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[ Navy Training System Plans ]






July 1995




This Navy Training Plan (NTP) has been developed to identify the lifecycle manpower, personnel, and training requirements associated with the AN/USM-636(V) Consolidated Automated Support System (CASS) that is being introduced into the Navy and Marine Corps. The objective of the CASS program is to consolidate electronic and avionics support into one standard Automatic Test Equipment (ATE) system. The CASS program is currently at Milestone III (full rate production) in the acquisition process. The Initial Operational Capability was achieved in October 1993.

CASS is a five rack integrated test system. A sixth rack configures CASS into three additional specialized testers. CASS is designed to accommodate variations in workload and to allow for Test Program Set transferability among the different configurations. To alleviate a repeat of problems and deficiencies currently experienced in the fleet with existing ATE hardware and software, the CASS procurement process includes the same requirements placed upon major weapon systems, including development and operational testing directed by Test and Evaluation Master Plan guidelines.

Operation and maintenance of CASS will be performed by Navy personnel from the Aviation Electronics Technician (AT) and Electronics Technician (ET) ratings with the Navy Enlisted Classification (NEC) 6704. The ET Rating is being included due to PMA-205 submitting an NEC change requirement to include the ET Rating as a source rating. AT and ET personnel with the NEC 6705 will perform on-line calibration and advanced maintenance. Marine Corps personnel with the Military Occupational Specialty (MOS) 6467 (E-1 through E-5) will operate CASS and perform all maintenance including calibration.

During the initial introduction period, CASS will generate some additional manpower requirements. However, there will be a significant reduction in Navy billets in FY97 and in Marine Corps billets in FY98 when

old ATE systems begin phasing out of active service.

Initial training for CASS operation, maintenance, and calibration was provided by the contractor for test and evaluation personnel, Naval Air Maintenance Training Group Detachment (NAMTRAGRUDET) instructors, depot support personnel, and fleet cadre personnel. All initial training courses have been completed.

CASS follow-on training has been established at two sites: Maintenance Training Unit (MTU) 3010, NAMTRAGRUDET Oceana, and MTU 3011, NAMTRAGRUDET Miramar. MTU 3010 was ready for training in January 1994 and MTU 3011 was ready for training in January 1995. If the student throughput requirements dictate, additional training sites will be established. Three training tracks have been established for NEC 6704, NEC 6705, and MOS 6467.





Executive Summary .......................................... i

Introduction ............................................... iii

List of Acronyms ........................................... iv


A. Title-Nomenclature-Program ................... I-1

B. Security Classification ...................... I-1

C. NTP Principals ............................... I-1

D. Operational Uses ............................. I-2

E. Technical and/or Operational Evaluation ...... I-2

F. Equipment/System/Subsystem Replaced .......... I-3

G. Description .................................. I-4

H. New Features, Configuration, or Material ..... I-7

I. Concepts ..................................... I-7

J. Logistics .................................... I-9

K. Schedules .................................... I-12

L. Manpower Requirements ........................ I-14

M. Training Concept ............................. I-15

N. On-Board Training ............................ I-18

O. List of Related Navy Training Plans

and Applicable Documents ..................... I-19


PART III - TRAINING REQUIREMENTS ........................ III-1


PART V - MAJOR MILESTONES ............................. V-1

PART VI - ACTION AND/OR DECISIONS ...................... VI-1

PART VII - POINTS OF CONTACT ............................ VII-1




The AN/USM-636(V) Consolidated Automated Support System (CASS) Navy Training Plan (NTP) was last approved in September 1993. This NTP includes the latest information on the CASS program and incorporates comments from the fleet. Specific changes include the revised Navy Support Dates and Material Support Dates, updated Technical Data Plan, revised delivery schedule, and the amended training concept including revised training dates and course lengths. Another change described in this NTP concerns the Marine Corps Military Occupational Specialty 6467, which is now dedicated solely to CASS vice all automated test equipment as previously assigned. The Sample Analysis of AN/AAM-60(V)6 Man-Hour Transfer from Shipboard to Shore AIMDs, Appendix A of this NTP, has been omitted.


AIMD Aircraft Intermediate Maintenance Department

AIP Acquisition Improvement Program

AMRAAM Advanced Medium Range Air-to-Air Missile

ASW Anti-Submarine Warfare

AT Aviation Electronics Technician

ATE Automatic Test Equipment

ATI Automated Technical Information

ATS Automatic Test Set

Avionics Test Set

BIT Built-In Test

CASS Consolidated Automated Support System

CIP CASS Implementation Plan

CMC Commandant of The Marine Corps

CNO Chief of Naval Operations

CNI Communication, Navigation, and Identification

CTS Computer Test Station

DT Development Test

EO Electro-Optical

EOSTS Electro-Optical System Test Set

ET Electronics Technician

FMS Foreign Military Sales

FOT&E Follow-On Test and Evaluation

GE General Electric

GPWS Ground Proximity Warning System

HARM Highspeed Anti-Radiation Missile

HATS Hybrid Automatic Test Set

HTS Hybrid Test Set

HYB Hybrid

ILSP Integrated Logistics Support Plan

IMA Intermediate Maintenance Activity

IMU Inertial Measurement Unit

IMUTS Inertial Measurement Unit Test Set

IO Input-Output

IOC Initial Operational Capability

IPB Illustrated Parts Breakdown

JTIDS Joint Tactical Information Distribution System

LAN Local Area Network

LHA Amphibious Assault Ship (General Purpose)

LHD Amphibious Assault Ship (Multi-Purpose)


LSA Logistics Support Analysis

MALS Marine Aviation Logistics Squadron

MATMEP Maintenance Training Management and Evaluation Program

MMH/OH Maintenance Man-Hours per Operating Hour

MOS Military Occupational Specialty

MSD Material Support Date

MTIP Maintenance Training Improvement Program

MTU Maintenance Training Unit

NAESU Naval Aviation Engineering Service Unit

NAMP Naval Aviation Maintenance Program

NAMTGD Naval Aviation Maintenance Training Group Detachment

NAMTRAGRU Naval Aviation Maintenance Training Group

NAMTRAGRUDET Naval Aviation Maintenance Training Group Detachment

NAVAIRSYSCOM Naval Air Systems Command

NAVAVNDEPOT Naval Aviation Depot

NAVSEA Naval Sea Systems Command

NAWCAD Naval Air Warfare Center Aircraft Division

NEC Navy Enlisted Classification

NETS Navy Engineering and Technical Services

NOAA National Oceanographic and Atmospheric Agency

NSD Navy Support Date

NTP Navy Training Plan

NWS Naval Weapon Station

OPEVAL Operational Evaluation

OPTEVFOR Operational Test and Evaluation Force

OT Operational Test

OTPS Operational Test Program Set

RF Radio Frequency

RFOU Ready For Operational Use

RFT Ready For Training

SEAOPDET Sea Operational Detachment

SELRES Selected Reserve

SIMA Shore Intermediate Maintenance Activity

SMAT Self Maintenance Test

SOS Support of Support

SPAWAR Space and Naval Warfare Systems Command

SRA Shop Replaceable Assembly

TECHEVAL Technical Evaluation

TIF Test Integration Facility

TTE Technical Training Equipment

TP Test Program

TPS Test Program Set

UUT Unit Under Test


VAST Versatile Avionics Shop Test

WRA Weapon Replaceable Assembly


NTP No.: A-50-8515B/A

Date: July 1995


1. Title-Nomenclature-Acronym. AN/USM-636(V) Consolidated Automated

Support System (CASS)

2. Program Element. 64215N


1. Characteristics ........... Unclassified

2. Performance ............... Unclassified

3. Navy Training Plan ........ Unclassified


1. Assistant Chief of Naval Operations/

Director Major Staff Office

(ACNO/DMSO) Program Sponsor ................ CNO (N881C)

2. ACNO/DMSO Resource Sponsor ................. CNO (N881C)

3. Marine Corps Program Sponsor ............... CMC (ASL-34)

4. Principal Development Activity (PDA) ....... NAVAIRSYSCOM (PMA260)

5. Training Agents (TA) ....................... CINCLANTFLT



MCCDC (C-461)

6. Training Support Agent (TSA) ............... NAVAIRSYSCOM (PMA205)

7. Manpower and Personnel (MP) Mission Sponsor CNO (N1)

8. Bureau of Naval Personnel (BUPERS) ......... BUPERS (PERS-4, PERS-40),


9. Commandant of the Marine Corps

Manpower Management (CMC MM) ............... CMC (ASM/ASL)

10. Commander, Naval Reserve Forces ............ CNARF (Code 541)


1. Purpose. The AN/USM-636(V) Consolidated Automated Support System (CASS) is a product of the latest Automatic Test Equipment (ATE) technology. It is used at Intermediate Maintenance Activities (IMAs) ashore and afloat to test various electronic components. With four distinct configurations and appropriate Operational Test Program Sets (OTPSs), CASS will provide automated testing of Navy and Marine Corps electronic systems which are testable by automated means.

CASS will achieve operational effectiveness by increasing the test throughput of electronic Units Under Test (UUT), providing the electronic repair site manager flexibility in assigning test workloads, reducing ATE shipboard space requirements, and providing improved capability for tailoring ATE configurations to meet specific site workload requirements. Cost effectiveness will be achieved through Navy-wide reduction of spare and repair parts and reduction in personnel, training, and other logistics elements.

CASS is currently targeted to support weapon systems in the AV-8B,

EA-6B, F/A-18, F-14, S-3B, and SH-60 aircraft. CASS will also provide maintenance support for the Advanced Medium Range Air-to-Air Missile (AMRAAM) and Highspeed Anti-Radiation Missile (HARM), airborne and battlegroup Joint Tactical Information Distribution System (JTIDS), and the SQQ-89 Aegis Antisubmarine Warfare (ASW) Combat System. Several ATE systems will transition their workload to CASS; these include AN/USM-247 Versatile Avionics Shop Test (VAST), AN/AAM-60(V)6 Electro-Optical System Test Set (EOSTS), and AN/USM-403 Hybrid Automatic Test Set (HATS) off-loads. Other ATE, non-ATE, and interim support equipment workloads will transition as new systems emerge.

Future CASS applications will include other Naval Air Systems Command (NAVAIRSYSCOM), Naval Sea Systems Command (NAVSEASYSCOM), and Space and Naval Warfare Systems Command (SPAWARSYSCOM) weapon systems. Detailed information on CASS program objectives and policies, performance requirements, test results, and implementation planning including weapon system transition to CASS support is contained in the CASS Implementation Plan (CIP) dated 03 March 1995.

2. Foreign Military Sales (FMS) and Other Source Procurements. The National Oceanographic and Atmospheric Agency (NOAA) has procured CASS to support its electronic weather monitoring systems. No FMS are planned at this time; however, this option will be pursued by NAVAIRSYSCOM PMA260 and results incorporated in future updates to this Navy Training Plan (NTP).

E. TECHNICAL AND/OR OPERATIONAL EVALUATION (TECHEVAL/OPEVAL). NAVAIRSYSCOM (PMA260) has the overall responsibility for the development and coordination of testing for CASS. The System Engineering Test Directorate,SY-50 at the Naval Air Warfare Center Aircraft Division (NAWCAD), Patuxent River, Maryland, is responsible for TECHEVAL. Operational Test and Evaluation Force (OPTEVFOR) is responsible for conducting OPEVAL. General Electric (GE)/Martin Marietta provided the necessary training for TECHEVAL and OPEVAL personnel; six courses were conducted from February 1990 through March 1992.

Additional TECHEVAL will be required for CASS as new Test Program Sets (TPSs) and advancements in the CASS program are developed. As other CASS configurations are developed in the future, they will require OPEVAL.

1. TECHEVAL. Development Tests (DTs) IIA and IIB were conducted at the GE facilities in Huntsville, Alabama, from October 1987 to March 1990. DT-IIC, Phase I through III, was conducted at NAWCAD Patuxent River from April 1990 to April 1993.

2. OPEVAL. Operational Tests (OTs) IIA through IIC were conducted under OPTEVFOR guidance at Aircraft Intermediate Maintenance Department (AIMD), Naval Air Station (NAS) Patuxent River, from April 1990 to July 1993.

3. JTIDS Follow-on Test and Evaluation (FOT&E). The JTIDS FOT&E was conducted at the Test Integration Facility (TIF), Jacksonville, from May through June 1993. During this FOT&E, CASS was used to support JTIDS. Navy personnel performed JTIDS maintenance using the appropriate TPS to demonstrate their ability to perform the required tasks using CASS.


is to consolidate electronic and avionics support into one standard ATE system. Systems to be introduced or transitioned to CASS will be identified based on the following NAVAIRSYSCOM policy (NAVAIR ltr ser 0140 of 19 Jun 87):

o Systems with Initial Operational Capability (IOC) dated FY92 and beyond will be supported on CASS.

o Existing electronic systems will be transitioned to CASS as

they are modified or upgraded.

o Systems with an IOC date of FY90 through FY92 will have interim

support until supported by CASS.

o Obsolete ATE which can no longer be economically supported will be

off-loaded to CASS based on fleet support priorities and economic


The following ATE systems are expected to be replaced by CASS as they

become obsolete or are no longer cost effective to support:

AN/AAM-60(V)4/6 Electro-Optical System Test Set (EOSTS)

AN/APM-446 Radar Test Bench Set (RTBS)

AN/ASM-604 Electrical Equipment Test Set (EETS)

AN/ASM-608(V) Inertial Measurement Unit Test Set II (IMUTS II)

AN/ASM-614 Electronic System Test Set (ESTS)

AN/ASM-686 Night Attack Intermediate Avionics Test Set (NIATS)

AN/AWM-23 Computer Test Station (CTS)

AN/USM-247 Versatile Avionics Shop Test (VAST)

AN/USM-392B Digital Module Test Set

AN/USM-403 Hybrid Automatic Test Set (HATS)

AN/USM-429 Computerized Automatic Test (CAT-IIID)

AN/USM-449(V) Automatic Test Set (ATS)

AN/USM-458C(V) New Electronic Warfare Test Set (NEWTS)

AN/USM-467 Weapon System Test Station (WSTS) RADCOM

AN/USM-470(V)1 Avionics Test Set [ATS(V)1]

AN/USM-470(V)2 Avionics Test Set [ATS(V)2]

AN/USM-484 Hybrid Test Set (HTS)

L-22000 BSY-1, SQQ-32, UYK-44 Tester (NAVSEA)

TSM-192 TAT Tester (NAVSEA)


1. Functional Description

a. CASS Station. The basic CASS station is a five-rack integrated test system known as the Hybrid Tester. The addition of a sixth specialized rack to the Hybrid Tester allows CASS to be configured into three additional types of testers. CASS is designed to accommodate variations in workload and to allow for TPS transferability among the different configurations. Currently, there are four configurations:

o Hybrid (HYB)

o Radio Frequency (RF)

o Communication, Navigation, Identification (CNI)

o Electro-Optical (EO)

CASS features instrument-on-a-card architecture. The instruments communicate with the asset controller card which, in turn, communicates with the host computer via an ethernet communications network. CASS also contains an external ethernet line for Local Area Network (LAN) communications between CASS stations. CASS is capable of performing simultaneous stimulus and measurements, either synchronously or asychronously controlled. For the Operator/Maintainer, CASS offers a 79-key keyboard, a barcode reader wand, and a trackball assembly as control input devices. The Operator/Maintainer input will be primarily implemented via the trackball assembly, which moves the cursor pointer around the screen when moving the ball. CASS software for the Operator/Maintainer interface is menu driven and symbolized by icons (small graphic figures) on a flat panel screen. Each icon represents actions to be performed by the system. Each symbol is self-explanatory; however, an explanation in the form of a small English-language caption is also provided.

(1) Automated Technical Information (ATI). CASS technical manuals have been developed in digital format suitable for display on CASS. Technical infomation for TPSs may or may not be in digtal format.

(2) Plasma Displays. Plasma displays are flat screen displays which use a gas to convert electrical energy into light. Plasma displays work on a principle similar to that of neon signs. A narrow gap filled with neon and argon gas separates two glass plates. An alternating current applied between closely spaced row and column electrodes ionizes the gases, causing them to glow. The displays are 12 inches by 14 inches and swivel to provide maximum visual access to the Operator/Maintainer. Each of the four non-portable CASS configurations will have a plasma display.

(3) Ethernet LAN. The ethernet is a high speed LAN used to interface between CASS stations. Ethernet uses Carrier-Sense-Multiple-Access with Collision Detection. A device listens for a clear channel before transmitting. If the channel is in use (carrier sensed), the device delays transmission. Since all of the devices have equal access to the network, ethernet is deemed a multiple access network. If two devices try to transmit data simultaneously over a previously clear channel, ethernet will sense this condition (collision), stop the transmission, and attempt to retransmit the data after waiting a randomly selected time.

b. CASS TPS. A TPS is used to verify the performance of a UUT and to isolate a failure to a required level. A TPS is usually developed for a unique UUT and contains four basic elements:

o Test Program (TP) - Contains a coded sequence which, when executed by CASS, provides a set of instructions that automatically determines the performance (operational readiness condition) of the UUT. For diagnostic programs, the TP isolates to a faulty subassembly or piece part.

o Interface Device (ID) - Provides mechanical connections, electrical connections, and signal conditioning, as required, between CASS and the UUT. It may contain additional electronics that augment CASS's capability.

o Test Program Instruction (TPI) - Provides information needed for testing (i.e., hook-up, probe point locations, extra equipment) which cannot be conveniently provided or displayed by CASS under TP control.

o Supplementary Data - Consists of information, text, schematics, and logic diagrams necessary for analysis of the TPS and UUT in the event of a problem or anomaly during the testing process.

The current CASS CIP indicates plans for CASS TPS development for the following specific systems:







AN/ALR-67(V)3/4 F-14 5400B Computer IFTE Development (Army)




AN/APG-73 SRAs, WRAs F-14 DAFCS LPI Altimeter




AN/ASN-163 MAGR F-14D Radar SRAs P-3C AIP

AN/SQQ-89(V) Aegis ASW F-14D SMS/CFE SRAs P-3C AN/APS-137


AV-8BII+ F/A-18C/D FLIR SH-60B Block II


CEC F/A-18E/F FADEC T-45 Test Set




AAM-60 S-3 ASM-614 SH-60F HATS S-3

APM-446 RSTS ASM-438 S-3 (AN/APS-137) High Power ATE

APM-457 S-3B Radar ATS(V)1 F/A-18 HTS AV-8B

ASM-614 EA-6B ATS(V)2 F-14B VAST F-14

ASM-614 S-3 EETS(V)1 AV-8B VAST S-3

c. Ancillary Equipment. Several pieces of ancillary equipment are or will be used with CASS for varying applications or to run specific TPS. These include the Pneumatic Function Generator, Inertial Navigation System (INS), Advanced Communications Bus Interface, Video Pattern Generator, 1397 Bus Interface, High Power Device Tester with cooling cart, additional Digital Test Unit channels, common antenna stand, and dot matrix printer.

d. Off-Line Reader System (OLRS). A prototype Off-Line Reader was developed to provide access to the ATI without diverting a CASS station. The Off-Line Reader consists of a viewing screen, a micro-vax, and an optical hard drive. It will be employed both in the fleet and the classroom.

2. Physical Description. The CASS Hybrid configuration consists of five electronic equipment bays (or racks) connected together with the appropriate cabling. A sixth specialized rack is added to produce the other three main CASS configurations.




Hybrid 72 124 72 4944

EO 72 176 93 6094

RF 72 148 72 6013

CNI 72 148 72 6013

Hybrid, RF, and CNI CASS stations use up-flow ambient air (80 degrees Fahrenheit) as a cooling medium, thus eliminating the requirement for external air conditioning. Ambient air flow is accomplished using internal fans and heat sinks with adequate surface areas to enhance heat dissipation. The EO configuration collimator (sixth rack) requires a top down ducted air cooling system with 55 degrees Fahrenheit air and 1.5 inches of water pressure at the flow rate of 3000 cubic feet per minute.

3. Description of Introduction. CASS is being introduced as new production equipment. It will be installed on aircraft carriers during the fleet modernization program and as an initial installation item on new construction ships. At shore installations, CASS will be installed to support designed systems and will eventually replace existing ATE.

4. Significant Interfaces and/or Impacts. NA

H. NEW FEATURES, CONFIGURATION, OR MATERIAL. A Computer Test System (CTS) is in development to support All-Up-Round and sectional testing requirements of missiles. This will be a stand-alone unit using only some CASS components and will not be compatible with other CASS configurations. The AMRAAM will be the first missile to be supported by the CTS at Joint Service Depots. Future updates to this NTP will include additional information as it becomes available.


1. Maintenance Concept. The design requirements for CASS include Built-In Test (BIT), Built-In Test Equipment, and Self Maintenance Test (SMAT). CASS will detect system malfunctions on-line and automatically fault isolate to the failed Shop Replaceable Assembly (SRA). Applicable CASS work center personnel will remove and replace the defective assembly. Removed components will be replaced or repaired and then calibrated, as required, at the designated level of repair (Intermediate or Depot). All maintenance requirements for CASS are at the Intermediate and Depot Levels. The maintenance concept for the CASS is based on the Naval Aviation Maintenance Program (NAMP) Manual, OPNAVINST 4790.2E, and each system's Maintenance Plan.

a. Organizational Level Maintenance. Organizational level maintenance will be performed at the IMA by CASS Operator/Maintainers.

(1) Preventive Maintenance. Preventive maintenance consists of daily confidence tests and scheduled maintenance tasks at prescribed calendar

or operating time intervals. CASS embedded standards are scheduled for periodic calibration at the depot maintenance level.

(2) Corrective Maintenance. On-line corrective maintenance on the various modular CASS stations will consist of fault isolation and the removal and replacement of defective or unserviceable modules or SRAs.

b. Intermediate Level Maintenance. CASS has four levels of testing that monitor operation and, in the event of a failure, notify the operator of the failure and the cause. Levels One and Two are Power-Up BIT and the SMAT Confidence Test. Both are automatically executed when the test set is powered up. Level Three is SMAT (background SMAT is automatically initiated; foreground SMAT is operator initiated). SMAT will check for most component failures within the test set, but cannot check electrical paths associated with interface points in the test set. SMAT runs automatically at power up and when the test set is idle. No operator intervention is required.

Level Four is SMAT Input-Output (IO) testing, which checks electrical interface points and associated components. SMAT IO must be initiated by the operator and requires an OTPS. In the event of a failure in the test set, repair is accomplished by removal and replacement of the failed component. Some cables may be repaired on the equipment. Maintenance actions will be accomplished using common and peculiar test equipment and hand tools. Peculiar items have been kept to a minimum.

CASS will be operated and maintained by CASS Operator/Maintainers and Calibration/Advanced Maintenance Technicians assigned to the various work centers where CASS is installed. Off-line maintenance will consist of fault isolation to the component level using Support of Support (SOS) OTPSs and the subsequent removal and replacement of defective components. If an embedded standard is removed and replaced as the result of maintenance actions, the CASS system must be recalibrated before use. Embedded standards will be used to calibrate the system as required by the appropriate maintenance instruction manual.

c. Depot Level Maintenance. Depot Level Maintenance will consist of fault isolation of all new design SRAs using SOS OTPSs and the repair of defective SRAs. In addition, depot level personnel will repair specified SRAs, calibrate CASS embedded standards, and perform those tasks considered to be beyond the capability of intermediate maintenance.

d. Technical Assistance. Navy Engineering and Technical Services (NETS) from the Naval Aviation Engineering Support Unit (NAESU) will provide technical assistance to fleet activities. NETS will be provided on an on-call basis in support of the CASS program.

e. Interim Maintenance. The contractor will provide interim support under a phased support concept until Navy organic support is established. The Navy Support Date (NSD) for the Hybrid, CNI, and RF stations is October 1995. NSD for the EO station is January 1997.

2. Operational Concept. CASS is intended for use in AIMDs ashore and afloat, Marine Aviation Logistics Squadrons (MALS), Shore Intermediate Maintenance Activities (SIMAs), Naval Aviation Depots (NAVAVNDEPOTs), Naval Weapon Stations (NWSs), and other support sites. CASS is capable of operating 22 hours a day. Two hours are scheduled for daily maintenance.

3. Manning Concept. CASS manpower is driven by the requirement for Operator/Maintainers, Calibration/Advanced Maintenance Technicians, and the preventive and corrective maintenance requirements. Manpower requirements are predicated by the number of CASS stations employed at a particular site. This number is determined by the System Synthesis Model which is a two-part system that projects the expected workload and the CASS configurations and quantities that will be required at each site. The results of these projections are contained in the CIP and are the basis for the manpower requirements displayed in this NTP. Ultimately, manpower requirements will be determined by the actual workload at a particular site.

a. Navy Personnel. CASS stations will be manned to operate two eight-hour shifts, five days per week at shore AIMDs and two 12-hour shifts, seven days per week on deployed carrier AIMDs. Sea Operational Detachment (SEAOPDET) personnel will augment their host AIMDs by manning some billets with personnel who are currently not deployed to a carrier. The current manpower ratio for Operator/Maintainer is approximately 1.3 per station per shift, based on the Navy Standard Workweek. The manpower ratio for Calibration/Advanced Technician is one per ten stations per shift.

Two new Navy Enlisted Classifications (NECs) have been established to designate the trained CASS Operator/Maintainers and Calibration/Advanced Maintenance Technicians. Aviation Electronics Technician (AT) and Electronics Technician (ET) personnel with the NEC 6704 (E-3 through E-6), CASS Test Station Intermediate Maintenance Operator/Maintainer, will operate CASS and perform SMAT. AT and ET personnel with the NEC 6705 (E-5 and E-7), CASS Test Station Intermediate Maintenance Calibration/Advanced Maintenance Technician, will perform on-line calibration and advanced maintenance of the CASS. (Due to NAVSEASYSCOM and SPAWARSYSCOM's future requirements for CASS qualified technicians, the ET rating has been added as a source rating for NECs 6704 and 6705.)

b. Marine Corps Personnel. The Marine Corps will man CASS stations to operate two 12-hour shifts, seven days per week at all sites. The current manpower ratio for Marine Corps personnel is one technician per station per shift. Marine Corps personnel with Military Occupational Specialties (MOS) 6467 (E-1 through E-5) will operate CASS and perform all the required maintenance including on-line calibration and advanced maintenance. The Marine Corps has determined that the MOS 6467 will be devoted exclusively to CASS and will no longer be employed for all other ATE.


1. Manufacturer. Martin-Marietta Corporation, Americus, Georgia

The Automated Systems Department of GE which developed CASS and conducted much of the initial training is now part of the Martin-Marietta Corporation. Previously, Martin-Marietta was the secondary manufacturing source.

2. Contract Number. N00019-85-C-0439

3. Integrated Logistics Support Plan (ILSP) Development. The most recent ILSP, CASS30A-SE001, was published in May 1992 and updated in September 1992. The updated ILSP was approved in July 1994.

4. Technical Data Plan. CASS contains digitally formatted technical manuals, ATI, and provides the ability to print a hard copy of the technical information. Updates of CASS ATI will be provided for upload to the system as needed to maintain technical manual accuracy. Manuals for TPS may or may not be in ATI format. Each CASS configuration has the following manuals available.


NAVAIR 16-30USM636-1-1 Station Operation

NAVAIR 16-30USM636-2-1 Intermediate Maintenance for On-Equipment

Maintenance with Illustrated Parts Breakdown


NAVAIR 16-30USM636-2-2 Intermediate and Depot Maintenance for CASS

SRAs with IPB

NAVAIR 16-30USM636-3-1 Intermediate Maintenance for CASS SMAT with IPB

NAVAIR 16-30USM636-3-2 Intermediate Maintenance for Calibration Support

Equipment with IPB

5. Special Test Sets, Tools, and Test Equipment. Special tools and test equipment requirements were identified as part of the CASS Logistics Support Analysis (LSA) process. The following special tools and support equipment have been identified in the CASS Phased Support Plan for the Naval Air Maintenance Training Group Detachment (NAMTRAGRUDET) Oceana, dated 30 October 1992.





10x10 PGA Extraction Tool 1000014 | 26.5 GHz DC Attenuator 8493C/OPT.30

15x15 PGA Extraction Tool 1000019 | DTU Card Puller 854-605-00

16X16 PGA Extraction Tool 1000048 | DTU Ground Strap 854-895-54

2.4mm(f) to Type N(m) 11903D | Coaxial Fixed 909D

Adapter | Terminator





BNC(f) to Banana Plug 1246 | Contact Pin Extraction 910110102

Adapter | Tool

APC-3.5mm(f) to Type N(m) 1250-1744 | Mini Coax/Mini Power 910121104

Adapter | Extraction Tool

APC-3.5mm(m) to Type N(f) 1250-1750 | Center Conductor 910121119

Adapter | Forming Tool

10x10 PGA Insertion Tool 162 | RF Cable FBOHGOHG038

15x15 PGA Insertion Tool 167 | Presto Hydraulic Lift M866-2000-

16x16 PGA Insertion Tool 168 | MODGE

SMAT Interface Device 2042AS006-01| Planar Crown to N(m) OJB

SMAT Cable Set 2043AS303-01| Connector Adapter

SMAT Adapter Set 2047AS258-01| Planar Crown to 3.5(m) OJF

BNC to BNC Cable 2249-C-48 | Connector Adapter

Drawer Removal Fixture 47C479831 | 24/28 Pin Dip Insertion P/N-113

CCA Extraction Tool 6126-978 | Tool

7mm to APC 3.5mm(f) 8022A1 | 24/28 Pin Dip Extraction P/N-203

Power Sensor 8487A | Tool

BNC Termination Feed Thru 4119-50 | Range Calibrator 11683A

SMA(m) to BNC(f) Adapter 4290 | 2.4mm to APC-3.5 119010

| Connector Adapter

HP-436A Power Meter 436A-OPT22 | Power Splitter 11667B

w/Opt 022 | 2.4mm(m) to Type N(f) 11903C

AC Measurement Standard 4920M | Adapter

BNC Shorting Plug 5085 | BNC(f) to Banana Plug 1246





Synthesized RF Signal 6060B-488 | Type N(f) to BNC(m) 1250-0077

Generator | Adapter

Portable Pressure Gauge 6220-19 | Type N(m) to BNC(f) 1250-0780

Portable Pressure Gauge 6220-50 | Adapter

DC Reference Standard 732B | APC-3.5mm(m) to Type 1250-1743

1 ohm Resistor Standard 742A-1 | N(m) Adapter

10 ohm Resistor Standard 742A-10K | APC-3.5mm(f) to Type 1250-1750

Power Sensor 8482A | N(m) Adapter

Power Sensor 8487A | SMA(m) to BNC(m) Adapter 1250-1787

Fixed Attenuator 8493C/OPT.30| BNC(f) to Banana(m) 1269

Measuring Receiver 8902A | Adapter

RF Cable FBOHGOHGO38 | CAL OTPS Interface Dev. 2042AS005-01

Synchro/Resolver L200-U1S | CAL OTPS Cable Set 2043AS302-01

Simulator | CAL OTPS Adapter Set 2043AS337-01

Planar Crown Connector OJB | CAL OTPS Load Set 2046AS337-01

Type N(m) | BNC to BNC Cable 2249-C-48





Planar Crown Connector OJF | DMM OPT 100 3458A

3.5mm(m) | Pressure Hose 35.5PFFJ-4SSW/ME

Planar Crown Connector OJK | Pressure Hose 36.OPFMEFP9100

2.4mm(m) | 28.5 psi Relief Valve SS4CPA2-3

IEEE-488 Cable 10833A | 75 psi Relief Valve SS4CPA2-50

6. Repair Parts. CASS spare parts and repair parts requirements will be determined through the LSA process and listed in the support material list. Interim support spare and repair parts will be managed under the Interim Contractor Supply Support Program. This will provide a smooth transition to the Material Support Date (MSD). MSD will be concurrent with the NSD; Hybrid, CNI, and RF in October 1995, and EO in January 1997.

7. Contractor Engineering Technical Services (CETS). NA


1. Schedule of Events

a. Installation Schedule. The CASS delivery schedule for the years 1991 to 2007 has been revised in the CIP dated 05 March 1995. This schedule depicts delivery dates for the years FY92 through FY00. The schedule for FY01 through FY07 are projected dates for planning purposes only and are subject to change. Refer to Part II.A.1.a in this NTP for the CASS station delivery schedule at Navy, Marine Corps, and NAVAVNDEPOT sites through FY99. Refer to the most current CIP for any changes to post-FY99 deliveries, TPS delivery dates, and the delivery schedules for TIF, Product Support Development, and contractor sites.

Aboard CV's, most CASS installations will replace obsolete ATE on a system-for-system basis. Aboard Amphibious Assault Ships, both General-Purpose (LHAs) and Multi-Purpose (LHDs), CASS will be installed in vans initially and later "hard sited" to replace obsolete ATE. At shore AIMDs, both the CASS and obsolete ATE may be supported until the particular AIMD no longer requires the obsolete ATE to support its normal complement of aircraft. The NAMTRAGRUDETs will phase out the obsolete ATE when there is no longer a training requirement. Obsolete non-ATE will phase out in accordance with new emerging system acquisition schedules. Future deliveries of CASS will include SIMAs and other surface ships.

b. Ready For Operational Use (RFOU). CASS units will be RFOU within ten days of delivery if units are preassembled or within 30 days if on-site assembly is required. IOC was achieved in October 1993.

c. Foreign Military Sales (FMS) and Other Source Delivery Schedules. NOAA received CASS in January 1994 to support its electronic weather monitoring systems. No FMS are planned at this time; however, this option will be pursued by the Program Manager and results incorporated in future updates to this NTP.

d. Training Device and Technical Training Equipment (TTE) Delivery Schedule.

(1) CASS Stations. Maintenance Training Unit (MTU) 3010, NAMTRAGRUDET Oceana, and MTU 3011, NAMTRAGRUDET Miramar, have received six CASS stations each and the associated ancillary equipment as TTE. If student throughput requirements indicate the need for additional training sites, the location of these sites will be determined by overall fleet requirements.


MTU 3010, NAMTGD Oceana HYB Sep 92 Delivered

Nov 93 Delivered

Dec 94 Delivered

CNI Oct 93 Delivered

Jun 94 Delivered

EO Dec 94 Delivered

MTU 3011, NAMTGD Miramar HYB Jan 94 Delivered

Feb 94 Delivered

Dec 94 Delivered

CNI Mar 94 Delivered

Mar 95 Delivered

EO Dec 94 Delivered

(2) Off-Line Readers. As an alternative to procuring a large number of CASS stations for the training activities, an off-line reader which allows viewing of the ATI in the classroom environment will be procured. Initially, each MTU received six prototype off-line readers; MTU 3010 received six off-line readers in mid-FY94 and MTU 3011 received their six in fourth quarter FY94. The prototype off-line reader was evaluated by NAMTRAGRUDET Oceana for fleet and classroom use. MTUs 3010 and 3011 will receive a total of fifteen off-line readers by fourth quarter FY95 to be employed in the classroom environment.

(3) ATI Validation. NAMTRAGRUDET Oceana participated in the ATI validation and verification process. For this evaluation, a CASS station in the RF configuration was delivered to MTU 3010 in December 1992 (and has since been transferred to NAS Norfolk, VA.). A prototype off-line reader was also used for the ATI validation and verification; it was delivered to MTU 3010 in July 1993.

2. Time Required to Install. CASS installation and verification will require between 10 and 30 days. Actual time required will depend on whether CASS stations are preassembled before delivery or if on-site assembly is required.


1. Equipment, Subsystems, and Systems. NA

2. Aircraft Equipment, Systems, and Subsystems

a. Aircrew Requirements. NA

b. Estimated Maintenance Man-Hours per Operating Hour (MMH/OH). Information from the CASS Operational Test Readiness Review (for OT-IIC), dated May 1993 and provided by NAVAIRSYSCOM (PMA260), was used to calculate

an estimated CASS MMH/OH. After CASS enters the fleet and sufficient data is available, these calculations can be accurately updated. An NEC change for the ET rating has been submitted by PMA-205



650 AT/ET 6704/6467 NA 0.0095

650 AT/ET 6705/6467 NA 0.0068

c. Proposed Utilization. The CASS design is predicated on a wartime operating environment of 5,875 hours annually; approximately 16.3 hours per day, 360 days per year. Peacetime supportability is based on usage of 368 hours per month ashore and 450 hours per month afloat.

d. Recommended Manpower Requirements

(1) Officer. NA

(2) Enlisted

(a) MTU 3010


AT/ET 6705/9502 2 3 1 6

AT/ET 6704/9502 4 2 6


(b) MTU 3011


AT 6705/9502 2 3 1 6

AT 6704/9502 4 3 7


(c) AIMD Ashore. Manpower requirements are not the same

for all AIMDs ashore. Each AIMD will be manned based on the number of CASS stations that are to be operated and maintained. Some AIMDs will be augmented with SEAOPDET personnel who are not currently deployed. Refer to Part II.A.1.c for individual AIMD manpower requirements.

(d) AIMD Afloat. Some CASS Operator/Maintainers, NEC 6704, will be assigned to the carrier as ship's company and the remainder will be available from supporting SEAOPDETs during deployment periods. CASS Calibration/Advanced Maintenance Technicians, NEC 6705, will be assigned as ship's company personnel. Manpower requirements are based on one technician per shift per ten CASS stations. Based on current CIP requirements, each carrier will be manned with either two or four AT 6705 personnel. Refer to Part II.A.1.c for individual carrier manpower requirements.

(e) SEAOPDET. Billets will be apportioned among the SEAOPDETs located at AIMDs which service aircraft requiring CASS support. Refer to Section II.A.1.c for individual SEAOPDET manpower requirements.

(f) MALS. Marine Corps billets, as depicted in the appropriate Tables of Organization, are basically the same for all MALS ashore. However, since each MALS is augmented by squadron personnel, the total manpower requirement is determined by the number of squadrons requiring CASS support. Refer to Section II.A.1.c for individual MALS manpower requirements.

(g) LHA and LHD. Marine Corps billets will be assigned to AV-8B squadrons (MALS augment) to support CASS stations installed in vans aboard LHAs and LHDs during deployments.

(h) Surface and Subsurface. Manpower requirements for other types of ships will be determined as workload requirements and CASS station delivery schedules become available.


1. Training Applicable to Military, Civilian, and Foreign Personnel. CASS training has been established to ensure that qualified personnel are available to operate, maintain, calibrate, and troubleshoot CASS in support

of fleet activities. Contractor training services were provided for the initial training of NAMTRAGRUDET instructors, TECHEVAL and OPEVAL personnel, industrial personnel, and cadre personnel. CASS follow-on training was established at MTU 3010, NAMTRAGRUDET Oceana, in January 1994. CASS follow-on training courses at MTU 3011, NAMTRAGRUDET Miramar, was Ready For Training (RFT) in January 1995.

Follow-on training currently consists of a three week Operator/Maintainer Course and a seven week Calibration/Advanced Maintenance Technician Course. However, in response to Naval Air Maintenance Training Group (NAMTRAGRU) and fleet concerns about the Operator/Maintainer's skill levels, much of the course curriculum from the Calibration/Advanced Technician Course was be transferred to the Operator/Maintainer course. The curricula for these courses was revised to a seven week Operator/Maintainer course and a two week Calibration/Advanced Technician Course. The new courses were RFT in January 1995.

In FY96, NAS Miramar will be disestablished as a Navy base and will transfer to the Marine Corps. Whether CASS training at NAMTRAGRUDET Miramar will move to another location or remain at this site is under evaluation by NAMTRAGRU Headquarters. When CASS training requirements for NAVSEASYSCOM and SPAWARSYSCOM are identified, these students will attend CASS training at MTUs 3010 and 3011. If the student throughput for follow-on training warrants an additional CASS training site in the future, the location will be determined at that time to best serve the needs of the fleet.

a. Initial Training. CASS initial training was provided to NAMTRAGRUDET instructors, TECHEVAL and OPEVAL personnel, NAESU personnel, NAVAVNDEPOTs North Island, Jacksonville, and Norfolk personnel as well as fleet personnel. Initial training was conducted first by GE then, by Martin-Marietta at the Daytona Beach, Florida, facilities and consisted of a three week Operator/Maintainer Course and a seven week Calibration/Advanced Technician Course. These courses were conducted for several sessions from June 1991 through November 1993. Initial training for CASS has been completed. However, as new CASS configurations are developed, additional initial training may be required at a future date.

b. Follow-On Training. CASS follow-on training was established at MTU 3010, NAMTRAGRUDET Oceana in January 1994 and at MTU 3011, NAMTRAGRUDET Miramar, in January 1995. CASS training includes Operator/Maintainer and Calibration/Advanced Maintenance Technician courses. Students will develop the appropriate skills through classroom and laboratory instruction for the all CASS configurations. The RFT date for the revised course curricula is January 1995.

(1) CASS Operator/Maintainer

Track number .......... D/E-198-6102

Track length .......... 51 Days(revised)

RFT dates/locations ... Jan 94/MTU 3010, NAMTGD Oceana

Jan 95/MTU 3011, NAMTGD Miramar

Source rating ......... AT, ET

Skill identifier ...... NEC 6704

Prerequisite training.. AV A1, ET A1, or equivalent

Quota Control ......... NAMTRAGRUDET Oceana


(2) CASS Calibration/Advanced Maintenance Technician. During

the first few years of follow-on training (from FY94 through FY97), Navy personnel, who are training to attain the NEC 6705, will attend the Operator/Maintainer course C-198-3044 as a prerequisite to attending the Calibration/Advanced Maintenance Technician training track, D/E-198-6101. In subsequent years, prospective Calibration/Advanced Maintenance Technicians will be selected from an established pool of experienced personnel with the NEC 6704 who have previously completed CASS Operator/Maintainer training.

Marine Corps students who are training to attain MOS 6467 will follow training track D/E-198-6103 which includes both the CASS Operator/Maintainer and CASS Calibration/Advanced Maintenance Technician training.

(a) CASS Calibration/Advanced Maintenance Technician

Track number .......... D/E-198-6101

Track length .......... 16 Days

RFT dates/locations ... Jan 94/MTU 3010, NAMTGD Oceana

Jan 95/MTU 3011, NAMTGD Miramar

Source ratings ........ AT, ET

Skill identifier ...... NEC 6705

Prerequisite .......... NEC 6704, E-5 through E-7

Quota Control ......... NAMTRAGRUDET Oceana


(b) CASS Test Station Intermediate Operator/Maintainer


Track number .......... D/E-198-6103

Track length .......... 65 Days

RFT dates/locations ... Jan 94/MTU 3010, NAMTGD Oceana

Jan 95/MTU 3011, NAMTGD Miramar

Source ratings ........ AT

Skill identifier ...... MOSs 6467

Prerequisite .......... AV A1 or equivalent, E-2 and


Quota Control ......... EAMTMU Millington, Tenn.

(3) Team. NA

(4) Officer. NA

(5) Industrial Personnel. The NAVAVNDEPOTs, NWSs, and NAESU will be required to maintain a trained manpower pool to support CASS. The follow-on training of industrial personnel will be accomplished using organic CASS assets or a combination of organic and NAMTRAGRUDET training. Once NAMTRAGRUDET courses become RFT, industrial personnel will compete for quotas on a priority determined basis. Specific training requirements will be determined by the individual industrial activities. Refer to Part II.B.3.

2. New Training Pipelines or Tracks. Training tracks have been established to identify Navy and Marine Corps CASS skill training. Revisions required to the existing CASS training tracks are as follows:

a. D/E-198-6101, CASS Calibration/Advanced Intermediate Maintenance Technician. Revisions required are:

(1) In Phase II, change C-198-3043 course length to 2.0 weeks vice 7.0 weeks. Change Phase II length to 2.0 weeks.

(2) Change total track length to 2.4 weeks.

b. D/E-198-6102, CASS Intermediate Operator/Maintainer. Revisions required are:

(1) In Phase II, change C-198-3044 course length to 7.0 weeks vice 3.0 weeks. Delete C-602-3770, Laser Safety Fundamentals, (as required); course length 0.2 weeks. Change Phase II length to 7.0 weeks.

(2) Change total track length to 7.4 weeks.

c. D/E-198-6103, CASS Test Station Intermediate Operator/Maintainer Technician. Revisions required are:

(1) In Phase II, change C-198-3043 course length to 2.0 weeks vice 7.0 weeks. Change C-198-3044 course length to 7.0 weeks vice 3.0 weeks. Delete C-602-3770, Laser Safety Fundamentals (as required) course length 0.2 weeks. Change Phase II length to 9.0 weeks.

(2) Change total track length to 9.4 weeks.

3. Explosive Ordnance Disposal Training. NA

4. Selected Reserve (SELRES) Training. Due to the training time required to attain NECs 6704 and 6705, CASS NECs will not be awardable to SELRES personnel (except on an individual basis).


1. Proficiency or Other Training Organic to New Development. The Maintenance Training Improvement Program (MTIP) will be used to establish an effective and efficient training system that is responsive to fleet training requirements.

2. Operator and/or Maintenance Personnel Qualification Standards Requirements. NA

3. MTIP Requirements. The MTIP is a training management tool that, through diagnostic testing, identifies individual training deficiencies at both the organizational and intermediate levels of maintenance. The MTIP will allow increased effectiveness in the application of training resources through identification of skill and knowledge deficiencies at the activity, work center, or individual technician level. Remedial training will be concentrated where needed to combat identified skill and knowledge shortfalls.

NAVAIRSYSCOM (PMA205) will contract for the development of a question and answer bank for operation and maintenance on CASS. Test questions will be based upon Section II of the Task and Skill Analysis Report. Questions will be indexed to Work Unit Codes and curriculum learning objective numbers (where applicable). Development of MTIP question and answer banks are unfunded at this time. Refer to Action Item 6-90 in Part VI, page VI-2.

4. Other On-Board Training. Marine Corps on-board training is based on the current series of MCO P4790.12, Individual Training Standards System Maintenance Training Management and Evaluation Program (MATMEP). This program is designed to meet Marine as well as NAMP (OPNAVINST 4790) training requirements. It is a performance-based, standardized, level progressive, documentable, training management and evaluation program. It identifies and prioritizes task inventories by MOS through a front-end analysis process that identifies task, skill, and knowledge requirements of each MOS. MTIP questions coupled to MATMEP tasks will help identify training deficiencies that can be addressed with remedial training.




Phased Support Plan PSP-CSE- Proposed

for CASS AN/USM-636A(V) NAMTGD Oceana Aug 1994


Operational Test Readi- PMA260 May 1993

ness Review for OT-IIC

CASS Implementation Plan PMA260 Mar 1995

Advanced TACAIR Recon- PMA253 Draft under

naissance System development

AGM-88A HARM A-50-8101B/D PMA242 Draft

Missile May 1994

AIM-120 AMRAAM A-50-8111C/D PMA268 Draft

Advanced Medium Jun 1994

Range Air-to-Air




AIM/RIM-7P Sparrow/ A-50-8008B/A PMA259 Approved

Seasparrow Missile Nov 1994

AN/ALE-47 Counter- A-50-9001A/A PMA272 Approved

measures Dispenser Dec 1991


AN/ALQ-165 Airborne A-50-8407B/A PMA272 Approved

Self Protection Jammer Feb 1992

AN/ALR-67(V) A-50-9102A/A PMA272 Approved

Countermeasure Receiver Jul 1995


AN/APN-217 Radar A-50-8814B/D PDA209 Draft

Navigation Set Jan 1994

AN/ARC-210(V) A-50-9012B/D PMA209 Draft

Electronic Protection Sep 1994

Radio Set

AN/USM-429(V)1 A-50-8709A/D PMA260 Draft

CAT-IIID(V)1 includ- Jun 1995

ing the OQ-293-A-7

Analog Augmentation

Test Group

AN/USM-467 Weapons A-50-8710/A PMA260 Approved

System Test Station- Jul 1993


AN/USM-470(V)1 Auto- A-50-8706A/A PMA260 Approved

matic Test System Jun 1995


AN/USM-470(V)2 Auto- A-50-8707A/A PMA260 Approved

matic Test System Jun 1995


AN/USM-484 Hybrid A-50-8708B/A PMA260 Approved

Test Set (HTS) Feb 1995

AN/ASM-608(V) Inertial A-50-8116A/A PMA260 Approved

Measurement Unit Jul 1990


AV-8B Harrier II A-50-8210D/A PMA257 Approved

Weapons System Aug 1993



EA-6B ICAP II/Block A-50-7904C/D PMA234 Draft

86 HARM Integration Jul 1993

F-14A/F-14B/F-14D A-50-8511A/A PMA241 Approved

Aircraft Oct 1993

F/A-18 Weapon System A-50-7703F/A PMA265 Approved

Jan 1995

Ground Proximity A-50-8815A PMA209A Approved

Warning System (GPWS) Mar 1995

Joint Tactical Infor- E-70-8901A/D PMW-159-3C Draft

mation Distribution Jul 1992

System (JTIDS)

Light Airborne Multi- A-50-7702D/P PMA299 Proposed

purpose System (LAMPS) Oct 1994

Mark III Part B (SH-

60B) Aircraft Subsystem

S-3B Aircraft A-50-8310C/A PMA244 Approved

Jul 1995

SH-60F Carrier Inner- A-50-8508C/A PMA266 Approved

Zone ASW Helicopter Sept 1994

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