6J10-4-34-28-2 Testing.pdf

TO 6J10-4-34-28-2

CHAPTER 3

TEST PROCEDURES

a. Inspect UUT for the following:3.1 GENERAL.

(1) Cracks, dents, nicks, or other damage.This chapter provides information for evaluating the per-formance of a Unit Under Test (UUT) and diagnostic of (2) Cracked, burred, or broken shaft splines.

any malfunction encountered.

(3) Damaged threads.

3.2 PREPARATION FOR TESTING.

(4) Contamination or damage to sealing surface.

3.2.1 Visual Inspection. Visually inspect UUT support

b. If damage is found, return UUT for repair.assembly fixture, UUT, Interface Test Adapter (ITA) kit, sink cart, and test station for damage that might jeopardize 3.2.1.3 ITA Kit Inspection. Refer to Figure 6-2 for safe operation during test as follows.

listed items to inspect. Inspect ITA kit for the following:

3.2.1.1 UUT Support Assembly Fixture Inspec-

a. Inspect ITA kit configuration plug assembly for:

tion. Refer to Figure 3-1 for physical location.

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

a. Inspect UUT support assembly fixture for the following: (2) Loose tag cable.

(1) Nicks, roughness, or other imperfections on (3) Bent, broken, loose, missing, or worn contact carriage rods. pins.

(2) Uneven or incomplete operation of adapter lock- (4) Damaged threads.

ing lever handle and screw actuator handwheel.

(5) Moisture or contamination of contact area.

(3) Rough or no movement of plungers.

b. Inspect ITA kit hose assemblies and test fittings

(4) Damaged threads. for:

(5) Contamination of sleeve and mating holes. (1) Cut, kinked, or frayed calibration fluid (Cal- Fluid), hydraulic, and pneumatic hoses.

b. Repair or replace damaged UUT support assembly fixture parts. (2) Damaged hose ends and test fittings.

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

cal location.

3-1

Figure 3-1. UUT Support Assembly Fixture

3-2

Figure 3-2. UUT Port and Component Location Diagram

3-3

(3) Foreign material inside CalFluid hoses, hydrau- b. Damaged electrical connector sockets of Interface lic hoses, pneumatic hoses, and test fittings. Connector Assembly (ICA).

c. Inspect ITA kit drive adapter assembly for: c. Foreign material inside electrical connector sockets of ICA.

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

d. Loose or leaking ICA connectors.

(2) Cracked, burred, or broken splines.

e. Repair or replace damaged test station parts prior

(3) Contamination or damage to sealing surface. to test. Refer to TO 33D4-6-755-1 for test station maintenance procedures.

(4) Damaged threads.

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

d. Repair or replace damaged ITA kit parts prior to bly fixture and sink cart and make necessary connectionstest. Refer to Chapter 5, Maintenance Instructions.

using ITA kit to set-up UUT for test.

3.2.1.4 Sink Cart Inspection. Refer to Figure 2-2 for 3.2.2.1 UUT Support Assembly Fixture Installa-physical location. Inspect sink cart for the following: tion. Refer to Figure 3-3 for physical location. Install

UUT support assembly fixture on sink cart as follows:a. Secure sink cart floor lock.

b. Damaged sink cart Bulkhead Connector Panel WARNING(BCP) electrical connectors, CalFluid, hydraulic, and pneumatic fittings.

Lifting the UUT support assembly fixture is ac. Foreign material inside sink cart BCP electrical two person task. Injury to personnel may result.connectors, CalFluid, hydraulic, and pneumatic fittings. a. Secure sink cart floor lock.

d. Loose or leaking Mating Interface Connector b. Attach four retaining blocks to bottom of UUT (MIC) plate assembly connectors or loose support assembly fixture with four hex screws. Do assemblies. not tighten. Leave 1/4 inch between retaining blocks and bottom of UUT support assemblye. Repair or replace damaged sink cart parts prior to fixture.test. Refer to TO 33D7-50-1988-2 for sink cart maintenance procedures. c. Align all four retaining blocks with retaining slots in top of sink cart.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.

3-4

Figure 3-3. UUT Support Assembly Fixture Installation

3-5

d. Move UUT support assembly fixture until all four b. Insert drive adapter assembly onto the UUT splined retaining blocks drop into the retaining slots. shaft. Align UUT alignment stud with drive adapter assembly and mate UUT with drive adapter

e. Slide UUT support assembly fixture forward to assembly.

engage retaining blocks in retaining slots.

c. Secure UUT and drive adapter assembly using six

f. Align detent pinhole in UUT support assembly washers and nuts.

fixture with pinhole in sink cart and insert detent

3.2.2.3 Drive Adapter Assembly/UUT Supportpin through UUT support assembly fixture and into sink cart. Assembly Fixture Installation. Refer to Figure 3-4 for physical location. Install drive adapter assembly on UUT

g. Tighten two forward retaining block screws, mak- support assembly fixture as follows:

ing sure retaining blocks are seated in retaining slots.

NOTE

h. Remove detent pin and slide UUT support assem-

The UUT, due to its size and weight, is to bebly fixture forward on carriage system.

lifted with a hoist, capable of lifting 100 lbs, for

i. Tighten two aft retaining block screws, making safe operation and ease of mounting drive sure retaining blocks are seated in retaining slots. adapter assembly on UUT support assembly fixture.

j. Slide UUT support assembly fixture aft on carriage system and insert detent pin through UUT support a. Using sling, PN 3383T446, and hydraulic crane, assembly fixture and into sink cart. PN MIC-75-STD3/4TN, lift drive adapter assembly.

3.2.2.2 Drive Adapter Assembly Installation. Refer to

b. Make sure UUT support assembly fixture adapterFigure 3-4 for physical location. Install the drive adapter locking lever is at 12 o’clock and the lower handassembly on UUT as follows:

retractable plunger is seated.

NOTE

c. Position drain adapter on drive adapter assembly at

6 o’clock and move it into the aft side of UUT Due to the size and weight of UUT, install the support assembly fixture.

drive adapter assembly on the UUT prior to mounting the drive adapter assembly on the d. Install four screws, heads forward, through UUT UUT support assembly fixture. support assembly fixture and into threaded holes in drive adapter assembly. Tighten screws to secure

a. Position UUT as shown in Figure 3-4 with seal drive adapter assembly to UUT support assembly drain on drive adapter assembly 180 degrees from fixture.

pump discharge ports.

NOTE

Ensure drain adapter on drive assembly assem-bly is at the 6 o’clock position.

3-6

Figure 3-4. Drive Adapter Assembly and UUT Installation

3-7

e. Release tension on hydraulic hoist and remove (6) Place the Actuator valve assembly (23) into the sling. center of the sink cart, just to the right side of

(8).

f. Install drain tube on drive adapter assembly.

c. Refer to Figure 3-2 for physical location. Install

3.2.2.4 ITA Kit Installation. ITA kit test fittings on UUT as follows:

3.2.2.4.1 Hydraulic Set-up. Refer to Figure 3-5 for test (1) Apply an even coat of petrolatum, VV-P-236A, to UUT packing. Install inlet adapter assemblyset-up diagram. Refer to Figure 3-6 for sink cart Bulkhead

(3) on FUEL IN port of UUT with elbowConnector Panel (BCP) locations. Install ITA kit fittings pointed aft. Secure using four washers and nuts.and hose assemblies as follows:

(2) Apply an even coat of petrolatum, VV-P-236A, WARNING to UUT packing. Install filter bypass valve test cover assembly (9) on BY PS RET port of UUT, secure using four washers and nuts.

Loose tube and hose connections subject to fluid or pneumatic pressure may separate and (3) Apply an even coat of petrolatum, VV-P-236A, cause injury to personnel and damage to equip- to three packings (18). Install packings on three ment. Make sure all tube and hose connections elbows (6).

are tight before pressurizing system.

(a) Connect the pipe end of the Actuator valve assembly (23) to the control valve on flowNOTE control valve assembly (8).

Sink cart BCP cap nuts are not removed from

(4) Install elbows (6) in BOOST STAGE DISCHsink cart BCP unless a hose connection is

PR TAP BRT, MAIN STAGE RET PR TAP,made.

and INLET FUEL PR TAP ports of UUT.

a. Secure sink cart floor lock.

(5) Connect hose assembly (HP) (13) to the Actua-tor valve assembly (23). Connect other end tob. Install ITA kit test fittings on sink cart BCP PRIM RET on adapter and clamp assembly (2)(Figure 3-6) as follows:

on UUT. Tighten hose assembly fittings.

(1) Install nut (16, Figure 3-5) and reducer (20) at

(6) Apply an even coat of petrolatum, VV-P-236A,location (LOC) 5 on sink cart BCP.

to UUT packings. Install adapter and clamp assembly (2) on SEC OUT, SEC RET, PRIM(2) Install elbow (5) at LOC 8 on sink cart BCP.

RET, and PRIM OUT ports of UUT, secure

(3) Install nut (17), reducer (21) and elbow (7) at using eight washers and nuts.

LOC 22 on sink cart BCP.

(7) Install screen bleed assembly (22) to adapter (4)

(4) Install nut (15) and reducer (19) at LOC 17 on and elbow (6) at MAIN DISCH PR TAP and sink cart BCP. BOOST STAGE PR TAP BRT. Make sure flow direction arrow is pointing away from UUT.

(5) Place flow control valve assembly (8) in sink of sink cart, with filter on the right side.

3-8 Change 1

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

Change 1 3-9

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

3-10

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

Change 1 3-11

d. Refer to Figure 3-5 for physical location. Install (9) Connect straight end of hose assembly (10) to ITA kit hose assemblies as follows: elbow (6) at MAIN STAGE RET PR TAP port of UUT. Connect elbow end to LOC 28 of sink cart BCP. Tighten hose assembly fittings.

WARNING

(10) Connect straight end of hose assembly (10) to screen bleed assembly (22) at MAIN STAGE Broken strands on braided hose assemblies can DISCH PR TAP port of UUT. Connect elbow cause injury. Handle with care. end to LOC 33 of sink cart BCP. Tighten hose assembly fittings.(1) Connect straight end of hose assembly (HP)

(14) to elbow (7) at LOC 22 of sink cart BCP. (11) Ensure sink cart BCP cap nuts are installed and Connect elbow end to filter assembly on flow secure.

control valve assembly (8). Tighten hose assem-bly and fittings. (12) Connect the straight end of hose assembly (10) to the elbow of the Actuator valve assembly

(2) Connect hose assembly (HP) (12) to elbow (5) (23). Connect the elbow end to LOC 13 of the at LOC 8 of sink cart BCP. Connect other end sink cart BCP. Tighten hose assembly fittings.

to control valve on flow control valve assembly (8). Tighten hose assembly and fittings. 3.2.2.4.2 Electrical Set-up. Make ITA kit electrical connections as follows.(3) Connect hose assembly (HP) (13) to tee on flow control valve assembly (8). Connect other end to 3.2.2.4.2.1 Configuration Plug Assembly PRIM OUT on adapter and clamp assembly (2) Installation.

on UUT. Tighten hose assembly fittings.

a. Make sure that ITA kit serial number on configura-(4) Connect hose assembly (HP) (13) to control tion plug assembly tag (Figure 3-7) matches ITAvalve on flow control valve assembly (8). Con-kit serial number on ITA kit storage container.nect other end to PRIM RET on adapter and clamp assembly (2) on UUT. Tighten hose NOTEassembly fittings.

Correct configuration plug assembly serial(5) Connect elbow end of hose assembly (11) to number must be installed for the anticipatedreducer (20) at LOC 5 of sink cart BCP. Con-test. Connecting the wrong plug may result innect other end to inlet adapter assembly (3) on the test station preventing test start-up or inac-UUT. Tighten hose assembly fittings.

curate UUT test parameters and results.

(6) Connect straight end of hose assembly (10) to

b. Install configuration plug assembly (1, Figure 3-5)elbow (6) at INLET FUEL PR TAP port. Con-in sink cart BCP electrical connector J4A,nect elbow end to LOC 26 of sink cart BCP.

Figure 3-6.Tighten hose assembly fittings.

3.2.3 Sink Cart Connection. Connect sink cart to test(7) Connect straight end of hose assembly (10) to adapter on inlet adapter assembly (3) at INLET station as follows:

FUEL PR TAP port of UUT. Connect elbow

a. When test station power-up process is complete,end to reducer (19) at LOC 17 of sink cart BCP.

the Operator Display Monitor (ODM) will displayTighten hose assembly fittings.

a menu that offers the following selections:

(8) Connect straight end of hose assembly (10) to

• Connect ITA.screen bleed assembly (22) at BOOST STAGE

• Start Session.DISCH PR TAP BRT port of UUT. Connect elbow end to LOC 27 of sink cart BCP. Tighten fittings.

3-12 Change 1

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

3-13

b. Select Connect ITA. A message will appear on assembly fixture callout locations. Refer to Table 3-1 for ODM related to the test station ICA sliding door. If test station drive motor interlock functions.

the sliding door is closed, open it prior to attempt-

3.2.5 Sound Suppression Cart Installation. Installing sink cart connection.

sound suppression cart as follows:

c. Mate the cart to the test station using the following procedures. a. Make sure all windows on sound suppression cart are closed (up) and securely latched.

WARNING

CAUTION

To avoid a serious foot injury, do not stand near the cart wheels when it is moving. To prevent damage to ITA kit fittings and hose assemblies, do not force sound suppression cart into position. If impeded movement of sound

CAUTION suppression cart is felt during installation, adjust ITA kit fittings and hose assemblies to clear sound suppression cart.When positioning cart at the front of test sta-tion, do not force the mating connections b. Gently roll sound suppression cart over sink cart together. To do so can cause damage to mating and against test station. Maneuver sound suppres-connections. sion cart as close as possible to test station. Secure sound suppression cart to test station.(1) Position sink cart in front of test station, align-ing test station ICA and sink cart MIC plate

3.3 ADJUSTMENT DIAGNOSTICS/FAULTassembly.

ISOLATION PROCEDURES.

(2) Using a slow and smooth movement, push sink cart toward test station until some resistance is Adjustment diagnostics and fault isolation procedures are encountered. At this point, the test station designed to run in conjunction with testing software.

autoconnect sequence will take over. The sink Adjustment diagnostics will guide the test station operator cart will be pulled toward the test station until in performing adjustments on the UUT. When adjustments the ICA and MIC are properly mated. fail to bring the desired parameter within limits or when adjustments are not available, 3.3.2, Fault Isolation Proce-3.2.4 UUT Support Assembly Fixture Connec-dures, will assist the test station operator in determining the tion. When prompted, connect UUT support assembly cause of the problem.

fixture to test station drive motor in accordance with instructions on ODM. Refer to Figure 3-1 for UUT support

Table 3-1. Drive Motor Interlock Functions

Drive Adapter Position Interlock Conditions Support Assembly Forward VSD_SW 1 MATED

Support Assembly Aft VSD_SW 1 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 - -

3-14

3.3.1 Adjustment Diagnostics. The availability of the a. When the cart connection process is complete, touch Proceed and the ODM will display a menuadjustment diagnostic procedures depends upon the current that offers the following selections:DIAGNOSTIC LEVEL setting (under SET-UP). The

DIAGNOSTIC LEVEL settings are explained in Chapter 4,

• Disconnect ITA.Set-up Options. If adjustment is required during an auto-

• Start Session.matic test adjustment, procedures will be displayed on

ODM. This information will contain adjustment magnitude NOTEand direction and forecast performance values after adjust-ments have been accomplished. The test station operator If ITA cart is not already connected, displayedwill be given three attempts to bring the test point within sections will be Connect ITA and Start Session.limits. If, after the third attempt, the performance values are still out of limits, available fault isolation procedures will

b. Select Start Session and touch Proceed.be initiated. If there is no fault isolation procedure available for the parameters in question, the program will revert to NOTEthe last display on ODM.

3.3.2 Fault Isolation Procedures. The availability of For security protection of the operator identifi-cation, the number is displayed on ODM as Xs,the fault isolation procedures depends upon the current one for each digit entered.FAULT ISOLATION setting (under SET-UP). The

FAULT ISOLATION settings are explained in Chapter 4,

c. Using the keypad presented on ODM, enter yourSet-up Options. Fault isolation procedures are initiated operator identification number and touch Enter.whenever a parameter is out-of-limits and adjustment can-not correct the condition. The fault isolation procedures d. Depending on the identification number that was will provide a table that contains recommendations for entered, the ODM will display the appropriate solving the current problem. The table is shown in three menus for further testing.

columns. The table headings are as follows:

3.4.1.2 UUT Serial Number Entry. Enter the serial• TROUBLE: A single phrase that identifies the failure.

number for the UUT as follows:• PROBABLE CAUSE: A list of faults that could cause stated trouble, shown in most-to-least probable order.

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

A full keyboard will be displayed on ODM for

3.3.2.1 Following the summary of the out-of-limits condi- the UUT serial number entry. Its use is the tion, a prompt will appear on the monitor. The prompt will same as typical computer keyboard. A maxi-inquire if fault isolation conclusion should be saved in the mum of 15 characters is allowable for a UUT UUT activity log. A YES response will copy this informa- serial number.

tion to the data logger. A NO response will resume with the

a. Enter the serial number for UUT on ODM key-testing process. The test station operator can also obtain a board and touch ENTER.printout (summary log) of the out-of-limit conditions.

When this occurs, a printout will receive information from

b. Enter the UUT control number for the UUT on thethe data logger as an input to this summary log.

ODM keyboard and touch ENTER.

3.4 TEST. c. The ODM will now display the starting menu for

the test procedure.

3.4.1 Automatic Test Procedure. Refer to Figure 3-8

for Options/Self Test Menu Tree. Perform the automatic testing on the UUT.

3.4.1.1 Operator Login. Perform the test station opera-

tor login using the following procedures:

3-15

Figure 3-8. Options/Self Test Menu Tree

3-16

3.4.1.4.2 Wet Check.3.4.1.3 Level of Testing Selection. Refer to Figure 3-9 for UUT Menu Tree Diagram. Select the appropriate level

a. After completion of the Dry Check, the ODM willof testing as follows:

prompt the operator to observe for possible line leakage. Carefully observe the UUT and connect-a. Before starting any test procedures, select Set-Up ing hoses for leaks. Two responses are available:option on ODM. When Set-up screen appears on

ODM, make sure that diagnostic level reads ALL

• YES: If no leaks are observed, continues withand fault isolation reads ENABLED. If OOL is presetting of parameters.selected, only out-of-limit options will appear on

• NO: If leaks are observed, performs shutdownODM. Selecting a diagnostics level ALL will dis-of the UUT and provides instructions to correctplay all limits of testing.

leaks.

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

b. Connect, tighten, or replace hoses as required.desired. Two selections are available, CHECK

AND TEST or CALIBRATION.

3.4.1.5 Test Points. The following test point numbers

are for Check and Test/Calibration test specifications.c. After selecting the level of testing, a Main Menu Instructions for performing test procedures are provided onwill appear on ODM for the appropriate choice.

the ODM. Instructions contained in this manual will sup-

3.4.1.4 UUT Initiation Procedures. UUT start-up is the plement instructions on the ODM. Perform instructions in accordance with test procedures. Refer to Figure 3-10 forprocess that brings the UUT parameters up to a minimal filter element removal and inspection. Table 3-2 providesoperating (or testing) condition. This process occurs when- UUT Read Parameters and Table 3-3 provides Test Stationever automatic testing starts or as a result of menu options.

Set Parameters. All parameters are listed on the PDDM ofAt the beginning of UUT start-up, a question will appear on the test station. Information contained in parentheses of theODM asking if the UUT appears to be set up properly.

Description column of Table 3-3 identifies the specificInstructions concerning UUT start-up are as follows:

using PARAMETER and controller used by test station for controlling READ PARAMETER GAUGES displayed on

WARNING the PDDM.

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

UUT initialization procedures which contain a test using instructions on ODM. No operator intervention Dry Check and a Wet Check are performed required. Refer to TO 6J10-4-34-43 to determine surge prior to starting the test. These checks will cycles for break-in run.

verify all electrical, pneumatic (air pressure), and hydraulic connections have been properly

NOTEmade, and are determined only by test station operator observation. Observation of problems

Break-In Test (1.000 Break-in) is only per-are required before responding to prompts on formed when running calibration menu. Ifthe ODM. Improper connections could result in Check and Test is selected, proceed toinjury to personnel.

3.4.1.5.2.

3.4.1.4.1 Dry Check. 3.4.1.5.2 Test Procedures (2.000 Leak

Test). Perform test using instructions on ODM. No oper-

a. Carefully observe the set-up of the UUT. Look for ator intervention required.

loose or disconnected hoses. Two responses are available: 3.4.1.5.3 Test (3.000 Main Stage Pressure Relief

Valve Test). Perform test using instructions on ODM• YES: To initiate a WET CHECK of test lines.

and the following:• 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.

3-17

Figure 3-9. UUT Menu Tree Diagram

3-18

3.4.1.5.5 Test (5.000 Minimum Flow Schedule

Test). Perform test using instructions on ODM. No oper-

CAUTION

ator intervention required.

3.4.1.5.6 Test (6.000 Univ Flow Test Filter InspectionThe ‘‘A’’ Valve Access cover plate Test). Perform test using instructions on ODM and the(Figure 3-2) is heavily spring loaded.

following:

a. When instructed by ODM to shim relief valve,

a. When instructed by ODM, loosen handle on clampposition clamp handle foot clamp on adapter and on flow test filter of flow control valve assembly (clamp assembly against ‘‘A’’ Valve Access cover Figure 3-10).plate on UUT.

b. Remove top of flow test filter, and remove paperb. Loosen four screws and washers securing main filter element.stage pressure relief valve cover.

c. Visually inspect paper filter element for evidencec. Release clamp handle on adapter and clamp assem-of bronze powder, or bronze chip deposits onbly (2, Figure 3-5). Remove screws, washers and element.cover with relief valve components.

d. If inspection reveals bronze powder, or bronze chipd. Remove plate, ball bearing and two springs. Add or deposits, refer to TO 6J10-4-34-43 for repair ofsubtract washers as required to increase, or UUT.decrease the value point specified on ODM.

3.4.1.5.7 Test (7.000 Static Leak Test). Perform teste. Install two springs, plate and ball bearing. Install cover and assembled items into Main Stage Pres- using instructions on ODM. No operator intervention sure Relief Valve Port. required.

f. Using clamp, compress springs and position cover 3.4.1.6 Test Results. A printout of the test results may to align threaded bores. Secure cover using four be requested during automatic testing and after testing.

washers and screws.

a. If not already displayed, select Check and Test or

g. If unable to obtain required value point, refer to Calibration Main Menu on the ODM.

TO 6J10-4-34-43 for repair of UUT.

b. Select Print Test Results.

3.4.1.5.4 Test (4.000 Boost Stage Pressure

Regulator Valve Test). Perform test using instructions c. After several minutes, test results will print out at printer of pump module servicing that test station.on ODM. No operator intervention required.

3-19

Figure 3-10. Filter Element Removal and Inspection

3-20

Table 3-2. UUT Read Parameters List

Name MIN ACTUAL MAX Description

CHECK AND TEST:

2.000 Leak Test

Pt1_H Speed Pt4

PSIG RPM PSIG

2.010 50.0 3260 1000 NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

Pt1 PSIG Speed Pt4 NO ________ NO Lkg_Pmp_Bdy

RPM PSIG

2.020 5.0 3260 150 NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

NO ________ NO Lkg_Pmp_Bdy

3.000 Main Stage Pressure Relief Valve (A

valve) Test. Shim the Relief Valve as nec-essary to obtain limits.

Pt1 PSIG Speed Pt4_A

RPM PSIG

3.010 10.0 3000 AR 1025 ________ X Pt4_A_Set

3.020 10.0 1750 975 X ________ X Wf_H

3.030 10.0 1750 1000 X ________ X Wf_H

-300 ________ X Wf_Diff

3.040 10.0 1750 AR -200 ________ +200 Wf_H

X ________ 1300 Pt4_A_Max

4.000 Boost Stage Press Regulating Valve (D

Valve) Test

Pt1 PSIG Speed Pt4 Wf_L

RPM PSIG PPH

4.010 10.0 800 225 -- X ________ X Wf_D

4.020 10.0 800 225 875 837 ________ 913 Wf_L

X ________ X Pt2

X ________ X Pt1

28 ________ 46 Pt2-Pt1

5.000 Minimum Flow Schedule

Pt1 PSIG Speed Pt4

RPM PSIG

5.010 10.0 500 350 951 ________ X Wf_L

75 ________ 85 Tf0

5.020 10.0 3260 1000 15825 ________ X Wf_H

X ________ 70 Torque

75 ________ 85 Tf0

6.000 Universal Flow Test Filter Inspection

Pt1 PSIG Speed Pt4

RPM PSIG

6.010 - - - - - - NO ________ NO Excsv_Contam

7.000 Static Leak Test

3-21

Table 3-2. UUT Read Parameters List - Continued

Name MIN ACTUAL MAX Description Pt1 PSIG Speed Pt4

RPM PSIG

7.010 50.0 - - - - NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

NO ________ NO Lkg_Pmp_Bdy

CALIBRATION:

1.000 Break-in

Pt1 PSIG Speed Pt4

RPM PSIG

1.001 - - - - - - YES ________ YES Leakage

- - - - - - YES ________ YES Full_Brk_In

1.010 25.0 1800 MIN X ________ X Pt4

1.020 25.0 1800 MIN to 200 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.030 25.0 1800 MIN to 400 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.040 25.0 1800 400 X ________ X Hold for 5 minutes (full run) or 2-1/2 minutes (half run)

Pt1 PSIG Speed Pt4

RPM PSIG

1.050 25.0 1800 MIN to 600 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.060 25.0 1800 600 X ________ X Hold for 5 minutes (full run) or 2-1/2 minutes (half run)

1.070 25.0 3300 MIN X ________ X Pt4

1.080 25.0 3300 MIN to 400 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.090 25.0 3300 MIN to 600 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.100 25.0 3300 MIN to 800 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.110 25.0 3300 800 X ________ X Hold for 5 minutes (full run) or 2-1/2 minutes (half run)

1.120 25.0 3300 MIN to 1000 X ________ X Cycle 10 times (full run) or 5 times (half run)

1.130 25.0 3300 1000 X ________ X Hold for 5 minutes (full run) or 2-1/2 minutes (half run)

1.140 Filter Examination NO ________ NO Excsv_Contam

2.000 Leak Test

PT1 PSIG Speed Pt4

RPM PSIG

2.010 50.0 3260 1000 NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

X ________ NO Lkg_Pmp_Bdy

3-22

Table 3-2. UUT Read Parameters List - Continued

Name MIN ACTUAL MAX Description

2.020 5.0 3260 150 NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

NO ________ NO Lkg_Pmp_Bdy

3.000 Main Stage Pressure Relief Valve (A

valve) Test

Pt1 PSIG Speed Pt4_A

RPM PSIG

10.0 3000 AR 1025 ________ X Pt4_A_Set

3.020 10.0 1750 975 X ________ X Wf_H

3.030 10.0 1750 1000 X ________ X Wf_H

-300 ________ X Wf_Diff

3.040 10.0 1750 AR -200 ________ +200 Wf_H

X ________ 1300 Pt4_A_Max

4.000 Boost Stage Press Regulating Valve (D

Valve) Test

Pt1 PSIG Speed PT4

RPM PSIG

4.010 10.0 800 225 X ________ X Wf_D

4.020 10.0 800 225 837 ________ 913 Wf_L

X ________ X Pt2

X ________ X Pt1

28 ________ 46 Pt2-Pt1

5.000 Minimum Flow Schedule

Pt1 PSIG Speed Pt4

RPM PSIG

5.010 10.0 500 350 951 ________ X Wf_L

75 ________ 85 Tf0

5.020 10.0 3260 1000 15825 ________ X Wf_H

X ________ 70 Torque

75 ________ 85 Tf0

6.000 Universal Flow Test Filter Inspection

6.010 NO ________ NO Excsv_Contam

7.000 Static Leak Test

Pt1 PSIG

7.010 50.0 - - - - NO ________ NO External_Lkg

X ________ 10.0 Seal_Dr_Lkg

NO ________ NO Lkg_Pmp_Bdy

3-23

Table 3-3. Test Station Set Parameters List

Name Final Tolerance Engineering Units Description Pt1 ±2 PSIG Pressure, Inlet Pump (Test Station US-

ING_PARAMETER MP1, controlled by

CONTROLLER_PORT CP4).

Pt4 ±20 PSIG Pressure, Main Stage Discharge (Test Sta-tion USING_PARAMETER MP8, con-trolled by CONTROLLER_PORT CP11).

Speed ±2 RPM Pump Speed (Test Station US-

ING_PARAMETER MSPD).

Wf_L ±0.5% of point PP Flow, Weighted (Test Station US- ING_PARAMETER MF15, controlled by

CONTROLLER_PORT CA8).

Wf_H ±0.5% of point PPH Flow, Weighted (Test Station US- ING_PARAMETER MF14, controlled by

CONTROLLER_PORT CA9).

Wf_D ±0.5% of point PPH Flow, Weighted (Test Station US- ING_PARAMETER MF14, controlled by

CONTROLLER_PORT CA8).

Torque ±0.2% of point lb-in Torque (Test Station US-

ING_PARAMETER MTORQ).

3.5 POST TEST.

WARNING

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. • Removal of hose assemblies and draining of

CalFluid MIL-C-7024, Type II from UUT

3.5.2 Sound Suppression Cart Removal. Disconnect and applicable ITA kit components shall be sound suppression cart from test station and gently roll performed prior to ITA cart disconnection away. from test station. ITA Set-Up and Storage

Area is not explosion-proof. Failure to per-

3.5.3 Drive Motor Disconnection. When prompted, form the tasks in the test station area may disconnect UUT support assembly fixture from drive motor result in injury or death.

in accordance with instructions on ODM. Refer to • CalFluid MIL-C-7024, Type II is flammableFigure 3-1 for UUT support assembly fixture callout and toxic. Keep away from heat and openlocations.

flames. Keep away from skin and eyes.

Avoid prolonged breathing of vapors. Fail-3.5.4 Sink Cart Disconnection. After test is completed, ure to do so may result in injury or death.disconnect sink cart as follows:

a. Disconnect hoses from UUT and sink cart BCP (Figure 3-6). Drain CalFluid MIL-C-7024, Type II and hoses into sink cart.

3-24 and drive adapter assembly in ITA kit storage container.

WARNING

WARNING

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

Lifting the UUT support assembly fixture is a

b. Touch Exit Menu until the Disconnect ITA option two person task. Injury to personnel may result.

appears on the ODM. Select Disconnect ITA and touch Proceed. NOTE

c. After sink cart stops moving, slowly pull it away Removal of UUT support assembly fixturefrom test station.

should only be performed when necessary to repair fixture, perform sink cart maintenance,3.5.5 ITA Kit Disconnection. Disconnect and remove or when installation of a different fixture isITA kit parts, UUT, and UUT support assembly fixture as required.follows:

i. Remove UUT support assembly fixture from sinka. Move sink cart to ITA Set-up and Storage Area.

cart as follows (Figure 3-3).

b. Remove configuration plug assembly (1,

(1) Loosen two forward retaining block screws.Figure 3-5) from sink cart BCP electrical connector

J4A. Store configuration plug assembly in ITA kit (2) Remove detent pin and slide UUT support storage container. assembly fixture forward on carriage system.

c. Remove all test fittings from UUT and sink cart (3) Loosen two aft retaining block screws.

BCP.

(4) Slide UUT support assembly fixture aft until

d. Store hose assemblies and test fittings in ITA kit retaining blocks clear the retaining slots in sink storage container. cart.

e. Remove the washers and nuts securing the UUT to (5) Remove UUT support assembly fixture from UUT support assembly fixture. Remove UUT from sink cart.

drive adapter assembly ( Figure 3-4). Store washers and nuts in ITA kit storage container. 3.5.6 ITA Kit Storage. Return all ITA kit parts to ITA kit storage container. Return ITA kit to ITA Set-up andf. Use a clean, low-lint cleaning cloth, MIL-C-85043, Storage Area.Type I, to remove any spilled fluid from ITA kit parts, sink cart, and ITA Set-up and Storage Area. 3.5.7 UUT Disposition. When testing is complete, dis-position will be in accordance with local establishedg. Install caps on all sink cart BCP fittings.

procedures.

h. Remove four screws securing drive adapter assem-bly to UUT support assembly fixture. Store screws

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