33D4-6-755-1.pdf

TO 33D4-6-755-1

TECHNICAL MANUAL

OPERATION AND MAINTENANCE INSTRUCTIONS

ADVANCED FUEL ACCESSORIES TEST SYSTEM

INTERMEDIATE LEVEL

FUEL CONTROL SYSTEM

COMPONENTS TEST STATION

A/F46T-5

PART NUMBERS 8230001-0501,

8230001-0502, 8230001-0503, 8230001-0505, 8230001-0507, 8230001-0508, 8230001-0509

ALLIED SIGNAL INC.

AEROSPACE EQUIPMENT SYSTEMS

F41608-91-C-1276

This publication incorporates Special Handling AFTO Form 252 (51M0WRLEET2401SH), dated 30 May 2012.

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 C - Distribution authorized to U.S. Government Agencies and their contractors (Administrative or Operational Use) (15 March 2002). Other requests for this document shall be referred to 406 SCMS/GULAC, Robins AFB, GA 31098. Questions concerning technical content shall be referred to WR-ALC/GRNEC.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and 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

15 JANUARY 1999 CHANGE 3 - 9 JULY 2012

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

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T.O. 33D4-6-755-1

TABLE OF CONTENTS CONT

Chapter Page Chapter Page

4-2.6 Hydraulic Control Section 4-8.2.2 Process Data Display (A2) 4-12 Monitor 4-72

4-2.6.1 Hydraulic Theory 4-12 4-8.3 Screen Options 4-72 4-2.6.2 Hydraulic System 4-17 4-8.3.1 Options Menu 4-72 4-2.6.3 Pneumatic System 4-19 4-8.3.2 Help Display 4-72 4-2.6.4 Interface Connector Assembly 4-8.3.3 Set-Up Options 4-72

(A2A8) (ICA) 4-22 4-8.3.4 Menu Options 4-76 4-3 Controls and Indicators 4-25 4-8.4 Interactive Mode of 4-4 Operation Instructions 4-63 Operation 4-76 4-4.1 Warm-Up 4-63 4-4.2 Start-Up and Operation 4-63 5 MAINTENANCE INSTRUCTIONS 5-1 4-4.3 Shutdown 4-64 4-5 Operation Instructions for 5-1 General Information 5-1

TPS Kit 4-64 5-1.1 Maintenance Log 5-1 4-6 Test Configuration 4-64 5-1.2 Maintenance Shutdown 5-1 4-6.1 Kit Identity 4-64 5-1.2.1 Maintenance Lock Out 5-1 4-6.2 UUT Identity 4-64 5-1.2.2 Power Off Pushbutton 4-6.3 Test Type 4-64 Shutdown 5-1 4-6.4 Configuration Plug 5-1.2.3 Main Circuit Breaker

Assembly Operation 4-64 Shutdown 5-3 4-7 Test Termination and 5-1.3 Startup After Maintenance 5-3

Restart 4-65 5-1.3.1 Startup After Maintenance 4-7.1 Emergency Shutdown 4-65 Lock Out 5-3 4-7.1.1 Emergency Stop Buttons 4-65 5-1.3.2 Power On Pushbutton 4-7.1.2 Buid Shutdown Switch 4-65 Startup 5-3

4-7.1.3 Test Station or TPS 5-1.3.3 Main Circuit Breaker Alarms 4-65 Startup 5-3

4-7.2 Test Station Power-Up 4-71 5-2 Operational Checkout 5-4

4-7.3 Normal Test Station 5-3 Inspection and Preventive Shutdown 4-71 Maintenance 5-4

4-8 Operator Intervention 4-71 5-3.1 Visual Inspection 5-4 4-8.1 Test Station Display Monitor 5-3.2 Cleaning 5-5

Characteristics 4-71 5-3.2.1 General Cleaning 5-5 4-8.1.1 Touch Sensitive Screen 4-71 5-3.2.2 Corrosion Removal and 4-8.1.2 Touch Sensitive Screen Cleaning 5-6

Functions 4-71 5-3.2.3 Measurement Control Module 4-8.2 Test Station Display (A1A13 and A1A14) Air

Monitors 4-72 Filter Cleaning 5-6 4-8.2.1 Operator Display 5-3.2.4 Y-Type Strainer (A1A34ST1

Monitor 4-72 and A1A34ST2) Cleaning 5-9

5-3.2.5 Cable and Connector Cleaning 5-10 ii

Chapter Page Page

5-3.2.6 Air Conditioner (A1A30) 5-6.1.10 Graphics Driver Coil Back Flush (A1A4A4) 5-197 Cleaning 5-10 5-6.1.11 Embedded Computer System

5-3.2.7 Fluid Filters 5-11 (A1A4) 5-201 5-3.2.8 Hydraulic Power Unit 5-11 5-6.1.12 Power Supply (A1A5PS1) 5-202 5-3.2.9 Lubrication Panel 5-11 5-6.1.13 Overvoltage Protection 5-3.2.10 CPU Battery Pack (A1A5PS10VP1) 5-202

Connection Point Removal 5-6.1.14 Power Supply (A1A5PS2) 5-203 and Cleaning 5-12 5-6.1.15 Power Supply (A1A5PS3) 5-204

5-3.2.11 Corrosion Removal and 5-6.1.16 Overvoltage Protection Cleaning 5-12 (A1A5PS30VP1) 5-205

5-4 Storage Inspection 5-12 5-6.1.17 Power Supply (A1A5PS4) 5-206 5-5 Troubleshooting 5-12 5-6.1.18 Power Supply (A1A5PS5) 5-207 5-6 Repair 5-13 5-6.1.19 Power Meter (A1A6) 5-207 5-6.1 Process Control Section 5-6.1.20 AC Power Supply

Removal and (A1A7) 5-210 Replacement 5-13 5-6.1.21 Multispeed Starter

5-6.1.1 DC Power Supply (A1MV1 (A1A8A1) 5-210 and A1MV2) 5-13 5-6.1.22 DC Interface (A1A8DC11

5-6.1.2 Operator Display Monitor and A1A8DC12) 5-212 (ODM) (A1A3) and 5-6.1.23 Function Generator Process Data Display (A1A9A1) 5-213 Monitor (PDDM) 5-6.1.24 Meter (A1A9M1) 5-214 (A1A11) 5-181 5-6.1.25 Meter/Motor Control

5-6.1.3 CPU (A1A4A1) and Assembly (A1A10M1) 5-214 Memory (A1A4A1A1) 5-185 5-6.1.26 Circuit Cards (A1A12A2

5-6.1.4 Graphics Driver through A1A12A18) 5-215 (A1A4A2) 5-186 5-6.1.27 Circuit Card (A1A12A1) 5-216

5-6.1.5 Tape Controller 5-6.1.28 Switch Chassis Assembly (A1A4A3) 5-187 (A1A12) 5-217

5-6.1.6 RS-232 Controller 5-6.1.29 Circuit Cards (A1A13A1 (A1A4A8) 5-189 through A1A13A20) 5-221

5-6.1.7 Q-Bus Jumper Board 5-6.1.30 Measurement Control Module

(A1A4A5) 5-191 (MCM) (A1A13A21) 5-223

5-6.1.8 IEEE-488 Controller 5-6.1.31 Circuit Cards (A1A14A1 (A1A4A6) 5-193 through A1A14A9) 5-224

5-6.1.9 IEEE-583 Controller 5-6.1.32 MCM (A1A14) 5-225 (A1A4A7) 5-196 iii

Chapter Page Chapter Page

5-6.1.33 32-Channel A/D 5-6.1.48 Bridge Sensor Amplifier Termination Panel (A1A20A4) 5-238 (A1A15) 5-226 5-6.1.49 Bridge Sensor Amplifier

5-6.1.34 32-Channel A/D (A7) 5-238 Termination Panel 5-6.1.50 Signal Conditioners (A1A16) 5-227 (A1A21A1A1 or

5-6.1.35 Termination Filter Panel A1A21A1A2) 5-239 (A1A17) 5-228 5-6.1.51 Intrinsic Repeater Relays

5-6.1.36 RI-16 DIP Module (AlA21AlISR10or (A1A18TB2A1 and A1A21A1ISR11) 5-239 A1A18TB2A2) 5-229 5-6.1.52 Safety Barriers

5-6.1.37 RI-16 DIP Module (A1A21A1SB 1 through

(A1A19A1A1) 5-230 A1A21A1SB10,

5-6.1.38 Safety Barriers A1A21A1SB12 through (A1A19A1SB1 through A1A21A1SB14, A1A19A1SB39) 5-230 A1A21A1SB16 through

5-6.1.39 Safety Barriers A1A21A1SB37) 5-240 (A1A19A2SB1 through 5-6.1.53 Timer Relay

A1A19A2SB43) 5-231 (A1A21TR2) 5-240

5-6.1.40 Safety Barriers 5-6.1.54 Electrical Lubrication

(A1A19A3SB1 through Enclosure (A1A22) 5-241 A1A19A3SB56) 5-231 5-6.1.55 Circuit Breaker (A1A24CB1

5-6.1.41 Signal Conditioners (RTD through A1A24CB8) 5-241 Transmitters (A1A20A1A1 5-6.1.56 Combustible Gas Transmitter through A1A20A1A3) 5-233 (A1A25MCGD1) 5-242 5-6.1.42 Relay Contactor 5-6.1.57 Tumbler Switch

(A1A20A1CR4) 5-233 (A1A25S1) 5-243

5-6.1.43 Intrinsic Repeater Relays 5-6.1.58 Temperature Switch

(A1A20A1ISR1 through (A1A25S2) 5-243 A1A20A1ISR9) 5-234 5-6.1.59 Terminal Block

5-6.1.44 Relays (A1A20A1K1 (A1A25TB1) 5-244 throughAlA20A!K14) 5-234 5-6.1.60 Frequency-to-Current Circuit

5-6.1.45 Safety Barriers Module (AlA25TX 1 (A1A20A1SB 1 through through A1A25TX3) 5-244 A1A20A1SB9) 5-235 5-6.1.61 Incandescent Bulb

5-6.1.46 Timer Relay (A1A25WLT1) 5-245 (A1A20A1TR1) 5-237 5-6.1.62 Frequency-to-Current Circuit

5-6.1.47 Signal Conditioner Module (A1A26) 5-246 (A1A20A3) 5-237 5-6.1.63 Frequency-to-Current Circuit

Module (A6) 5-246

5-6.1.64 RS-232/RS-422/RS-485

Converter (A1A28) 5-247 iv

Chapter Page Chapter Page

5-6.1.65 Air Conditioner Assembly 5-6.1.82 Safety Barrier

(A1A30) 5-249 (A1A34A2A1A3SB1

5-6.1.66 Water Cooling through Coil (A1A30CC1) 5-251 A1A34A2A1A3SB9) 5-264

5-6.1.67 Air Filter (A1A30FL1) 5-253 5-6.1.83 Power Supply 5-6.1.68 Pressure Gauge (A1A34A2A1A3PS1) 5-265

(A1A30GA4 through 5-6.1.84 Contactor A1A30GA6) 5-253 (A1A34A3A2CR1 and

5-6.1.69 Heater Coil A1A34A3A2CR3) 5-266 (A1A30HC1 5-6.1.85 Contactor and A1A30HC2) 5-254 (A1A34A3A2CR2) 5-266

5-6.1.70 Purge Blower 5-6.1.86 Contactor

(A1A30MOT2) 5-255 (A1A34A3A3MS1) 5-267

5-6.1.71 Single Temperature 5-6.1.87 Multi-Speed Starter Thermostat (A1A34A3A3MS3A and

(AlA30SlandAlA30S2) 5-256 A1A34A3A3MS3B) 5-268 5-6.1.72 Differential Pressure 5-6.1.88 Contactor

Switch (A1A30S3) 5-257 (A1A34A3A3MS5) 5-269 5-6.1.73 Control Valve 5-6.1.89 Contactor

(A1A30V1 (A1A34A3A4MS2) 5-270

and A1A30V2) 5-258 5-6.1.90 Contactor

5-6.1.74 Pressure Reducing (A1A34A3A4MS4) 5-271 Valve (A1A30V3) 5-259 5-6.1.91 Circuit Breaker

5-6.1.75 Ball Valve (A1A30V4) 5-260 (A1A34A3CB1) 5-272 5-6.1.76 Impedance Test Amplifier 5-6.1.92 Current Operated Switch

Board (A1A31) 5-260 (A1A34A3S1) 5-272 5-6.1.77 Solenoid Pilot 5-6.1.93 Transformer

(A1A32L1 through (A1A34A3T1) 5-273 A1A32L34) 5-261 5-6.1.94 Exhaust Blower Assembly

5-6.1.78 Solenoid Valve (A1A34A5) 5-274 (A1A32SV1 through 5-6.1.95 Check Valve

A1A32SV34) 5-261 (A1A34CV1) 5-274

5-6.1.79 Signal Conditioner 5-6.1.96 Check Valve Assembly (A1A33) 5-262 (A1A34CV2) 5-275

5-6.1.80 Power Control Module 5-6.1.97 Differential Pressure (PCM) Gauge (A1A34GA1) 5-276 (A1A34A2A1A1) 5-263 5-6.1.98 Strainer

5-6.1.81 Safety Barrier (A1A34ST1 (A1A34A2A1A2SB1 and A1A34ST2) 5-276 through 5-6.1.99 Ball Valve (A1A34V1) 5-278 A1A34A2A1A2SB17) 5-264 5-6.1.100 Ball Valve (A1A34V2) 5-279

5-6.1.101 Filter (A1A34FL1) 5-279 v

Chapter Page Chapter Page

5-6.1.102 Purge Damper 5-6.2.11 Pressure Reducing Actuator Assembly Regulators

(A1A36PC1) 5-280 (A2A2PRV1

5-6.1.103 Air Pressure Switch through A2A2PRV5) 5-290 (A1S1) 5-280 5-6.2.12 Solenoid Valves

5-6.1.104 Power Conditioner (A2A2SV36 (A1T1) 5-281 through A2A2SV39

5-6.1.105 Relay Timer andA2A2SV64 (A1A34A2A1A2TR1) 5-282 through A2A2SV71) 5-291

5-6.1.106 Power Supply 5-6.2.13 Doser Valve

(A1A34A2A1PS1) 5-282 (A2A3DV6 through 5-6.1.107 Bubble Tight Damper A2A3DV8) 5-292

(A1A34A4) 5-283 5-6.2.14 Pressure Reducing 5-6.2 Hydraulic Control Section Regulator (A2A3PRV6

Removal and through A2A3PRV8) 5-292

Replacement 5-283 5-6.2.15 Solenoid Valve 5-6.2.1 Crossover Valve with (A2A3SV40

Actuator (A2AV31 through A2A3SV51) 5-293 and A2AV32) 5-283 5-6.2.16 Screened Bleeds

5-6.2.2 Check Valve (A2CV2) 5-284 (A2A4SCB18 5-6.2.3 Strainer (A2FL7) 5-285 and A2A4SCB19) 5-294 5-6.2.4 Ball Valve (A2MV12) 5-286 5-6.2.17 Doser Valves 5-6.2.5 Service Panel Gauges (A2A4DV9 through

(A2A1GA1, A2A1GA2, A2A4DV13) 5-294

A2A1GA3) 5-287 5-6.2.18 Pressure Reducing 5-6.2.6 Pressure Reducing Regulators (A2A4PRV9

Regulators through A2A4PRV13) 5-295

(A2A1PRV2, 5-6.2.19 Solenoid Valves A2A1PRV16, (A2A4SV52 through

A2A1PRV22) 5-287 A2A4SV63) 5-296

5-6.2.7 Pressure Switch Assemblies 5-6.2.20 Actuator Valve (A2A1S1 through (A2A5AVOA) 5-297 A2A1S6) 5-288 5-6.2.21 Actuator Valve

5-6.2.8 Screened Bleed (A2A5AVOB) 5-298 (A2A1SCB12) 5-289 5-6.2.22 Filters (A2A5FL17A and

5-6.2.9 Screened Bleeds A2A5FL17B) 5-298

(A2A2SCB3, 5-6.2.23 Filter (A2A5FL18) 5-299 A2A2SCB5 and 5-6.2.24 Air Supply Valves

A2A2SCB15) 5-289 (A2A5MV11 and

5-6.2.10 Doser Valve (A2A2DV1 A2A5MV13) 5-300 through A2A2DV5) 5-289 5-6.2.25 Pressure Reducing Regulators (A2A5PRV19 and

A2A5PRV20) 5-300

vi

Chapter Page Chapter Page

5-6.2.26 Screened Bleed 5-6.2.40 Actuator, Positioner CCA, (A2A5SCB11) 5-301 and Valve

5-6.2.27 Transducers (A2A6MP1 (A2A10MV21A, through A2A6MP10 and A2A1OMV21B, A2A6MP19 through A2A10MV21C) 5-314 A2A6MP22) 5-301 5-6.2.41 Ball Valve

5-6.2.28 Transducers (A2A6MP11 (A2A10AV10) 5-315 through A2A6MP16 and 5-6.2.42 Back Pressure Regulator A2A6MP23) 5-302 Valve (A2A10BPV1) 5-316

5-6.2.29 Transducer 5-6.2.43 Resistance Temperature (A2A6MP17) 5-303 Detector (RTD) Assembly

5-6.2.30 Transducer (A2A10MT3) 5-316 (A2A6MP18) 5-303 5-6.2.44 Relief Valve

5-6.2.31 Actuator Valves (A2A10BPV2) 5-317 (A2A6AV20A through 5-6.2.45 Actuator Valve

A2A6AV20H, (A2A10DFC2) 5-318

A2A6AV20J through 5-6.2.46 Check Valve A2A6AV20N, and (A2A10CV1) 5-318 A2A6AV20P) 5-304 5-6.2.47 Flow Control Valve

5-6.2.32 Gauge Guards (A2A6GG1 (A2A10FCV1) 5-319 and A2A6GG2) 5-304 5-6.2.48 Flowmeter (A2A10MF5A or

5-6.2.33 Check Valves (A2A6CV23 A2A10MF6A) / Signal through A2A6CV31) 5-305 Conditioner

5-6.2.34 Resistance Temperature (A2A10MF5B or Detector (RTD) Assembly A2A10MF6B) 5-320 (A2A7MT5) 5-305 5-6.2.49 Quick Disconnect Fitting

5-6.2.35 Filter Assembly (A2A10QD1 or

(A2A7FL8) 5-305 A2A10QD2) 5-320

5-6.2.36 Flowmeter (A2A7MF10A) 5-6.2.50 Flowmeter (A2A10MF7A) with Signal Conditioner and Signal Conditioner

(A2A7MF10B) 5-306 (A2A10MF7B) 5-321

5-6.2.37 Check Valve 5-6.2.51 Deleted 5-322 (A2A7CV7) 5-306 5-6.2.52 Pressure Regulator

5-6.2.38 Interface Connector (A2A10BPV3) 5-322 Assembly (A2A8) 5-308 5-6.2.53 Back Pressure Valve

5-6.2.39 Ball Valve with Actuator (A2A10BPV3) (A2A9AV5, A2A9AV13, Diaphragm 5-323 A2A9AV21 through 5-6.2.54 Pressure Regulator A2A9AV23, and (A2A10PRV17) 5-325 A2A9AV25) 5-313 5-6.2.55 Differential Pressure

Transducer Assembly

(A2A10RP1) 5-326

vii

Chapter Page Chapter Page

5-6.2.56 Screened Bleed 5-6.2.72 Resistance Temperature (A2A10SCB6) 5-327 Detector (RTD) Assembly

5-6.2.57 Screened Bleed (A2A12MT1) 5-339 (A2A10SCB17) 5-327 5-6.2.73 Flowmeter (A2A12MF1A or

5-6.2.58 Ball Valve (A2A10AV7A) A2A12MF2A) with Signal and Actuator Conditioner

(A2A10AV7B) 5-328 (A2A12MF1B or

5-6.2.59 Ball Valve (A2A10AV11A) A2A12MF2B) 5-340 and Actuator 5-6.2.74 Flow Control Valve

(A2A10AV11B) 5-328 (A2A12FCV2) 5-340

5-6.2.60 Ball Valve (A2A10AV12A) 5-6.2.75 Ball Valve and Actuator (A2A12AV2) 5-341

(A2A10AV12B) 5-329 5-6.2.76 Screened Bleed 5-6.2.61 Ball Valve (A2A12SCB9) 5-342

(A2A10AV8 and 5-6.2.77 Check Valve

A2A10AV9) 5-330 (A2A12CV3) 5-342

5-6.2.62 Differential Pressure 5-6.2.78 Pressure Regulator

Transmitter (A2A12PRV18) 5-343

(A2A11RP2) 5-332 5-6.2.79 Ball Valve 5-6.2.63 Resistance Temperature (A2A12AV1) 5-343

Detector (RTD) Assembly 5-6.2.80 Check Valve

(A2A11MT2) 5-332 (A2A13CV17) 5-344

5-6.2.64 Flowmeter (A2A11MF3A or 5-6.2.81 Check Valve

A2A11MF4A) with Signal (A2A13CV11) 5-345 Conditioner 5-6.2.82 Check Valve

(A2A11MF3B or (A2A13CV16) 5-345 A2A11MF4B) 5-333 5-6.2.83 Resistance Temperature

5-6.2.65 Ball Valve Detector (RTD) Assembly

(A2A11AV6) 5-333 (A2A13MT13) 5-345

5-6.2.66 Ball Valve 5-6.2.84 Throttle Valve

(A2A11AV28) 5-334 (A2A13DFC3) 5-346

5-6.2.67 Ball Valve 5-6.2.85 Valve (A2A13MV10) 5-347

(A2A11AV14) 5-335 5-6.2.86 Filter (A2A14FL6) 5-347

5-6.2.68 Flow Control Valve 5-6.2.87 Ball Valve (A2A14AV14A) (A2A11FCV3) 5-336 and Pneumatic Actuator

5-6.2.69 Throttle Valve (A2A14AV14B) 5-348

(A2A11DFC1) 5-337 5-6.2.88 Pressure Reducing Regulator 5-6.2.70 Regulator (A2A14PRV15) 5-349

(A2A11PRV14) 5-338 5-6.2.89 Ball Valve 5-6.2.71 Screened Bleed (A2A14MV20) 5-350

(A2A11SCB10) 5-339 5-6.2.90 Manual Valve

(A2A14MV9) 5-350

viii

Chapter Page Chapter Page

5-6.2.91 Strainer (A2A15FL20) 5-351 5-6.2.112 Ultraporous Filter 5-6.2.92 Ball Valve (A2A19FL5) 5-366

(A2A15MV18) 5-352 5-6.2.113 Flow Rate Meter 5-6.2.93 Resistance Temperature (A2A19MF9A) and

Detector (RTD) Assembly Rate of Flow (A2A15MT14) 5-353 Transmitter

5-6.2.94 Ball Valve (A2A19MF9B) 5-366 (A2A16MV19) 5-353 5-6.2.114 Flow Control Valve

5-6.2.95 Hydraulic Power Unit (A2A19FCV4) 5-367 (A2A17MOT4) 5-354 5-6.2.115 Filter (A2A20FL1 and

5-6.2.96 Salvage Pump A2A20FL2) 5-368 (A2A17MOT2) 5-355 5-6.2.116 Drain and Vent Valves

5-6.2.97 Heat Exchanger (A2A20MV1 and

(A2A17HE1) 5-356 A2A20MV2) 5-368

5-6.2.98 Float Switch 5-6.2.117 Ball Valve

(A2A17S8) 5-357 (A2A20MV3) 5-369

5-6.2.99 Back Pressure Regulator 5-6.2.118 Resistance Temperature (A2A17BPV11) 5-358 Detector (RTD) Assembly

5-6.2.100 Check Valve (A2A21MT8) 5-369 (A2A17CV6) 5-358 5-6.2.119 Filter Assembly

5-6.2.101 Filter (A2A17FL16) 5-358 (A2A21FL11) 5-370 5-6.2.102 Strainer (A2A17FL19) 5-359 5-6.2.120 Flowmeter(A2A21MF13A) 5-6.2.103 Diverter Valve Assembly and Signal Conditioner

(A2A18AV3) and Actuator (A2A21MF13B) 5-370 (A2A18AV3A) 5-359 5-6.2.121 Check Valve

5-6.2.104 Diverter Valve (A2A21CV10) 5-371 (A2A18AV3B or 5-6.2.122 Connector Panel A2A18AV3C) 5-360 Assembly (A2A22)

5-6.2.105 Heat Exchanger Components 5-371 (A2A18HE2) 5-360 5-6.2.123 Resistance Temperature

5-6.2.106 Thermocouple (A2A18TC1 Detector (RTD) Assembly through A2A18TC4) 5-363 (A2A23MT7) 5-372

5-6.2.107 Valve (A2A18MV14 5-6.2.124 Doser Metering Valve through A2A18MV17) 5-363 Assembly

5-6.2.108 Check Valve (A2A23BPV4) 5-372 (A2A18CV20) 5-364 5-6.2.125 Filter Assembly

5-6.2.109 Thermo Control Valve (A2A23FL10) 5-373 (A2A18PRV21) 5-364 5-6.2.126 Flowmeter

5-6.2.110 Leakage Circuit Assembly (A2A23MF12A) and Signal (A2A19) 5-365 Conditioner

5-6.2.111 Resistance Temperature (A2A23MF12B) 5-374 Detector (RTD) Assembly 5-6.2.127 Check Valve

(A2A19MT4) 5-366 (A2A23CV9) 5-374

ix

TABLE OF CONTENTS - CONT

Chapter Page Chapter Page

5-6.2.128 Check Valve (A2A24CV15). . . . . . . . . . 5-375

5-6.2.129 Air Hoist (A2MOT4) . . . . . . . . . . . . . . . 5-375

5-6.2.130 Resistance Temperature Detector (RTD) Assembly

(A2A25MT10) . . . . . . . . . . . . . . . . . . . 5-376

5-6.2.131 Filter Assembly (A2A25FL13). . . . . . . . 5-376

5-6.2.132 Flowmeter (A2A25MF16A) and Signal Conditioner

(A2A25MF16B). . . . . . . . . . . . . . . . . . 5-376

5-6.2.133 Back Pressure Valve

(A2A25BPV8) . . . . . . . . . . . . . . . . . . . 5-377

5-6.2.134 Resistance Temperature Detector (RTD) Assembly (A2A26MT9) . . . . . 5-378

5-6.2.135 Ball Valve (A2A26AV19) . . . . . . . . . . . 5-379

5-6.2.136 Ball Valve (A2A26AV18) . . . . . . . . . . . 5-379

5-6.2.137 Filter Assembly (A2A26FL12). . . . . . . . 5-380

5-6.2.138 Flow Control Valve (A2A26FCV5) . . . . 5-380

5-6.2.139 Flowmeter (A2A26MF14A) and Signal Conditioner

(A2A26MF14B). . . . . . . . . . . . . . . . . . 5-381

5-6.2.140 Flowmeter (A2A26MF15A) and Signal Conditioner

(A2A26MF15B). . . . . . . . . . . . . . . . . . 5-382

5-6.2.141 Back Pressure Valve

(A2A26BPV6) . . . . . . . . . . . . . . . . . . . 5-382

5-6.2.142 Resistance Temperature Detector (RTD) Assembly (A2A27MT11) . . . . 5-383

5-6.2.143 Filter Assembly (A2A27FL14). . . . . . . . 5-384

5-6.2.144 Flowmeter (A2A27MF17A) with Signal Conditioner

(A2A27MF17B). . . . . . . . . . . . . . . . . . 5-384

5-6.2.145 Back Pressure Regulator Valve (A2A27BPV9). . . . . . . . . . . . . . 5-385

5-6.2.146 Check Valve (A2A27CV13). . . . . . . . . . 5-386

5-6.2.147 Relief Valve (A2A27CV18) . . . . . . . . . . 5-386

5-6.2.148 Filter (A2A28FL3 or A2A28FL4) . . . . . 5-386

5-6.2.149 Bleed Valve (A2A28MV4). . . . . . . . . . . 5-387

5-6.2.150 Vent Valve (A2A28MV5) . . . . . . . . . . . 5-387

5-6.2.151 Isolation Valve (A2A28MV6) . . . . . . . . 5-388

5-6.2.152 Bypass Valve (A2A28MV7) . . . . . . . . . 5-388

5-6.2.153 Ball Valve (A2A28MV8) . . . . . . . . . . . 5-389

5-6.2.154 Resistance Temperature Detector (RTD) Assembly (A2A29MT6) . . . . . 5-389

5-6.2.155 Filter Assembly (A2A29FL9). . . . . . . . . 5-390

5-6.2.156 Flowmeter (A2A29MF11A) and Signal Conditioner

(A2A29MF11B) . . . . . . . . . . . . . . . . . 5-390

5-6.2.157 Check Valve (A2A29CV8). . . . . . . . . . 5-391

5-6.2.158 Resistance Temperature Detector (RTD) Assembly (A2A30MT12) . . . . 5-391

5-6.2.159 Filter Assembly (A2A30FL15). . . . . . . . 5-391

5-6.2.160 Flowmeter (A2A30MF18A) and Signal Conditioner

(A2A30MF18B) . . . . . . . . . . . . . . . . . 5-392

5-6.2.161 Back Pressure Regulator Valve

(A2A30BPV10) . . . . . . . . . . . . . . . . . . 5-392

5-6.2.162 Check Valve (A2A30CV14). . . . . . . . . . 5-393

5-6.2.163 Relief Valve (A2A30CV19) . . . . . . . . . . 5-393

5-6.2.164 Incandescent Bulb (A2WLT1) . . . . . . . . 5-394 x Change 3

Chapter Page Chapter Page

5-6.2.165 Tumbler Switch 5-7.8 Doser Stem

(A2S10) 5-394 (A2A23BPV4)

5-6.2.166 Lubrication Enclosure Adjustment for

(A2A32) 5-394 CP19 5-410

5-6.2.167 Trolley Hoist (A2A31) 5-394 5-7.9 Doser Stem (A2A2PRV4) 5-6.2.168 Ball Valve (A2AV16) 5-394 Adjustment for CP1 and 5-6.2.169 Ball Valve (A2AV17) 5-395 (A2A2PRV3) CP4 5-411 5-6.2.170 Ball Valve (A2AV15) 5-396 5-7.10 Doser Stem (A2A27BPV9) 5-6.2.171 Optical Level Switch Adjustment for CP6 5-414

(A2S9) 5-397 5-7.11 Doser Stem (A2A30BPV10) 5-6.2.172 Screened Bleed Adjustment for CP7 5-415

(A2SCB13) 5-397 5-7.12 Doser Stem (A2A3PRV6) 5-6.2.173 Back Pressure Valve Adjustment for CP13 5-416

(A2A10BPV1) 5-398 5-7.13 Doser Stem (A2A30BPV10) 5-6.2.174 Filter (A2A1FL21) 5-398 Adjustment for CP17 5-418 5-6.2.175 Screened Bleed 5-7.14 Doser Stem (A2A2PRV1)

(A2A2SCB1) 5-399 Adjustment for CP11 5-419 5-6.2.176 Screened Bleed 5-7.15 Doser Stem (A2A2PRV2)

(A2A4SCB20) 5-399 Adjustment for CP12 5-421 5-7 Adjustment 5-399 5-7.16 Doser Stem (A2A3DV7) 5-7.1 Pressure Switch Adjustment for CT3 5-422

(A1S1) Adjustment 5-399 5-7.17 Frequency to Current Module 5-7.2 Gauge Guard (GG1 (A1A25TX1, A1A25TX2 and GG2) Adjustment 5-400 and A1A25TX3) 5-7.3 Pressure Reducing Regulator Alignment 5-423

(A2A1PRV16, 5-7.18 Signal Conditioner (A33) A2A1PRV22 and Alignment 5-424 A2A1RV2) Adjustment 5-402 5-7.19 Combustible Gas Detector

5-7.4 Flow Control Valves (MCGD1) Alignment 5-424 (A2A11DFC1 and 5-7.20 Power Control Module

A2A13DFC3) (A34A2A1A1)

Adjustment 5-402 Alignment 5-427

5-7.5 Interface Connector 5-7.21 Frequency to Current Module Assembly (ICA) (A2A8) (A26) Alignment 5-427 Alignment 5-402 5-7.22 Current Operated Switch

5-7.6 Row Control Valves (A34A3S1) (FCV1 through FCV5) Alignment 5-427 Adjustment 5-403 5-7.23 Air Conditioner Thermostats

5-7.7 Hydraulic Power Unit (A30S1 and A30S2) (HPU) (A2A17MOT4) Alignment 5-427 Adjustment 5-408 xi

T.0. 33D4-6-755-1

Chapter Page Chapter Page

5-7.24 Differential Pressure Switch 5-8 Test 5-430

(A30S3) Alignment 5-428 5-9 Calibration 5-430 5-7.25 Positioner CCA 5-9.1 Test Station Calibration 5-430

(A2A10MV21B) 5-9.2 Display Calibration

Alignment 5-428 Tables 5-430 5-7.26 Electric Actuator

(A2A10MV21A) 6 DIAGRAMS 6-1

Alignment 5-428

5-7.27 Power Supply 6-1 General 6-1

(A1A5PS10VP1 and

A1A5PS30VP3) 7 ILLUSTRATED PARTS

Overvoltage Protection BREAKDOWN 7-1

Adjustment 5-428 5-7.28 Power Supply (A1A5PS2, 7-1 Introduction 7-1

AlA5PS4 andAlA5PS5) Adjustment 5-430 8 DIFFERENCE DATA 8-1

8-1 Introduction 8-1 xii

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Fuel Control System 4-9 Digital Multimeter (A1A10M1) Components Test Station Controls and Indicators 4-45 A/F46T-5 1-2 4-10 Meter (A1A9) Controls and

1-2 Test Station Interface Diagram 1-9 Indicators 4-48 1-3 Major Component Location 1-17 4-11 MCM Assembly (A1A12 and

A1A14) Controls and 2-1 Hydraulic Crane 2-2 Indicators 4-52 2-2 Portable Temperature 4-12 Test Station Operator Controls

Laboratory 2-3 and Indicators 4-55 2-3 Platform Lift 2-4 4-13 Emergency Stop Button/Process 2-4 2" Nylon Web Sling 2-4 Control Section Door 2-5 -32 Tube Nut Wrench 2-5 Locations 4-69 2-6 Thermometer 0 to 180 F 2-5 4-14 Test Station Power Control 2-7 Button and Lens Removal Tool 2-6 Panel/Display Monitor 2-8 Bleed Extractor 2-6 Locations 4-70 2-9 Heater Removal Adapter 2-7 4-15 Monitor Screen Diagram 4-73

4-16 Set-Up Display Screen 4-1 AC Power Distribution Diagram 4-76

Block Diagram 4-3 4-17 Test Station Maintenance 4-2 Interface Connector Assembly Menu Tree 4-79

(A2A8) Component Locations 4-24 5-1 Sample Test Station

4-3 DC Power Supply (A1MV1 and Maintenance Log 5-2 A1MV2) Controls and 5-2 Measurement Control Module Indicators 4-26 (A1A13 and A1A14)

4-4 Video Display Terminal (ODM Air Filters 5-7 and PDDM) (A1A3 and 5-3 Process Control Section and A1A11) Controls and Component Location 5-37 Indicators 4-30 5-4 Hydraulic Control Section

4-5 Embedded Computer System Component Location 5-105 (A1A4) Controls and 5-5 Remote Electrical Cabinet Indicators 4-34 Assembly (A3) 5-179

4-6 AC Analyzer Power Meter 5-6 DC Power Supply (A1MV1 or (A1A6) Controls and A1MV2) Dip Switch Setting 5-182 Indicators 4-36 5-7 COMM Cable Pin Out 5-184

4-7 AC Power Supply (A1A7) 5-8 Graphics Driver (A1A4A2) Controls and Indicators 4-39 Address Setting 5-188

4-8 12MHz Synthesized FCTN 5-9 RS-232 Controller (A1A4A4) GEN (A9A1) Controls Card Dip Switch Setting 5-192 and Indicators 4-41 xiii

LIST OF ILLUSTRATIONS -CONT

Number Title Page Number Title Page

5-10 IEEE-488 Controller (A1A4A6) 5-27 Hydraulic Power Supply Test Board Dip Switch Setting 5-195 Set-Up 5-409

5-11 IEEE-583 Controller (A1A4A7) 5-28 Doser Stem Adjustment for CP1 Card Switch Setting 5-198 through CP4 5-412

5-12 Graphics Driver Card (A1A4A4) 5-29 Doser Stem Adjustment Set-Up Address Setting 5-200 for CP6, CP7, CP13, 5-13 Power Meter (A1A6) Dip Switch CP17 and CT3 5-413 Setting 5-209 5-30 Doser Stem Adjustment Set-Up For

5-14 AC Power Supply (A1A7) Dip CP11 and CP12 5-420 Switch Setting 5-211 5-31 Combustible Gas Detector

5-15 Meter/Motor Control Assembly Adjustment 5-425 (A1A10M1) Dip Switch 5-32 Process Control Module Setting 5-218 Jumpers 5-426

5-16 Switch Matrix Card (A1A12A2) 5-33 Test Station Calibration

Dip Switch Setting 5-220 Option Menu 5-432 5-17 Safety Barrier Removal 5-232 5-34 Channels Selection Menu 5-432 5-18 Intrinsic Repeater Relays 5-35 Pressure Channels Selection

(A1A20A1ISR10 and Menu 5-433 A1A20A1ISR11) Switch 5-36 Temperature Channels Selection

Settings 5-236 Menu 5-433 5-19 RS-232/RS-422/RS-485 5-37 Flow Channels Selection Menu 5-434

Converter (A1A28) 5-38 Electrical Channels Selection Jumper Setting 5-248 Menu 5-434

5-20 Air Conditioner Assembly 5-39 Calibration Interactive Menu 5-435 Removal and Replacement 5-250 5-40 Calibration Tables Selection

5-21 Cooling Coil Removal and Menu 5-435 Replacement 5-252 5-41 Electrical Parameters Selection

5-22 Interface Connector Assembly (ICA) Menu 5-436 (A2A8) Removal and 5-42 Pressure Parameters Selection

Replacement 5-307 Menu 5-436 5-23 Interface Connector Assembly 5-43 Flow Parameters Selection

(ICA) Electrical Connector Menu 5-437 Removal and Replacement 5-309 5-44 Temperature Parameters Selection

5-24 Interface Connector Assembly Menu 5-437 (ICA) (A2A8) Electrical 5-45 Dynamic Parameters Selection Connector Removal and Menu 5-438 Replacement 5-310

5-25 Gauge Guard Adjustment Test 6-1 Electrical Schematic

Set-Up 5-401 Symbology Diagram 6-55 5-26 Flow Control Valve Adjustment 5-404 6-2 Test Station Electrical Schematic

Diagram 6-57 xiv

LIST OF ILLUSTRATIONS -CONT

Number Title Page Number Title Page

6-3 Hydraulic Control Section 6-6 Cable Assembly Wiring Symbology Diagram 6-153 Diagrams 6-169

6-4 Hydraulic Control Section 6-7 AC Distribution Diagram 6-199 Schematic Diagram 6-155

6-5 Air Conditioner Hydraulic Schematic Diagram 6-167 xv

LIST OF TABLES

Number Title Page Number Title Page

1-1 List of Abbreviations 1-3 4-11 MCM Assembly (A1A12 and 1-2 Related Publications List 1-4 A1A14) Controls and 1-3 Leading Particulars 1-5 Indicators 4-53

4-12 Test Station Operator Controls 2-1 Special Tools and Test and Indicators 4-61

Equipment 2-1 4-13 Critical Alarm Parameters 4-66 2-2 Consumable Materials 2-8 4-14 List of Screen Options 4-74

4-15 List of Options Menu Screen 4-1 Measurement Control Module Options 4-75

(A13/A14) Slot 4-16 List of Menu Options 4-77 Allocations 4-9

4-2 Interface Connector Assembly 5-1 Preventive Maintenance

(A2A8) (ICA) Location Summary 5-5 Interface 4-23 5-2 Test Station Troubleshooting

4-3 DC Power Supply (A1MV1 Guide 5-14 and A1MV2) Controls 5-3 Circuit Cards (A1A13A1 and Indicators .. 4-27 through A1A13A20)

4-4 Video Display Terminal (ODM Jumper Setting 5-222 and PDDM) (A1A3 and A1A11) 5-4 Circuit Cards (A1A14A1 Controls and Indicators 4-31 through A1A14A9)

4-5 Embedded Computer System Jumper Settings 5-225 (A1A4) Controls and 5-5 32-Channel A/D Termination Indicators 4-35 Panel (A1A15) Jumper

4-6 AC Analyzer Power Meter Settings 5-227 (A1A6) Controls and 5-6 32-Channel A/D Termination Indicators 4-37 Panel (A1A16) Jumper

4-7 AC Power Supply (A1A7) Settings 5-228 Controls and Indicators 4-40 5-7 Interface Connector Assembly

4-8 12MHz Synthesizer FCTN (ICA) (A2A8) Connections 5-311 GEN (A9A1) Controls and 5-8 Flow Control Valve Set Indicators 4-42 Points 5-404

4-9 Digital Multimeter (A1A10M1) Controls and 6-1 Diagrams 6-1 Indicators 4-46 6-2 Wire List for Process

4-10 Meter (A1A9) Controls and Control Section 6-2 Indicators 4-49 6-3 Channel Identification (CH ID)

Reference List 6-53 xvi

SAFETY SUMMARY

Personnel performing maintenance procedures and practices included in this manual shall be familiar with safety precautions associated with chemicals and other hazardous materials or equipment. The following are general safety precautions and instructions that shall be understood and applied during operations and maintenance to ensure personal safety and health and minimize system and equipment damage. These precautions are not inclusive. The Material Safety Data Sheets (MSDS), the local safety office, and Air Force Occupational Safety and Health (AFOSH) standards should be consulted for specific information. WARNINGS (for personnel protection) or CAUTIONS (for equipment protection) may also precede selected procedures in this manual for additional emphasis. Disregarding either a WARNING or CAUTION or performing unauthorized maintenance can cause engine or equipment damage, serious injury, or illness.

AVOID COMPLACENCY

The computer used in the AFATS test station is a modem, state-of-the-art machine. Although it is unlikely, the possibility always exists that there could be a malfunction in this area. If this should happen, its ability to automatically detect hazards could become inoperative. For this reason, the test station operator will always remain alert and attentive to the functions being performed by the test station. Failure to do this could result in serious injury.

CLEANERS AND SOLVENTS

Many cleaning fluids and solvents are easily ignited and are irritating to skin, eyes, and respiratory system. Contact with some of these cleaners and solvents over an extended period of time can result in an accumulation of toxins in the body. Solvents used for cleaning can cause internal corrosion of engine controls if the solvents are not removed during storing or shipping the control. Keep ignition sources away, ensure adequate ventilation, wear protective clothing/equipment, store cleaners and solvents in approved containers, and read and follow all label directions. Observe manufacturers warning labels, material safety data sheets (MSDS) instructions for proper handling, storage, and disposal, and current safety directives.

COMPRESSED AIR

Compressed air can generate flying debris and can cause severe injury if air blast penetrates the skin or eyes. Reduce compressed air pressure for cleaning or drying to less than 30 PSIG. Do not direct air blast toward other personnel. Use with effective chip guarding and appropriate personnel protective equipment. Use with effective chip guarding and personal protective equipment.

xvii

DANGEROUS PRESSURE

Pressure system precautions apply to all equipment using gases and fluids at all ranges of pressure. To avoid injury, stand clear of tooling and parts being pressure-tested when pressure is being applied. Proper tool installation and hose connections shall be ensured before applying pressure. All system components shall be compatible with pressures applied and the pressure medium used. Pressure shall be applied slowly. Personnel must be protected by a safety shield or at a distance sufficient to prevent injury.

DO NOT WEAR JEWELRY

Remove rings, watches, necklaces, and other metallic objects that may be snagged or cause shock or bum hazards.

FOOD AND TOBACCO

Do not smoke tobacco products or eat food before washing hands and face thoroughly. Residue of the materials used in engine and equipment maintenance can cause serious health problems if eaten or inhaled in the smoke.

HYDRAULIC HOSE CONNECTIONS

Under operational conditions, hydraulic hoses are under high pressure. When making hydraulic hose connections, always ensure that all connections are tight and secure. Failure to comply may result in serious injury.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must think safety at all times. Do not replace components or make adjustments to equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. These circuits shall be properly discharged and grounded prior to servicing. Adhere to all lockout/tagout requirements.

RESUSCITATION

Personnel working with or near dangerous voltage shall be trained in current methods of resuscitation. Information and training sources may be obtained from the Director of Base Medical Services.

xviii

WARNINGS AND CAUTIONS

The following WARNINGS and CAUTIONS appear throughout the manual and shall be strictly heeded:

WARNING |

Whenever a condition is experienced during UUT testing which is abnormal (leaks, equipment failures, unusual noises), the test must be stopped using either the test station EMERGENCY STOP or FLUID SHUTDOWN switches. Do not attempt to halt one of these conditions by using the CANCEL TEST or SUSPEND TEST (on the Operator Display Monitor (ODM)). Failure to comply may result in injury to personnel or damage to equipment.

WARNING |

The interactive mode of operation aids troubleshooting and engineering evaluation/development for the test equipment and the UUT. Danger exists during the use of this mode. When operating the test station in the interactive mode, the test station operator must have thorough knowledge of the test equipment and the UUT in order to avoid hazardous conditions. Failure to comply may result in serious injury or death to personnel and/or damage to equipment.

WARNING |

Maintenance lockout pushbutton (A1A34XS3) does not remove all electrical power. Power from 24 VDC power supply is still available to the test station.

WARNING |

Power OFF pushbutton (A1A34S4) will shutdown the PCS (Al) and disables the hydraulic control section circuits, but will not remove 24 VDC power from the PCS. Using the power OFF pushbutton shutdown in place of main circuit breaker (A1A34A3CB1) shutdown can result in death or injury.

xix

WARNING |

Main circuit breaker (A1A34A3CB1) does not remove the power coming into main circuit breaker from facility.

WARNING |

The Process Control Section carries lethal voltages which can cause injury or death. All enclosure doors must be closed and all door safety guards must be in place before starting the test station.

WARNING |

The process control section (Al) and hydraulic control section (A2) carry lethal voltages which can cause injury or death. All enclosure doors must be closed and all door safety guards must be in place before starting the test station.

WARNING |

Before cleaning, make sure electrical power to test station is off. Electricity causes shocks, bums, or death.

WARNING |

Use dry cleaning solvent, P-D-680, Type ffl, in a well-ventilated area. Avoid excessive skin contact or prolonged inhalation of vapors. Do not use near open flames or in areas where high temperatures exist.

WARNING |

Denatured alcohol is flammable and toxic. Use in a well-ventilated area. Keep away from heat and open flames. Wear skin and eye protection. Avoid prolonged inhalation of vapors. Failure to do so may result in injury or death.

xx

To prevent injury to personnel, two maintenance personnel are required to lift display monitor (A1A3 or A1A11) during removal/installation.

WARNING |

Soldering or de-soldering is not allowed in the test station area. Soldering is only allowed in the ITA Calibration (ITACal) room. Performing soldering in the test station area may result in injury or death.

WARNING |

Use care when using a soldering iron. Soldering iron tip is extremely hot. Hot surfaces can cause skin bums or injury.

WARNING |

To prevent injury to personnel, two maintenance personnel are required to lift the power meter (A1A6) during removal/installation.

WARNING |

To prevent injury to personnel, use lift platform to lift power supply (A1A7) during removal/installation from equipment rack.

WARNING |

Air conditioner assembly weighs in excess of 150 pounds, use lift platform for removal/instal ation.

xxi

To prevent injury to personnel, two maintenance personnel are required to lift direct drive blower

(A1A30MOT2) during removal/installation.

WARNING |

To prevent injury to personnel or damage to equipment, the facility power to the test station must be shutdown before performing removal and replacement procedures.

WARNING |

To prevent injury to personnel or damage to equipment, move exhaust blower assembly using lift platform. Exhaust blower assembly weighs in excess of 100 pounds.

WARNING |

CalFluid is flammable and toxic to skin, eyes, and respiratory tract. Skin eyes, and respiratory protection is required. Avoid repeated or prolonged contact.

WARNING |

Plate assembly (A2A8) weighs in excess of 400 pounds. Use extreme care during removal/installation to avoid personal injury.

WARNING |

Due to weight (500 pounds) heat exchanger a suitable lifting device must be used to stabilize and move heat exchanger. Failure to do so may result in personal injury.

xxii

Electrical power shall be off before connecting or disconnecting electrical connections.

Electricity causes shock, bums, and death.

[ CAUTION^]

Do not rub alcohol on meter displays or plastic surfaces. Chemicals in alcohol will damage plastic surfaces.

PCAUTIC^N ]

To prevent damage, use only approved general purpose detergent to clean plastic or glass screens, windows, and gauges. Use of aromatic hydrocarbons and chlorinated solvents on instrumentation and electrical contacts could react chemically with plastic components and damage equipment.

["CAUTION"]

Circuit cards may be damaged by Electrostatic Discharge (ESD) during removal and repair. Use ESD precautionary procedures in DOD-STD-1686, DOD-HNBK-263B, and T.O. 00-25-234, Section VII, for special handling procedures for ESD equipment. Failure to comply could lead to damage of equipment.

PCAUTIOIN^]

Slide rail halves in equipment rack can be damaged if slide rail halves installed on monitor are not level.

[ CAUTION ]

Mounting rails may be seriously damaged when removing/installing ECS. The ECS rails must be accurately and carefully separated from rails on equipment rack.

FCAUTIOIN^]

Wires may be damaged when installing enclosure if not carefully guided through connector openings.

xxiii

[ CAUTION

To prevent equipment damage and ensure proper operation of replacement termination panel, the signal channel strapping options must be identical to those used on replaced termination panel.

FCAUTION^]

The capillary tube can be damaged if not properly handled during installation.

[ CAUTION ]

To prevent damage to equipment, solenoid valves (A1A32SV1 through A1A32SV35) should be detached from solenoid panel bracket before disconnecting inaccessible air lines at rear of faulty valve. Only disconnect air lines necessary to remove faulty valve.

CAUTION

.-^-^^^-^A

To prevent damage to equipment, air lines should be connected to rear of replacement valve before attaching solenoid valves (A1A32SV1 through A1A32SV35) to solenoid panel bracket.

[ CAUTION

Pressure range of switch assemblies are not the same. Make sure switch assembly range is correct before installing. Switch assembly can be damaged if incorrect pressure is applied.

[ CAUTION ]

Pressure switch assembly must be locked into receptacle before applying pressure to switch assembly. Pressure switch can be damaged if not properly secured.

FCAUTION^]

Failure to back out adjustment stem in doser valve before installing Pressure Reducing Regulator (PRV) may damage PRV.

F CAUTION ^^^._^_^_.^^.^.-^*

Be careful when removing/installing plate assembly to avoid damaging lines and surrounding structure.

xxiv

CAUTION }

Arrow on flow control valve must be pointing downstream or flow control valve will not work.

[ CAUTION

Arrow on pressure regulator must be pointing downstream or regulator will not work.

r^cAunoN^J Arrow on check valve must be pointing downstream or check valve will not work.

[ CAUTION ]

Arrow on installed flowmeter must be pointing downstream or flowmeter will not work.

PCAUTION^

The flow transmitter is sensitive to contamination. Be careful to keep connection ports clean.

[ CAUTION

Increasing pressure over full scale range of pressure switch will damage the pressure switch.

PcAimoN ]

When entering an open loop set, enter a value that will increase flow gradually to prevent damaging equipment.

xxv/(xxvi blank)

CHAPTER 1

INTRODUCTION AND GENERAL INFORMATION

1-1 INTRODUCTION. Chapter 3 PREPARATION FOR USE AND SHIPMENT. This chapter provides instructions

1-1.1 Purpose This manual provides information to convert between operational and storage or for the Fuel Control System Components Test shipment conditions.

Station, A/F46T-5 (figure 1-1), hereafter referred to as the test station. This information is intended Chapter 4 OPERATION INSTRUCTIONS.

for use by operation and maintenance personnel. This chapter provides a functional theory of The test station is used with the Test Station operation and operation instructions for the test Pump Unit PMU-64/E (T.O. 33D4-6-756-1), station.

Mechanical Test Adapter ADU-762/E (T.O. 33D7-50-1989-2), Mechanical Test Adapter Chapter 5 MAINTENANCE INSTRUCTIONS.

ADU-763/E (T.O. 33D7-50-1988-2) and the This chapter provides instructions to maintain the Secondary Reference Standards Calibration Set test station in an operational condition and to A/E48T-6 (T.O. 33DA92-3-1). This equipment is identify and correct an inoperative condition.

manufactured by AlliedSignal Inc., Aerospace Equipment Systems, 717 North Bendix Drive, Chapter 6 DIAGRAMS. This chapter provides South Bend, Indiana 46620-1000. electrical, hydraulic, and pneumatic schematic diagrams for the test station.

1-1.2 Scope This manual provides maintenance information for the test station. The Hlustrated Chapter 7 ILLUSTRATED PARTS Parts Breakdown (IPB) information is located in BREAKDOWN. This chapter references T.O. 33D4-6-755-4. T.O. 33D4-6-755-4 for the test station.

1-1.3 Arrangement This manual is divided into Chapter 8 DIFFERENCE DATA. This chapter eight chapters numbered 1 through 8. Chapter provides the differences for the test station.

titles and content are as follows:

1-1.4 Abbreviations Abbreviations used in this Chapter 1 INTRODUCTION AND GENERAL manual are in accordance with MIL-STD-12, INFORMATION. This chapter provides an except as listed in table 1-1.

overview of the test station, its purpose, and features. 1-1.5 Related Publications Table 1-2 provides a list of Technical Orders (T.O.s) and related Chapter 2 SPECIAL TOOLS, TEST publications that supplement the information EQUIPMENT AND CONSUMABLE contained in this manual.

MATERIALS. This chapter describes nonstandard tools, test equipment, and 1-1.6 Leading Particulars The leading consumable materials needed to perform particulars for the test station are listed in table procedures in the following chapters. 1-3.

1-1

HYDRAULIC ^^ /^~^\ \ ^CONTROL ^^ >^^ /~~^\\ \^-\

SECTION ^^ ^\’<< ^’ ^r \\ <

^^ ^^^JT "\ \ ^^\ PROCESS

,^-’ ^^< ^<^^ CONTROL

.^^ ^^^.s’- .^^^ SECTION

^K ^ f^] ^ ’0 ^lo >^

75510100

Figure 1-1. Fuel Control System Components Test Station A/F46T-5

1-2

Table 1-1. List of Abbreviations

Abbreviation Definition

A/D Analog-to-Digital AC Alternating Current AFATS Advanced Fuel Accessories Test System AFOSH Air Force Occupational Safety and Health CalFluid Calibration Fluid CC Central Computer CCA Circuit Card Assembly CCW Counterclockwise CKT Circuit Card CVT Current Value Table CW Clockwise DC Direct Current DMA Direct Memory Access ECS Embedded Computer System EP Explosion Proof ESTOP Emergency Stop FAC Facility Connection Point FISO Fault Isolation FWS Fuel-Wetted Section HPS Hydraulic Power Supply (Hydraulic Aircraft Component Power Supply) HPU Hydraulic Power Unit HW Hardware ICA Interface Connector Adapter IS Intrinsically Safe ITA Interface Test Adapter ITACal Interface Test Adapter Calibration Station LAM Look At Me LCN Local Communication Network LOC Location LPPM Low Pressure Pump Module (Test Station Pump Unit) MCM Measurement Control Module MIC Mating Interface Connector MSDS Material Safety Data Sheet ODM Operator Display Monitor OPTO Optical Coupler PCM Power Control Module PCS Process Control Section PDDM Process Data Display Monitor PM Pump Module PMP1 Pump PPH Pounds Per Hour PRV Pressure Reducing Valve PSI Pounds Per Square Inch PSIA Pounds Per Square Inch Absolute PSID PSI Differential PSIG Pounds Per Square Inch Gauge RAM Random Access Memory RTD Resistance Temperature Detector Assemblies scfm Standard Cubic Feet Per Minute UUT Unit Under Test VAC Volts Alternating Current VSD Variable Speed Drive

1-3

Table 1-2. Related Publications List

T.O. Number T.O. Title

DOD-STD-1686A Electrostatic Discharge Control Program For Protection of Electrical and Electronic Pans, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

DOD-HNBK-263B Electrostatic Discharge Control Handbook For Protection of Electrical and

Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices)

T.O. 00-5-1 AF Technical Order System

T.O. 00-20-14 Air Force Metrology and Calibration Program

T.O. 00-25-195 AF Technical Order System Source, Maintenance, and Recoverability Coding of Air Force Weapons, Systems, and Equipments

T.O. 00-25-234 General Shop Practice Requirement for Repair, Maintenance and Test of Electrical Equipment

T.O. 1-1-689 Organizational/Unit and Intermediate Maintenance, Avionics Cleaning and Corrosion Prevention/Control

T.O. 1-1-691 Aircraft Weapons Systems, Cleaning and Corrosion Control (Multiple Aircraft)

T.O. 33A2-2-71-1 Power Supply, Aircraft Component, Hydraulic

T.O. 33DA92-3-1 Operation Instructions, Secondary Reference Standards Calibration Set A/E48T-6, Part Number 8231300-0501

T.O. 33D4-6-755-4 Illustrated Parts Breakdown, Fuel Control Components Test Station, A/F46T-5, Part Numbers 8230001-0501, 8230001-0502, and 8230001-0503

T.O. 33D4-6-756-1 Operation and Maintenance Instructions, Advanced Fuel Accessories Test System, Test Station

Pump Unit PMU-64/E, Pan Number 8230800-0501

T.O. 33D7-50-1987-1 Operation Instructions,…