6J10-3-136-3 Testing.pdf

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T his chapter provides instructions for testing the fuelbooster pum p and/or pum p housing assem bly after overhaul to in-sure that the units function as required.

Fuel booster pum p tests are given in

Paragraph 7.2.Pum p housing tests are pro-vided in Paragraph

7.3.

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7.2.1 Test

E quipm ent.

B reak-in, calibration, and external leakage testing m ust be done on Fuel

Pum p

Test Stand, P/N 83518.

E xternal leakage testing shall be accom plished using the 15-gallon, rotatable, static test tank.

B reak-in and cali-bration testing shall be accom plished using the

125-gallon, fixed-position, flow test tank and

E lectrical

Pow er

C able, P/N 90381-1.

F igure

7-1.

F uel B ooster P um p

E xternal

L eakage

Test Setup

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7.2.2 Test Conditions.

The following involve dangerous voltages which may cause severe shock or injury. Avoid contact with energized components. Remove rings, watches and other metallic objects which may cause shock or burn hazards.

Unless otherwise specified, all tests shall be conducted under the following conditions:

1. Fluid. The test fluid used must be in accordance with MIL-PRF-7024, Type II, and shall be main-tained at a temperature of 60 to 90°F.

2. Submergence. During break-in and calibration testing, fluid level must be as indicated in Figure 7-2.

3. Ambient Air. Temperature should be maintained between 60 and 90°F. Barometric pressure should be that prevailing in the test area.

4. Electrical Power. Three phase, 200 volts ac, 400 hertz.

7.2.3 Test Procedures. Conduct the fuel booster pump

tests in Paragraph 7.2.4 through Paragraph 7.2.9 in the se-quence listed.

7.2.4 Examination of Fuel Booster Pump. Examine the

pump visually to determine quality of workmanship, and to detect visible defects or any imperfections which could re-sult in leakage or other malfunction. In particular, check all packings to insure freedom from imperfections such as cuts or nicks. Examine the rotating assembly for freedom from sticking or rubbing.

7.2.5 External Leakage Test.

To prevent injury to personnel, make sure pump element is secured and lever in locked position.

For safety reasons rotate tank 90 so pump element is pointing down or in vertical position.

Refer to Figure 7-1. Attach the slave pump housing to the adapter plate and install as a unit on the static test tank.

Insert the pump element in the housing and lock in place.

Fill the 15-gallon static test tank with test fluid to sight glass FS2. Rotate tank until booster pump is in position shown.

Apply a pressure of 15.0 ±1.0 psig to static test tank for a period of 5 minutes. There shall be no visible leakage through and/or around the pump element assembly or part thereof.

7.2.6 Break-In Run. Refer to Figure 7-2. Install pump el-

ement in the permanently mounted slave pump housing lo-cated in bottom of 125-gallon test tank. Connect the Electri-cal Power Cable to the pump element connector and to the receptacle on the test stand. Conduct a break-in run at a flow rate of 100 to 125 gpm (38,500 to 48,125 pph) for a period of 15 minutes with power setting at 200 ±2 volts and a fre-quency of 400 ±2 hertz. Observe for indications of overheat-ing, vibration, or unusual noise. Reject the pump if any of these conditions are noted.

7.2.7 Pump Calibration. Install pump element as de-

scribed in Paragraph 7.2.6. Maintain test conditions as indi-cated in Paragraph 7.2.2. Adjust voltage to 200 ±2 volts ac with frequency set at 400 ±2 hertz. Operate fuel booster pump as indicated in Figure 7-3. If pump fails to meet cali-bration acceptance, reject it.

7.2.8 Impeller Rub Check Dry Run. Wet the pump bear-

ings by direct application of or immersion in the test fluid.

Drain excess fluid until the pump is visually dry. Run the pump dry for a period of 3 to 5 minutes. While the unit is running dry, any sound detected from start to stop which indicates an impeller rub shall be cause for rejection. Scream-ing indicates a continuous rub, growling indicates spot rub-bing, and pinging indicates wobble or end play.

7.2.9 Electrical Integrity Tests.

The following involve dangerous voltages which may cause severe shock or injury. Avoid contact with energized components. Remove rings, watches and other metallic objects which may cause shock or burn hazards.

a. Dielectric Strength Test. Use insulation test set to check the fuel booster pump circuits. Pump must withstand the application of 700 ±10 volts rms at commercial frequency, applied for 1 minute between the circuit ter-minals (pins A, B, C, D) joined together and ground (pin E), without electrical breakdown. There shall be no arcing or insulation breakdown (failure may be evi-denced by fluctuations in leakage current or a steady increase in leakage current), nor shall, leakage current exceed 1,000 micro-amps.

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Figure 7-2. Fuel Booster Pump Test Setup

Figure 7-3. Pump Calibration Acceptance

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b. Insulation Resistance. Use ohmmeter to check insula-tion resistance of the pump circuits. The insulation re-sistance of the pump motor and wiring shall not be less than 100 meg-ohms when exposed to 500 ±10 volts dc applied between the circuit terminals (pins A, B, C, D) joined together and ground (pin E) for 2 min-utes.

7.3 TESTING PUMP HOUSING ASSEMBLY.

7.3.1 Test Equipment. Tests must be performed on Fuel

Pump Test Stand, P/N 83518. Refer to Figure 7-5 for test setup.

7.3.2 Test Conditions. Unless otherwise specified, all tests

shall be conducted under the following conditions.

1. Fluid. The test fluid used must be in accordance with MIL-PRF-7024, Type II, and shall be main-tained at a temperature of 60 to 90°F.

2. Submergence. Fluid level must be as indicated in Figure 7-5.

3. Ambient Air. Temperature should be maintained between 60 to 90°F. Barometric pressure should be that prevailing in the test area.

4. Electrical Power. Three phase, 200 volts ac, 400 hertz.

7.3.3 Test Procedures. Conduct the pump housing tests

in Paragraph 7.3.4 through Paragraph 7.3.6 in the sequence listed.

7.3.4 Examination of Housing. Examine the pump hous-

ing visually at assembly to determine quality of workman-ship and to detect visible defects or any imperfections which could result in leakage or other malfunction. Examine the check valves and inlet valve system prior to and after leak-age testing to insure they operate freely without sticking or binding.

7.3.5 Inlet and Discharge Valve Leakage Test. Mount

pump housing (with auxiliary discharge port capped off) to adapter plate, and install pump housing and adapter as a unit in the static test tank. (See Figure 7-5, except remove booster pump element.) To obtain pressure of 0.5 ±0.25 psig, fill tank with test fluid to sight glass FS2. No air pressure ap-plied. Rotate static test tank to position shown in Figure 7-5.

Collect and measure any leakage into the interior of the pump housing for a 5 minute period. Apply and maintain air pres-sure of 30 ±1.0 psig to the test tank for 5 minutes. Record the leakage; it must not exceed 10.0cc per minute average for either 5 minute period.

7.3.6 External Leakage Test. Refer to Figure 7-5. Use

the same setup as in Paragraph 7.3.5. Install fuel booster pump element and retain it in the normal manner within the housing. Apply air pressure of 15.0 ±1.0 psig to the test tank for a period of 5 minutes. There shall be no visible leakage.

Figure 7-4. Power Factor Acceptance

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Figure 7-5. Fuel Booster Pump Housing Test Setup

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