6J10-4-34-28-1 Testing.pdf

CHAPTER 3

TEST PROCEDURES

3.1 GENERAL.

This chapter provides information for evaluating the perfor-mance of a Unit Under Test (UUT) and diagnostics of any malfunction encountered.

3.2 PREPARATION FOR TESTING.

3.2.1 Visual Inspection. Visually inspect UUT support

assembly fixture, UUT, Interface Test Adapter (ITA) kit, sink cart, and test station for damage that might jeopardize safe operation during test as follows.

3.2.1.1 UUT Support Assembly Fixture Inspection. Re-

fer to Figure 3-1 for physical location.

a. Inspect UUT support assembly fixture for the follow-ing:

(1) Nicks, roughness, or other imperfections on car-riage rods.

(2) Uneven or incomplete operation of adapter lock-ing lever handle and screw actuator handwheel.

(3) Rough or no movement of plungers.

(4) Damaged threads.

(5) Contamination of sleeve and mating holes.

b. Repair or replace damaged UUT support assembly fix-ture parts.

3.2.1.2 UUT Inspection. Refer to Figure 3-2 for physical

location.

a. Inspect UUT for the following:

(1) Cracks, dents, nicks, or other damage.

(2) Cracked, burred, or broken shaft splines.

(3) Damaged threads.

(4) Contamination or damage to sealing surface.

b. If damage is found, return UUT for repair.

3.2.1.3 ITA Kit Inspection. Refer to Figure 6-1 for listed

items to inspect. Inspect ITA kit for the following:

a. Inspect ITA kit configuration plug assembly for:

(1) Loose or cracked wires on back of plug.

(2) Loose tag cable.

(3) Bent, broken, loose, missing, or worn contact pins.

(4) Damaged threads.

(5) Moisture or contamination of contact area.

b. Inspect ITA kit hose assemblies and test fittings for:

(1) Cut, kinked, or frayed calibration fluid (CalFluid), hydraulic, and pneumatic hoses.

(2) Damaged hose ends and test fittings.

(3) Foreign material inside CalFluid hoses, hydraulic hoses, pneumatic hoses, and test fittings.

c. Inspect ITA kit drive adapter assembly for:

(1) Cracks, dents, nicks, or other damage.

(2) Cracked, burred, or broken splines.

TO 6J10-4-34-28-1

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Figure 3-1. UUT Support Assembly Fixture

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Figure 3-2. UUT Port and Component Location Diagram

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(3) Contamination or damage to sealing surface.

(4) Damaged threads.

d. Repair or replace damaged ITA kit parts prior to test.

Refer to Chapter 5, Maintenance Instructions.

3.2.1.4 Sink Cart Inspection. Refer to Figure 2-2 for

physical location. Inspect sink cart for the following:

a. Secure sink cart floor lock.

b. Damaged sink cart Bulkhead Connector Panel (BCP) electrical connectors, CalFluid, hydraulic, and pneu-matic fittings.

c. Foreign material inside sink cart BCP electrical con-nectors, CalFluid, hydraulic, and pneumatic fittings.

d. Loose or leaking Mating Interface Connector (MIC) plate assembly connectors or loose assemblies.

e. Repair or replace damaged sink cart parts prior to test.

Refer to TO 33D7-50-1988-2 for sink cart maintenance procedures.

3.2.1.5 Test Station Inspection. Refer to Figure 2-5 for

physical location. Inspect test station for the following:

a. Contamination or damage on drive motor shaft.

b. Damaged electrical connector sockets of Interface Con-nector Assembly (ICA).

c. Foreign material inside electrical connector sockets of

ICA.

d. Loose or leaking ICA connectors.

e. Repair or replace damaged test station parts prior to test. Refer to TO 33D4-6-755-1 for test station main-tenance procedures.

3.2.2 Test Set-up. Install UUT on UUT support assembly

fixture and sink cart. Make necessary connections using ITA kit to set-up UUT for test.

3.2.2.1 UUT Support Assembly Fixture Installation. Re-

fer to Figure 3-3 for physical location. Install UUT support assembly fixture on sink cart as follows:

Lifting the UUT support assembly fixture is a two person task. Injury to personnel may result.

a. Secure sink cart floor lock.

b. Attach four retaining blocks to bottom of UUT support assembly fixture with four hex screws. Do not tighten.

Leave 1/4 inch between retaining blocks and bottom of UUT support assembly fixture.

c. Align all four retaining blocks with retaining slots in top of sink cart.

d. Move UUT support assembly fixture until all four re-taining blocks drop into the retaining slots.

e. Slide UUT support assembly fixture forward to engage retaining blocks in retaining slots.

f. Align detent pinhole in UUT support assembly fixture with pinhole in sink cart and insert detent pin through UUT support assembly fixture and into sink cart.

g. Tighten two forward retaining block screws, making sure retaining blocks are seated in retaining slots.

h. Remove detent pin and slide UUT support assembly fixture forward on carriage system.

i. Tighten two aft retaining block screws, making sure retaining blocks are seated in retaining slots.

j. Slide UUT support assembly fixture aft on carriage system and insert detent pin through UUT support as-sembly fixture and into sink cart.

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Figure 3-3. UUT Support Assembly Fixture Installation

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3.2.2.2 Drive Adapter Assembly Installation. Refer to

Figure 3-4 for physical location. Install the drive adapter assembly on UUT as follows:

NOTE

Due to the size and weight of UUT, install the drive adapter assembly on the UUT prior to mounting the drive adapter assembly on the UUT support assembly fixture.

a. Position UUT as shown in Figure 3-4. Make sure the seal drain on drive adapter assembly is positioned 180 degrees from UUT seal drain.

b. Insert drive adapter assembly onto the UUT splined shaft. Align UUT alignment stud with drive adapter assembly and mate UUT with drive adapter assembly.

c. Secure UUT and drive adapter assembly using six washers and nuts.

3.2.2.3 Drive Adapter Assembly/UUT Support Assem-

bly Fixture Installation. Refer to Figure 3-4 for physical location. Install drive adapter assembly on UUT support as-sembly fixture as follows:

The UUT, due to its size and weight, is to be lifted with a hydraulic crane, capable of lifting 100 lbs, for safe operation and ease of mounting drive adapter assembly on UUT support assembly fix-ture. UUT can be damaged.

a. Using sling and hydraulic crane, lift drive adapter as-sembly.

b. Make sure UUT support assembly fixture adapter lock-ing lever is at 12 o’clock and the lower hand retract-able plunger is seated (Figure 3-4).

c. Position seal drain on drive adapter assembly at 6 o’clock and move it into the aft side of UUT support assembly fixture.

d. Install four screws, heads forward, through UUT sup-port assembly fixture and into threaded holes in drive adapter assembly. Tighten screws to secure drive adapter assembly to UUT support assembly fixture.

e. Release tension on hydraulic crane and remove sling.

f. Install drain tube on drive adapter assembly.

3.2.2.4 ITA Kit Installation.

3.2.2.4.1 Hydraulic Set-up. Refer to Figure 3-5 and Fig-

ure 3-6. Install ITA kit fittings and hose assemblies as fol-lows:

Loose tube and hose connections subject to fluid or pneumatic pressure may separate and cause in-jury to personnel and damage to equipment. Make sure all tube and hose connections are tight before pressurizing system.

a. Secure sink cart floor lock.

NOTE

Sink cart BCP cap nuts are not removed from sink cart BCP unless a hose connection is made.

b. Install ITA kit test fittings on sink cart BCP as follows:

(1) Install nut (17), reducer (22) and elbow (8) at location (LOC) 5, on sink cart BCP.

(2) Install nut (18) and reducer (23) and elbow (8) at LOC 22 on sink cart BCP.

(3) Install reducer (20) and nut (15) at LOC 17 on sink cart BCP.

(4) Install tee (24) at LOC 26 on sink cart BCP.

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Figure 3-4. Drive Adapter Assembly and UUT Installation

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Figure 3-5. Test Set-up Diagram (Sheet 1 of 2)

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Legend for Figure 3-5:

1. Configuration Plug Assembly, SN 113 or SN 120 22. Elbow, Female Pipe, 1-1/2”

2. Adapter Assembly, Inlet 23. Reducer, -32 to - 16

3. Adapter Assembly, Flow Test Pump 24. Tee, Swivel to tube, -4

4. Adapter, -4 25. Test Cover Assembly, Filter Bypass Valve

5. Cap, - 16 26. Metering Valve, 1” (Note 1)

6. Elbow, Swivel to tube, -4 27. Burst Disk (Note 2)

7. Elbow, Tube to boss, -4 28. Regulator, Back Pressure (Note 3)

8. Elbow, Swivel to tube, - 16 29. Nipple, Pipe, 1-1/2” x 1”

9. Filter Assembly STD 61431 (GFE) 30. Tee, Male Run, - 16

10. Hose Assembly, No. 4, 12.00 in. 31. Tee, Female Pipe, 1”

11. Hose Assembly, No. 4,36.00 in. 32. Tee, Swivel Run, - 16

12. Hose Assembly, No. 4, 48.00 in. 33. Hose, Assembly, No. 16 36.00 in.

13. Hose Assembly, No. 16, 48.00 in. 34. Hose, Assembly, No. 16 48.00 in.

14. Hose Assembly, (HP) No. 16 48.00 in. 35. Elbow, Swivel to tube, - 16

15. Nut, - 12 36. Throttle Valve, 1”

16. Nut, -20 Notes:

17. Swivel Connector, -24 x 1-1/2” 1. Set at 60 gpm @ 1000 psid.

18. Nut, -32 2. Burst pressure rating 75 psig @72°F.

19. Packing 3. Set at 60 psig.

20. Reducer, - 12 to -4 4. All hoses shall be compatible with MIL-PRF-7024,

21. Reducer, -20 to - 16 with a minimum working pressure of 1200 psig@85°F for inlet lines and 2000 psig@85°F for outlet lines.

Figure 3-5. Test Set-up Diagram (Sheet 2)

c. Refer to Figure 3-2 for physical location. Install ITA kit test fittings on UUT as follows:

(1) Apply an even coat of petrolatum, VV-P-236A, to UUT packing. Install inlet adapter assembly (Figure 3-5, 2) to FUEL IN port on UUT with elbow pointed aft. Secure using four washers and nuts.

(2) Apply an even coat petrolatum, VV-P-236A, to UUT packing. Install filter bypass valve test cover assembly (25) at LOW RET port on UUT, secure using four washers and screws.

(3) Apply an even coat of petrolatum, VV-P-236A, to packings (19). Install packings on three elbows (7) and adapter (4).

(4) Install elbows (7) in INLET PT, INLET PT

FUEL PRESS 2, DISCH PT FUEL PRESS 3

ports of UUT.

(5) Install adapter (4) in FUEL PRESS 8 port of UUT. Install elbow (6) on adapter (4).

(6) Make sure that four packings, PN MS29512-16, are installed in packing grooves of UUT. Install flow test pump adapter assembly (3) on TO HEAT, FROM HEAT, BYPASS, and OUTLET ports of UUT. Secure adapter with washers and nuts.

(7) Install cap (5) on BYPASS port of flow test pump adapter assembly (3).

(8) Place filter assembly STD 61431 (GFE) (9) in sink of sink cart.

(9) Connect nut (16) and reducer (21) to bottom inlet of filter assembly (9).

d. Refer to Figure 3-5 and Figure 3-6 for physical location. Install ITA kit hose assemblies as follows:

Broken strands on braided hose assemblies can cause injury. Handle with care.

(1) Connect straight end of hose assembly (HP) (14) to elbow (8) at LOC 22 of sink cart BCP. Con-nect elbow end to lower port of filter assembly (9). Tighten hose assembly fittings.

(2) Connect straight end of hose assembly (HP) (14) to top port of filter assembly (9). Connect elbow end to the OUTLET port of flow test pump adapter assembly (3). Tighten hose assembly fit-tings.

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(3) Connect straight end of hose assembly (12) to run of tee (24) installed at INLET PT port of UUT.

Connect elbow end to run of tee (24) at LOC 26 of sink cart BCP. Tighten hose assembly fittings.

(4) Connect straight end of hose assembly (12) to branch on tee (24) installed at INLET PT port of UUT. Connect elbow end to reducer (20) at LOC 17 of sink cart BCP. Tighten hose assembly fit-tings.

(5) Connect straight end of hose assembly (12) to elbow (7) at INLET PT FUEL PRESS 2 port of UUT. Connect elbow end at LOC 27 of sink cart BCP. Tighten hose assembly fittings.

(6) Connect straight end of hose assembly (11) to el-bow (6) installed at FUEL PRESS 8 port of UUT.

Connect elbow end to LOC 40 of sink cart BCP.

Tighten hose assembly fittings.

(7) Connect straight end of hose assembly (12) to elbow (7) installed at DISCH PT FUEL PRESS 3 port. Connect elbow end to LOC 33 of sink cart BCP. Tighten hose assembly fittings.

(8) Connect straight end of hose assembly (10) to branch of tee (24) installed at LOC 26 of sink cart BCP. Connect elbow end to LOC 41 of sink cart BCP. Tighten hose assembly fittings.

(9) Connect elbow end of hose assembly (13) to adapter inlet assembly (2) installed at FUEL IN port of UUT. Connect straight end to elbow (8) at LOC 5 of sink cart BCP. Tighten hose assembly fittings.

(10) Ensure sink cart BCP cap nuts are installed and secure.

3.2.2.4.2 Electrical Set-up. Make ITA kit electrical con-

nections as follows.

3.2.2.4.2.1 Configuration Plug Assembly Installation.

a. Make sure that ITA kit serial number on configuration plug assembly tag (Figure 3-7) matches ITA kit serial number on ITA kit storage container.

NOTE

Correct configuration plug assembly serial number must be installed for the anticipated test. Connect-ing the wrong plug may result in the test station preventing test start-up or inaccurate UUT test pa-rameters and results.

b. Install configuration plug assembly (Figure 3-5, 1) in sink cart BCP electrical connector J4A, Figure 3-6.

3.2.3 Sink Cart Connection. Connect sink cart to test

station as follows:

a. When test station power-up process is complete, the Operator Display Monitor (ODM) will display a menu that offers the following selections:

• Connect ITA.

• Start Session.

b. Select Connect ITA. A message will appear on ODM related to the test station ICA sliding door. If the slid-ing door is closed, open it prior to attempting sink cart connection.

c. Mate the cart to the test station using the following procedures.

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Figure 3-6. Sink Cart Bulkhead Connector Panel (BCP) Locations

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Figure 3-7. Configuration Plug Assembly Tag and Wiring Diagram

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To avoid a serious foot injury, do not stand near the cart wheels when it is moving.

When positioning cart at the front of test station, do not force the mating connections together. To do so can cause damage to mating connections.

(1) Position sink cart in front of test station, aligning test station ICA and sink cart MIC plate assem-bly.

(2) Using a slow and smooth movement, push sink cart toward test station until some resistance is encountered. At this point, the test station auto-connect sequence will take over. The sink cart will be pulled toward the test station until the ICA and MIC are properly mated.

3.2.3.1 UUT Support Assembly Fixture Connection.

When prompted, connect UUT support assembly fixture to test station drive motor in accordance with instructions on ODM. Refer to Figure 3-1 for UUT support assembly fixture callout locations. Refer to Table 3-1 for test station drive motor interlock functions.

3.2.3.2 Sound Suppression Cart Installation. Install

sound suppression cart as follows:

a. Make sure all windows on sound suppression cart are closed (up) and securely latched.

To prevent damage to ITA kit fittings and hose assemblies, do not force sound suppression cart into position. If impeded movement of sound sup-pression cart is felt during installation, adjust ITA kit fittings and hose assemblies to clear sound suppression cart.

b. Gently roll sound suppression cart over sink cart and against test station. Maneuver sound suppression cart as close as possible to test station.

3.3 ADJUSTMENT DIAGNOSTICS/FAULT ISOLA-

TION PROCEDURES.

Adjustment diagnostics and fault isolation procedures are designed to run in conjunction with testing software. Adjust-ment diagnostics will guide the test station operator in per-forming adjustments on the UUT. When adjustments fail to bring the desired parameter within limits or when adjust-ments are not available, Paragraph 3.3.2, Fault Isolation Pro-cedures, will assist the test station operator in determining the cause of the problem.

3.3.1 Adjustment Diagnostics. The availability of the

adjustment diagnostic procedures depends upon the current DIAGNOSTIC LEVEL setting (under SET-UP). The DIAG- NOSTIC LEVEL settings are explained in Chapter 4, Set-up Options. If adjustment is required during an automatic test adjustment, procedures will be displayed on ODM. This in-formation will contain adjustment magnitude and direction and forecast performance values after adjustments have been accomplished. The test station operator will be given three attempts to bring the test point within limits. If, after the third attempt, the performance values are still out of limits, available fault isolation procedures will be initiated. If there is no fault isolation procedure available for the parameters in question, the program will revert to the last display on ODM.

Table 3-1. Drive Motor Interlock Functions

Drive Adapter Position Interlock Conditions Support Assembly Forward VSD_SW1 MATED Support Assembly Aft VSD_SW1 NOT MATED Locking Lever Handle UP/Upper VSD_SW2 LOCKED Hand Retractable Plunger IN Locking Lever Handle DOWN/Upper VSD_SW2 UNLOCKED Hand Retractable Plunger OUT

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3.3.2 Fault Isolation Procedures. The availability of the

fault isolation procedures depends upon the current FAULT ISOLATION setting (under SET-UP). The FAULT ISOLA- TION settings are explained in Chapter 4, Set-up Options.

Fault isolation procedures are initiated whenever a parameter is out-of-limits and adjustment cannot correct the condition.

The fault isolation procedures will provide a table that con-tains recommendations for solving the current problem. The table is shown in three columns. The table headings are as follows:

• TROUBLE: A single phrase that identifies the fail-ure.

• PROBABLE CAUSE: A list of faults that could cause stated trouble, shown in most-to-least prob-able order.

• ACTION: A list of remedies for correcting stated trouble, each being relative to a probable cause.

3.3.2.1 Following the summary of the out-of-limits condi-

tion, a prompt will appear on the monitor. The prompt will inquire if fault isolation conclusion should be saved in the UUT activity log. A YES response will copy this information to the data logger. A NO response will resume with the test-ing process. The test station operator can also obtain a print-out (summary log) of the out-of-limit conditions.

3.4 TEST.

3.4.1 Automatic Test Procedure. Refer to Figure 3-8 for

Options/Self Test Menu Tree, when performing the automatic testing on the UUT.

3.4.1.1 Operator Login. Perform the test station operator

login using the following procedures:

a. When the cart connection process is complete, touch Proceed and the ODM will display a menu that offers the following selections:

• Disconnect ITA.

• Start Session.

NOTE

If ITA cart is not already connected, displayed se-lections will be Connect ITA and Start Session.

b. Select Start Session and touch Proceed.

NOTE

For security protection of the operator identifica-tion, the number is displayed on ODM as Xs, one for each digit entered.

c. Using the keypad presented on ODM, enter your op-erator identification number and touch Enter.

d. Depending on the identification number that was en-tered, the ODM will display the appropriate menus for further testing.

3.4.1.2 UUT Serial Number Entry. Enter the serial num-

ber for the UUT as follows:

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Figure 3-8. Options/Self Test Menu Tree

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NOTE

A full keyboard will be displayed on ODM for the UUT serial number entry. Its use is the same as typical computer keyboard. A maximum of 15 characters is allowable for a UUT serial number.

a. Enter the serial number for UUT on ODM keyboard and touch Enter.

b. Enter the UUT control number for the UUT on the ODM keyboard and touch Enter.

c. The ODM will now display the starting menu for the test procedure.

3.4.1.3 Level of Testing Selection. Refer to Figure 3-9

for UUT Menu Tree Diagram. Select the appropriate level of testing as follows:

a. Before starting any test procedures, select Set-Up op-tion on ODM. When Set-up screen appears on ODM, make sure that diagnostic level reads ALL and fault isolation reads ENABLED. If OOL is selected, only out-of-limit options will appear on ODM. Selecting a diagnostics level of ALL will display all limits of test-ing.

b. On the ODM, select the level of testing that is desired.

Two selections are available, CHECK AND TEST or

CALIBRATION.

c. After selecting the level of testing, a Main Menu will appear on ODM for the appropriate choice.

3.4.1.4 UUT Initiation Procedures.

UUT initialization procedures which contain a Dry Check and a Wet Check are performed prior to starting the test. These checks will verify all elec-trical, pneumatic (air pressure), and hydraulic con-nections have been properly made, and are deter-mined only by test station operator observation.

Observation of problems are required before re-sponding to prompts on the ODM. Improper con-nections could result in injury to personnel.

UUT start-up is the process that brings the UUT parameters up to a minimal operating (or testing) condition. This pro-cess occurs whenever automatic testing starts or as a result of menu options. At the beginning of UUT start-up, a ques-tion will appear on ODM asking if the UUT appears to be set up properly. Instructions concerning UUT start-up are as follows:

3.4.1.4.1 Dry Check.

a. Carefully observe the set-up of the UUT. Look for loose or disconnected hoses. Two responses are avail-able:

• YES: To initiate a WET CHECK of test lines.

• NO: To return to MENU selections.

b. Connect, tighten, or replace hoses as required.

c. If the UUT is observed to be set-up correctly, respond to the question by selecting the YES box on ODM.

3.4.1.4.2 Wet Check.

a. After completion of the Dry Check, the ODM will prompt the operator to observe for possible line leak-age. Carefully observe the UUT and connecting hoses for leaks. Two responses are available:

• YES: If no leaks are observed, continues with presetting of parameters.

• NO: If leaks are observed, performs shutdown of the UUT and provides instructions to correct leaks.

b. Connect, tighten, or replace hoses as required.

3.4.1.5 Test Points. The following test point numbers are

for Check and Test/Calibration test specifications. Instruc-tions for performing test procedures are provided on the ODM. Instructions contained in this manual will supplement instructions on the ODM. Perform instructions in accordance with test procedures. Refer to Figure 3-10 for UUT recon-figuration diagram. Table 3-2 provides UUT read parameters and Table 3-3 provides Test Station Set Parameters. All pa-rameters are listed on the PDDM of the test station. Informa-tion contained in parentheses of the Description column, Table 3-3, identifies the specific using PARAMETER and controller used by test station for controlling READ PA- RAMETER GAUGES displayed on the PDDM.

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Figure 3-9. UUT Menu Tree Diagram

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3.4.1.5.1 Break-In Test (1.000 Break-in). Perform test

using instructions on ODM. No operator intervention re-quired.

NOTE

Break-In Test (1.000 Break-in) is only performed when running calibration menu. If Check and Test is selected, proceed to Paragraph 3.4.1.5.2.

3.4.1.5.2 Test Procedures (2.000 Relief Valve Test).

Perform test using instructions on ODM.

Cover on high pressure relief valve is under spring tension. Use care when removing nuts.

a. In the event shims are to be added or removed, align and install clamp of flow test pump adapter assembly (Figure 3-5, 3) over UUT high pressure relief valve cover (Figure 3-2) and secure using washer and bolt.

Refer to TO 6J10-4-34-63. Tighten screw clamp tight against high pressure relief valve cover of UUT.

b. See Figure 3-5 for installation of the pump.

c. Perform test points 2.010, 2.020 and 2.030 per current software instructions.

DO NOT EXCEED 1170 psid Pt3-Pt4 AT ANY

TIME WHILE CLOSING THROTTLE VALVE.

(1) If pressure exceeds 1170 psid completely open flow throttle valve and if all shims have been re-moved, enter 1170 psid for Pt4-Pt3.

(2) If relief valve is shimmed, re-shim as per TO 6J10-4-34-63 and re-test starting at Paragraph 3.4.1.5.2, Step c above.

DO NOT ALLOW THROTTLING VALVE TO

REMAIN IN PARTIALLY CLOSED POSITION

DURING TESTING FOR MORE THAN 15 SEC-

ONDS OR FULLY CLOSED VALVE FOR MORE

THAN 5 SECONDS.

d. If Pt4-Pt3 maximum value does not exceed 1170 psid pump is considered serviceable.

e. If Pt4-Pt3 maximum value exceeds 1170 psid with no shims in relief valve assembly contact cognizant engi-neering authority for additional guidance.

3.4.1.5.3 Test (3.000 Calibration Test). Perform test us-

ing instructions on ODM and the following:

3.4.1.5.4 Test (4.000 Inspection). Perform inspection of

UUT using instructions on ODM and the following:

a. When prompted by ODM, loosen handle on clamp on flow test filter (Figure 3-10).

b. Remove top of flow test filter, and remove paper filter element.

c. Visually inspect paper filter element for evidence of aluminum or bronze powder, or aluminum or bronze chip deposits on element.

d. If inspection reveals aluminum deposits, clean filter el-ement and repeat calibration test.

e. If inspection reveals bronze deposits, refer to TO 6J10- 4-34-63 for repair of UUT.

3.4.1.6 Test Results. A printout of the test results may be

requested during automatic testing and after testing.

a. If not already displayed, select Check and Test or Cali-bration Main Menu on the ODM.

b. Select Print Test Results.

c. After several minutes, test results will print out at printer of pump module servicing that test station.

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Figure 3-10. Filter Element Removal and Inspection

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Table 3-2. UUT Read Parameters List

Name MIN ACTUAL MAX Description

CHECK AND TEST:

2.000 Relief Valve Test

Pt2 Speed Pt4_R

PSIG RPM PSIG

2.010 5.0 3550 1050 X _____ X Wf Pt2 Speed Pt4-Pt3

PSIG RPM PSIG

2.020 - - - - 1050 1040 _____ 1060 Pt4-Pt3 X _____ X Wf -500 _____ 0 Wf_Diff

Pt2 Speed Pt4_R

PSIG RPM PSIG

2.030 5.0 3550 - - X _____ 1170 Pt4-Pt3 X _____ X Wf

3.000 Calibration Test and Leak Check

Pt2 Speed Pt4

PSIG RPM PSIG

3.010 17.5 500 250 1900 _____ X Wf X _____ X Pt8-Pt2

3.020 17.5 2000 250 X _____ X Wf X _____ X Pt8-Pt2

3.030 17.5 2900 800 14800 _____ X Wf X _____ X Pt8-Pt2

3.040 17.5 3550 250 X _____ X Wf X _____ X Pt8-Pt2

3.050 17.5 3550 1000 18500 _____ X Wf

55.0 _____ X Pt8-Pt2

Pt2 Speed Pt4

PSIG RPM PSIG

3.060 17.5 3550 1000 NO _____ NO External_Lkg X _____ 1.0 Pt_Line_Lkg X _____ 10.0 Seal_Dr_Lkg

4.000 Inspection

Pt2 Speed Pt4

PSIG RPM PSIG

4.010 0.0 0.0 0.0 NO _____ NO Excsv_Con-tam

CALIBRATION:

1.000 Break-in

Pt2 Speed Pt4

PSIG RPM PSIG

1.001 - - - - - - YES _____ YES Full_Brk_In

1.010 17.5 2000 MIN X _____ X Pt4

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Table 3-2. UUT Read Parameters List - Continued

1.020 17.5 2000 MIN to 200 X _____ X Cycle 5 times, 30 seconds (full pe-riod) or 15 seconds (half pe-riod)

1.040 17.5 2000 MIN to 400 X _____ X Cycle 5 times, 30 seconds (full pe-riod) or 15 seconds (half pe-riod)

1.060 17.5 2000 MIN to 600 X _____ X Cycle 10 times, 3 minutes (full pe-riod) or l- 1/2 min-utes (half period)

1.080 17.5 2000 MIN to 800 X _____ X Cycle 10 times

1.090 17.5 2000 MIN to 900 X _____ X Cycle 10 times

1.100 17.5 2000 MIN to 1000 X _____ X Cycle 10 times

1.110 17.5 2000 1000 X _____ X Hold for 5 minutes (full pe-riod) or 2- 1/2 min-utes (half period)

1.120 17.5 2000 to 3550 MIN X _____ X Pt4

1.130 17.5 3550 600 X _____ X Hold for 3 minutes (full pe-riod) or 1- 1/2 min-utes (half period)

Pt2 Speed Pt4

PSIG RPM PSIG

1.140 17.5 3550 MIN to 800 X _____ X Cycle 10 times

1.150 17.5 3550 MIN to 900 X _____ X Cycle 10 times

1.160 17.5 3550 MIN to 1000 X _____ X Cycle 10 times

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Table 3-2. UUT Read Parameters List - Continued

1.170 17.5 3550 1000 X _____ X Hold for 15 minutes (full pe-riod) or 7- 1/2 min-utes (half period)

1.180 Filter Examination NO _____ NO Excsv_Con-

tam

2.000 Relief Valve Test

Pt2 Speed Pt4_R

PSIG RPM PSIG

2.010 5.0 3550 1050 X _____ X Wf

2.020 5.0 3550 1050 1040 _____ 1060 Pt4-Pt3

X _____ X Wf -500 _____ 0 Wf_Diff

2.030 5.0 3550 X _____ 1170 Pt4-Pt3 X _____ X Wf

3.000 Calibration Test and Leak Check

Pt2 Speed Pt4

PSIG RPM PSIG

3.010 17.5 500 250 1900 _____ X Wf X _____ X Pt8-Pt2

3.020 17.5 2000 250 X _____ X Wf X _____ X Pt8-Pt2

3.030 17.5 2900 800 14800 _____ X Wf X _____ X Pt8-Pt2

3.040 17.5 3550 250 X _____ X Wf X _____ X Pt8-Pt2

Pt2 Speed Pt4

PSIG RPM PSIG

3.050 17.5 3550 1000 18500 _____ X Wf

55.0 _____ X Pt8-Pt2

3.060 17.5 3550 1000 NO _____ NO External_Lkg X _____ 1.0 Pt_Line_Lkg X _____ 10.0 Seal_Dr_Lkg

4.000 Inspection

Pt2 Speed Pt4

PSIG RPM PSIG

4.010 Filter Examination

0.0 - - 0.0 NO _____ NO Excsv_Contam

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Table 3-3. Test Station Set Parameters List

Name Final Tolerance Engineering Units Description Pt2 ±5 PSIG Pressure, Pump Inlet (Test

Station USING_PARAM- ETER MP1, controlled by

CONTROLLER_PORT

CP4).

Pt4 ±20 PSIG Pressure, Pump Discharge (Test Station USING_PA- RAMETER MP8, con-trolled by CONTROL-

LER_PORT CP11).

Speed ±5 RPM Speed, Pump (Test Station

USING_PARAMETER

MSPD).

Wf ±0.5% of point PPH Flow, Weighted Fuel (Test Station USING_PARAM- ETER MF14, controlled by CONTROLLER_PORT

CA9).

Pt8-Pt2 ±0.2% of full scale PSID Pressure, Impeller Stage- Pt2 Differential (Test Sta-tion USING_PARAM-

ETER MP13).

Pt3 ±0.2% of full scale PSIG Pressure, After Filter (Test Station USING_PARAM-

ETER MP2).

3.5 POST TEST.

3.5.1 Normal Test Station Shutdown. After normal

Shutdown select Go to Options and respond to prompts on ODM in the order they appear.

3.5.2 Sound Suppression Cart Removal. Disconnect

sound suppression cart from test station and gently roll away.

3.5.3 Drive Motor Disconnection. When prompted, dis-

connect UUT support assembly fixture from drive motor in accordance with instructions on ODM. Refer to Figure 3-1 for UUT support assembly fixture callout locations.

3.5.4 Sink Cart Disconnection. After test is completed, disconnect sink cart as follows:

• Removal of hose assemblies and draining of CalFluid MIL-C-7024, Type II from UUT and applicable ITA kit components shall be per-formed prior to ITA cart disconnection from test station. ITA Set-up and Storage Area is not ex-plosion-proof. Failure to perform the tasks in the test station area may result in injury or death.

• CalFluid MIL-C-7024, Type II is flammable and toxic. Keep away from heat and open flames. Keep away from skin and eyes. Avoid prolonged breathing of vapors. Failure to do so may result in injury or death.

a. Disconnect hoses from UUT and sink cart BCP ( Fig-ure 3-6). Drain CalFluid and hoses into sink cart.

To avoid a serious foot injury, do not stand near the cart wheels when it is moving.

b. Touch Exit Menu until the Disconnect ITA option ap-pears on the ODM. Select Disconnect ITA and touch Proceed.

c. After sink cart stops moving, slowly pull it away from test station.

3.5.5 ITA Kit Disconnection. Disconnect and remove ITA

kit parts, UUT, and UUT support assembly fixture as fol-lows:

a. Move sink cart to ITA Set-up and Storage Area.

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b. Remove configuration plug assembly (Figure 3-5, 1) from sink cart BCP electrical connector J4A. Store configuration plug assembly in ITA kit storage con-tainer.

c. Remove test fittings from UUT and sink cart BCP (Figure 3-6).

d. Store hose assemblies and test fittings in ITA kit stor-age container.

e. Remove the washers and nuts securing the UUT to UUT support assembly fixture. Remove UUT from drive adapter assembly (Figure 3-4). Store washers and nuts in ITA kit storage container.

f. Use a clean, low-lint cleaning cloth, MIL-C-85043, Type I, to remove any spilled fluid from ITA kit parts and sink cart.

g. Install caps on all sink cart BCP fittings.

h. Remove four screws securing drive adapter assembly to UUT support assembly fixture. Store screws and drive adapter assembly in ITA kit storage container.

Lifting the UUT support assembly fixture is a two person task. Injury to personnel may result.

NOTE

Removal of UUT support assembly fixture should only be performed when necessary to repair fix-ture, perform sink cart maintenance, or when in-stallation of a different fixture is required.

i. Remove UUT support assembly fixture from sink cart as follows (Figure 3-3).

(1) Loosen two forward retaining block screws.

(2) Remove detent pin and slide UUT support assem-bly fixture forward on carriage system.

(3) Loosen two aft retaining block screws.

(4) Slide UUT support assembly fixture aft until re-taining blocks clear the retaining slots in the sink cart.

(5) Remove UUT support assembly fixture from sink cart.

3.5.6 ITA Kit Storage. Return all ITA kit parts to ITA kit

storage container. Return ITA kit to ITA Set-up and Storage Area.

3.5.7 UUT Disposition. When testing is complete, dispo-

sition will be in accordance with local established proce-dures.

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