||NAVSO P-3641A: More Power For The Dollar
Appendix B. Design Review Checklists
for Power Systems and Power Supplies
- Have all replaceable modules, subassemblies, or components been made
plug-in for rapid replacement?
- Have screw holes for mounting components, cover plates, access panels and
similar components that do not require precise alignment, been made oversize
to facilitate assembly?
- Have replaceable components and assemblies (modules, printed wiring
boards, etc.) been grouped functionally?
- Do any replaceable modules contain any components or circuits that are not
- Does chassis design provide sufficient structural support, rails, integral
rests or other devices to prevent component damage during bench repair or
- Have guide channels, positioning pins, or other aligning devices been
provided for all plug-in units to prevent pin damage or improper assembly?
- Have connectors been keyed, coded, or otherwise polarized to prevent
- Is captive hardware (screws, fasteners, etc.) used on access panels, cover
plates and similar devices to prevent dropping or loss of screws, and to avoid
possible damage to other assemblies?
- Has proper storage and protection been provided for slack harnesses or
service loops attached to pull-out or hinged assemblies, to prevent pinching,
chafing, sharp angle bending, or wire breakage due to repeated flexing?
- Have all terminals and components been spaced so that maintenance action
will not damage adjacent leads or components?
- Have access panels and covers been fitted with quick-disconnect fasteners9
- Do any modules exceed the throwaway cost limit established by the
level-of-repair analysis? Explain.
- Are all fuses located so that they can be seen and replaced without
removing any other components or subassemblies? Are colocated
ready-service spares required?
- Are provisions made for support of units while they are being removed or
- When tool-operated fasteners are necessary, do these require only standard
- Do units weighing more than 10 pounds have grasping features to assist in
removing, replacing or carrying?
Labeling and Identification
- -Are all replaceable modules, subassemblies or components readily
identifiable with adequate labeling or marking?
- Are all significant labels or markings in full and unobstructed view in
the mounted position?
- Have all wire terminals and connections been properly identified?
- Is each wire properly identified according to its terminal, connector pin,
- Has clear functional identification been provided for each control,
indicator, connector and test point?
- Does the exposed surface of installed modules contain only that
information required by the maintenance technician for positive and accurate
- Are all controls labeled?
- Do all module mounting positions have alphanumeric or color-coded symbols
clearly identifiable and adjacent to the corresponding code on the module when
Controls and Displays
- Have screwdriver adjustments been placed so that there is sufficient
clearance for the screwdriver handle?
- Have recessed screwdriver adjustments been provided with screwdriver
- Are all controls and displays clearly, accurately and uniformly
- Do meters or other displays used for maintenance provide information which
requires a minimum or interpretation by the technician?
- Is uniformity observed in shape, size, arrangement and operation of
controls (e.g., all toggle switches in "up" position for normal operation)?
- Are connectors located and mounted in a manner that facilitates rapid
assembly or disassembly during repair or replacement?
- Is the design such that malfunctioning components, modules or assemblies
can be removed without the removal of adjacent components or assemblies?
- Are the multi-pin connectors of the type that permits removal and
replacement of individual pins without disassembly of the entire connector?
- Are any components mounted in such a manner that the mounting screwheads
are "blind," i.e., underneath, or hidden by other mounting plates, panels, or
- Have adjustments been minimized?
- Have all unnecessary blind (hidden) screwdriver adjustments been avoided?
- Where blind screwdriver adjustments cannot be avoided, have screwdriver
guides (or extension shafts) been provided?
- Have critical, close-tolerance, and interacting adjustments been avoided?
- If critical adjustments are necessary, have vernier devices been provided?
- Are positive locking devices provided to assure retention of settings of
adjustments or alignment devices that are susceptible to vibration or shock?