NOTE Ensure that the increased air pressure is not detrimental or damaging to the parts before applying high-pressured jets

An essential operating or maintenance proce- of air.

dure, condition, or statement which must be highlighted. • Lubricating Oil. Lubricating oil in liquid, vapor, or mist form is flammable, irritating to the skin and respira-

2. GENERAL PRECAUTIONS. tory tract, and poisonous in the digestive tract. Remove saturated clothing, wash skin well, do not swallow liquid, The following are general safety precautions that are not and do not breath mist and vapors.

related to any specific procedure and do not appear else-where in this publication. These are precautions that per- • Dangerous Pressures. Pressure systems precau-sonnel must understand and apply during the various tions apply to all ranges of pressure. Care must be taken phases of equipment operation and maintenance. during testing to ensure that all test connections are proper and tight before applying pressure to test setup; all system

• Keep Away From Live Circuits. Operating per- components must be compatible with pressures applied.

sonnel must think safety at all times. Do not replace Personnel must be protected by a safety shield or located at components or make adjustments inside equipment with the a distance sufficient to prevent injury.

electrical supply turned on. Under certain conditions, dan-ger may exist even when power control is in the off • Personal Protective Equipment. Wear protec-position due to charges retained by capacitors. To avoid tive clothing/equipment (gloves, apron, eye protection, etc.)

injuries, always remove power, discharge, and ground a approved for the materials, procedures, and tools being circuit before touching it. Adhere to all lock out/tag out used. Contact supervisor for guidance. If necessary, the requirements. Bioenvironmental Engineer or Base Safety Office should be contacted for guidance.

• Do Not Wear Jewelry. Remove rings, watches, and other metallic objects which may cause shock or burn 3. ASBESTOS/CADMIUM.

hazards.

This support equipment may contain small amounts of

• Finger Rings. Snagged finger rings have caused asbestos or cadmium. When working with this equipment, many serious injuries. Unless specifically allowed by shop the following precautions shall be rigidly adhered to:

safety procedures, remove finger rings during all mainte-nance activity. Parts: A limited number of parts, such as bolts, nuts, and fasteners, are cadmium-plated. Since you cannot visually

Change 1 v determine if a part contains asbestos or cadmium, or if it is or sanding is necessary, appropriate personal protective cadmium-plated, refer to the appropriate Illustrated Parts equipment shall be used and national environmental con- Breakdown to find these parts. Before handling, replacing, trols shall be strictly complied with. Ensure that Material or disposing of parts containing asbestos or cadmium, Safety Data Sheets are available and followed for all of the ensure that all environmental controls are strictly followed. materials used during any process or operation.

Repairs: It is highly recommended that parts containing asbestos or cadmium not be repaired. If, however, mechani-cal removal of material through grinding, buffing, drilling, vi Change 1

CHAPTER 1

GENERAL INFORMATION

1.1 GENERAL INFORMATION . 1.1.2 Test Stand - Purpose . The test stand is manu-factured by GE Aircraft Engines 1 Neumann Way PO Box

1.1.1 Location Of Items . Refer to T.O. 33D4-6-668-4, 156301 Cincinnati, Ohio 45215-6301.

Illustrated Parts Breakdown (IPB), for locations of assem-

a. The test stand tests performance and operatingblies, components, and parts not referenced to figures in characteristics of the F101-GE-102, F108-CF-100,this manual. Nomenclature used in this manual is the same F110-GE-100, F110-GE-129, and F118-GE-100as that used in the IPB. Relative position locations (front, engine lube accessory components.rear, left, and right) refer to the test stand as viewed from the operator position. Significant item numbers (SIN) are

b. An item being tested by the test stand is referred toused on nameplates and tags on the test stand. These same as a unit under test (UUT). Table 1–1 lists techni-numbers appear in text, figures, and tables in this manual.

cal orders for UUT tested by this test stand.

Figure 1-1. Lube Accessory Test Stand

1.2 SIGNIFICANT ITEM NUMBERS (SIN) - 1.2.1 Test Stand - Significant Item Numbers . The DESCRIPTION . SIN identifier consists of three digits and two letters. Each combination of digits and letters identifies the item. The The test stand and adapter kit are each assigned a different first four characters define a major component. The fifth set of significant item numbers (SIN). Significant item character defines multiple usage of a like item.

numbers are assigned to assemblies, subassemblies, and

a. Digits. The digits are assigned according to thepiece parts as an aid in identifying and referring to those type of equipment: for example, PSIG pressureitems. Any item that is assigned a SIN is referred to by that transducers (062 and 069), check valves (220), andSIN in text, tables, charts, and illustrations throughout this motor starters (705). The numeric range and func-manual. The SIN is also referenced in the description tion categories are as follows:column of the test stand IPB (TO 33D4-6-668-4).

• 020 through 150 - hydraulic and pneumatic instruments

1-1

• 200 through 390 - hydraulic and pneumatic the item, usually starting with A. For instance, if controls and conditioners five motor starters with the same part number are

• 400 through 540 - mechanical hardware (coded installed, the SIN are 705LA through 705LE.

by size) When the SIN is followed by -P, the component is

• 550 through 599 - mechanical hardware (not on the control panel. When the SIN is followed by coded by size) -SP, the component is on the service panel. When

• 600 through 685 - electrical instrumentation the SIN is followed by -S, the component is on the

• 700 through 749 - electrical controls and con- sink. When the SIN is followed by -WS, the ditioners component is on the water sink.

• 750 through 765 - automation electronics

1.2.2 Adapter Kit - Significant Item Numbers. The• 800 through 845 - electrical hardware

• 905 through 950 - refrigeration SIN identifier consists of four digits and one letter. This combination applies only to adapter kit components. The

b. Letters. The two letters in each SIN are selected same SIN is used when listing more than one item. For total from letters A through Z, excluding I and O. The quantity of an item used, check quantity column in IPB.

first letter classifies the major component by part number. The second letter shows repeated usage of

Table 1-1. Technical Orders for Units Under Test

Technical Order Title F101-GE-102 Engine

TO 7J1-84-3 Overhaul With Illustrated Parts Breakdown, Fuel/Oil Cooler

TO 7J4-2-57-3 Overhaul, Hydraulic Pump

TO 7J10-19-3 Overhaul, AFT Tank Assembly

TO 7J14-4-3 Overhaul With Illustrated Parts Breakdown, Lube Flow Sensor Assembly

TO 7J14-5-3 Overhaul With Illustrated Parts Breakdown, Oil Level/Temperature Sensor

F108-CF-100 Engine

TO 6J24-10-3 Overhaul With Illustrated Parts Breakdown, Servo Fuel Heater

TO 7J1-85-3 Overhaul With Illustrated Parts Breakdown, Oil/Fuel Heat Exchanger

TO 7J10-21-3 Overhaul Instructions, Lube Tank

F110-GE-100 Engine

TO 7J1-91-3 Overhaul With Illustrated Parts Breakdown, Fuel/Oil Cooler

TO 7J10-22-3 Overhaul With Illustrated Parts Breakdown, Oil Tank Assembly

TO 7J14-6-3 Overhaul With Illustrated Parts Breakdown, Oil Level Sensor and Temperature Switch

TO 8S2-5-8-3 Overhaul With Illustrated Parts Breakdown, Oil Differential Pressure Switch

F110-GE-129 Engine

TO 7J10-22-3 Overhaul With Illustrated Parts Breakdown, Oil Tank Assembly

TO 7J14-6-3 Overhaul With Illustrated Parts Breakdown, Oil Level Sensor and Temperature Switch

TO 7J1-96-3 Overhaul With Illustrated Parts Breakdown, Fuel, Lube, and Hydraulic Oil Cooler

F118-GE-100 Engine

TO 7J1-91-3 Overhaul With Illustrated Parts Breakdown, Fuel/Oil Cooler

TO 7J10-23-3 Overhaul With Illustrated Parts Breakdown, Oil Tank Assembly

1.3 TEST STAND ASSEMBLY. framework mounted on a channel base. The test stand is enclosed and has removable, hinged doors on the sides and

The test stand assembly ( Figure 1–1 ) consists of back. Primary controls for test stand operation are located Section A and Section B, bolted together to form an L- on front panels of Section A and Section B. A sink on the shaped structure. The two sections are designed to operate front of section A is used when testing a UUT.

only in a nonhazardous area. Each section is a monocoque

1-2

1.3.1 Section A. Section A contains a 75-gallon oil tools, fixtures, hoses, and fittings required to test UUT.

Refer to test stand IPB (TO 33D4-6-668-4) for illustrationstank, four pumps, heat exchanger, oil temperature bath, and listing of kit components.water sink, and electrical equipment cabinet. The electrical equipment cabinet houses relays, contactors, circuit break-

1.4 LEADING PARTICULARS .ers, transformers, and related electrical equipment.

Refer to Table 1–2 for leading particulars of the lube1.3.2 Section B. Section B contains a 10-gallon accessory test stand.collector tank, two 3-gallon static pressure oil tanks, two oil pumps, heat exchanger, pressure transducer box, air blow 1.5 CONSUMABLE MATERIALS .

gun, and Micro-Flo 100. Section B supports the test sink, UUT and its test fixtures. A safety enclosure over the test Consumable materials required for test stand maintenance sink isolates the operator from UUT. are listed in alphabetical order in Table 1-3.

1.3.3 Adapter Kit . The adapter kit consists of hardware

required for testing a component. The adapter kit includes

Table 1-2. Leading Particulars

Component/service Requirement/specification Air System

Air/oil mixture 3 SCFM/11 GPM at 100 PSI

Blow gun 29 PSIG

Dedicated transducer 0-50 PSIG

Metered supply 0-4 SCFM at 30 PSI, 70 to 120°F

Muffled exhaust 0-5 SCFM

Regulated test stand supply 90 PSIG

Regulated test stand supply 20 PSIG

Static 1.5-170 PSIG

Utility air supply 29 PSIG

Dimensions

Test stand overall

Depth 168 inches

Height 84 inches

Width 252 inches

Test stand sections (A and B)

Depth 84 inches

Height 84 inches

Width 168 inches

Instrumentation

Differential pressure gages (071AA, 071AB, 071AC, 071AD, and

071AE)

Accuracy 2-5% of full scale

Range 0-50 PSID

Flowmeters

Air

0.13-2.5 ACFM (022LB) ±0.5% of reading

0.04-1.5 ACFM (022MA) ±0.5% of reading

Fluid

0.05-0.42 GPM (021DA) 0.5% of reading

1-3

Table 1-2. Leading Particulars - Continued

Component/service Requirement/specification 0.06-6.0 GPM (022BA) 0.5% of reading

0.09-9.5 GPM (022DA) 0.5% of reading

0.16-15.5 GPM (029DA and 0.5% of reading

029DB)

0.45-65 GPM (024AA) 0.5% of reading

Micro-Flo 100 (601NA)

Pressure circuits

Range Transducer dependent

System accuracy; using the ±0.5% of full scale following transducers:

(061HB, 061LA, 061RA,

062GA, 062GB, 062HA,

062HB, 062HC,

and 062PA)

(061HA) ±0.15% of full scale

(061PA) ±0.2% of full scale

Temperature circuits

Accuracy ±1.0°F

Range -100 to 400°F

Turbine flowmeter circuits

Accuracy

Liquid flowmeters ±0.3% of reading

Air flowmeters ±0.3% of reading

Range Flowmeter dependent

Multimeter (645QA)

Part number 1732M52G01

Accuracy ±0.014% of reading

Range 0 to 20 OHMS

Part number 9494M66P01

Accuracy ±0.12 OHMS

Range 0 to 20 OHMS

Pressure gage (072KA)

Accuracy ±0.5% of full scale

Range 0-160 PSIG

Pressure gage (072UA)

Range 0-100 PSIG

Accuracy ±0.5% of full scale

Pressure transducers

0-15 PSID (061RA) ±0.1% of full scale

0-50 PSID (061HA and ±0.1% of full scale

061HB)

0-50 PSIG (062HA, 062HB, ±0.1% of full scale and 062HC)

0-100 PSID (061LA) ±0.1% of full scale

0-150 PSIG (062GA and ±0.1% of full scale

062GB)

1-4

Table 1-2. Leading Particulars - Continued

Component/service Requirement/specification 0-200 PSID (061PA) ±0.1% of full scale

0-1000 PSIG (062PA) ±0.1% of full scale

Stopwatch timer/counter

Accuracy ±3 seconds for 10 minutes

Range 0 to 9 minutes, 59 seconds

Temperature gages (077BA and 077BB)

Accuracy ±1% of full scale

Range 20 to 240°F

Temperature indicator (649DA)

Accuracy ±1°F

Range -328 to 752°F

Thermocouples

-350 to +700°F (090EA ±1.5°F of reading through 090ER, 090HA, and 090HB)

32 to 660°F (090DA) ±1.5°F of reading

Voltage ratiometer (645PA)

Range 0 to 1.0 VDC

Accuracy ±0.001 VDC

Oil System

Oil type MIL-L-7808

Oil tank (551NA) 75-gallon capacity

Oil tank (551MA) 10-gallon capacity

Static pressure oil tanks (551RA and 3-gallon capacity

551RB)

Services Required

Drip pan drain Gravity

Electrical power 480 V, 60 Hz, 50 kVA, 3 phase

Ground stud Connect to earth ground

Oil tank drain 20 GPM

Shop air 130 SCFM at 90-125 PSIG

Sink drain 1 gallon/day

Test stand interior and sink Facility exhaust vent 4-inch duct

Water return 30 GPM at 30 PSIG maximum back pressure

Water supply 30 GPM at 40 PSIG, 70°F maximum

Table 1-3. Consumable Materials

Specification or Nomenclature part number CAGE General use

Barrier material, water-vapor MIL-B-121, Grade - - Packing of components proof A, CL 1

Cleaner, general purpose P-D-1747 - - Cleaning of components

1-5

Table 1-3. Consumable Materials - Continued

Specification or Nomenclature part number CAGE General use

Cloth, cleaning CCC-C-46 - - Cleaning of components

Oil, lubricating MIL-L-7808 - - Test fluid

Petrolatum VV-P-236 - - Thread lubrication

1-6

CHAPTER 2

SPECIAL TOOLS AND TEST EQUIPMENT

2.1 INTRODUCTION. the test stand. An equivalent item may be used if the recommended test equipment is not available.

This chapter contains special tools and test equipment

2.3 SPECIAL TOOLS AND TEST EQUIPMENT -required for operation, maintenance, and calibration of the test stand. FABRICATION .

2.2 SPECIAL TOOLS AND TEST EQUIPMENT . A thermocouple cable is used during calibration of temper-ature measurement circuits. Order thermocouple cable from

The special tool required consists of locally fabricated Omega Engineering Inc., PO Box 4047, Stamford, CT thermocouple cable ( Figure 2-1). Table 2-1 lists test 06907-0047, or fabricate as follows:

equipment required for calibration and maintenance of test stand instrumentation. This equipment is not supplied with a. Obtain parts listed in Figure 2-1.

b. Connect wires (TO 00-25-234).

Figure 2-1. Thermocouple Cable - Fabrication

2-1

Table 2-1. Test Equipment

Model Number Nomenclature Accuracy Use and Application AT-60 Aerotrak gas flow calibrator ±0.25% of reading Air flowmeter calibration

10-10525 Mansfield and Green deadweight ±0.1% of reading Pressure transducer calibra-tester tion

1433-9700 General Radio decade resistance ±0.01% of setting Voltage ratiometer calibra-box (2 required) tion

2190A/ Y2003 Fluke thermocouple calibrator ±0.46°F of setting Simulated thermocouple signal

311AHT-T Cox liquid flowmeter calibrator ±0.25% of reading Fluid flowmeter calibration

3325A Hewlett-Packard precision frequen- ±0.03% of setting Micro-Flo 100 calibration cy generator

7250A Fluke universal counter ±0.001 second Timer/counter calibration

77 Princo thermometer set ±0.2°F of reading Thermocouple testing

7780-20 Ashcroft digital pressure indicator ±0.01 PSIA Pressure transducer calibra-tion

7780-50 Ashcroft digital pressure indicator ±0.025 PSI Pressure transducer calibra-tion

7780-200 Ashcroft digital pressure indicator ±0.025 PSI Pressure transducer calibra-tion

8840A/AF Fluke digital multimeter ±0.0006% of reading Micro-Flo 100 Analog-to- Digital converter board calibration

913AC1 Rosemount temperature calibration ±0.1°C Thermocouple testing bath

2-2

CHAPTER 3

PREPARATION FOR USE AND SHIPMENT

3.1 INTRODUCTION. (1) All items on shipping list are accounted for.

(2) Frame is not bent, sprung, or otherwiseThis chapter contains instructions for unpacking and pre-damaged.paring the test stand for use, and preparing it for shipment or storage.

(3) Glass is not broken.

3.2 PREPARATION FOR USE .

(4) Instruments are not damaged.

The test stand is shipped in five sections. Each section is (5) Piping and tubing are securely mounted and wrapped with water-vapor proof barrier material, MIL-B- undamaged.

121, to prevent contamination. It is then completely enclosed in a wooden shipping crate and mounted on a (6) Controls and valves operate freely, but without shipping skid. Loose items are packed in cartons and stored excessive looseness.

inside test stand during shipping.

(7) Major equipment is securely mounted.

3.3 INSTALLATION FACILITIES .

d. Move test stand sections into place, using forklift The test stand is designed to operate in a nonhazardous area channels provided.

with ambient temperature from 45 to 125°F. Service

e. Level sections when in place.requirements are listed in Table 1-2.

f. Align sections and bolt together.3.4 INSTALLATION REQUIREMENTS .

3.6 SERVICE CONNECTIONS .

WARNING

Connect facility services, with exception of ventilation and electrical, at service connection panel at rear of test stand.

The test stand is not designed for use in an Table 3-1 lists these connections and connector sizes.

explosive atmosphere. Do not install or operate Service connection locations are shown in Figure 3-1.

where explosive conditions exist. Installation or

3.6.1 Air and Water Requirements. Provide theoperation of this equipment in an explosive atmosphere can cause fire or an explosion, following:

resulting in injury or death to personnel.

a. Shop air supply of 90-125 PSIG at 130 SCFM.

The test stand requires 168 by 252 inches of floor space for

b. Cold water supply of 30 GPM at 40 PSIG, 70°Finstallation. Additional space is required for maintenance maximum.and operation access.

c. Cold water return of 30 GPM at 30 PSIG maxi-3.5 UNPACKING AND LOCATING .

mum back pressure.

Unpack and provide locations for test stand components as

3.6.2 Oil Requirements. Provide the following:follows:

a. Fill provisions for oil tanks.

CAUTION

b. Two 20-GPM oil drains.

c. Two drip pan drains, one each for sections A andTake care in unpacking the test stand to prevent B.damage to finish, instruments, and loose parts.

3.6.3 Ventilation Requirements. Provide thea. Remove top and sides of shipping crates, leaving the units on skids. following:

b. Remove barrier material. a. Facility exhaust ducts.

c. Inspect for the following: b. Vacuum exhaust line.

3-1

3.6.4 Electrical Requirements. Test stand intercon- (1) 480-volt, 60-Hz, 3-phase (76-kVA), facility power.necting wiring is routed from the remote drive control cabinet through roof panels of the test stand. Wires and

(2) Facility absolute zero potential electricalconduit for connecting sections of the test stand are ground.supplied.

b. Refer to Chapter 6 wiring diagrams to make proper connections between test stand and remote cabinetsWARNING and between remote drive cabinet and facility ground.

• Ensure that facility power disconnects are

c. Check continuity and ground before connectingopen before connecting 480-volt circuits.

wires.Serious injury or death could result from electrical shock.

d. Connect all sections of the test stand and remote

• The external facility ground system must be cabinets to an external facility earth ground system.

an absolute zero potential ground to prevent

e. Check for proper routing and continuity after wiresinjury to personnel.

are connected.

a. Provide the following:

f. Facility electrical ground.

Table 3-1. Service Connections

SIN Service Type Connection Size

- - Test stand ventilation 4-inch duct

413AA Shop air supply 3/4-inch NPT

414AB Sink drain 1-inch NPT

414AA Oil tank fill 1-inch NPT

418AA Water supply 2-inch NPT

418AB Water return 2-inch NPT

418AC Oil tank drain 2-inch NPT

418AD Oil tank drain 2-inch NPT

822AA and 822AB Ground studs 1/2-13 UNC

3-2

Figure 3-1. Service Connections

3-3

3.7 PREPARATION FOR SHIPMENT . f. Check that all items listed on original shipping document are accounted for.

Prepare the test stand for shipment as follows:

g. Install blocks, straps, hold down bolts, and pack-

a. Drain test stand oil system as follows: ings on pumps, drive motors, pressure gages, relays, motor starters, and instruments, as required.

(1) Drain sink by placing 3-way ball valve (270BA) in OVERBOARD DRAIN 414AB position. h. Disconnect section interconnecting hoses as Place ball valve in COLLECTOR TANK posi- required.

tion when draining is completed.

i. Properly label and protect hose ends and

(2) Open ball valve (208CA) and drain 75-gallon connectors.

reservoir (551NA). Close ball valve when drain-

j. Disconnect electrical section interconnecting elec-ing is completed.

trical wiring as required. Ensure wires are correctly

(3) Open ball valve (208CD) and drain 10-gallon labeled before removing.

collector tank (551MA). Close ball valve when

k. Secure wiring to prevent terminal end damage.draining is completed.

l. Disconnect ground straps and remove mountingb. Remove all power from test stand and disconnect bolts attaching section A to section B.power and ground connections.

m. If test stand is to be shipped or stored, pack loosec. Turn off and disconnect service connections listed items carefully in cartons. Store cartons inside testin Table 3-1 at service connection panel ( stand.Figure 3-1).

n. Separate the two sections, using a forklift.d. Disconnect oil tank fill lines and drip pan drains.

o. Secure all doors and panels and wrap sections ine. Disconnect 4-inch exhaust duct.

flexible barrier material, MIL-B-121.

NOTE

p. Pack test stand sections in wooden shipping crates on skids appropriate to shipping requirements.

The following step is not necessary if the test stand is only being moved within its present facility.

3-4

CHAPTER 4

OPERATION INSTRUCTIONS

4.1 INTRODUCTION. b. Level Indication and Control Oil level is dis-played by tank level gage (120CA). Maximum

This chapter contains a description of controls and indica- (LL-2) and minimum (LL-1) oil levels are detected tors, theory of operation, safety features, and operating by level switch (724AA). When oil levels are procedures for the lube accessory test stand. Refer to exceeded, test stand is shut down and channel 2, Chapter 6 for significant item number (SIN) locator table, HYD RESERVOIR LEVEL LOW, or channel 3, wiring diagram, and schematics. HYD RESERVOIR LEVEL HIGH, lights on annunciator.

4.2 CONTROLS AND INDICATORS .

c. Draining. Opening ball valve (208CA) allows oil Table 4-1 lists the panel-mounted controls and indicators to drain through a 2-inch drain port on service with their functions. Figure 4-1 shows locations of all connection panel.

panels. Each control and indicator is referenced to an

4.4.2 Temperature Control and Indication. The 75-illustration ( Figure 4-2 through Figure 4-10).

gallon oil tank (551NA) is not heated. Cooled oil is

4.3 THEORY OF OPERATION . returned to tank through heat exchanger (329GA). Temper-ature of oil within tank is monitored by temperature switch

The test stand tests and calibrates engine lube and hydraulic (722JA) set at 125±5°F. When oil reaches this temperature, oil supply system components and subassemblies (referred the switch closes. This shuts down test stand and lights to in text as a unit under test (UUT)). The following HYD RESERVOIR TEMP HIGH indicator on channel 4 of paragraphs describe the theory of operation of the test stand annunciator.

system. See Figure 4-1 for locations of control panels.

4.4.3 Differential Static Pressure and Static PressureRefer to Chapter 6 for significant item number (SIN) locator table, wiring diagram, and schematics. Supply. The 75-gallon oil tank (551NA) provides a static pressure and a differential static pressure supply. Oil

4.4 HYDRAULIC SYSTEM - THEORY OF flows from tank to valve (208CB) through strainer OPERATION . (358DA) to pressure switch (721VA). When tank discharge pressure falls below 25±2 inches of Hg, pressure switch The hydraulic system consists of the following major (721VA) activates annunciator (734FA) and shuts down components and circuits with related piping and valves: test stand. Differential static pressure and static pressure supply are provided as follows:• 75-gallon oil tank (551NA) circuit

• Boost pump (348AA) and hydraulic pumps (348DA a. Static Pressure Supply Adapter. Oil is supplied and 348DB) from 75-gallon oil tank to the smaller chamber of

• F101 eductor test circuit air-driven pump (340EA). Air pressure regulator

• F101 scavenge return circuit (290EB) on panel K controls air to the pump. The

• Metered supply circuit pump, with an air to oil ratio of 14:1, generates

• Oil fill circuit 1200 PSIG at 90 PSIG air pressure. Pressure reduc-

• Heat exchangers (328FA and 329GA) ing regulator valve (250DA) on panel K sets oil

• Collector tank (551MA) pressure to sink-mounted adapter (530AB) by

• Oil return circuits relieving excess pressure. Excess oil from pressure

• F110/F118 oil tank circuit regulator is returned to oil tank (551NA) through check valve (220BA). Oil flows through 5-micron4.4.1 Seventy-Five-Gallon Oil Tank (551NA) Cir-filter (311BB) and ball valve (200CC) to adapter.

cuit. The 75-gallon oil tank (551NA) is filled and circuits Temperature of oil at adapter is measured by operate as described in the following paragraphs: thermocouple (090EN) and is displayed by Micro-

Flo 100.

a. Filling. The tank is gravity filled through flame arrester (508EA) on top of tank, or pressure filled b. Differential Static Pressure Supply. The differential through adapter (bezel (414AA)) on service con- static pressure supply to sink-mounted adapter nection panel. Tank is filled from service connec- (530AC) is fed from a line tapped off static pres-tion panel by opening valve (204EA). When filling sure supply line to sink-mounted adapter (530AB).

tank from service connection panel, oil flows Flow to sink-mounted adapter (530AC) is con-through 5-micron filter (313DA) and flame arrester trolled by ball valves (200CA and 200CB) on panel (508EB) to tank.

4-1

K. The valves are located upstream and down- flows out of both scavenge tanks at the same time through stream of pressure regulator (250EA) on panel K. ball valves (204JA and 204JB) to sink-mounted adapters Excess oil from pressure regulator is returned to oil (534AB and 534AD). The ball valves are activated by tank (551NA) through check valve (220BA). Tem- selector switch (725DA) on panel L.

perature at adapter (530AC) is measured by ther-

4.4.6 F101 Scavenge Return Circuit. A scavengemocouple (090EN) and is displayed by Micro-Flo

100. return air-oil mixture for UUT is supplied to sink-mounted adapter (534AC) by scavenge pump (348DD). The air-oil

4.4.4 Boost Pump (348AA) and Hydraulic Pumps mixture to the adapter is described in the following (348DA and 348DB) Circuit. Oil is supplied to the F101 paragraphs:

tank eductor test circuit, F101 scavenge return circuit,

a. Low pressure oil to receiver tank flows throughmetered supply circuit, and oil fill circuit by boost pump pressure reducing regulator (253CA) on panel K,(348AA) and hydraulic pumps No. 1 (348DA) and No. 2 flowmeter (029DB), needle valve (243EC) on(348DB). The pumps operate and are controlled as follows:

panel K, and check valve (223BB) to fill air-oil receiver tank (550BB). A relief valve (263YA), seta. Operator station (733AA) on panel J starts and at 75 PSIG, limits oil pressure to avoid seal dam-stops boost pump and hydraulic pump No. 1.

age when the hydraulic pump is not running. Tem-Pressure switch (721YA) enables pump No. 1 to perature of oil upstream of flowmeter (029DA) isstart when the proper boost pressure is reached.

measured by thermocouple (090EJ) and is dis-Hydraulic pump No. 2 is turned on by pressing played by Micro-Flo 100.black pushbutton switch at operator station

(733AB).

b. Shop air pressure to air-oil receiver tank (550BB) is reduced to 20 PSIG by pressure regulatorb. Boost pump (348AA) supplies oil to hydraulic (292AB), routed through flowmeter (022LB), nee-pumps No. 1 (348DA) and No. 2 (348DB) through dle valve (242GG) on panel K, and check valvefilters (316SA and 316SB) and pressure switch (222BB) to tank. Air temperature at flowmeter(721YA). Pressure switch (721YA) monitors boost (022LB) is measured by thermocouple (090EH)pump discharge pressure and shuts down hydraulic and displayed by Micro-Flo 100. Scavenge tank airpumps No. 1 and No. 2 when boost pump pressure pressure to adapter (539BS) on panel L is con-is less than 7 PSI. Differential pressure for both nected downstream of flowmeter. Toggle valvefilters is displayed by differential pressure gage (210CH) on panel M controls air flow to adapter.(071AE) on service panel. Closing needle valves Air pressure to adapter (539BS) is measured by(240PL and 240PM) isolates gage from service transducer (062HB) and displayed by Micro-Flolines. Opening ball valves (200FG and 200FB)

100. Flow through adapter is controlled by needledrains condensation from filters.

valve (249LS) on panel L.

c. Hydraulic pumps No. 1 and No. 2 discharge

c. The air-oil mixture from air tank (550BB) to sink-through relief valve (236XA), set to open at mounted adapter (534AC) is controlled by pressure260±10 PSIG. Temperature switch (722JB), set at regulator (290CC) on panel K. The air-oil mixture125±5°F, monitors pump discharge temperature.

from air tank is connected to suction side of F101When discharge temperature limit is exceeded, test scavenge pump (348DD). Pressure switch (721VB)stand is shut down and channel 11, SUPPLY will shut down pump if pump inlet pressure fallsPUMPS DISCH TEMP HIGH, lights on annuncia-below 25 inches Hg. Relief valve (263CB) limitstor (734FA). Output of No. 1 and No. 2 hydraulic scavenge pump discharge to 105 PSIG. Air-oilpumps is fed through check valves (226BA and mixture to sink-mounted adapter (534AC) is mea-226BB) and filters (316NB and 316NC) for the sured by thermocouple (090EK) and displayed byfour separate circuits. Differential pressure for both Micro-Flo 100. The pressure regulator controlsfilter is displayed by differential pressure gage operation of control valve (236CB) for air-oil mix-(071AC) on service panel. Closing needle valves ture to adapter.(240PG and 240PH) isolates gage from system.

Opening ball valves (200FD and 200FE) drains

4.4.7 Metered Oil Supply Circuit. Oil flows from sup-condensation from filters.

ply line to valve (234VA) which regulates and routes flow

4.4.5 F101 Eductor Hydraulic Test Circuit. Low through flowmeter (024AA) and filter (316NA) to sink-mounted adapter (535AA). Needle valve (242GE) on panelpressure oil is used to fill the two 3-gallon oil tanks K bypasses oil from valve (234VA) to 75-gallon oil tank(551RA and 551RB through valves (242GH and 242GJ) on (551NA) and provides fine control of flow to adapter.panel M. Level gages (120LA and 120LB) on panel M Relief valve (263PA) on panel K, adjustable between 75display fluid level in oil tanks. Overflow indicator (102AA) and 1500 PSIG, controls inlet pressure to control valveon panel M displays excess fluid flowing through scavenge (234VA). Oil from relief valve returns to 75-gallon oil tanktank standpipes and routes it directly to collector tank. Oil

4-2

(551NA). Pressure regulator (290CB) on panel K sets valve exceeded, test stand is shut down and channel 6, COLLEC- (234VA) to desired open position by applying air pressure TOR TANK TEMP HIGH, lights on annunciator (734FA).

to it. Temperature of oil downstream of flowmeter The tank vent extends through the ceiling of the test stand (024AA) is measured by thermocouple (090EE) and dis- and is equipped with flame arrester (504AB). The tank can played by Micro-Flo 100. Oil flows through 5-micron filter be drained through ball valve (208CD) to port on service (316NA) to sink-mounted adapter (535AA). Differential connection panel.

pressure for filter is displayed by differential pressure gage

4.4.11 Oil Return Circuits. Oil used in testing returns(071AB) on service panel. Opening ball valve (200FC) drains condensation from filter (316NA) to drip pan. Nee- to the 75-gallon oil tank through the following circuits:

dle valve (242GK) provides fine control of pressure and oil

a. Oil from collector tank (551MA) is returned to theflow to adapter (535AA).

75-gallon oil tank (551NA) as follows:

4.4.8 Oil Fill Circuit. Oil is supplied to sink-mounted

(1) Oil from 10-gallon oil collector tank (551MA)adapter (532CC). Oil flow to adapter flows through 5-is pumped directly to 75-gallon oil tankmicron filter (311BA) for filling UUT.